Rittal BC 1007 HS Manual Download

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Spindle Replacement Procedure – HSD 939

Perforex BC 1008/2014 HS and BC 1007/2007 HS

Note: The newer HSD 951 replacement is similar to the HSD 939 with the exception of the alignment
measurement noted in Section 3.17.2.

3.17.1

Removal



Before powering down the machine, move the Y-Axis to a comfortable position for
maintenance and full access to the top and bottom of the spindle. A lift cart works well
as a work bench, if jacked directly beneath the spindle assembly.



Once you have the spindle in a good working position, Power Down the machine and
properly lock out/tag out according to company procedures.



Shut off and lock out the machine air supply.



Remove the outer and inner spindle

covers.



The outer cover has four screws, two

on top and two on the bottom.



The inner cover has multiple screws

along the spindle face flange and screws
under the outer cover.

Summary of Contents for BC 1007 HS

Page 1: ...revisions Important The maintenance procedures discussed in this manual should only be performed by trained individuals Extreme caution should be used when changing any machine parameter or setting Consult Rittal Automation Systems Technical Support prior to any change The user takes full responsibility for any unintended results ...

Page 2: ... Pressure Plate 8 Rotating Clamp system 9 Linear Bearings 9 2 5 1 Recommended Lubricant 9 2 5 2 Recommended Grease Gun 10 2 5 3 Grease Points 10 3 0 Preventative Maintenance 12 Pressure Plate 13 3 1 1 Pressure Roller Cleaning 13 3 1 2 Pressure Roller Replacement 14 Pressure Plate Guides 15 3 2 1 Cleaning 15 3 2 2 Pressure Plate Removal 15 3 2 3 Pressure Plate Replacement 16 Vacuum Seal Replacement...

Page 3: ...Chip Trap Dropout 22 3 5 5 Vacuum Seal 22 3 5 6 Testing the Vacuum System F Test Manual Operation 23 Spindle 23 3 6 1 Spindle Chuck 23 3 6 2 Cooling Fan 24 Tools 24 Tool Breakage Sensor 25 Clamping System 25 3 9 1 Panel Clamp Cleaning and Lubrication 25 3 9 2 Enclosure Clamp Cleaning 25 Electrical Enclosure 26 3 10 1 Fan Intake and Exhaust Filters 26 3 10 2 Electrical Power Incoming Voltage 26 3 1...

Page 4: ...ng V05 20 05 with V05 20 15 Module 36 Spindle Servo Drive Module 38 3 15 1 Removal 38 3 15 2 Replacement 41 X Y Z Servo Drive Modules 42 3 16 1 Removal 42 3 16 2 Replacement 45 Spindle Replacement Procedure HSD 939 46 3 17 1 Removal 46 3 17 2 Replacement 52 3 17 3 Spindle Proximity Sensors Location and Troubleshooting 53 3 17 4 Spindle Sensor Adjustments 58 3 17 5 HSD Spindle Parts 61 X Axis Motor...

Page 5: ...Test Program 75 3 21 2 Axis Alignment IB Start Drilling 75 3 21 3 Axis Alignment Step Operation 76 3 21 4 Correcting the Axis Base Offset Value 77 Air Pressure Cutout Switch 80 3 22 1 Pressure Switch Troubleshooting 80 3 22 2 Pressure Switch Electrical Checks 80 Pneumatic Valve Locations 82 3 23 1 Clamping Valve Blocks 82 3 23 2 Spindle Valve Blocks 83 3 23 3 Lubrication Valve Blocks 84 Clamping S...

Page 6: ...fluid lubrication system is located on the spindle carriage to the right of the spindle Loosen the thumb screws located under the spindle carriage to open the cover Check the oil reservoir sight tube shown below to check the oil level If oil is needed unscrew the metal cap on the top of the reservoir body fill and then re install the cap Note Always keep the fluid level above 50 for best operation...

Page 7: ...umber 4050 862 2 2 2 Checking and Filling The rack and pinion lubrication system is located on the spindle carriage to the right of the spindle Loosen the thumb screws located under the spindle carriage to open the cover Check the oil reservoir cup shown below If oil is needed unscrew the cup from the reservoir body fill to the upper Max line and then re install the oil cup ...

