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TRAK Machine Tools

Southwestern Industries, Inc.

TRAK VMC Mills with ProtoTRAK RMX CNC Safety, Installation, Maintenance, Service & Parts List

1.0 Safety

The safe operation of the TRAK VMC depends on its proper use and the precautions taken by each
operator.

•

Read and study this manual and the ProtoTRAK VMC Programming, Operating, and Care
Manual. Be certain every operator understands the operation and safety requirements of this
machine before its use.

•

Never run the machine with enclosure doors open when in production ops.

•

Always wear safety glasses and safety shoes.

•

Always stop the spindle and check to ensure the CNC control is in the stop mode before
changing or adjusting the tool or workpiece.

•

Never wear gloves, rings, watches, long sleeves, neckties, jewelry, or other loose items when
operating or around the machine.

•

Use adequate point of operation safeguarding. It is the responsibility of the employer to
provide and ensure point of operation safeguarding per OSHA 1910.212 - Milling Machine.

1.1 Safety Publications

Refer to and study the following publications for assistance in enhancing the safe use of this machine.

Safety Requirements for Machining Centers and Automatic, Numerically Controlled Milling,
Drilling and Boring Machines

(ANSI B11.23-2002) (R2007). Available from The American National

Standards Institute, 1819 L Street N.W., Washington D.C. 20036

Concepts and Techniques of Machine Safeguarding

(OSHA Publication Number 3067). Available

from The Publication Office - O.S.H.A., U.S. Department of Labor, 200 Constitution Avenue, NW,
Washington, DC 0210.

1.2 Danger, Warning, Caution, Note Labels & Notices As Used In This Manual

DANGER

- Immediate hazards that

will

result in severe personal injury or death. Danger labels on the

machine are red in color.

WARNING

- Hazards or unsafe practices which

could

result in severe personal injury and/or damage to

the equipment. Warning labels on the machine are orange in color.

CAUTION

- Hazards or unsafe practices, which

could

result in minor personal injury or

equipment/product damage. Caution labels on the machine are yellow in color.

NOTE:

Call attention to specific issues requiring special attention or understanding.

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Содержание VMC10

Страница 1: ...arts List Covers Current Models TRAK VMC5 TRAK VMC7 TRAK VMC10 Document P N 31551 Version 051820 2615 Homestead Place Rancho Dominguez CA 90220 5610 USA T 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales trakmt com service trakmt com web www trakmt com ...

Страница 2: ... the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders TRAK Machine Tools Southwestern Industries Inc 2615 Homestea...

Страница 3: ...ing the VMC 16 2 5 1 Releasing the Head Support Bracket 19 2 6 Leveling Procedure 19 2 6 1 Leveling Pad Specifications 19 2 6 2 Leveling Procedure 20 2 6 3 Adjusting Level for Tram 21 2 7 Shortages Inventory Checklist 21 2 8 Electrical Connection 23 2 8 1 Main Power to the Machine Connections 24 2 8 2 Transformer Option 25 2 9 Air Connection 25 2 9 1 Air Regulators and Solenoids 26 2 10 Placing th...

Страница 4: ... Stop Error 51 3 3 7 Overlay Keys Not Responding 54 4 0 Automatic Tool Changer Operation and Service Codes 56 4 1 Tool Changer Operation 56 4 2 Spindle Orientation 56 4 3 Tool Change Height 56 4 4 Tool Changer Sensors 57 4 4 1 ATC Home Position Sensor 57 4 4 2 ATC Counter Sensor 58 4 4 3 ATC Tool Detect Sensor 58 4 4 4 ATC In 60 4 4 5 ATC Out 60 4 4 6 Tool Unclamp 60 4 4 7 Tool Clamp 61 4 5 ATC Fl...

Страница 5: ...on Machine 79 5 1 6 Electronic Handwheel Option 79 5 1 7 Electronic Handwheel and Sensor Replacement 82 5 1 8 Auger Motor Coolant and Coolant Wash Down Pump Replacements 83 5 1 9 Servomotor Replacement 86 5 2 Maintenance 90 5 2 1 How to Clean the Touchscreen 90 5 2 2 Periodic Maintenance 90 5 3 Laser Calibration 91 5 3 1 Accuracy 91 5 3 2 Code 123 Calibration 91 5 3 3 Calibration Table 92 6 0 Intr...

Страница 6: ...12 Milling Machine 1 1 Safety Publications Refer to and study the following publications for assistance in enhancing the safe use of this machine Safety Requirements for Machining Centers and Automatic Numerically Controlled Milling Drilling and Boring Machines ANSI B11 23 2002 R2007 Available from The American National Standards Institute 1819 L Street N W Washington D C 20036 Concepts and Techni...

