General CNC InformationWhen a machine tool continually over travels when attempting zero return, makesure the overt ravel switch is not being made before the zero return functionis finished. On most machines, when reference returning, the decel dog makesthe switch, the machine decels and continues at this low feed rate until theswitch drops off of the back of the decel dog. At this exact instant thecontrol commands a one revolution of the motor. after the one rev it looksfor the marker. One revolution on most machines equals about .200" of axismovement. So, if the over travel switch is closer to the back side of thedecel dog than .200" it may be engaged while the control is trying to findthe marker. Unless you are very confident of the travel limits of the machineyou should move the decel dog a little in the negative direction rather thanmoving the over travel dog. But either one will have the desired effect.When working with 50 Hz inductive devices the voltage tolerance is 20% ofthe rated value. When 60 Hz it is 10%.Normally, double arm tool changers don't use a G30. The Z axis stays putwhile the arm moves up and down. Therefore the machines home position isthe tool change position. Also on double arm tool changers, when the arm isin the up position the spring loaded grippers can be pushed in easily. Whenthe arm is in the down position the locking pins go up which locks thefingers in on the tool holder. This prevents the tool from being thrown.On most cylindrical grinders the table traversing left to right is done bymechanical means. The lever in the center of the travel is connected by ashaft to a directional valve so that when the lever is moved either by handor by contact with the travel dog it switches the valve which changesdirection. Normally, there will be limit switches which are actuated by acam on the lever. These switches have nothing to do with the tabletraversing. What they do is cause the wheel to move in by the selected amounteach time the table reaches the end of travel in each direction.On a Leadwell MCV-1300S, the standby tool is stored in Diagnostic 382. Thisnumber can be seen to change as the tool positions are counted. They willchange only during an Automatic Tool Change not when magazine is jogged.Diagnostic 387 records when tool position 1 is up. It should always be a 1.Diagnostic 380 is the ATC capacity. If the tool number becomes confused:1. Manually move the magazine to tool position 1.2. Set Diagnostic 382 to 1.3. Set Diagnostic 387 to 1.4. Make sure Diagnostic 380 reflects the correct capacity.5. Do a tool change in MDI to check operation.When setting the tool capacity, you must insert a whole number in BCD. Inthe case of the MCV-1300S, the tool capacity is 30 tools. So Diagnostic 380must be 00110000. In true BCD, it would look like 0011 0000.Remember BCD works this way:8 4 2 1     8 4 2 10 0 1 1     0 0 0 0=3          =0There is an instruction in the Ladder rung for M06 which checks Diagnostic380. This instruction (LEC1) (R551.2) checks the tool number called againstD380 (Tool Capacity). If the tool called is higher than D380(i.e, M06 T31),

M06 will not execute. There will be no alarm, the M Code simply will notexecute. If the contents of D380 is higher than the actual capacity, theresult will be tool confusion. Setting D380 to a very high number will causethe magazine to continually rotate when a tool is called. Another symptom ofa D380 incorrect setting is that if a number lower than the tool capacity buthigher than the current tool is input, any tool number lower than the currenttool or the magazine capacity can be called but nothing higher.RS232 Pin outs:9 Pin12    Receive Data (RD)3    Transmit Data (TD)45    Signal Ground (SG)7815 Pin1    Signal Ground (SG)6    Transmit Data (TD)7    Receive Data (RD)11   Request to Send (RTS)12   Clear to Send (CTS)13   Data Set Ready (DSR)14   Data Terminal Ready (DTR)25 Pin2    Transmit Data (TD)3    Receive Data (RD)4    Request to Send (RTS)5    Clear to Send (CTS)6    Data Set Ready (DSR)7    Signal Ground (SG)8    Data Carrier Detect (DCD)20   Data Terminal Ready (DTR)

                                    15 Pin Male                                                                                     1                                                 o o o o o o o o                                    o o o o o o o                                                15                                     15 Pin Female                                                1                                   o o o o o o o o                                     o o o o o o o                                   15                                                  25 Pin Male                              1                              o o o o o o o o o o o o o                               o o o o o o o o o o o o                                                      25                                     25 Pin Female

                                                      1                              o o o o o o o o o o o o o                                o o o o o o o o o o o o                              25                                     9 Pin Male                                     1                                            o o o o o                                      o o o o                                            9                                     9 Pin Female                                             1                                     o o o o o                                      o o o o                                      950 pin Honda18        50     32     191         33This is looking at the pins, the notch is at the top.Jumper requirements for RS232 on most controls.9 Pin7-86-1-415 Pin13-1411-12 (In some cases)25 Pin4-56-8-20Pin 25 on Fanuc controls is 24vdc.If 440 volts is applied to a Bridgeport Series 1 CNC when it is wired for220 volts, the most likely result is that the ACC board will be damaged.The Bridgeport Boss controls use open loop stepper motors. Mounted to theside door of the electrics cabinet are four nearly identical boards. Threeare the X, Y and Z axis drives. The fourth is the ACC board. The final ampstage for the axes is mounted to the large heat sink. Their are four foreach axis.Most parts for these controls are only available through Electrical South.800-950-9550.Whenever working with a machine that is in a not ready state or the axes areinhibited or interlock for a reason that is difficult to discern, make surethat the ATC or tool turret, as the case may be, is ready. All machinesrequire that the tool changing mechanism is ready before the machine can beready. In the case of a machining center, be sure the tool pot is horizontal.In the case of a turning center, be sure the turret is clamped.LeBlond Makino does not use the Fanuc built in PMC, it builds it's own. Inmost cases the components are Fuji Electric. So if you try to access theLadder, you may not be able to by normal Fanuc means. You will usually need

to consult the Makino manual for the proper operation.On a Makino FNC74, if you have problems with the tool changer, check thesolenoids on the side of the machine. Solenoids 70, 71, 74 and 75 shouldhave the A side turned on when the tool changer is at home. If they are not,the ATC is not ready. If any of them are on B you must:1. Electrically (by switching the coil wires at the solenoid) shift the valve   to A. If solenoid 75 is on B, do it first.2. While keeping the valve switched (holding the wire) press the E-Stop.3. Release the E-Stop.4. Shift the next one. If 74 is on B, do it after 75.5. Repeat the E-Stop procedure as above.6. Do the remaining valves which require being careful to note the function of   the valve before you switch it to prevent slamming one part of the tool   changer into another.7. Cycle power on the control.SOL 75 = Pot HorizontalSOL 71 = Arm InSOL 70 = Arm 60 DegreesSOL 74 is somehow related to the tool pot horizontal function.If a machine leaves a bump at the quadrants during circular interpolation,the control is probably overcompensating for backlash.On most EDM machines trying to discharge without polarity selected causes thegenerator power to shut down. In most cases, polarity is selected by pullingin a contactor.On all machines Feed Hold is disabled when in Rigid Tapping mode.To find the feed rate needed for the G84 line, divide the desired pitch into1.If the turret on a Yam CK-2, when commanded to index, indexes then clampsthen unclamps on it's own, check the turret clamp/unclamp confirmationswitches. In this case one of them is normally stuck. if the machine has aFanuc 0 control check Diagnostic bits 2.5 and 2.6. They should never both be1 at the same time or 0 at the same time.HURCO AUTOBEND7Amplifier Balancing Procedure for V1.10 PLC Software:1.  Press the MODE key.2.  Enter a number which is one greater than the last visible selection in the    mode menu. (i.e. If the menu has 9 selections, enter 10.)3.  Press ENTER.4.  The message "Press RUN button" will be displayed.5.  Press RUN.6.  The balance menu will be displayed. Only one servo axis will be active at    one time.7.  To select different axes, pres UP or DOWN arrows.8.  The PLUS and MINUS keys are used to select the DAC output value.9.  The balance menu will display:    - The axis number    - Zero, positive, or negative DAC output voltage    - Position change value10. The first screen will be for ZERO DAC output voltage. Adjust the balance

    pot on the servo amp until the delta value displayed is zero.11. Press the UP arrow button to change to negative DAC output voltage.    Check the delta value displayed.12. Press the UP arrow button to change to positive DAC output voltage. Check    the delta value displayed.13. Compare the negative and positive DAC output voltage. This value should    be close.14. Press the MODE key to exit the amp balance screen.To access the Hurco Autobend 7 Parameter screen:1. Press the MODE button.2. Press the 0 button then the ENTER ADV button.3. Enter 14753 then the ENTER ADV button.   ( The word ACCESS appears under the Hurco logo.)4. Press 6 (Configuration Menu) then ENTER ADV button.   ( Configuration Menu is now displayed.)5. Select Axis Configuration Menu.   ( Move orange cursor to selection using green arrow keys.)6. Press ENTER ADV button.7. Make changes to Parameters as necessary.   - Move cursor left and right using (+) and (-) buttons.   - Move cursor up and down using green arrow buttons.   - Once cursor is over field to be changed, press ENTER ADV button.   - The number moves to bottom of screen.   - Change number to new value.   - Press ENTER ADV button.   - The number returns to original location.8. Press BACK button.    * Only after all necessary changes have been made.      New menu is now displayed.9. Select "Save and Exit" then press ENTER ADV button.    (Move orange cursor with green arrow buttons.)10. Turn off power, wait 30 seconds, turn power back on.On a Hurco control, every time it turns on all necessary data is loaded fromthe Flash Eprom to RAM. If you replace the Main board, you must take theblank eprom from the new board and replace it with the one from the oldboard. Before you do this you should do a Master Save to be sure everythingin RAM is stored to the EPROM. A Master Clear will erase everything fromRAM but will not affect the EPROM. This is sometimes helpful in solvingproblems. If you have some strange problems you can try doing a Master Clearthen disconnect the backup battery from the Main Board with a piece of paperbetween the battery and the contacts for about two minutes with the poweroff. Then remove the paper and turn the power back on.If you have a Golden Sun Rotary Table that misindexes intermittently,remove the drive motor and check the gear pulley. The gear is a taper lockwith six bolts. They can come loose allowing the table to misindex. Ifyou remove the encoder to check it you must put it back with the coupler inthe same orientation. It can go back one of two ways. Either correctly or180 degrees out. If it is 180 degrees out, the table will zero return onedegree from where it would otherwise.On a 15" Colchester lathe, the brake is a caliper type. It is:

Matrix Engineering1CD040-03C15993For problems with RS-232, especially in one direction only suspect pin 2 or3 wiring problem depending on which direction the problem is in. If theproblem is in both directions suspect pin 7 of the 25 pin connector or pin5 of the 9 pin connector. A poor connection will cause a situation wheredata can be transferred at a slow baud rate but not at a higher one.On a Kia KIT30A you have to push the Standby button for the hydraulics tocome on and make the machine ready. If the machine hits a hard limit switch,you must hold in the Standby button.With servo systems a motor running at a constant speed will have an equalnumber of command pulses and feedback pulses.Proximity switches:RED--------- 24vdc ---------BROWNBLACK-------  GND  ---------BLUEWHITE-------OUTPUT----------BLACKIn most cases a three wire proximity switch can be replaced with a two wire(BROWN,BLUE).The Manual/Absolute signal determines whether or not the control adds travelperformed manually to the Absolute coordinate.The cable supplied by SWI for the Haas indexer pins out this way. Pins 1 and2 go to the pins for Cycle Start. Pins 3 and 4 go to the pins for FinishSignal.Pin outs for a Yuasa SUDX Indexer:#   Wire Color     Signal2   Black         +24vdc __________ ________  Internal Relay3   Green         M-Code Start ____|4   Red/White     +24vdc5   Orange        M-Code Finish #16   White         +24vdc7   Blue          M-Code Finish #28   Orange/Black  Emergency Stop9   Clear         Do Not Use10  Red/Black     _____ _________ Feed Hold (N.O.)11  White/Black   _____|12  Black/White   _____ _________ Remote Home (M-Code or other circuit)(N.C.)13  Blue/White    _____|When a Yuasa indexer is connected to a SWI control, parameter i32 should beset to 1:0. This sets the indexer up for no handshake.Fanuc, GE Fanuc and General Numeric controls are basically the same in termsof parts, manuals, etc. For example, a GN0 is the same control as a Fanuc 0.The manual for this machine would be a part number GN61404E for GeneralNumeric and B61404E for a Fanuc and GFZ61404E for a GE Fanuc.The Mori Seiki MH63 has a door switch on the NC cabinet. If this switch isnot made, the NC will not turn on. If an axis of this machine has a jerkymovement, it could be the scale but always first check the amount of backlashin the axis. Particularly with the Y axis which is moving a great deal ofweight. The Y axis of a horizontal machining center carries not only it'sown weight but the Z axis and the spindle. Excessive backlash in the system

can cause a stick/slip condition especially on an older machine where theways may be worn in the middle of the travel but like new at the ends.Mori-Seiki vertical machines typically use a Yasnac MX2 or MX3 control.To search for an address in the Diagnostic pages:1.Press the DGN button.2.Enter the address (i.e. 1872).  As with a Fanuc control, the address you type will be displayed in the  lower left corner of the screen.3.Press the Cursor Down button.On a Mori-Seiki MV-65 it is normal after turning on the NC power to see thealarm 310:SERVO OFF. To clear this alarm, press the NC power on button again.When reading the hard copy of the ladder on a Yasnac MX2, the decimal pointis omitted from the addresses. So 1872.4 would be written as #18724The MV-65 uses NC driver boards to operate solenoids etc. These are Moriboards that have an MR connector from the control. It has two edge card conn-ectors that contain the power to feed the loads, normally 24vdc as well asthe wires going to the loads. The boards are just small relay boards. Thetool clamp/unclamp for this machine is air over oil. It uses four air valves.It has two oil filled cylinders, one mounted horizontally the other mountedvertically. The one mounted vertically is a long aluminum cylinder. It has aplastic line on the outside that runs from top to bottom and indicates theoil level in the cylinder. It also has a switch in the bottom, I think is fordetection of oil level. As far as the switches related to the drawbar clampand unclamp there are three. The switch at the top of the unit indicateswhen the tool is clamped or unclamped. It is made when the tool is clamped.It is pressed in by the small inner cylinder. It is LS18, the address is#1024.2, it's name is TOOL CLAMP DETECTION. The large outer cylinder has twoswitches associated with it. The upper switch is LS25, the address is #1024.6it's name is BELLVILLE SPRING FLEX. It should be made when the tool is clamp-ed. The lower switch is LS24, the address is #1024.7, it's name is BELLVILLESPRING RETURN.The manual clamping switch is address #1024.0, wire numbers are 180 and 24NC.The manual unclamping switch is address #1024.1, wire numbers are 181 and24NC.This machine uses three driver boards. They are identical. They are basicallysmall relay boards. At the top of each board there is a Honda 16 pin MRconnector that appears to be connected to the NC I/O board. This connector isdesignated CN1. There are also two eight pin edge board connectors at thebottom of the board. One is CN2, the other is CN3. Each board also has tenLEDs from the top of the board to the bottom. These LEDs correspond to theten relays on the board. The board farthest to the right controls 24 vdcoutputs. The two boards to the left of this board control 220 vac outputs. The DC board pins out like this:CN2 1    2    3    4    5    6    7    8 |    |    |    |    |    |    |    |      |    |    |    |    |    |    |    |     N24  U23  U24  U25  N24  U30  U31CN3 1    2    3    4    5    6    7    8 |    |    |    |    |    |    |    |

 |    |    |    |    |    |    |    |N24  N32  U33  U27  N24       N24N24 is the 24 vdc power feed, P24 is the return. It originates from a smallpower supply to the right of the driver boards. The input to the power supplyis 220 volts on wires R11 and S11. The output of the power supply is 24vdc onwires P24 and N24. There is a terminal strip behind the driver boards thatcontains a number of supply wires such as P24, N24, 24NC and 0NC. The boardsto the left of this one are wired the same except that they control AC loadsso that N24 is replaced with R11.There are three servo amplifiers. Each one has a seven segment LED as well asthree green LEDs from the top of the drive to the bottom.The spindle amplifier is a Yasnac (Yaskawa) Varispeed 626 MTII.The NC is mounted to the left door. It has three boards. The top board is theCPU. It has a three volt Lithium battery for memory backup. The middle boardis the I/O board. The bottom board is the SERVO board.This machine has a geared head. The cylinder used for shifting gears is mount-ed vertically. It has three switches that are activated by the rod end toindicate gear selection.If you have electrical problems, check the condition of all of the N24 andP24 wires.The Ladder cannot be monitored on the Yasnac MX2 control.For troubleshooting ATC problems on the MV-65 there is a manual ATC mode.To enter this mode there is a MANUAL ATC button that must be pressed. Thebutton is behind a door on the right hand side of the Operators Panel cabinetAlso behind this cover is the Over travel Release, the RS-232 port and the110 VAC outlet.Once the Manual ATC button is pressed, the machine enters the EDIT mode andthe ERROR lamp starts flashing. Press the ALM button, the ATC MANUAL screenis displayed. The screen looks like this:                 ATC MANUAL          1. POT UP          2. POT DOWN          3. ARM FORWARD          4. ARM REVERSENow you can perform these four functions by pressing buttons that are redesignated for that function while in the Manual ATC mode. If you look closelyat the buttons for things like Single Block Coolant On and Off, Block Skip,etc., you will find that there are small numbers in the right hand corner.When working in screens like ATC Manual, these numbers operate the functionlisted beside the number. For example, if while in the Manual ATC mode, youpress the Single Block button which has a 1 on it, the pot will go up. Press-ing the Coolant On button which has a 2 on it, the pot will go down. Pressingthe Coolant Off button which has a 4 on it will make the ATC arm rotate inreverse.When you are finished with the ATC Manual mode you have to push the buttonagain to turn it off. If you don't do this and you cycle power, the controlwill remember and issue an alarm. When the ATC is at home, Diagnostics 7408,7409,7410 and 7413 will be 0.If you get alarm ALM140 TOOL DATA NOT EQUAL or ALM240 EMPTY POT NOT FOUND,take the tool out of the spindle, put it in the correct pot. Then set the

spindle tool number in the Tool Registration to 0.The pot up/down on the MV-65 with a 30 tool magazine is done with a pneumaticcylinder. The cylinder is located behind the tool pot which is in the standbyposition. It is mounted vertically. The pot up limit switch is mounted tothe left of and just above the standby pot position. The pot down limitswitch is mounted directly behind the tool pot. The cylinder is controlled bya two way valve which is located in an enclosure to the left of the magazine.The A port of the valve moves the cylinder down, the B port moves it up. Thisvalve has a manual override for each port. There is a regulator in each ofthe lines coming from the ports. They are located in the enclosure with thevalve. The overrides are the slotted screw type. They are labeled OFF and ON.If the slot is horizontal the valve is manually ON. If the slot is verticalthe valve is controlled by the electrical signal.The electrical signal for the A side of the valve is on wires P24 and U25.The B side is P24 and U24. The voltage is 24 vdc.The magazine is rotated by an electric gear motor. The magazine is locked witha pneumatic cylinder. The cylinder has a roller on the end of the shaft thatrides on a cam plate that is mounted on the drive sprocket. There is also aproximity switch mounted two tool pots to the left of the standby pot posit-ion. It counts the tool pots by picking up on the pot itself. There is amanual switch for rotating the magazine in both directions. The switchesare mounted on the cover of the enclosure mentioned above. The switch to theleft is for clockwise rotation while the one to the right is for counter-clockwise rotation. The wire numbers for the CW are MGCW and 24NC. The numbers forthe CCW button are MGCCW and 24NC.When troubleshooting problems where feedback seems to fail intermittentlycan be traced to moisture inside an encoder. In addition, the moisture canbecome a vapor under certain conditions causing reading problems that seemto occur only when ambient temperatures are high or may take the form of aproblem which occurs and seems to go away after the machine sits for awhile.Chen Ho MCV-2300 I/O:INPUTSFUNCTION                               ADDRESS     CONNECTOR      WIRE#Low Gear                                          X4A           CMD21-34          135High Gear                                         X4B           CMD21-2             136Tool Release                                    X4C           CMD21-20          137Tool Hold                                           X4D           CMD21-35          138Tool Counter                                     X50            CMD21-26          139Arm Up                                              X51            CMD21-42          140Arm Down                                         X52            CMD21-10          141Pot Up                                                X4               CMD12-5            142Pot Down                                           X2E            CMD12-14          143Manual Magazine Rotation              X48            CMD22-1             121X+OT                                                  X28            CMD12-12           125XDEC                                                 X18            CMD12-24           126X-OT                                                   X20            CMD12-47           1274th Axis Clamp                                  X53            CMD22-27           150Foot Switch                                        X46            CMD22-38           128Z+OT                                                   X2A            CMD12-45           129Z-OT                                                    X22            CMD12-32           130ZDEC                                                  X1A           CMD12-7              131

