Takumi Seiki

Takumi Taiwan Phone: 886-4-23583838

Fax : 886-4-23580176
Eric : 886-9-18422596 (cell)
Eric's e-mail: [email protected]
Most of the information in this file applies to machines with either a Fanuc
18M control or a Mitsubishi 520, 530 or 535 control. A Takumi with a Fanuc 0
control exists but is rare. Information which pertains to these machines
will be noted as such.
If the phase rotation is wrong on a Takumi, the oil cooler will display
"In". If you try to run the spindle the Spindle Lube Alarm will be generated.
If the tool called in the program is already in the spindle the message
1024 T CODE = SPINDLE TOOL will be displayed and the control will switch to
Single Block operation and display the message No. 2000 Single Block.
Pressing the Cycle Button again will cause the program to resume.
MITSUBISHI
To run a machine in DNC:
1. Switch to TAPE mode.
2. Press the SINGLE BLOCK button.
3. Push the CYCLE START button. (The machine is now waiting for program)
4. Go to the PC and send the program.
Before using Computer Link B you must set the Parameters this way:
[OPTION] S_PARAM 1. 1/3
#
1 m_op 01 FF 13 m_op 13 C6
2 02 A1 14 14 06
3 03 7F 15 15 30
4 04 BF 16 16 40
5 05 FC 17 17 00
6 06 DB 18 18 00
7 07 BF 19 19 00
8 08 F5 20 20 00
9 09 FF 21 21 00
10 10 99 22 22 00
11 11 32 23 23 00
12 12 1F 24 24 00
#() DATA()
NOTE: [DIAGN I/O],(758) () (S),[TOOL PARAM],MENU
[I/O BASE PARAM] IN/OUT 8.1/8
# <PORT> <DEVICE>
1 DATA IN 3 0:
2 DATA OUT 3 0:
3 NC RUNNING 3 0:
4 MACRO PRINT 1 0:
5 PLC IN/OUT 1 0:
6 HOST LINK 3 0:
7 PAGER 1 0:
8 CHIS IN/OUT 1 0:
9
10
11
12
#() DATA() ()
[COMPUTER LINK PARAMETER] IN/OUT 8.5/8
#
1 BAUD RATE 1 11 LINK PARAM.3 00 21 DC1OUT SIZE 4096
2 STOP BIT 3 12 LINK PARAM.4 00 22 POLL TIMER 0
3 PARITY EFF. 0 13 LINK PARAM.5 00 23 TRANS WAIT T. 0
4 EVEN PARITY 0 14 START CODE 0 24 RETRY COUNT. 0
5 CHR. LENGTH 3 15 CTRL. CODE OUT 3
6 HAND SHAKE 3 16 CTRL. INTERVAL 0
7 TIME OUT SET 200 17 WAIT TIME 0
8 DATA CODE 1 18 PACKET LENGTH 0
9 LINK PARAM.1 00 19 BUFFER SIZE 4096
10 LINK PARAM.2 02 20 START SIZE 248
#() DATA()
[CONTROL PARAM.]
#46 HOST LINK ON
To send a large program to the control with Computer Link B:
1. Turn the HOST LINK off. [CONTROL PARAM] #46
2. Input the program as usual. (See C:\machine\mit)
To run a machine in DNC with Computer Link B:
1. Turn HOST LINK on. [CONTROL PARAM] #46
2. Switch to TAPE mode.
3. Set RAPID OVERRIDE to 25%.
4. Turn SINGLE BLOCK on.
5. Press the CYCLE START button.
6. Press the MONITOR button.
( A capital C will be displayed to show that Computer Link B is running)
7. Go to the PC and start the download.
To run high speed DNC with Computer Link B:
1. Set the PC Baud Rate to 19200 bits per second.
2. Set [I/O DEVICE PARAM] #2 BAUDRATE to 0.
3. Set the [COMPUTER LINK PARAM] #1 BAUDRATE to 0.
4. Turn HOST LINK on. [CONTROL PARAM] #46
5. Switch to TAPE mode.
6. Set RAPID OVERRIDE to 25%.
7. Turn SINGLE BLOCK on.
8. Press the CYCLE START button.
9. Press the MONITOR button.
( A large C will be displayed to show that Computer Link B is running)
10.Go to the PC and start the download.
If you have trouble in Auto mode with the machine wanting to pick up the tool
offset after G28, check Parameter 19.3. It should be 0 in most cases. This
parameter selects the Tool Compensation System A or B/C.
The way lube timer on the V11A is stored at T41 and T42. T41 is for the time
on of the pump. T42 is for the time off. For setting method and values see
C:\MACHINE\MIT
To reset the tool table on a 24 tool machine with a Mitsubishi control:
1. Index magazine to tool number 1.
2. Press the TOOL/PARAM button.
3. Press the MENU soft key until you see PLC-SW.
4. Press the PLC-SW soft key.
5. At the #() prompt enter 4.
6. Press the INPUT/CALC button.
7. Press the MENU soft key until you see REGIST.
8. Press the REGIST soft key.
9. At the MG() prompt enter SP.
10. At the TOOL() prompt enter 25.
11. Press the INPUT/CALC button.
If this procedure does not work, go to the Tool Table and look for a zero in
one of the pots (MG) or the same number in two different pots. If two of
them are the same, one number has to be missing. This missing number will
cause Alarm 1032 when it is called. To fix this go to the one of the pot
numbers (MG) that has a duplicate Tool number and change it to the tool
number that causes the alarm.
During the course of normal ATC function if you look at the tool table you
will see the 25 listed as a tool even though there are only 24 tools.
On a Takumi with a Mitsubishi control you must make a written record of the
Latch Parameters when the machine is installed. If the memory is lost these
must be reloaded by hand. They cannot be loaded or saved with a PC.
On V8 S/N F8255, all Latch Parameters are zero except L1, L10, L40, L43, and
L84 are one.
On a V11 with a Fanuc 0 control, the spindle cannot be clamped or unclamped
if the spindle is maintaining orient position (Orient lamp on). So if you
command M19 then try to manually unclamp the tool nothing will happen.
You must first press the Reset button on the control. The lamp will go off,
then you can unclamp.
The procedure for a jammed tool changer:
1. Press RESET.
2. Switch to MDI.
3. Press MONITOR button twice.
4. Enter and execute M80.
5. " " " M82. (Pot Down)
6. " " " M87.
7. " " " M88.
8. " " " M89.
9. " " " M84.
10.Press RESET.
11.Cycle Power. (5 seconds)
12.ZRN all axes, verify position of tools.
The procedure for jammed tool changer (PLC ATC version 2.00 or later)
1. Press RESET.
2. Switch to MDI.
3. Press MONITOR button twice.
4. Enter and execute M19.
5. " " " M82. (Pot Down)
6. " " " M80.
7. " " " M80.
8. " " " M80.
9. " " " M84. (Pot Up)
10.Press RESET.
11.Cycle Power. (5 seconds)
12.ZRN all axes, verify position of tools.