Страница 7: ...Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Safety Information Labels Used on The TRAK Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels ...

Страница 8: ...3 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Safety Information Labels Used on The TRAK Milling Machines ...

Страница 9: ...4 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Safety Information Labels Used on The TRAK Milling Machines ...

Страница 10: ...5 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Safety Information Labels Used on The TRAK Milling Machines ...

Страница 11: ...Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Safety Information Labels Used on The TRAK Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels ...

Страница 12: ...Production Operation 1 000 ipm rapid 8 000 maximum rpm Interlocked door ATC Automatic Tool Changer operation Auto spindle start after tool change Full 3 Axis operation Tool Room Operation 400 ipm rapid 5 000 maximum rpm Programs run with door open or closed No ATC operation Manual Spindle by operator Allows manual 2 axis and 3 axis operation Figure 1 3 shows the VMC Console Programming Panel and R...

Страница 13: ...r or brush Before you make an adjustment to the part fixture coolant nozzle or take measurements Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard 11 Protect your eyes and the machine as well Don t use compressed air to remove the chips or clean the machine 12 Disconnect power to the machine before you change belts pulley and gears 13 Kee...

Страница 14: ...quired result in accidents and damaged parts 25 Inspect the retention knobs for damage or excessive wear before each use 26 Prevent fires When machining certain materials magnesium etc the chips and dust are highly flammable Obtain special instruction from you supervisor before machining these materials Keep flammable materials and fluids away from the machine and hot flying chips 27 Always be cer...

Страница 15: ...Series Machining Centers IMPORTANT Read and understand this entire installation section before beginning the VMC installation 2 1 Installation Requirements Before an Authorized Field Service Technician can perform the machine s final checkout detailed requirements must be met Please refer to the Site Preparation Guide for the needed set up for your specific VMC model ...

Страница 16: ... TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List 2 2 Overall Dimensions VMC 5 VMC 5 Front View VMC 5 Left Side View ...

Страница 17: ...12 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List VMC 7 VMC 7 Front View VMC 7 Left Side View ...

Страница 18: ...13 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List VMC 10 VMC 10 Front View VMC 10 Left Side View ...

Страница 19: ... IN THESE AREAS It may be necessary to move the table saddle and head left and right up and down when cleaning 3 Clean the way covers as they come shipped with a rust prevention spray on them WD 40 works well to remove this agent 4 When cleaning the windows use a suitable cleaner that DOES NOT contain ammonia or solvents that could damage the polycarbonate windows Warning Do not use water based cl...

Страница 20: ... and or moved with a forklift with a minimum capacity of 15 000 lbs from the rear of the machine or from either side Make certain that the blades of the forklift are completely through the casting cutouts beneath the machine before lifting as shown in Figures 2 4a 2 4b Figure 2 4a Fork Lift with VMC5 Cargo Figure 2 4b Detail of Fork lift blades set in VMC base and proper set up of Leveling Pads ...

Страница 21: ...uctions to assemble will be found in the kit Optional Equipment 3 Remove the 5 M6x15 SHCS that secure the saddle and table support brackets and remove the brackets See figure 2 5 a 4 Remove the 4 M12x40 SHCS that secure the column support bracket from the table and the head but DO NOT ATTEMPT TO REMOVE THE SUPPORT AT THIS TIME See figure 2 5 b 5 Remove the ATC cover left Remove the M8x60 SHCS that...

Страница 22: ...17 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Figure 2 5 b Figure 2 5 c ...

Страница 23: ...18 TRAK Machine Tools Southwestern Industries Inc TRAK VMC Mills with ProtoTRAK RMX CNC Safety Installation Maintenance Service Parts List Figure 2 5 d Figure 2 5 e ...

Страница 24: ...ervos on 4 Run SERV CODE 505 select EHW select Z axis using 0 01 resolution 5 Slowly rotate Z EHW clockwise to raise Z Axis off head support bracket 6 Remove support 2 6 Leveling Procedure Leveling the VMC in the field consists of leveling the machine and then adjusting the level if necessary to make sure the tram of the spindle is perpendicular to the table Refer to figure 2 6 1a or 2 6 1b for th...

Страница 25: ...he same If not have the level recalibrated 3 On the VMC7 and VMC10 leveling is achieved by using leveling screws R1 R2 L1 and L2 See figure 2 6 1b Adjusting screws R3 and L3 should be left loose with the leveling pads and have no pressure at this time A 36 mm wrench is required to adjust the leveling bolts 4 On the VMC5 leveling is achieved by using leveling screws R1 R3 L1 and L3 See figure 2 6 1...