YDEC                                                  X19            CMD12-39           132Y+OT                                                   X29            CMD12-29           133Y-OT                                                    X21            CMD12-15           134Chip Conveyor                                   X42            CMD22-22             93Optional Stop                                     X43            CMD22-37             94Coolant                                               X44            CMD22-5                95Key Switch                                          X45            CMD22-23              96Dry Run                                               X3C            CMD11-2                89Man/Abs                                             X3D            CMD11-9                90Machine Lock                                    X40            CMD22-36              91Override Cancel                                X35             CMD11-5                84Single Block                                      X38              CMD11-14             85Block Delete                                      X39             CMD11-1                86ZNG (Z Axis Neglect)                        X3A             CMD11-8               87Cycle Start                                          X24              CMD12-16            78Feed Hold                                          X25              CMD12-49            79+Jog                                                    X26               CMD12-17           80-Jog                                                     X30              CMD11-10            81Auto Reference                                  X33              CMD11-11            82Program Restart                                X34              CMD11-18            83Spindle Start                                      X16               CMD12-28           70Spindle Stop                                      X17               CMD12-44           71X (Handle)                                          X1F              CMD12-9              74Y (Handle)                                          X2C              CMD12-30            75Z (Handle)                                          X2D              CMD12-46            764 (Handle)                                          X2F              CMD12-31            77Handle Multiplier (X1,X10,X100)    X1D              CMD12-8              72                                                            X1E              CMD12-41            73Memory Mode                                   X5                CMD12-23             51Tape Mode                                        X6                CMD12-38             52MDI Mode                                          X7                CMD12-6               53Jog Mode                                          X8                CMD12-1               54Rapid Mode                                      X31              CMD11-17             55Handle Mode                                    X9                CMD12-19             56Reference Mode                              XB                CMD12-2               57OUTPUTSFUNCTION                             ADDRESS     CONNECTOR       WIRE#CR1   (Chip Conveyor)                Y1A               CFD13-7               1CR2   (Hydraulic Pump)               Y0                 CFD13-36             2CR3   (High Speed)                     Y1                 CFD13-4                3CR4   (Coolant)                             Y2                CFD13-22              4CR5   (Sleep Switch)                   Y3                 CFD13-37              5CR6   (Low Gear)                         Y5                 CFD13-23              6CR7   (High Gear)                        Y6                 CFD13-38              7CR8   (Tool Release)                   Y7                 CFD13-6                8CR9   (Air Blow)                           Y10               CFD13-26CR10  (Taper Air Solenoid)        Y11               CFD13-42CR11  (Magazine Rotation)        Y12               CFD13-10CR12  (Arm 70 Degrees)            Y13               CFD13-27CR13  (Arm Down)                       Y14               CFD13-43           13CR14  (Arm Up)                            Y15               CFD13-11           14

CR15  (Arm 180 Degrees)          Y16               CFD13-28           15CR16  (Z Axis Brake)                   Y17               CFD13-44           16CR19  (Pot Down)                        Y22               CFD13-32           50CR20  (Track Lube)                      Y9                 CFD13-19           23The E-Stop button is in series with the Sleep Switch relay (CR5).Solenoids on MCV-2300:SOL1     Low GearSOL2     High GearSOL3     Tool ReleaseSOL4     Air BlowSOL6     Magazine RotationSOL7     Arm 70 DegreesSOL8     Arm DownSOL9     Arm UpSOL10    Arm 180 DegreesFor machines in general if you have trouble with leaving chatter marks orother poor finishes make sure the gibs are not too loose because loose gibsWILL cause this problem.If you have a machine that the tool gets stuck in the spindle, check thetemperature rise of the spindle. Thermal expansion will cause the tools tosometimes stick.On the Chevalier 2040MV with Fanuc 0-MD control, if reference return is comm-anded on the X axis while the dog is on the switch, the axis will move in theplus direction until it comes off of the switch then it will reference returnThe X axis decel switch for this machine is SQ3. The wires on the normallyclosed switch are +24 and 97. The cable pin out in the case of a Fanuc 0-MDcontrol is M201 pin 38 of the I/O board. The diagnostic bit is 16.5, itshould be 1 when the dog is not on the switch.For repair of Mitsubishi, Mazak and Yaskawa motors contact Driesilker inIllinois at 630-469-7510.On a Kiwa KNH-426X, if you get alarm 1300 NO PALLET SITTING CONFIRMATION whenthe machine tries to execute it's warm-up program, check the value of timernumber 38 (No.38) in the case of an 18i control. On the TIMER page this isNo.38 T72. The value is in milliseconds. The machine may come from thefactory with this timer set for 1000 (1 second). This time is sometimes tooshort to allow the air pressure switch to be activated. The switch is PS5.It's bit is X6.6, symbol is PSPLSA. This bit is made high by relay CR28being energized. CR28 is energized when 24vdc is applied to it's coil throughPS5. The timer box is on the rung with the alarm, it is:SUB 3TMR       38The air supplied to this machine should normally be between .5 and .55 Mpa.Also, on this Kiwa, if the spindle will not start and coolant pumps one, twoand three will not start but there are no alarms, check the door that isbetween the ATC and the spindle. If this door is not fully closed so that theproxomity switch is made, the spindle and the pumps will not start but noalarms will be generated.Bridgeport Interact 412 with Heidenhain TNC 2500 control:If either the X axis or Y axis faults, it is possible that when the servoscut out and before the Z axis brake can engage, the head can drop a little

causing a GROSS POSITIONING ERROR alarm instead of the X or Y DRIVE FAULTalarm. The way to prevent this is to block the head so it can not drop.Anytime one of the motors moves without being commanded to do so will gener-ate the GROSS POSITIONING ERROR alarm.The AXIS FAULT alarm can be either the motor or the servo card. The driversused on this machine are made by Bosch. It is a conventional system whichconsists of a chassis with a power supply card and three axis drive cards.The axis cards are identical and can be slid in and out of the chassis with-out removing connectors. These cards have the usual potentiometers such asTach and Offset adjustments. The motors are DC with a permanent magnet field.They have encoders attached to the back and a tach. The motors are made bySEM. The type is MT30M4-24. The output from the drive cards go to the mainboard of the chassis before going to the motors. At the upper left hand corn-er of this board there are six wires (two for each motor) where the outputof the board can be checked. From here one of the leads goes through a chokethen to the motor. There are also three connectors at the bottom of the mainboard which correspond to the three drives. these connectors are the tach andencoder wires. These connectors can be unplugged and swapped with one anotherfor testing.The encoders model number for X and Y are ERO 115-200. For Z it is ERO 115-125. The first number (115) is the series of encoder. The second number (125or 200) is the Line count.Machine Parameter 330.0, 330.1 and 330.2 for X,Y and Z tells the controlwhat the line count is, that is, it works with the ball screw pitch parameterto measure correctly. If at some point you have to use a motor with the wrongencoder line count you can try changing this parameter to make it measureproperly.The access code to get into the Machine Parameters is 95148.On a machine with a DC motor driven axis, roughness can be caused by either acommutator problem or grounded armature. This can cause a loud growling thatsounds a lot like a thrust bearing problem.On a Heidenhain TNC2500 control you can check for an IN-POSITION problem byusing the LAG display. You have to set parameter 1390 from 0 to 1 in order tosee the true lag, be sure to set it back when you are done. You check thesame way you would any other lag display, when moving at a fairly high pro-grammed feed rate and look for it to level off and remain constant. Also needsto be the same in both directions of axis travel. When the axis is at rest,should be as close to zero as possible and not moving around. Another thingis for any axes that perform linear interpolation together such as X and Y tohave the same lag value.On a Heidenhain TNC124 the alarm GROSS POSITIONING ERROR means that the valueset in machine parameter 1720 (MP1720) has been exceeded. When setting thisparameter it is recommended to use the value of the Lag for the axis duringrapid multiplied by 1.4 but will often be set considerably higher by the OEM.MP1720 is a bit parameter, 1720.0 for first axis, 1720.1 for second axis, etcSome Heidenhain controls use Position Coded Reference Marks on the scales.These allow the machine to know where an axis is by moving just far enough,usually an inch or two, to find the nearest coded mark. This is the normalReference Return procedure for some machines with Heidenhain controls. Whenreference return is commanded the axis will move just a little until it findsthe mark then position itself based on that mark. This way no battery is

required as in the case of rotary absolute encoders.Dainichi with Fanuc 10T control:When cycle start is commanded, message START REJECTED is displayed. Rapidsare not available, the machine acts as though the axes have not been refer-ence returned even though the ZRN lights turn on after homing. Also, thebuzzer that should beep during boot up does not beep. Check for a break inthe connection of N24. The machine will act like the command to cycle startis being sent form the PLC to the NC but the NC is not executing. For spindle orientation problems on machines using a magnetic sensor checkthe file FANUC.TXTMori-Seiki MH-63It uses four I/O modules that plug into a backplane along with a controllermodule and a power supply. The first two modules from the left are outputmodules. They are Fanuc OD24A 24 vdc modules. Each has two 50 pin Honda con-nectors. The Fanuc designation for the ports are C21A and C21B. The Moridesignations are C007 and C008 respectively. The second module is C005 andC006 on C21A and C21B. The input modules are ID24A. The first module hasC003 and C004 on ports C20A and C20B. The last module has C001 and C002 onports C20A and C20B. Next on the rack is the rack controller IF01A. It plugsinto the backplane like the other modules and has only one cable COP4. Thisis a fibre optic cable that goes to port COP2 of the main board. COP1 of themain board goes to COP3 of the CRT/MDI. The last module on the rack is thepower supply. It has no connectors but there are four terminals on the rackitself. They are from top to bottom ALC, ALC, 24NC and 0NC. If the lights onthe operator's panel don't work check the cables and connectors of C003 andC004. The schematic shows a C208 but I have not been able to find it on themachine.Mori-Seiki MV Junior with Yasnac MX2 control: If you get a 391, 392 or 393TG/OC/OV ERROR for X, Y or Z axis respectively, check the servo amplifier forthe axis. One of the LED's will be on, either OV, OC or TG. There is also anLED for FUSE and one for OL. The TG LED indicates a problem with the Tacho-generator. Normally the alarm 310 SERVO OFF will be displayed along with theother alarm. Servo tuning on these drives is done by adjusting pots on thetop board. One of these pots, 16VR, sets the trip level for the above alarm.Setting this pot to the minimum (fully CCW) will cause the alarm to trip assoon as the servo power comes on. The LEDs are all red.TG LED: Check the in-position signal. On the Yasnac MX2 control this is doneby going to the position screen and scrolling down to the proper screen.Also check the power supply voltages at the drive(+5,+12,+15,-15,+24).All of these voltages are supplied by a single power supply and all can beadjusted separately by potentiometers on the front of the power supply.The tachogenerator operates off of the 5 volt power. You can monitor thetacho input to the drive at TG-M. This is the TG MONITOR. The signal is ref-erenced to ground. The output of the tach is 7 vdc per 1000 rpm +/-15%.As far as adjusting pots, you can try turning IN-ADJ(2VR) one notch counter-clockwise. Also, try L-GAIN(4VR). Be careful adjusting the IN-ADJ pot sinceit is very sensitive, one notch too far can cause the axis to fault or tooscillate violently. Oscillation is normally associated with moving the potCW. There is a pot to the right of this pot (FINE) which is a fine adjustmentfor IN-ADJ. Also, adjusting the IN-ADJ pot can cause the TG fault to be gener-ated. It is important to note that very slight changes in just some of the

potentiometers can cause what looks like serious servo problems. Anotherpoint of interest is that having the L-GAIN and/or IN-ADJ pot out of adjust-ment can cause the 341 (in the case of the X axis) but if the one of the potsis moved a little further, the alarm will change to 391 with the TG indicatorcoming on. If you suspect that the pots have been moved it may or may nothelp to set them back to their original positions (paint mark) but it's agood place to start. What usually works better is to set all of the pots thesame as an axis that is working properly. This is especially true if you areworking on the X or Y axis of a vertical mill because these two axes shouldneed virtually identical settings. When setting the pots this way, pay atten-tion to the dial marks of the pot. There are two dots on one end of the screwslot, make sure this end of the pot is in the same position as the go-by.Once you get close, you can use the IN-ADJ, FINE and L-GAIN to dial it in.The best way to do this is to set the thumbwheel switch to position 4 (TEST).When set to this position, go to the POSITION page of the CRT. Keep pressingthe PAGE DOWN button until the ERROR PULSE screen is displayed. When youmove the X and Y axes at the same feed rate, you should get the same value onboth. If you don't, adjust IN-ADJ and/or FINE until you do. This is partic-ularly useful when you have an axis that runs fine at 25% or 50% rapid butnot at 100% rapid without generating either alarm 391 or 341 (for X axis).In most cases if you go to the ERROR PULSE screen and set it the same as agood axis, when you get finished you will usually be in good shape. Initiallyyou may have to make the adjustments while in 25% or 50% rapid. Also, if theERROR PULSE display of an axis is very far from zero while at rest you canbring it to zero with the ZERO pot. For vibration or oscillation of an axisat certain feed rates you can try adjusting 6VR C.FRQ-ADJ, this changes thecarrier frequency to avoid noise and roughness caused by resonance.For service issues on Yasnac controls call 1-800-YASKAWATo change parameters on the Yasnac MX2 you must set the thumbwheel switch to1. It is normally set to 0. The thumbwheel switch is just below the controlin the electrics cabinet. Once the switch is set cursor to the parameter youwant to change, type the value you want then press the WR button. Setting thethumbwheel switch to some of it's other positions will allow access to otherscreens of the control not normally seen when the switch is in position 0.If the tachometer leads are reversed the axis will runaway when servo powercomes on.The drives, motors and feedback units are all Yaskawa. The motors are DC.The feedback unit consists of an encoder and a tachogenerator. Complete lossof feedback such as the feedback unit being disconnected will cause the axisto runaway, usually in the positive direction, as soon as servo power comeson. If you replace one of the units, you have to orient it the same as theold one to keep it from over traveling at zero return. This can be done bypositioning the set screw that holds the optical disk on the same as the oldone. To access the leads to the tachogenerator, remove the cover on the veryback of the motor by removing the two small screws.Motor:YaskawaHicup MotorUGHMED-06-MC13Drive:Yaskawa

ServopackCPCR-MR085K2Feedback UnitYaskawaFeedback UnitTFUE-25ZD7Parameter 6280 sets the X Axis Rapid Feed rate, 6281 sets Y, 6282 for Z.Yasnac controls are made by Yaskawa.When working on servo problems, there is a RESET button on the Servo pack soyou don't have to keep cycling power to clear faults.The following list is the potentiometers of the Yasnac Servo pack CPCR-MR085K2servo amplifier and what I know about them:1VRAuxiliary Input AdjustmentAdjusts speed reference and motor characteristics when auxiliary input 2CN(1) 2CN(2) is used. Turning 1VR CW increases speed. If the auxiliary input isnot used turn 1VR fully CCW.2VR IN-ADJMotor Speed AdjustmentAdjusts speed reference and motor characteristics when speed reference issupplied to 1CN(7) and 1CN(13). Turning 2VR CW increases motor speed. Checkthis signal at terminals IN-M and TG-M.3VR ZERO ADJZero Drift AdjustmentAdjust this to keep the motor from turning when the speed reference is 0V.Turning the pot CW allows the motor to be finely adjusted in normal rotationand CCW in reverse rotation. Observe the rotation of the motor until it is atstandstill when reference is 0V.4VR L-GAINSpeed loop Gain AdjustmentAdjusts proportional gain. Turning this pot CW increases gain. Monitor thissignal at CUR-M and TG-M.5VR C.GAIN-ADJCurrent Loop Gain AdjustmentTurning this pot CW increases the current loop gain. Increase the gain untilthe hunting of starting current stops. This signal is a square wave and canbe monitored at CUR-M.6VR C.FRQ-ADJCarrier Frequency AdjustmentTurn this pot CW to increase the carrier frequency. Adjust this pot when themotor noise and roughness is excessive due to frequency of the carrier is inresonance with the natural frequency of the mechanical axis. Observe thissignal at OSC-M.7VR C.LIM-ADJStarting Current AdjustmentYaskawa recommends against adjusting.Turning this pot CW increases starting current. Check this by monitoring theactual motor current during ramp up. This is basically a torque setting.8VR OS-ADJOverspeed Detection Speed Adjustment

