Makino V55 Maintenance Manual
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Makino V55 Maintenance Manual

Makino V55 Maintenance Manual

Cnc vertical machining center with makino professional 3 control
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Table of Contents

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This guide is intended for use by Makino customers and Makino employ-
ees and assigns for the safe operation and maintenance of Makino equip-
ment.
This guide was developed through the combined efforts of:
Makino R&D Groups - FujiKatsuyama Japan
Makino Documentation Group - Mason USA
TM & Associates (Thos Mercer)
MBS Associates (Lynne Hays & Mark Hebbeler)
Makino Customer Support (Randy Ashley)
1st Release Date: April 1 1999
Revision(s) Date:
1. Revision B 6/21/99 Typos and DI # 4v-0865
Copyright © 1999 Makino, Inc. All Rights Reserved
•
No part of this manual may be reproduced or transmitted by any means or in any
form to parties other than which it is intended, without the expressed written
permission of Makino.
•
All specifications and designs may change without notice.
Every attempt was made to ensure that the information in this publication was correct at
the time of printing. As specifications and designs change, Makino is not responsible for
information that becomes incorrect or inaccurate after publication.
4V2B1563 (E)
  
V55 High-speed Vertical
Machining Center
with Makino Professional 3 Control
Maintenance Guide

i

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  • Page 1 All specifications and designs may change without notice. Every attempt was made to ensure that the information in this publication was correct at the time of printing. As specifications and designs change, Makino is not responsible for information that becomes incorrect or inaccurate after publication.
  • Page 2 • In addition, all safety requirements and guidelines found in Chapter 1 - Safety, the ANSI safety guidelines the Makino Safety Manual, shipped with the machine, and established company safety requirements and regulations must be followed. Taking personal responsibility for safety will prevent most accidents.
  • Page 3 Mon.-Fri. 7:00 a.m. to 8:00 p.m. Sat. 8:00 a.m. to 2:00 p.m. (Eastern Standard Time) Parts Express (888) Makino1 (625-4661) 24 hours, 7 days a week Fax: (888)-881-9289 Training Services (888) Makino1 (625-4661) or contact us on the World Wide Web at: www.makino.com 4V2B1563 (E)
  • Page 4    AVISO! Las personas que no pueden leer o entender en Ingles deben mandar traducir este manual y solicitar entrenamiento antes de operar o mantener la maquina. Todos los que trabajen en esta maquina deberan saber como operarla con toda seguridad y en forma correcta para evitar un posible dano.
  • Page 5    Chapter 1 Safety Precautions Chapter 2 Specifications Chapter 3 Preventive Maintenance Chapter 4 Machine Tool System Overview Chapter 5 Troubleshooting Chapter 6 Spindle Head Unit Chapter 7 Feed Axis Unit Chapter 8 A25 ATC (Automatic Tool Changer) Unit Chapter 9 Oil Controller Appendix A Alarms...
  • Page 6   ...
  • Page 7    Chapter 1 Safety Precautions For a Safe Working Environment Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 01-4va Safety.fm...

  • Page 8: Table Of Contents

    1.8 Electrical Maintenance Safety ......1 - 15 1.9 V55 Vertical Machining Center Safety ....1 - 16 1.9.1 Machine Safety Features .

  • Page 9: Overview

    This includes, but is not limited to, allowing only prop- erly trained and technically qualified personnel to program, operate and maintain the machining center. It is Makino’s policy and responsibility to design, manufacture, and market machining centers that are as reasonably safe as possible for their intended use.

  • Page 10: Danger, Warning, Caution Statements And Symbols

    It is important Table 1-1 that all employees recognize and understand the meaning of the safety symbols shown in Table 1-2 The location of safety labels for specific hazards on the V55 is described section 1.9.3 (pg 1-16) 1 - 2...
  • Page 11    ABLE DEFINITION OF DANGER WARNING AND CAUTION STATEMENTS Statement Meaning DANGER is the most severe safety statement. This statement DANGER means that either severe personal injury or death may result if the instruction(s) is not followed. WARNING is the next level of safety statement. It indicates that if WARNING the instruction(s) is not followed severe personal injury could result.

  • Page 12: Access To Information

       1.2.2 Access to Information We strongly recommend that a copy of these safety instructions and all provided guides, manuals, and technical information be kept near the machine. This information should be organized for quick access and use by operators, maintenance, and other personnel with duties related to the machining center.

  • Page 13: Lockout/Tagout Procedure

       1.2.4 Lockout/Tagout Procedure The machining center is powered by high voltage and other energy sources that represent potential hazards. To reduce the risk of injury or death establish, define, and practice a Lockout/Tagout procedure for the equipment in your facility. Lockout/Tagout defines a minimum safe procedure to be followed by per- sons who might be confronted with unexpected energizing, start-up, or release of stored energy that could cause injury or death.

  • Page 14: Personal And Professional Safety

       Personal and Professional Safety General safety precautions should be practiced everyday, but never become common place. Safety is the responsibility of every person on the job site. In this regard, consider yourself responsible for safety in your workplace. No one is better positioned to eliminate or prevent unsafe con- ditions than you.

  • Page 15: Equipment And Operation Safety

       • Obtain an MSDS for each chemical (such as cutting fluids, lubricating oils, greases, etc.) used on or around the machining center. Practice safe working habits and wear all protective equipment required. Know and understand the procedures to follow in the event: Your skin is exposed to the chemical.
  • Page 16    Be sure to Always: • Take steps to protect the machine tool and control cabinets from moisture and condensation. Moisture can damage electrical components, causing unwanted machine motion, leading to injury or machine damage. • Maintain the exact original color and vividness of any machining areas that are color coded as safety precautions.
  • Page 17 Never paint, alter, deface, or remove any danger, warning, or cau- tion label. (Replacement labels are available from Makino) Never change or by-pass the location of the stroke limit dogs, limit switches, interlock circuitry, etc.

  • Page 18: Environmental Safety

       Environmental Safety Follow these specific practices when working at the machining center: • The area around the machine should be well lighted, dry, and free from obstructions. Keep the area around the machine clean and in good order at all times. •...

  • Page 19: Lifting Safety

       Lifting Safety These lifting safety precautions must be followed by all persons responsi- ble for lifting. This includes, but is not limited to lifting machinery, machine components, and workpieces: • All lifting equipment must be properly rated for the weight being lifted. •...

  • Page 20: Hooks

       1.6.3 Hooks When using hooks: • Never exceed the lifting capacity of any lift hook. • Do not repair lifting hooks. • Destroy and discard bent lifting hooks. 1.6.4 Eye Bolts To ensure a safe load carrying capacity: •...

  • Page 21: Lifting The Machine Or Components

    Pre-Installation Guide. Before lifting, refer to shipping documents to obtain the weight of the machine or component being lifted. If the necessary weights cannot be determined, consult Makino. In addition: • Only qualified riggers should perform machine lifting operations.

  • Page 22: Mechanical Maintenance Safety

       Mechanical Maintenance Safety Mechanical maintenance procedures for Makino machining centers should be performed by properly trained and technically qualified person- nel. They should adhere to these specific practices when working with the machining center: • Always perform a Lockout/Tagout procedure before removing any safety guard, cover, barrier, or any basic component of the machining center.

  • Page 23: Electrical Maintenance Safety

    • Oscilloscopes. • Static Ground Wrist Straps. Machine Grounding All Makino machining centers must be properly grounded at the time of installation. • Proper grounding requires an isolated earth ground. • Ground the machine in accordance with local, state, and federal regulations.

  • Page 24: V55 Vertical Machining Center Safety

    1.9.1 Machine Safety Features The Makino V55 provides the following safety features: • Manual handle interrupt buttons, located on auxiliary operation panels, to prevent automatic operation of that unit, when active.
  • Page 25    Tools and fragments thrown out when machining with door open can cause injury or death. During machining, keep Door Interlock Release switch set to OFF. IGURE SPLASH GUARD DOOR SAFETY LABEL AND OPERATION PANEL E STOP BUTTON Improper insertion of tool can cause tool to be thrown during ATC cycle,...
  • Page 26 Before approaching, turn OFF power. IGURE SCRAPER CONVEYOR SAFETY LABEL AND MTC E STOP BUTTON DANGER MAKINO Touching rotating tool can cause injury or death. Do not approach rotating tool or spindle. Stop spindle before working on or near spindle.

  • Page 27: Tooling Safety

       Contact with moving parts can lead to entanglement and serious injury. Do not reach into conveyor during operation. Before approaching, turn OFF power. IGURE LIFT UP CHIP CONVEYOR SAFETY LABEL 1.10 Tooling Safety Standard Tooling Safety Precautions Always: •...
  • Page 28 Using tooling rated for maximum rpm prevents unsafe conditions due to improper spindle speed selection. • Balance all tooling to Makino’s recommendation. • Not all tools are designed for HSM and balancing alone will not make them safe for this application.

  • Page 29: Equipment And Operation Safety

    Prior to Machining • Check with the manufacturer of any accessory not designed, built, or supplied by Makino to ensure the device will operate properly and safely under the proposed operating conditions. • Load or unload workpieces only when the machine is completely stopped and the control is in STOP or RESET status.

  • Page 30: Coolant Safety

    V55: section 1.6 • The V55 has a maximum allowable table capacity of 700kg (1,543lb). Never exceed this weight limit. • Load and unload workpieces or fixturing only when the machine is completely stopped and the control is in STOP or RESET status or the Main Power switch is Off.

  • Page 31: Installation Safety Instructions

    Table 1-3 ABLE REQUIRED READING Publication Manual Title 1560 V55 Pre-Installation Guide 1563 V55 Maintenance Guide 1564 V55 Operation Guide Programming Manual for Horizontal/Vertical Machining Centers With 0794 Fanuc Computer Numerical Control Data Server - DNC Function User’s Guide †...
  • Page 32    OTES KETCHES 1 - 24...
  • Page 33    Chapter 2 Specifications Machine Unit and Control Specifications Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 02-4vb Specifications.fm...
  • Page 34 2.2.7 Coolant Unit ........2-10 2.3 Makino Professional 3 Control ......2-11 2.3.1 Control Panel .
  • Page 35    Overview This chapter contains the specifications for the machine’s main compo- nents (units), the control, and external dimensions and floor plans for the machining center and its various optional features. Information Subject to Change Every effort was made to ensure the accuracy of the data presented in this chapter at the time of its publication.
  • Page 36    2.2.1 Spindle The V55 11A spindle is a 14,000 rpm (standard) and available in a 20,000 rpm version (option). the spindle is driven by an integral AC motor. The spindle has a positive mechanical clamping mechanism to securely retain tooling and electric orientation system to facilitate automatic tool changes.
  • Page 37    IGURE SPINDLE POWER AND TORQUE CHARACTERISTICS 4V2A1563 (E) 2 - 3...
  • Page 38 Machine travel specifications are listed Table 2-2 The V55 uses a Fanuc digital servo system with 3.5 kW AC servo motors. This servo system reach full rapid traverse (50,000mm/min. (1968 ipm)) in less than 38mm (1.5") of travel, while maintaining positioning accuracies.
  • Page 39    IGURE AXIS CONFIGURATION TRAVEL AND WORK CUBE 4V2A1563 (E) 2 - 5...
  • Page 40    2.2.3 Table Table specifications are listed and shown in Table 2-4 Figure 2-3 Workpiece size limitations are shown in Figure 2-4 ABLE TABLE SPECIFICATIONS Specification Item (approx. US) Table Dimensions [L × W] 1,000 × 500 mm (39.37 × 19.7") T-Slots, Five 18 ×...
  • Page 41    IGURE WORKPIECE SIZE LIMITATIONS 4V2A1563 (E) 2 - 7...
  • Page 42    2.2.4 Automatic Tool Changer An ATC (Automatic Tool Changer) provides several advantages in extending no or low-attendant machining, automating multiple operations, assigning spare tools for long job runs, etc. lists the ATC specifications and illustrates tool limita- Table 2-5 Figure 2-5 tions.
  • Page 43    IGURE AUTOMATIC TOOL CHANGER TOOLING LENGTH AND DIAMETER LIMITATIONS 2.2.5 Oil Controller Oil controller specifications are listed in Table 2-6 ABLE SPINDLE OIL TEMPERATURE CONTROLLER SPECIFICATION Specification Item (approx. US) Cooling Capacity 7270/8370 W (50/60 Hz) Cooling Compressor 2.2 kW (2.95 hp) Tank Capacity...
  • Page 44 2.2kW (2.95 hp) 2.2.7 Coolant Unit Water-based coolant is recommended for this machining center to avoid the possibility of fire. Please consult Makino before using an oil-based coolant. Coolant system specifications are listed in Table 2-8 ABLE COOLANT UNIT SPECIFICATIONS...