Diagnostic List for V11A
# Description Standard Setting
D300 Flash Timer 1 (R596.0) 800
D305 " " 2 (R596.1) 800
D310 Spindle Lube Alarm Delay (R596.2) 5000
D315 Gear Change ON Delay (R596.3) 500
D320 Lube Pump ON Timer (R596.4) 20000
D325 Lube Pump OFF Timer (R596.5) 240000
D330 Emergency Stop On Delay While Auto Power Off 3200
Function Valid (R665.2)
D335 Power Off Delay While Auto Power Off Function 3200
Valid
D340 (R597.0)
D345 (R597.1)
D350 PLC Window Display Delay (R597.2) 400
D355 Axis Lock Release Delay (R597.3) 100
D360 (R597.4)
D365 (R597.5)
D370 M07 ON Delay (R597.6) 400
D375 Spindle Not Orient Delay (R608.1) 10000
D380 (R598.0)
D385 M30 Output Signal ON Timer (R598.1) 500
D390 (R598.2)
D395 (R598.3)
D400 (R598.4)
D405 (R598.5)
D410 (R598.6)
D415 (R598.7)
D530.0 Magazine Type 0
D530.1 " " 1
* Bit 0 = 0 and Bit 1 = 0 for 16 Tool Magazine
Bit 0 = 1 and Bit 1 = 0 for 20 Tool Magazine
Bit 0 = 0 and Bit 1 = 1 for 24 Tool Magazine
Bit 0 = 1 and Bit 1 = 1 for No Tool Magazine
D530.2 0
D530.3 Tool Change Cycle for T Code 0
D530.4 0
D530.5 0
D530.6 X Axis ZRN in Positive Direction 0
D530.7 CRT Operations Panel Valid 0
D531.0 Lube Pump Controlled by Timer 0
D531.1 Spindle Oil Cooler Alarm Detector Invalid 0
D531.2 Spindle Stop by Feed Hold 0
D531.3 0
D531.4 G00 Valid by Dry Run On 0
D531.5 X Axis ZRN in Positive Direction 0
D531.6 Three Axes ZRN is Not Necessary for Cycle Start 0
D531.7 Fourth Axes ZRN Automatic Holding 0
D532.0 Spindle Stop Rotation When Z Axis Been Reference Point 0
D532.1 0
D532.2 Rigid Tapping Valid 1
D532.3 Manual Absolute Keep On 0
D532.4 Three Axes ZRN Automatic Holding 1
D532.5 0
D532.6 0
D532.7 1
D533.0 0
D533.1 Auto Power Off Valid 1
D533.2 M07 Valid 1
D533.3 No Gear Box 1
D533.4 Fourth Axis Valid 0
D533.5 Alarm Display Valid 1
D533.6 Operation Display Valid 1
D533.7 0
D534.0 Tool Life Management Valid 0
D534.1 0
D534.2 0
D534.3 0
D534.4 When Air Pressure is Low Program Can Be Executed 0
D534.5 " " " " " " " " " 0
D534.6 Buzzer Will Act At Program End 0
D534.7 0
D535.0 0
D535.1 Alarm Lamp Valid 1
D535.2 0
D535.3 0
D535.4 0
D535.5 0
D535.6 0
D535.7 0
D536.0 0
D536.1 0
D536.2 0
D536.3 0
D536.4 1 MPG Valid 0 0
D450
D452
D460 Magazine Tool Counter 24
D462 Standby Tool Number Display
D480 Spindle Tool Number Display (Arm Type)
D481 Tool Register (Arm Type)
to
D504
D522 T Code Display (Arm Type)
R550 Magazine Motor Brake Timer (R594.0) 100
R553 ATC Arm Motor Brake Timer (Arm Type) (R594.1) 100
R556 M29 Finish Timer (R594.2) 100
R559 T Code Execution Delay (Armless Type) (R549.3) 100
R562 M06 Execution Delay (R549.4)
R565 Door Lock Delay (R594.5) 100
R568 ATC Rotate to 55.5 Degrees While Pot Down 200
(Arm Type) (R594.6)
R571 ATC Rotation Delay While Spindle Unclamp 200
(Arm Type) (R594.7)
R574 ATC Overtime Alarm (R595.0) 20000
R577 T Code Finish Delay (R595.1) 500
R580 ATC Forced Hold Timer (R595.2) 5000
R583 (R595.3)
Tool Confuse on 24 Tool Magazine:
1. Select JOG Mode.
2. Set Diagnostics D462 and D525 = 1.
3. Set the Spindle Tool at D480.
4. Set the Tools in Magazine Pots in D480 - D504.
D480 = 1
|
|
|
D504 = 24
5.Cycle Power.
24 Tool ATC:
D462 is the Pot currently in standby position. To change, move the desired
Pot to the Standby position. Change D462 to desired number. The Magazine
does not have definite Pot assignments so you can make it what you want.
D480 is the Tool currently in the Spindle.
D481 - D504 is the Tool Table. D481 corresponds to Pot 1. D482 corresponds to
Pot 2, etc. As you look at the Tool Table, you will see a 25 in on of the
Pot assignments. This is because the control counts the Spindle Tool as an
available Pot.
To find out which Pot the NC thinks is Pot 1, go to the Tool Table and see
which tool is in D481. Call up this tool and the Pot that the magazine goes
to is what the NC is calling Pot 1.
The Magazine In Position Sensor and the Pot Counter are the same. It consists
of a proximity sensor on top of the machine that detects a cam on the
Magazine motor shaft. When Alarm 1035 is generated it is because the
magazine
has stopped with the cam not in detection range of the sensor. If this
condition occurs and the magazine has not been jammed or anything it may be
a simple matter of adjusting a timer. If the magazine has been jammed, it
may be necessary to unbolt the magazine motor, move it until the LED is on,
Reset the alarm, jog the magazine. While the magazine is turning, rotate the
motor back into it's proper position. The magazine should stop in position.
You can then bolt the motor back. On a machine with a Mitsubishi control you
can avoid most of this by forcing the Proximity Switch input on so that the
alarm can be reset. Unless the magazine was jammed badly you will now be able
to index the magazine and it will stop in the correct position.
V11-A M-Code Table
M00 Program Stop
M01 Option Stop
M02 End of Program
M03 Spindle CW
M04 Spindle CCW
M05 Spindle stop
M06 Auto Tool Change
M07 Gun Drill Coolant ON
M08 Coolant ON
M09 Coolant OFF
M10 Fourth Axis Lock
M11 Fourth Axis Unlock
M12
M13
M14
M15
M19 Spindle Orient
M20 External M Code Lock (Option)
M21 External M21 Start (Option)
M22 External M22 Start (Option)
M23 External M23 Start (Option)
M24 External M24 Start (Option)
M29 Rigidity Tapping Start
M30 End of Program
M31
M51 Air Blow ON
M52 Air blow OFF
M53 Chip Conveyor Start
M54 Chip Conveyor Stop
M55 Clean Water Start
M56 Clean Water Stop
M57 X Axis Mirror Image ON
M58 Y Axis Mirror Image ON
M59 Mirror Image OFF
M80 Initiate Separate Movement of Tool Change
ARM TYPE
M82 Pot Down
M84 Pot Up
M87 ATC Arm Rotate to 55.5 Degree and Spindle Unclamp
M88 ATC Arm Rotate to 180 Degrees and Spindle Clamp
M89 ATC Arm Rotate to Home Position
ARMLESS TYPE
M81 Magazine Forward and Spindle Unclamp
M82 Z Axis UP to Second Reference Point (Tool Change Position)
M83 Z Axis DOWN to First Reference Point and Spindle Clamp
M84 Magazine Back
M98 Sub Program Call
M99 Return to Main Program
To turn off the 4th axis, go to User Axis Parameter AX RELEASE and make it a
1. You must also turn the 4th axis off in the PLC in order to avoid alarm
AL1024 XYZ or A Not Return Home Yet. This is done by changing Latch
Parameter
L12 to 0. 1 = 4th axis activated, 0 = 4th axis not activated.
Alarm 1036 ( PIN IN FAIL ) means that the locking pin did not go back in to
the ATC in the amount of time set in timer T61. This alarm normally results
from the pin being simply stuck. It is possible that the the magazine could
be out of position keeping the pin from going back in. But if this is the
case, you should also see a magazine alarm such as 1038 ( MAGAZINE
BACKWARD
FAIL ) or 1039 ( MAGAZINE FORWARD FAIL ).
The same is true for Alarm 1038 ( PIN OUT FAIL ).
The following program is used to check for Backlash. Have the machine in
Metric.
G01 G91 X50. F3000;
X50.;
G4 X2.;
Z30.;
X50.;
X-50.;
Z-30.;
G4 X3.;
M99;
For the Y axis, substitute the X's with Y's.
Place an indicator in or on the spindle and touch off in X. Run the program in
50%, 100% and 150% Override. The Backlash amount should be less
than .0002.
If the Backlash is excessive, adjust Machine Axis Parameter #12 G1 BACK for
(X). Change in increments of 2.5 at a time.
When the Backlash is no longer excessive, run the program in RAPID. Change
G01 to G0. Run in 25% or 50% Override. Anything else is too fast. If the
Backlash is excessive, adjust Machine Axis Parameter #11 G0 BACK.
On a V10, the hydraulic lines are not labeled and if they are switched, the
ATC will hang up at 55 degrees because the spindle clamps the spindle instead
of unclamping. When installing one be sure to check these lines first if you
have ATC trouble.
Takumi recommends that you do not switch to manual mode and unclamp the
tool
when an ATC alarm occurs. On most machines this is ok to do and is a good
troubleshooting method, but not on the V10.
If you have a machine with a Fanuc 18M control you may have a problem with
the ATC cycle in that when you call tool one when it is in the spindle, the
cycle may hang up. If this happens you probably need to change the tool
change macro. If so do this:
Set Parameter #6073 = 6
Make the tool change program:
%
O9003 (M6 PROGRAM)
(#515 = TOOL IN SPINDLE)
(#516 = TOOL BEING CALLED)
(SET #515 = SPINDLE TOOL #)
#516 = #4120 (SET LAST TOOL CALLED = #516)
IF [#516 EQ 0] GOTO 100
IF [#515 EQ #516] GOTO 100
#101 = #4001
#102 = #4002
#103 = #4003
G0G17G80G91D0
G28Z0
M06
#515 = #516
G#101G#102G#103
N100 M99
%
The timer for the Oil Mist unit on the V10 is T80.
In order to Rigid Tap you must turn on the Control Switch for Synchronous
Tap. Command Rigid Tap by: G84 Z F R P, R1
Z = Depth
F = Feed Rate
R = Retract Amount
P = Pitch
,R1 must be entered
Do not use M29 on a Mitsubishi control. This is for Fanuc only.