Page 8: ...such as 3 in 1 Super Lube or air tool oil Clean the guide shafts before lubricating Note When the compressed air to the machine is turned off the pressure plate should move freely If movement is not smooth and without binds refer to Section 2 2 for proper pressure plate maintenance procedures ...

Page 9: ...r clamping Linear Bearings Each axis X Y Z Enclosure table has four linear bearings with grease inserts 16 total Note It is important that only a recommended grease gun be used to grease the bearings The standard North American grease gun will lock on the grease fitting removing it could tear the grease insert out of the bearing housing 2 5 1 Recommended Lubricant The recommended lubricant used fo...

Page 10: ...gun will not lock onto the grease fitting it will seal against it when filling the bearing Another disadvantage with the standard grease gun is that the tip will not fit between the spindle mounting plate and the Y Axis linear ways To order contact Rittal Automation Systems technical support 2 5 3 Grease Points X Axis Locations o Two on the upper linear guide rail right left upper end of the gantr...

Page 11: ...hoto o Moving the Y Axis may be required to gain access to these grease locations Z Axis Locations Note Removal of the spindle covers will be required to grease the two fittings furthest from the spindle chuck o Two bearings will be located on the linear guide rail near the spindle chuck and two on the opposite end of the spindle near the spindle fan Motorized Table for enclosure clamping o Two be...

Page 12: ...ht curtain sensors Weekly Drain compressed air water trap Weekly Check and clean the vacuum empty the shaving bin Monthly Check and clean the electrical cabinet filters Monthly Check and clean all linear bearing rails Monthly Check and clean all pinion racks Monthly Check and clean pinion rack for enclosure clamping system Monthly Remove all support pegs and inspect for excessive damage Monthly Cl...

Page 13: ...er day depending on the amount of machine usage Metal shavings will become lodged in the recesses of the pressure roller and possibly stop the movement Use a face shield and gloves when cleaning the pressure rollers Focus compressed air on the center of the pressure roller hub between the upper and lower rollers this will make the roller spin and force the metal shavings out of the recesses Do not...

Page 14: ...ps at each end of the roller shaft and the newer have a bolt with a nut located at the bottom o For the machines with C clips remove the lower C clip and lift the shaft up to remove the pressure roller o For the machines with a bolt and nut remove the bottom nut and lift the bolt up to remove the pressure roller Install new rollers as the shaft is lowered back into its normal position Re install t...

Page 15: ...re Plate Removal The pressure plate can be removed for maintenance cleaning To remove Turn off air pressure to the machine Disconnect the vacuum hose Remove the tool lubricant nozzle and hose Remove the cylinder nut from the face of the pressure plate Remove the lower guide bolt Remove the upper guide bolt The pressure plate should be free of the machine and can be moved to a workbench for service...

Page 16: ...ng the guide shafts be sure that the Guide Shaft end stops line up with the end stop bolts and they do not contact the spindle mounting plate When the pressure plate is fully installed the plate should slide in and out freely When compressed air is turned off If a bind is felt adjust the alignment of the upper and lower guide bolts and recheck the movement The pressure plate must be evenly spaced ...

Page 17: ... the seal starts to deteriorate Replacement can be done while the pressure plate is on the machine Remove the six retention screws and metal wedge rings Pull out the old vacuum seal Clean the vacuum seal seat with solvent or cleaner Install the new seal and align the cutout for the tool lube nozzle Replace all six retention screws and wedge rings ...

Page 18: ...rication override valve See Section 3 23 3 for valve location Place a piece of paper or cardboard in front of the spray nozzle for about 2 3 seconds A light film of oil should appear but should not be enough to run or drip down the paper or cardboard If you see an oil fog or cloud when milling the adjustment is set too high Refer to Section 3 4 4 for oil adjustment Turn off the pneumatic valve man...

Page 19: ...ustment knob stop post 2 Turn the adjustment knob past the stop or depending on the direction you are trying to adjust 3 Replace the adjustment knob stop post This will allow one more revolution for more or less oil flow Note The amount of oil delivered to the tool should not create a fog or cloud of mist 3 4 5 Oil Conversion from MK 150 to MK 200 Due to the higher viscosity of the MK 200 20 mm fr...