Sets the speed at which overspeed detection is activated. Turning the pot CWincreases the speed at which overspeed detection is activated. Normally, setthe overspeed detection speed at 120 to 140% of the motor rated speed. Thissignal can be monitored at TG-M and OS-M.9VR OL-ADJOverload Detection Current AdjustmentYaskawa recommends against adjusting.Sets the operating current overload detecting circuit. Turning this pot CWincreases the operating current and operating time.10VROverload Detection Offset AdjustmentYaskawa recommends against adjusting.Adjusts the offset of current detection circuit. Turning this pot CW incr-eases output. Adjust this pot so that the overload detection output is 0V whenthe motor current is 0 amps.11VRCurrent Detection Circuit Offset AdjustmentAdjusts the offset of current detection circuit. Turning the pot CW incr-eases output. Adjust so that the signal at CUR-M is 0 volts when the motorcurrent is 0 amps.12VRCurrent Detection AdjustmentYaskawa recommends against adjusting.Turning this pot CW increases output. Adjust 12VR so that the signal at I-Mis 2V when the motor is operating at 100% of it's rated current. If this potis set too high, overload detection operates prematurely, if it is set toolow, the overload function does not operate.16VR TRIP-ADJTrip Voltage SettingYaskawa recommends against adjusting.This pot adjusts the main circuit voltage at which an alarm is issued. Analarm should be issued when the DC voltage in the main circuit exceeds 400V.Turning the pot CW increases the voltage at which the alarm is issued. Setthis pot so that the signal at TV-M is 2.85 volts. Improper adjustment ofthis pot can CAUSE DAMAGE TO THE SERVO UNIT!The following is a list of Test Points:SG0V Signal 0V0 volt common terminal for waveform observation.IN-M (CH4)Input MonitorFor monitoring speed reference input.TG-M (CH5)TG MonitorFor observing the TG output waveform from transient speed. Should be 7vdc+/-15% at 1000 rpm.S.AMP-M (CH6)Speed Amplifier MonitorFor observing the current reference (speed deflection amplified waveform).OSC-M

Triangle Pulse OSC MonitorFor observing the operation of triangle waveform pulse oscillator which det-ermines carrier frequency. This waveform has a positive peak of +4 volts anda negative peak of -4 volts. The cycle time is 1.0 milliseconds.CUR-M (CH1)Current MonitorFor determining the amount of current being drawn by the motor armature.Use this table to discern how many amps are represented per volt based on theservo model.Servo Model        Amps per VoltMR054K             12.1 A/VMR050K             18.9 A/VMR084K             14.4 A/VMR080K             18.9 A/VMR154K2            18.9 A/VMR154K             24.2 A/VMR220K             30.3 A/VMR374K             32.6 A/VMR370K             53.0 A/VI-MI MonitorFor detecting motor armature current. Output should be 2 volts when motorcurrent is at 100%.V-MV MonitorFor detecting motor speed.Should be 3.6 volts +/-15% per 1000 rpm.1DR-M1 Drive MonitorFor observing the signal driving 1Tr. This signal is a square wave, the pos-itive peak is +8 volts, the negative peak is -8 volts.2DR-M2 Drive MonitorFor observing the signal driving 2Tr. Square wave +8 volts to -8 volts.3DR-M3 Drive MonitorFor observing the signal driving 3Tr. Square wave +8 volts to -8 volts.4DR-M4 Drive MonitorFor observing the signal driving 4Tr. Square wave +8 volts to -8 volts.OS-MOverspeed MonitorSets the speed for overspeed detection.270rpm/Volt +/-10%OL-MOverload MonitorSets the level for detecting overload.Set at 0.343 Volts.TV-MTrip Voltage MonitorSets the level of the trip voltage. To measure this voltage, observe the dec-

ibel 0V connected to 024. Yaskawa recommends against adjustment.The following is a list of the LEDs and what they mean:POWERGreen LEDPowerIndicates that 200 volts is applied to the main terminals R and T.INGreen LEDSpeed Reference InputIndicates that the speed reference is being input.TGGreen LEDMotor RotationIndicates the motor is rotating. Use output of tachogenerator.TGRed LEDIndicates activation of TACHOGENERATOR failure detection circuit.If the LED comes on and stays on when control power is applied to powerterminals R and T, the Servopack is probably defective. If TG comes on andstays on and the motor rotates when main circuit power is applied, check forone of the following:Tachogenerator failureTachogenerator cable open or shortedTachogenerator leads reversedMotor leads reversedIf TG turns on when the feedrate is increased check the value of the OverspeedSetting, may be necessary to adjust 8VR (OS-ADJ).OCRed LEDIndicates activation of OVERCURRENT detecting circuit.If OC comes on and stays on when control power is applied, the Servopack isprobably defective. If OC comes on and stays on when main circuit power isapplied, check for a short circuit of the DC Reactor, a gounded Motor or adefective power transistor in the Servopack. If OC comes on when the motor isstarting and/or stopping, check the adjustment of potentiometer I.LIM-A.OVRed LEDIndicates activation of OVERVOLTAGE detecting circuit.If OV comes on and stays on when the control power is applied, the Servopackis likely defective. If it turns on while the motor is stopping, the GD2 loadis too great or the wrong type of regenerative unit is being used.OLRed LEDIndicates activation of OVERLOAD detecting circuit.If this LED turns on when the control power is applied either the Servopackis defective or the Thermostat circuit has failed. If it comes on when themain circuit power is applied but the motor is not started check for a lockedrotor condition. If the LED comes on while the motor is running, check for anoverload condition.FUSERed LED

Indicates blown fuse.If this LED comes on replace the blown fuse. If it blows again there is like-ly a defective power transistor.The Yaskawa Servopack has three green LEDs. From top to bottom they are:TGINPOWERThe POWER LED should be on whenever servo power is supplied.The TG should be on when the tach signal is being received.The IN LED should be on when the axis is in motion.Both TG and IN normally come on when the axis starts and moving and more orless increase in brightness as feedrate goes up. In any case, they will bothburn bright when the axis moves in rapid.On the Mori-Seiki MV Junior, the Z axis servo is a single amplifier. The Xand Y axes are controlled by one dual amplifier.Power Supply LEDsPOWERGreen LEDIndicates 200 volts is applied to control power terminals R and S or R and T.ALARMRed LEDIndicates that the power supply is defective or the regenerative resistorunit is not connected.If the ALARM LED of the power supply turns on when the control power is app-lied, the power supply is probably bad. If the LED turns on approximately.5 to 1 second after the main circuit power is applied there is likely a pro-blem with the either the regenerative resistor unit or the regenerative tran-sistor. Check the resistance at terminals R1 and R2.

 Heidenhain TNC124:        The alarm CONTAMINATION Z AXIS (or X Y, etc.) means that the signal        from the scale is too low. Normally, this alarm can be cleared with        the CE button and you can continue running.If you need to operate this control without the interference of the scalefeedback such as when tackling sevo problems, you can make the control run inOpen Loop by applying 24vdc from the power supply to Input 7 (Pin 8 of X42).

PWM Servo AmplifierServo DynamicsModel: SD1-3060-162-1P/N: 3300-0106Potentiometers:AUXILLARY INPUT ADJUSTMENTSIGNAL INPUT ADJUSTMENTTACHOMETER INPUT ADJUSTMENTCOMPENSATION ADJUSTMENTCURRENT LIMIT ADJUSTMENTBALANCE ADJUSTMENTThese are all multi-turn pots accessible from the front of the amplifierwithout removing the cover.RMS ADJUSTMENT

This is a single turn pot for adjusting the RMS output. It is located on thebottom of the board on the left side. The cover must be removed to access it.The initial setting for these pots is:AUX - Fully CCW.SIGNAL - 10 turns from fully CCWTAC - 7 turns from fully CCWCOMP - 10 turns from fully CCWCURRENT LIMIT - Fully CCWBALANCE - 10 turns from fully CCWThe Current Limit pot will have to be increased right off the bat since it isnow set way too low for the motor to run.The motor output terminals should measure about 3.4 meg between each other.You can run the servo without using the tach by disconnecting it from thedrive and shorting between pins 1 and 2 on connector J3. If there is a prob-lem with the tach or the tach circuit this will allow the motor to run moresmoothly. The motor will have very little torque(gain) due to the fact thatthere is no tach in the circuit to tell the drive that the motor has sloweddown. You can acheive more gain by using a resistor instead of a junper, buttorue will still be lacking. The resistor shoul be from 10k to 100k ohms.LED's:OVERVOLTAGE/LOSS OF +15 INDICATIONGROUND FAULT INDICATIONOVERTEMP/EXCESSIVE RMS INDICATIONTRANSISTOR SURGE INDICATIONIf the OVERTEMP/EXCESSIVE RMS INDICATION alarm issues causing the drive toshut off, you can try working with the RMS ADJUSTMENT potentiometer. Thisalarm is normally issued because the output exceeded 30 amps for a set periodof time. It can also be caused by excessive temperature of the heatsinks ofthe output transistors. You can monitor the output current at J1-P5. This isa 0-10 vdc signal which is proportional to the output current, 10 voltsequals 60 amps. The signal is referenced to chassis ground. For this alarmcheck the armature for a grounded condition. Excessive fault current shouldcause the GROUND FAULT INDICATION fault but sometimes will not.For other questions about this drive call Servo Dynamics at 818-700-8600.On any machine that uses DC servo motors, if the motor does not have as muchpower as it should or if the feedrate has to be reduced to keep the servofrom faulting, check the armature for a grounded condition. In this case, afault current can flow causing the lack of power or faulting.Also, when working with DC servo motors keep in mind that the voltage appliedto the motor is not true DC. It is rectified or pulsating DC. This means thatthere is a frequency component to the voltage, also called carrier frequency.In situations where this frequency closely matches the natural vibration ofthe machine at certain feedrates and/or at certain locations on the machine,resonance occurs and can cause excessive noise and vibration. This can beadjusted out if you find the correct potentiometer or parameter. In the caseof a Fanuc control, use the Filter Parameter, for example. This conditionexplains why a new machine can develop noise and vibration of a particularaxis after a few days or weeks of operation or why a machine may behave thisway after many years. Mechanical conditions change, floors settle, etc.Of course, the same thing can be observed on an AC servo system.YASNAC MX3 PARAMETERS

6219Parameter Write Enable Switch                    0 = Parameters Locked                                                                          1 = Write Enabled6004 D3Programs O8000-O8999                               0 = Can be displayed and edited                                                                          1 = Cannot be displayed or edited6006 D0Automatic Coordinate System Setting         0 = Disabled                                                                          1 = Enabled(Also refer to 6015, 6630 - 6639)  6006 D2Dry Run                                                            0 = Jog Feed                                                                          1 = Rapid6007 D7Reset After Editting                                        0 = Required                                                                          1 = Not Required6008 D5O Number with ALT Command                     0 = Not Changeable                                                                          1 = Changeable6015 D0-D4Automatic Coordinate System Setting         0 = OffX=D0, Y=D1, Z=D2, 4th=D3, 5th=D4           1 = On6021 D2Program Displayed When Power On            0 = Program O0                                                                           1 = Same Program at Power Off6021 D0M2, M30 and M99                                            0 = Not Seen as End of Program                                                                           1 = Seen as End of Program6021 D6Loading RS-232 Program Already                0 = ALREADY IN Alarm Issuesin Memory                                                         1 = Writes Over Program6021 D7Editting of Programs O9000-O9999             0 = Enabled                                                                           1 = Disabled6022 D5Display of Programs O9000-O9999             0 = Enabled                                                                           1 = Disabled6022 D6Binary Search in Edit/Memory Mode             0 = Disabled                                                                           1 = Enabled6066 D6Condition at Power On                                    0 = M96                                                                           1 = M976304X Axis Grid Shift Amount6305Y Axis Grid Shift Amount6306Z Axis Grid Shift Amount

63074th Axis Grid Shift Amount63085th Axis Grid Shift Amount6400X Axis Backlash Amount6401Y Axis Backlash Amount6402Z Axis Backlash Amount64034th Axis Backlash Amount64045th Axis Backlash Amount6630X Axis Inch Value for Automatic Coordinate System Setting6631Y Axis Inch Value for Automatic Coordinate System Setting6632Z Axis Inch Value for Automatic Coordinate System Setting66334th Axis Inch Value for Automatic Coordinate System Setting66345th Axis Inch Value for Automatic Coordinate System Setting6636X Axis Metric Value for Automatic Coordinate System Setting6637Y Axis Metric Value for Automatic Coordinate System Setting6638Z Axis Metric Value for Automatic Coordinate System Setting66394th Axis Metric Value for Automatic Coordinate System Setting66405th Axis Metric Value for Automatic Coordinate System SettingOn a Strippit SPM500, there is a top and bottom carousel for the punches.They are mechanically independent with seperate drive trains but driven by acommon motor and common shaft. There is a plate at the motor with four posit-ions. The motor must stop at one of these positions regardless of which ofthe ten tools are called up. A Yamatake Honeywell proximity witch is used fordetecting this position. The plate is basically a round piece of sheet metalwith four notches cut the width of the proximity switch 90 degrees apart.When the motor stops, the switch should be positioned in one of these slots.The bottom carousel has a flat piece welded to the bottom which is detectedby a proximity switch. This proximity switch appears to be the home positionfor the carousels. Each carousel also has a shot pin which is driven by apneumatic solenoid into an alignment hole for each position. The top shot pindrives down into the holes, the bottom one drives up into the holes. Eachair cylinder has has two proximity switches, one for in and one for out.Sometimes the carousels will stop in between positions, additionally, theymay not be aligned with one another. This normally occurs as a result of a

punch getting hung up in the part. One condition which can make this situat-ion worse is if the two carousels are in tension with one another. That is,if the tension and direction of tension of one of them is acting to pull theother one. Once the carousels have gotten out of position with one another youshould take the  chains loose so you can move them indepently. Push both shotpins out of the holes, you may have to turn the air off. Move the bottomcarousel so that the dog is aligned with the proximity switch then move thetop carousel to the position which corresponds to this. Push the shot pinsinto the holes. Loosen the sprocket at the top of the drive shaft. This isa taper lock sprocket. Release the taper enough to allow the sprocket to spinon the shaft. This will let the chain center itself while being tightened soas not to pull the lower chain and put the two in tension with one another.Now, with carousels aligned and shot pins in, you can tighten the chains. Itmay be necessary to loosen the tension on the chain from the motor to thedrive shaft but it may not. The entire drive shaft and motor are mounted on alarge plate bolted to the machine with four bolts. There are two jack screws,one on the top and one on the bottom. Adjust the chains to the proper tensionone at a time making sure that the chain is riding in the sprocket and in thecenter of the idlers. Once the plate is tightened back down tighten the topsprocket. If you did everything correctly you can pull the shot pins back oneat a time and the carousels will stay in alignment. If you did not do it allcorrectly when you pull a pin back, the carousel will spring back, beingpulled by the chain tension. Last but not least make sure the plate is posit-ioned over the proximity switch at the motor. You can loosen the four screwsthat hold the plate and move it into alignment. A good thing to do once youfinish is to tighten all of the sprockets then use a permanent marker to puttiming marks on every moving part so that if something ever slips you willknow what moved relative to what.ACU-RITE MILLPOWER:Has motors like SWI, the sevo amplifier is attached to the motor. The scaleplugs into this amplifier via a D subminiature connector. The servo power(120 vac) is sent from the pendant to the Y axis motor assembly, then jumpsfrom there to the X axis, then to the Z axis. There is a connector on the Zaxis motor like the rest of them for servo power out but is capped. This is aconvienient place to check the servo power. If an axis seems to be losingservo power check these screw on amp connectors. The servo power in to eachmotor is a strain relief connector. The encoder cable on the motor is alsoa strain relief, the cable goes back to the pendant where it is a D submini-ature conector.CHEVALIER SMART 818:Uses Syntec Baby-1 PC Controller and Mitsubishi MR Servo Amplifiers. Thiscontroller operates on 5vdc and 12vdc like other PC controllers but does notuse a typical switching power supply. It has a power supply mounted againstthe back wall behind the controller. Sometimes a machine may start re-bootingon it's own. This can be caused by the 5 volt signal being too low, it needsto be 5.1 volts. There is a potentiometer (VR1) to adjust this voltage. Thepower supply is accessed by removing the two philips head screws on the topof the controller about halfway back. Now the entire controller can be liftedup and pulled out of the way, the bottom screws are in keyhole slots. Youwill need a small screwdriver. You can monitor the voltage either at the testpoints on the mother board or at any of the spare connectors. These are like

any other PC, a plug with a red and black (5vdc) and a yellow and black (12vdc).On the Hyd-Mech saws with the PLC100 you can access the special functionscreens (status, etc.) by presssing the Start button while powering up themachine. On the PLC500 you hold the clear key while powering up.If a DC motor controlled axis moves with a jerking motion check the tachfeedback. In addition to this a tach problem can cause a machine to havetrouble finding it's position, often overshooting or undershooting. Sometimesthis can be compensated for if the drive has a tach adjustment. If a tacharmature has an open winding it may run fine at high rpm but very rough atlow rpm. If the rpm is reduced to a very slow rate the motor may be seen torotate normally through part of the revolution then take off at a high rateof speed, then slow back down and repeat the cycle. This is due to the drivelosing the feedback signal during the time that the open winding is in cont-act with the brushes. This can be detected by measuring the resistance of thewindings and slowly rotating the motor. In some cases the tach can be elimin-ated from the circuit by disconnecting the tach leads from the drive andeither placing a jumper across two pins, moving a shorting pin, flipping aDIP switch, etc. to put the drive into open loop control. If the tach is theproblem the motor will now run smoothly but without tach feedback the gainwill be almost nothing so the motor will have very little torque. For generalinformation on DC drives you can check file AUTO.TXT. Much of the informationon Servo Dynamics can be used for servo drives in general.If you need the password for a Hyd-Mech saw, try one from this list. The num-ber on the left is the Hyd-Mech Program Name.PROGRAM            PASSWORD100Lv1.0           1197100Lv1.1           0198100Lv2.0           0598100Lv2.1           0699100Lv2.2           1099100Lv2.3           1099100Lv2.4           0500 (102)100Lv2.5           0301 (102 Battery Password)50PEv2.1           099850PEv2.2           019950PEv2.3           129950PEv2.4           0700100Ev1.1           0198100Ev1.2           0198100Ev1.3           0598100Ev1.5           1098100Ev2.0           0698100Ev2.1           1098100Ev2.2           1198100Ev2.3           1198100Ev2.4           0399100Ev2.5           0699100Ev2.6           1199100Ev2.7           0500100Ev2.7a          0500