  • Page 45: Control Panel

       Makino Professional 3 Control The Makino Professional 3 (PRO 3) control provides user friendly features with Custom side PMC functionality and vivid graphic displays. Standard configuration of the control is listed below. 2.3.1 Control Panel Feature Detail LCD and MDI Panel...
  • Page 46 GI software optimizes the feedrate-to-tool path and sends readable data directly to the drives. SGI (Super Geometric Intelligence), also a Makino technology, is based on the GI control software. SGI (option) provides enhanced capabilities, like improved processing of small NC data blocks. SGI is especially effec- tive for machining 3-D shapes of molds and dies involving continuous exe- cution of minute blocks under 1mm (0.040").
  • Page 47    2.3.3 Machine Communications Feature Detail RBU (Remote Buffer Unit) Standard Memory Capacity 2,000 Characters / 16.6 ft Software Interface Protocol A, B RS-232 Baud Rate – 50 to 19,200 Maximum Cable Length – 330ft at 4,800 baud and 150 ft I/O Communication at 9,600 baud Ports...
  • Page 48    2.3.4 Maintenance and Safety Feature Detail Emergency Stop Axis Overtravel Protection Software Interlocks Maintenance and Safety Self-diagnostics – CNC and Custom side Alarm History – CNC and Custom side Help Function – CNC and Custom side 2.3.5 Controlled Axes and Coordinate Systems Feature Detail Number of Axis –...
  • Page 49    2.3.6 Programming Feature Detail Memory – 31,680 characters or 80 meters (264’) of tape. Storage Number of registrable programs – 63 Standard CNC Language Minimum Input Increment – 0.001 mm (0.0001”) Maximum Programmable Increment – ±8 digits ±99999.999 mm (±9999.9999”) Subprogramming –...
  • Page 50    2.3.7 Tool Offsets Feature Detail Tool Length Offset – G43, G44, and G49 Tool Radius Offset C – G41, G42, and G40 Tool Offsets Number Of Tool Offsets – 99 Tool Offset Memory – Type A 2.3.8 Operational Support Feature Detail Label Skip...
  • Page 51    2.3.9 Compensation Functions Feature Detail Stored Pitch Error Compensation Backlash Compensation Control Compensation Functions Friction Compensation – for GI motion control Feed Forward Look Ahead – for GI motion control Unidirectional Positioning – G50 2.3.10 Interpolation and Feeds Feature Detail Rapid Positioning –...
  • Page 52    Installation Information This section contains information on machine size, electrical power, and air pressure specifications required by the machining center. 2.4.1 Machine Size Machine dimensions are listed in and shown in Table 2-9 Figure 2-6 • External dimensions and floor plans are presented in section 2.5 (pg 2- ABLE...
  • Page 53    IGURE FLOOR SPACE FOR STANDARD MACHINE 4V2A1563 (E) 2 - 19...
  • Page 54 100 ohms or less, must be provided. A step down transformer is provided to help regulate voltage and allow for different voltages. The V55 is set up to run on 200/220 VAC, 55 kVa, 50/60 Hz ±2% off the secondary side of the transformer. Secondary voltage output is connected to a terminal point in the MTC.
  • Page 55 Transformer Specification An additional transformer is provided for machines in different countries. Do Not Turn Power Make Connections only. All connections and settings must be confirmed by a Makino service representative, prior to applying power. North America The North American transformer is an external, stand-alone, floor type that can be located within a six-foot radius of the MTC.
  • Page 56 Makino recommends you have your air delivery system checked for dirt and moisture at or near the machining center’s point of connection. Add additional filters or water traps, as required.
  • Page 57 (Right), and APC – V55 with 40 or 80-Tool ATC Figure 2-12 (pg. 2-29) – V55 with 40 or 80-Tool ATC and Lift-Up Chip Con- Figure 2-13 (pg. 2-30) veyor (Left) – V55 with 40 or 80-Tool ATC and Lift-Up Chip Con- Figure 2-14 (pg.
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  • Page 68    OTES KETCHES 2 - 34...
  • Page 69    Chapter 3 Preventive Maintenance Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 03-4va Preventive Maintenance.fm...
  • Page 70 3.2.2.1 Guidelines for Grease Lubricated Systems ..3 -4 3.2.3 Makino Recommended Lubricants ....3 -5 3.2.3.1 Automatic Lube.
  • Page 71 This chapter presents information on the recommended schedule for rou- tine maintenance and lubrication and Preventive Maintenance (PM) schedule for the V55 Vertical Machining Center with Makino Professional (PRO) 3 control. The importance of periodic maintenance and lubrication for any piece of equipment cannot be over emphasized.
  • Page 72 3.2.1 Oils The V55 components using lubricating oils include: the Oil Controller and the Hydraulic System. The Oil Controller - uses Makino Spindle Luricant to lubricate the spindle and ball screw TAC bearings; and for cooling the spindle, ball screws, and other machine components.
  • Page 73 Using oil of different viscosity affects the system running temperature, load, and pressure promoting wear and premature failure of system components. • Makino recommends using our listed oils only. Tests have proven these oils to be superior pertaining to the machine tool and its performance. •...
  • Page 74 These greases are incompatible and may result in an undesirable chemical reaction causing premature failure of components. The V55 components using lubricating grease include: the X, Y, and Z axes ball nuts and LM (Linear Motion) guide way systems. X, Y, and Z Axes Ball Nuts - are grease lubricated, manually from two central sources or automatically from the optional, cartridge type, Auto- matic Grease Supply Unit.
  • Page 75 Makino for use Table 3-1 on the V55 and are supplied with the machine. Using other oils or greases may result in damage to the machine tool or its components. Regular oil changes and cleaning of the reservoirs keeps lacquer build-up to a minimum and reduces component failure.
  • Page 76 LM guides at specific intervals. This unit uses a grease car- tridge and is equipped with a limit switch to generate an alarm when the cartridge needs replaced. Recommended Grease Cartridge: Unilub DL No2T Grease • Replacement cartridges are available from Makino; part number GKL- 2-050 3 - 6...
  • Page 77    Lubrication Breakout Chart provides detail for units requiring oil lubrication. Use Table 3-2 Fig- (pg. 3-8) for the locations of related fill and drain ports. ure 3-1 IGURE LUBRICATION BREAKOUT DRAWING 4V2A1563 (E) 3 - 7...
  • Page 78 Change every 2000 hours of operation. Quantity 30 liters (7.9 gallons) Lubricant Makino Spindle Oil Method TO TOP OFF OIL: Remove the fill cap and top of the reser- voir. Add oil until oil level meets the full line in the sight glass.
  • Page 79    ABLE LUBRICATION BREAKOUT CHART CONTINUED X and Z Axes Ball Nuts Figure 3-1 - See DETAIL C - Lubrication Point Grease fittings located on right side of column. Frequency Every 1000 hours (6 months) of operation. Quantity 40cc each ball nut. Lubricant Kluber Isoflex NBU 15 grease.10 liters (2.6 gallons) Method...
  • Page 80 The following tables provide PM and Lubrication checks on a Daily, Weekly, Monthly, Semi-Annual and Annual basis. Makino recommends you copy these tables and use them as a PM and Lubrication Schedule for your machine. Each table provides "blank" rows for you to add PM or Lube tasks that may be specific to your machine.
  • Page 81    3.4.1 Initial Checks Perform these checks three months after installation of the machine tool. Though performed only once, these tasks are the most important PM items to be performed. It is during the first three months of operation that the initial "break-in"...
  • Page 82    3.4.2 Daily Checks Perform Daily PM checks at the beginning of each shift. These are simple visual checks, performed in a few minutes. Use the Daily Inspection chart ) mounted on the side of the machine as a guide to component Figure 3-4 locations.
  • Page 83    ABLE DAILY PM CHECKS SHEET Checked Daily PM Checks Action Date GENERAL CHECKS 1. Clean dirt, dust, and chips off the tapered shank of all tooling. 2. Clear all obstacles from around or within the range of machine movement.
  • Page 84    ABLE DAILY PM CHECKS SHEET Checked Daily PM Checks Action Date COOLANT UNIT 1. Check coolant level and concentration. Add as necessary. 2. Clean the chip pan of chips MAIN AIR SUPPLY (FR UNIT) 1. Check air pressure. Air pressure should be 0.5 MPa (70 psi) AIR DRYER 1.
  • Page 85    3.4.3 Weekly Checks ABLE WEEKLY PM CHECKS Checked Weekly PM Checks Action Date GENERAL CHECKS 1. Perform all listed Daily checks. OIL CONTROLLER 1. Perform all listed Daily checks. 2. Clean the air filter. MAIN AIR SUPPLY 1. Inspect incoming air hose for cuts and leaks.
  • Page 86    3.4.4 Monthly Checks ABLE MONTHLY PM CHECKS Checked Monthly PM Checks Action Date GENERAL CHECKS 1. Perform all listed Daily checks. 2. Perform all listed Weekly checks. MAIN POWER SWITCH Check operation of Main Power switch: 1. Turn the Main Power Switch Off. 2.
  • Page 87    3.4.5 Semi-Annual (1000 Hour) Checks ABLE SEMI ANNUAL PM CHECKS SHEET Checked Semi-annual PM Checks Action Date GENERAL CHECKS 1. Perform all listed Daily checks. 2. Perform all listed Weekly checks. 3. Perform all listed Monthly checks. 4. Inspect all piping, connections, actuators, etc.
  • Page 88    ABLE SEMI ANNUAL PM CHECKS SHEET Checked Semi-annual PM Checks Action Date 5. ATC shutter door - Clean door and opening. Check for damage and proper operation. Adjust positioning rate and cushioning, as necessary MACHINE LEVEL AND ALIGNMENTS 1.
  • Page 89    3.4.6 Annual (2000 Hour) Checks ABLE ANNUAL PM CHECKS SHEET Checked Annual PM Checks Action Date GENERAL CHECKS 1. Perform all listed Daily checks. 2. Perform all listed Weekly checks. 3. Perform all listed Monthly checks. 4. Perform all listed Semi-Annual checks.
  • Page 90    ABLE ANNUAL PM CHECKS SHEET Checked Annual PM Checks Action Date MACHINE LEVEL AND ALIGNMENTS 1. Check machine level, adjust as necessary. MACHINE ALIGNMENTS 1. Perform the Backlash Measurement procedure and, if necessary, adjust Parameter 1851. chapter 7 COOLANT TANK 1.
  • Page 91    Leveling the Machine When the equipment is first installed, the level and alignments are set. There are many variables which can affect the level and alignment (i.e. foundation or surrounding equipment and activity). It is a good practice to check the level and alignment of new equipment every three months until a proper assessment of the machine environment can be predicted.
  • Page 92    Level the Machine The leveling procedure describe using two levels. If only one level is used, set the level in the X axis plane, note the reading and make a level adjustment; move to the Y axis plane, note the reading and make a level adjustment.
  • Page 93    IGURE LEVELING BASE POSITIONS AND BED TO FLOOR CLEARANCE 4V2A1563 (E) 3 - 23...
  • Page 94    OTES KETCHES 3 - 24...
  • Page 95    Chapter 4 Machine Tool System Overview Description of Basic Components, Communication Interface, and the PMC Address Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 04-4va MT system.fm...
  • Page 96 4.3 Makino Professional 3 Control ......4 -6 4.3.1 Makino PRO 3 Features ......4 -6 4.3.2 Basic Components .
  • Page 97 Effective troubleshooting of any system or component must begin with a basic understanding of the operation of the system or component. An explanation of the Makino V55 machine tool system, its basic compo- nents, and operating principles follows. An overview of the machine tool proper, its main components, and the machine tool system.
  • Page 98    Description of Main Machine Components The V55 provides efficient, highly accurate machining, and standard Makino control features. Unique design features include: • Unitized design with rigid column and bed that permits 3-point leveling, reducing special foundation requirements. •...
  • Page 99    IGURE MACHINE CORE ELEMENTS 4V2A1563 (E) 4 - 3...
  • Page 100 (down to and up from the table) and is mounted to the front of the saddle by LM (Linear Motion) guides. The spindle head is mounted to the ram. The V55 spindle has an integral motor with a standard speed range of 15 to 14,000 rpm, programmable in 1 rpm increments.
  • Page 101    13. Main operation panel – provides the controls and screen display used to operate the machine. The panel swings 90°, allowing flexibility of operation. 14. Splash Guard – fully encloses the work zone containing chips and coolant and protecting the operator. The splash guard door slides to provide a 920mm (36") opening with top access, for loading and unloading.
  • Page 102    Makino Professional 3 Control Makino uses the PRO 3 (Professional 3) series control to operate the V55. The PRO 3 consists of: • Fanuc 16M hardware for both the CNC and the PMC • Fanuc 16M operating software for control of the CNC •...
  • Page 103    MPC5 IGURE MAKINO PROFESSIONAL CONTROL WITH 4V2A1563 (E) 4 - 7...
  • Page 104    4.3.2 Basic Components The V55 machine tool system has three basic components, shown in Fig- and described below. ure 4-4 1. The CNC (Computerized Numerical Controller) – The CNC is the initial controller/processor in the machine tool system as it receives and performs the initial processing of the program data.
  • Page 105    3. The MT (Machine Tool) – The MT is the machine itself. The machine proper consists of the axes (X, Y, and Z), the spindle, ATC (Automatic Tool Changer), tool magazine and related components, and any options such as AMS (Automatic Measuring System), ATLM (Automatic Tool Length Measuring), APC (Automatic Pallet Changer), etc.
  • Page 106    OTES KETCHES 4 - 10...
  • Page 107    Machine Tool System Interface The machine tool system includes the basic machine tool system components; the MT and PRO 3 control (which includes the CNC and PMC). The system interface provides a method of controlling and communicating data and infor- mation among the separate components.
  • Page 108    4.4.1 CNC to PMC Communication The basic components of the CNC to PMC communication interface are shown in Figure • The CNC controls axis positioning, internal I/O, program storage/execution, and communication with the PMC. When program data is input (via MDI, Mem- ory, or Tape) the CNC processes the data on several levels and assigns the data as either: CNC (Control side) data –...
  • Page 109    Since the PMC to MT communication signals require very low voltages (usually 5VDC) the F-BUS terminates at the PMC and an I/O rack forms the communication link from the PMC to MT. The I/O rack contains a num- ber of I/O Modules (based on machine configuration).
  • Page 110    The PMC Address As the intermediate processor in the system interface, the PMC sends and receives signals to and from the CNC and MT. System communications is designed using the PMC as the center of communication and labels these signals with a PMC address to denote the direction of signal flow, within the system ( Figure 4-9...
  • Page 111 F address denotes a DI to the PMC from the CNC and a G address denotes a DO to the CNC from the PMC • These signals are considered internal to the Makino PRO 3 system and are not typically shown in the schematics. •...
  • Page 112    Data Bit Location and Display There are eight data bits per PMC address. The number to the right of the decimal point represents a signal's data bit location. • Data bits are numbered zero (0) through seven (7) and read from right to left, as shown in Figure 4-11 •...
  • Page 113    Troubleshooting and the PMC Address The PMC address is a powerful tool on troubleshooting and diagnosing system faults. The PMC address is used in the: • Schematics (Machine Electrical Drawings) to indicate signal names. • PMC Diagnostic I/O function on both the CNC and Custom side displays.
  • Page 114    OTES KETCHES 4 - 18...
  • Page 115    Chapter 5 Troubleshooting MT System Troubleshooting Guidelines and Techniques Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 05-4va Troubleshooting.fm...
  • Page 116    Chapter 5 Troubleshooting Contents 5.1 Overview ......... . . 5 -1 5.2 Troubleshooting Guidelines .
  • Page 117    5.4.8.4 CNC and I/O Rack Fuses ..... . 5 -40 5.4.9 Axis Servo Components ......5 -42 5.4.9.1 PIL and ALM LEDs .
  • Page 118    5.7.4.1 Wiring Material Application Table Detail ... . 5 -71 5.8 Schematic Interpretation ......5 -72 5.8.1 Page Format .
  • Page 119 Use this chapter in conjunction with other chapters in this guide, the sche- matics, and the CNC Maintenance Manual. • In the event your preliminary checks prove unsuccessful, call your Makino service group. 4V2A1563 (E) 5 - 1...
  • Page 120    Troubleshooting Guidelines When diagnosing a problem on any piece of equipment, regardless of the fault, follow these basic guidelines: Confirm The Fault This is simply making certain you know what the symptoms are. Be sure you understand the situation surrounding the occurrence. This is particularly important when investigating a fault for someone else who may not have described it accurately.
  • Page 121 The first step in any fault finding (troubleshooting) is deciding where to begin the investigation. • Makino equipment is set up with two-level alarm and diagnostic displays, which provide key starting places for pursuing faults. • In troubleshooting, a calm and logical approach will prove to be of the greatest benefit.
  • Page 122    Basic Troubleshooting Troubleshooting is the logical elimination of all necessary steps in a pro- cess or the potential variables within a step until the “Fault” is uncovered. 1. When a fault arises, gather as much information as possible about the events leading up to the fault.
  • Page 123    IGURE BASIC TROUBLESHOOTING FLOW CHART 4V2A1563 (E) 5 - 5...
  • Page 124    OTES KETCHES 5 - 6...
  • Page 125    CNC Troubleshooting Details for troubleshooting CNC faults are presented below. The informa- tion includes: • References to other chapters in this Maintenance Guide and the CNC Maintenance Manual. • Information on the use of the CNC troubleshooting tools. •...
  • Page 126    5.4.2 Troubleshooting and the CNC Maintenance Manual The CNC Maintenance Manual contains information required for investi- gating most CNC, axis servo, and spindle drive problems. Look through the table of contents for headings related to your current sit- uation.
  • Page 127    8. TROUBLESHOOTING B-62445E/03 When a failure occurs, it is important to correctly grasp what kind of failure occured and take appropriate action, to promptly recover the CORRECTIVE machine. ACTION FOR Check for the failure according to the following procedures: FAILURES With what When?
  • Page 128    5.4.3 Troubleshooter's Road map This road map is provided to facilitate getting started troubleshooting the CNC. The CNC side of the machine tool system consists of the CNC, axis servo drive, and the spindle servo drive. Each unit is Fanuc hardware and should be troubleshot accordingly.
  • Page 129    5.4.3.2 CNC Alarm is Displayed screen is displayed automatically when a CNC alarm ALARM MESSAGE occurs. Axis and spindle servos are controlled by the CNC. Some servo alarms are displayed on the CRT and others are displayed on the drive unit’s self- diagnostic display.
  • Page 130    5.4.4 CNC Alarm Display The CNC alarm function consists of the ALARM MESSAGE ALARM HIS- screens. CNC alarms are divided into types by number groups, as TORY shown in . An overview of the CNC alarm function follows. Table 5-1 •...
  • Page 131    ABLE ALARM TYPES Alarm Alarm Alarm Type Description Range Type 000-299 Program/Set up alarms are caused by operator error or program- ming/set up errors (i.e. error in program format). 300-349 Absolute Pulse Coder alarms, relate to storage/transfer of abso- lute position data.
  • Page 132    5.4.4.2 Alarm History screen, ALARM HISTORY Fig- , provides a record of the ure 5-4 last 25 CNC alarms generated. Each record consists of; the date (year/month/date), the time (military time), the alarm num- ber, and a brief error message. The first alarm record on page 1 is the most recent alarm and the alarm at the bottom of page 5 is...
  • Page 133    5.4.5 CNC Diagnostic Status Function This function displays signal status for internal CNC and CNC to PMC communication. Six diagnostic status displays categories are provided: GENERAL (000 - 031) SERVO ALARM (200 - 280) SERVO STATUS (300 - 311) SPINDLE STATUS (400 - 420) RIGID TAPPING (450 - 457) INDUCTOSYN (380 - 381)
  • Page 134    5.4.5.2 Diagnostic (General) Screen DIAGNOSTIC (GENERAL) screen ( ) displays Figure 5-5 internal CNC status for: COMMANDS APPARENTLY NOT EXECUTED (000 - 016) STOP/IDLE STATUS (020 - 025) TH ALARM STATUS (030 - 031) and as detailed in Table 5-2 IGURE DIAGNOSTIC...
  • Page 135    ABLE DETAILS OF CNC STATUS CONTINUED WAITING FOR RESET, ESP, RRW One of the following conditions exists: 1. E-Stop *ESP (X08.4 or G8.4) is 0. 2. External reset ERS (G8.7) is 1. 3. The MDI panel reset button is on. EXT.
  • Page 136    5.4.5.3 Diagnostic (Servo Alarm) Screen DIAGNOSTIC (SERVO ALARM) screen ( ) displays Figure 5-6 internal CNC status for various axes servo system alarm condi- tions. Some servo alarms display a CNC alarm, on the CRT. Alarm conditions are diagnosed by viewing signal status on the DIAGNOSTIC (SERVO ALARM) screens.
  • Page 137    5.4.5.4 Diagnostic (Servo Status) Screen DIAGNOSTIC (SERVO STATUS) screen ( ) displays Figure 5-7 internal CNC status for the axes servo system. lists the items dis- Table 5-4 played in the DIAGNOSTIC screens. (SERVO STATUS) IGURE DIAGNOSTIC SERVO STATUS SCREEN ABLE DIAGNOSTIC...
  • Page 138    5.4.5.5 Diagnostic (Spindle Status) Screen DIAGNOSTIC (SPINDLE STA- screen ( ) displays Figure 5-8 TUS) internal CNC status for spindle drive system. Spindle drive system related diagnostic numbers range from 400 to 420. lists the items dis- Table 5-5 played on the DIAGNOSTIC (SPIN- screens.
  • Page 139    ABLE DIAGNOSTIC SPINDLE STATUS SCREEN ITEMS CONTINUED SPINDLE-2 MOTION Position error in 2nd spindle synchro- ERROR nous control mode. SPINDLE SYNCHRO Absolute value of synchronous error ERROR between 1st and 2nd spindle. SPINDLE-1 POS. CODER Feedback information of 1st spindle position coder.
  • Page 140    5.4.5.6 Diagnostic (Rigid Tapping) Screen DIAGNOSTIC (RIGID TAPPING) screen ( ) displays Figure 5-9 internal CNC status for rigid tap- ping. Diagnostic numbers relative to rigid tapping range from 450 to 457. lists the items dis- Table 5-6 played on the DIAGNOSTIC (RIGID screens.
  • Page 141 Distance between the absolute position of the motor and offset data. OFFSET DATA Offset data from the Inductosyn. Option Detail This screen and description applies only to inductosyn type feedback scales and does not apply to the V55. 4V2A1563 (E) 5 - 23...
  • Page 142    5.4.6 CNC Diagnostic Display PMC diagnostics are useful in troubleshooting the CNC, PMC, and the MT. Diagnostics allow you to see the current state (On/Off) of specific I/O signals, as viewed by the PMC. The PMC is the origin of system communication and must see proper sig- nal conditions to continue program processing.
  • Page 143    OTES KETCHES 4V2A1563 (E) 5 - 25...
  • Page 144 I/O rack is shown in ure 5-11 Figure 5-12 • For more information on the CRT/MDI - Operation Panel, refer to the CNC Maintenance Manual or the V55 Operation Guide. Legend RISC-B Board Main Status/Alarm Display RISC-B Status/Alarm Display...
  • Page 145 Card Cage The card cage houses several boards (based on machine configuration). The standard boards used for the V55 are listed below: PSU B1 board – The PSU (Power Supply Unit) supplies AC and DC volt- ages to other components of the CNC system. Incoming 200-240VAC is supplied through CP1.
  • Page 146 IGURE O RACK AND MODULES A V55 with all options (except APC (Automatic Pallet Changer)) has one I/ O rack. This rack is named Group#0 and contains eleven slots numbered Group#0, Slot 0 through Slot 10, reading left to right.
  • Page 147    ABLE GROUP BASE O RACK MODULE DETAIL Group#0 Base#0 Slot I/O Address Module Type Model No. Range Interface/Power Supply - AIF01A Input AID32F2 C42 X00.0 - X03.7 Input AID32F2 C42 X04.0 - X07.7 Input AID32F2 C42 X08.0 - X11.7 Output AOD32D2 C43 Y00.0 - Y03.7...
  • Page 148 Name of the second, five slot, I/O rack. Supplied on machines equipped with APC. BASE #0 The BASE number is always “0” for the V55. A BASE number other than “0” references a remote I/O rack. SLOT #n The module slot number (location), read from left to right.
  • Page 149 The Alarm display contains three LEDs that light in different patterns to indicate specific alarm conditions. Some of the boards signal alarm conditions by displaying patterns in both the Status and Alarm dis- plays. On the V55, these CNC boards have Status and Alarm displays: • MAIN •...
  • Page 150    Main Board Status/Alarm Displays The Status/Alarm display is located on the top face of the MAIN board and consists of two rows of LEDs. The top row (labeled STATUS) indicates CNC startup and operating status. The bottom row (labeled ALARM) dis- plays alarm conditions related to CNC system failures.
  • Page 151    5-10 ABLE MAIN BOARD NORMAL STATUS DISPLAY AT POWER ON GREEN LED LED Dis- Step play     Power is not turned ON.     Software is being loaded into DRAM after power is applied, or CPU fault due to failure.
  • Page 152    OPT3 Board Status/Alarm Displays STATUS Display – indicates OPT3 operating status. These green LEDs show the normal ‘boot up‘ process steps and should progress through the steps indicated in Table 5-12 • If boot up is interrupted, the STATUS LEDs indicate the cause. ALARM Display –...
  • Page 153    OTES KETCHES 4V2A1563 (E) 5 - 35...
  • Page 154    Data Server Board Status/Alarm Displays STATUS Display – at Power ON – Indicates Data Server board ‘boot up‘ status. These green LEDs show the normal ‘boot up‘ process and should progress through the steps indicated in Table 5-14 •...
  • Page 155 NO MEANING (slow flash rate) and Short, indicates a short LED on/off time (fast flash rate). The LED flash pattern repeats, until the error condition is corrected. † Contact your Makino service group. 5-16 ABLE DATA SERVER BOARD ALARM DISPLAY...
  • Page 156    RISC-B Board Status/Alarm Displays STATUS Display – indicates the RISC-B board operating status. These green LEDs show the normal ‘boot up‘ process and should progress through the steps indicated in Table 5-17 • If boot up is interrupted, the STATUS LEDs indicate the cause. ALARM Display –...
  • Page 157    5-17 – ABLE RISC B BOARD POWER ON STATUS DISPLAY CONTINUED LED Display Step     A sync signal from the main CPU was not detected.     An error occurred when the F-Bus was accessed.     System error.
  • Page 158    5.4.8.4 CNC and I/O Rack Fuses Several CNC Card Cage boards and all I/O Rack Modules, have face mounted fusing. Each fuse has an indicator window that displays a white marker, if the fuse has blown. lists the CNC fuses, their location and rating, the area pro- Table 5-19 tected, and part number.
  • Page 159    OTES KETCHES 4V2A1563 (E) 5 - 41...
  • Page 160    5.4.9 Axis Servo Components The CNC controls the axes servo unit forming a true digital servo system, controlling the X, Y, and Z axes and the ATC magazine. The servo unit ( ) consists of; one PSM (Power Supply Module) Figure 5-13 and four SVMs (Servo Amplifier Modules) –...
  • Page 161    Legend Power Supply Module (PSM) [11] Status Display PIL and Alarm LEDs [12] Fuse Status/Alarm Display [13] Battery Backup X Amplifier Module [14] Fuse Status Display [15] Battery Backup Y Amplifier Module [16] Fuse Status Display [17] Battery Backup Z Amplifier Module [18] Fuse...
  • Page 162    5.4.9.3 Axis Servo Drive Fuses The PSM and each SVM is equipped with a fuse. Each fuse has an indica- tor window that displays a white marker, if the fuse has blown. lists the CNC fuses, their location and rating, the area pro- Table 5-19 tected, and part number.
  • Page 163    5.4.10 Spindle Drive Components The CNC controls the SDU (Spindle Drive Unit) forming a true digital spin- dle drive system, controlling the V55 spindle. The SDU ( ) consists of; one PSM (Power Supply Module) and Figure 5-14 one SPM (Spindle Amplifier Module).
  • Page 164    5.4.10.1 PIL, ALM and ERR LEDs The PSM has PIL and ALM LEDs to indicate status. The amplifier module has PIL, ALM, ERR LEDs to indicate amplifier status. The LEDs are included with the 7-segment display, on both modules, as shown in Fig- ure 5-14 PIL (Power Indicator Light)
  • Page 165    On the Amplifier Module: When the PIL LED is , power is supplied to module. When the ALM LED is On, the number or letter showing in the 7- segment display represents an Alarm number. When the ERR LED is On, the number or letter showing in the 7-segment display represents an Error number.
  • Page 166    OTES KETCHES 5 - 48...
  • Page 167    PMC (Machine) Troubleshooting Details for troubleshooting Machine side faults are presented below. Machine side faults include the MT (Machine Tool) proper and the Custom software of the PMC (Programmable Machine Controller). Use this information as a guide to the troubleshooting tools provided on the machine tool system and follow the references to other chapters (in this Maintenance Guide) and manuals provided with the machine.
  • Page 168    5.5.2.1 Mechanical Chapter Format The mechanical chapters are formatted as follows: Charts, figure drawings, or tables are placed on the same or facing pages, whenever possible, to eliminate flipping from text to illustration. When components related to DI/DO signals (limit switches, solenoids, or command signals) are referenced, the PMC address is provided to mini- mize searching to other pages or chapters.
  • Page 169 2. Document program number and function Failure commands involved at fault. 3. Document timing of occurrences. 4. Contact the Makino Customer Support Depart. The Machine Not Ready diagnostic signals are vital machine status signals and will prove extremely useful in troubleshooting.
  • Page 170    5.5.6 Alarm Is Displayed The machine tool system provides an alarm indication for most faults gen- erated on the Machine side. The cause of the fault is provided or “nar- rowed down” by the displayed alarm description. Machine alarms are indicated by the red alarm and yel- low warning status lamp (on the Main Operation Panel).
  • Page 171    5.5.7 Custom Side Alarm Display Custom side or machine alarms are of two (2) types; Alarms and Warnings. • Alarms are faults causing a halt in operations • Warnings are conditional alerts affecting operation or needs attention, before it becomes an alarm.
  • Page 172    Softkey Menus [RETRY] – Displayed only when the RETRY function is possible. RETRY allows resuming an interrupted automatic sequence, after the fault is cor- rected. [EXAMPL] – Displays several “sample” screens. Step through the ALARM samples by pressing [EXAMPL]. [NEXT ALARM] –...
  • Page 173    Softkey Menus The softkey menus for the screen are described below. ALARM RECORD [ALARM] – Displays the ALARM screen. [CLEAR] – Clears or deletes all alarm records on the screen. 4V2A1563 (E) 5 - 55...
  • Page 174    5.5.8 Primary Operation (PO) Screen Primary Operation PO ( screen is the initial Custom side display. This screen provides; access to all other Custom screens and an overview of the machine's current operating condition or MACHINE STATUS Figure 5-17 To display the PO screen: 1.
  • Page 175    Standby Conditions To prevent personal injury and machine damage, the PMC must “know” that the ATC (Automatic Tool Changer) and APC (Automatic Pallet Changer) are in a safe position before allowing automatic operation. This safe position is called the condition.
  • Page 176    5.5.10 Maintenance Screens Makino's custom side screen provides two machine status MAINTENANCE and maintenance related functions. • page, provides detail on the current status of MAINTENANCE MENU , and conditions, as EMERGENCY INTERLOCK FEED HOLD SERVO OFF shown in...
  • Page 177    Order of Operation 1. Not all status conditions indicate a fault; some INTERLOCK, FEED HOLD, and SERVO OFF conditions are “normal” during machine operation. 2. MENU page layout and data are arranged in descending order. For example, an EMERGENCY condition causes INTERLOCK, FEED HOLD, and SERVO OFF conditions.
  • Page 178    5.5.10.2 Maintenance Mode The Maintenance mode provides access to ATC, ATC magazine “automatic” operations. Mainte- nance mode allows step-by-step control of ATC related operations. • This function is useful for setup, adjustment and alignment of ATC components, and recovery of an interrupted automatic action.
  • Page 179    Basic Operation Sequence When using maintenance mode proceed as follows: 1. Display the MAINTENANCE screen page. MENU 2. Activate Maintenance mode. Press [MODE SELECT]. 3. Press [ATC MAINTE] or [MGZ MAINTE], based on ATC unit and current requirements. 4.
  • Page 180 A diagnostic display is provided on both the CNC and Custom side of the system. Both functions provide the same data although there are some format differences. Makino developed its diagnostic display to provide enhanced capability and recommends using the Custom side diagnose screen for trouble- shooting.
  • Page 181    5.6.1 Diagnostic Basics Like the rest of the system we can divide the diagnostics into two types or sides: CNC to PMC Generally, there is little need to pursue specific CNC to PMC communica- tion (F and G) signals: Communication is transmitted on the F-BUS (Fanuc Bus).
  • Page 182    5.6.2 CNC Diagnostic (I/O) Display CNC diagnostics or PMC SIGNAL screen displays the MT STATUS system I/O communication sig- nals, as viewed by the PMC. Signals are organized and searched by their PMC address and prefix (F, G, X, and Y). •...
  • Page 183    To display the screen: DIAGNOSE 1. Press the [CUSTOM] function button. 2. Press the [PO] softkey (if screen is not displayed). 3. Press the [MS] softkey to display the [DIAGNOSE] softkey. 4. Press the [DIAGNOSE] softkey. 5-22 IGURE DIAGNOSE SCREEN Screen Display No.
  • Page 184    Schematic Overview Electrical Hazard As in all electrical/electronic devices, the potential for electrical shock exists. Use extreme care when troubleshooting electrical problems on the machine tool. The infor- mation provided in this chapter is presented to assist qualified electrical technicians ONLY! It is not intended and should not be construed as a training course on basic electricity or electronics.
  • Page 185 5.7.2.1 Record of Maintenance Drawing Detail EDITION No. – the edition number for this set of V55 CONTROLLER MAINTENANCE DRAWINGS. VERSION – the version (or revision level) of this edition. SEQUENCE – the number symbol of the change applied to the indicated drawing.
  • Page 186    RECORD OF MAINTENANCE DRAWING EDITION VERSION SEQUENCE DATE DRAWING CONTENT CHANGE RELATED INFORMATION No. DRAWING No. INFORMATION 97.10.13 -------- THE FIRST EDITION ------- 97.12.01 æ CHG. FUSE ADDRES TEC02-0101E200-1 97.12.01 æ CHG. FUSE ADDRES TEC02-0101E200-131 97.12.01 E4V-0177 CHG. LS99 TEC02-0101E200-272 97.12.01 E4V-0177...
  • Page 187    5.7.3 Contents provides an example of SHEET 1 of the CONTENTS drawing. Figure 5-24 CONTENTS CONTENT DRAWING NO. PAGE OPTION TABLE TEC02-0101E120 CONNECTION TEC02-0101E130 1∼5 WIRING MATERIAL APPLICATION TABLE TEC02-0101E140 1∼4 REMARK TEC02-0101E150 MAIN POWER ⋅ H&H COOLANT ⋅ EXTERNAL TRANSFORMER CIRCUIT INPUT TEC02-0101E200...
  • Page 188 ) with the sub-system names or Table 5-23 description, drawing numbers, and page numbers (SHEET No. on the drawing) in the adjacent columns. The major circuits (in alphabetical order) in the V55 CONTROLLER MAINTENANCE DRAWINGS are: 5-23 ABLE MAJOR CIRCUITS...
  • Page 189    5.7.4 Wiring Material Application Table provides an example of SHEET 1 of the WIRING MATERIAL Figure 5-25 APPLICATION TABLE drawing. SPECIFICATION SIGNAL NAME CONNECTION WIRING MATERIAL TERMINAL ∼ TERMINAL POWER AC200/220V R, S, T MFLC 60mmsq BLACK SOURCE U, V, W MFLC 38mmsq BLACK 200A, B...
  • Page 190    Schematic Interpretation This section presents two different schematic page examples. Explana- tions and specific detail on annotations, symbols, names, and other con- ventions used in the schematics follow each example. • Zone locators are provided across the top and bottom and down both sides of each schematic sheet.
  • Page 191    4V2A1563 (E) 5 - 73...
  • Page 192    5.8.2 Example 1 shows a portion of Figure 5-27 the MOTOR DYNAMIC FORCE drawing, Sheet 31, of Drawing No. TEC02-0101E200. This example shows Zones 1A through 2E. Example 1 Detail provides an explana- Table 5-24 tion of the symbols, device names and location techniques used in Example 1 ( Figure 5-27...
  • Page 193    5-24 ABLE SCHEMATIC INTERPRETATION DETAIL EXAMPLE Zone Item Name Explanation Power Source CB2 is the circuit breaker for the M2 motor circuit. This cir- and Wires cuit continues on Sheet 3, Zone 1D (3/1D). The symbol to the right indicates that this is input. The Earth Ground symbol and R2, S2, and T2 are wire names that supply power to CB2.
  • Page 194    5.8.3 Example 2 shows a portion of Figure 5-28 the SPINDLE HEAD drawing, Sheet 202, of Drawing No. TEC02-0101E200. This exam- ple shows Zones 1A through 2E. Example 2 Detail provides an explana- Table 5-25 tion of the symbols, device names and location techniques used in Example 1 ( Figure 5-28...
  • Page 195    5-25 ABLE SCHEMATIC INTERPRETATION DETAIL EXAMPLE Zone Item Name Explanation System I/O UNIT MT system area shown. GROUP#0 is the I/O Component rack number, BASE#0 is the I/O rack base No., and SLOT4 is the I/O module slot location. If one I/O rack is supplied its is GROUP#0, a second I/O rack would be GROUP#1.
  • Page 196    5.8.4 Schematic Symbol Table shows the common graphic symbols and meaning used in the Figure 5-29 V55 Controller Maintenance Drawings. Make a copy of this page and place it in front of your schematics for refer- ence. 5-29 IGURE...
  • Page 197    OTES KETCHES 4V2A1563 (E) 5 - 79...
  • Page 198    OTES KETCHES 5 - 80...
  • Page 199    Chapter 6 Spindle Head Unit 4V11A Type #40 Taper, 14,000 or 20,000 RPM, and Through Spindle Coolant and Air Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 06-4vA11A Spindle 14k #40 TSC.fm...
  • Page 200    Chapter 6 Spindle Head Unit Contents 6.1 Overview ......... . .6 - 1 6.2 Spindle Design.
  • Page 201    6.5.6.2 Operation ........6 - 26 6.5.6.3 LS00 and LS01 Adjustment .
  • Page 202    OTES KETCHES...