Страница 26: ... the R3 and L3 leveling bolts to adjust the tram within specification This will tend to help adjust any error you have in the Y axis for the tram By adjusting these bolts you can in affect slightly affect the column and bring in the tram 3 If the tram measurement is not 0008 TIR on the VMC5 adjust the R2 and L2 leveling bolts to adjust the tram within specification This will tend to help adjust an...

Страница 27: ... Safety Installation Maintenance Service Parts List Loose Accessories Checklist Loose Parts Photo 2 7a 1 Self coiling air hose P N 26961 1 Air nozzle P N 26960 1 Coolant nozzle and fitting P N 26958 1 10 120 PSI rated hose P N 26959 1 Air and coolant nozzle bracket Loose Parts Photo 2 7a ...

Страница 28: ...3 phase power is present you must use a step down transformer to 208 volt 3 phase Incoming 208 V power connects to the machine through the electrical box located on the back of the column The power cable enters the electrics box through a hole on the top of the box Southwestern Industries recommends the machine be earth grounded by driving a copper rod into the ground It is the responsibility of t...

Страница 29: ...fety Installation Maintenance Service Parts List 2 8 1 Main Power to the Machine Connections The 3 phase 220 voltage 208 240 V acceptable is connected to L1 L2 and L3 at the power switch inside the electrical box Connect the ground wire as shown in the figures 2 8 1a and 2 8 2a Figure 2 8 1a ...

Страница 30: ... transformer to be between 220 and 230 volts On a rare occasion where the customer s shop is around 500 volts it may be necessary to move the wires from the 220 to 200 volt tap You should also place the primary side wires on the 480 taps In the case of 415 volts it is better to place the wires on the 400 volt taps as the output voltage will be closer to 230 volts Figure 2 8 2a 2 9 Air Connection C...

Страница 31: ...g the cap upward and rotating the cap clockwise to increase the air pressure and CCW to decrease the air pressure The 3 air flow valves should be set at the factory but can be checked as follows For the valve that controls the flow of air through the spindle during a tool change close this valve and open it 6 or 7 turns and then lock it in place as shown in figure 2 9 1a For the other 2 valves tha...

Страница 32: ...K RMX CNC Safety Installation Maintenance Service Parts List Figure 2 9 1b The 3 air solenoids standard on the VMC provide switches to regulate air flow for the ATC In and Out air blast for tool and air flow thru the spindle and locations are shown in figure 2 9 1c Figure 2 9 1c ...

Страница 33: ...lant tank beneath the rear of the machine 2 Remove loose ends of coolant hoses from the underside of the VMC enclosure and route them to the pumps The hoses and fittings are labeled prior to shipping 3 Attach and secure these hoses with hose clamps per the figure 2 10 below Figure 2 10 Note The Auger shown in figure 2 10 is an option on our VMC5 while standard on the VMC7 and VMC10 ...

Страница 34: ...e cabinet Have the customer repair any wiring discrepancies See figure 2 8 1a and 2 8 2a Double check how the machine has been grounded and notify user if it is not done per our recommendations See sections 2 8 2 8 1 for recommended grounding 3 If 480 volt transformer option is installed measure incoming voltage and adjust transformer taps as necessary See section 2 8 2a 4 Clean the machine if nee...

Страница 35: ...pump and coolant wash pumps per section 5 1 8 9 Re attach the Z motor power and encoder cable if it was disconnected during shipment Make sure to thread the cables on all the way 10 Install the X and Y EHW s if they were sold with the machine Reattached the cable carriers to the bottom portion of the EHW trough 11 Turn on the power to the machine Verify the lube pump cycles 1 time when machine is ...

Страница 36: ...when the machine is leveled the coolant chip chutes at the rear of the machine are 8 5 from the floor with the chute all the way up This will allow the coolant tank to be installed and have the coolant chip chutes come down to touch the coolant tank and minimize any coolant splashing Note One of the coolant chip chutes will need to be reattached as it is shipped separately 14 Check the level of th...

Страница 37: ...the Z axis home properly Did the ATC home properly Station 1 should be at the tool change position 18 Jog the X Y and Z axis back and forth until the linear guide surfaces are well lubricated Oil should be visible on all the linear guide surfaces and ball screws Once lubrication is verified attach all way covers 19 Go to DRO mode and move each axis in a positive direction Select the X axis does th...