Page 20: ...st angle Drill tap or mill a machined surface Visually check the machined surface and look for oil residue o If oil residue could not be seen turn up the mist volume see Section 3 4 3 When the angle of the mist is correct o of the residue should be above the cut when not using the pressure plate o of the residue should be above the cut when using the pressure plate Adjust the spray angle if needed...

Page 21: ...llection of metal The on off switch will remain in the on position the Perforex software will energize the vacuum circuit when needed by the application 3 5 2 Vacuum Hose The flexible vacuum hose connects the vacuum intake to the pressure plate assembly Check the suction at the pressure plate regularly to insure there are no blockages within the hose To reduce the possible blockages empty the Chip...

Page 22: ...hip Dropout requires the operator to pull down while twisting the trap discard the debris and re insert the cup into the manifold 3 5 5 Vacuum Seal The Vacuum Seal is a foam rubber seal that increases the air flow around the milling tool and helps vacuum the metal shavings away from the cut Daily cleaning of the vacuum seal is required to remove metal shavings and cutting oil Do not use chemicals ...

Page 23: ...ould highlight and appear depressed 4 Locate the output for Vacuum On Spänesauger Ein and select that line item 5 Toggle the output using the associated F Keys When you close the F test screen all over rides will be reverted to normal operation Spindle The Spindle usually requires minimal maintenance however the areas below can reduce possible problems 3 6 1 Spindle Chuck The spindle chuck can ret...

Page 24: ...SD ES 939 but all locations will be the similar Tools The tools should be checked daily for Dirt or dust buildup on the tool holders Look for dark spots on the surface of the tool holder this will indicate a buildup of residue Metal cuttings lodged in the tool or the collet o Metal cuttings lodged in the tool will cause Halos or circular scratches in paint and stainless steel Remove any that colle...

Page 25: ...s Used for clamping Junction Boxes and Enclosures Each of these systems require some preventative maintenance and cleaning 3 9 1 Panel Clamp Cleaning and Lubrication The lower automated clamping systems incorporates a rotation movement and a clamping action Both movements require the cleaning and lubrication of the shafts See Section 2 5 Rotating Clamp System for more details 3 9 2 Enclosure Clamp...

Page 26: ...pull up on the upper Rittal tab and pull out on the filter cover Remove the filter and clean with compressed air or replace if needed 3 10 2 Electrical Power Incoming Voltage Have a qualified electrician check the incoming voltage annually to insure that the machine is receiving between 380 405vac 3 3 10 3 Air Pressure Cutout Switch When air pressure drops below 4 bar pressure the machine should s...

Page 27: ...Machine Parameters Maintenance To locate the Maintenance page o Select 3 Service 1 Machine 1 Machine Parameters o Select the Maintenance tab o Select the maintenance item completed Usually displayed in red if due o Pressing SHIFT F5 will enter the current production hours and restart the PM count down for the selected item o Only one item can be selected at a time If multiple PM items need to be r...

Page 28: ...ce for turning on control power Acknowledge Safety Barrier Control Power On and Servo Power On o E DARC C controllers will have a two button start sequence for turning on control power Acknowledge Safety Barrier and Control Power On Open the electrical enclosure and look at the servo drive modules and compare Note BC 2014 HS machines will have one additional servo drive known as Axis X2 This drive...

Page 29: ...put leads from the bottom of 110T1 Using a multimeter check for resistance between o L1 to Ground Should read o L2 to Ground Should read o L3 to Ground Should read o L1 to L2 Should not indicate low resistance or short o L2 to L3 Should not indicate low resistance or short o L1 to L3 Should not indicate low resistance or short If a short to ground or low resistance is measured on any input lead it...

Page 30: ...successive against U V and W In this circuit the multimeter should show a forward bias of about 0 42v Many digital multimeters make a short beep If the voltage ok skip to step 3 13 4 If the forward voltage is under 0 42v or a continuous beep the diode is likely inoperative Reverse the polarity of the multimeter and repeat the measurement above When the polarity is reversed the multimeter should no...