  • Page 203: Overview

       Overview This chapter contains information on maintaining the Makino V55 14,000 and 20,000 rpm, (11A Type) spindle heads, at peak operation. Descriptions of the design, principle of operations, and procedures for maintenance and adjustment of the spindle’s main assemblies, and peripheral components are provided.
  • Page 204    The spindle assembly is cooled and lubricated by Makino Spindle Lubri- cant which is pumped through the assembly by three pumps used for dif- ferent cooling/lubricating functions. A compressor mounted pump supplies cooled and filtered oil from the oil controller through the unclamp cylinder housing into the area between the draw bar and spindle shaft I.D.
  • Page 205    Legend Motor Rotor Angular Contact Bearing Cooling Jacket Spindle Taper Cylindrical Roller Bearing Drive Key Thru Spindle Coolant Tube [10] Collet Finger Assembly Draw Tube Assembly [11] Motor Stator Spindle IGURE MAIN SPINDLE COMPONENTS 4V2A1563 (E) 6 - 3...

  • Page 206: Specifications

       Specifications Spindle specifications are presented in . Additional detail on tool- Table 6-1 ing balance, related tooling information, and force and moment calcula- tions follows. ABLE SPINDLE SPECIFICATIONS Item Specification Metric (Inch U.s.) Spindle Motor Integral Rotor/Stator Cooling Spindle Core Cooling Horsepower (25% ED/Continuous) 22 / 18.5 kW...

  • Page 207: Spindle Power And Torque

       6.3.1 Spindle Power and Torque Spindle Side Load High-speed spindle bearings are susceptible to high radial thrust (force) and side load (moment). Exceeding the allowable force and moment limits of the spindle will; reduce tool life and part finish and cause premature bearing failure. section 6.4 for more detail on tooling balance, concentricity, overhang and force and moment calculations.

  • Page 208: Spindle Motor Output Specifications

       6.3.2 Spindle Motor Output Specifications Motor specifications are provided in Table 6-2 14,000 ABLE RPM SPINDLE MOTOR SPECIFICATION Type A06B-1233-B421 #xxxx Model No. B112L-18.5/14000 Power Factor Motor Input 139 – 230V Amp. Input 200V 50/60Hz 3-Phase Ambient Temp. 0 - 40°...
  • Page 209    20,000 ABLE RPM SPINDLE MOTOR SPECIFICATION Type A06B-1233-B421 #xxxx Model No. B112L-18.5/20000 Power Factor Motor Input 139 – 230V Amp. Input 200V 50/60Hz 3-Phase Ambient Temp. 0 - 40° C (32 - 104° F) Poles Standard IEC#$-1/A2 1998 Insulation Class Output Winding...

  • Page 210: Application Considerations And Limitations

    Using balanced tools enhances surface finishes and reduces the potential for pre-mature spindle bearing failure. All tools used on the V55 MUST be balanced to within G2.5, or lower to prevent machin- ing and machine problems, due to the forces from unbalanced tooling. An out of balance tool: •...

  • Page 211: Specification And Calculation

    6.4.1.1 Specification and Calculation Makino has established a balance specification of G2.5, or lower, for the V55 (the lower the specification the better the balance). The balance specification establishes a range from which a “target bal- ance”, for a tool at a given rpm, is calculated.

  • Page 212: Balanced Tool Holders

       6.4.1.2 Balanced Tool Holders Tooling manufacturers can supply holders that are either balanced or bal- anceable. Balanced and balanceable holders cost more, but the benefit in surface quality alone will offset this cost in reduced time on the finishing bench.

  • Page 213: Rigidity

       Other sources of runout are dirty tool shanks, unmatched tapers (holder to spindle taper), and a bell-mouth condition in the holder or spindle taper. To protect against runout: • Do not use extensions and adapters. • Keep tool holder and spindle tapers clean. •...

  • Page 214: Gage Length

    Radial Load - Force and Moment Operating equipment within its limitations reduces machining problems, maintenance, and down time while prolonging machine life. V55 high-speed spindles have two load limits – force and moment – which must not be exceeded. •...

  • Page 215: Moment

    Moment Moment – 10,00 kg·mm (866.14lb·in.) Moment is the combined effects of force and tool length. The allowable moment on a V55 spindle is less than 10,000kg·mm (866.14lb·in.). The metric and inch moment formula are presented in Table 6-7 ABLE...

  • Page 216: Force And Moment Macro

       6.4.5.3 Force and Moment Macro provides a Macro program, developed by Makino, to simplify Table 6-8 force and moment calculations. This program is to be entered into the control and used by Operators during set-up. The program automates the calculations for both metric or inch.
  • Page 217    ABLE FORCE AND MOMENT MACRO PROGRAM CONTINUED #13 = 866.14 (MAX. INCH MOMENT); Maximum inch tool moment (lb in.) #15 = 100 (MAX. FORCE IN POUNDS); Maximum side force in lb N2 #14 = #9 * #3 * #19; Calculate feedrate per minute #101 = [#10 * #18 * #1 * #14 * #3] / #12;...

  • Page 218: Spindle Clamp/Unclamp

       Spindle Clamp/Unclamp shows the main components of the spindle clamp/unclamp Figure 6-7 mechanism. Tooling is clamped in the spindle taper by the gripping action of the collet finger assembly on the tool holder retention knob. A clamping force of 1980kg (4366lb) is generated by a set of coned disc (Belleville) springs mounted on the draw bar.
  • Page 219    Legend Sleeve LS601 Proximity Switch Piston Cylinder LS01 Limit Switch LS00 Limit Switch Cylinder Retainer Cylinder Case LS602 Proximity Switch [10] Spindle Head [11] Lock Nut [12] Draw Bar - Upper Section [13] Draw Bar - Lower Section [14] Collet Fingers Sleeve [15]...

  • Page 220: Clamp/Unclamp Mechanism

       6.5.1 Clamp/Unclamp Mechanism During unclamp – ( ) the Figure 6-8 unclamp solenoid SOL01 (Y01.0) is energized porting hydraulic oil to the top of the unclamp cylinder [1] and piston [2] moves (down- ward) advancing the entire draw bar assembly.

  • Page 221: Draw Bar Assembly

    For Reference Only The draw bar assembly is an integral part of the high-speed spindle assembly. Removal and installation should be performed only by Makino technicians. Maintaining critical alignments and balance, during assembly, is extremely important. Makino requests that our customers do NOT attempt to repair this assembly.

  • Page 222: Drawbar Retention Force

    This design provides a positive mechan- ical clamping mechanism. The normal state of the spindle is clamped. Makino recommends checking the retention force periodically to ensure that the clamping mechanism is providing the proper force. Loss of retention force is the result of weakened or cracked disc springs.

  • Page 223: Collet Finger Assembly

    For Reference Only The collet finger assembly is an integral part of this high-speed spindle assembly. Removal and installation should be performed only by Makino technicians. Maintaining critical alignments and balance, during assembly, is extremely important. Makino requests that our customers do NOT attempt to repair this assembly.

  • Page 224: Hydraulic Equipment

       6.5.5 Hydraulic Equipment Spindle clamp/unclamp is accomplished by system hydraulic pressure (set to 7 MPa (1017 psi)), the unclamp assem- bly, and solenoid valve SOL01 (clamp). The unclamp cylinder ( Figure 6- ) is an integral part of the spin- dle assembly and consists of the cylinder retainer [1], cylinder case [3], cylinder [2], and the...

  • Page 225: Unclamp Cylinder Removal And Replacement

    Unclamp Cylinder Removal The unclamp cylinder is an integral part of this high-speed spindle assembly. Removal and installation should be performed by Makino, in a clean room environment. Main- taining critical alignments and balance during assembly is extremely important. Makino requests that our customers do NOT attempt to repair this assembly.
  • Page 226 If the unclamp action is within the limits, proceed to STEP If the unclamp action continues to exceed 0.3 seconds, contact your Makino service group. 14. Check for hydraulic leaks. 15. Install the upper spindle cover. 6 - 24...
  • Page 227    OTES KETCHES 4V2A1563 (E) 6 - 25...

  • Page 228: Clamp/Unclamp Limit Switches (Ls00/Ls01)

       6.5.6 Clamp/Unclamp Limit Switches (LS00/LS01) Spindle clamp/unclamp operation is confirmed by two plunger type limit switches. LS00 detects spindle clamp and LS01 detects spindle unclamp. Software INTERLOCKS halt operation, if the clamp/unclamp limit switch conditions are improper or if the clamp state is lost during machining. 6.5.6.1 Location Limit switches LS00 and LS01 are located behind the upper spindle cover.