100Ev2.8           0301100Ev2.8a          0301100Ev2.9           1001100Ev1.4           0698100LEv2.0          0698100LEv2.1          0199500MEv1.0          0398500Mv2.0           0698500Mv2.1           1198500Mv2.2           0399500Mv2.2a          0499500Mv2.3           0699500Mv2.4           1099500Mv2.5           0300500Mv2.6           0600500Mv2.7           03022100v1.0           0801 (Batt Low 1099)2100v1.1           1001 (Batt Low 1099)For Mitsubishi PLC E200 password is 801.Mori-Seiki MH63OVR ON (Red LED) comes on anytime the Feed rate Override is set on anythingother than 100%.On this machine, if the following alarms are displayed at the same time checkcircuit breaker NFB4, it is likely tripped. A possible cause for this is aproblem with the coolant motor. The alarms are:SV103 Y IMPROPER V READY OFFOT100 SPINDLE ALARMEX04 COOLANT PUMP OVERLOADIf this breaker is already tripped when the power is turned on you will norm-ally see:OT100 SPINDLE ALARMSW000 PARAMETER ENABLE SWITCH ONThe Johnford TC-20 with the Fanuc 0-TC control uses Baraffauldi TOE-160/12-3twelve station turret, part number 12-4811-14. This turret has a VDI tooldisk. It looks and operates much like a comparable Duplomatic turret. It hasa 220 vac electric motor for indexing. It has a solenoid activated shot pinwhich is top mounted much like the Duplomatic. When the round plate on top ofthe turret is removed, there is access to the proximity switches for the shotpin and the locking. Just like the Duplomatic, when this turret indexes onecontactor energizes to rotate the turret. Once in position, this contactordrops out, the other one energizes momentarily to back the turret up whichallows the shot pin to go in. Before the turret indexes, the shot pin is upwhich means the proximity switch is clear of the flag. The associated wirenumber 10 is 0vdc and diagnostic bit 17.1 = 0. This proximity switch ismounted to the left horizontally and can be viewed in it's entirety. Also atthis time the locking proximity switch will be made. It's associated wirenumber 11 will be 24vdc and it's associated diagnostic bit 17.2 will be 1.This switch is mounted to the right of the other switch and is mounted vert-ically. There is very little visible other than the LED on the back of theswitch. The binary representation of the tool number output by the encoder isat Diagnostics 16.0, 16.1, 16.2 and 16.3. The wire numbers are 32, 33, 34 and

35. The other two outputs from the turret encoder are Strobe which is wirenumber 48, diagnostic 17.0 and Parity which is diagnostic 16.7, wire number40. Another signal is Y51.6, this is the output for the brake. It's associat-ed relay is R3. This bit should be 1 at all times except when the turret isindexing. The relays for CW and CCW of the indexing motor are R1 and R2.On the machine schematics the shot pin is called "Pre-indexing". When theturret is at rest the Parity and Strobe bits should be 1 but the turret willindex if the parity bit is 0. The encoder is like the Duplomatic in that itmounts horizontally on the indexing shaft and can be adjusted by looseningthe two hold down screws and turning the encoder until the diagnostics disp-lay the correct tool number and Parity and Strobe equal 1. When commanded toindex, the brake (relay R3) should drop out, the appropriate contactor shouldenergize, the motor rotates to the approximate position, the shot pin goesdown, the motor backs up, the shot pin drops in, the brake turns back on, theshot pin comes back up. I think the shot pin is relay R4, diagnostic Y52.4On a Mori-Seiki MH-63 with the Fanuc 11M control, the Grid Shift Parameter is1850. Adjusting this parameter by adding 1000 to it's value will shift theaxis one millimeter or .03937 inches. The value in 1850 needs to be the sameas in 1816 (Reference Counter Capacity) or less. Normally on these machines,1816 is set for 1001 on bits 0-3, this correlates to 10000.BEFORE USING THE PROCEDURE BELOW BE SURE TO UNDERSTAND THAT THE ATC WILL DOJUST WHAT YOU TELL IT TO, TAKE CARE THAT THE DOOR IS OPEN BEFORE MOVING THETOOL ARM, ETC!!!!!!!!!!!On the MH-63 independent operation of the ATC is possible but is not done byM-Code. Instead Counter Presets are used. The procedure is:1. Select MDI mode.2. Press the NC/PC button (If in PC screen).3. Press the PROGRAM soft key to call up the Program screen.4. Input M31;5. Press the INSERT soft key.6. Press the START button.   (The FEED HOLD lamp will start flashing.)7. Press the NC/PC button to call up the PC display.8. Set the key switch to EDIT.9. Press the PCPRM soft key.10.Press the COUNTER soft key.11.Enter the Preset number which corresponds to the desired operation in   Counter 1 C00. If the machine has more than one magazine, C02-C04 may also   be used.12.Press the INPUT button. (The Preset value will change from zero to the   value you entered).13.Press the FEED HOLD button. (When the selected operation is completed and   the limit switch associated with the operation is satisfied, the Preset   value will once again become 0.14.Once you are finished with the independent operation, resume to normal   operation by executing M32. The FEED HOLD lamp will turn off.Below is a list of operations performed by entering the associated Presetvalue during independent operation:C00(Preset Value)        OPERATION0                        No Operation

1                        Door Opens2                        Main Arm moves toward the Spindle3                        Tool is Unclamped4                        Tool is Pulled5                        Arm Rotates Clockwise6                        Arm Rotates Counterclockwise7                        Tool is Pushed8                        Tool is Clamped9                        Main Arm moves toward it's Original Position10                       Door Closes11                       Main Arm moves toward the Magazine12                       Tool is Pulled13                       Main Arm removes toward it's Original Position14                       Tool is Pushed15                       Magazine Pot is Locked16                       Magazine Pot is UnlockedSome of the operations appear to be duplicated but which value you used isdependent upon the direction of movement. Keep in mind that the arm's home(original) position is not all the way to the magazine but between the magaz-ine and the spindle.Another method for moving the ATC is by using the +/- STEP buttons if themachine is equipped with them. The procedure is:1.Perform reference return (ZRN) for the Y and Z axes.2.Perform spindle orientation.3.Select MDI mode.4.Set Keep Relay K5.4 = 1.5.Execute M31.6.Execute M35.  (The ATCHP and FEED HOLD lamps will start flashing).7.Press the +STEP button to move the ATC forward, -STEP to move it backward.  Once the ATC has moved completely forward with the +STEP then all the way  back to it's original point with the -STEP button, pressing the +STEP butt-  on again will end the step operation and the lamps will stop flashing.If the machine does not have the STEP buttons, make Keep Relay K5.6 = 1 soyou can use the +X and -X Feed buttons in this capacity. SOME MACHINES WILLPERFORM THE STEP OPERATION EVEN IF THE X AND Y AXES ARE NOT AT HOME, GET INTHE HABIT OF RETURNING ALL AXES HOME BEFORE USING THIS PROCEDURE.For Spindle +/- Step Operation make K5.4 = 1 and use M31, M35.For Magazine +/- Step Operation make K5.5 = 0 and use M31, M34.For Sub-Arm +/- Step Operation make K5.5 = 1 and use M31, M34.The Tos SN71 uses mechanical clutches. Both the forward and reverse clutchesare mounted on the main shaft. This shaft is driven directly from the motor.The clutches can be located by following the shaft from the driven pulley tothe left. The forward clutch is the one closest to the pulley. Both clutchescan be accessed and adjusted by means of an access cover located on the BACKof the headstock. The access cover has six screws. This cover can be removedwithout draining the headstock but the machine cannot be run with it off dueto the oil pump. When the lever is placed in either forward or reverse ashifting fork moves a slider which squeezes the plates of the correspondingclutch together. The slider is located at the center of the shaft betweenthe two clutches. The adjustment is very simple. It is a split nut with a

screw which pulls the two ends together. The nut is threaded onto the shaftnext to the clutch. There is a nut for each clutch. To adjust, loosen thescrew and turn the nut, then tighten the screw. To tighten the clutch turnthe nut as you would to tighten on a right hand thread. If you get the clutchtoo tight the spindle will turn in that direction without being engaged. Alsothe lever may not feel right and may not stay engaged.If only one clutch is worn or out of adjustment the spindle will stall or runat reduced rpm in one direction but run fine in the other direction. The nut should turn very easily when you adjust on the clutch. On the END ofthe headstock there is a flange with a T-handle bolt in it's center. This isthe metal oil filter. It should be turned from time to time to keep it clean.You can turn it as much as you want. When changing the oil it should be removedand the buildup removed from it. If you remove it before the oil is drainedyou will have a mess to clean up. The headstock oil is supposed to be MobileDTE Medium (AW46) but AW32 is OK. When the lever is raised the machine runsin reverse, when it is lowered it runs in forward. The fill hole for the head-stock is located on the very top of the headstock.On the KIA KIT30A with the Fanuc 0-Mate control if everything works exceptthe spindle won't run, check the door switch. This switch will keep thespindle from starting but doesn't stop the spindle once it is running. TheDiagnostic bit is 20.0, the wire number is X200. It is fed by wire +24N.This switch does not always show up in the hard copy of the ladder where itshould. There is a rung which ends with the the internal relay coil R639.0which has four instructions showing on the hard copy. The instruction for theswitch should be here but is not.Sometimes you can turn on the Ladder by changing bit 2 of parameter 60.Some of the LNS bar feeders used on the Ecocas have a limit switch on thetrack that it moves back and forth on. If the bar feeder is pushed back andthis switch is not made, the machine is placed in E-Stop mode.If an axis mispositions by the same amount sometimes try to determine if theamount it mispositions by is approximately one revolution of the ballscrew.If it is try to determine if the axis zero returns in the same place everytime. Sometimes the decel dog of an axis can be set so that occasionally theencoder will just miss the marker pulse and make a whole revolution to findit. This will cause the position to be of by one grid space. The problem isnormally noticed when a position is commanded by G54 or some other work coor-dinate. Normally, when this occurs the axis will over travel every time ittries to reference return even after the power is cycled. It will only stopexceeding the soft limit once P+CANCEL has been performed. The long term fixis to move the decel dog away from the zero return point (normally the minusdirection) a little, only .0500 or so.The Toyokoki press brake model 8025W is sold through Mitsubishi Heavy Indust-ries. It uses a TNC-ACII control. It has both Okuma and Panasonic servo amps.For help on this machine you can try Aaron at MC Machinery 630-350-7061.If you get the alarm "UNUSUAL COMMUNICATION" first check all connections be-cause this alarm means just what it says, there is a communication problembetween the OSP and the HP1601. Also check the connections to the servo amps.Another thing to try is a RAM clear. To do this, hold the F5 and F8 keyswhile powering up. If the machine loses it's parameters you need a specialdevice so someone from MC Machinery will likely have to do it.Supertec G30P-100CII

The infeed of this grinder uses hydraulics to move the wheelhead during man-ual operation and a stepping motor for automatic operation. Once the hydraul-ic pump is running, pressing the retract button will cause the wheelhead tomove toward the operator. The normal state of the hydraulic valve causes thewheelhead to be in it's retracted position unless the button is pressed. Ifthe hydraulics are turned off while the wheelhead is in any position otherthan fully retracted, it will retract automatically when the hydraulics comeon. The hydraulic valve is controlled by output Y6 of the PLC via wire number21. If the head is fully retracted when the retract button is pressed Y6turns and the head moves toward the operator. According to Supertec, a timerin the PLC causes the the head to traverse for 5 seconds in either directionbut in observing the machine operating, output Y6 once turned on stays onuntil the retract button is pressed again, likewise for the reverse operationIt appears that the movement is stopped by reaching a positive stop. In anycase the head will move the same amount, about 3.5 inches regardless of whereit has been positioned by the handwheel. Any problems with this operationshould be treated as a hydraulic problem, sticking valve, etc. The PLC is aMitsubishi MELSEC FX2N-16MR.The phone number for Mitsui Seiki in California is 562-948-4009. In New Jer-sey is 201-337-1300. Ask for John.Mitsui-Seiki VR5A with Fanuc 6M controlThis machine has a hydraulic ATC. It does not use a tool change macro so whenyou want to do a tool change you may have to command the Z axis to a secondreference return point. For example, G91 G30 Z0. Depending on the machine youmay have to include Y0 and X0. The standby/spindle tool is stored in paramet-er 4999. Parameters 4000-4020 are the tool registration table. As with othermachines you cannot have the same number in more than one of the parameters.On most of these machines the tool must be commanded on a block other thanthe one in which the M06 is commanded. For example:T01;G91 G0 G30 X0 Y0 Z0;M06;The tool must be commanded first.If the magazine rotates, the spindle orients and the pot comes down but theATC arm will not rotate check the spindle orientation signal.  In the caseof spindle amplifier with an orientation board make sure the IN-POSITION LED(LED 6)is on. If this LED is not on, the spindle orientation completion sig-nal will not be output from the NC to the ladder. This LED should be on any-time the position of the spindle is within one degree of it's orientationposition. If the spindle is in position but the LED is not on you can adjustRV7 to bring it on.The VR5A with the Fanuc 6M control does not issue machine alarms. When analarm condition does occur there are a couple of red LEDs on the operator'spanel that will either turn on or flicker. When this happens, check PC param-eters 200-207 for the details of the alarm. To access the PC parameters:1.Press the PARAM button twice.  (PC PARAMETER 01 should be displayed in the upper left hand corner.2.Page to the desired PC parameter.The screens of this control update very slowly so you have to be patient.PC PARAMETER200.0  CYCLE ALARM

   .1  MACHINE ALARM 1   SOLID STATE RELAY TRIPPED   .2  MACHINE ALARM 2   CONTROL CIRCUIT BLOWN FUSE (TRIPPED BREAKER)   .3  MACHINE ALARM 3   HYDRAULIC PUMP MOTOR OVERLOAD   .4  MACHINE ALARM 4   LST COOLANT PUMP MOTOR OVERLOAD   .5  MACHINE ALARM 5   CHIP CONVEYOR MOTOR OVERLOAD   .6  MACHINE ALARM 6   SECOND COOLANT PUMP MOTOR OVERLOAD   .7  MACHINE ALARM 7   LUBRICATION PUMP MOTOR OVERLOAD201.0  MACHINE ALARM 8   SPINDLE LUBRICATION PUMP MOTOR OVERLOAD   .1  MACHINE ALARM 9   ABNORMAL SPINDLE LUBRICATION AND COOLING UNIT   .2  MACHINE ALARM 10  EXCESSIVE OIL TEMPERATURE IN THE HYDRAULIC OIL TANK   .3  MACHINE ALARM 11  LUBE LEVEL LOW   .4  MACHINE ALARM 12  ABNORMAL SPINDLE SPEED CONTROLLER   .5  MACHINE ALARM 13  CHIP CONVEYOR TORQUE LIMIT   .6  MACHINE ALARM 14  OVERLOAD OF HYDRAULIC PUMP FOR CLAMPING A/C AXIS   .7  MACHINE ALARM 15  ABNORMAL LUBRICATION203.0  WORK SET HOLD   .1  APC HOLD   .2   .3  T00L LIFE ALARM, NO SPARE FOR TOOL EXPIRING IT'S LIFE TIME   .4  ABNORMAL TOOL DETECTING DEVICE   .5  NEGLIGENCE OF RESETTING M30 POWER CUT-OFF   .6  EXCESS OF AUTOMATIC CYCLE OF ROTARY TYPE APC   .7  ABNORMAL TOOL CHANGE COMMAND204.0  BROKEN TOOL   .1  SPINDLE HOLD   .2  ORIENTATION HOLD   .3  MAGAZINE ALARM   .4  T CODE ALARM   .5  PROGRAM ERROR   .6  DATA SEARCH ALARM   .7  TOOL ALARM205.0   .1   .2  ATC HOLD   .3  ATC STOP 1   .4  ATC STOP 2   .5  HYDRAULIC OIL TEMPERATURE UPPER LIMIT DETECTION ALARM   .6  NC EXTERNAL RESET ALARM   .7  NEXT T CODE ALARM207.0  OIL SHOT PUMP MOTOR OVERLOAD   .1  INSUFFICIENT OIL SHOT COOLANT   .2  DEFECT OF PC FOR ROTARY TYPE APC CONTROL   .3  ROTARY TYPE APC ALARM   .4  EXCESSIVE CUTTING LOAD SETTING ON ACS UNIT   .5  ABNORMAL APC OPERATION CONFIRMATION SWITCH   .6All of the bits should normally be zero unless an alarm condition is present.There is a box on the ATC side of the machine with an LED display. This boxis used to move a tool pot to the tool loading position. There is a positionto the left of the standby position where loading the tool is facilitated.There is a lever at this position for removing the tool from the pot. To use

this box.1.Press the + and - buttons at the same time.2.Press either the + or - button to display the number of tool you want.3.Press the START button.The pot will move to the loading position.This machine's spindle is a three stage geared head. It uses the old digitalspindle drive. You can adjust the gear ranges individually by adjusting oneof three gain pots on the drive.When the alarm lamps light on the operators panel check Diagnostics 200-210.Use the maintenance manual to find out what the Diagnostics indicate.Generally speaking, if a machine does not use a tool change macro for ATCoperation, you will have to command the head to tool change position with aG30 command.Kiwa 426X:Uses absolute pulse coders on the X, Y and Z axes, reference return switch onthe B axis. To zero return the B axis:1.Press the ZRN button.2.Press the 4th button.3.Press the + button.The coolant through the tool pump (#3) has a pressure switch that must besatisfied. If for some reason it cannot be you can bypass it to prevent thelow pressure alarm from being issued. This is done by changing the value ofkeep relay K3.4If the pallet does not sweep in true with the spindle after reference return,adjust the grid shift parameter (1850) until it does.The manual operation of the pallet changer cannot be performed until the Zaxis has been sent to it's second reference point (G91 G30 Z0). Once this hasbeen done, select JOG mode, place the selector switch on UNCLAMP, press theSTART button. The pallet will unclamp. Place the selector switch in UP, pressthe START BUTTON, the pallets will raise up. Place the selector switch inCW, etc.For questions about Mitsubishi made press breaks, regardless of other brandname, call 212-397-6118 or 630-860-4666.If a spindle which uses a magsensor for orientation has trouble finding theorientation position check that the spindle deceleration is not too long. Inthis case the spindle may jerk back and forth searching for the positionbecause it can't stop fast enough to stop in the middle of the sensor. If themechanics of the machine will allow you can open the window of the orientposition to make it easier for the spindle to find a stoping position.The Heidenhain Pilot VRZ739/779 DRO is a digital readout which can interfacewith an inverter to perform constant surface operation. The port on the DROwhich is used to interface with the inverter is X41(EXT). This DRO is usedon the Clausing VS lathes. In this case, X41 connects to CN18 of the relayboard. These machines typically use the Mitsubishi Freqrol A-200 spindleinverter. If the DRO is turned off the spindle will not run at all. Pressingthe RUN/RESET button will cause it to turn on (green), but when released itwill turn off. On the Clausing lathes which use this DRO, you must push thegreen button (RUN/RESET) to make the machine ready, the green light shouldstay on after you release the button. If it does not, make sure that thespindle lever is in the neutral position and the chuck guard is closed.When the green button is pressed, relay K6 on the PCB should energize. K8 on

