Maintenance Manual - Flint Machine Tools

Fadal Maintenance Manual

INDEX

Numerics15/15XT 515K Air/Oil Spindle Installation 293

Install Component Plumbing 297Plumbing Spindle 296Wiring Harness Installation 295

2016L 122216 83016 103016L 143020 264020 164020A 184525 2850 Taper Dual Arm Tool Changer 151

Alignment 163Arm Installation 161Inserting the Arm Assembly 162Installation 156Installation Notice 157Maintenance 161Sending the Tool Changer Spindle to Home Position 161Sub-Assemblies 152Tool Changer Specifications 151Troubleshooting 158

5020A 206030 226535 308030 24

AAir Positive Flow System 287Air Supply 45Alternate Service 50ATC Motor Replacement Procedure 120

Pulley Alignment 122Replacing the Slide Motor 121Replacing the Turret Motor on a Geneva Wheel ATC 120

March 2003 INDEX 647


Replacing the Turret Motor on a Servo Turret ATC 121Turret Factor Setting 122

Attached Optional Devices 325Access from Program Using Macro Statement #DISK 339

Macro Statement Format 339Restrictions on File Content and Format 339Restrictions on User Defined Subroutines 340Subprograms and Fixed Subroutines ARE Allowed 340

CNC 88 HS Optional Diskette Drive 336CNC88HS Optional Diskette Drive- Miscellaneous 338

Access from Control 338Requirements 338Specifications 338

Diskette Drive Error Codes 340Dynamic Tool Load Compensation 332

Servo Coolant Assembly 333Servo Coolant Control 334Troubleshooting Checklist 335

M-Function Board Use and Setup 3251050-3A M-Function PCBA (PCB-0008) - Two M Functions. 327Fadal M Functions 326Fadal Normally Supplied M-Functions 327Fadal Optional M-Functions 327M-Function Contacts 329M-Function Hook-up 329Miscellaneous Functions (M-Codes) 325Reset Options 328U7 (Dip Switch) 328

Remote Manual Pulse Generator 330Installation Procedure 331

Auger 80Chip Removal from the Exit Tube 81Chip Removal from the Machine Interior 81Cleaning and Freeing Chips from the Auger Chip Removal System 80

Automatic Tool Changers 107Adjustments 114

ATC Slide Belt Replacement & Adjustment 119ATC Turret Slide Adjustment 116Spring Configuration 21 & 30 Tool Changers 116Tool Turret Rotational Adjustment 118Z Axis Cold Start Adjustment 114

Operation 107ATC Fault Messages 110ATC Sensors & Switch 110ATC Servo Turret Operation 111

648 INDEX March 2003


Electrical Operation 107Programming 107Servo Turret Controller and Amplifier Boards (PCB-0108) 113Tool Change Sequence 109

BBall Pockets Incorrect 279Belt Drive Systems 265

Motor Plate Tensioner Cable 269Posi-Drive Belt System 265

CChecking Grounding Integrity of Fadal VMCs 48

Inspection 49Specification 48Verification 49

Chip Removal Devices 447Auger, Chip Removal System 449

Daily and Weekly Safety Tests for Door Monitor 452PCB-0197 Auger Control & Door Interlock Monitor Board 1310-0C 449

Chip Conveyor 453Cause of Trouble and Corrective Action 458Chip Conveyor Power and Controls 455Installation Procedure 453Maintenance Schedule Chip Conveyor 459Observance and Inspection 457Pre-Startup Safety Inspection 456Restarting the Chip Conveyor 456Stopping the Chip Conveyor on US and CE Machines 456

HydroSweep 447Maintenance Schedule 447

Circuit Breakers 50Clamp-on Ammeter Testing 490

Ballscrew Alignment 491ExTech AC/DC Clamp-On Ammeter 490Gib and Gib Strap Verification 490Limit Stop Check 491

CNC Controls 3051460-1 Memory Expansion Boards 320DC Power Supply 312Door Interlock Monitor Board 2000-1B (PCB-0196 312