Страница 38: ...d verify the spindle and axis stops You will need to press the POWER RESET button once this is done Make sure the Z axis does not move when the E stop is pressed The brake on the Z axis motor will hold the head 25 Turn the auger chip conveyor an option on VMC5 on in the forward and reverse directions and make sure it turns in the correct direction You need to hold the REVERSE key down for the auge...

Страница 39: ... the tool table The door must be closed and you must be in Production Ops Also make sure the ATC is rotating in the correct direction 34 Double check the tool change height with service code 501 Once verified check to make sure that the tools load and unload properly into the tool carousel the tool should not deflect as the tool is being loaded automatically into the spindle 35 Physically load a t...

Страница 40: ...go that comes in the hardware kit to the cart 44 Remove front door sill protective material 45 Wipe down machine 2 12 Lubrication 2 12 1 Way Lubrication The auto lube system provides centralized automatic lubrication for the linear guides and ballscrews The lube pumps 1 liter reservoir is serviced with Mobil Vactra Oil No 1 or equivalent ISO32 The pump is factory set to distributor 2 7 ml of oil f...

Страница 41: ... Air Over Oil cylinder and should not require replenishment However if it does fill the oil cup on the front of this cylinder with an ISO32 oil or equivalent 2 Oiler Once every 2 weeks Fill the oiler that supplies lubrication to the solenoid valves and other various components within the pneumatic system with an ISO32 oil or equivalent It holds approximately 5 ounces 3 Grease fitting on ATC Yearly...

Страница 42: ...stops 21 25 x 17 50 x 21 25 30 75 x 21 25 x 21 25 42 x 21 25 x 21 25 Spindle Taper 40 Taper Spindle Speed Range Production OPs 50 8000 Spindle Speed Range Tool Room OPs 50 5000 Spindle Nose Diameter 3 Tool Clamping force 90 psi 1500 lbs Tool Holder Type CAT 40 or BT40 ATC Tool Capacity 16 Maximum tool weight including holder 15 lbs Maximum tool diameter 3 14 Carousel speed 8 sec from station to st...

Страница 43: ...height to fit VMC s through doorway 84 84 84 Length pendant enclosure rotated at 90 and coolant tank in place 129 134 134 Overall width of machine no auger chute auger motor or chip container With optional auger installed 84 94 97 111 Overall width of machine with side doors open and auger chute and chip container in place 138 167 25 165 50 Overall length of machine with electrical cabinet full op...

Страница 44: ...et The cable way for Z axis also needs to be removed The lifting point on the electrical cabinet is now the highest point height changes slightly based on how machine is leveled on leveling screws can vary slightly due to home switch location and soft limit settings 2 13 1 Maximum Spindle Torque HP The following graphs illustrate the continuous and peak torque vs RPM figure 2 13 1a and horsepower ...

Страница 45: ...2 flute high speed steel sharp Coolant Flood coolant Cool Tool or Kerosene 1 Mount vise and indicate the back jaw parallel to the table within 0005 2 Clamp material in vice with a minimum of 800 above the vise jaws 3 Load in the Euclid block program It is found under the C drive PROTOTRAK folder and VMC INSPECTION PROGRAMS folder click on EUCLID PT10 to run and follow instructions 4 Use an edge fi...

Страница 46: ...egular profile cuts material from corners remaining on Euclid block and cuts triangle on Euclid block 0 500 13 rectangular frame cuts outer 2 750 rectangle 0 750 14 position event check for accuracy of circle 0 050 7 After the program runs the program will locate to the following position X 1 318 Y 1 318 8 Mount a dial indicator in the quill and check the circles using figure 2 14 as a reference 9...

Страница 47: ...ing is mechanically loose and the backlash values are not higher than what physically is in the system Friction feed forward set too high or low Check the value of code 134 and adjust as required Machine Tool Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture Check the condition and type of cutter being used type of material RPM and Feed rate etc Inadequate or...

Страница 48: ...odes and document values Code 33 Software Identification This is needed if you call SWI Customer Service Code 128 Enter backlash compensation Code 134 Friction Feed Forward Possible Cause Check This Backlash values set too high or low Check code 128 Typically values for backlash should be less than 0 0005 Reset values as necessary Friction feed forward set too high or low Check the value of code 1...

Страница 49: ...C SET when ABS SET is meant This is especially suspected if the dimensional errors are larger than a few thousandths See the Controls Programming Operations and Care manual Configuration file that contains calibration file that has been erased or corrupted Make sure there are values for calibration under service code 123 Default values would read all zero s which means the machine needs to be cali...