the PCB should energize whenever power is supplied to the PCB through fuseF1 on the PCB. Relay K5 on the PCB energizes whenever the E-Stop button ispulled out. Also, when the E-Stop is pulled out, contactor K1 should energ-ize.To use the constant surface feature, press the CSS button, move the X axis tothe point where you want maximum rpm to be reached, adjust the spindle speedcontrol to this rpm, press the RPM MAX button. Move the X axis to the pointwhere machining will begin, adjust the spindle speed to the desired startrpm. As the X axis is moved in toward the centerline the rpm will increase upto the maximum rpm.The phone number for the Duplomatic dealer in Charlotte (Macoser) is 704-392-0110. The contact is Dan Britton.On the Kiwa horizontal, if the magazine has less than 100 tools, parameter6810 can be 100. If it has more than 100 tools, make it 1000. If the paramet-er is set too low, alarm 151 (Fanuc 18) will be issued.If a machine with a high/low geared head stalls in a cut, check the high/lowgear confirmation switches. A temporary loss of one of these signals maycause the spindle to drop in and out.Typical parameter settings for the Yaskawa spindle inverter on the Sharp1118H are:REFERENCE SOURCE          TerminalsRUN SOURCE                TerminalsSTOPPING METHOD           Ramp to StopACCEL TIME 1              3.0 Sec.DECEL TIME 1              3.0 Sec.REFERENCE  1              60.00 Hz           2               0.00 Hz           3               0.00 Hz           4               0.00 HzJOG REFERENCE              6.00 HzINPUT VOLTAGE             220.00 VACMOTOR SELECTION           Std Blower CooledV/F SELECTION             Custom V/FMAX FREQUENCY             204.00 HzMAX VOLTAGE               220.00 VACBASE FREQUENCY             60.00 HzMIN FREQUENCY                 .5 HzBASE VOLTAGE              220.00 VACMOTOR RATED FLA             1.59 HzNO-LOAD CURRENT             5.88 AOn the Mori-Seiki MH-40, alarm EX49 occurs when a cycle such as ATC,SBC,ZRN,etc. does not finish. The control remembers the alarm even if the main powerhas been turned off, it can not be reset. When the alarm occurs, a Keep Relaywill be changed by the control from 0 to 1. The relays to check are K14.5,6and 7. If you get the alarm even though all cycles are complete, you can re-move the alarm by changing the keep relay back to 0. To change a keep relayon a machine with a Fanuc 11 control:1.Select MDI mode.2.Press the SERVICE soft key.3.Press the PARAMETER soft key.4.Enter the 8900 and press the INP-NO soft key or page to parameter 8900.

5.Change bit 0 to 1.6.Press the NC/PC button.7.Press the PCPRM soft key.8.Press the KEEPRL soft key.9.Cursor to the Keep Relay, enter desired value, press the INPUT button.The Mori-Seiki horizontals have wear pads on the bottom of the column, thesecan wear to the point where the column can drop down on one end. This willcausing machining problems and rough movement in the Z axis.                                         Alarm OT102 on a Mori-Seiki horizontal mill means that the spindle amplifierhas alarm AL02 EXCESSIVE SPEED DEVIATION. If you look at the spindle amplif-ier, LED 2 will be on.On the older Yasnac controls (MX1, MX2, etc.) the motor encoders are calledFeedback Units, if you pull these off the end of the motor and turn them overthere are pots you can adjust. One of the pots is a sensitivity adjustment.This adjustment is useful in cases where the optical reader gets weak overtime. A symptom of this is that it has trouble seeing the marker pulse so itis difficult for it to complete zero return. If you remove the cover from thenewer Optical Encoders on the MX3 controls you will find pots as well but youshould not adjust these. According to Yaskawa these encoders should not be ad-justed, even their field service technicians are not allowed to adjust them.The encoder should be either replaced or sent in for repair.Often when an axis on a machine with a Yasnac MX3 control gets alarm 242 (inthe case of the Y axis) when it is being zero returned, you can adjust para-meter 6316-6320 (approach speed 2) to make the axis approach the zero pointslower. Also in this case check the ZRN decel switch to make sure it's notsticking.On Heidenhain controls to access the Ladder you enter the code 807667 at theCODE NUMBER = prompt. Keep in mind that some controls will not display theladder such as the TNC124. On these controls you must have the software on aPC to extract the binary file from the EPROM in the control. Even then youcannot see the ladder, only gated logic ( AND, OR, etc.)Communication parameters for a Yasnac LX3:The parameters for this control are grouped according to INPUT or OUTPUT andfor INOUT/OUTPUT DEVICE 1 (SIO1) or INPUT/OUTPUT DEVICE 2 (SIO2).Parameter 6026 is for setting the baud rate for Input Device 1, parameter6027 is for Input Device 2. Parameter 6028 is for setting the baud rate forOutput Device 1, parameter 6029 is for Output Device 2. So, to set the baudrate the same for input and output on device 2 you would set parameters 6027and 6027 to the same value. Only the first four bits (0-3) of the parameterare used for the baud rate setting. The table below applies in all cases.BAUD RATE   BIT 3   BIT 2   BIT 1   BIT 050          0       0       0       0100         0       0       0       1110         0       0       1       0150         0       0       1       1200         0       1       0       0300         0       1       0       1600         0       1       1       01200        0       1       1       12400        1       0       0       0

4800        1       0       0       1Bit 4 of these parameters sets the number of stop bits, 0 = one stop bit,1 = two stop bits.Bit 5 of these parameters is for control codes, 0 = DC1/DC4 are used,1 = DC1/DC4 are not used.To change a parameter on a Yasnac LX3 control:1.Press the SET button. The SETTING page will be displayed.2.Type 6219, press the Cursor Down button.3.Change it's value to 1.4.Press the WR button.  (This is equivalent to the PWE of a Fanuc control, if power is cycled  while 6219 = 1, the alarm "SYSTEM SETTING NO.(6219):[1]" will be displayed)5.Press the PRM button.6.Type the number of the parameter you want to change, press the Cursor Down  button or page to the parameter.7.The cursor will be on the #, press the INSRT button. The cursor will move  to the first bit (Bit 7).8.Use the cursor button to move the bit desired.9.Change the bit from 1 to 0 or vice versa, press the WR button.As with a Fanuc control, if you want to send or receive the parameters youmust go to the parameter page. Then press either the IN or the OUT button.The CRT will flash either IN or OUT depending on the operation.Heidenhain LS500 series reading heads: The intensity of the light source canbe increased by replacing the resistor, it is accessed by removing the coveron the bottom of the reader.According to Hyd-Mech the head of the S-20A can drift down as much as .080/inwhile in HOLD mode and be within specification. Also according to Hyd-Mech ifthe front vise and shuttle vise are not aligned they recommend to shim outthe wear plates on the front vise.For parts on an Acer grinder call KLIM at 732-752-9100.When replacing thrust bearings, if the new ones are the same manufacturerthey are probably the same thickness but you should check. If not the samemanufacturer, stack the older bearings as they go in the machine and measurethe overall thickness. It will normally be different from the old ones. Ifthe new ones are thicker you will have to turn the difference off of theretention plate. If thinner you will have to make a spacer.For service support on the Fuji Frenic spindle drives call OESS at 201-288-4422.On the Fuji Frenic 5000V2 the buss should normally be about 300 vdc. It itgoes above 400vdc the over voltage alarm is issued. This indicated by leds 3and 4 being on at the same time.When the DDF valve is replaced on the Hyd-Mech S20-A saw, the feed forcevalve must be adjusted:1.Remove the cap from the hydraulic fitting at the bottom of the DDF.2.Connect a hydraulic hose and gage. (You can use one of the pressure gages  from the hydraulic compartment door and put the cap on the line.3.Bring the head down to rest on a block of wood. Leave the selector switch  in the DOWN mode.4.Loosen the setscrew on the black knob (feed force adjustment) and remove  the knob.

5.Use an allen wrench to turn the valve fully clockwise.6.Adjust CCW until the gage reads 330 psi.7.Put the knob back on with the pointer indicating 0%.Only adjust the feed force valve when the DOWN mode is selected.The S-20A with the Sequencer has three switches to control the movement ofthe shuttle vise. The top switch on the right is the confirmation switch forthe forward travel, the middle switch stops the vise in it's reverse travel.This is how the work piece is measured. The part that contacts the switch isthe spindle face of a micrometer. The micrometer moves with the length adj-uster along the distance of the tape. Once the pointer is set to the desiredlength it can be fine adjusted with the micrometer. The micrometer is norm-ally set for .250 so that the position can be adjusted a quarter inch eitherway. If the piece is cut too short the shuttle is not moving back far enoughso move the micrometer back away from the switch. The bottom switch placesthe shuttle in slowdown mode. On the Yaskawa 616PC, terminals FV and FC are the 0-10vdc speed command inputThe W.F. Wells B-25-1 horizontal band saw works in the following manner:As the head moves down through the part the blade will under some circum-stances be pushed up toward the blade guides (eight side bearings) which isundesirable, particularly because if the kerf of the blade is allowed to runwithin the guides for any length of time the blade will lose it's set. Thiswill normally cause the saw to cut out of square from top to bottom. The sawis designed to prevent this by using two metering valves, one mounted on eachguide arm. The valves are connected to the down feed force assembly by twohydraulic lines on each valve. These output of these valves is inverselyproportional to the amount of displacement of the actuator. The input actuat-or of each valve is connected a tie rod which connects to a pivot arm onwhich the top bearing is mounted. The top bearing rides on the blade back.As the blade is pushed up by the material, the metering valves are forcedclosed in proportion and, in turn, decrease the rate of downfeed. If thevalves are properly adjusted, the downfeed of the head will be stopped compl-etely before the blade displacement reaches .050". To adjust this mechanism,first adjust the top bearings so that they just kiss the blade back with thesw cutting air. (It may be necessary to make this adjustment with the bladeactually cutting material at a very low down feed setting, in this case, tryto make the adjustment during the first moments of the cut). The adjustmentis accomplished using the set screw and jam nut on the pivot arms. Next,place the saw in down feed condition, again cutting air. As the head feedsdown, use a screwdriver to raise one of the top bearings off of the blade.You should see the head movement slow down and then eventually stop. Aplunge dial indicator can be very helpful in determining if the head is beingproperly controlled by the valves. Adjustment is acheived by either increas-in oe decreasing the length of the tie rods. As previously mentioned, thetwo valves work together and generally speaking both top bearings will moveinto the material simultaneously so if possible try to raise both bearingsat the same time, you will find that the down feed will more affected thisway rather than raising one at a time. Another thing to keep in mind is thatnot only is any adjustment of one side linked to the other side but alsoadjustment of the top bearings will affect the metering valve adjustment.As far as adjusting the blade guides, they should be set for .001" greaterthan the thickness of the blade. Most blades for this saw are normally either

.042 or .050". An easy way to make this adjustment is to find a short piece ofa broken blade, put it together with a .001" feeler gage, put the two of thembetween the blade guides, turn the movable bearings until they close on theblade and feeler to where you can just get them out, then tighten the nut.If the blade tension needs adjusting there is a metering valve located behindthe blade tension solenoid valve. This valve is located beneath the electri-cal cabinet. It consists of a setscrew on the bottom of the valve.

On the Kiwa KNH-426X, to bypass the coolant pressure switch change the valueof Keep Relay K3.4The Cincinnati Arrow 750 uses the Control Techniques control. To access theLadder on this control, press and hold CTRL + D. The PROGRAM PROTECT KEY canbe found at Net 183.The magnescales used on some Sony DRO systems, particularly the LH51, have agreen LED which indicates when the gap between the reader and the scale isthe correct distance. If the reader is either too close or too far away, theLED will go out. Once the correct distance is achieved it will burn brightly.On the Yuasa UDNC-100, to use the work zero function:1.Select manual mode with the MAN\REMOTE switch.2.Zero return the table using the zero return switch.3.Use either the Jog button or handwheel to move to desired work zero.4.Press the W-Z SET button and hold until the display reads all zeros.To remove the chuck from a CNC lathe (hydraulic chuck):1.Remove the bolts from the face of the chuck (usually six socket head cap  screws).2.Press the chuck pedal so that the chuck is pushed away from the spindle.3.Unscrew the chuck from the draw tube. (It should turn freely and the  threads are standard direction.To install a chuck:1.Screw the chuck onto the draw tube until it runs out of threads.2.Back it off until the alignment pin lines up with the NEAREST alignment  hole on the back of the chuck.(This may take a few attempts)3.Press the chuck pedal so that the chuck is pulled toward the spindle.4.Once pin is aligned and chuck is pulled flush against the face of the spin-  dle, insert and tighten the six bolts.5.Check for run out.Sometimes a new chuck will come with a blank draw nut, that is, the draw nuthas not been threaded. In this case you can re-order the chuck with a thread-ed nut, thread the nut yourself or in some cases the draw nut on the oldchuck may be interchangeable with the new chuck. This is particularly truewhen the old chuck is a Kitigawa since many chucks are copies of these,notably the strong chucks.Be careful when removing and installing a draw nut that you do not lose thesteel ball that rides in the detents of the draw nut, it is very small andeasy to miss.The primary difference between AC servo motors and AC induction motors isthat servo motors use permanent magnets. These magnets allow for precisepositioning but the drawback is that the magnets can be demagnetized or themagnetic fields can be scrambled. This normally results in a motor that doesnot rotate smoothly, when the motor is turned by hand it will cog, that is,you will feel notches as it is rotated. When the motor is operated it's

movement will be rough and jerked. It will also pull high current and themotor will have very little torque. In most cases you will be able to keepthe motor from turning by holding it by hand. When this happens the motorcan be repaired by re-magnetizing it but requires special equipment. Onecompany that can do this is Endeavour Technologies in Chicago.It is also important to know that this condition can be caused by a bad servoamplifier so it is not uncommon to find a machine with the symptoms above andwhen you replace either the motor or the amplifier, you still have basicallythe same problem with the machine until you have replaced both of them.To perform linear compensation on a Sony LH30 DRO:1.With the DRO turned off, hold the RESET button while turning the unit on.2.Press either the X or the YZ button until LC _ _ _ is displayed.3.Enter the value from the table corresponds to the required amount.4.Press the P button.5.Cycle the power.The actual amount of error cannot be entered so a number from the table whichmost closely matches the error must be used. Use the table below:AMOUNT OF ERROR PER INCH               LC.000002                                002.000004                                004.000006                                006.000008                                008.000010                                010.000015                                015.000020                                020      |      |      |      |.000600                                600To compensate for an axis that measures a standard as longer than it is usenegative values:AMOUNT OF ERROR PER INCH               LC.000002                                -002.000004                                -004.000008                                -006.000010                                -010.000015                                -015.000020                                -020      |      |      |.000600                                -600The newer TRL 1840 machines use a Yaskawa GPD 315/V7 inverter to control thespindle. If this inverter displays an alarm message that consists of a largeupper case S, a large lower case r and a large upper case P, this indicatesan emergency stop condition that is originating from a source external to theinverter. In the case of the 1840, try removing the computer module and re-seating the boards into the motherboard or look for some other hardware pro-blem. This alarm is related to parameter n005.

The manual for this inverter as well as other Yaskawa inverters can be down-loaded and or viewed directly from the website DRIVES.COMAlarm 1300 NO PALLET SITTING CONFIRMATION on the Kiwa KNH-400 is issued whenpressure switch PS5 detects a lack of back pressure. This switch is locatedin the back of the machine with the main air input and solenoids, etc. Theswitch is labeled AIR CATCH SENSOR. There is an air line from this sensor tothe pallet. The sensor has four LEDs, two red and two green. At least one ofthe greed LEDs must be on to prevent the alarm from being generated. It doesnot matter about the two red ones unless they are the only ones on. In thiscase X0006.6 (PSPLSA) will be zero, making the alarm rung true. There is anadjustment on the switch that is normally sufficient to correct the problem.The output of the switch does not go directly to the I/O module, instead itturns on relay CR28, the output of which is tied to the I/O module. Thisrelay can be hard to find, it is one of the tiny black solid state relays inthe electrical cabinet. Anytime you have this alarm, make sure that the mainair supply has not changed. Also raise the pallet and blow out any chips thatmay be keeping the pallet from seating.The Clausing Mastiff lathe with the Fanuc 20T uses a rolling column matrixfor the operator's panel (A10). There are four 24 volt output transistors andeight current sink transistors (all from the Fanuc I/O board(A1) ) which to-gether control 32 LEDs. In order for an LED to turn on, both it's correspond-ing output transistor (Y address) and corresponding current sink transistormust be turned on. The anode of eight of the LEDs will be tied, in parallelwith one of the 24vdc output transistors while four of the LED cathodes willbe tied, in parallel, with one of the current sinking transistors. Each LEDwill have a different Output address (Y address) which, apparently, whencalled by the control will activate both transistors. The four outputs arefrom the I/O board (A1), connector CM31, pins B13 A13 B12 A12 to the relayboard (A4) through the fuses on the relay board F5 F6 F7 F8 respectively.The current sinks are supplied from the I/O board connector CM31 A14 B14 A15B15 and so on. The output addresses are Y1000.0 Y1000.1 Y1000.2 and so on.The Mori-Seiki MV Junior uses a Yasnac MX2 control. If the CRT is blank,check the 24vdc supply from the power supply. This power supply is located atthe bottom of the electrical cabinet. The only input of this board is 220VAC, the outputs are 5vdc, 12vdc, 15vdc and 24vdc. These are output on fiveconnectors A, B, C, D and E. The output of connector C is +24vdc. All ofthese voltages go first to the top of the card rack and are jumpered fromthere to the boards. In the case of the 24vdc, when it goes to the I/O boardit feeds a bridge rectifier which if it shorts will cause the power supplyto shut down and the CRT will be blank. This power supply can be hard totroubleshoot because even though a short on one of the outputs will cause thepower supply to shut down, disconnecting the connector to remove the shortwill cause the same problem since removing one of the connectors on even ahealthy power supply will cause shutdown.Hyd-Mech H-14One revolution of the length encoder equals 3.142 inches of linear travel.The encoder supply voltage should be 22-26 vdc.Encoder outputs:0v to Channel A should be 10-13 vdc while encoder is in motion.0v to Channel B should be 10-13 vdc while encoder is in motion.LEDs X0 and X1 correspond to encoder channel A and B outputs.