Page 31: ...31 3 13 3 Reverse Polarity The procedure and the results of the measurement with L is the same as noted in section 3 13 2 Please pay attention to the reverse polarity of the multimeter leads ...

Page 32: ...nce check is ok the diodes may still be damaged Checking the circuits for short circuit is the same as in Section 3 13 2 and 3 13 4 but polarity does not matter The value of the resistance should be between 1 4 to 1 6 MΩ If the measured value is lower you could have a short circuit in a diode In this case you must check the diodes with a digital multimeter with step 3 13 2 and 3 13 4 before you tu...

Page 33: ...ring Remove front cover by pushing down on the cover indentation below the yellow caution sticker and pull cover away from the Servo Controller Lift straight up to disconnect the upper hinge Disconnect cables from X6 X10 Note the DIP switch settings for S1 Address 1 and S2 Can Bus Baud rate 1 Mb s DIP switch 1 should be set with bottom switch on left and all others off right DIP switch 2 top three...

Page 34: ...from servo drive 111T1 to the left of the servo control module Remove the three bus bar screws from 111T1 and the bus bars connected to 110T1 All the cables should now be disconnected be sure to cut the small zip ties that retain the wires to the module housing Loosen the upper and lower mounting screws there is no need to completely remove them from the backing plate Lift the Power Control Module...

Page 35: ...have been terminated and checked remove the lock out and power can be applied to the machine When first starting up leave the electrical cabinet door open and observe the startup sequence on the servo drives After cycling through a sequence of numbers 3 4 5 7 an error code of 6 3 2 0 will cycle on most of the servo drives The Power Control Module will have LED 1 2 3 on or flashing green LED BTB wi...

Page 36: ...e four screws that retain the upper front face of the Power Module You will need to remove the seal in the lower right to reveal the lower right screw Pull the front face off of the module but take caution when manipulating the wiring Locate the FBIR40 card as shown in the photo Remove the two mounting screws and remove the FBIR40 card Be sure to refer to the note below when installing firmware fo...

Page 37: ...37 Note When installing the firmware for the first time an additional message will appear Answer Yes to this message to accept the changes then install the firmware and parameters from the hard disk ...

Page 38: ...ve string for all BC 2014 machines it is one module from the left It is considerably larger in height than the other modules Remove front cover of the C Axis and Z Axis BC 2014 remove X2 also servo modules by pushing down on the cover indentation below the yellow caution sticker and pull cover away from the Servo Controller Lift straight up to disconnect the upper hinge Disconnect cables from X15 ...

Page 39: ...l not come ready BC 2014 machines the termination plug will be in the X2 module Mark the cables connected to X5 located on the lower edge of the controller U V W PE These cables should have a printed number on each cable of 1 2 3 but to insure they are re installed correctly it is a good practice to mark them anyway Disconnect the cables on X5 ...

Page 40: ...4T1 BC 2014 the above step will have to be done on the X2 Axis also All the cables should now be disconnected be sure to cut the small zip ties that retain the wires to the module housing Loosen the upper and lower mounting screws there is no need to completely remove them from the backing plate Lift the Servo Control Module off the mounting screws and set it aside ...

Page 41: ...l connections have been terminated and checked remove the lock out and power can be applied to the machine Note When first starting up leave the electrical cabinet door open and observe the startup sequence on the servo drives After cycling through a sequence of numbers 3 4 5 7 The Power Control Module will have LED 1 2 3 on or flashing green LED BTB will be on Telling us that we installed the ter...

Page 42: ...1 o Y Axis 112T1 o Z Axis 113T1 Remove front covers of the servo drives by pushing down on the cover indentation below the yellow caution sticker and pull cover away from the Servo drive Lift straight up to disconnect the upper hinge Disconnect cables from X15 X16 Encoder cable and I O cable On the top of the drive disconnect X20 Blue White 24vdc wires and the ribbon cable that connects to the ser...

Page 43: ...5 located on the lower edge of the controller U V W PE These cables should have a printed number on each cable of 1 2 3 but to insure they are re installed correctly it is a good practice to mark them anyway Disconnect the cables on X5 ...