Indicators (LEDs) 313Inputs 312Operation 312Outputs 312



Power 312Terminals 312

Electrostatic Discharge (ESD) 306Emergency Stop Circuit Overview 313

Axis Controller 1010-6 319Basic Hardware Operation Description

Normal Operation (No Fault) 313Basic Software Operational Description 314Configurations 316Fadal Axis Board Jumper 316Fault Condition 314Troubleshooting Tips 315

Fadal’s Block Diagram 305Feedrate Potentiometer (Pot) Adjustment 321Functional Description 306

Axis Controller Boards 309Boards in Motherboard or Backplane 306Boards Outside the Motherboard 311J14 310Slot 1 to 4 306Slot 10 308Slot 11 308Slot 12 308Slot 13 308Slot 14 310Slot 15 311Slot 16 311Slot 17 311Slot 5 307Slot 6 308Slot 7 308Slot 8 308Slot 9 308

Master Feedrate 320PCBA Compatibility Chart 325Zero Out Memory Procedure 322Zero-out Memory 324

Conduit 51Coolant Thru the Spindle 300

Coolant-Thru Spindle Seal Kit Instructions 300Determining the Leak Location 301Electrical 300Hydraulic Actuator Set-up 303Mechanical 300

Coolant-Thru Drawbar Cylinder 278



DDiagnostic System Commands 483

DS - Display Switches 483Diagnostics 483Drawbar Cylinder Bushing 277Drawbar Cylinder Plate 277Drive Control 6 Pin Molex Connector 240Drive Ground 240Dual Arm Tool Changer 124

Errors 141Installation & Testing 129Operation 137Scheduled Maintenance 150Sensors 139Set-Up 135Software & Mechanical Test 134Sub-Assemblies 125Sys 101.4 Software Update 139Tool Changer Specifications 124Tool Loading Procedures 137Troubleshooting 140

EElectrical Grounding 46

Primary Grounding 47Electrical Service 50

Alternate Service 50Circuit Breakers 50Conduit 51Preferred Service 50Wiring 50

Emergency Error Codes 530Error Numbers From the Axis or Spindle Controller 530

Error Messages 497Exhaust Valve 277Exhaust Valve Nipple 277

FFadal Bolt Torque Specifications 32Foundation 41Fuses, Heaters, Parameters 627

FORMAT 633

GGeneral Information 461



Binary Number Groupings 477Binary Numbers 475

Number Systems 475Communications Troubleshooting 463

Cables 466Computer and Computer IO Port 467Environment 463File 463Software 468VMC 464

Fadal Machining Centers Serial Numbers 462Helpful Formulas 461

Conversion Factors 461Electrical References 461Expansion Coefficients 461Temperature 461

Reading Status Group 477Solving the Thermal Expansion Problem 474

Ambient Sources 475Cooling Systems 475General Considerations 474Radiant Heat 475Sunlight 475

Thermal Expansion 470Accuracy and Repeatability 470Ambient Temperature 472Expansion Coefficients 471Fixtures / Sub Plates 473Friction 471Heat Sources 471Machine Assemblies 473Machining Practices 472Material Differences 473Non-Uniform Expansion 473Overview 470Recognizing Thermal Expansion 470

VMC Maintenance 478Cabinet Fans 478Conclusion 481Coolant 479Coolant Through Spindle 480Cooled Ball Screws and Spindle 480Glass Scales 480Lubrication 478Machining Practices 478



Monitoring Position Changes 479Probe 480Rough Cut / Cool Down / Finish Cut 479VMC Options 479Warm Up 478

HHeidenhain Tester 428Hold Down Clamps 74Hydraulic Actuator Assembly Bolts 278Hydraulic Brakes 367

4th Axis Brake Check-Out 3684th Axis Brake Installation 3674th, 5th Axis Brake Check-Out 3694th, 5th Axis Brake Installation 368

Hydraulic Hi/low System 2707,500 RPM Poly Chain Belt 271

Spindle Belt Replacement 271Filling 270

HydroSweep 447HydroSweep Only 96

6-Month Planned Maintenance 97Daily Maintenance 96Each Part Cycle 96Monthly Maintenance 97Weekly Maintenance 97