If a machine wants to get the tool in the pot beside it when called, the tool
table probably needs to be reset. Also called tool registration.
The procedure for a machine with a Fanuc 18M:
1. Switch to JOG mode.
2. Move pot number 1 to the standby position.
3. Switch to MDI mode.
4. Press the (OFFSET SETTING) button.
5. Cursor to PARAMETER WRITE, change the 0 to 1. Press the (INPUT) button.
6. Press the (SYSTEM) button.
7. Press these soft keys PMC, PMCPRM, DATA. You will see:
NO. ADDRESS PARAMETER TYPE NO. OF DATA
001 D0000 00000000 0 33
If the machine has 24 tools, this number must be 25. If it has 32 tools, it
must be 33, etc.
8. Press the (PROG) button.
9. Enter M90 press the (INPUT) button.
10.Press the (CYCLE START) button.
11.Set PARAMETER WRITE back to 0.
The procedure for operating the ATC cycle in MDI for a machine with the PLC
version 3.4 is:
1. Press the MONITOR button.
2. Enter M19 to orient the spindle. Press INPUT.
3. Enter M80. Press INPUT.
 (The tool arm will move to the spindle. Alarm 1029 - ATC NOT AT HOME will
be issued. This is normal and the alarm can not be reset.)
4. Enter M80. Press INPUT.
(The spindle will unclamp and the arm will swing 180 degrees. Alarm 1029
is still present.)
5. Enter M80. Press INPUT.
(The arm goes to it's home position. The spindle clamps. Alarm 1029 is
still present but can now be reset.)
You can do the complete tool change by manually rotating the magazine to the
tool you want before beginning the above procedure. You will have to lower
the tool pot yourself using M82 and raise it yourself using M84.
If you try to execute M80 without first orienting the spindle, you will get
the 1031 - SP. NOT ORIENT YET alarm. Reset the alarm and orient the spindle.
The procedure to turn on the Cutter Comp option is:
1.Backup all data in memory to a PC.
2.Access option parameters (758) ( ) (S), INPUT.
3.Go to Option parameters and switch #37 from A to D.
4.Format the control (Machine Parameters, Base, #6 Fix-P from 0 to 1,
ERASE, #( ) (FORMAT), INPUT , #(4) ( ), INPUT, cycle power.
5.Check Offset page to see if H and D Wear Offsets appear together.
6.Set Fix-P back to 0.
Note: On 530MR(H) Fix-P is #38.
Tool confusion on machine with Mitsubishi control:
1.Switch to JOG mode and move pot #1 to the Standby position.
2.Switch to MDI mode.
3.Turn on PLC-SW #4 Tool Table Reset. (TOOL/PARAM, MENU, PLC-SW).
4.Go to the Tool Registration Table. (TOOL/PARAM, REGIST)
5.Enter MG(SP) (25) INPUT.
Note: For armless or Geneva type (16 tools ) everything the same except
MG(SP)
(1) INPUT.
For Fanuc 0 control:
1.Jog pot #1 to Standby.
2.Change PWE to 1.
3.Set Diagnostic 462 to 1. (Next)
4.Set Diagnostic 480 to 25. (Spindle)
5.Set Diagnostic 481-504 to 1-24. (Tool register Table)
Note: For armless or Geneva type (16 tools) everything the same except
Diagnostic 481-496 to 1-16.
Anytime you manually free a jammed ATC, make sure if there is a tool in the
spindle that it is unclamped!!!
A spare M code that can be used on the Takumi is M22. It controls relay CR32
whose output contact (N.O.) is tied to wire terminal numbers 342 and 343 on
the relay board. On a machine with a Fanuc control, M22 can be finished with
an M32 or a finish signal (24V) supplied to terminal 145 on the relay board.
In the ladder diagram CR32 is activated by Y21. On the input side, terminal
145 is X3F. If the control is a Mitsubishi, the ladder must be upgraded to
allow M22 to finish with a hardware signal (X3F). For maximum functionality
you can connect CR32 and CR33 in parallel. Then you can use M23 when you
want
to finish an operation with an M code (M33), and use M22 when you want to
finish with a hardware signal. Otherwise, if you wire in CR32 only, you must
switch from M code finish to hardware finish with a Latch Parameter (L22).
L22 = 1 means M22 needs to finish with M32. L22 = 0 means M22 will finish
with X3F = 1.
On a machine with a 4th axis, M10 clamps the axis and M11 unclamps it. When
the axis is unclamped the indicator is turned off.
The headstock reservoir sight glass is on the right side facing the machine.
The Spindle Chiller alarm can be bypassed by making X15 = 1. This bypasses
the two pressure switches. A common cause for the alarm is a lack of oil.
On the V18/V22/V32 way lube oiler, capacity is six liters, the discharge
capacity is 120 cc's per cycle, discharge pressure is 15 kg/cm2.
Remote Buffer Installation for Fanuc 18M control:
1. Install REMOTE BUFFER CARD. (With power off)
2. Turn power on.
3. Select MDI mode.
4. Set PARAMETER WRITE to 1.
5. Set I/O CHANNEL to 3.
6. Set PARAMETER 131 to 00000001.
7. Set PARAMETER 132 to 3.
8. Set PARAMETER 133 to 12.
9. Set PARAMETER 134 to 00010000.
10.Set PARAMETER 135 to 00000000.
11.Set PARAMETER 9934.1 to 1.
12.Set PARAMETER WRITE to 0.
13.Cycle power.
Parameter 133 = 1 sets the Baud Rate to 19200.
On a Fanuc 18 controlled machine, the way M codes M21,M22,M23 and M24
can
be finished by two different methods depending on the setting of Keep Relays.
If Keep Relay K1.0 equals 0, M21 is finished by a hardware signal. If it
equals 1 M21 is finished by Timer T31.
If Keep Relay K1.1 equals 0, M22 is finished by a hardware signal. If it
equals 1 M22 is finished by Timer T32.
If Keep Relay K1.2 equals 0, M23 is finished by a hardware signal. If it
equals 1 M23 is finished by Timer T33.
If Keep Relay K1.3 equals 0, M24 is finished by a hardware signal. If it
equals 1 M24 is finished by Timer T34.
The maximum dimensions for tools on V18/V22 are:
Length - 300mm
Diameter - 110mm (200mm if adjacent pots are empty)
Weight - 15Kg
The air pressure requirement for V18/V22 is 6Kg.
On the V-8A with a 530MH control, the version of software which allows you to
finish a spare M-Code with a Finish signal instead of an M-Code is PLC
ATCVER3.7
Version 3.5 may also work.
If you have a V-11 with version 2.0 and you replace it with 3.5 you have to
change a PSW (position switch) to allow the M6 to execute properly.
Otherwise you have to send the Z axis home and orient the spindle first.
There are four switches to be concerned with, they are PSW1, PSW2, PSW3
and PSW4. Their values should be:
# <AXIS> Dog 1 Dog2
1 Z 0.0 0.5
2 Z -50.5 0.0
3 Z -300.0 -50.5
4 Z -170.0 0.
Switch #1 is for the Z axis position for tool change.
Switch #2 and Switch #3 are for executing tool change at a second reference
(G30) point.
Switch #4 is for the Z axis position when the spindle starts to orient during
ATC cycle. It is meant to prevent the spindle from orienting until the tool
has escaped the surface of the work piece.
If Switch #4 is not set, the ATC cycle will not execute but there will not be
any alarms.
The procedure for executing the Separate Movement of the ATC is:
M19
M82
M80
M80
M80
M84
This works for all machines with a Fanuc 18 control.
Normally, on a machine with a 520 control the Ladder will reside on a SRAM
card in the Right hand slot of the CPU board. The Mitsubishi designation will
be QX812. In the case of a 530 control it may be a QX815.
If the tool pot is down and you try to perform a tool change it usually will
not execute but there will be no alarm. In this case the ATC cycle will not
get even so far as to orient the spindle. Go to MDI, command M84 to raise
the pot.
The oil chiller on the V-15 is:
Habor
HBO-600PSB
The control board has an IC which is:
ZILOG Z8
Z86E3116PSC
9813
It is a 28 pin DIP labeled JANDER-5
There is an 8 position DIP switch on this board. It's normal setting is:
#1,#5 and #8 OFF
#2,#3,#4,#6 and #7 ON
There are also two pots on the board which may be helpful in preventing
faults.
It also has and ambient sensor and an oil sensor.
There is a plug on the board which has no designation. It's pin outs are:
1 - 9 ------------- Red Wire
These two are labeled COOL
2 - 8 ------------- Red Wire
3 - 7 ------------- Red Wire
These two are labeled PUMP
4 - 6 ------------- Red Wire
5 - 11 ------------- Orange Wire (24V)
These two are labeled ALM
6 - 12 ------------- Orange Wire (134)
There is a shorting pin on the board with three pins. The two outside pins
appear to be labeled A and B. It looks like the jumper shorts pin A to the
middle pin.