Page 44: ... as the connecting bus bars to 114T1 All the cables should now be disconnected be sure to cut the small zip ties that retain the wires to the module housing Loosen the upper and lower mounting screws there is no need to completely remove them from the backing plate Lift the Servo Drive Module off the mounting screws and set it aside ...

Page 45: ...e applied Once all connections have been terminated and checked remove the lock out and power can be applied to the machine Note When first starting up leave the electrical cabinet door open and observe the startup sequence on the servo drives After cycling through a sequence of numbers 3 4 5 7 The Power Control Module will have LED 1 2 3 on or flashing green LED BTB will be on Telling us that we ...

Page 46: ...nd full access to the top and bottom of the spindle A lift cart works well as a work bench if jacked directly beneath the spindle assembly Once you have the spindle in a good working position Power Down the machine and properly lock out tag out according to company procedures Shut off and lock out the machine air supply Remove the outer and inner spindle covers The outer cover has four screws two ...

Page 47: ...ll give us a true position or alignment of the spindle plate in relation to the Z Axis pinion gear when reassembling The Z Axis is moved by a rack and pinion gear system When removing the spindle mounting plate the Z Axis pinion rack will be removed as well it is mounted to the spindle plate Mark Location with Felt Pen ...

Page 48: ...ion gear and the pinion rack will make calibrations much easier once the job is complete Unfortunately it is impossible to mark the positions while the assembly is installed The upcoming procedure should help keep the alignments correct ...

Page 49: ...ck We want to remove the existing pressure being applied to the pinion and rack Be sure not to move the pinion gear while removing the spindle this will throw off the final calibrations after the new spindle is installed It is important that the very top pinion gear tooth gets re installed into the corresponding rack location This is the reason to mark the positions of the linear way bearings and ...

Page 50: ...nector forward or away from the machine Please see the attached photos Note The HSD 951 has slightly different electrical and air connections Disconnect the solenoid wire by using the turn locking nut Secure all the electrical cabling out of the way of the spindle Mark all the air hoses that connect to the spindle making note of their orientation Remove lines and secure them safely out of the way ...

Page 51: ... bearings each bearing has four bolts fastening the motor mount plate to the linear way bearing Once the motor is supported remove the mounting bolts from the lower linear way bearings then carefully remove the bolts from the top linear way bearings The motor and mounting plate should now be free of the machine and can be placed on a work surface The motor mount plate can be removed from the motor...

Page 52: ...r way bearings be sure to keep them in their original position which was marked before removal This will correctly align the Z Axis rack to the pinion gear Reinstall the spindle mount plate to the linear way bearings and tighten the 16 mounting bolts Now that the spindle and mount plate are back in place the Z Axis adjustment bolt can be tightened slightly so that the pinion gear firmly meshes wit...

Page 53: ...e Proximity Sensors Location and Troubleshooting Note The information in Sections 3 17 3 3 17 5 pertains to the HS 939 Electro Spindle For the HS 951 refer to the HSD CD which was shipped with the machine documentation ...

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Page 55: ...55 ...

Page 56: ...unted in a brass eccentric bushing It is important to mark each sensor showing the exact rotation of the sensor This will make reassembly and calibrations much easier o Sensor 1 and 5 will operate the Tool in Spindle Clamped feedback Clamped and Present Both feedbacks are required for a Tool in Spindle Clamped ON signal o Sensor 2 operates the Tool in Spindle Ejected feedback but also requires Too...

Page 57: ...s received sensor S1 has failed If a Tool in Spindle Clamped is still not received mark the rotation of sensor S5 and place a metal object near the tip of sensors S1 and S5 o Signal received sensor S5 needs to be adjusted o Signal not received sensor S5 has failed o Once complete be sure to install all the sensors with the same original orientation the eccentric bushing should match the same rotat...

Page 58: ...tation of the eccentric bushing the sensor S1 or S5 could be defective S5 and S1 are in series a failure of either sensor could hinder a Spindle Clamped feedback Adjusting sensor S2 Tool Ejected 1 View the F Test Inputs tab ALT F1 See Figure 3 below 2 Press the Tool Eject button on the front of the spindle covers 3 Observe the inputs Tool Chuck Release Button and Tool in Spindle Ejected a The Tool...