IIllustrations & Data for All VMC Models 1

VMC 15/15XT 5VMC 2016L 12VMC 2216 8VMC 3016 10VMC 3016L 14VMC 3020 26VMC 4020 16VMC 4020A 18VMC 4525 28VMC 5020A 20VMC 6030 22VMC 6535 30VMC 8030 24

Input Three Phase Power 240Installation & Hook-Up 53

Air Supply 58



Moving the VMC-Crane 55Moving the VMC-Fork Lift 54Placing the VMC 56Power Check 58Unlocking Front Doors with CE Door Locks 53Unpacking 53

Installation Procedures 53Inverter Wye Delta 6 Pin Molex Connector 241Inverter/Vector Drive Inputs & Outputs 240

Drive Control 6 Pin Molex Connector 240Drive Ground 240Input Three Phase Power 240Inverter Wye Delta 6 Pin Molex Connector 241Load Meter Output 241Output Three Phase Power 240Vector Drive Encoder 9 pin Molex Connector 242Vector Drive with Rigid Tapping 243

Inverter/Vector Drives 239

LLaser Calibration-Renishaw 84

Aligning the laser 88Axis Calibration 89Calibration Requirements and Limits 86Definitions 84Documentation 85Download Survey 89Laser Setup 86Laser Shut Down 93Materials and Equipment 84Procedure 84Reference Documentation 84Responsibilities 84Safety and Environmental 84Sample output from a laser measurement system. 91Scope 84Standard Fadal Cnc88hs 85

Leveling 69Box Way VMCs 69For All VMCs 69Linear Way VMCs 70

Load Meter Output 241

MMachine Maintenance 75



Machine Parameters 6323 PHASE NO 5% LOW NO 6385TH AXIS HEAD 644A-AXIS RATIO 635AIR VALVE FEEDBACK 645A-PALLET 644ASPECT 641AT SPEED 645AUTO BRAKE 643AXES X,Y,Z 634AXIS DISPLAY 643BAUD RATE 633B-AXIS RATIO 636BINARY BUFFERS 255 640B-PALLET 644CMD MENU 640CRC MODE 639DEFAULT G0 635DEFAULT G17 636DEFAULT G90 635DEFAULT INCH 638FORMAT 633G0 DETAIL 644GAIN 641HIGH TORQUE 640IMM. FIXED CYCLE 637IPM 642M60/A-AXIS BRAKE 635M62/B-AXIS BRAKE 636M7-FLOOD M8- MIST 638N-WORDS ORDERED 639ORIENTATION FACTOR 638OVERLOAD 642PALLET 641PENDANT 634PU FORMAT 639RAMP 641RPM FACTOR 637SCREW 642SPINDLE AFTER M6 633SPINDLE OFF 640SPINDLE TYPE 637TIMERS 641TOOL CHANGER 636TOOL TABLE 639



TRAVEL 634TURRET FACTOR 640VECTOR 643XYZ RAMP 642Z TAP GAIN 643

Menu Diagnostics 486Menu Page 1 486Menu Page 2 488Menu Page 3 488Menu Page 4 489Menu Page 5 489

Moving the VMC-Crane 55Moving the VMC-Fork Lift 54

OOutput Three Phase Power 240Oversized Diameter 278

PPallet Changer 431

Installation of Light CurtainMirror Alignment 437

Installation of Light curtain 436Installation of Pallet Changer 431Maintenance Schedule 444Operation 439

Manual Operation 440M-Functions 439Pallets 439

Setting the Sensor on the 1840 Board 438Purpose 438

Pallet Changer/Hydro Sweep 94Daily Maintenance 94Each Part Cycle 94Monthly Maintenance 95Weekly Maintenance 94

PCB-0213 Dual Arm ATC Controller Card 167Currents 169Description and Explanation of Operation of PCB-0213 (1330-0A) 167Functional Explanations 169Inputs 167LED Indicators 168Outputs 168