Страница 50: ...mp when problem occurs Bad Motor Encoder Contact TRAK to arrange service Computer module See section 5 1 2 to replace computer module 3 2 2 Axis Will Not Jog with Electronic Handwheel The system powers up but will not respond to the jog command using the electronic handwheel Do the following Service Codes and procedures Code 33 Software Identification This is needed if you call SWI Customer Servic...

Страница 51: ...ion where all other positions and offset are derived from This function is to be performed every time the system has been turned on or reset The homing function will cause the tool changer to move to tool position one it will also cause each axis to move in the most positive direction that it can Do the following Service Code and procedures Code 505 Overtravel Soft Limits Possible Cause Check This...

Страница 52: ...is USB drive not working Verify USB works on known good PC replace USB drive if it failed Device driver not loaded on control Device driver may not be installed for USB device or be corrupted Run service code 540 and load USB driver Poor USB cable connections Check different USB port If good problem with previous USB port Check cable from bad USB to computer board following cable from USB to compu...

Страница 53: ... are connected Power not getting to programming panel Verify 24 VDC is making it to the programming panel enclosure Remove programming panel rear cover leaving the two screws at the top for easy removal Check LEDs on the inside of the programming panel enclosure as shown below If no LEDs are on then the computer likely has no power Make sure the computer module is getting power Motherboard failure...

Страница 54: ...s loose Check for working LEDs on run panel if working press keys on programming panel Should hear a beep if not working check two cables backlight and LCD comm cables as shown Failure on programming panel Replace programming panel Power is not getting to programming panel Check for working LEDs on run panel If LEDs not working move to electric cabinet and check power cord is plugged into the pane...

Страница 55: ...ation cable is connected correctly as shown Failure on Programming Panel Replace programming panel 3 3 5 System will not boot VMC will not boot up VMC has power run panel and programming panel are operational There is text on the screen again a black background A flashlight might help to see the reflection of the text on the black screen Possible Cause Check This Boot process failed on motherboard...

Страница 56: ...hed correctly and single screw is in place as shown below Motherboard failure Replace Programming Panel 3 3 6 E Stop Error The Warning button is flashing and has an E stop message error code 261 It will not allow the machine to be moved around Possible Cause Check This Make sure E Stop switch is out and not pressed Clear message and make sure Power Reset button is turned on If problem persists reb...

Страница 57: ...nd connected properly as shown below If connected restart VMC Computer module internal failure Make sure both E Stop jumper lights are on If either is off computer module failure call TRAK for service If both are on more to next step Computer module internal failure Check E Stop lights in electric cabinet make sure 2 LEDs are on as shown below Either light off computer module failure call TRAK If ...

Страница 58: ... Check E Stop 4 LEDs on the programming panel overlay interface board as shown below If any of the lights are off check RS232 cable to electric cabinet If the connection is good programming panel likely needs to be replaced Faulty E Stop switch or wiring Check E Stop switch inside pendant and its cable to circuit board for connections on both ends If hardware problem replace parts otherwise run pa...

Страница 59: ...product model Run Service Code 81 and verify that the screen displays the same key panels as the VMC If wrong key panels reboot and retest Code 81 If problem persists call customer service Keys work but erratic some work some don t Open the rear panel and check to make sure all 4 ribbon cables are tight and seated correctly as shown If they are call TRAK customer service Likely need programming pa...

Страница 60: ...enance Service Parts List Possible Cause Check This Connection problem with DB25 cable These are critical keys and can be checked by running Code 81 If problem check ribbon cables in step 2 as well as DB25 cable on lower left of programming panel as shown Likely programming panel problem Call TRAK Customer Service ...

Страница 61: ...start with spindle orientation Spindle orientation is like any other setting regarding the ATC it is a critical one as a crash would be the result of an improper setting Spindle orientation centers the drive dogs of the spindle for proper engagement of the CAT40 tool holder when it is held in the tool carousel of the ATC Service code 510 will safely walk you through this procedure Make sure to fol...

Страница 62: ... location as shown in figure 4 4 1 During the Homing sequence the carousel will continue to index in the clockwise direction until the home position stud is detected If for some reason the stud is not detected the ATC will simply time out At which point it must be determined whether or not the sensor is functioning or not At the pendent index the tool changer until it is in the home position Run s...

Страница 63: ...ect Sensor The tool detect sensor is used as the name suggests to detect whether a tool is present in the tool carousel at the tool change position If a tool change was attempted with a tool in the spindle and in the tool change position in the carousel a crash would occur If the tool detect sensor detects a tool that is not present check the sensor lens for contamination Debris on the lens can ca...