  • Page 229: Ls00 And Ls01 Adjustment

       6.5.6.3 LS00 and LS01 Adjustment The following procedures are for use in adjusting limit switches LS00 (spindle clamp) and LS01 (spindle unclamp). A switch’s trip position is set by adjusting its trip dog set screw. The objective is to set both switches, slightly beyond the position, where they change state from low (0) to high (1).
  • Page 230    Testing Switch Operation Use this procedure to determine if LS00 or LS01 require adjustment 1. Display the Custom - screen ( Figure 6- DIAGNOSE A. Press the [CUSTOM] function key. (If required, press [PO] to display the [MS] softkey.) B.
  • Page 231    Adjusting LS00 1. Display the Custom - screen ( Figure 6- DIAGNOSE A. Press the [CUSTOM] function key. (If required, press [PO] to display the [MS] softkey.) B. Press [MS], to display [DIAGNOSE]. C. Press the [DIAGNOSE]. 2. Use [NO. SEARCH], to display Diagnostic No.
  • Page 232    Adjusting LS01 1. Display the Custom - screen ( Figure 6- DIAGNOSE A. Press the [CUSTOM] function key. (If required, press [PO] to display the [MS] softkey.) B. Press [MS], to display [DIAGNOSE]. C. Press the [DIAGNOSE]. 2. Use [NO. SEARCH], to display Diagnostic No.

  • Page 233: Removal And Replacement - Ls00 Or Ls01

       6.5.6.4 Removal and Replacement - LS00 or LS01 This procedure is for the removal and replacement of LS00 or LS01. 1. Remove the upper spindle cover, section 6.10 2. Reference the Z axis. 3. Power down the machine and perform Lockout/Tagout procedures. 4.

  • Page 234: Tool Confirmation Limit Switches (Ls601/Ls602)

       6.5.7 Tool Confirmation Limit Switches (LS601/LS602) The design of the through-spin- dle-coolant system and draw bar mechanism requires that tooling be properly clamped and seated in the taper before the spindle is started. Two proximity switches are provided to confirm proper tool to spindle status.
  • Page 235    6-11 LS601 LS602 ABLE SIGNAL STATUS LED Color Input Status Condition LS601 LS602 LS601 LS602 Tool In Spindle, Clamped GREEN (ON) RED (OFF) X00.2 = 1 X00.3 = 0 Spindle Unclamped RED (OFF) RED (OFF) X00.2 = 0 X00.3 = 0 Spindle Empty, Clamped GREEN (ON) GREEN (ON) X00.2 = 1 X00.3 = 1 The operating condition for LS601 (X00.2) and LS602 (X00.3) are shown...

  • Page 236: Ls601 And Ls602 Adjustment

       6.5.7.3 LS601 and LS602 Adjustment Use the following procedures for adjusting proximity switches LS601 (tool in spindle) and LS602 (spindle empty). The trip position is set by adjusting both the gap between the switch face and trip dog and the vertical position where the switch state changes from low (0) to high (1).
  • Page 237    Testing Switch Operation Before making adjustments to LS601 and LS602, use this procedure to determine which switch requires adjustment. 1. Display the Custom - screen ( Figure 6- DIAGNOSE A. Press the [CUSTOM] function key. (If required, press [PO] to display the [MS] softkey.) B.
  • Page 238    Adjusting LS601 When setting LS601, its On/Off status is determined by viewing the ampli- fier LED or the input status on the Custom - screen. This proce- DIAGNOSE dure uses the amplifier LED. • The objective of this setting procedure is to first set the switch gap then set the trip position.
  • Page 239    4. Loosen screws [1], to allow bracket [2] to move, but keep it against the casting. 5. Slide bracket [2] “up” as far as it can go. LED should change from green to red. If not, the gap is set too close, repeat 6.
  • Page 240    Adjusting LS602 When setting LS602, its On/Off status can be viewed on its amplifier (LED) or the Custom - screen. This procedure uses the ampli- DIAGNOSE fier LED. • The objective of this setting procedure is to first set the switch gap then set the trip position.
  • Page 241    4. Loosen the mounting screws [1] to allow bracket [2] to move but hold it against the casting. 5. Slide the bracket “down” as far as it can go. LS602 LED should change from green to red. If not, the gap is set too close, repeat 6.

  • Page 242: Removal And Replacement - Ls601 Or Ls602

       6.5.7.4 Removal and Replacement - LS601 or LS602 The procedure for removing and replacing LS601 and LS602 is the same. After replacing either switch, follow the appropriate adjustment procedure; Adjusting LS601 Adjusting LS602 (pg 6-36) (pg 6-38) IMPORTANT When replacing a switch, it is important that the switch sensor does not extend too far out of its holder and that the overall dimension from the back face of the switch bracket to the sensor face is maintained.
  • Page 243    9. Remove O-ring [3] ( Figure 6- 10. Determine initial switch setting ( Figure 6-28 A. Measure from the sensor face to the back face of the switch bracket, dimension B. Measure from the sensor face to the end of switch 6-27 IGURE SWITCH BRACKET...

  • Page 244: Spindle-To-Table Squareness

       Spindle-To-Table Squareness Spindle-to-table squareness should be checked whenever the spindle head position has been disturbed. This includes; head moving due to a collision or removal for repair. shows the spindle-to-table squareness check in the machine Table 6-12 runoff record. Refer to your machine's runoff record for the actual square- ness reading at assembly.
  • Page 245    1. Clean the table surface. A. Remove all workpieces, fixtures, vices, etc., from the table. B. Thoroughly clean the table surface using a safe solvent and lightly stone the table surface to remove any high spots. C. Wipe the surface clean, using a safe solvent. 2.

  • Page 246: Correcting Squareness

    Z or X axes linear motion guides. Machine out-of-level may also affect spindle-to-table squareness. Level the machine as described in . If this does not correct the spindle- chapter 3 to-table squareness, contact your Makino service group for assistance. 6 - 44...

  • Page 247: Spindle Drive System

       Spindle Drive System The V55 spindle drive system consists of the following components: • Integral spindle motor with built-in position coder • Power Supply Module, Fanuc model - PSM-26 for the 14,000 rpm spindle (PSM-30 for the 20,000 rpm spindle) •...

  • Page 248: Integral Spindle Motor

       6.7.1 Integral Spindle Motor The spindle drive motor is integral to the spindle assembly. The rotor is mounted on the spindle shaft and the stator is mounted to the spindle casting. The spindle motor has dual windings ( ) which pro- section 6.7.1.1 vides:...
  • Page 249    6-14 ABLE WINDING CHANGEOVER CONDITIONS Range Contactor RCHP RCH1 RCH2 High MCC1 = 0 MCC2 = 1 Y00.6 = 0 X00.6 = 1 X00.7 = 0 MCC1 = 1 MCC2 = 0 Y00.6 = 1 X00.6 = 0 X00.7 = 1 6-31 IGURE...

  • Page 250: Pulse Coder

       6.7.1.2 Pulse Coder The orientation sequence occurs as follows: 1. The orient command (M19 or M319) is output from the CNC to the PMC. 2. The spindle decelerates to the parameter defined orientation speed. 3. The spindle rotates ½ to 2 ½ turns after reaching the orientation speed and stops at the 1 revolution signal position of the pulse coder.
  • Page 251    TABLE 12-14 lists the general specifications for the pulse coder. 6-15 ABLE GENERAL PULSE CODER SPECIFICATIONS Item Explanation Stop Position Internal Stop Position External Setting Command Position Coder Coupled to the spindle one-to-one ratio. 1024 pulses/rota- tion (A-phase and B-phase signals).1 pulse/rotation (One pulse/revolution signal).
  • Page 252    OTES KETCHES 6 - 50...

  • Page 253: Spindle Orientation

       6.7.2 Spindle Orientation The spindle is equipped with an orientation mechanism, which stops the spindle at a specific or constant angle, known as the orient position. The spindle must stop at the orient position to ensure proper engagement of the spindle drive keys with the tool magazine grippers during ATC (Auto- matic Tool Change) operation.

  • Page 254: Orient Adjustment With Parameter

    The angle error is then used to find the number of “detection units” to input into parameter 4077. • On all V55 models, the orientation drive key orients in the –X direction. 6 - 52...
  • Page 255 ORIENTATION ANGLE CALCULATIONS EXAMPLE: Since the V55 uses a 1024 pulse position coder, divide 360 by (1024 x 4) and determine that 0.088× equals one “detection unit”. Knowing this, we can indicate the drive key and find the value for input to parameter 4077.

  • Page 256: Spindle Drive Unit (Sdu)

       6.7.3 Spindle Drive Unit (SDU) The SDU (Spindle Drive Unit), shown in ,is located in the MTC Figure 6-35 (Machine Tool Cabinet) and consists of a PSM (Power Supply Module) and an SPM (Spindle Amplifier Module). Legend Power Supply Module (PSM) PIL and ALM LEDs Status Display Amplifier Module (SPM)

  • Page 257: Power Supply Module (Psm)

       6.7.3.1 Power Supply Module (PSM) The PSM supplies power to the spindle amplifier module. It converts 3- phase AC input voltage to DC voltage. During servo deceleration, the PSM returns the generated energy to the power supply (referred to as, power supply regeneration).The PSM is mounted in the MTC and contains protection and error detection functions.

  • Page 258: Spindle Amplifier Module (Spm)

       6.7.3.2 Spindle Amplifier Module (SPM) The Fanuc SPM controls the speed of the AC spindle motor using a PWM (Pulse Width Modulation) inverter to regulate the DC power converted by the PSM. The SPM is mounted in the MTC and contains its own protection and error detection functions.

  • Page 259: Troubleshooting (Spindle Motor)

       Troubleshooting (Spindle Motor) Initial spindle troubleshooting checks are provided in Table 6-19 For maintenance and troubleshooting detail on the spindle motor and drive unit, refer to the CNC Maintenance Manual. 6-19 ABLE SPINDLE MOTOR TROUBLESHOOTING Problem Main Causes Checks/Remedies Abnormal 1.

  • Page 260: Fluid Systems And Circuits

       Fluid Systems and Circuits The spindle uses four fluid systems: 1. Hydraulics 2. Pneumatics 3. Spindle Lubrication and Cooling 4. Coolant (Cutting Fluid). 6.9.1 Hydraulic Circuit The hydraulic system consists of a hydraulic pump, oil reservoir, and a heat exchanger unit, located inside the Hydraulic and Air Cabinet.
  • Page 261    6-36 IGURE SPINDLE HYDRAULIC CIRCUIT 4V2A1563 (E) 6 - 59...

  • Page 262: Pneumatics

       6.9.2 Pneumatics The pneumatic system consists of a filter regulator and various air cylin- ders and solenoid valves located about the machine. The filter regulator and related components are located inside the Hydraulic and Air Cabinet. System main air pressure (incoming) is set to 0.5 MPa (70 psi) with a main air pressure switch (LS905) set to 0.25 MPa (36 psi) to provide a low air alarm.

  • Page 263: Spindle Cooling And Lubrication

       6.9.3 Spindle Cooling and Lubrication The spindle is cooled and lubricated by temperature controlled Makino Spindle Lubricant. Spindle Lubricant temperature is maintained by the oil controller to within ±1° C (±2° F) of the machine bed temperature. Oil controller operation is controlled by PMC parameters and setup to cycle: •...

  • Page 264: Lubrication/Cooling System Detail

       6.9.4 Lubrication/Cooling System Detail The spindle is both lubricated and cooled by Makino Spindle Lubricant supplied by the oil controller. The entire lubrication and cooling system includes: • The oil controller with compressor unit and pump (P1) •...
  • Page 265    Lubricant piping is of two basic types; L (Lubrication) ports which circulate lubricant to areas of the spindle/machine and V (Vacuum) ports which draw off of suction lubricant from areas of the spindle. shows L and V port connections at pumps P2 and P3. Figure 6-39 shows L port piping Figure 6-40...
  • Page 266    L Port Piping The L port piping, ( ), circulates Makino Spindle Lubricant from Figure 6-40 various areas of the spindle head and is basically the portion of the sys- tem that provides cooling for the spindle assembly.
  • Page 267    6-40 IGURE L PORT SPINDLE LUBRICATION 4V2A1563 (E) 6 - 65...
  • Page 268    V Port Piping The V port piping ( ) pulls Makino Spindle Lubricant from various Figure 6-41 areas of the spindle head. The vacuum helps overcome the rotational effects and keeps the lubricant flowing, while suctioning excess lubricant at sealing areas.
  • Page 269    6-41 V IGURE PORT SPINDLE LUBRICATION 4V2A1563 (E) 6 - 67...

  • Page 270: Coolant Delivery Systems

    Through Spindle Coolant Assembly The through spindle coolant assembly is an integral part of this high-speed spindle assembly. Removal and installation should be performed by Makino, in a clean room environment. Maintaining critical alignments and balance, during assembly, is extremely IMPORTANT. Makino requests that our customers do NOT attempt to repair this assembly.
  • Page 271    Legend Coolant Pipe Coolant Rod Spring Piston Cylinder Cap Rotating Shaft Coolant Rod Support Spring Joint [10] Spindle [11] Joint [12] Inner Sleeve [13] Rubber Seal [14] Sealing Rod [15] Draw Bar 6-42 IGURE TSC MAIN COMPONENTS 4V2A1563 (E) 6 - 69...
  • Page 272 Replacement for O-rings [5] and [6] ( 6-44 Rubber Seal 13M11G704 Figure 6-44 Replacement for Seal [4] ( 1. The spindle catch jig and T-wrench are supplied with the machine. The replacement O-rings and seals must be purchased from Makino. 6 - 70...
  • Page 273    shows the sealing Figure 6-44 rod assembly that must be removed to replace the seal. The parts that make-up the assembly include the sealing rod [10], inner sleeve [9], O-ring [6], and rubber seal [7]. Other parts important to the sealing rod assembly, but not part of the assembly, include the pin [2] and O-ring [5].
  • Page 274    Sealing Rod Assembly Removal Use this procedure to remove the sealing rod assembly. 1. Position the Z axis to a convenient height for working under the spindle. A minimum clearance of 210mm (8.3") plus the distance the T- wrench extends below the spindle face is required.
  • Page 275    T-wrench Installation and Use Do not over tighten the T-wrench. If over tightened it may break off inside the sleeve. Do not apply side-to-side force to the T-wrench, during use. Side force may break off the T-wrench inside the sleeve. 6.
  • Page 276    Seal Replacement With the sealing rod assembly removed from the spindle, replace the O- rings and rubber seal as follows. 1. Using a 4mm hex wrench, unscrew inner sleeve [1] from sealing rod [2]. 2. Remove old O-ring [3] and rubber seal [4]. 3.
  • Page 277    OTES KETCHES 4V2A1563 (E) 6 - 75...
  • Page 278    Sealing Rod Installation Sealing Rod Installation When installing the sealing rod assembly, it is VERY IMPORTANT to properly align the sealing rod slots with the draw bar pins. Improper alignment will result in damage to the draw bar pins during operation of the spindle clamp/unclamp mechanism. Draw bar pin replacement requires removing the entire draw bar assembly from the spindle.
  • Page 279    6-48 IGURE SEALING ROD INSTALLATION 4V2A1563 (E) 6 - 77...

  • Page 280: External Nozzle Coolant

       6.9.5.2 External Nozzle Coolant The standard external nozzle coolant system consists of eight nozzles for directing coolant externally to the cutting tool. Four flexible hose nozzles are located to the right of the spindle. These hoses are generally used with longer tools when coolant can not be effectively applied using the fours nozzles located...
  • Page 281    1. Unscrew the nozzle [5] from the insert [2]. 2. Capture the O-ring [6], valve case [1], spring [4] and ball [3] as the nozzle is unscrewed from the insert [2]. 3. Clean all components, disassembled in Step 2., in a solution suitable for removing cutting fluid residue.

  • Page 282: Upper Spindle Cover Removal

       6.10 Upper Spindle Cover Removal The upper spindle cover [1] ( ) pro- Figure 6-51 tects spindle mounted components from exposure to chips, coolant, and undesired contact during automatic operations. Removal of the upper spindle cover is required to access these components for adjustment.

  • Page 283: Preventive Maintenance

       6.11 Preventive Maintenance Check the following items, at the recommended frequencies, to ensure proper machine performance, accuracies, and capabilities, are and main- tained, throughout its life. 6.11.1 Daily Checks/Maintenance 1. Clean the spindle taper with cleaning tool. Dirt and/or chips in the taper may cause the tool holder to “stick”...
  • Page 284    OTES KETCHES 6 - 82...
  • Page 285    Chapter 7 Feed Axis Unit 4V20A,30A,40A Type Standard Machine and Axis Configuration Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 07-4vA20,30,40A Feed Axis.fm...
  • Page 286    Chapter 7 Feed Axis Unit Contents 7.1 Overview ......... . .7 - 1 7.2 Axis Configuration .
  • Page 287    7.7.1 LM Guide Specifications ......7 - 31 7.7.2 LM Guide Lubrication ......7 - 31 7.7.3 LM Guide Installation .
  • Page 288    7.10.2 Pitch Error Compensation ......7 - 75 7.11 Setting CNC Parameters ......7 - 76 7.12 Periodic Maintenance.

  • Page 289: Overview

       Overview The V55 is a ram type vertical machining center. The X axis is formed by the saddle which is mounted on top of the column. The Y axis is formed by the table which is mounted on top of the bed casting. The Z axis (ram) is mounted to the front of the saddle.

  • Page 290: Axis Configuration

       Axis Configuration The V55 axes configuration includes the three basic axes of the machine coordinate system X, Y, and Z. The machine is designed to provide a work cube or machining envelope ) that is 900mm (35.4") in the X axis plane, 500mm (19.7") in the Figure 7-1 Y axis plane, and 450mm (17.7") in the Z axis plane.

  • Page 291: Y Axis

       7.2.2 Y Axis The Y axis is formed by the table. The table is mounted to the bed casting and moves in and out, perpendicular to the X axis. • The Y axis references to the extreme + end of its stroke, toward the operator.

  • Page 292: Principle Of Operation

    Each axis component is mounted to sliding members. The V55 uses LM (Linear Motion) guides as the sliding members for all axes. Sliding mem- bers maintain the axis component's geometry (squareness, height, paral- lelism) related to other axis components and ensures that the axis travels accurately along its coordinate plane.
  • Page 293    4V2A1563 (E) 7 - 5...

  • Page 294: Axis Design

    The type of bearings and method of ball screw support may vary with different systems. On the V55, the ball screw [1] is supported at both ends by TAC bearings.
  • Page 295 AXIS MECHANICAL CONSTRUCTION Driving Components 1. This basic operating principle is true for all V55 axes drive systems. The Z axis is the gravity axis and has some differences in design and construction. Axis specifics are discussed in detail, when relevant.

  • Page 296: Electrical Components

       7.4.1.2 Electrical Components The main electrical components of the V55 servo system are the Fanuc α Series servo motors. The servo motor is controlled by the servo drive unit, which sends commands and receives feedback from the CNC position control circuit.
  • Page 297    OTES KETCHES 4V2A1563 (E) 7 - 9...
  • Page 298    Legend[ Power Supply Module [11] Status Display PIL and ALM LED'S [12] Fuse Status And Alarm Display [13] Battery Backup X Amplifier Module [14] Fuse Status Display [15] Battery Backup Y Amplifier Module [16] Fuse Status Display [17] Battery Backup Z Amplifier Module [18] Fuse Status Display...

  • Page 299: Electronic Assembly

       7.4.2 Electronic Assembly The main electronic assembly for the V55 servo system is the servo drive unit ( ). This unit includes: one PSM (Power Supply Module), Figure 7-5 three SVM (Servo Amplifier Modules), one for each axis, and a fourth amplifier module for the ATC magazine.