The input and output of the chiller consists of six wire going to an eight
pin terminal strip in the chiller. The pin outs are:
1 - R8
2 - S8
3 - T8
4 - Jumpered to terminal 5
5 - Jumpered to terminal 4
6 - Ground
7 - 24V
8 - 134
The Golden Sun rotary table should hold an indexing accuracy of 15" (seconds)
With most Latch Parameters it is necessary to cycle power after changing the
value in order to make effective.
If fix_P = 0 #4 Fixed Cycle will not be displayed on the Data In/Out page.
The programs will not be displayed either.
Formatting the control erases the programs including fixed cycles but does
not affect parameters.
If you try to re-load the fixed cycles without formatting alarm E65 Program
No. Duplicate will be issued. If you try again without pressing the Reset
button alarm E64 Program No. Err will be issued.
The electrical manual shows the oil chiller fault contact (24V and 134) in
series with another switch. I think this is a pressure switch on the head
but I do not know what the wire number is. Either way, if you have the alarm
for Spindle Oil Chiller Error, forcing X15 to 1 will bypass it. As with L43
for the air pressure, this bypass will not keep the M Fail light from being
on. Only jumping out the electrical connection will do this.
If the machine gets the wrong tool sometimes, the tool pot counter may be
skipping a count. Also, according to Eric, the PLC cartridge may have to be
replaced.
The M07 connector is for the front auger.
The output pressure on the V-15 way lube pump is about 200 psi.
If a machine with a hydraulic drawbar (i.e V10) will not properly execute the
ATC cycle, check the hydraulic lines for correct connection. If they are
reversed the ATC cycle will hang up when it's time to unclamp the tool
because the drawbar can't come down to make the unclamp switch.
If you have an alarm for the tool in the wrong position, make sure it is not
talking about the Magazine position. Most of the ATC's count the tool pots
and detect correct position by sensing a key on the output shaft of the
motor with a proximity switch.
On Fanuc controlled machines the OT RELEASE lamp is on under normal
conditions. On Mitsubishi machines it comes on when the machine over travels.
If a machine will not display any Machine Builder alarms, check Bit Select
50 and 51. This is a normal result of a Mitsubishi controlled machine being
initialized.
If the spindle will not run, check Latch Parameter L10. (High/Low Gear)
When a Takumi changes tools, the ATC motor stops at each position. The
contactor drops out.
Whe troubleshooting the Habor oil chillers on Takumi machines they have a
label on the chiller with a great deal of useful information. Here is some
of it:
Sn = Oil sensor problem or thermostat problem.
Ol
Sn = Ambient sensor problem or thermostat problem.
ro
AH = Oil temperature too high, thermostat failure, cooling system failure,
OL ambient temperature too high.
The oil temperature should be below 45 degrees Centigrade, ambient
temperature should be below 40 degrees Centigrade.
AL = Oil temperature too low, thermostat failure, electromagnetic switch
OL (contactor?) failure. The oil temperature should be above 10 degrees
Centigrade.
In = This alarm works with the LED indicators to indicate problem. The
following LED's along with the In indicate:
PRESS (Failure of Pressure) Bad pump motor
Clogged oil line
Oil viscosity too high
COMP (Failure of Compressor) Abnormal Power
Bad Compressor
Bad fan motor
 Cannot dissipate heat fast enough
Load is too high
Failure of Cooling System
OP (Failure of Oil System) No or low oil
Pressure setting too high
Bad pressure switch
Air in the oil
Motor and pump decoupled
Bad pump motor
REV Phase reversed
Phase missing
The oil pump is mounted to and driven by the fan motor. It's pressure is
monitored by a pressure switch connected by a capillary tube.
The top LED display (PV) shows either the temperature of the oil or the room
depending on which one you select. There is an Oil Temp LED and a Room
Temp
LED which will indicate which one is being displayed. There is an OIL/ROOM
button to toggle between the two.
The bottom LED display (SV) shows either the Setpoint or the temperature
differential. If the chiller is set up to maintain a certain temperature,
that value (Setpoint) will be displayed. If it is set up to maintain a
certain differential between the ambient and the oil temperature, this
difference will be displayed.
There is also an LED to indicate if the pump is running and if the compressor
is running.
Normally, if you remove and replace the PLC cartridge the tool table will
become confused, it will have to be reset. What you can do is check the
Tool Register and record the tool locations (MG). After replacing the PLC,
just put the MG numbers back the way they were.
Alarm AL-1015 means the control is looking for an input from either the low
gear or high gear switch. If you need to replace a PLC cartridge that is
a different PLC version you may run into a conflict in this area. For example
if you replace PLC version ATCVER2.0 on a V-11A that has a straight spindle
with version ATCVER3.5 in order to make the M22 Finish Signal enable for an
indexer the machine may issue the alarm when you try to run the spindle. In
this case you can run the machine if you jump out one of the switches. Both
switches are normally open and in normal operation on a machine with a geared
head one of them is closed. It is either in High Gear or Low Gear, not in
between. So, to prevent the alarm, the machine just needs to see one of them
closed. Jumping either one will cause the machine to run and run the correct
spindle speed (commanded speed). The Low Gear switch is QS13, it's input
address is X14 and the wire number is 133. The High Gear switch is QS12, it's
input address is X13 and the wire number is 132. These wires should be found
on the relay board. There should be two connectors, each one is a two pin
male connector. CN40 has pins 132 and 24V. CN41 has pins 133 and 24V.
Sometimes if you have a Servo Alarm you need to get rid of for example a 4th
axis that is not in use:
1.TOOL/PARAM button.
2.RIGHT CHAPTER button.
3.AXIS soft key.
4.# ( 4 ) AXIS < A > DATA ( 1 )
5.INPUT button.
The above example is for turning off the 4th axis.
V11A
Normal indications for ATC proximity switches:
Home
Top and Bottom LEDs on. Middle off.
After arm engages spindle
Top and Middle LEDs on. Bottom off.
After arm swaps tools
Top and Middle LEDs on. Bottom off.
If after installing a 4th axis the table rotates less than it is commanded,
try increasing Parameter PC2.
If an axis seems to go to the wrong place when commanded after Reference
Return (ZRN), check the Decel switch. Especially on the X axis since chips
can pile up and become trapped causing the switch to be made prematurely.
On Takumi electrics, the wire numbers and relay numbers correspond between
Mitsubishi and Fanuc controls.
When working with Takumi Timer numbers, don't confuse the number the manual
shows with the Fanuc Timer number. For example, T33 in the Takumi manual
refers to:
PMCPRM (TIMER)
NO. ADDRESS DATA
33 T64 ******
The timer in this example is used to finish a spare M-Code after a specified
amount of time. The setting range for this timer is 0-255552.
Before beginning the installation of a 4th axis, be sure to save the Tool
Data in case you lose it. If you FORMAT the control, you will definitely lose
the Tool Data.
If you work with the Machine Parameters, installing a 4th axis for example,
and you start getting S02 INIT. PARAM. ALARM alarms, check the Spindle Spec
parameters. If they are missing, the control is not recognizing the Spindle.
Check Base Spec. Parameter #4 if a 4th axis is not installed and #5 if it is.
This parameter acts like a software version on an amplifier terminator.
A 0 assigned to axtype enables the axis named under sysnu and axname on that
line. So, if the machine has three controlled axes it should look like:
[BASE SPEC. PARAM]
# axistype sysnu axname
1 axis01 0 1 x
2 0 1 y
3 0 1 z
4 1
The 1 on #4 acts as a terminator of some sort. If it = 0, you will get the
S02 alarms and missing spindle parameters.
If the machine has a 4th axis, it should look like:
[BASE SPEC. PARAM]
# axistype sysnu axname
1 axis01 0 1 x
2 0 1 y
3 0 1 z
4 0 1 a
5 1
If the 1 is left off of #5, the S02 alarms will occur.
Anytime a 4th axis is installed, the Spindle Spec and Spindle Adjust
parameters will be lost. They must be re-entered by hand.
If you use R1900 for Tool Confusion, you have to cycle the NC power.
If a Big Tool is assigned to a pot, the PLC will not allow a tool to be
assigned to a pot next to it. The MG# for the pot in question will have four
question marks (????) in it instead of a tool number. If you try to assign a
tool number it, the number in put will be displayed for an instant and then
go back to ????. To turn the Big Tool function off:
1.Press TOOL/PARAM button.
2.Press the MENU soft key.
3.Press the PLC-SW soft key.
4.#( 3 )
5.Press the INPUT button.
On Takumis, the TLM FUNCTION #(8) is almost always turned on.
With PLC ATCVER2.0, Latch Parameter L46 makes the Air Blow valid or invalid
during tapping.
0 = No Air Blow during tapping.
1 = Air Blow when Spindle is moving up during tapping.