Страница 64: ...se no more than 1 8 of a turn The sensor LED should be orange Now test the adjustment by commanding the carousel to rotate 1 position to either side of tool change position to verify the sensor sees the tool when it is in tool change position and it doesn t see the tool when it is not in tool change position See figures 4 4 3a and 4 4 3b See section 6 2 for replacement instructions The angle of th...

Страница 65: ...etects that the ATC has retracted all the way back from the spindle 4 4 6 Tool Unclamp Is a limit switch that detects that the tool unclamp mechanism is in the unclamped state If this limit switch is not set or functioning properly there is the potential that the draw bar could get friction welded to the air cylinder adjusting screw This switch is triggered only when you are physically loading a t...

Страница 66: ...d needs to be unclamped to proceed The clamp limit switch is detecting that the tool clamping mechanism is still in the clamped state this might occur when a tool has been returned to the tool carousel but is still clamped in the spindle In this state if the Z axis was to move the tool gripper in the ATC could be damaged 128 The ATC carousel was unable to find its home position This likely occurs ...

Страница 67: ...roperly Please use code 513 to reset the ATC If problem persists check that the carousel is in location properly and that the ATC counter sensor is functioning properly See Section 4 4 2 150 System has timed out waiting for the ATC Counter Sensor to change state Confirm that ATC Carousel is moving Then check to make sure that the ATC Counter Sensor is free of any oil or debris and retry Use code 5...

Страница 68: ...tch Supply 90 psi air to the machine Make certain the in line air switch is in the open position upward please refer to pneumatic assembly drawing 26930 found at the rear of this manual Find the cause of the low air pressure Pressure should be 90 psi at the machine s regulator Check that the solenoid has not been manually over ridden Replace and re route pinched tubing Remove the obstruction ATC w...

Страница 69: ...ing used The pull fingers inside the spindle are damaged or missing Locate and use the proper retention knob Visually inspect the pull fingers 4 8 Service Codes These are the most commonly used service codes for the TRAK VMC s Service codes are broken down into the following categories software machine setup diagnostics user options defaults lube pump and I O testing All Service Codes are accessed...

Страница 70: ...t ATC Return Auto Tool Changer to initial position pointing to tool 1 530 Serial Numbers Display serial numbers of major VMC components 540 Disable File Based Write Filter Enable is default Disable allows changes to Windows system settings i e network or driver changes Note Save any programs in memory this command forces a system reboot Software Services Codes Code Description Comment 33 Software ...

Страница 71: ...splays memory availability of various devices 521 Check Control Indexer IO Launches application to test all system I Os 522 Diagnostic Charting Tool Diagnostic used for plotting various inputs Operator Defaults Options Service Codes Code Description Comment 79 Turn On Beeper Turn the beeper on when pressing keys on either of the front panels 328 EPA On Off Enables Disable EPA section 600 Manager U...

Страница 72: ... configuration file consists of items such as calibration backlash constants ball lock locations base tool length and tool changer height This code is used when a computer module or compact flash card needs to be replaced This stores the configuration file from the machine s compact flash drive to a portable USB flash drive It is a good idea to do this code after the machine is initially setup so ...

Страница 73: ...n to the DRO the motor index angle for each axis relative to the limit switch can be seen This is to ensure that the index pulse for the motor is close to 180 degrees when it hits the limit switch This is done to obtain maximum reliability when the machine performs its homing routine The angle should be 180 degrees 45 degrees Values from 135 to 225 degrees are acceptable Failure to set this correc...

Страница 74: ...lly would Press MODE SET UP C Code 54 INC SET The program run will start automatically Press STOP to stop and GO to continue 4 8 3 2 Code 81 Program Panel Test This code is used to check if the buttons located on the program panel are functioning correctly It allows you to test each key individually When you press the keys the corresponding box for that key will highlight on the screen The pendant...

Страница 75: ... the original file is cleared and data is once again captured Once again as the file reaches a size of 20 MB it copies over the previous backup file From here the user can save the file to a USB flash drive by pressing the F8 softkey Once this is done it prompts you to save the file The file will be saved as a zip file to your USB device The file will be called errorlog zip To clear the contents o...

Страница 76: ...oaded into the new computer The user may crash the tool into the tool changer and damage key components Repairs could be expensive and time consuming to replace Some of these items refer to when working on the Z axis 4 505 checking the motor index angle Must be set to 180º 45º 1 Motor removed or replaced 2 Ballscrew coupling slips 3 Limit switch replaced or a major mounting adjustment is made 4 Li...