  • Page 300: Servo Amplifier Modules - Svm

       7.4.2.2 Servo Amplifier Modules – SVM Each axis (X, Y, and Z) is equipped with its own Fanuc SVM to control the speed of its AC servo motor by using a PWM (Pulse Width Modulator) inverter to regulate the DC power converted by the PSM.

  • Page 301: Sliding Member Components

    7.4.2.3 Sliding Member Components Axis design requires axis components that move or slide. On the V55 these sliding members consist of the castings and related components that make up the saddle, table, and ram. These members form the X, Y, and Z axes respectively.

  • Page 302: Axis Construction

    7.6.4 All V55 ball screws are core cooled by temperature controlled Makino Spindle Lubricant supplied by the oil controller. Oil is pumped into the out- board end of the ball screw and exits the motor end. This oil also lubri- cates the TAC bearings at both ends of the ball screw.

  • Page 303: Axes Couplings

       7.5.1 Axes Couplings This procedure is for mounting the coupling components to the motor out- put shaft and ball screw. SPANN Rings SPANN ring couplings eliminate hard-keyed shafts and allow slippage at the coupling to minimize machine and drive component damage in the event of a “crash”. This slip- page may change the ball screw-to-motor pulse coder relationship, changing the loca- tion of the axis reference point, which can be corrected using the CNC Grid Shift parameter.
  • Page 304    6. Install the clamp ring retainer [10] using six (M6x20) screws [9]. Tighten the screws just enough to hold the clamp rings captive, but not compressed. 7-11 IGURE BALL SCREW MOTOR COUPLING 7. Install the coupling assembly onto the motor shaft ( Figure 7-11 A.

  • Page 305: Z Axis Construction

       Coupling Rotation The following Steps may require turning the machine ON and using the axis MPG to rotate the coupling for access to the screws. If this is necessary, ALWAYS turn the HANDLE mode OFF, before working in the coupling area, to AVOID accidental cou- pling rotation.

  • Page 306: Ball Screw

    A single or double ball nut is mounted on each ball screw, depending on the type of ball screw specification. The V55 is available with standard specification - 16mm lead ball screws or with optional Die/Mold specification - 8mm lead ball screws. The Stan- dard Specification screws use single ball nuts on each axis and the Die Mold Specification screws have double nuts on each axis.
  • Page 307    ABLE STANDARD BALL SCREW SPECIFICATIONS Axis Item Model Designation BKN-4516S-14 BKN-4516S-14 BKN-4516S-14 Threaded Shaft OD 45 mm 45 mm 45 mm Shaft Length 1715 mm 1015 mm 903 mm Lead 16 mm 16 mm 16 mm Ball Circle Diameter 46.

  • Page 308: Ball Screw/Servo Motor Lubrication And Cooling

    7.6.2.1 Ball Screw Nut Lubrication The V55 ball nuts are lubricated from two locations. The Y axis ball nut is lubricated at the front of the table. The X and Z ball nuts are lubricated at the right side of the saddle. See for details.
  • Page 309    7-12 IGURE BALL SCREW COOLING OIL AND BEARING LUBRICATION PIPING 4V2A1563 (E) 7 - 21...

  • Page 310: Ball Screw Tac Bearing Lubrication

       7.6.2.3 Ball Screw TAC Bearing Lubrication The oil controller supplies Makino Spindle Lubricant to cool and lubricate the TAC bearings Figure 7-13 Oil fed to the ball screw core exits through the sides of the ball screw, at the motor end, and flows through the TAC bearing assembly.
  • Page 311    OTES KETCHES 4V2A1563 (E) 7 - 23...

  • Page 312: Servo Motor Cooling

       7.6.2.4 Servo Motor Cooling The X, Y, and Z servo motors are cooled by oil from the ball screw TAC bearings. Oil is fed to distribution plates between the servo motors and bearing housings. Oil flows through the plates cooling the motors back to the distribution plates and returned to tank.
  • Page 313    Legend Distribution Plate S150 O-ring S120 O-ring Servo Motor Ball Screw Tac Bearings 7-16 IGURE Z SERVO MOTOR COOLING PIPING Servo Motor Installation When installing a servo motor, the distribution plate must be properly oriented with the two O-rings installed, to distribute and contain the oil 4V2A1563 (E) 7 - 25...

  • Page 314: Ball Screw Mounting

       7.6.3 Ball Screw Mounting When mounting a ball screw, ensure proper orientation of the TAC bear- ings (at both ends of the screw) and the installation of seals and O-rings. Service Tips 1. Proper bearing orientation sets the correct bearing pre-load. Improper bearing orientation leads to excessive backlash and premature bearing failure.
  • Page 315    Mounting outboard end components ( Figure 7-17 1. Remove the TAC bearing (temporarily installed in Step 3 for mounting the motor end components). 2. Install rotary seal [24], orient the seal as shown 3. Install outer race collar [25], orient the collar as shown.

  • Page 316: Ball Screw Pre-Tension

       7.6.4 Ball Screw Pre-Tension The X, Y, and Z ball screws are pre-tensioned (stretched) at installation to minimize changes in axis positioning due to thermal growth of the screw. When an axis moves, heat is generated by the recirculating balls in the nut.
  • Page 317    7-18 IGURE BALL SCREW PRE TENSION PROCEDURE 4V2A1563 (E) 7 - 29...

  • Page 318: Lm (Linear Motion) Guide Ways

       LM (Linear Motion) Guide Ways The V55 uses LM (Linear Motion) guides on all three axes (X, Y, and Z). These LM guides are specifically design for machine tool applications and provide excellent damping characteristics and high strength when sub- jected to shocks and vibration.

  • Page 319: Lm Guide Specifications

    7.7.2 LM Guide Lubrication The V55 LM guide systems are lubricated from distribution blocks at two locations. Y axis guides are lubricated at grease fittings on the front of the table. X and Z axis guides are lubricated at grease fittings on the right side of the saddle.

  • Page 320: Lm Guide Installation

    Damage to the guide rails and blocks may occur in the event of a machine wreck. Makino recommends replacing the guide rail and block assembly if either component is damaged. Rail damage may not be apparent to the naked eye.

  • Page 321: Axis Limit Switches

       Axis Limit Switches Each axis is equipped with one limit switch for Deceleration (DEC) and one for over travel (OT2). These limit switches are plunger type mecha- nisms, actuated by dogs mounted parallel to the axes travel and in-line with the switches.

  • Page 322: Hard Over Travel (Ot2) Limit Switches

       7.8.2 Hard Over Travel (OT2) Limit Switches Each axis is equipped with one over travel switch and a dog at each end of the axis stroke. These switches are used to protect the machine axis from being over traveled, prior to a reference return operation. OT2 is a hard limit established by the dog.

  • Page 323: Ot2 - Hard Over Travel

       7.8.3.2 OT2 - Hard Over Travel OT2 or Hard over travel is set by the trip dogs along the axis. When these dogs contact the OT2 limit switch, the machine enters an E-Stop condi- tion, halting all axis movement and other machine functions immediately. •...
  • Page 324    To Recover From an OT2 Hard Over Travel: If the axis in OT2 is not apparent, view the screen. One of Custom - ALARM the alarms in is displayed, indicating the axis and direction of Table 7-10 over travel. 7-10 ABLE ALARM MESSAGES...

  • Page 325: Location Of Axes Limit Switches

       7.8.5 Location of Axes Limit Switches The location of each axis limit switches are described below. 7.8.5.1 X Axis Limit Switch shows the X axis limit switches [1] mounted to the back of the Figure 7-20 saddle [3]. The switch travels with the X axis. X axis dogs are stationary and mounted on the top of the column [2], just below the saddle, in-line with the switches.

  • Page 326: Y Axis Limit Switch

       7.8.5.2 Y Axis Limit Switch shows the Y axis the limit switches [2] mounted to the table [3]. Figure 7-21 The switch travels with the Y axis. Y axis dogs are stationary and mounted to the bed [1], in-line with the switches. 7-21 IGURE Y AXIS LIMIT SWITCH LAYOUT...

  • Page 327: Z Axis Limit Switch

       7.8.5.3 Z Axis Limit Switch shows the Z axis Figure 7-22 limit switches [2]. The switch is stationary and mounted to the right side of the saddle. The Z axis dogs are mounted to the ram [1], in-line with the switches and travel with the Z axis.

  • Page 328: Relationship Of Limit Switches And Dogs

       7.8.5.4 Relationship of Limit Switches and Dogs For proper life and operation it is important to maintain the correct relation- ship between the limit switches and their actuator dogs. Switch to dog relationships are set at the factory, during assembly. If the switch or dog must be moved or replaced, during maintenance, ensure the position and relationship of the switch or dog is maintained.
  • Page 329    Setting DEC Limit Switches shows the DEC limit switch-to-dog relationship. Switch plunger Figure 7-24 stroke is 5.2mm (0.204"), with switch actuation occurring after 2.0mm (0.080") of plunger stroke. Set the switch to actuate with 4mm (0.157") of axis travel from the actuation point to the top of its trip dog. Setting the switch so that there is more than 4mm (0.157") of axis travel from the point of actuation to the top of its dog could result in exceeding the switch's total plunger stroke of 5.2mm (0.204")

  • Page 330: Machine Range Of Movement

       7.8.6 Machine Range of Movement The limit switch-to-dog set-up dimensions for the X, Y, and Z axes are shown in , and , respectively. Figure 7-25 7-26 7-27 • The switch dogs are set in location (at assembly) and there is no reason they should be moved or adjusted.
  • Page 331    7-26 IGURE Y AXIS LIMIT SWITCH DOG SETTINGS 7-27 IGURE Z AXIS LIMIT SWITCH DOG SETTINGS 4V2A1563 (E) 7 - 43...

  • Page 332: Machine Reference (Zero) Point

       7.8.7 Machine Reference (Zero) Point The reference position (zero point) for an axis is detected by the decelera- tion (*DEC n ) limit switch, located in the switch package, for each axis. *DEC n = the deceleration (DEC) switch, with n representing any axis (X, Y, or Z).

  • Page 333: Principle Of Operation

       7.8.7.1 Principle of Operation When [ mode is active and an axis is moved (at the preset REFERENCE] 4000mm/min. rate) in the plus (+) direction, toward its zero point, the DEC n limit switch is in its normal state (DEC n = 1), as shown in Figure 7- As the axis nears its zero point, the DEC n switch is actuated by its DEC dog and the switch state changes (DEC n = 0).

  • Page 334: Establishing Machine Zero Positions

    The V55 uses absolute position pulse coders in the servo motors. This means that the machine zero positions are always remembered (stored), even through a machine power Off and On sequence. Even though machine zero is stored, the PMC software requires that all machine axes be aligned by performing a reference operation at machine power On.
  • Page 335    X Axis Machine Zero X axis machine zero is set relative to the ATC magazine tool pot centerline ). The normal X axis stroke (program travel) is 900mm. For X Figure 7-29 to reach the tool magazine, the “extended stroke” feature is turned On allowing X to travel an additional 300mm.
  • Page 336    10. Place a “test ring” in the pot at the ready position. If a test ring is unavailable, place an end mill holder upside down in the magazine pot. 11. Using the MPG position X to the pot and tram the test ring I.D. 12.
  • Page 337    4. Using the alpha-numeric key pad, simultaneously press [P] and [CAN] keys to cancel the stored machine zero. 5. Set the control to metric (G21). 6. Reference the Y axis. 7. Place a tool holder/indicator setup in the spindle. 8.
  • Page 338    Z Axis Machine Zero Z axis machine zero is set rela- tive to the table top ( Figure 7-31 The Z axis stroke (program travel) is 450mm. The minimum distance from the table top to the spindle face is 150mm. •...
  • Page 339    A. Subtract the value recorded in Step 11 from -600.000 EXAMPLE: 1. The recorded value is –601.234, Subtract –601.234 from –600.000, the result is +1.234. This indicates, Y has traveled 1.234mm beyond (plus) the 600mm stroke. Therefore the pulse coder grid position must be shifted by 1.234mm in the negative direction.

  • Page 340: Axis Covers And Chip Scraper Unit

       Axis Covers and Chip Scraper Unit The machine is equipped with numerous sheet metal covers enclosing the machining area to contain coolant, chips, and machine surfaces. A major- ity of the covers are stationary and do not require removal for mainte- nance procedures.
  • Page 341    Adjusting Cable Tension: The tensioning device is spring loaded and should be adjusted to obtain an approximate 30mm (1 3/16") gap ( ). The Figure 7-32 gap should be set with the inter- nal spring compressed. 1. Loosen set screw [2] in the end of the tensioner.

  • Page 342: Roll-Up Cover Removal And Disassembly

       7.9.1.2 Roll-up Cover Removal and Disassembly This procedure is for removing the left hand cover assembly and is the same for the right hand assembly. Legend Machine Framework Saddle Cover Locking Screw Bracket Housing [10] M5 X 8 Screws Cable [11] Cover Guide Roller...
  • Page 343    To Remove the Cover Assembly: 1. Position the X axis to the minus end of stroke. Y and Z can be at any position. If removing the right hand cover, reference X. 2. Turn the machine Off: A. Press the [POWER OFF] button. B.

  • Page 344: Roll-Up Cover Assembly And Installation

       7.9.1.3 Roll-up Cover Assembly and Installation Cover Assembly: 1. Attach the new cover to the roller. Use extreme CAUTION when performing Step 2, since this step spring loads the roll-up mechanism. 2. Roll up the new cover by the same number turns used to unroll the old cover off the roller.
  • Page 345    Legend Machine Framework Saddle Cover Locking Screw Bracket Housing [10] M5 X 8 Screws Cable [11] Cover Guide Roller [12] Cover Wiper [13] M5 X 8 Screws Cover Guide [14] Wiper Bracket 7-34 IGURE ROLL UP COVER INSTALLATION 4V2A1563 (E) 7 - 57...
  • Page 346    OTES KETCHES 7 - 58...

  • Page 347: Y Axis Cover System

       7.9.2 Y Axis Cover System The Y axis cover system includes several covers, but consists mainly of the: • Left hand, telescopic, guide way covers • Right hand, telescopic guide way covers • Y axis ball screw cover The guide way covers expand and collapse as the Y axis (table) is posi- tioned in and out and consist of a two piece left-hand set and a two piece right-hand set.
  • Page 348    7-35 IGURE Y AXIS COVER SYSTEM 7 - 60...
  • Page 349    illustrates the Y axis cover system. lists the covers Figure 7-35 Table 7-12 and associated hardware by key number in Figure 7-35 Component names shown in brackets [….] are names used in the Parts Manual. Abbreviations PHS (Phillips Head or cross-head) Screw) and SHCS (Socket Head Cap Screw) are used.
  • Page 350    7-12 ABLE Y AXIS COVER SYSTEM AND HARDWARE LEGEND CONTINUED Mounting Hardware Name Type Size Amt. [13] Lubrication Cover [(Cover (6)] M5 x 8 [14] Bracket M5 x 8 [15] Chip Deflector [Chip Cover] M5 x 8 [16] Bracket M5 x 8 [17] LH Front Telescopic Cover SHCS (at Table)
  • Page 351    OTES KETCHES 4V2A1563 (E) 7 - 63...

  • Page 352: Guide Way Cover Removal Sequence

       7.9.2.1 Guide Way Cover Removal Sequence The telescoping guide way covers can be removed in sections. Depend- ing on the section being accessed, only certain covers must be removed. The sequence for cover removal and, where necessary, comments related to specific cover removal is described below Right or Left Front Section Removal Sequence This removal sequence (...
  • Page 353    Lockout/Tagout Turn the machine Off and perform a Lockout/TagOut, before starting cover removal. 7-13 ABLE FRONT SECTION GUIDE WAY COVER REMOVAL SEQUENCE Seq. Name Comments Side Cover Side Cover Bracket Joint Cover Front Table Cover Bracket Chip Deflector Telescopic Covers Remove the five (M6x12 SHCS, M6 Washers, and Nuts) attaching front and rear sections.
  • Page 354    Right or Left Rear Section Removal Sequence This removal sequence ( ) is for the right rear guide way section. Table 7-14 This same sequence applies when removing the left rear section. See for the associated cover hardware. Table 7-12 7-37 IGURE...
  • Page 355    Lockout/Tagout Turn the machine Off and perform a Lockout/TagOut, before starting cover removal. 7-14 ABLE REAR SECTION GUIDE WAY COVER REMOVAL SEQUENCE Seq. Name Comments Upper Column Cover This cover contains an oil line for cooling the column casting. To prevent contamination and excessive oil loss, individually disconnect (4 places) and cap the oil line at the supply and return fittings.

  • Page 356: Ball Screw Cover Removal Sequence

       7.9.2.2 Ball Screw Cover Removal Sequence describes the sequence for removing covers to access the Y Table 7-15 axis ball screw. Where necessary, comments relative to specific cover removal are provided. See for the associated cover hardware. Table 7-12 7-38 IGURE BALL SCREW COVER...
  • Page 357    Lockout/Tagout Turn the machine Off and perform a Lockout/TagOut, before starting cover removal. 7-15 ABLE BALL SCREW COVER REMOVAL SEQUENCE Seq. Name Comments Upper Column Cover Remove this cover only If removing cover [3]. This cover contains an oil line for cooling the column casting.

  • Page 358: Chip Scraper Unit

       7.9.3 Chip Scraper Unit The chip scraper unit is basically a built-in conveyor system used to scrape chips from beneath the table and carry them to the back of the machine for deposit in the chip pan or lift-up chip conveyor. The unit consists of: •...
  • Page 359    6. Remove the two (M6x16) locking screws and washers [7]. 7. Measure the scraper height, then loosen the two (M6) lock nuts [9] and lower scraper using the two (M6x25) jack screws [8]. 8. Remove scraper alignment bracket [12]. Two (M6x12) screws and washers [11] and five (M6x14) flat head screws [10].

  • Page 360: Scraper Repair Or Replacement

       7.9.3.2 Scraper Repair or Replacement Replace individual scrapers if they become damaged and are no longer effectively removing chips. • Depending on the severity of damage, scrapers can be repaired (straighten). • The scrapers are bolted to brackets attached to the chains ( Figure 7-40 To Replace a Scraper:...

  • Page 361: Axis Position Compensation

       7.10 Axis Position Compensation There are two axis positioning compensation systems on the V55. These compensation systems are backlash and pitch error and reside in the CNC. These compensations are set at the factory. As with any compensation system be aware: •...

  • Page 362: 7.10.1.1 Measurement Of Axis Backlash

       7.10.1.1 Measurement of Axis Backlash This procedure is used to measure an axis' backlash. Measure backlash at three points along the axis, then use an average of these measure- ments as the backlash amount. If the backlash check readings are high (0.02mm (0.0008")), inspect the entire feed mechanism for possible mechanical failures.

  • Page 363: Pitch Error Compensation

    2. Improper set up or compensation for the laser may affect the accuracy of pitch error measurement, be certain to check with your Makino service group for details and assistance. 4V2A1563 (E)

  • Page 364: Setting Cnc Parameters

       7.11 Setting CNC Parameters Certain maintenance functions require setting or adjusting related CNC parameters to restore the machine to original operating condition. The fol- lowing procedure provides the basic steps to set CNC parameters. Setting values differ depending the parameter number. Refer CNC Maintenance Manual details related to specific parameter setting values.

  • Page 365: Periodic Maintenance

       7.12 Periodic Maintenance Check the following items, at the recommended frequencies, to ensure proper machine performance, accuracies, and capabilities, are and main- tained, throughout its life. 7.12.1 Daily Checks 1. Check main system air pressure; pressure should be set at 0.5 MPa (70 psi).