The pin outs for the Golden Sun 4th axis motor connector on the Takumi side
are:
PIN TAKUMI WIRE NUMBER
A 24V
B 141
C 142
N 64
P 110B
R 143
S 24V (Sometimes jumpered from Pin A)
J U
K V
L W
M E (Earth Ground)
64 and 110B go to connector N14 on the Relay Board.
143 and 24V go to connector N44 on the Relay Board.
141, 142 and 24V go to connector N47 on the Relay Board.
J, K, L AND E go to the Servo Amplifier.
When installing a 4th axis on Mitsubishi, BASE SPEC. PARAM #13 (axname2)
must
be set in order for the axis name to be displayed on the monitor.
If a machine displays alarm AL1002 F25 FUSE BREAK check the 4 amp fuse on
the
machine but keep in mind that there is also a F25 on the Relay Board. In
addition, if Latch Parameter L20 is set to 0, this alarm may be displayed
when there is no fuse blown at all.
The address for F25 Fuse Break Check on Fanuc control is X1005.5. CR46
normally open contact closes on wire 135 to make this go high. The coil of
CR46 is energized by 111A and 110B. Failure of F25 causes CR46 to drop out.
On a Mitsubishi control, alarms have the address designation F. So if you
want to solve an alarm through the ladder you have to search F addreses.
Address F2 would be for Alarm AL1002, for example. F3 would be for alarm
AL1002, etc.
1.FO button.
2.LADDER soft key.
3.2 CIRCUIT soft key.
4.MENU soft key.
5.6 MONIT soft key.
6.MENU soft key.
7.-< >- soft key.
8.Enter the address (F2, F3, etc.)
9.INPUT button.
On a Fanuc, the address is A.
If a machine with a Mitsubishi control goes into Feed Hold sometimes after
executing an ATC cycle, check Latch Parameter L100. It should be 1. If it is 0,
this problem can and usually will occur. This parameter should always be set to 1
on a 530 control.
If the air (spindle nozzle) turns on during a tapping cycle, check Latch
Parameter L29. It should be 1. This function is actually meant for control of
tapping oil. If it is set to 0, the air(oil) will turn on automatically as
the machine taps. If set to 1, this function is turned on with M25 and off by
M26. L29 can be changed even while the program is running.
Latch Parameter List
L00 and L01 work together to set the ATC type. L0=0,L1=0 for 16 tool ATC.
L0=0,L1=1 for 24 tool ATC.
L0=1,L1=0 for no ATC.
L0=1,L1=1 for 32 tool ATC.
L03 After M6 Command Execution. If L03=1, the Coolant and/or Air Blow will be
turned on after the ATC cycle if they were on
 before M6 was commanded.
If L03=0, they will not be turned on.
L06 Direction of X Axis ZRN. If L06=1, the X axis will perform reference
return in the positive direction (Right side
of the table).
If L06=0, the X axis will perform reference
return in the negative direction (Left side
of the table).
L07 Oil/Air Unit Set L07=1 if the Oil/Air unit is supplied.
Set L07=0 if it is not supplied.
L08 Chip Conveyor Auto Start If L08=1, the chip conveyor will start and
stop with the program.
If L08=0, it will be controlled by the M53
command and/or Operator's Panel.
L09 ATC Type Set L09=1 if the machine is Geneva type.
Set L09=0 if the machine is Arm type.
L10 Head Type Set L10=1 if the head is direct driven.
Set L10=0 if the head is geared (High/Low).
L12 4th Axis If L12=1, the 4th axis is Valid.
If L12=0, the 4th axis is Invalid.
L14 Tool Change Area If L12=1, when tool change is executed the X
axis will move to the position specified by
the Position Switch setting.
If L12=0, the X axis will not move for tool
change.
L15 Hydraulics If L15=1, the hydraulic motor will turn on
only when hydraulics are needed. For example,
when the ATC cycle begins.
If L15=0, the hydraulic motor will turn on
when the power is turned on.
L16 Clean Water Control If L16=1, the Clean Water Pump is controlled
by timers T87 and T88 after M55 is called.
If L16=0, the pump turns on and off with M55.
L17 Chip Conveyor Auto CCW If L17=1, Chip Conveyor Auto CCW is Valid.
If L17=0, Chip Conveyor Auto CCW is Invalid.
On 12000 RPM machines L17 is for the Air/Oil Unit. In this case:
L17 Oil-Air Unit Active by If L17=1, Oil/Air Mist Unit is turned on when
Spindle Rotation the spindle runs.
If L17=0, Oil/Air Unit is active when L7=1.
L19 Lamp Function Set L19=1 if the machine has one lamp for
M30, Alarm and machining condition.
Set L19=0 if the machine has three lamps.
L20 Pump Fuse Alarm If L20=1, Pump Fuse Alarm (F25) is Valid.
If L20=0, the alarm is Invalid.
L21 M21 Function If L21=1, M21 will direct finish.
If L21=0, M21 will finish by FIN signal
(High signal at X3D).
L22 M22 Function If L22=1, M22 will direct finish.
If L22=0, M22 will finish by FIN signal
(High signal at X3F).
L23 M23 Function If L23=1, M23 will direct finish.
If L23=0, M23 will finish by FIN signal
(High signal at X3E).
L24 M24 Function If L24=1, M24 will direct finish.
If L24=0, M24 will finish by FIN signal
(High signal at X36).
L26 MPG Numbers If L26=1, three MPG supplied
L27 MPG Numbers If L27=1, two MPG supplied
L29 Tapping Oil Control If L29=1, tapping oil is turned on by M25
and turned off by M26.
If L29=0, tapping oil is automatically
turned on when tapping.
L30 Operation Panel Setting If L30=1, new type.
If L30=0, old type.
L32 ATC Position Setting If L32=1, tool change at second reference
position.
If L32=0, tool change at first reference
position.
L33 F0 Speed Setting If L33=1, when F0 is selected rapids are 0%.
If L33=0, when F0 is selected rapids are 1%.
L34 CTS Coolant Sensor Type If L34=1, CTS coolant floating sensor is
normally closed.
If L34=0, CTS coolant floating sensor is
normally open.
L35 Water Pressure Setting If L35=1,CTS water pressure check is valid.
If L35=0,CTS water pressure check is invalid.
L36 CTS Setting If L36=1, coolant thru spindle is valid.
If L36=0, coolant thru spindle is invalid.
L37 External Deceleration If L37=1, external deceleration is valid.
If L37=0, external deceleration is invalid.
L38 Pot Number for 32T ATC If L38=1, magazine pot number follows pot.
If L38=0, magazine pot number does not follow
pot.
L40 MAN/ABS Setting If L40=1, manual/absolute is always valid.
If L40=0, manual/absolute is controlled by
operators panel.
L43 Low Air Pressure If L43=1, the machine can run with the low
air pressure signal active. Alarm LED will be
flashing but no alarm displayed.
 If L43=0, the machine cannot run with the low
air pressure signal active. Alarm LED will be
flashing and the NC alarm is displayed.
L47 4th Axis Solenoid Valve If L47=1, the unclamp switch for the 4th axis
is normally open.
If L47=0, the unclamp switch for the 4th axis
normally open.
L48 Chip Conveyor Button If L48=1, the chip conveyor button is not
used.
If L48=0, the chip conveyor button is used.
L60 M60 Function If L60=1, M60 will direct finish.
If L60=0, M60 will finish by FIN signal.
(High signal at X2F)
L61 M61 Function If L61=1, M61 will direct finish.
If L61=0, M61 will finish by FIN signal.
(High signal at X25)
L62 M62 Function If L62=1, M62 will direct finish.
If L62=0, M62 will finish by FIN signal.
(High signal at X7)
L63 M63 Function If L63=1, M63 will direct finish.
If L63=0, M63 will finish by FIN signal.
(High signal at X1E)
L64 M64 Function If L64=1, M64 will direct finish.
If L64=0, M64 will finish by FIN signal.
(High signal at X6)
L65 M65 Function If L65=1, M65 will direct finish.
If L65=0, M65 will finish by FIN signal.
(High at XA)
L71 CE Setting If L71=1, the machine is CE type.
If L71=0, the machine is not CE type.
L100 If L100=1, single block signal is not turned
on during tool change.
If L100=0, single block signal is turned on
during tool change.
* Always set to 1 for 64 and 530 controls.
If you switch a machine from CAT tooling to BT tooling or vice-versa, you
will have a difference in the ATC position due to the difference in the arms.
On some machines, you can change only the tool grippers instead of the whole
arm. In this case, no adjustment is necessary. If an adjustment does need to
be made or if you need to change the reference return position of an axis for
some other reason, you must change the Reference Point Shift Amount. This is
done by parameter. In the case of a Mitsubishi control, the parameter is
ZERO-RTN PARAM #3 G28sft. This value is in microns of actual linear
movement
of the axis. The actual procedure to change the parameter can be found in the
file TAK. For a Fanuc 0 control, the parameter is 508 for the X axis, 509 for
the Y axis and 510 for the Z axis. The parameter for an 18 control is 1850X,
1850Y and 1850Z. Unlike the Mitsubishi, the Fanuc grid shift parameters are
stored as detection units and the size of their value as well as the sign
(+ or -) is difficult to relate to actual linear movement. The best method
for setting them is by trial and error.