Страница 77: ... Remove the three green ground wires labeled GND by removing the green screws on the bottom left corner of the unit 7 Mount the new servo drive in the cabinet using 4 M5 0 8X10 25B cap screws 8 Reconnect the green ground wires followed by the two digital cables and 8 or 10 power wires based upon the drive Figure 5 1 1 Servo Drive and Motor 5 1 2 Programming Panel Run Panel and Computer Module Repl...

Страница 78: ...bottom of medal pendant casing as shown in image Figure 5 1 2 1a Panel Cabling 4 Support programming panel from the front and remove the 8 bolts from the programming panel perimeter and remove the panel from the front of the pendant as shown in figure 5 1 2 1a 5 Replace programming panel replace the bolts and tighten just past finger tight connect the data wires listed in step 3 and shown in figur...

Страница 79: ...2 3 Pendant Hand Wheel Key Lock Switch or Emergency Off Knob Replacement 1 Turn power off to the machine and control 2 Remove the wires and hardware to the part being replaced as shown in figure 5 1 2 2a 3 Replace the part and reconnect hardware and wires 4 Replace the rear cover and tighten bolts 5 Power up the VMC 5 1 2 4 Computer Module Replacement 1 Turn power off to the machine and control Di...

Страница 80: ...Service Code 33 See section 4 8 Software Service Codes 5 1 2 5 VMC Computer Components VMC Computer Components Item P N Description 1 31601 VMC PROGRAMMING PANEL In Pendant 2 31602 VMC RUN PANEL In Pendant 3 29100 1 VMC COMPUTER MODULE In Electric Box 5 1 3 Updating the Pendant and CM Software 1 On the pendant touch the Status soft key on the upper left portion of the touch screen This will displa...

Страница 81: ...r this kit is MEM VMC or 31508 This provides an archive of production programs in the Pendant readily accessible for operations and reduce the need to transfer programs from other storage devices 1 Power down the VMC Pendant rear cover must be removed Use caution this is a heavy cover There are slots for each bolt that allow the technician to loosen the upper bolts to support the weight of the cov...

Страница 82: ...ervice Parts List Figure 5 1 4a 4 The memory card needs to be installed on the bracket with the four small screws provided from the rear of the bracket into the memory card The bracket is then installed on the four standoffs with screws provided Figure 5 1 4b shows the bracket installed and where to locate the memory card ...

Страница 83: ...be installed one way due to the matching notch on the memory card and the sizes of the wires as shown in Figure 5 1 4c Figure 5 1 4c 6 The memory card cable branches into a data and power cables to be connected into the circuit board behind and below the memory card just installed The data cable terminates with same type of notch as used in the large end preventing an error while attaching the con...

Страница 84: ...ss the Windows key on the lower left hand corner of the keyboard to bring up Windows Menu Select Devices Printers and the Device Display lists the USB Copy a test file from the USB to drive D the new memory card 5 1 5 Cable Routing on Machine Whenever you replace a cable or reroute a cable it is very important to keep the power cables and logic cables separated from each other The power cables con...

Страница 85: ...th our hand wheel option Our ProtoTRAK software provides control of these handwheels at various speeds There is a fast course mode to allow rapid movement on a mill when not close to a work area or other objects We also provide precise fine control over the hand wheels when needed for slow accurate movement while zeroing out an axis as well as other tasks Figure 5 1 6a shows a detailed photo of a ...

Страница 86: ...RAK Mills Two EHWs are attached to the rail and easily adjustable Wiring for X Y EHWs are protected in a special conduit which is also protected by the rail and can be adjusted many times Figure 5 1 6c shows the external EHWs installed on a VMC and a detailed enlargement photo showing the conduit protecting the wires and how our rail design protects the wiring and conduit from damage on the shop f...

Страница 87: ...t move X Axis to negative soft limit 2 Remove right side window or door 3 Two cables from electrical cabinet should be disconnected from bracket on spindle side panel as shown in figure 5 1 7 2a 4 Remove liquid tight fitting from panel 5 Cut tie wraps holding cable to slide 6 Disconnect Z EHW cable connector from bracket on side panel shown in figure 5 1 7 2a 7 Remove 3 screws from EHW to slide an...

Страница 88: ...W cable for access 7 Unplug front or rear sensor cable from bracket on side panel shown in figure 5 1 7 2a viewed while removed from VMC for access 8 Remove single Philips head screw holding sensor along rail without losing bracket behind sensor 9 Reinstall rear stop bracket and wiper 10 Install sensor cable to Y connector 11 Reinstall panel to Z Axis head while connecting cables from electrical c...