Page 59: ...59 Figure 2 Tool in Spindle Clamped Feedback ...

Page 60: ...60 Figure 3 Tool in Spindle Ejected Feedback ...

Page 61: ...00601 HSD Spindle Sensor 2 Drawbar Down Tool Eject o A4180500601 HSD Spindle Sensor 3 Long Drawbar o A4180500601 HSD Sensor 5 Piston at Upper End Stop o 5664H0026 Fan Assembly o AH5661H0009 o Rittal PN 5051 502 Note On all HS 939 spindles sensors 1 4 use the 2 sensor ...

Page 62: ...sen the motor grub screws these do not exist in earlier models 2 For ease of motor removal remove both grub screw mounts right and left from the gantry frame 3 Be sure the motor is supported with a jack or wooden blocks 4 Remove the four mounting bolts which hold the motor gearbox to the gantry frame 5 Lower the motor and slide it toward the rear of the machine to give access to the two cable conn...

Page 63: ...low the previous steps in reverse order but insure of the following items Be sure that the pinion gear mount screw is tight Be sure that the gearbox coupling is tight Firmly secure the pinion to rack by using the grub screw mounts Tighten until snug but do not exert an excessive amount of torque on the grub screws Tighten locking nuts when completed Contact Rittal RAS Technical Support to remotely...

Page 64: ...an view the Y Axis from the top Note When removing the Y Axis the spindle assembly must be supported with either the original shipping bracket a jack forklift or overhead crane The motor brake is the only means of supporting the weight of the spindle assembly and will fall if not supported properly If the Y Axis can be jogged using DARC Service continue with the next step If the Y Axis is inoperab...

Page 65: ...gearbox coupling Use a flashlight to locate the Allen screw that tightens the coupling You may have to raise or lower the Y Axis several times to get the correct alignment DO NOT LOOSEN THIS COUPLING UNTIL THE SPINDLE IS SUPPORTED Figure 2 Access Plug and Cabling Coupling Access Plug Motor Cables ...

Page 66: ... safely to the side of the motor to ensure they do not get damaged Loosen the motor gearbox coupling using a 5mm Allen wrench See Figure 3 Loosen the four mounting bolts that secure the motor to the gearbox Only one can be seen from the photo below Carefully slide the Y Axis motor off the gearbox coupling Figure 3 Coupling Access Port Mount bolts ...

Page 67: ...e removal of the gearbox pinion housing and motor as one assembly Disconnect the encoder cable and the power cable that are attached to the motor See Figure 2 Insure that the spindle assembly is supported before moving to the next step Gearbox Mount Gearbox Motor Figure 4 Pinion Housing Gearbox Motor and upper mount bolts ...

Page 68: ... impossible to use a standard Allen wrench due to the tight proximity to the objects next to the gearbox Loosen the 10 mm locknut grub screw that locks the pinion housing tight to the gear rack This grub screw will need to be unscrewed until it is flush with its mounting block to provide space for the pinion housing to clear the rack gear Some older machine may not have this grub screw assembly Fi...

Page 69: ...ed in Figure 4 and carefully move it away from the gear rack to gain access to the lower pinion lubrication hose Remove the lower pinion lubrication hose Slide the motor gearbox assembly out of the machine and place on a working surface Upper Lube Line Grub Screw and Lock Nut Figure 6 Gearbox Grub Screw and Lube Line ...

Page 70: ...to the Section 3 19 3 Pinion Gear Replacement 3 19 3 Pinion Gear Replacement To replace the pinion gear the motor and gearbox must be removed first Y axis only remove the four bolts nuts that secure the gearbox mount remove the mounting plate Using an Allan wrench remove the pinion gear bolt and washer Remove the pinion gear using a gear puller Reinstall the new pinion gear and Y axis gearbox moun...

Page 71: ...motor and preform the initial Master Reference of the motor encoder Once the Master Reference has been accomplished the axis will need to be calibrated and the Base offset established Do not attempt to pick up a tool until the calibration has been performed the spindle will collide with the tool magazine Refer to Calibrating the Base Offset procedure Preforming an Axis Master Reference Note TRAINE...