Phase Converter Rotary 68Positioning 44



Preferred Service 50Pre-Installation Procedures 41Primary Grounding 47Probes 371

MP-11 Probe 371MP-12 Probe 372TS-27 372

Probes & Scales 371

RRecommended Mainline Fuses / Circuit Breakers 39Rigid Tapping 260

Fadal Rigid Tapping Procedure 260Rigid Tap with AC-0017 Software 262

Rotary Tables 3414th Axis 341

Adjusting the Cold Start 351Balancing the Amplifier 344Connecting the VH-65 Motor Cable 342Evaluating the Following Error 345FADAL RT-175 360FADAL RT-225 361FADAL RT-275 362FADAL V-300 (V-400) Rotary Table 355FADAL VH-65 & VH-5C 354Horizontal Installation Difference(s) 343Installation 342Installing the Servo Control 343Maintenance 352Pre-installation 341Remove the Rotary Table from the Shipping Crate 342Rotary Set-Up 353Setting Backlash at the Control 345Setting the VH-65 Worm Gear Backlash 346Setting the VMC Parameters 344Setting the Voltage 345Squaring the VH-65 342Technara MD-200R 357Technara MD-300R 358Troyke NC-10 356Tsudakoma RNCV-401 359Verifying Air Brake Engagement 351

SScale Box Installation / Side Mount 416



Scale Box Installation / Top Mount 421Scales 373

1580 Board Setup 414Installing Scales 373

Scheduled Maintenance 75Cooling Fans 78Dual Arm Tool Changer 82

Cleaning 82Daily Maintenance 83Grease 82Inspection 83Lubricant 82Miscellaneous Maintenance 83Weekly Maintenance 83

Fuses, Heaters, & Relays 80Auger 80Fluids 80

Lubrication of the Ways 76Flushing a Contaminated Waylube System 77Waylube System 76

Maintenance & Lubrication Schedule 75Daily 75Every 4 months 76Weekly 75

Pump Filter 78Spindle & Ballscrew Cooling System 78Tank Reservoir 79

Pressure 79Source for Dowfrost 79

Sequence of Dual Arm-ATC Operation When Used With The Fadal Control 171DA-ATC Tool Change Cycle Fadal Control 172Feedback 171Part Numbers 171

Service Programs 581TA,2 Programs 581

O5801-45 Deg Test 581O5802-X Resolver Test 582O5803-Y Resolver Test 582O5804-Z Resolver Test 582O5805-Work Toolchanger 582O5806-Scrape Z Head 584O5807-X Vibration 584O5808-Y Vibration 585O5809-Z Vibration 585O5810-Orientation 586



O5811-Balance Inch 595, Metric 700ipm 302 586O5812-X Balance 680 587O5813-Y Balance 680 587O5814-Z Balance 680 588O5815-A or B 680 Balance 588O5817-Spin Fwd Rev 589O5818-Workout 2216 589O5819-Workout 4020 591O5820-Workout 6030 594O5821- X Calib 2216 596O5822 -Y Calib 2216 597O5823-X Calib 4020 597O5824 — Y Calib 4020 598O5825 — X Calib 6030 598O5826-Y Calib 6030 599O5828-Scrape 6030 Table 600O5829 — Mill 6030 Table 601O5830-Scrape 4020 Table 601O5831-Mill 4020 Table 603O5832-Scrape 2216 Table 603O5833-Mill VMC 2216 604O5834-Scrape 20 Table 605O5835-Test Scales 606O5836-Test Cut 607O5837-Probe Cycle Test 609O5838-Spindle Break In 610O5839-Pallet Changer 611O5840-Mill Pallet Table 614O5842-Engrave Pallet A 615O5843 — Center Bearing Assy. 615O5844-Mill VMC 20 616O5845-Mill VMC 15 617O6000-Rigid Tap Cycle 617

TA,2 ProgramsO5841-Mill Pallet Slot .687-.689 615TA,5 Programs 618

6001-Ballbar Test 625O5827-Cycle Test 618

Tool Offsets for the Service Programs 581Shipping Dimensions 43Single Phase Input Power 67Specification -Grounding for the Fadal machine

48Specifications 1Spindle Belleville Springs Quantity Chart 285Spindle Drawbar and Belleville Spring Replacement 283



Drawbar Removal 283Remove Floater (This will rarely be necessary.) 284Replace Belleville Springs 284