Generally speaking on Takumi machines, V8 in particular, G28sft for the Z
axis should be around 3000. X and Y are normally zero.
Takumi machining centers, like other machining centers, locks the spindle
while the tool drawbar is unclamped so if a spindle is tight or seems to be
locked up, make sure the unclamp cylinder is in proper working order. In some
cases the hydraulic valve that controls the drawbar can fail and cause the
drawbar to be partially unclamped which puts a great deal of drag on the
spindle.
If you have problems with Rigid Tapping, check the following parameters:
Control Parameter #29 SYNCHRONOUS TAPPING
Option Parameter 19.6 (m_op 19.6)
Option Parameter 23.4
M29 is only needed for Rigid Tapping on machines with Fanuc controls.
When G84 executes, the spindle is oriented before actual tapping begins. The
Spindle Oriented lamp on the operator's panel does not light.
The Spindle Clamp/Unclamp cylinder for the V8 is air over oil. The piston is
actuated by air in both directions. The spindle air blast comes in on a sep-
erate air line that gets to the spindle through the base of the lower cylind-
er.
On a Takumi with Fanuc 18 control, the following Keep Relays are related to
to the Air/Oil Mist Unit:
K4.1 OIL/AIR UNIT SUPPLIED = 1
OIL/AIR UNIT NOT SUPPLIED = 0
K4.2 AIR LUBE SPINDLE BEARING WHEN SERVO READY = 0
AIR LUBE SPINDLE BEARING WHEN SPINDLE ROTATING = 1
(0 = Air to mister is on whenever the NC is in Ready state)
The Mitsubishi equivalent to K4.1 is L7. The equivalent to K4.2 is L17.
The air and oil portions of the mister unit are separate. The oil portion
consists of a reservoir of oil. At intervals determined by Timer settings,
an air solenoid opens to apply air pressure to the reservoir forcing oil
through the line to the spindle. This interval is normally 10-15 seconds
every 4 or 5 minutes. The air either blows anytime the NC is in ready state
or when the spindle is running as defined by the Keep Relay above. The air
and oil are combined at the spindle via separate lines to form a mist. You
must be careful not to over use the mister since applying too much oil to
the spindle will damage the bearings.
According to Eric you should not use M21 or M22 as spare outputs on a any
machines that have a 12000 RPM spindle. The reason for this is that Takumi
sometimes will use these M-Codes to operate certain things. A good example is
using M21 for the Air/Oil mist unit. In this case, the logic for M21 is very
complicated whereas the logic for M23 and M24 are always simple, consisting
of the M-Code call, a Latch Parameter instruction to enable and disable and,
of course, the output itself. If you are trying to use M21 on a 12000 RPM
machine for an indexer, for example, you may go into the ladder to try to
make the M-Code do what you want. If you start changing Latch Parameters you
may get some very unexpected results. In this example, you could very easily
make the Air/Oil Unit invalid causing the failure of the spindle. On these
high RPM machines, anytime you work with parameters, format the control, etc.
make sure you check the operation of the Air/Oil Unit afterward. Make sure
that the air comes on when it is supposed to and that the oil comes on at the
prescribed interval. Timer T80 is useful in this regard.
If you need a spare output use M23 and M24. The related Keep Relays are:
K1.2 0 = M23 FINISH BY SIGNAL
1 = M23 FINISH BY TIMER T33
K1.3 0 = M24 FINISH BY SIGNAL
M24 FINISH BY TIMER T34
Always write down the Latch Parameters before replacing a PLC cartridge. The
reason for this is that sometimes replacing the cartridge with a different
version will cause some of the Latches to be reset. Normally, the ones that
will be reset are L0 and L1. These latches will cause alarms related to the
ATC magazine capacity and whether the head is geared or not.
If a machine will not perform Tool Length Measurement correctly, check the
condition of PLC Switch #8 (PLC-SW). This is TLM FUNCTION. It should be
turned on (highlighted). The symptom is that when the Z axis is brought down
the Z axis measurement will not be displayed. This is one of the parameters
which is normally lost during memory initialization along with certain Latch
Parameters and Bit Select parameters.
The proximity switch for magazine counting and position on the V-10 is:
Schonbuch Electronic
ILCT 214
10-35 vdc
PNP
The switch measures 1.800 in length with 1.570 being threaded. The diameter
is .470, it has three wires, they are:
Color Takumi Wire #
Black 164
Brown 24V
Blue 0V
The ATC magazine motor uses a three phase brake. There is no timer to cont-
rol the stopping position. The brake is wired into the motor leads. When the
the correct pot has been reached the control looks at the proximity switch.
When it sees the leading edge, it drops out the contactor which removes power
from the brake which should immediately stop the motor if it is in good work-
ing order and properly adjusted mechanically. According to Eric there may be
some sort of a time delay between when the leading edge is seen and when the
contactor is told to drop out but this is done in the ladder and would be
very difficult to track down and worked with.
The replacement motors we have are:
Tung Lee Gearmotor
1/4 HP 4 Pole
220V/380V
.85A/.5A
60Hz/50Hz
1680 rpm/1380 rpm
Ratio 20:1
They come in wired for 380 volts.
The proper connection for 220 volts is
L1 L2 L3
| | |
U V W
| | |
Z X Y
Instead of a three phase brake, these motors use a DC brake module. It is:
Power Supply Mode:P-03
AC In 200-220V
DC Out 80-100V
The module has a circuit board and an ice cube relay which can be serviced in
the case of an emergency. The new gearmotors do not mount flush like the
original one unless you remove the snap ring. Of course, you should do this
on a case by case basis. Also, you might want to look at your situation to
see if it would be best to make it fit by machining, etc. The hole pattern is
also different so you will have to open the bolt holes up from .370 to close
to .450
The Tool Table Reset for the V-10 with Fanuc control according to the
Takumi manual is:
1. JOG mode.
2. Move Pot 1 to Standby position.
3. Remove Spindle Tool.
4. Set PWE to 1.
5. Press SYSTEM button.
6. Press PMC soft key.
7. Press PMCPRM soft key.
8. Press COUNTER soft key.
9. NO ADDRESS PRESET CURRENT
1 C00 24 1
*For 24 tool ATC.
10.Press SYSTEM button.
11.Press PMC soft key.
12.Press PMCPRM soft key.
13.Press KEEPRL soft key.
14.Set K10 to 00000001.
15.Set PWE to 0.
The Golden Sun CNC-401RV uses an HA100NS-OSE104 Mitsubishi
Motor/Encoder.
The gear ratio is 180:1. the zero return switch is located on the left side
at the top under a small plate. There is another small plate on top of the
tables for viewing a portion of the ring gear. There is a round plate at the
top for working on one end of the worm gear. There is a large plate on the
bottom for accessing the other end of the worm gear, the idler gear and the
motor end gear.
The V-10 machines use a hydraulic cylinder to unclamp the tool instead of a
pneumatic cylinder. There is no real reason for this other than most of the
V-10s have a 10000 0r 12000 rpm spindle which the spindle maker specified a
hydraulic system for it's stability so Takumi used it. The high rpm spindle
still clamps with spring pressure. One difference with the high rpm spindle
is that it uses a collet type draw bar rather than one with steel balls. This
collet type uses fingers or grippers to hold the tool and offers much greater
clamping force. This type of clamping system is also used with the 50 taper
spindle. If you have trouble with one of these not holding the tool tightly
enough, you can increase the clamping force by inserting an allen wrench into
the end of the lower end of the spindle and tightening. It may be necessary
to orient the spindle for holding purposes.
If the PIN IN/OUT cylinder of the magazine comes out to the switch then goes
part the way back when it is supposed to move out and stay out to unlock the
magazine, make sure the hydraulic pump is running. Given that the hydraulic
pump only runs when needed, it is possible that a situation could arise where
the pump does not come on when the magazine is commanded to run. Anytime
you
have trouble with the ATC, be sure to check all of the operations such as the
pot up/down etc...
Takumis, whether Fanuc controlled or Mitsubishi controlled, normally use
either a proximity switch or a magsensor for spindle orientation. If it uses
a magsensor, it will be made by Macome. The part number for the sensor is
BKO-C1730H02. The part number of the pre-amplifier is BKO-C1730H01. The
pre-
amplifier is mounted near the sensor and is connected by a short cable. The
part number of the magnet is BKO-C1730H09.
These components are available from Mitsubishi Electric (847-478-2500) but
must be purchased as a kit (magnet, sensor, pre-amplifier). The Mitsubishi
part number is W0397.