The folowing parameters are with regard to length measurement and control.ACCEL DISTANCE   -   How far the shuttle vise moves in slow feed before                     engaging fast feed.DECEL DISTANCE   -   How far the shuttle vise moves in slow feed following a                     fast feed movement.TRIG.WINDOW      -   Allowable length tolerance.ACTUAL POSITION  -   Normally set to 0. Set to 1 to display actual position.If you program a length of cut whose length is shorter than the DECEL DIST-ANCE parameter, the shuttle vise will travel this entire distance in slowfeed.To change the BLADE KERF setting:1.Select AUTO mode.2.Press and hold the KERF CLEAR/HOME button until the Kerf value is shown.3.Type in the new value.You can view the I/O states at the PLC in the main electrical cabinet of theH-14.To calibrate the length measurement:Before you start make sure there is a piece of material in the saw which islonger than the maximum stroke of the shuttle vise.1.Select MANUAL mode.2.Place the FRONT VISE switch in the CLOSE position.3.Press and hold the FWD and REV buttons at the same time until prompted for  the password.4.Enter the password. (The password corresponds to the version of software  that the PLC uses. The version is displayed when the machine is powered on.  To which password corresponds to your version of software check the list  above or call Hyd-Mech).5.Display will normally show the Height Calibration screen. Cursor to the  Length Calibration screen. It will look like this:  LTH.CLB.  "ENTER" [0]  ACT.LTH.   00.0006.Press the ENTER button. The CYCLE START should start flashing and the [0]  should change to [1].7.Start the blade. The saw will make a trim cut, raise the head then the  shuttle vise will move fully back in slow, clamp on the material, bring it  fully forward in slow and make the cut. The 1 will change back to 0.8.Measure the cut.9.Cursor to ACT.LTH.10.Enter the length you measured plus the kerf of the blade.11.Press the AUTO/MAN button. The PLC will calculate and store the calibrat-   ion factor.If you find that you need to adjust the calibration factor, you must go thruthe above procedure to change the ACT.LTH. parameter but you don't have toactually cut material. If length measurement error increases as measuredlength increases, increase the ACT.LTH. parameter. If the error decreases asthe length decreases, decrease the parameter.Whenever troubleshooting length error problems, make sure the cushion period(slow approach distance) is set correctly. This will normally be set for oneinch.

Hitach-Seiki HT20S with Yasnac i80L:When the machine is turned on it is normal to have alarm 3000 SERVO OFF. Thisis because the NC does not energize 1K3 (large contactor) which sends threephase power to the servo unit. To turn on the servo unit, press either theSTANDBY button or the NC POWER ON again depending on the PLC version.When the STANDBY button is pressed the output Y57 (#11057) should turn on andstay on while the button is held. It should also stay on for about five sec-onds after the button is released. This output is from the FC-860 board. Thisis the I/O board for the i80 control and is distinguishable from the othercontrol components since it is not a plug in module of the chassis. It isnormally mounted away from the control chassis and is connected to the cont-rol through a communication cable from CN11 of the FC-860 to CN21 of theFC-210. Some machines may use a FC-211 instead of FC-210 but in either casethis is the PLC module mounted on the control chassis. The Y57 output is24vdc from connector CN2 pin 7 on FC-860 to connector X23 pin 7 of DSB1 whichfeeds relay 1K1A (MACHINE READY P.B.).This relay is an ice cube relay located on the distribution board (DSB1).The distribution board is basically a central location for input and outputconnectors but it also has the 24vdc pc mounted relays which control mostmachine I/O functions. The majority of PLC controlled outputs are 24vdc sign-als from CN1 of FC-860 to DSB1. If the control is ready for Servo Power On,pc mount relay on DSB1 (1K3A) will be energized by 24vdc supplied from CN27pin 10 on FC-230 through the relay to CN27 pin 17 ( /SVMX ). The normallyopen contact of this relay feeds 110 vac from connector X8 pin 1 of DSB1 to1K3, the return side of the relay is tied to wire number 2. An important noteabout this relative to the HT20 is that X8 pin 1 on DSB1 actually is not con-nected to anything else on the PCB. In order for this board to work on theHT20, it needs to have a series of jumpers soldered to the back of the boardto route the 110 volts to relay 1K3A.Diagnostic #3005.0 (SVON) should be a 1 while the STANDBY button is held.Diagnostic #3503.0 (SVONS) should be a 1 while the STANDBY button is held andfor about five seconds after it is released.Alarm 79727 TURRET CLAMP FAULT will occur at power up if the turret is notclamped. The machine determines if the turret is clamped using a proximityswitch located behind the index gear. This alarm can be cleared by manuallyturning the gear until the proximity switch is made (the red LED comes on).The E-Stop circuit consists of 24vdc output at address Y43 which feeds theE-Stop buttons on wires D101, D102, D103, etc. Make sure that you have 24vdcleaving FC-230 connector CN27 pins 10 and 11, going through E-Stop circuitreturning to CN27 pin 19.Y43, in the ladder, is #11043 which is turned on by #14510 which in turn isturned on by a string of inputs including *ESP, NCOHT and SVALM.The X axis brake is released when the 24vdc output at address Y44 from conn-ector X8 pin B3 of DSB1 goes through a normally open contact of 1K3 to conn-ector X8 pin A3 of DSB1 to ice cube relay 1K5 (BRAKE RELEASE RELAY). The re-turn side of 1K5 is FC-230 CN27 pin 18.To access the Ladder on the i80 control:1.Press the NC SCREEN button.2.Press the FUNC SELECT soft key (F9).3.Press F9 again.

4.Press the LADDER soft key.The ladder of the i80 searches from the top so that if the address you arelooking for is located above the current position the CRT will display NOTFOUND. If this happens, press the FUNC. SELECT (F9) then press the BT/TOPSoft key. The first press will take the display to the bottom of the ladder,press it again to go to the top.To search for a Diagnostic address:1.Press NC SCREEN soft key (F9).2.Press FUNC. SELECT soft key (F9).3.Press DIAGN soft key (F4).4.Type the desired address (i.e. 3005)5.Press the CURSOR DOWN button.The CRT will display 10 addresses (i.e. #3000-#3009). The diagnostics aredisplayed as an eight bit binary number with it's corresponding Hex value tothe right.If the machine has alarm 3000 SERVO OFF and 2190 MACHINE UNREADY at the sametime, alarm 2190 will be masked because 3000 is a higher priority.Like most CNC controls, the servo unit of the i80 has control power appliedat power on in order to do self-diagnostics, etc., but the three phase drivepower is not applied to the machine is ready.LNS Quick Load barfeeder:If the LCD displays EMERGENCY STOP LINE IS OPEN, check the two S8 terminals.They should be closed. If it displays other alarms about the collet, etc.make sure that the signals have not been bypassed and a jumper is loose.Often times the chuck close confirmation switches, etc will not be present onthe machine tool so a number of the inputs to the barfeeder will be tied toa dry contact or 24 volt source.Some SEM servo motors have an encoder mounted to the back of the motor withtwo set screws. If these become loose the machine will have trouble repeatingespecially with regard to reference return to zero.If you are working on a Servo Dynamics drive with which the Lag value can notbe adjusted close enough to zero, check the connections of J1 and J2. A badconnection here, or even a dirty connection can prevent the Lag from beingdecreased.A 2500 line rotary encoder connected to a 10mm ball screw should give a .0001"resolution.The position sensor for spindle orientation on a Kiwa KNH-426 is BZI type,Fanuc part number A860-2120-T401.On the Hyd-Mech H-12 with the Mitsubishi PLC, if the hydraulics cut off whenyou release the button and the number three LED is flashing, the program isprobably either lost or scrambled. If the LED is on steady, their is likelya hardware problem with the PLC. If the LED is flashing you can order a mem-ory card from Hyd-Mech and plug it into the PLC it will load the program.In this case the full the model number of the machine will be H-12 MITS.On the Rhino ST/8 lathe with the new spindle amplifier there is a row of 7LEDs. The first LED from the left should indicate the PWM signal to theamplifier which should be seen to flash in sympathy with the speed signal tothe amplifier. The second LED should come on when CW rotation is commandedand be off when CCW rotation is commanded.To transfer the parameters from one Yaskawa V7 inverter to another V7:

1.Change n177 of the source drive from 0 to 1. This will allow the parameters  to be read and written.2.Change n176 from Rdy to rEd. This will transfer the parameters from the  drive to the digital operator.3.Remove the digital operator and install on the target drive.4.Change n177 to 1 if it is not already.5.Change n176 to CPy. This will transfer the parameters from the digital  operator to the inverter.6.Change n176 to vFy. This will verify that the parameters in the digital  operator match the parameters in the drive.7.Change n177 back to 0 on both drives. This will prevent accidental over-  writing.If a Yaskawa inverter will not run when commanded, check the digital operatorto be sure that the display is on FREQ or at least some other selection witha green LED. If the display is on LO/REM or PRGM (red LEDs) the drive willnot respond to a remote command.The parameter for setting the rapid rate of the Z axis on a machine with aYasnac MX2 control is 6282.To run a cycle on the new Hyd-Mech S-20A Series II:1.Turn the power on.2.Release the E-Stop.3.Hold the F1 key until the hydraulics turn on. The F1 key is on the  operators interface. Switches must be in the NEUTRAL and HOLD positions.4.Close the front vise. The display will change to another screen.5.Press the F4 key.6.Hold the NUM key while typing the desired length.7.Release the NUM key, press the Enter key.8.Cursor to R and enter the required number of parts. This number has to be  greater than the value in C.9.Press the CYCLE START button.These machines have a relay board where all of the inputs and outputs areconnected. The relay board is connected to the PLC by two ribbon cables, CN1and CN4.If the display will not come on check the cable that connects it to PLC. Thisis a PS2 type connector which if unplugged will keep the LCD screen fromcoming on.The Kia 21LMS turret uses a Fanuc Beta motor and drive for indexing. The tur-ret uses an absolute pulse coder. The turret can become confused for a coupleof reasons one of which is PMM parameter 11.0, this parameter has to be 1 forthe turret home position. If this parameter gets set to 0 it causes a strangecondition in that the turret will be able to index and go the correct toolbut after the index the cycle start lamp will stay on because the TFIN is notgenerated. There will be no alarm and if the machine is turned off and back onthe turret can be indexed again. To change this parameter you must access thePower Mate CNC Manager screen. The parameters stored here are used for Betadrives only. The parameters are stored in the drive itself so if you replacethe drive the parameters go with it.1.Press the SYSTEM button.2.Press the Right Chapter button three times.3.Press the PMM soft key.4.Press the SYSTEM soft key.

5.Press the PARAM soft key.Another important PMM parameter is 11.7 because it must be 1 for the absol-ute pulse coder.Anytime the turret becomes confused or exhibits the condition described abovethe following procedure must be performed.1.Go to the PMM parameters and make 11.0 = 0. With this parameter all eight  bits must be entered so make sure you change the value of bit 0 only.2.Set Keep Relay 5.0 to 1.3.Unclamp the turret by pressing SPINDLE STOP, SELECT and FEED HOLD buttons  simultaneously. The SELECT button in this case is the button which shows  two arrows pointing in opposite directions and is located next to the  SPINDLE FORWARD button.4.Once the turret is unclamped turn it by hand until it is on tool station 1  and the two red arrows are aligned with one another.5.Press the CALL/BZ button. The turret should clamp. Check the turret clamp  confirmation switch at X0.7 to make sure it is clamped.6.Set Keep Relay 5.0 back to 0.7.Press the SPINDLE STOP, SELECT and FEED HOLD button simultaneously. This  time the SELECT button is the button which shows an arrow pointing to the  left and is located next to the MACHINE LOCK button. On some machines it  may not have an arrow but may be a blank button labeled SELECT only.8.Go to the PMM parameter 11.0 and make it a 1.  The hydraulic solenoid on the Kiwa KNH-400 that sends the single arm backfrom the chain pot to home position is Sol 52,53 (wire numbers Y542C andY543C).The way lube pump on the Kiwa KNH-400 comes every on eight minutes whether thespindle is running or not. It is controlled by counter C02. This oiler alsooils the spindle bearings and is lighter than the usual 68.When looking at angular contact (thrust) bearings their direction can be det-ermined by the arrows etched on the side of the outer race if the bearing hasan arrow. Not all bearing makers place an arrow on the bearing. In this caseyou can find direction based on the fact that the inner race is wide (fat) onone side and narrow (skinny) on the other side. The arrow should point to thefat side. As far as how the bearings are stacked, there are different config-urations for different loads such as high axial loads, etc.If a machine's control turns off at the end of a program or anytime it readseither a M02 or M30, check to see if the Auto Power Off function is turnedon. On many machines this is in the form of a push button the operator'spanel but in the case of a Fanuc control, particularly a 0-D control, thiscan be in the Software Operators Panel or take the form of a Keep Relay. On aMitsubishi control it can be done with a Latch Parameter.If a machine with a double arm ATC hangs up at the spindle and especiallyif the ATC arm motor trips the overload check the tool grippers. Sometimesthe plungers will get tight and have trouble pushing back far enough to beable to engage the tool. In this case you might see the magazine pot moveexcessively when the arm engages it.Mori-Seiki machines, the MV-55 in particular, use a number of timers forseperate events of the ATC cycle. Unlike most machines, changing things likehydraulic cylinder speed, switch positions, etc., can have great and unexp-

ected effects. For example, on most machines if you suspect that the spindleunclamp confirmation switch is not being depressed far enough you can movethe dog closer to the switch. Doing this on a Mori-Seiki may well prevent theATC cycle from executing at all since the timing is so close.When working with cam follower bearings, most of the time they are availablewith either a straight screwdriver slot or an allen head. In either case theywill often have a Torx head within the allen or the straight slot.If the X, Y and Z axes of a Mori MH63 will not move and the B axis will butthere are no alarms check the pallet (B axis). The other axes are interlockedthrough the pallet down confirmation switch. On a machine with a Fanuc 6Mcontrol the signals are:ITX - G96.4 (X32.4)ITY - G97.4 (X33.4)ITZ - G98.4 (X34.4)These G signals are active low signals so they should be 0 for axis motion tobe allowed.In the case of a machine with an indexer it may be necessary to lock it(M10/M11).The LeBlond Regal lathes use the Servo Shift mechanism to change spindlespeeds. This mechanism is entirely hydraulic with the exception of the pulseswitch located on dial A. This switched is open and closed anytime the dial ismoved to another speed setting. This is done with detents on the dial. Thedial has a shaft which connects it's center to the Servo Shift unit in theheadstock. This unit sits just below the top cover and is easily accessible.Turning the dial turns the shaft which opens and closes the various ports inthe Servo Shift unit but the shift does not actually occur until dial B isplaced in the BRAKE position. Dial A should only be turned while dial B is inone of the two OFF positions. If dial A is turned while dial B is in theBRAKE position the Servo Shift will try to shift to the next speed range asthe dial is rotated. The correct operation is:1.Place dial B in one of the OFF positions.2.Rotate dial A to the desired RPM.3.Rotate dial B to the BRAKE position.  The spindle will begin to oscillate back and forth. The higher RPM selected  the wider the oscillation.4.After several oscillations, rotate dial B to either the FORWARD or REVERSE  run position.Dial A speeds:N45697513317925635149493712821800Dial B

 _________|         | Reverse|_________||         | Off|_________||         | Brake|_________||         | Off|_________||         | Forward|_________|Below Dial A is a plate held on by six screws. Behind this plate are two pla-stic half gears with detents. As the drive gears are shifted these half gearsmove, their detents ride on levers, the other ends of which work against aspring.If the Servo Shift is operated improperly such as turning Dial A when Dial Bis in the BRAKE position it can result in a condition in which the gearsshift as soon as Dial A is moved off of the current speed before it reachesthe next RPM setting. When the machine is run and then Dial B is turned backto the BRAKE position, the spindle may start to oscillate in an effort toshift to the next speed. In some cases this may not occur immediately butinstead it may happen as a result of the vibration of putting a part in thechuck, etc.On a machining center if there is a popping sound when the tool is removedfrom the spindle it could be that the collet is not releasing all the way butanother cause is if the tool clean (air blast) is leaking through which willcause air pressure to build up behind the tool so that when it is releasedthe air shoots it out causing the noise.On a Kiwa horizontal if you get alarms 2050 and 1030, etc. when you call atool number over 64 on a machine that has a 120 tool magazine try runningM100 to reset the tool table and then M101 to register the tools but checkthe Keep Relay K2.0 first. For 64 tools it should be 0, for 120 tools itshould be 1.Machines that use a built-in (integrated) spindle do not have a pulse coderon the motor like other spindle motors, it uses a PLG unit. this unit cons-ists of an inductive sensor that is sensing a plastic gear. There is a PCBbetween the sensor and connector CN5. This PCB has several potentiometerswhich are used to adjust the signal strength for PA and PB. If a machine likethis exhibits a condition where the spindle oscillates and makes a high pitchnoise, this PCB probably needs to be adjusted. Typically, the signals PA andPB need a signal strength of 3 Vpp. The gap between the sensor face and thegear is critical and should be about .006". The plastic gear has one tooththat is longer than the others and represents the reference marker.To check the parameters on an S-23A with a sequencer:1.Turn the sequencer on while holding the INDEX button.2.Release the INDEX button.3.Use the INDEX button to scroll through the parameters. (The sequencer nor-  mally has only five parameters).After pressing the INDEX button for the fourth time, the display will defaultback to the normal display (current settings for INDEX and REQ. QUANTITY) soyou really have to watch closely to see what the setting is for parameter 5.