  • Page 366: Axis Lubrication

       7.12.3 Axis Lubrication Proper axis lubrication is essential to maintaining smooth and consistent axis movement and positioning accuracy. • A axes LM guides and ball nuts are lubricated from two distribution points. • A grease gun is provided for greasing the ball nuts, LM guides, ATC, and APC mechanisms.
  • Page 367    X and Z Lubrication Procedure: 1. Reference the X axis. 2. Open the lubrication access door, located on the right hand side of the machine. 3. Using or machine mounted lubrication plate, locate the Figure 7-42 fittings for the component (LM guides or ball nut) being lubricated. Four grease fittings for the X axis guide blocks Six fittings for the Z axis guide blocks One fitting each for the X and Z ball nuts...

  • Page 368: 7.12.3.2 Y Axis Lubrication Points

       7.12.3.2 Y Axis Lubrication Points The grease fittings for the Y axis LM guides and ball nut are accessed by positioning the Y axis to its mid-stroke position and removing the cover from the front of the table. See Figure 7-43 7-43 Y IGURE...
  • Page 369    OTES KETCHES 4V2A1563 (E) 7 - 81...
  • Page 370    OTES KETCHES 7 - 82...
  • Page 371    Chapter 8 A25 ATC (Automatic Tool Changer) Unit 4V61A Type 25 Tool Armless Magazine Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 08-4vA61A A25 Armless ATC.fm...
  • Page 372    Chapter 8 A25 ATC (Automatic Tool Changer) Unit Contents 8.1 Overview ......... . .8 - 1 8.2 Principles of Operation.
  • Page 373    8.8.1.1 Positioning Rate Adjustment ....8 - 41 8.8.1.2 Cylinder Cushion Adjustments ....8 - 42 8.8.2 Shutter Lubrication .
  • Page 374    OTES KETCHES...

  • Page 375: Overview

       Overview The V55 is available with a 25 tool magazine ATC (Automatic Tool Changer). The ATC is armless type tool changer, referred to as an A25. The ATC unit is located on the left side of the machine and isolated from the machining area by an air operated ATC shutter (door).

  • Page 376: Principles Of Operation

       Principles of Operation Several operating principles, beyond the ATC mechanism(s), should be understood and considered when troubleshooting or operating the ATC. These include the: • ATC Operation Panel • Sequence of events • ATC standby conditions • ATC positions •...
  • Page 377    [Manual Interrupt] – Toggles the ATC unit between manual (X01.5 = 1) and automatic (X01.5 = 0) mode. In automatic mode (button lamp Off (Y05.7 = 0)); the ATC functions normally and opening the ATC door interrupts machine operation and generates an alarm. In manual mode (button lamp On (Y05.7 = 1));...

  • Page 378: Atc - Sequence Of Events

       8.2.2 ATC - Sequence of Events Tools loaded into the magazine must have PTN's (Programmed Tool Numbers) assigned for identification within the machine tool system. A PTN represents the T-code assigned in the part program. the tools in the magazine must then be registered in the PMC to assign the PTN to a magazine (pot) location, see for detail on tool regis-...
  • Page 379    Tool Change Sequence - Tool in Spindle: With a tool clamped in the spindle, the tool change must first unload the spindle tool, then pick up the commanded tool. When a tool call and tool change are commanded, T15;...

  • Page 380: Atc Standby Condition

       8.2.3 ATC Standby Condition ATC Standby is a conditional check, made by the PMC, confirming that the ATC unit is in the proper state to perform a tool change. The PMC determines Standby condition by viewing the status of specific inputs and outputs.

  • Page 381: Atc Positions

       8.2.4 ATC Positions The ATC unit has several different positions that must be properly set, or defined, to complete an automatic tool change. These positions include: • Tool magazine ready position; radial location of pot. Established by the axis word of Grid Shift parameter 1850.

  • Page 382: O9020 - Program Description

    In this program, # is read as variable and #0 is read as vacant. #0 is used in conditional expressions to test for missing variable data. ABLE ATC PROGRAM AND DETAIL Program Detail 9020 (V55 ATC15/25 AND TLS VER.4) ; Program# and identifying comment M5 ; Spindle stop G91 G28 Z0 ; Z reference G91 G30 Y0 ;...
  • Page 383    ABLE ATC PROGRAM AND DETAIL CONTINUED Program Detail G91 G30 X0. Z0. M663 ; X and Z 2 reference G49 ; Cancel tool length compensation G91 G0 Z[105/#10] M663 ; Incremental Z positive move of 105 mm/1 G91 G30 Z0. M663 ; reference IF [#11EQ#0] GOTO30 ;...
  • Page 384    ABLE ATC PROGRAM AND DETAIL CONTINUED Program Detail IF [#104EQ7] GOTO90 ; Jump to N90 if #104 = 7 G90 G53 G0 X[-1085/#10] ; X move (machine coordinate) M559 ; G40 ; Cancel cutter radius compensation IF [#104EQ6] GOTO80 ; Jump forward to N80 if #104 is equal to 6 G91 G30 X0.

  • Page 385: Tool Registration Program - O5700

       8.2.6 Tool Registration Program - O5700 The tool registration program assigns PTN's (Program Tool Numbers) in the PTN column of the Custom side - screen. PTN's are TOOL DETAIL assigned to the POT# column corresponding to the tool location or maga- zine pot numbers.
  • Page 386    OTES KETCHES 8 - 12...

  • Page 387: Atc Maintenance Mode And Screens

       ATC Maintenance Mode and Screens The Custom side provides screen pages to allow manual MAINTENANCE operation of the ATC mechanisms when performing maintenance or recovery procedures. These screens include: • - (initial screen) for activating and MAINTENANCE MENU MAINTENANCE deactivating Maintenance mode.

  • Page 388: Maintenance Menu Page

       8.3.1 Maintenance Menu Page To display the page and turn Maintenance mode On MAINTENANCE MENU or Off: 1. Press the [CUSTOM] function key. Press the [PO] softkey, if the screen is not displayed. 2. Press [MS] to display the [MAINTENANCE] softkey. 3.
  • Page 389    shows the Figure 8-4 ATC MAIN- page. TENANCE The standard screen features are present; screen name [4], and page numbers [7]. At center top of the screen, MAINTENANCE [6] is displayed if the MODE Maintenance mode is active. Current status is indicated by STROKE NORMAL/STROKE [3] indicating if stroke...

  • Page 390: Atc Mgzn Mainte Screen

       8.3.3 ATC MGZN MAINTE Screen (Magazine Maintenance) page allow tool magazine ATC MGZN MAINTE operation for referencing and setup of magazine positioning modes, with Maintenance mode active. To access the page: ATC MGZN MAINTE 1. Display the maintenance menu screen - section 8.3.1 2.
  • Page 391    The softkey menus [10] provide access to the screens. MENU PAGE [SET] - activates the highlighted (white) feature selected in the FEED MODE fields. FEED OVER RIDE Feed Mode and Feed Over Ride fields are used for magazine posi- FEED MODE FEED OVER RIDE tioning operations.

  • Page 392: Atc Recovery

       ATC Recovery The following recovery procedures are for resuming normal operation, if the machine stopped during a tool change cycle. • ATC recovery depends on where the machine is in the tool change cycle. See section 8.4.1 section 8.4.2 •...

  • Page 393: Spindle Clamped On Tool In Magazine

       8.4.1 Spindle Clamped on Tool in Magazine In this condition: • Spindle is clamped on tool in magazine • ATC shutter is open (SOL711A - Output = 1) • Stroke Extend mode is On (EXLM - Output = 1) Confirm conditions on the screen, section 8.3.2...

  • Page 394: Spindle At Magazine And Not Clamped On Tool

       8.4.2 Spindle at Magazine and Not Clamped on Tool In this condition: • Spindle is in the magazine area, NOT clamped on a tool • ATC shutter is open (SOL711A - Output = 1) • Stroke Extend mode is On (EXLM - Output = 1) Confirm conditions on the screen, section 8.3.2...

  • Page 395: Magazine Gripper Assemblies

       Magazine Gripper Assemblies The A25 tool magazine contains 25 sets of gripper assemblies, called pots ( Figure 8-6 Each finger set is mounted to the magazine [1] using two #40 pins [3] attached by M5x25 screws [5]. The pins [3] serve as pivot points for the fingers [2] and [8].

  • Page 396: Magazine Driving Components

       Magazine Driving Components The A25 magazine driving components are: mechanical, electrical, and electronic devices. The servo motor is controlled by the servo drive sys- tem, which sends commands and receives feedback signals from the CNC position control circuit. 8.6.1 Mechanical Components The mechanical components and construction of the magazine are shown...

  • Page 397: Electrical Components

       8.6.1.1 Electrical Components The main electrical component of the A25 servo system is the Fanuc α E Series servo motor. This servo motor includes such features as: • Large frame of reduced motor length. • Drip proof construction complying with IP55 Standard. •...

  • Page 398: Electronic Assemblies

       8.6.1.2 Electronic Assemblies The A25 drive system electronic assemblies include one Power Supply Module (PSM) and one Servo Amplifier Module (SVM). These compo- nents are in the servo drive unit, located in the MTC (Machine Tool Cabi- net). •...

  • Page 399: Servo Amplifier Module - Svm

       8.6.1.3 Servo Amplifier Module – SVM The A25 is equipped with a Fanuc SVM to con- trol the AC servo motor by using a PWM (Pulse Width Modulation) inverter to regulate the DC power converted by the PSM. The SVM is a: Model No.

  • Page 400: Atc - Limit Switches

       ATC - Limit Switches The A25 uses both limit and proximity (prox) switches for feedback signals to the PMC. • One limit switch on the ATC door is used for the safety interlock • Two prox switches on the ATC shutter to signal open and closed conditions •...

  • Page 401: Atc Door Limit Switch - Ls942

       8.7.1 ATC Door Limit Switch - LS942 The ATC door is equipped with a safety inter- lock limit switch [1], wired into the E-Stop cir- cuit. The machine enters an E-Stop condition if the ATC door is opened without first placing the ATC in the Manual Interrupt mode.
  • Page 402    Testing LS942 Operation: Perform the following checks to confirm proper switch operation. 1. Display the Custom - screen: DIAGNOSTIC A. Press the [CUSTOM] key. Press [PO] if screen is not displayed. B. Press [MS] to display the menu. DIAGNOSE 2.
  • Page 403    OTES KETCHES 4V2A1563 (E) 8 - 29...

  • Page 404: Atc Shutter Limit Switches - Ls747 And Ls748

       8.7.2 ATC Shutter Limit Switches - LS747 and LS748 The ATC shutter has two reed type prox switches mounted to the shutter air cylinder [2] ( ) and confirm shutter closed and opened status. Figure 8-12 These switches actuate by sensing the presence of the cylinder piston through the cylinder body.
  • Page 405    Testing LS747 and LS748 Operation Confirm switch operation, before adjusting or replacing either switch. If a switch is malfunctioning, adjust it as described in LS747 and LS748 Adjust- . If adjustment fails to correct switch operation, replace it as ment (pg 8-32) described in...
  • Page 406    LS747 and LS748 Adjustment Adjustment of LS747 and LS748 is performed by loosening the mounting strap and sliding the switch along the cylinder until the switch actuates. The objective in switch adjustment is to have LS747 actuated when the ATC shutter is closed and LS748 actuated when the ATC shutter is open.
  • Page 407    LS747 and LS748 Replacement 1. Press [CONTROL POWER OFF], turn the Main Power switch Off, and perform Lockout/Tagout at the facility (machine) power supply. 2. Remove the necessary covers to access the switches, see LS747 and LS748 Adjustment 3.

  • Page 408: Magazine Tool Exists Prox Switch - Ls99

       8.7.3 Magazine Tool Exists Prox Switch - LS99 The ATC magazine uses one prox switch to confirm if a tool is present (exists) in the pot, at the ready position. • If there are tools in the spindle and the pot at the ready position, the tool change is inhibited.
  • Page 409    LS99 Adjustment LS99 is a proximity switch with a broad sensing range. This switch is non- adjustable and must be replaced if malfunctioning, see LS99 Replacement LS99 Replacement 1. Press [CONTROL POWER OFF], turn the Main Power switch Off, and perform Lockout/Tagout at the facility (machine) power supply.

  • Page 410: Magazine Reference Slow Down - Ls700

       8.7.4 Magazine Reference Slow Down - LS700 Magazine indexing is actually the 6 axis, in the MT system, and per- formed by a servo motor with a position coder with a reference position like other axes. Unlike the machine axes, the magazine refer- ences automatically when the first T code is commanded.
  • Page 411    Testing LS700 Operation Confirm operation of LS700 before adjusting or replacing the switch. If the switch is malfunctioning; adjust as described in . If switch LS700 Adjustment adjustment fails to correct a malfunctioning switch, replace it as described LS700 Replacement Switch operation can be viewed by the status of its LED.
  • Page 412    Switch Adjustment and replacement Testing LS700 Operation (pg 8-37) Confirm switch operation ( ) before adjusting or replac- ing this switch. Changes to this switch setting may affect the magazine radial pot (ready position) alignment. Changes in ready position alignment may result in misoperation and damage to the ATC and spindle.
  • Page 413    LS700 Replacement 1. Using the [CW] or [CCW] button index pot 25 to the ready position. 2. Press [CONTROL POWER OFF], turn the Main Power switch Off, and perform Lockout/Tagout at the facility (machine) power supply. 3. Remove the ATC magazine joint box cover. Six (M4x8) cross-head screws.

  • Page 414: Atc Shutter

       ATC Shutter The ATC shutter isolates the tool magazine from the machining area and is opened and closed upon commands from the PMC. Shutter positioning is by an air cylinder with both rate and cushioning adjustments. Limit switches are provided at both ends of the shutter stroke to confirm open and closed conditions, see for details.

  • Page 415: Positioning Rate Adjustment

       8.8.1.1 Positioning Rate Adjustment ATC shutter motion is driven by an air cylinder which is actuated by a dou- ble sided solenoid valve SOL711A /B ( ). Flow control valves [3] Figure 8-20 and [4] are installed in the solenoid output air lines for adjusting the shutter opening and closing rates.

  • Page 416: Cylinder Cushion Adjustments

       8.8.1.2 Cylinder Cushion Adjustments The ATC shutter air cylinder has cushion adjustments, on both ends of the cylinder, for adjusting the stopping rate at the end of each stroke. The objective is to set these adjustments to obtain a slow down at the end of stroke and prevent hard stops when the shutter is opened and closed.

  • Page 417: Shutter Lubrication

       8.8.2 Shutter Lubrication The ATC shutter LM guide blocks are equipped with grease fittings for periodic lubri- cation. The grease fittings are installed in the outer ends of each guide block and accessed by removing the cover left of the rolling S/G door. •...

  • Page 418: Atc Alignments

       ATC Alignments ATC alignments include: spindle orientation, the X and Z tool change posi- tions, and the tool magazine ready position. • Spindle orientation is described in of this Maintenance Guide. chapter 6 This section describes how to check and set the: •...

  • Page 419: Checking X Tool Change And Ready Position

       8.9.1 Checking X Tool Change and Ready Position This procedure verifies that the tool pot and spindle centerlines are in-line when X is at the tool change position and the magazine at the ready posi- tion. To achieve pot-to-spindle centerline alignment, positioning the maga- zine and X axis is necessary.
  • Page 420    5. Reference the tool magazine, using Maintenance mode. A. Display the maintenance menu screen - section 8.3.1 B. Press [MODE SELECT] to activate Maintenance mode. C. Press the [ATC MGZN] softkey. D. Using the cursor keys, highlight ZERO RETURN E.
  • Page 421 8.10 If a deviation greater than 1.500mm is found, other problems may exist. Contact your Makino service group. 19. Using the MPG, position: A. Z (plus), moving the indicator clear of the test ring. B. X (plus), into its normal operating range (right of the ATC shutter).
  • Page 422    22. Input required changes to parameter 1850 ( section 8.10 23. After changing the parameter settings, power down the machine. 24. Cancel the “stored” reference positions. A. From a power Off condition, press [CONTROL POWER ON]. B. During the control boot process, simultaneously press and hold the [P] and [CAN] keys.
  • Page 423    OTES KETCHES 4V2A1563 (E) 8 - 49...

  • Page 424: Z Axis - 2Nd Reference Position Alignment

       8.9.2 Z Axis - 2 Reference Position Alignment The Z 2 reference position, parameter 1241, is used to estab- lish the proper Z axis position (height) for placing tools in and out of the magazine. When prop- erly set, this position allows for “tool knockout”...
  • Page 425    5. Manually load a tool holder into the spindle. 6. Select MDI and position Z axis to its 2 reference position. A. Key-in ’G30 G91 Z0’. B. Press the [EOB] key. C. Press the [INSERT] key. D. Press Cycle [START]. 7.
  • Page 426    Be Alert Machine movements are unprotected in this state. Set MPG to lowest feed setting. Stop axis motion immediately if tool holder-to-gripper finger interference or binding is noticed. Failure to follow this caution may result in machine damage. 13.
  • Page 427    17. On the page: ATC MAINTENANCE A. Close the ATC shutter. B. Deactivate mode. STROKE EXTEND 18. Display the page and deactivate Maintenance MAINTENANCE MENU mode. 19. Enter the necessary change to parameter 1241, see section 8.10 20. Input required changes to parameter 1850 ( section 8.10 21.

  • Page 428: Setting Atc Position Related Cnc Parameters

       8.10 Setting ATC Position Related CNC Parameters The following ATC positions are defined by CNC parameters, as follows: • X tool change position – X axis 2 reference position parameter 1241 set relative to X machine zero. See for procedure to establish chapter 8 X machine zero.

  • Page 429: Cnc Parameter Setting Procedure

       8.10.1 CNC Parameter Setting Procedure • The control provides the capability to “password” protect the CNC parameters. If this feature is active, the password must be known in order to activate the Parameter Write Enable function. 1. Activate PWE (Parameter Write Enable) to unlock CNC parameters. A.

  • Page 430: And Z Axes - Operating Range Related Parameters

       8.10.2 X and Z Axes - Operating Range Related Parameters When a change is made to a 2 reference position parameter, the follow- ing CNC parameters must also be checked and, if necessary, reset as described below: Parameter 1327 - Stored Stroke Limit 1 (Negative Direction) This parameter sets the coordinate values of stored stroke limit 1 in the negative direction for each axis, in the machine coordinate system.

  • Page 431: Periodic Maintenance

       8.11 Periodic Maintenance Check the following items, at the recommended frequencies, to ensure proper machine performance, accuracies, and capabilities, are and main- tained, throughout its life. 8.11.1 Daily Checks 1. Thoroughly clean the shank of tool holders in the magazine. Remove all chips, coolant residue, and oil from the tool holder shanks.
  • Page 432    OTES KETCHES 8 - 58...
  • Page 433    Chapter 9 Oil Controller 4V81A Type Daikin Model AKZ306-D41B Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 09-4va OiI Controller.fm...
  • Page 434    Chapter 9 Oil Controller Contents 9.1 Overview ......... . . 9 -1 9.1.1 Safety Precautions .

  • Page 435: Overview

    14,000 rpm spindle. The 20,000 rpm spindle uses a second floor mounted unit [1], set directly behind the machine. • The system uses Makino Spindle Lubricant, supplied from the tank next to the machine mounted oil controller. Considerations for installation of...

  • Page 436: The Oil Controller Unit

       The Oil Controller Unit The oil controller(s) on the V55 are Model No. AKZ 306-D14B manufac- tured by Daikin Industries Ltd. These are self-contained refrigeration units connected to Makino supplied components consisting mainly of a pump/ tank unit and two machine mounted pumps.
  • Page 437    Legend Condenser Unit Expansion Valve Filter [10] Fan Temperature Controller [11] Oil Pump (P1) With Relief Valve Operation Panel [12] Oil Inlet Port Oil Outlet Port [13] Oil Pan With Drain Port Oil Return Thermistor (Th-2) [14] High Pressure Switch Evaporator [15] Compressor And Motor Oil Inlet Thermistor (Th-4)

  • Page 438: Oil Controller Specifications

       9.2.1 Oil Controller Specifications ABLE OIL CONTROLLER SPECIFICATIONS Item Specification Detail Manufacturer Daikin Industries Ltd. Model AKZ306-D41B Cooling Capacity [50/60 Hz] 8000/9000kW (6800/7700kcal/hr) Power Capacity 200V-9.7kVa/220V-10.3kVa Source Main Circuit 3Φ 200/200 – 220V [50/60 Hz] Operation Circuit 1Φ 24VAC Dimensions (HxWxD) 1220 x 560 x 620mm Weight...
  • Page 439    OTES KETCHES 4V2A1563 (E) 9 - 5...