For problems with spindle orientation on a Takumi, check the file FANUC.TXT
If the magsensor is completely removed, disconnected from the spindle amp-
lifier, when M19 is commanded the spindle will run at the orientation speed
normally 200 rpm. There will be no alarms, it will just keep running.
V-15
MC03 is the contactor for the ATC arm motor. Pressing in in manually will
release the brake and rotate the arm. The arm will go through it's full mot-
ion with this contactor which runs the motor in only one direction, the cam
box takes care of the reversing motion at the end of the movement which puts
the arm in it's home position.
Alarm 1005 - SP. CAN'T ORIENT
Make sure that the ATC arm is FULLY in it's home position (top and bottom
LEDs on only) and that the spindle is clamped. Sometimes even after all of
these conditions are met the NC power will still have to be cycled.
If you get either alarm 1018 POT DOWN FAIL or 1019 POT UP FAIL, you must
cycle the NC power before you can use M82 or M84 to move the pot to it's
correct position.
When doing a tool table reset make sure the toggle switch icon actually flips
up and back down. Sometimes they don't and you have to do it more than once.
This actually applies to all of the PLC-SW inputs but the tool table reset is
worse about it than others. Also, in some cases the icon won't change at all
but the tool table will reset anyway. The procedure is:
1.TOOL PARAM button.
2.PLC-SW soft key.
3.Enter a 4 in the #( ) field.
4.INPUT button.
If a Mitsubishi controlled machine shows an indicated movement on the CRT
which is greater than the actual moved distance, check Servo Machine
Parameter
SV018 PIT. On most Takumis this should be set to 10mm. Sometimes when the
parameters are loaded into the machine this will reset to 12. This causes the
displayed position to be about 20 percent greater than the actual distance.
If you have trouble doing RS-232 communications on a Takumi, check the man-
ual that has the paper copy of the PLC ladder. This manual normally includes
a listing of the device parameters, if you set the control to these values it
may help. This is normally only true for Mitsubishi controlled machines.
V8 S/N F8255, and possibly other machines, is wired differently from most
Takumis. In particular are the overload relays. The way they are wired can
cause some confusion. On most machines the normally open contact of the over-
load relay has wire 24V connected to one side so that when the relay trips
24 volts is sent to the wire tied to the other side of the contact causing
the associated address to go high. in the case of the coolant pump (MC02) it
would be wire 350. In the case of the machine in question wire 24 volts is
not tied to the overload. Rather, wire number 35 is tied to one side of each
normally open contact. Wire 35 is apparently a 110 volt input. What follows
is an explanation of how this circuit works in the case of the coolant func-
tion and is typical for all contactors. When the coolant is turned on the
relay sends 110 volts (111A) on wire 23 to the normally open contact of the
MC02 contactor's overload relay. Wire 23 is jumped to one side of the norm-
ally closed contact which is passed on to the coil. The other side of the
coil is 110B. If the overload is tripped, relay CR46 on the relay board is
energized and alarm AL1002 is issued. The consequence of this wiring is that
if an overload is tripped when it's associated contactor is not energized
no alarm will be issued because there is no signal present at the overload
until the contactor is energized. In this case, the control has no way of
knowing which overload relay was tripped other than knowing that a particular
function was in motion at the time of the signal to wire 35. So if for exam-
ple the ATC arm motor is the only contactor energized when the signal to wire
35 goes high the control could deduce that and display an alarm for the ATC
motor overload.
On a V-10 with a Fanuc 18M, the Keep Relay which determines if the hydraulics
stay on all of the time or come on when a hydraulic function is used is K5.3
On the machines which use the magsensor for spindle orientation and have a
Mitsubishi control it should not be necessary to orient the spindle after
changing the position shift parameter (OPST). If the spindle is already or-
iented when you change the parameter and press the INPUT button, the spindle
will move the difference in the shift amount.
The Takumi V8 with the Mitsubishi 520 control also uses R2970 for registering
the tool in the spindle for ATC operation like the YCI Max-1. For tool change
problems refer to the file YCI.TXT.
For alarm Y03 AMP UNEQUIPPED EMERGENCY LIN alarm check all of the
serial
communication cables on the control as well the drives. Also check the rotary
selector switches at the top of the drives in the case of a Mitsubishi cont-
rol. They servo drives should all be set for a different number. On an older
machine you might want to move the selector switch around a little in case
there is corrosion. Normally on a Mitsubishi controlled machine the serial
communication cable from the CPU will go to CN1A of the power supply module,
CN1B of the power supply module will go to CN1A of the first servo amp, CN1B
of this amp will go to CN1A of the second amp, CN1B of the second amp will go
to CN1A of the third amp. CN1B of the third amp will have a terminator unless
the machine has a fourth axis. CN4 of the spindle amplifier should go to CN4
of the power supply module.
During the ATC cycle, the spindle tool number on the monitor page changes to
the new number when the spindle clamps on the new tool.
If an axis is on an over travel (hard limit) switch pressing and holding the
OT RELEASE switch will allow you to move the axes but the overtravel alarm
will still be displayed and certain functions will still be inhibited. In
other words, the OT RELEASE does not completely bypass the switch, the
control
still knows that the limit switch is made.
The machines with the oil cooled ball screws (high rapids) have a thermistor
located at the Y axis ball screw (beneath the rear Y axis way cover). This
sensor is connected to the Habor oil chiller. The resistance of the thermist-
or should be about 6.3 kohms at room temperature. If it is bad or disconnect-
ed the oil cooler will display "Sn ro". This sensor is considered the "room"
sensor. The "oil" sensor is in a tee at the return to the reservoir. If this
one is disconnected "Sn OL" is displayed. It's resistance is the same as the
room sensor. Removing the control fuse of the chiller will not clear the
alarms, the 220 vac must be removed.
The V-11 spindle oil cooler three phase power is supplied from the electrical
cabinet by three six amp fuses (F13,F14 and F15) on wires R8,S8 and TS.
Normally on a machine which uses a proximity switch for orientation, once the
spindle orients it does not matter about the signal from the switch. The
spindle motor will maintain it's position and remain steady regardless of the
signal.
If a V-22 or V32 with the 32 tool ATC magazine has a problem where it will
not do a tool change and testing shows that the tool pot will not go up or
down even when commanding M82 and M84 in MDI mode and the Cycle Start
lamp
just flashes, check the output to CR17 and CR18 (POT DOWN and POT UP)
(Y1003.5 and Y1001.6). If these are not turned on check the condition of the
MAG PIN. If the mag pin is out (disengaged from the sprocket) it will cause
the above condition. Check the MAG PIN IN switch (X1007.1) and the MAG PIN
OUT switch (X1005.4). The usual problem here is a bad hydraulic valve which
causes the cylinder to be stuck in the out position.
On the V-22 or any machine with a 32 tool magazine, if the tool pot stops
out of position, one possible cause is that the pot counter proximity switch
is out of position either left to right or up and down. If the prox switch
is too close to the pots the index motor will stop too soon causing the index
pin to contact the sprocket too high. When this happens the magazine will
eventually reach the correct point since the pin pushes it's way slowly to-
ward the middle of the lobe and in so doing moves the entire magazine. The
hydraulic index motor on this machine is not like others with a number of
definite stopping points, it simply runs until the proximity switch is made.
Once it is made a time delay is executed after which the motor stops. The
timer is set in the PLC and despite what is shown in the electrical manual,
the timers cannot be changed.
On the V-22 with the coolant through the spindle (CTS) the clamp/unclamp
proximity switches are different from other machines. The switches are mount-
ed to the top of the rotary union so that when the tool is unclamped the top
of the union moves down, the switches move with it. Once clamped the top
switch is made. When unclamped, the bottom switch is made. This is important
to note when troubleshooting over the phone.
The rotary union used on the V-22 is a Berg OHLK35-1 cylinder while the union
itself is KDE 8-1 (604.14033.000.0). This unit uses two ceramic disks which
are pressed together and rotate face on face when the top of the union moves
down. This movement is a result of the coolant pressure when the CTS pump is
turned on by the m-code M07. This coolant is supplied by the large line at
the top of the union. The rotary cylinder is bolted to the top of the drawbar
actuator. The bottom portion of the union is screwed into the top of the
drawbar. Normally when the ceramic disks are worn or damaged, coolant will
leak through to hose which is used for coolant through the tool (CTT). To
replace these disks you must take the top off of the cylinder (three bolts).
If you have a special wrench that will fit the flat without being too big for
the i.d. of the cylinder you can simply unscrew (right hand thread) the bott-
om disk, screw the new one in and bolt the new top portion (with top disk)
onto the cylinder. If not, you can carefully pry up the bottom portion, the
i.d. of which will press against the bottom flange of the bottom disk hous-
ing. The inner plate of the bottom portion will separate from the outer part
but it will be tight because of an o-ring. This will allow you to access the
flats on the ceramic disk housing. If a machine gets coolant in the headstock
the rotary union is probably not the cause although it is possible. Most of
the time when coolant is present in the oil it is due to a bad o-ring in the
side of the spindle. There is also an air line connected to the rotary union.