The typical settings for parameters 1-5 are:1 - 752 - 503 - 3204 - 505 - 50If the Auto cycle will not execute on this machine, check that the limitswitch for shuttle vise forward is made, if not the cycle will not continue.In some cases the sequencer can become confused causing the INDEX # displayto reset itself to 0. This will, of course, cause the Auto cycle to stopbecause the saw needs to make at least one index to execute the cut. Some-times this can be resolved by simply accessing and scrolling through theparameters. The condition may occur as a result of switching the Mode selectswitch directly from MANUAL to AUTO without stopping at the NEUTRAL position,according to Hyd-Mech you should always stop at NEUTRAL for a second.In Auto mode the machine should execute the cycle with or without the bladerunning with the exception that the head will not come down.In Auto mode CR10 should be energized and CR11 should be de-energized. InManual mode CR11 should be energized and CR 10 should be de-energized. InNeutral mode both CR10 and CR11 should be de-energized. 3CR should be energ-ized anytime the hydraulics is on.The S-23 with a sequencer like the S-20 uses a limit switch to position theshuttle vise for the proper length, this is the top left limit switch and hasa vernier dial (micrometer) for fine adjustment. The bottom left switch isthe approach switch and it is placed ahead (in terms of travel) of the topswitch. When the shuttle contacts this switch the feed rate slows to allowmore precise positioning. The limit switch on the right is used only forconfirmation of the shuttle vise fully forward.The B axis for the KNH-400 has two proximity switches that confirm the stateof the axis, either clamped or unclamped. The CLAMP confirmation switch isLS36, it's symbol is LSBRCL, the I/O address is X0009.7. The UNCLAMP confirm-ation switch is LS37, it's symbol is LSBRUC, the I/O address is X0009.6.Both switches are two-wire devices, their source is wire HP. These switchesare actuated by a piston in the base of the B axis. It is accessed by remov-ing the eight screws and cover located on the ATC side of the B axis. Thepiston is held on by two bolts and is easily removed once the cover is out ofthe way. The piston is pushed out by hydraulic pressure when the axis isunclamped and is returned to it's original position by a spring. A dog isattached to the piston by a collar and set screw and moves over the face ofthe proximity switches. With the two bolts removed, the piston and spring canbe removed as an assembly. It is not uncommon for the piston shaft to becomeworn and start to stick due to lateral motion of the shaft. Normally whenthis occurs the piston will move out under the hydraulic pressure but thespring is not strong enough to pull it back so the axis thinks it is unclamp-ed all of the time.If you need a password to access the ladder of a Mori-Seiki, try entering theletter L, then input.The Yasnac 3000G control has only 100 parameters (00-99) but parameter 65consists of 8 groups of parameters with each group consisting of 8 bits.If you replace the main board (CP03) board of a Yasnac 3000G control and itexhibits strange behavior, it may be necessary to regenerate the control. To

do this:1.  Place the thumbwheel switch (located in the tape reader enclosure) to 5.2.  Turn NC off.3.  Hold Cancel, Reset and Parameter (PRM) while powering up.    Clears Parameters.4.  Turn NC off.5.  Hold Cancel, Reset and Offset (OFS) while powering up.    Clears Offsets.6.  Turn NC off.7.  Hold Cancel, Reset, Communication (COM) and Erase (ERS) while powering up.    Clears Programs.8.  Reload parameters by hand.9.  Cycle power.10. Reload programs.When reloading the parameters you need to be aware that N65 is for the Option-al Features (option parameters). This parameter appears as a single zero (0)when viewed normally, but when viewed with the thumbwheel switch in position5, it appears as an eight bit binary number. The Optional Features are set ingroups of 8. The groups appear as 65X,65Y,65Z,65A,65I,65J,65K,65R. Thesevalues are altered by typing the letter of the group (i.e., X, Z, J, etc.).The eight bits of each group are designated D0-D7 corresponding to bits 0-7.On some machines, the keypad may not have the letter A so you must use thenumber 4 to access group 65A. Also, if you press a key that does not repres-ent a valid group (S, T, G, etc.), the parameter N65 will disappear from themachine. Pressing a valid letter such as X or J will cause N65 to reappear.Reloading the parameters is a simple matter of typing in the value that youwant the parameter to be and pressing the Write (WR) button. Make sure thatyou select the correct letter designation first. For example, to change thevalue of parameter 71Y you would use the Page Up/Down and the Line Up/Downbuttons to get to parameter 71, then type in the letter Y. Now the value thatyou enter will affect 71Y but not 71X, 71Z, etc.Parameter 65 is different. Since these are option parameters, there is anadditional step. Once you have paged to parameter 65 and selected X, Y, etc.you must press the Insert (INS) button. this will place an asterisk underthe first bit (D7). Now type in the eight bits from left to right (7-0) thenpress the write (WR) button. Now you MUST press the RESET button for theparameter to become effective. After performing this procedure, cyclethe power all the way back to the breaker.In some cases you may need to clear the program storage area again in orderto load the programs.The Strong model N212 chuck like the ones used on the Ecoca SJ-25, etc. hasa jaw stroke of .417" on the diameter, the plunger stroke is .905". The act-uators used on these machines have a piston stroke of .915".The electrical boxes of the LNS bar feeders are wired for the lathe they areto be installed on and LNS keeps a copy of the wiring diagram that can bereferenced by the drawing number.Yasnac MX3:To access the RUN TIME, CYCLE TIME, etc, press the ALM button, then page down until TIMER is displayed at the top of the screen. You should see:1. POWER ON2. CYCLE START

3. CUTTING FEED4. OPTIONALTo clear a timer value, press the desired number (1,2,3 or 4) along with the origin (ORG) button.On the Kia SKT21 with a parts catcher, catcher up confirmation is X3.0, down is X3.1. In the case of the Kia SKT15 with a Fanuc 0i control, the main spindle parts catcher up confirmation signal is X8.2, X8.3 is parts catcher down. On the SKT15 the output coils for parts catcher up/down are Y8.2 and Y8.3 respectively. The relays are 2KA11 and 2KA12. The M-code for parts catcher up is M63, down is M64. These are configured to finish with a hardware signal. The parts catcher function for the SKT15 is enabled and disabled by way of a G.DATA bit. This bit is D0009.6 and must be set to a value of 1 in order for the parts catcher to be valid. Typically the value displayed will be in decimal so you must convert the 8 bit binary number to decimal then input. If the value in D0009 is currently 0 you must enter a value of 64 (01000000). Normally on this machine the value of D0009 will be set at 32 from the factory so you would add the two and enter 96.The Krras Bend 70.30 with PGP601 back gage controller uses only 12 parameters in the controller. They are:Parameter      Definition                                          Setting                                   1              Index Quote Programming                           2              Overrun Distance                                    0.0003              Slowing Down                                        0.4004              Inertia Quote (PGP calculates every 2 positions)    0.0045              Position Tolerance                                  0.0046              Retraction                                          0.2007              Time Before Retraction                              0.0048              Negative Limit Switch                               0.4509              Positive Limit Switch                              23.20010             Encoder Multiplier (1, 2, 4)                        411             Encoder Divide Factor                               9.862512             Programmable Point Decimals (0, 1, 2, 3)            0.003

• The above settings are typical and may be different for other machines.

• The Index Quote Programming value is defined by the customer and varies depending on how far the fingers, etc. are from the die. For a twelve lead AC motor there are six windings with two leads for each set. The numbering for the sets is typically:U1-X1U2-X2V1-Y1V2-Y2W1-Z1W2-Z2The resistance of each winding is normally in the range of 1 ohm. When the motor is wired for DELTA (low voltage) operation there are essentially three sets of two windings with the two windings of each set in series. Using the numbering above, this is accomplished by connecting the leads as follows:U1 to Z2X1 to U2X2 to V1Y1 to V2Y2 to W1Z1 to W2The three phase voltage would be connected this way:

L1 to U1, Z2L2 to X2, V1L3 to Y2, W1For WYE operation, connect the leads as follows:X1 to U2Y1 to V2Z1 to W2X2 to Y2 to Z2The three phase voltage for WYE operation is connected:L1 to U1L2 to V1L3 to W1This connection places four windings in series with respect to any two phases.Regardless of how the windings are numbered, you can wire the motor by ringing out the leads to find individual windings and wiring accordingly.Another thing to be aware of is that the wire numbering using alpha numeric such as U1, V1, W1, X, Y and Z is IEC nomenclature while numbering that uses numbers only such as 1,2,3,4 etc., is NEMA nomenclature.9 Lead Motor (Wye):Low Voltage4, 5 and 6 together, 1 to 7, 2 to 8 and 3 to 9, line voltage to 1/7, 2/8 and 3/9.High Voltage4 to 7, 5 to 8 and 6 to 9, line voltage to 1, 2 and 3.9 Lead Motor (Delta):Low Voltage1, 6 and 7 together, 2, 4 and 8 together, 3, 5 and 9 together. One phase of voltage to each set.High VoltageSame as for Wye connection.KIWA KNH-400B axis clamp/unclamp information:24vdc is supplied by wire HP at terminal block TB5 to Unclamp limit switch LS37 and Clamp limit switch LS36. Both switches are normally open. Closure of LS37 sends 24vdc through TM2-16 to wire X096 then to Fanuc I/O Module CB151 pin 16 turning on input X9.6. Closure of LS36 sends 24vdc through TM2-17 to wire X097 then to I/O Module CB151 pin 17 turning on input X9.7. On the output side Y3.7 (B AXIS CLAMP) sends 24vdc from Fanuc I/O module CB151 pin 9 to wire Y037 through TM2-9 connecting to CR18 coil. The return is wire HN. CR18 contact closure sends 110 vac from L1-9 to wire Y37C through connector CN1-L to B Axis Clamp solenoid SOL27. The return is L2-9. The solenoid valve is Daikin KS)-G02-3BA-30-E 100 vac.Stankoservis VTL:If the table will run at some speeds but not others check the glass fuses that feed the clutches. Each fuse feeds a different set of clutches. So if, for example, the 7th fuse from the left blows speeds 1.25-6.3 will not work. In this case the table brake also will not work. When the table is started and the arm feed engaged after a set time the table speed is locked and cannot be changed. If the feed is stopped, the table speed can then be changed and feed resumed. This function may be tied to the V=C switch.*** Model A163-2000 100 ***When replacing old faceplate with adapter cable must be ordered from Anilamand rewired according to drawing number AOC 1 in Anilam file. Also, on thismodel readout, if an axis direction indication is backward the wire harness from the scale can be reversed on the PCB to give proper indication.

Series 1100To run in Auto, make sure the AUTO/MAN switch is in AUTO.If no program is selected, won't go into Auto.There are four LEDs on the Motion Board, if the second one from the top isoff the machine is in E-Stop condition.There is a small power supply to the left of the relay board which suppliesthe 24 vdc for most things. The 110 volt supply for this unit comes from therelay board, from the connector on the lower right corner of the board. Itis a four pin connector, the other two pins are the 24vdc from the powersupply. K4 on the relay board has to energize first. The +24vdc for the coilof the relay is supplied directly to the coil, the -24vdc (common) is routedthrough the motion board. The common is a yellow wire on the power supply.The common signal from the motion board is at P1-1. It goes to P3-3 on therelay board. Having all of this in place will cause K4 to energize. To ener-gize the other relays and make the machine ready you have to press the SERVOENABLE soft key.On the 1100 control you change the direction of the motors by accessing theSetup Utilities. Direction +/- is shown as inverting/non-inverting.To access the CMOS setup you need a keyboard. There is a port on the controlto plug an AT keyboard but if you have a PS2 keyboard you have to plug itinto the CPU board. You have to press either F2 or DEL to enter setup. If thekeypad and VGA ports are both on the same board (CPU), use F2. Sometimes acontrol will default to a drive other than the one where the startup filesare stored. This may be caused when the CMOS battery dies. If you go to thesetup utility and change this but it does not hold, the battery is probablydead. The CMOS battery is Rayovac BR2335 or BR2330. Some of the CPUs use abattery inside the chip, these cannot be replaced. The board has to be upgrad-ed at a cost of about $1000.The password to access the setup utility is Y10.The Anilam 3300 has a MANUAL/AUTO switch on the back of the pendant. If thisswitch is in the MANUAL position, the servos will not power up. In this casethe control will act as a DRO only. If the control is powered up in MANUALthen switched to AUTO, it will still not be able to operate servos, theswitch must be in AUTO during power up. There is an I.D. key installed on theback of the pendant which identifies which options are available to the cont-rol. If the key is missing or damaged the options will not be available.Miscellaneous functions such as spindle operation are options on this controlso if the key is missing or damaged the spindle will not turn on. In thiscase the serial number (SER.NO.) of the I.D. key which is normally displayedin the upper right hand corner of the CRT display will read all zeros. Thekey is like a gender changer so other cables can be plugged into the back ofit. Certain cables such as a RS-232 plugged into the key will prevent it fromworking. The Motion I/O board has a row of LED indicators from top to bottomwhich indicate several things such as the status of the E-Stop, overtravelswitches and if the servo on signal has been turned on. When the SERVO ON/RESET button is pressed the corresponding LED should come on and the K1 relay(ice cube) should turn on energizing the solid state relay K2 which is mount-ed to the backplane of the cabinet with connection to the board via screwsthrough the board. This relay sends the 115 vac to the drives. If there isno display of position change when an axis is moved check the external powersupply which provides the 5vdc to the motor encoders via connectors on the

Motion I/O board.FANUC CONTROLS COMMUNICATION CABLEThe following cable configuration is required for communication between aFanuc control and a PC.Pinouts for two 25 pin connectors.          25 pin                        25 pin         connector                     connector           Pin 7    ----------------     Pin 7           Pin 2    ----------------     Pin 3           Pin 3    ----------------     Pin 2           Pin 4    ____        ____     Pin 4                        |      |           Pin 5    ____|      |____     Pin 5                       Pin 6    ____        ____     Pin 6                        |      |           Pin 8    ____|      |____     Pin 8                        |      |           Pin 20   ____|      |____     Pin 20Pinouts for one 25 pin connector and one 9 pin connector.          9 pin                         25 pin        connector                      connector           Pin 5    ----------------     Pin 7           Pin 3    ----------------     Pin 3           Pin 2    ----------------     Pin 2           Pin 7    ____        ____     Pin 4                        |      |           Pin 8    ____|      |____     Pin 5           Pin 6    ____        ____     Pin 6                        |      |           Pin 1    ____|      |____     Pin 8                        |      |           Pin 4    ____|      |____     Pin 20In both cases, pins not shown are not used. A ordinary parallel cable willnot work and if attempted could cause damage to the PC or the control sincePin 25 of ALL Fanuc controls is a 24 vdc supply for use with specific Fanucdevices.NULL MODEM CABLES9 Pin Null Modem Cable           Pin 1    ----------------     Pin 4           Pin 2    ----------------     Pin 3           Pin 3    ----------------     Pin 2           Pin 4    ----------------     Pin 1 and 6           Pin 5    ----------------     Pin 5           Pin 6    ----------------     Pin 4           Pin 7    ----------------     Pin 8           Pin 8    ----------------     Pin 7           Pin 9    No Connection25 Pin Null Modem Cable

           Pin 1    ----------------     Pin 1           Pin 2    ----------------     Pin 3           Pin 3    ----------------     Pin 2           Pin 4    ----------------     Pin 5           Pin 5    ----------------     Pin 4           Pin 6    -|                     |--------------     Pin 20           Pin 8    -|           Pin 7    ----------------     Pin 7                                                                               |- Pin 6           Pin 20   ----------------  |                                         |- Pin 8Pins not shown are not used.Pinnouts for M5 cable on Fanuc control:20 Pin Honda (M5)                25 Pin (RS-232)  Pin 2  ---------------------------- Pin 9  Pin 3  ---------------------------- Pin 8  Pin 4  ---------------------------- Pin 20  Pin 5  ---------------------------- Pin 19  Pin 6  ---------------------------- Pin 18  Pin 7  ---------------------------- Pin 17  Pin 8  ---------------------------- Pin 16  Pin 20 ---------------------------- Pin 5  Pin 25 ---------------------------- Pin 14If you have a 25 pin to 9 pin molded RS-232 cable, the pin outs are probablylike this:25 Pin                           9 Pin    Pin 2  ---------------------------- Pin 3  Pin 3  ---------------------------- Pin 2  Pin 8  ---------------------------- Pin 1  Pin 20 ---------------------------- Pin 4  Pin 7  ---------------------------- Pin 5  Pin 6  ---------------------------- Pin 6  Pin 4  ---------------------------- Pin 7  Pin 5  ---------------------------- Pin 8  Pin 22 ---------------------------- Pin 9The adapter that I use to make this cable work with controls is purchasedfrom Radio Shack, it is configured this way:  Pin 2  ---------------------------- Pin 3  Pin 3  ---------------------------- Pin 2  Pin 4  --                        -- Pin 4           |                      |  Pin 5  --                        -- Pin 5  Pin 7  ---------------------------- Pin 7  Pin 6  --                        -- Pin 6           |                      |  Pin 8  --                        -- Pin 8           |                      |

  Pin 20 --                        -- Pin 20This adapter is a RS232 SHIELDED JUMPER BOX 276-1403A. I normally use this inconjunction with a Radio Shack DOUBLE SHIELDED RS232C CABLE (6 feet). Partnumber is 26-269.A source for Fanuc and Mitsubishi cables is Machine Tool Services, they canmake motor and feedback cables for many CNC controls. Their phone number is480-985-1941.