  • Page 440: Oil Controller Electrical Schematic

       9.2.2 Oil Controller Electrical Schematic shows the oil controller electrical drawings for use in trou- Figure 9-3 bleshooting, see section 9.7 9 - 6...
  • Page 441    4V2A1563 (E) 9 - 7...

  • Page 442: Oil Controller/Machine System

    Y-axis ball screw casting. Spindle bearing lubrication is performed by a method referred to as “under race lubrication”. Patented by Makino, this method of lubrication jets oil through orifices in the side of the spindle into the under side of the bearing races.
  • Page 443    IGURE OIL CONTROLLER MACHINE SYSTEM 4V2A1563 (E) 9 - 9...

  • Page 444: Second Oil Controller Unit Installation

       Second Oil Controller Unit Installation Install the second unit based on the following considerations: • Clear of interference to/from an optional lift up chip conveyor • On a solid and flat surface • Away from direct sunlight and other heat sources •...

  • Page 445: Remote Control And Alarm Connections

       9.4.3 Remote Control and Alarm Connections Oil controller operation is remotely controlled by the PMC including response to specific PMC alarms generated by machine mounted feedback devices. Oil controller side connections for these functions are made at - termi- nal block TeS1, located in the switch box.

  • Page 446: Operation Panel Description

       Operation Panel Description The Oil Controller Operation Panel ( ) is located at the Figure 9-6 top right of the oil controller. A description of the operation panel devices follows: IGURE OIL CONTROLLER OPERA TION PANEL 9.5.1 LED Indicators The five LED indicators, located across the top of the operation panel, indicate the general oper-...

  • Page 447: Lcd Displays

       9.5.2 LCD Displays The LCD’s display the seven oil controller func- tions, associated modes, and data. The data type is identified at right of the data with unit of measure (°C, K (Kilocalorie), % or Hz). The LCD display is detailed in Table 9-3 ABLE LCD DISPLAY DETAIL...

  • Page 448: Oil Controller Functions And Modes

    Troubleshooting Purposes Only . Do NOT Change Any Oil Controller Data The data setting values are specific to the V55. The values have been determined, and factory set, to maintain the oil at the proper temperature and minimize thermal growth of the machine components lubricated and cooled by this system.

  • Page 449: Oil Controller Modes

    The active mode is shown in the MODE display area. Do NOT Change Any Oil Controller Data The data setting values are specific to the V55. The values have been determined, and factory set, to maintain the oil at the proper temperature and minimize thermal growth of the machine components lubricated and cooled by this system.
  • Page 450 The TIMER function has two modes; MANUAL and AUTO. The active mode flashes, below the FNC display. • The V55 PMC controls oil controller operation. TIMER function MUST be set to MANUAL. SETTING (Flashing) When SETTING is flashing in the FNC display, the parameter setting func- tion is active.
  • Page 451    MONITOR (Flashing) When MONITOR is flashing in the FNC display, the SERVICE MONITOR function is active. In an oil controller alarm condition, the SERVICE MONITOR function dis- plays the alarm code in the DATA display and the alarm level in the MODE display area.

  • Page 452: Troubleshooting And Alarms

    Controller Operation Panel LED's and Service Monitor function be checked to determine if an oil controller problem exists. • If the troubleshooting procedures in the following sections do not correct the problem, your Makino service group. 9.7.1 Preliminary Troubleshooting to begin troubleshooting oil controller problems if no error Table 9-7 indications are present.
  • Page 453    ABLE PRELIMINARY TROUBLESHOOTING Condition Cause Remedy Power is On, but power 1. Indicator board. 1. Replace indicator board LED is not On. 2. Control circuit fuse is (PCB4). blown. 2. Replace fuse. 3. Check for short circuit in operation circuit.

  • Page 454: Oil Controller Alarms - General

       9.7.2 Oil Controller Alarms - General Oil controller alarm indications may appear as PMC (machine) alarms or may be internal oil controller system faults. When an oil controller related PMC alarm or abnormal oil controller operation occurs Check the Oil Con- troller Operation Panel for more detail.

  • Page 455: Clearing Alarms

    (burnout, rotor lock, etc.). • If an E6 alarm occurs, contact your Makino service group E6 Alarms E6 is a Level 2 alarm. If a Level 1 alarm occurs before the E6 is cleared, it is overwrit- ten, canceling the E6 condition.

  • Page 456: Oil Controller Pmc Alarms

       9.7.3 Oil Controller PMC Alarms lists PMC oil controller related alarms. This list is not all-inclu- Table 9-9 sive, other alarms may trigger alarms causing or reflecting oil controller operation problems. Any suspected oil controller abnormality, reflected in a PMC alarm, should be investigated through the Oil Controller Operation Panel.

  • Page 457: Oil Controller Alarm Codes

    50° C. connector is Temperature increases disconnected. if unit starts running at 4. PCB1 failure. lower than 50° C. 5. High-pressure switch Contact your Makino damaged. service group. 6. 49C Compressor 3. Check wiring. protection thermostat Disconnect CN27 from damaged.
  • Page 458    9-10 ABLE OIL CONTROLLER ALARM CONTINUED Alarm Condition Possible Cause Remedy (Level) 51C Compressor 7. Compressor motor over- 7. Reset E6 and check over-current relay current or the current for: 3-hp motor is activated. compressor rotor is less than 17A. 2-hp locked.
  • Page 459 CN22 from PCB2 and 3. Magnetic switch failure. reconnect. 3. Replace magnetic switch. High inlet oil tem- 1. Cooling efficiency going 1. Contact your Makino perature (over 60° down. service group. 2. Temperature above 60° 2. Wait until temperature goes below 50° C.
  • Page 460 1. Over voltage. Over 1. Check power source abnormality. 242V. voltage. 2. Out of phase. 2. Check wiring. Re-phase. Flash stop or 1. Contact your Makino shortage of volt- service group. age. Transmission 1. Broken wire or 1. Check wiring. abnormal PCB1 to...

  • Page 461: Operation Panel Alarm Codes

       9-10 ABLE OIL CONTROLLER ALARM CONTINUED Alarm Condition Possible Cause Remedy (Level) Serial or parallel 1. Broken wire or 1. Check wiring. transmission fail- connector is Disconnect CN30 and ure between disconnected. CN31 from PCB1 and machine and oil 2.

  • Page 462: Alarm Record In Memory

       9.7.6 Alarm Record in Memory When an alarm is generated, the current data values are stored in the EEPROM error parameter memory ( Table 9-12 9-12 ABLE ALARM MEMORY RECORD Mode Mode Alarm code Power supply frequency Not used Equipment temperature Oil outlet temperature Atmospheric temperature...

  • Page 463: Periodic Maintenance

       Periodic Maintenance Check the following items, at the recommended frequencies, to ensure proper machine performance, accuracies, and capabilities, are and main- tained, throughout its life. 9.8.1 Casing 1. Polish the casing with a dry cloth. If the casing is heavily, soiled, use a high quality soap or neutral detergent.
  • Page 464    OTES KETCHES 9 - 30...
  • Page 465    Appendix A Alarms Machine side (PMC), CNC side, Axis Servo, and Spindle Servo Module Alarms Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 0A-4va Alarms.fm...
  • Page 466    Appendix A Alarms Contents A.1 Overview ..........A -1 A.2 PMC (Programmable Machine Controller) Alarms .
  • Page 467    A.3.4 Background Edit (BP/S) Alarms ..... A -33 A.3.5 Absolute Pulse Coder (APC) Alarms ....A -33 A.3.6 Serial Pulse Coder (SPC) Alarms .
  • Page 468    OTES KETCHES...

  • Page 469: Overview

       Overview Listings of PMC, CNC, Axis Servo Drive Unit and Spindle Drive Unit alarms are provided in this chapter. Details on the display, reset, and meaning of each alarm type follows. • PMC alarms are described in section A.2 •...

  • Page 470: I/O Unit Alarms

       A.2.1 I/O Unit Alarms I/O Unit Alarms Type Message 00001 Group value parameter for the panel connection unit is too large 00002 Group value parameter for the I/O unit is doubly registered 00003 Group value parameter for the I/O unit is too large 00004 Wrong index type was set for the I/O unit 00005...
  • Page 471    Pallet Changer Alarms (continued) Type Message 01072 Pallet seat check is disabled as no pallet on table 01073 Pallet seat check is disabled as low air pressure 01074 Pallet is not seated correctly 01095 Arm advance initial condition is not arranged 01096 Arm advance condition is lost during motion 01097...

  • Page 472: Atc Magazine (1St Axis) Alarms

       Pallet Changer Alarms (continued) Type Message 01459 Pal. uncl & down & S/G close condition is lost during motion 01460 Pal. uncl & down & S/G close is not completed within the time 01461 APC signal open is disabled as spindle is not stopped 01462 APC signal open is disabled as coolant is not stopped 01463...

  • Page 473: Atc Sub-Arm Alarms

       A.2.4 ATC Sub-Arm Alarms ATC Sub-Arm Alarms Type Message 05037 Initial condition for pot move to standby pos. is not set 05038 Required position for pot move to standby pos. is lost 05039 Pot move to standby pos. is not end within the time 05040 Initial condition for pot return to mgzn-A is not set 05041...

  • Page 474: Atc Alarms

       ATC Sub-Arm Alarms (continued) Type Message 05067 initial condition for pot clamp of takeout from mgzn is not set 05068 required condition for pot clamp of takeout from mgzn is lost 05069 pot clamp of takeout from mgzn is not end within the time 05070 initial condition for pot takeout from mgzn is not set 05071...
  • Page 475    ATC Alarms (continued) Type Message 06268 ATC shutter close is not end within the time 06340 Tool uncl./clamp is disabled as S/G door is not open 06388 Spndl is not stopped when ATC shutter is to open 06389 Coolant is not stopped when ATC shutter is to open 06390 X pos.

  • Page 476: Spindle Alarms

       ATC Alarms (continued) Type Message 06419 Next tool return motion is not end 06420 ATC arm was moved but stop signal is not turned on A.2.6 Spindle Alarms Spindle Alarms Type Message 07000 Condition to perform spndl CW rotation are not satisfied 07001 Tool clamp signal took off during spindle CW rotation 07002...

  • Page 477: Coolant Alarms

       Spindle Alarms (continued) Type Message 07046 Spindle speed is not set when rigid tap was commanded 07050 Confirm signal don’t go on when switching spndl to high torque 07051 Contactor don’t turn on when switching spndl to high torque 07052 Fin signal does not go on when switching spndl to high torque 07053...

  • Page 478: Machine Parameter And Tool Data Dump Alarms

       A.2.8 Machine Parameter and Tool Data Dump Alarms Machine Parameter and Tool Data Dump Alarms Type Message 11000 NC command is incorrect 11001 NC memory is full 11002 This program is registered already 11003 Command cannot be executed as program screen is open 11004 Writing in nc program is disabled due to memory protection 11005...
  • Page 479    Thermal and Flow Switch Alarms (continued) Type Message 13050 Lift up chip conveyor did not start as manual mode 13058 S/G is opened 13063 Oilmatic filter is clogged 13064 Oilmatic filter is clogged 13086 Coolant level is too low 13093 Spindle lubricant flow sensor abnormal 13112...

  • Page 480: Measuring System And Feed Axis Alarms

       A.2.10 Measuring System and Feed Axis Alarms Measuring System and Feed Axis Alarms Type Message 14000 X-axis +OT2 alarm is being generated 14001 X-axis -OT2 alarm is being generated 14002 Y-axis +OT2 alarm is being generated 14003 Y-axis -OT2 alarm is being generated 14004 Z.-axis +OT2 alarm is being generated 14005...

  • Page 481: Atc Control Panel Alarms

       APC Control Panel Alarms (continued) Type Message 16073 Man. pallet load/unload is disabled as pc arm is not stndby 16074 Man. pallet load/unload is disabled during random operation 16075 Man. pallet load/unload is disabled as not all axes ref. 16076 Pallet to be loaded is not found 16077...

  • Page 482: Automatic Tool Monitor Alarms

       A.2.14 Automatic Tool Monitor Alarms Tool Monitor Alarms Type Message 21000 Z-axis command exceeds the check pos. in broken tool check 21001 Tool is broken 21005 TL monitor alarm is being generated 21011 Z-axis command exceeds the check pos. in broken tool check 21012 Tool is broken 21014...
  • Page 483    Cycle Start and Random Operation Alarms (continued) Type Message 23006 Automatic operation is being executed 23007 CNC alarm is being generated 23008 Memory or tape mode is not selected 23009 Reference point return is not completed 23011 Cannot reset CNC 23012 Work offset value exceed the allowable range 23013...

  • Page 484: Routine Functions Alarms

       A.2.16 Routine Functions Alarms Routine Function Alarms Type Message 25001 Cannot use routine function because feed hold is on 25002 Cannot use routine function during manual axis feed 25003 Cannot use routine function due to ref. return incomplete 25004 Cannot use routine function during automatic operation 25005...

  • Page 485: Atc Magazine (2Nd Axis) Alarms

       A.2.17 ATC Magazine (2ND Axis) Alarms ATC Magazine (2nd Axis) Alarms Type Message 26000 Index command for atc mgzn is ‘0’ or more than parameter data 26002 T-code cannot performed as maintenance mode is selected 26003 ATC mgzn motor axis (CNC axis) alarm 26004 ATC mgzn command is disabled as CNC buffer is full 26005...

  • Page 486: Gi Function Alarms

       Tool Index Condition Alarms (continued) Type Message 27101 At next tool return, indexed mgzn-B rack has a pot 27102 At next tool return, indexed mgzn-A rack has a pot 27103 At next tool return, mgzn-B rack has no pot 27104 At next tool return, mgzn-A rack has no pot 27105...
  • Page 487    M, S, T Code Alarms (continued) Type Message 30021 Cannot find the PTN commanded 30022 Data of tool length & diameter is out of the specified range 30023 Cannot use the PTN commanded 30025 Measured length data is illegal M920 M-variable#100 30026 T-no.
  • Page 488    M, S, T Code Alarms (continued) Type Message 30060 Pallet no. on machine table is unsettled 30061 Pallet no. on machine table is out of the specified range 30062 Cannot write pallet number into macro variable 30063 Cannot read macro variable properly in outputting pallet no. 30064 Cannot write pallet number properly 30065...
  • Page 489    M, S, T Code Alarms (continued) Type Message 30191 Probe power is not turned off within the time 30192 Probe power is not turned on within the time 30195 Spndl tool life is ‘0’. TL count by M919 is disabled 30207 CNC parameter cannot be written correctly 30216...
  • Page 490    OTES KETCHES A - 22...

  • Page 491: Cnc Alarms

       CNC Alarms A CNC alarm is generated by the CNC (Computerized Numerical Control) and are considered Control side alarms. When a CNC alarm is generated screen, with an Alarm number and brief Message, ALARM MESSAGE is automatically displayed. See for more detail on the CNC alarm chapter 5 display function.

  • Page 492: A.3.2.1 Detail Format

       A.3.2.1 Detail Format In the following tables, each alarm number is followed by the on screen message and a contents column which describes the probable cause(s) of the alarm. EXAMPLE: An example of the alarm table format is provided below. Message Contents 000 PLEASE TURN OFF...

  • Page 493: Program/Setup (P/S) Alarms

       A.3.3 Program/Setup (P/S) Alarms P/S Alarms Message Contents PLEASE TURN OFF A parameter which requires the power off was input, POWER turn off power. TH PARITY ALARM TH alarm (A character with incorrect parity was input). Correct the tape. TV PARITY ALARM TV Alarm (The number of characters in a block is odd).
  • Page 494    P/S Alarms (continued) Message Contents NO CIRCLE RADIUS The command for circular interpolation lacks are radius R or coordinate I, J, or K of the distance between the start point to the center of the arc. CANNOT COMMAND F0 (fast feed) was instructed by F1-digit column feed F0 IN G02/G02 in circular interpolation.
  • Page 495    P/S Alarms (continued) Message Contents G27-G30 NOT One of G27 to G30 is commanded in canned cycle ALLOWED IN FIXED mode. ILLEGAL REFER- Other than P2, P3, and P4 are commanded for 2nd, ENCE RETURN COM- 3rd, and 4th reference point return command. MAND ILLEGAL AXIS Two or more parallel axes (in parallel with a basic...
  • Page 496    P/S Alarms (continued) Message Contents TOO MANY PRO- The number of programs to be stored exceeded 63. GRAMS PROGRAM NUMBER The commanded program number has already been ALREADY IN USE used. ILLEGAL PROGRAM The program number is other than 1 to 9999. NUMBER PROTECT An attempt was made to register a program whose...
  • Page 497    P/S Alarms (continued) Message Contents P TYPE NOT P type cannot be specified when the program is ALLOWED (COORD restarted. (After automatic operation was inter- CHG) rupted, the coordinate system setting operation was performed.) P TYPE NOT P type cannot be specified when the program is ALLOWED (EXT OFS restarted.
  • Page 498    P/S Alarms (continued) Message Contents PARENTHESIS The nesting of bracket exceeds the upper limit (quin- NESTING ERROR tuple). ILLEGAL ARGUMENT The SQRT or BCD argument is negative, and other values than 0 to 9 are on each line of BIN argument. DUPLICATE MACRO The macro modal call is specified in double.
  • Page 499    P/S Alarms (continued) Message Contents M-CODE & MOVE A move command of other axes was specified to the CMD IN SAME BLK same block as M code related to spindle indexing. SUPERIMPOSED The total distribution amount of the CNC and PMC is DATA OVERFLOW too large during superimposed control of the extended functions for PMC axis control.
  • Page 500    P/S Alarms (continued) Message Contents RIGID MODE DI SIG- Rigid mode DI signal is not ON when G84 (G74) is NAL OFF executed though the rigid M code is specified. CANNOT CHANGE Plane changeover was instructed in the rigid mode. PLANE (RIGID TAP) CANNOT COMMAND M108 and M000 are executed in the schedule oper-...

  • Page 501: Background Edit (Bp/S) Alarms

       A.3.4 Background Edit (BP/S) Alarms BP/S Alarms Message Contents BP/S ALARM When a BP/S alarm occurs, the same number as the P/S alarm is displayed, but it is preceded by a B. Look up the “normal” P/S alarm (070, 071, 072, 073, 074 etc.).

  • Page 502: Serial Pulse Coder (Spc) Alarms

       APC Alarms (continued) Message Contents APC ALARM: nth-axis (n = 1-8) APC pulse error alarm. APC NTH-AXIS PULSE alarm. ERROR APC ALARM: nth-axis (n = 1-8) APC battery voltage has NTH-AXIS BATTERY decreased to a low level so that the data cannot be VOLTAGE 0 held.

  • Page 503: Servo (Sv) Alarms

       1. CNC Diagnostic display for SPC alarm 350. SPHA CSA – Check sum alarm is being generated. BLA – Battery low alarm is being generated. (No relation to alarm 350) PHA – Phase data fault alarm is being generated. PCA –...
  • Page 504    SV Alarms (continued) Message Contents SERVO ALARM: Position control system fault. Due to a CNC or servo (ZERO POINT system fault in the reference position return, there is RETURN FAULT) the possibility that reference position return could not be executed correctly. Try performing manual reference position return again.
  • Page 505    SV Alarms (continued) Message Contents SERVO ALARM: n-TH This alarm occurs when the n-th axis is in one of the AXIS PARAMETER conditions listed below (digital servo system alarm). INCORRECT 1. The value set in parameter No. 2020 (motor form) is out of the specified limit.