This air line is for the spindle air blast. The upper portion of the cylinder
has holes around it's perimeter on the bottom. The lower portion of the cyl-
inder has two holes on it's perimeter on the top. When the tool unclamps
the top moves down and contacts the top, the two surfaces seal and the air
is passed through the spindle.
Takumi only uses two kinds of DEX cam gear boxes on the ATC. One is for 50
taper and has a one horsepower (1 HP) ATC motor. The other is for the 40 tap-
er and has a one-half horsepower (1/2 HP) motor.
You can alter the direction that the x axis performs zero return by changing
Latch Parameter 6.
L6 = 0 NEGATIVE DIRECTION ZRN
L6 = 1 POSITIVE DIRECTION ZRN
If a spindle wants to keep running all of the time but will stop when RESET
button is pressed check the spindle hi/low gear confirmation switches since
the machine may be trying to get into a gear. This may occur if both of the
inputs are either high or low. In the case of a Fanuc 18 controlled machine
the inputs are X1005.3 for high gear and X1008.5 for low gear. Another cause
for this condition is a bad magsensor or proximity switch. In this case the
spindle will continually rotate once M19 or M6 is commanded.
The built in spindle that a few Takumi V-22s have has four ports on the top
which are labeled OA, OB, WA and WB. OA and OB are for the two lines from
the Showa oil/air mist unit distribution block. WA and WB are from the Habor
spindle oil chiller.
If the LED on the Pot Up proximity switch of a V-8 is off when the machine
power is turned on but comes on after M82/M84 is executed check the stroke of
the cylinder, the cylinder rod could be drifting slowly when the power is
off. It is important to note that the cam plate that is used to move the pot
is open on one end so that the positive stop is provided by the pot itself.
This means that the cylinder rod can still move after the pot has bottomed
out against the ATC. Where this becomes a problem is if the cushion at the
cylinder end is set too soft so that once the cylinder has nearly reached the
end of it's travel, the cushion allows the rod to drift very slowly even
though the pot is all the way up. In this case if you adjust the Pot Up con-
firmation switch for this point, the rod can continue to drift as long as
the air is on causing the situation where the LED is off in the morning after
sitting overnight. The fix for this is to adjust the cushion to be as hard as
possible without slamming the pot then adjust the confirmation proximity
switch for this position. Make sure you adjust the cushion (metering valve)
and not the flow control valve. The cushion is a small straight slotted screw
with a jam nut, the flow control valve is the valve that is connected to the
air line.
The X axis of the V-11 has three gibs. Two of these pull the table down, one
in the front and one in the back. Another gib in the front, pulls the table
back against the ways. On the front pull down gib the fat end is on the right
hand side, on the back it is on the left side. Each end of each gib has a
block that is bolted to the casting by two 6mm SHCS. There is another 6mm
bolt that screws into the threaded hole in the end of the gib. There are also
two 4mm set screws in each block that are used to push the gib. To tighten a
gib you must first loosen the 8mm bolt on the fat end as well as the set
screws on the skinny end. Run the set screws of the fat end in to the desired
position. Run the set screws of the skinny end in until they touch the gib,
then tighten the 8mm bolt on both ends of the gib.
The gibs of the V-11 are turcited.
Latch Parameter L12 is for the fourth axis.
L12 = 1 4th AXIS ACTIVATED
L12 = 0 4th AXIS NOT ACTIVATED
If L12 = 0, you will be able to move the fourth axis in manual mode but if
zero return is commanded it will ignore you.
When adjusting the position of the tool arm on the V-11, you can loosen the
eight bolts at the bottom of the arm and the large bolt in the center then
lower the arm although this should never really be necessary. What normally
happens is that over time there is wear in the cam box which causes the arm to
be too low so that it needs to be raised. To do this you have to remove the
eight small bolts and the large bolt and pull the arm off. There is a spacer
sleeve between the top of the arm and the bottom of the cam box, it fits over
the shaft. Remove this sleeve, put it in a lathe and turn back the sleeve the
amount that the arm needs to be adjusted up. Reassemble, be sure to adjust
the Z axis grid shift if the tool arm no longer aligns with the spindle. In
the case of a machine with a Fanuc 0 control, the Grid Shift parameter is
510.
The habor oil chiller on the Takumi machines use refrigerant R22.
On a V-22 with a 32 tool ATC, if latch parameters L0 and L1 are set wrong,
the pot may go down when commanded, then go back up on it's own. This is be-
cause the solenoid (SV6)is a single-acting valve so the relay (CR17) must re-
main energized for the pot to stay down. CR17 is controlled by output address
Y11. CR17 feeds voltage from 110A to wire number 56 to the coil of SV6. The
common is 110B. The logic for the pot down function, that is, the portion
that applies to this situation is shown below:
---| |-----| |-----| |------------------------------------------( ) M394
L1 L0 M395
---| |-----| |-----|/|------------------------------------------( ) Y11
Y11 M394 Y12
On this machine the POT UP portion of the electrical schematic can be ignor-
ed.
The following information is for the V-32A:
The ATC arm is a purely mechanical and driven by an AC motor. At the top of the
cam box there is a drum which contains three vertically aligned proximity
switches. These switches are fixed in place and the their associated dogs rotate
with the main shaft. The electrical manual gives sparse and in some cases
incorrect information concerning their wiring but what is outlined here is based on
actual machine observation. The proximity switches are identical three wire
devices. The three wires are:
BROWN – 24vdc
BLUE - 0vdc
BLACK – Signal (Output)
The output of the top switch is wire number 163, the middle is wire number 162
and the bottom is 161. The switches are NPN so the output will be 0 volts in the
absence of the dog. The diagnostic bits associated with the switches are:
TOP SWITCH – X1006.7
MIDDLE SWITCH – X1005.2
BOTTOM SWITCH – X1005.0
The switches each have an LED to indicate their status, when a dog is present at
a switch the LED will be on and the output will be 24 volts, the corresponding
diagnostic bit will equal 1.
When the ATC arm is at home (0 degrees) the top and bottom LEDs should be
on and the middle LED should be off. The diagnostic status will be:
X1006.7 = 1
X1005.2 = 0
X1005.0 = 1
After the arm rotates to the spindle the top and middle LEDs should be on and
the bottom LED should be off. The diagnostic status will be:
X1006.7 = 1
X1005.2 = 1
X1005.0 = 0
After the tools have been swapped by the arm and before returning home the
LED and diagnostic indications will be the same as above. Once the arm returns
home the LED and diagnostic indication will, of course, be as they were
originally.
The diagnostic for the tool clamp limit switch (TCL.S) is X1008.3, the diagnostic
for the tool unclamp limit switch (TUN.S) is X1006.6.
A very important thing to know about these machines is that they do not operate
like most other machines, in that, when the arm moves to the spindle it does not
wait for the tool unclamp signal before proceeding with it’s next movement (tool
swap). The operation of the ATC is based on timers in the PLC. Normally this is
not a problem but in the event of an improperly adjusted dog, etc. , problems can
occur such as tools being dropped or ripped out of the spindle. It is possible that
when a tool change is commanded the ATC arm may rotate continuously. If any
of these symptoms are exhibited check to see if the proximity switches are
working properly. Also check the dogs, they are held on the shaft by a set screw
and can sometimes work loose.
Alarm AL-1023 CLAMP/UNCLAMP L.S. ERROR only occurs when both switches
are closed on the draw bar actuator. For Mitsubishi control X11 and X12 will
equal 1 when this alarm is active. Normally occurs if the top switch (clamp) is
stuck when the draw bar is actuated.
The V-10 with the 12000 rpm spindle uses the M21 output (CR31) to turn on the
air solenoid which pressurizes the tank (air/oil unit) forcing oil to the mixing block
(Showa DM-2) at the head. The wire numbers are 340 and 341. The air/oil
sensor is attached to this block, the output of the sensor is tied to input X3D
which is normally used for the M21 finish signal. The wire numbers are 24V and
144. The output address for CR31 is Y20. The off interval for the air/oil mist unit
is set by timer T80 and is normally a value of 3500 (350,000 milliseconds). Latch
parameter L7 enables and disables the unit and should be set to 1 when then
machine is equipped with the unit. Latch parameter L17 determines if air is
supplied to the spindle all of the time or only when the spindle runs. If L17 equals
1 the air will come on when the spindle starts, if it equals 0 it will stay on all of the
time. If it equals 1 the air will also come on at power up. This air is for cooling the
spindle and is separate from the air/oil mist. A problem with the air/oil unit or the
sensor will generate alarm 1013 AIR/OIL SENSOR DETECT ERROR.
Information about this unit can not be found in the electrical manual.