Kia Turn 21 with Yasnac LX3.To enable the parts catcher you must make parameter 7005.1 equal 1. To do this:1.   Select MDI mode.2.   Press the SET button.3.   Cursor to Setting Parameter #6219 (PWE)4.   Enter 1.5.   Press the WR button.6.   Press the PRM button.7.   Cursor to parameter #7005.8.   Press the INSERT button.9.   Use the cursor down button to move to bit 1.10. Enter 1.11. Press the WR button.* Enter a value of 2 in parameter 7005.1 disables the parts catcher. If you do not change    the PWE back to 0 none of the M functions will work, etc.If the turret tools are confused on this machine:1. Rotate the turret to tool station 1.2. Set the PWE (parameter 6219) to 1.3. Select Jog mode.4. Press the TURRET SELECT and TURRET INDEX buttons together once.Hyd-Mech S-20A with Sequencer:The green light should be off until the hydraulics are started. The hydraul-ics will start with or without the switches in neutral, hold, etc. If thehydraulics start but shut off when the green button is released, check theblade tension switch (3LS). There is a handle on the left side of the machine.Turning the handle clockwise increases the blade tension and moves the dogtoward the limit switch. When this switch is open all of the machines funct-ions will work as long as the green button is held in except that the headwill not move down. Also when the switch is open the green pilot light thatis close to the blade tension adjustment will be off. The Required Quantity(Parts Count) display decrements each time the head reaches the bottom ofit's stroke. Once the count reaches 000 in Auto mode, the head should go upand everything shut off including the hydraulics (the sequencer display stayson). If when the shuttle moves back, enters slowdown then wants to keep goingcheck the stop switch. If the length adjuster is loose the switch can causeit to slide keeping it from making the switch. The Index and Required Quant-ity displays can not be changed unless the hydraulics are running.The circuit for the hydraulics:110V-------{ }------|/|------|/|------|/|------|/|------|  |-----(  )-----N           1FU      1OL      2OL      1PB  |   3LS       1M    |  1M                                           |                   |                                           |                   |                                            -------| |---------

                                                   2PB                                                   2PB1FU - 5 amp fuse1OL - Hydraulic motor overload2OL - Blade motor overload1PB - Stop pushbutton3LS - Blade break limit switch1M  - Hydraulic motor holding contact and motor starter2PB - Hydraulic start button (green button)PLC100 Error Codes:PLC100 Error Codes:00  Auto Mode Input Not Detected01  Hydraulics Run Input Not Detected02  Shuttle Vise Closed Input Not Detected05  Head Up Input Not Detected06  Head Down Input Not Detected09  Shuttle Home Input Not Detected10  PLC100 Did Not Reach Programmed Shuttle Length11  Shuttle Encoder Channel A and B Are Reversed12  No Encoder Input Has Been DetectedPLC100 Setup Parameters for H-12A S/N A0995418A:                                             #         Set ValueA  Machine Symbol                           N/A        H-12AB  Shuttle Length Constant                  0          31478C  Pulses Per Revolution of Encoder X10     1          40000D  Shuttle Length (Inches)                  2          40E  Rear Cushion                             3          1F  Front Cushion                            4          1G  Overshoot                                5          .016H  Front Vise Dwell                         6          750I  Shuttle Vise Dwell                       7          750J  Wheel Constant                           8          43K  Wheel Pulses Per Revolution              9          740L  Machine Characteristics                  A          1When "PAUSED" is displayed the Out Of Stock Limit Switch has been activated. If the hydraulics will not stay on, try holding the button in then usingthe manual buttons to open the vises. If the blade break proximity switchis bad or out of adjustment the machine will start and run until it "sees"that the blade is not moving. It does this by having the prox switch look atthe driven wheel.On V18APC, if the hydraulics will not start, the encoder cable may beshorted.On the V-18APC, if the length measurement is off on straight (90 degree) cuts, adjust the INCH/REV parameter. If the cut comes out too long, increase the value, if too short, decrease the value. If it is off on angle cuts, adjust the DP RADIUS parameter. The BP RADIUS parameter is normally used for when there is a measurement error when going from an angle cut to a straight cut.The S-20P Series III uses a Mitsubishi FR-S520E-2 inverter for the blade motor. If it displays alarm OV3 it normally means that the regenerative voltage was too high during deceleration. The decel time is set from the factory at .5 seconds so under certain conditions this may not be enough. You can increase the decel time by changing inverter parameter number 8. You have to change parameter number 79 from 2 to 1 to unlock the other parameters.Mazak Service        704-821-3340      Jim

This office should be used whenever possible but in case of dire need you cancall the Atlanta office:770-996-1030Most Mazaks use a main breaker which is interlocked through the door switches. If a door is opened, the main breaker will trip removing all powerfrom the machine.*** Micro Turn ***The tool turret uses Reed switches mounted in a circular pattern to controlindexing. Each position has two switches. One is for decelerating the turretmotor and the other is for locating. They are mounted to a PCB which is hardwired to the machine. It can only be removed by de-soldering all of the wires.An arm with a magnet on one end rotates counter clockwise to activate the switches. When working properly they can be heard closing as the magnetpasses each position. To orient the turret:1. Call up a tool.2. Once the turret locates, loosen the bolt holding the arm and move it to   toward the switch which corresponds to that number. (The tool positions   are printed on the PCB)3. Listen carefully and as soon as the switch closes, stop the arm and    tighten it down.If a position confirmation switch fails in the open state, the turret willindex continually when that tool is called. The height of the magnet relativeto the top of the switch is very important. It should be about .060". If theswitches are not located correctly the turret may stop at the correct position but will unable to locate and re-clamp. If this happens and you donot know which switch is out of position or if the height is wrong, a goodplace to start is to:Slightly raise the first switch from CCW (Decel switch) above the board.Press the second switch (Position confirmation) flush with the board.If the turret still has trouble re-clamping, try moving the second switch alittle away from the first. Remember, these are Reed switches soldered to theboard so be careful not to bend the leads too far.*** Micro Center V ***If Machine Fail light stays on, check the Head Lube Pressure switch. Thisswitch is on the right side of the spindle in a tee in the oil line. Thisswitch has only one wire. It is connected between the timer coil and ground.If the pressure is too low, it closes and energizes the timer. The Lubelight on the side of the machine will also be on.For CHECK SUM ERROR on Mazatrol M2, press the PARAMETER key in menu, press theNEXT key in menu (F3). The bad ROM causing the check sum error will be displ-ayed in CS20. If the first digit from the left is 0, the bad ROM is on boardFX84, if it is 1, the bad ROM is on FX84-1. The next two digits from the leftindicate the location of the bad ROM on the board.For M2V/B check CS24. If the first digit from the left is 0, the bad ROM ison board FX784-8, if it is 1, the bad ROM is on board FX784-9. Again, thenext two digits from the left indicate the location of the bad ROM on theboard.For Mazatrol T2/T3, select the DIAGNOSIS screen, select CHECK S/W VERSION,when a check sum error has occurred where the software version is normallydisplayed (MIL) will, instead, display the location of the bad ROM (i.e.5K). Should look like:

LANEIAMIL   5KDNCYASKAWAChicago Technical Center  847-291-2340 Technical Representative Eric Jozaitis direct line 847-291-6201Manuals and other publications  847-509-6057  Theresa Vanover direct line.AC Inverter model 616G3:If Ov (over voltage) alarm occurs, the deceleration time is probably tooshort. If a braking resistor is installed, the resistor may have opened.If a braking resistor is not installed, adding one may solve the over voltageproblem. This should be wired into the B1+ and B1- terminals to bleed off theexcess current in the DC buss. Another thing that may prove helpful is toadjust the S curve to decrease the linearity of the ramp. In some cases themotor that the inverter is driving can overdrive the inverter on decel whichcauses the Ov fault. Specifically, on the 6BVS the belts can be worn orloose in which case there is not enough load or drag and if the velocity ofthe motor is relatively great when decel is attempted the counter EMF willexceed the limit of the DC buss.Also check Parameter N032 Motor KW to be sure it is set high enough for thesize of the motor. Another thing to check for is the AC voltage parameters.If the incoming AC is 220 volts Vmtr, N003, and N011 should be 220.

On some inverter models the Fault outputs(FLT A, FLT B) are programmable.They can be made to open or close their contacts for conditions other than inverter faults (On Start-up, Up to Speed, Zero Speed, etc.) by changingparameters. In most cases, the associated parameters will be N036,N037,andN038. If changing these values does not provide the desired results thenconsult with Miles at Yaskawa.If constant n010 is set improperly, you will not be able to change constants11-18. On most units it is set to F, but this pattern will not work for allapplications and you will have to select another or build one yourself.Parameters for 616PC5 installed in 6BVS:Accel       5.0Decel       5.0Vmtr        220.0V/F         FFgain       100Fbias       0FLA         19.6PID         0kWsav       0PRGM        n068n001        3n002        3n003        220.0n004        1    n005        1n006        0n007        1

n008        1n009        1n010        Fn011        220.0n012        180.0n013        220.0n014        60.0n015        3.0n016        15.0n017        1.5n018        10.0n019        5.0n020        5.0n021        10.0n022        10.0n023        1n024        0n025        0.0n026        0.0n027        0.0n028        0.0n029        6.0n030        100n031        26n032        19.6n033        1n034        3n035        0n036        2n037        4n038        9n039        10n040        0n041        1n042        0n043        1n044        0n045        0n046        100n047        0n048        0n049        1.00n050        6n051        0n052        110n053        0.7n054        60n055        2.0n056        0n057        0n058        0.0n059        0.0

n060        1.0n061        1n062        1n063        0n064        50n065        0.5n066        0.0n067        1.0n068        0.434n069        172n070        1n071        170n072        160n073        0.0n074        0n075        160n076        0.1n077        0.0n078        0.0n079        0n080        7n081        8n082        0n083        0.2n084        0n085        1.00n086        1.0n087        10.0n088        0.00n089        0n090        100n091        0.0n092        0n093        0n094        1.0n095        0n096        94.75n097        50n098        12n099        1n100        0n101        0.5    n102        0.2n103        1n104        1n105        0n106        0n107        2n108        1n109        0.0n110        30n111        2.0

n112        0n113        2.0n114        0n115        5n116        0

The 616PC5 has a design defect in that the control card made by Saftronicsexhibits erratic behavior at frequencies between 124.5 and 160.1 Hz. Thisis caused by an older version of software which contains a program error.The software version is Ver. 1010 and has been replaced by Ver. 1015 whichdoes not exhibit these symptoms. The software is surface mounted to theboard and cannot be replaced. The memory is not EE so it cannot be changedeither. The only fix is to replace the control card with a ver. 1015. Theonly precaution is to be sure that the replacement card is for an inverterof the same KW rating as the one being replaced. To determine the softwareversion of a drive, look in U-10. this is where the version is stored. Youmust use the display key to scroll over to Montr. then use the arrow key toscroll up to U-10 then press enter. The version will be displayed.The phone number for Saftronics is  800-533-0031. Ask for Glen.The following is a current table for the 6BVS:Hz            60       80      100      120       140       160      180Gear LoMotor Lo      11.0     6.5     4.8      3.9       3.4       3.1      2.8Gear LoMotor Hi      7.1      4.3     3.3      2.9       2.8       2.8      3.0Gear HiMotor Lo      11.0     6.5     4.8      3.9       3.4       3.2      2.9Gear HiMotor Hi      7.1      4.3     3.4      3.2       3.4       3.5      4.0Some inverters will allow access to more constants than others. To gain access to more of them on the 616PC5, change constant n001 to a value of616. This should allow you to access up to constant n140. The newest versions of software for the 616 as of 11/97 is 2010 and 3010.Parameter Access of 616PC:When:n000=00   Constants 1-19 can be read but not writtenn000=01   Constants 1-19 can be read and writtenn000=02   Constants 1-29 can be read and writtenn000=03   constants 1-59 can be read and writtenES3000 EDM:The ES3000 with a Heidenhain control, as with most Heidenhain controlled EDMsuses the following procedure for operation. After power-up:1.Press CE.2.Press the Sine Wave (Symbol) button to turn on generator power.3.Home all axes by pressing Start once for each axis.4.Press the PGM RUN button. (This is usually a symbol pointing to the right)5.Press GOTO.6.Press 0.7.Press ENT.8.Press START.This will take you to the beginning of the program and begin the discharge.

On the ES3000 there are four contactors which select the polarity. Two ofthese select positive polarity and the other two select negative polarity.One of the polarities must be selected which means any time you are trying toburn two of these contactors must be pulled in. If not the generator powerwill shut off when discharge is attempted. The green LED on the DC9343 boardcomes on when the polarity is selected. There are six contactors at thebottom of the electrical cabinet. The four on the left are the polaritycontactors. When the first and third from the left are pulled in, Reversepolarity is selected. When the second and fourth are selected, Normalpolarity is selected. The fifth contactor is the Dielectric Pump, the sixthis Generator Power.If the machine will not release from the E-STOP condition and the button isnot depressed, check for an axis over travel. The axis limits are tied betweenX21 pin 34 and X22 Pin 4. You can eliminate a machine problem by removingthese connectors and connecting a jumper between the two pins. Theseconnectors go to the Interface Board TNC3062 on connector CN6. X21 Pin 34goes to the 14th pin from the top on the front row of pins on CN6.X22 Pin 4 goes to the 12th from the top on the same row. The E-Stop button istied to pins 1 and 2 of CN1 on the TNC3062.The TNC306 control is for use on EDM machines. The TNC360 is for mills.If the BUFFER BATTERY alarm is issued, you need to replace the three AAbatteries. They are located in a black plastic tube in the gold coloredchassis. On the ES3000 this chassis is behind the Operator's Panel.Heidenhain recommends Duracell batteries because of the physical style.If you have trouble with an EDM machine that it won't move down when dis-charging. The generator comes on but the ram does not move. Make sure it isoff of the travel limit switch. If it is off of the switch, try replacingone or both of the small PCB boards (OSC).On the 6BVS machines that I interfaced with the SWI AGE3 controls, I removedall of the power leads going to the two motor contactors (FWD/REV). I did notmess with the auxiliary contacts. I used one normally open contact from eachcontactor and tied them in parallel so that any time either one is pulled inthe spindle inverter is enabled. When the control stops the spindle for atool change, etc., the contactors drop out disabling the inverter. I alsoremoved the motor leads from the overload relay. One of the two wires fromthe normally open contacts is tied to my forward and reverse contactors inthe electrical cabinet to their common terminal. The other wire is tied to#1 in the cabinet, feeding the common.Normally when powering up the ES-3000 with the Heidenhain TNC306E and start-ing to run, the sequence is:1.Turn the breaker on.2.The first screen is POWER INTERRUPTED.3.Press the CE button.4.Next screen is RELAY EXT. DC VOLTAGE MISSING.5.Press the Sine Wave button on the Remote Operator twice.  You should hear the contactors energize. You should wait a second or two  after the first push before pushing again. If not you may get the Emergency  Stop message.6.Next screen is TRAVERSE REFERENCE POINTS                 Z-AXIS                 Y-AXIS

                 X-AXIS  ----------------------------------------  ACTL.  X  nn,nnnn    Y  nn,nnnn         Z  nn,nnnn7.Press the START button on the Remote Operator.  The Z axis will reference.  Press it again.  The Y axis will reference.  Press it again.  The Z axis will reference.  There are no reference switches, the axes just move a pre-determined dist-  ance in a pre-determined direction. While each axes is moving, there will  be an asterisk displayed below ACTL. This indicates that the axes is not  in position which is, of course, normal while moving. If after an axis  stops, the asterisk does not turn off the axis has excessive offset. This  is the same as the In-Position signal on other controls. In this case you  must remove the asterisk. This is done by either making an adjustment on  the servo driver or in some cases replacing it. The older style servo  drivers only have one pot to adjust. This will normally remove the offset  but you need to check the Lag. This pot has limited use in this so if the  Lag is excessive you usually have to replace the driver. The newer ones  have more pots to work with. Check the Lag by going to the Lag display as  explained below. If an axis does not stop in-position, the asterisk is on,  the control will not transition to the next screen and will not operate  properly.8.Next screen is MANUAL INTERPOLATION                 INTERPOLATION FACTOR:                 X  nn,nnnn                 Y  nn,nnnn                 Z  nn,nnnnAt this point the machine is ready to be operated in Manual Mode.The Lag value differs between axes and at different feed rates but generallyshould not exceed about 700. Normally, if the Lag is too high, the axis willmove with a rough or jerked motion. Also you will notice that after releasingthe Jog button, the axis continues to move an abnormally long time.In order to adjust Lag you need to access the Lag Display screen. This is oneof the position screens. To do this:1.Press the MOD button (For Auxiliary Mode).2.Press either the Up Arrow or Down Arrow key until POSITION DISPLAY is  shown at the top of the screen.3.Press the ENT button until the Lag screen is displayed.4.Press the END button to exit the Auxiliary Mode.

When troubleshooting an axis problem on a TNC 306, a useful tool is theability to swap the allocation of the encoder inputs in the PLC. This is donewith Machine Parameter MP 110. On a four axis machine the parameter is norm-ally set this way:MP 110.0  0MP 110.1  1MP 110.2  2MP 110.3  3

This configuration assigns the X axis to connector X1 of the Processor board,the Y axis to X2, the Z axis to X3 and the fourth axis to X4. If you swapthe X axis cable from port X1 to X2 and the Y axis cable from X2 to X1, forexample, you must change the parameter to:MP 110.0  1MP 110.1  0MP 110.2  2MP 110.3  3If the problem still exists on the X axis the culprit is probably the scaleor encoder or their cable. All of this is aimed at troubleshooting mainlyfeedback of positioning problems. The idea here is to eliminate the PLC asthe problem.When troubleshooting an X,Y or Z axis MEASURING SYSTEM DEFECT alarm, a goodplace to start is the scanning unit. You will almost certainly find that thecause of this problem to be in the scale or it's cable.The Service Manual for the TNC 306/360 is useful in working on otherHeidenhain controls because the parameter section also list parameters forother controls such as TNC2500, TNC234 and TNC355.Connector designation for the TNC306 Logic Unit are:Processor boardX1    Encoder 1X2    Encoder 2X3    Encoder 3X4    Encoder 4X6    Encoder SX8    Nominal Value Output 1,2,3,4,SX9    VDU (BE or BF)X11   Hand wheel HR 130/330X12   Touch Probe SystemB     Signal GroundPLC boardX21   PLC OutputX22   PLC InputX23   TNC Operating Panel (TE)X24   Power Supply 24V for PLCX25   Data Interface V.24/RS-232-CX26   PLC I/O board (PL 400)X27   Machine Operating Panel (MB)Power SupplyX31   Power Supply 24V for LEHeidenhain calls the reader heads of it's scales, scanning units. In the caseof the LS 603, these are optical devices. They can be replaced without thecable. Remove the four screws on the front of the unit. Inside there is anAmp connector. Unplug this connector and remove the unit from the body.When ordering a new scanning unit, you will need the ID number. This numberis on the unit, it looks like:Id.Nr. 24992275 for example.Another important number is the ML number, this is the measuring length. Thisnumber is typically in millimeters (i.e., ML1740mm).When in need of Heidenhain parts you can call Heidenhain at 847-490-1191 or

Machine Tool Technicians at 804-714-0700.The Com port for RS-232 is X25.For the Euro Source ES-3000 at Xaloy, the control is Heidenhain TNC 306E.The NC Software is 260030 03G. The PLC Software is 252555 13.For RS-232 operations:1.Press the MOD button (Not the one for Graphics)2.Press the Down Arrow button until RS-232-C INTERFACE = is displayed (Top of  screen)3.Press the Right Cursor button until EXT is displayed.4.Press the Cursor Up or Cursor Down button until BAUD RATE is displayed.5.Type in the desired baud rate.6.Press the ENT button.The Transfer Protocol for RS-232 is DC1/DC3.The cable pin out for RS-232 is the same as Fanuc Standard.To output the Machine Parameters:1.Press the MOD button.2.Press the Cursor Up or Cursor Down button until CODE NUMBER = is displayed.3.Enter 95148.4.Press the ENT button. (Activates the MP code)5.Press the EXT button then the ENT button. (Prepares the NC for data output)The 6BVS with the Dynapath control has four wires to the motor aside from themotor leads. The two yellow wires go to terminals AM and AC on the F7 inver-ter. These wires are for the brake, the parameter that controls this multi-function output should be set so that it monitors the output frequency. Thetwo blue wires go to the motor fan. The parameter for this multi-functionoutput should be set to close when the motor is running.In order for the brake to work properly on this machine, the parameter B1-03must be set to 1 so that the motor will coast to a stop. If you try to decelthe motor and use the brake, at higher RPM the brake will come on while themotor is still decelerating, cut off, then the motor will start runningagain until brought to a stop under normal decel. If you try to reduce thedecel time enough for the brake to come on at the end of the decel curve, thedrive will fault due to DC buss over voltage.

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