Page 72: ... that you wish to adjust It will highlight in blue 4 Select Homing from the drop down box below the axis as the action to perform 5 Acknowledge the safety barrier turn on control power and servo power 6 Press start from the Work Area screen The axis will move to the home position 7 On the far left side of the screen right click the axis desired ...

Page 73: ... connected turn control power and servo power back on This may generate an error saying the drive was not ready simply try this step again 12 When the Master Reference is complete the software will generate a new Master Reference value between 0 65 536 33 000 being the best If the value generated is less than 20 000 or greater than 50 000 the reference switch will need to be moved slightly and thi...

Page 74: ...the parameters are correct before saving permanently this cannot be undone To properly save the machine parameters 1 Navigate to 4 System 4 Darc Service 2 Right click Parameter Sets and select Connect from the list of options 3 Right click Parameter Sets 4 Select Save all Parameters Permanently or if in German Alle Geräte speichern dauerhaft 5 When asked to save to hard disk select Yes Note Be sur...

Page 75: ...follow the steps below 3 21 1 Axis Alignment Test Program To correct axis alignment a test program will be created with one drilled hole Create a main program containing one drilled hole preferably a smaller drill Give the Single Process SP the coordinates of 100mm in X and Y An accuracy measurement will be taken to compare the target and actual position Install a scrap test panel which will corre...

Page 76: ... the spindle It may be a good idea to slow down the speed override potentiometer for safety o When the hole has been drilled measure the X Y position of the hole in reference to X Y 0 00 Calculate the difference between the actual measurement and the target coordinates Record these values for use in the next step o Proceed to Section 3 21 4 ...

Page 77: ...77 3 21 4 Correcting the Axis Base Offset Value To determine the proper Base Offset o Go to 4 System 6 CNC 1 ExC Settings o Select Drive Parameters from the left menu and double click the desired axis ...

Page 78: ...78 o Select the Calculate Base Offset button in the lower portion of the popup screen ...

Page 79: ... in use o Exit out of ExC Settings o Modify the test main program and shift the drill SP and run a test of one drilled hole o Confirm that the test hole is in the correct location on the panel If the hole is in the correct position the base offset is complete proceed to the next step If the hole is different than what was expected re start this procedure o Go back to 3 Service 1 Machine 1 Machine ...

Page 80: ...e adjust the air pressure to just under 5 bar o If the state of 301B5 did not change adjust the adjustment screw on the top of 301B5 up until the indicator light switches state HMI should display a fault message o If after adjusting the pressure switch the state does not change the pressure switch may have water in it or may have failed In this case we need to replace it o Be sure to adjust the ai...

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Page 82: ...Clamping Valve Blocks All of the clamping valve blocks are located on the lower left side of the machine frame beside the electrical enclosure Valve Purpose Location Manual Operation Panel Clamps Clamp Unclamp Inner Has direct contact with the mounting plate No Panel Clamps Rotate Middle No Enclosure Clamps Outer Yes Caution Do not override the Enclosure Clamps for more than one second without dir...

Page 83: ...he spindle The photo below helps to define their purpose The Spindle Valve Blocks are located to the right of the spindle left side of the auto lubrication panel Valve Purpose Location Manual Operation Pressure Plate Extend Inner Has direct contact with the mounting plate Yes Spindle Cleanout Middle Yes Tool Release Outer Yes ...

Page 84: ...Lubrication Valve Blocks are located on the right side of the auto lubrication panel Valve Purpose Location Manual Operation Rack and Pinion Lubrication Inner Has direct contact with the mounting plate Yes Minimal Tool Lubrication Outer Yes ...

Page 85: ...check the associated actuator No rotation on all clamps Check lubricate or replace the clamp rotation valve Located on the lower left frame of the machine Visually inspect the I O lights on the solenoid block for an input from the PLC Replace the valve or solenoid No clamping action at the clamps Check lubricate or replace the clamping valve Located on the lower left frame of the machine Visually ...

Page 86: ...86 4 0 Perforex Error Codes The error list below pertains to the DARC2 servo systems For RTE and E DARC C systems contact Rittal Automation Systems technical support DARC2 Error Codes ...

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