Spindle Drive Systems 239Adjustments 244

Adjusting the AMC Vector Drive 256Adjusting the Baldor Vector Drives 244Adjustments 257Auto Tuning/ Zero Balance 244Baldor Spindle Drive Parameter Usage for Fadal VMC 245LEDs 256Motor Mag Amps for INV-0070 250Non Rigid Tap Machines 259Pot Adjustments 258Pots 257Regenerative Resistors 254Rigid Tap Machines 259Switch Positions 256Switch Settings 258Terms and Procedures

245Velocity Monitor Output 256

Motors 26310 HP Motor 26315 HP Motor 26320 HP Motor 263WYE / DELTA Motors 264

Spindle Drives 239Spindle Duty Cycle 286Spindle Pre-Load 286

Measuring the Spindle Pre-Load 286Spindles 288

15K Air/Oil Spindle 2887.5K & 10K Grease Packed Spindles 288Adjusting Spindle Tram 293Component Installation 290

Control Board Mounting 291Installing Spindle Lubrication Pump 290Pressure Manifold Mounting 291Regulator/ Separation Block Mounting 290Solenoid Modification 291Vacuum Pump Installation 290

Spindle Tram 292Spindle/Lube Pump/Control 289

Supplemental Grounding 47



TTable & T-Slot Dimensions 33

15 & 2016L Table 3315, 15XT, 2216, 3016, 2016L & 3016L T-Slots 3415XT & 3016L Table 342216 & 3016 Table 333020, 4525 Table & T-Slots 353020, 4525, 6535 T-Slots 384020 Table 354020, 4020A, 5020A, 6030 & 8030 T-Slots 384020A & 5020A Table 366030 Table 366535 Table 378030 Table 37

Tap-Tap Cycle 282Test Cut Procedure 492Tests for CE Safeguards on Fadal Machines 98

Daily 99Daily & Weekly Safety Tests for CE Safety Circuits 99Door Interlock Monitor (2000-1A) Weekly Test 100Door Interlock Monitor Daily Test for 2000-1A or 1310-0C 99Door Interlock Monitor on Auger Board (1310-0C) Weekly Test 102Door Interlock Monitor Weekly Test for 2000-1 B or -1 C 101Dual Arm Tool Changer (1330) Daily Test 99Dual Arm Tool Changer (1330) Weekly Test 103Front Door Lock Daily Test for 2030-OA 99Front Door Lock Weekly Test for 2030-OA 103Pallet Changer (1100-3A) Daily Test 100Pallet Changer (1100-3A) Weekly Test 104Weekly 100

Tilting Rotary Tables, 4th & 5th Axis 363A & B Axis Position Loop Gain (1010-5) 365FADAL TR-65 363

Tools Sticking in the Spindle During a Change Cycle 2761. Air Supply Pressure 27610. Orientation Bridge "Lifting" 27811. Black Oxide Tool Holders 27812. Dirty Tool Holders 27813. Spring Pilot 27814. Spring Pilot 27915. Drawbar Scored 27916. Damaged Drawbar 27917. Damaged Floater 27918. Testing Procedure 2792. Drawbar Cylinder Hall Effects Switch 277



3. Insufficient Air VolumeMAC In-Line Valve 277

4. Air Leaks 2775. Air Leaks 2776. Air Leaks 2777. Air Leaks 2778. Air Leaks 2789. Air Leaks 278DRB-0024 Sticking Tools Kit, 10K LDB 281DRB-0025 Sticking Tools Kit, 10K LDB-CT= 281MEASURING DRAWBAR PERFORMANCE 280

Transformer Sensor 68Transformer Tapping 66Troubleshooting 497Troubleshooting Charts 536

UUnlocking Front Doors with CE Door Locks 53Unpacking 53

VVector Drive Encoder 9 pin Molex Connector 242Vector Drive with Rigid Tapping 243Verification - Check grounding integrity with Fluke meter 49VMC Test Cut 494

Part 495

WWiring 50

ZZero-Out Memory Procedure 105Zero-Out Memory Settings 107


Maintenance Manual - Flint Machine Tools

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