Страница 89: ...o be taken not to lose brass plugs used at the end of the screws Remove old motor 6 Insert the motor into the housing using the 4 SCHS head screws and torque to specification 7 Verify brass plugs are in auger coupling tighten set screws 8 Route power cable back thru machine following the same route during removal 9 Connect L1 L2 L3 labeled wires as shown in figure 5 1 8 1a 10 Power up machine and ...

Страница 90: ...isconnect coolant hoses from motor Have container to catch any fluid remaining in lines 5 Remove 4 SCHS head screws holding motor and remove motor from machine 6 Replace motor and replace the 4 SCHS head screws and tighten 7 Route power cable back thru machine following the same route during removal 8 Connect L1 L2 L3 labeled wires and ground wire as shown in figure 5 1 8 2b 9 Power up machine che...

Страница 91: ...e machine may crash if these items are not set correctly Service Code 505 Reset the motor index angle machine may not home properly and reset soft limits Must be redone after any motor is removed Service Code 501 Reset the tool change height Performed after Z motor axis removal 5 1 9 1 X Axis Servomotor Removal and Replacement 1 Center X Axis E Stop machine and disconnect power to the machine 2 Re...

Страница 92: ...re 5 2 1c 3 Rotate the coupling until the slot is at twelve o clock and you have equal access to the jack screw and the two clamping screws CAUTION Edges of the way covers can be sharp use leather gloves while handling CAUTION Do not touch the ball screw or linear ways with your bare hands Wear latex or other suitable gloves to protect precision surfaces from your hands ...

Страница 93: ...UST be performed 5 1 9 2 Y Axis Servomotor Removal and Replacement 1 Jog the Y axis toward the operator as far as possible E Stop machine and disconnect mill power 2 Y axis access to the motor may require sliding the rear most way cover forward after removing way covers from inside the machine 3 Rotate the coupler until the slot is at twelve o clock and you have equal access to the jack screw and ...

Страница 94: ...to allow the head support bracket to be placed beneath it 3 Place the head support supplied with the machine on the protected table as shown in figure 5 2 5a and 5 2 5b Place wood foam or some protection on top and bottom of the head support as shown in figure 5 2 5c Figure 5 2 5a Figure 5 2 5b 4 Slowly and very gently jog head downward until contact is made with the table as shown in figure 5 2 5...

Страница 95: ...all the motor onto the ball screw Attach the four SHCS screws holding motor to mill to 30 ft lbs 15 Loosen the jack screw ball screw side then tighten the two clamp screws opposite the jack screw 16 Reconnect the power and encoder cables to the servo motor Turn the power on the machine 17 Enable servos perform Service Code 505 slowly jog Z axis into Z Axis hard stop Back out one ballscrew revoluti...

Страница 96: ...l cabinet every few months and clean 4 Check the level and tram of the machine every 6 months and adjust as necessary 5 Check the spindle motor belt tension every 6 months Yearly 1 Check backlash on each axis and adjust as necessary 2 Remove all covers and clean chips and debris that may have built up 3 Inspect the ATC by removing the covers 4 Inspect the tool change air cylinder 5 Apply grease to...

Страница 97: ...e you to the calibration offsets of the axis selected CLEAR ALL this will erase all values within the calibration tables for X Y and Z axis This should only be used in the event that the system is being recalibrated by a qualified technician 5 3 3 Calibration Table Once an axis is selected you will see the table where all the calibration offsets are stored ...

Страница 98: ...he travel So for example if after moving to the first position the mini DRO read 25 000mm but your laser system measured 25 002mm of actual movement you would enter 0 002 as the offset value Note This calibration table will always display metric values Press the GO button again to move to the next position Keep entering the offset values for each position as described above Once you have finished ...

Страница 99: ...ly into the SWI Customer Service Group If a Customer Service Representative CSR is not available within the first few of minutes your call is transferred into our voice mail system Our voice mail is continuously monitored If you have an emergency indicate this in your message Our Service Voice Mail box number is 555 SWI Service Department Direct Fax Number 310 886 8029 Customer Service Group Hours...

Страница 100: ...ce Parts List 6 2 2 Return Material Authorization RMA Number All shipments of replacement parts are accomplished through our Return Material Authorization RMA system At the same time the CSR is diagnosing the problem and ordering the part they will issue an RMA number that will allow us to efficiently process the return part ...

Страница 101: ...uding any implied warranty of merchantability or fitness for a particular purpose and of any other obligations or liability on the part of SWI or any producing entity if different Warranty repairs exchanges do not cover incidental costs such as installation labor freight etc SWI is not responsible for consequential damages from use or misuse of any of its products TRAK products are precision mecha...

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