  • Page 506: Overtravel (Ot) Alarms

       3. CNC Diagnostic for servo alarm 416. Alarm Details Built in pulse coder disconnection (hardware). Separately installed pulse coder disconnection (hardware). Pulse coder is disconnected due to software. A.3.8 Overtravel (OT) Alarms OT Alarms Message Contents OVER TRAVEL: + n Exceeded n-th axis + side stored stroke limit 1.

  • Page 507: Overheat (Oh) Alarms

       A.3.9 Overheat (OH) Alarms OH Alarms Message Contents OVERHEAT: CON- Master printed circuit board overheat. TROL UNIT OVERHEAT: FAN The fan motor on top of the cabinet for the control MOTOR unit is overheated. OVERHEAT: SPIN- Spindle overheat in the spindle fluctuation detection. A.3.10 Rigid Tap Alarms Rigid Tap Alarms...
  • Page 508    Spindle Alarms (continued) Message Contents SPINDLE SERIAL Spindle control unit is improperly set up in a system LINK START FAULT with a serial spindle. The four main reasons are listed below: 1. An improperly connected optic cable or the spindle control unit power is OFF.

  • Page 509: System Alarms

       1. CNC Diagnostics for spindle alarm 750. SPE: 0: Serial spindle control parameters match the spindle unit start up conditions. 1: Serial spindle control parameters do not match the spindle unit start up conditions. S1E: 0: The 1st spindle serial start up was normal. 1: The 1st spindle was detected to have a fault during serial start SHE: 0: The serial communication module in the CNC is normal.

  • Page 510: Pmc Alarms

       SYS Alarms (continued) Message Contents SERVO ALARM Servo alarm (Main CPU board). A watchdog alarm (MAIN) or a RAM parity error in the servo module occurred. Replace the servo control module on the Main CPU board. SERVO ALARM (3/4 Servo alarm (3rd or 4th axis).
  • Page 511    PMC Alarms Message Contents ALARM NOTHING Normal state. PROGRAM DATA Sequence program in the user ROM is incorrect or ERROR (ROM) defective. PROGRAM DATA Sequence program in the user RAM is incorrect or ERROR (RAM) defective. PROGRAM SIZE The size of a ladder program is out of range (only for OVER PMC-RC).
  • Page 512    PMC Alarms (continued) Message Contents NO I/O DEVICE No external I/O unit is connected. SLC ERROR The LSI chip for I/O Link is defective. SLC ERROR (xx) The LSI chip in the I/O unit of group xx is defective or a transmission error has occurred.
  • Page 513    PMC Alarms (continued) Message Contents GDT ERROR (BASE, User-defined GDT error (BASE, LIMIT, or entry LIMIT) over). COMMON MEM. The number of shared memory units is nine or more. COUNT OVER COMMON MEM. The GDT entry of shared memory is out of range. ENTRY OVER LADDER 3 PRIORITY LADDER LEVEL 3 priority error.
  • Page 514    PMC Alarms (continued) Message Contents NMI BOC bb xxxx The RAM parity error or NMI (Non Maskable Inter- yyyyy rupt) generated in module of PMC engine - refer to CNC Maintenance Manual for details. NMI SLC aa cc A communication error occurred in the I/O link - refer to CNC Maintenance Manual for details.

  • Page 515: Axis Servo Drive Alarms

       Axis Servo Drive Alarms Axis Drive status is indicated by a 7-segment STATUS display. The PSM (Power Supply Module) has two 7-segment displays and each SVM (Servo Amplifier Module) has one. As conditions change within a module the status display indicates the related number or letter indicating current status.

  • Page 516: Servo Amplifier Module Alarms

       A.4.2 Servo Amplifier Module Alarms lists the Servo Drive - Amplifier Module status display; symbols, Table A-3 meaning, and description. ABLE AXIS SVM SELF DIAGNOSTIC ALARMS Status Type Description *NOT READY Amplifier module is not ready to drive a motor. *READY Amplifier module is ready to drive a motor.
  • Page 517    ABLE AXIS SVM SELF DIAGNOSTIC ALARMS CONTINUED IPM ALARM (HCN) Error detected in the IPM in the Z axis amplifier. † IPM ALARM (HCLM) Error detected in the IPM on X and Y axes amplifi- ers. † IPM ALARM (HCMN) Error detected in the IPM's in the Y and Z axes amplifiers.

  • Page 518: Spindle Drive Alarms

       Spindle Drive Alarms Spindle drive unit status is indicated by A 7-segment STATUS display. Both the PSM (Power Supply Module) and the SPM (Spindle Amplifire Module) have two 7-segment displays. As module conditions/operations change the status display indicates a related number or letter, indicating current status.

  • Page 519: Spindle Amplifier Module Status Displays

       A.5.2 Spindle Amplifier Module Status Displays The spindle amplifier module 7-segment displays are used to indicate both alarm and error conditions. • If the amplifier module ALM LED is On, see section A.5.2.1 • If the amplifier module ERR LED is On, see section A.5.2.2 A.5.2.1 Spindle Amplifier Module Alarms When the SPM ALM LED is On, see...
  • Page 520    ABLE SPINDLE SPM SELF DIAGNOSTIC ALARMS CONTINUED OVERCURRENT An overcurrent flowed in the DC Link of the input THROUGH DC LINK circuit. CPU MEMORY The CPU internal data memory is erroneous. The ERROR CPU internal data memory is checked only when power is first turned ON.
  • Page 521    ABLE SPINDLE SPM SELF DIAGNOSTIC ALARMS CONTINUED DC LINK CHARGING A error generated when charging of the main cir- cuit is not completed within the specified time. PARAMETER DATA Parameter data was set outside the supported OUT OF RANGE range.

  • Page 522: A.5.2.2 Spindle Amplifier Module Errors

       ABLE SPINDLE SPM SELF DIAGNOSTIC ALARMS CONTINUED OVERCURRENT An overcurrent flowed in the motor for an extended period. SPINDLE or SPEED The switching request and power line condition RANGE SWITCHING check signals to not match. FAN ALARM The spindle amplifier module fan has failed. HARDWARE ERROR The control circuit is erroneous.
  • Page 523    ABLE SPINDLE SPM SELF DIAGNOSTIC ERRORS CONTINUED OPERATING Although option parameter for output switch-over SEQUENCE control function is not set, LOW winding is selected. OPERATING Although the Cs contouring command was SEQUENCE entered, SFR/SRV is not entered. OPERATING Although the servo mode control command was SEQUENCE input, SFR/SRV is not input.
  • Page 524    ABLE SPINDLE SPM SELF DIAGNOSTIC ERRORS CONTINUED OPERATING Slave mode command (SLV=1) was entered SEQUENCE under position control (servo mode, orientation, etc.) OPERATING The position control command (servo mode, ori- SEQUENCE entation, etc.) was entered in the slave operation mode (SLV=1).
  • Page 525    OTES KETCHES 4V2A1563 (E) A - 57...
  • Page 526    OTES KETCHES A - 58...
  • Page 527    Appendix B Machine Diagnostics I/O Communication Signals from PMC to MT and Operator Panel Makino V55 High-speed Vertical Machining Center 4V2A1563 (E) 0B-4va Machine Diagnostics.fm...
  • Page 528    Appendix B Machine Diagnostics Contents B.1 Overview ..........B -1 B.2 Format .

  • Page 529: Overview

    These signals are specific to the Makino V55 Vertical with Makino PRO 3 Control. Machine Diagnostics 1. The PMC is also referred to as the CUSTOM side because it contains Makino’s customized software. 2. DI/DO stands for Data Input/Data Output and allows the signal’s direction or flow to be established.
  • Page 530    B.2.1 Table Heading shows the Diagnostic I/O table heading information. Figure B-2 Diagnostic: The Diagnostic address number viewed on the CUSTOM diagnostic screen. PMC Address: The signal's PMC address as shown in the Schematics and Mechanical chapters. PMC Address I/O Unit Diagnostic: 000 Group 0/Base 0/Slot 1...

  • Page 531: B.2.2.1 In, Com, And Page

       B.2.2.1 IN, COM, and Page explains the IN, COM, and Page columns data. Figure B-4 COM: The “source” connector is shown at top (i.e. C24L (CMA)) with common voltage pin numbers listed below. IN: lists the pin number for the signal's “high leg”. Page: The page number and coordinate where the signal and circuit are found in the schematics.

  • Page 532: Abbreviations

       Abbreviations lists the abbreviations used in the DI/DO Tables. Table B-1 ABLE DIAGNOSTIC TABLE ABBREVIATIONS Abbreviation Meaning Clog. Clogged CONN. Connection Cool. Coolant Contr. or Cont Controller INTLK. Interlock J Box Junction Box Mag. Magazine OPE. or Ope. Operator’s PNL or Pnl.

  • Page 533: Diagnostic (I/O) Tables

    Diagnostic (I/O) Tables The communication signals between the PMC software and the MT (Machine Tool) are specific to the Makino V55 with Makino PRO 3 control. To simplify usage, the DI/DO Tables are divided into sections by signal types, as shown below: 9.3.1 MT (MACHINE TOOL) DATA INPUT SIGNALS...
  • Page 534    OTES KETCHES B - 6...

  • Page 535: Mt (Machine Tool) Data Input Signals

       B.4.1 MT (Machine Tool) Data Input Signals This section contains the DI signals from the MT to the PMC. These sig- nals are denoted by the PMC address X. • When using the CUSTOM diagnostic screen, use the following information to find the proper PMC address groups: X INPUT (MT to PMC) –...
  • Page 536    DATA INPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 1 Signal Meaning Page Name RCH2 Spindle Rotor Condition Confirm 2 C24L 13/6D (CMA) RCH1 Spindle Rotor Condition Confirm 1 13/6D LS1340 Union Abnormal Detection 201/6D LS602 Tool Not Detection 201/5D LS601 Tool Fitting Confirm...
  • Page 537    DATA INPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 1 Signal Meaning Page Name LS1307 Through Tool Coolant Flow Switch C24L 251/4D (CMC) LS1319 Coolant Tank Empty Detection 251/5D LS181 Nozzle Coolant Flow Switch 251/2D LS193 Through Spindle Coolant Flow Switch 251/3D MS11C Work Piece Washing Gun On...
  • Page 538    DATA INPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 2 Signal Meaning Page Name SKIP Skip Signal C24L 481/3E (CMA) LCREV Lift Up Chip Conveyor Reverse Switch 411/3D LCFWD Lift Up Chip Conveyor Forward Switch 411/2D LCMAS Lift Up Chip Conveyor Manual Switch 411/2D (XAE)
  • Page 539    DATA INPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 2 Signal Meaning Page Name OCALM Oil Controller Alarm C24L 244/5D (CMC OCFIS Oil Controller Filter Sign 244/4D DAIN Oil Controller Data Input 244/4D OCACK Oil Controller Data ACK 244/4D OCD13 Oil Controller Input Data 3...
  • Page 540    DATA INPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 3 Signal Meaning Page Name CPTP Inside Cabinet Protector Trip C24L 171/6D (CMA) 172/1D CBTP Inside Cabinet Breaker Trip 171/5D Emergency Stop 152/7B *ESP Emergency Stop Signal 162/2D Diagnostic: PMC Address I/O Unit...
  • Page 541    DATA INPUT Diagnostic: PMC Address I/O Unit X010 Group 0/Base 0/Slot 3 Signal Meaning Page Name C24L (CMC) LS1339 Through Spindle Filter Clog Detection 251/7D OT2Z Z - Axis OT2 161/4D OT2Y Y - Axis OT2 161/3D OT2X X - Axis OT2 161/2D Diagnostic:...
  • Page 542    DATA INPUT Diagnostic: PMC Address I/O Unit X012 Group 0/Base 0/Slot 7 Signal Meaning Page Name LS56 Pallet Unclamp C24L 298/2D (CMA) LS55 Pallet Clamp 298/2D LS136 S/G Shutter Middle Pos. 297/3D LS131 S/G Shutter Open. 297/2D LS130 S/G Shutter Close 297/2D LS971...
  • Page 543    DATA INPUT Diagnostic: PMC Address I/O Unit X014 Group 0/Base 0/Slot 7 Signal Meaning Page Name LS682 Shifter 3 Retract C24L 273/6D (CMB) LS681 Shifter 3 Advance 273/6D LS680 Shifter 2 Retract 273/5D LS679 Shifter 2 Advance 273/5D LS751 Shifter 1 Retract 273/4D...
  • Page 544    DATA INPUT Diagnostic: PMC Address I/O Unit X016 Group 1/Base 0/Slot 1 Signal Meaning Page Name LS105 Arm 2 Advance C24L 294/6B (CMA) LS1761 Arm 2 Slow Down 294/5D LS1714 Arm 2 Middle Pos. 294/5D LS104 Arm 2 Retract 294/4D LS101 Arm 1 Advance...
  • Page 545    DATA INPUT Diagnostic: PMC Address I/O Unit X022 Group 1/Base 0/Slot 1 Signal Meaning Page Name C24L (CMC) PCINS2 Pallet 2 Load Switch 301/6D PDYPB2 Pallet 2 Ready Switch 301/6D PCOUTS Pallet Unload Switch 301/3D PCINS1 Pallet 1 Load Switch 301/3D PDYPB1 Pallet 1 Ready Switch...
  • Page 546    OTES KETCHES B - 18...

  • Page 547: Mt (Machine Tool) Data Output Signals

       B.4.2 MT (Machine Tool) Data Output Signals This section contains the DO signals from the MT to the PMC. These sig- nals are denoted by the PMC address Y. • When using the CUSTOM diagnostic screen, use the following information to find the proper PMC address groups: Y OUTPUT (PMC to MT) –...
  • Page 548    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 4 Signal Meaning Page Name SL905 Main Air ON C24 HA 191/3B (CMA) RCHP Spindle Rotor Change 13/2B POUT1 Auto Power Out 171/3B OT Release 162/4A Servo Ready 171/2B NC Ready 171/2B...
  • Page 549    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 4 Signal Meaning Page Name MS15 Through Tool Coolant E24 HA 221/4B (CMC) MS10 Ceiling Shower Coolant 221/4B Through Spindle Coolant 222/3B MS19 Oil Mist Collector 192/3B 193/3B Nozzle Coolant 221/3B Diagnostic:...
  • Page 550    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 4 Signal Meaning Page Name C24 HB (CMA) SL171 Spindle Oil Pressure Air 202/5B MS102 Ball-Screw Cooling Pump 221/2B MS101 Spindle Oil Cont Joint Pump 221/2B MS83 Spindle Oil Cont Suction Pump 221/1B OMON Spindle Oil Temp.
  • Page 551    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 5 Signal Meaning Page Name C24 HB (CMC) DAOUT Spindle Oil Controller Data Output 243/4B OCSTB Spindle Oil Controller Data STB 243/3B Spindle Oil Controller Output Data 3 243/3B Spindle Oil Controller Output Data 2 243/3B...
  • Page 552    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 6 Signal Meaning Page Name LCRUNL L/C Run Lamp C24 HC 411/6B (CMA) LCALML L/C Alarm Lamp 411/6B LCMAL L/C Manual Lamp 411/5B MS6R Lift Up Chip Conveyor CCW 221/6B MS6F Lift Up Chip Conveyor CW...
  • Page 553    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 6 Signal Meaning Page Name STLR Auto Running C24 HC 451/2B (CMC) Spindle Running 451/2B SL150 341/6B -Axis Unclamp Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 6 Signal Meaning Page...
  • Page 554    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 8 Signal Meaning Page Name E24 HD (CMA) SL130B S/G Shutter Open 297/6B SL130A S/G Shutter Close 297/5B SL61B Pallet Lift 298/6B SL61A Pallet Down 298/5B SL52 Locate Pin Cleaning Air 298/5B SL51 Pallet Unclamp...
  • Page 555    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 0/Base 0/Slot 8 Signal Meaning Page Name MGBKB ATC Magazine B Brake Release C24 HD 26/7A (CMC) MGBKA ATC Magazine A Brake Release 26/6A IV1RST Inverter 1 Reset 262/4B IV1RM Inverter 1 Velocity 2 262/3B IV1RH...
  • Page 556    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 1/Base 0/Slot 2 Signal Meaning Page Name C24 HD (CMA) MS97 Arm 2 Drive 292/6B MS96 Arm 1 Drive 292/6B Diagnostic: PMC Address I/O Unit Group 1/Base 0/Slot 2 Signal Meaning Page Name...
  • Page 557    DATA OUTPUT Diagnostic: PMC Address I/O Unit Group 1/Base 0/Slot 2 Signal Meaning Page Name C24 HF (CMC) PCINL2 Pallet 2 Load Switch Lamp 302/6B PRDY2 Pallet 2 Ready Switch Lamp 302/5B PCOUTL Pallet Unload Switch Lamp 302/3B PCINL1 Pallet 1 Load Switch Lamp 302/3B...
  • Page 558    OTES KETCHES B - 30...

  • Page 559: Op (Operator Panel) Data Input Signals

       B.4.3 OP (Operator Panel) Data Input Signals This section contains the DI signals from the Operator panel. These sig- nals are denoted by the PMC address X. • When using the CUSTOM diagnostic screen, use the following information to find the proper PMC address groups: X INPUT (OP to PMC) –...
  • Page 560    DATA INPUTS Diagnostic: PMC Address I/O Unit Operator Panel Signal Meaning Page Name Handle Mode 112/4D Jog Mode 112/4D Rapid Mode 112/4D ZRNS Reference Mode 112/3D EDTS Editor Mode 112/3D MEMS Memory Mode 112/2D MDI Mode 112/2D Tape Mode 112/2D Diagnostic: PMC Address...
  • Page 561    DATA INPUTS Diagnostic: PMC Address I/O Unit Operator Panel Signal Meaning Page Name FXS03 Flexible Switch 03 (Scraper) 113/6D FXS02 Flexible Switch 02 (Nozzle Coolant) 113/6D FXS01 Flexible Switch 01 (Coolant ON/OFF) 113/5D Cycle Start 113/5D Feed Hold 113/4D SPST Spindle Start...
  • Page 562    DATA INPUTS Diagnostic: PMC Address I/O Unit X100 Operator Panel Signal Meaning Page Name Jog Feed Rate Switch Inhibit 115/3D JV16I Jog Feed Rate Switch 16 115/3D JV8I Jog Feed Rate Switch 8 115/3D JV4I Jog Feed Rate Switch 4 115/2D JV2I Jog Feed Rate Switch 2...
  • Page 563    DATA INPUTS Diagnostic: PMC Address I/O Unit X102 Operator Panel Signal Meaning Page Name Feed Override Switch Inhibit 116/4D FV16I Feed Override Switch 16 116/3D FV8I Feed Override Switch 8 116/3D FV4I Feed Override Switch 4 116/2D FV2I Feed Override Switch 2 116/2D FV1I...
  • Page 564    OTES KETCHES B - 36...

  • Page 565: Op (Operator Panel) Data Output Signals

       B.4.4 OP (Operator Panel) Data Output Signals This section contains the DO signals from the Operator panel. These sig- nals are denoted by the PMC address Y. • When using the CUSTOM diagnostic screen, use the following information to find the proper PMC address groups: Y OUTPUT (PMC to OP) –...
  • Page 566    DATA OUTPUT Diagnostic: PMC Address I/O Unit Operator Panel Signal Meaning Page Name C24H 114/3B MCREF Machine Reference 114/2B WRNL Warning 114/2B ALML Alarm Diagnostic: PMC Address I/O Unit Operator Panel Signal Meaning Page Name C24H B - 38...
  • Page 567    DATA OUTPUT Diagnostic: PMC Address I/O Unit Operator Panel Signal Meaning Page Name FXL03 Flexible Switch 03 (Scraper) C24H 113/6B FXL02 Flexible Switch 02 (Nozzle Coolant) 113/6B FXL01 Flexible Switch 01 (Coolant ON/OFF) 113/5B STLO Cycle Start 113/5B SPLO Feed Hold 113/4B...
  • Page 568    OTES KETCHES B - 40...

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