field service bulletin index

Transcription

FIELD SERVICE BULLETIN
INDEX
FSBINDEX.DOC Revised May 9, 1997
FSB NUMBER DESCRIPTION
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
MB1 TOOL CHANGER ALIGNMENT AND ADJUSTMENT.
B INTERFACE BOARD RELIABILITY IMPROVEMENT.
NUISANCE SHEAR PINING ON PARAJUST B DRIVE.
INSTALLATION OF REPLACEABLE ENCODER DISKS.
POWER DOWN MEMORY CIRCUIT ON B CONTROL MILLS.
PROPER AXIS CURRENT ON KMB1 MILLS.
MB1 SHOT PIN PROBLEM FIX.
CHOPPER BOARDS ON PARAJUST B DRIVES.
PARAJUST A SETUP AND ADJUSTMENT.
CHATTER IN THE SPINDLE OF KMB1 KMB1m.
INFO ON THE CRT BENT, B CONTROL FRONT PANEL BRD MOD
RECOMMENDED WAY OIL FOR MILLS.
MBII SHOT PIN ADJUSTMENT.
VARIDRIVE BELT REPLACEMENT.
MBII LIMIT SWITCH AND VALVE ADJUSTMENTS.
MILL GROUND ROD USE INFORMATION.
SNOW ON CRT OF MB1H MILLS.
SHEAR PIN DURING TAPPING ON PARAJUST B DRIVES.
MISSWIRED T2 TRANSFORMER ON MB3 MILLS.
HIGH SPEED SPINDLE DIFFERENCES.
MISPOSITION IN TOOLMASTER HMB1 BX RETROFIT.
SET-UP OF BX SERVO CONTROL BOARD.
PARAJUST 280V REFERENCE PROBLEM.
RS232 DATA CARRIER LOST ERROR ON BX CONTROL.
MB3/MD3 MOD. TO THE X5 BRD FOR MISPOSITION.
KMB-1 SPLINE COUPLING REPLACEMENT.
HURCO EDM SERVO AMP AND DIODE PUMP SETUP.
EDM OPTITRON TRIP POINT SETTINGS. (MKII)
SERIAL NUMBER ID ON ALL HURCO PRODUCTS.
OIL LUBE REGULATOR KMB TYPE MACHINES.
CONTROL TRANSFORMER REPLACEMENT SM1-CNC.
MISCOUNT ON TOOL CHANGER OF MD1 AND MBX1.
OIL FLOW INDICATOR RETROFIT MII.
ORIENT TIME-OUT IN MBII MB3.
MBXIH MD1 40V TOOL CHANGER SPRINGS WEAK.
INTERMITTENT PROBLEMS ON B AND BX MILLS.
B AND BX TAPE READER ADJUSTMENTS.
VOLTAGE CONVERSIONS ON SM1-CNC AND KM3 MACHINES.
BATTERY BACKUP ULTIMAX ONE CONTROL.
PARAJUST VOLTAGE CONTROL BOARD PROBLEM.
SM1-CNC Z AXIS PROBLEMS.
ULTIMAX ONE TAPE FORMATTING PROBLEM.
PARTS REPLACEMENT ON PARAJUST DRIVES.
SM1-CNC BALL SCREW REPLACEMENT.
MISSWIRED SPINDLE DAC ON MD1.
FSB NUMBER
1046
1047
1048
1049
1050
1051
1052
1053
1054
1055
1056
1057
1058
1059
1060
1061
1062
1063
1064
1065-B
1066
1067
1068
1069
1070
1071
1072
1073
1074
1075
1076
1077
1078
1079
1080
1081
1082
1083
1084
1085
1086
1087
1088
1089
1090
1091
1092
1093
1094
1095
1096
1097
1098
DESCRIPTION
MD3 Z AXIS SC FAULT PROBLEM WITH AUX BRIDGE.
WIRING MAIN TRANSFORMER.
SERVO DYNAMIC AMPLIFIER SET-UP.
CIRCLE AND POSITIONING ACCURACY.
SHOTPIN PROBLEMS AND ADJUSTMENTS ON MD3.
MD3 FAULT LOGIC BOARD PROBLEM.
SMI-CNC DOOR LATCH PROBLEM.
LUBE OF SPLINE COUPLING KMB1 TYPE MACHINE.
HONING KNEE MILL QUILL BORES.
KNEE MILL SPINDLE REBUILDS.
MISCOUNTS WITH MILLS USING HEIDNHAIN SCALES.
AIR LINES POPPING OFF FITTINGS.
MD1 CHIP REMOVAL BENEATH SADDLE.
MD1 Y AXIS LEAD SCREW COVER.
QUILLS FOR SMI-CNC.
MD1-3 PARAJUST WIRING DRESS PROBLEM.
SPINDLE ORIENT SPEED ADJUSTMENT MD1-3.
TAPE TRANSPORT GROUNDING ULTIMAX 1.
LUBE PRESSURE SWITCH SETUP ON MD3.
ULTIMAX POWER SUPPLY CHECKOUT. Revised 3/17/93
ULTIMAX SWITCH SETTINGS.
LUBE PROBLEMS ON SM1-CNC.
CRTS SHORTING OUT ON ULTIMAX ONE.
ENCODER DAMAGE.
NEW REPLACEMENT FOR HEIDENHAIN X5 BOARDS.
PARAJUST B DRIVE MAINTENANCE.
GROUND FAULT ON HURCO AMPS.
FRL UNIT BOWLS CRACKING.
AUTOLUBE SYSTEMS ALL MILLS.
ATC ERROR ON BMC-15 MILLS.
INDEX MISSWIRE ON KM3/P.
HI-LOW GEAR SWITCH PROBLEM MD3-BMC15.
MISSWIRE ON RS232 ON KM3 TYPE MACHINES.
MUTI-LOAD SCREENS ON B OR BX CONTROL MACHINES.
KMC3-P SPINDLE SPEED AND ROTATION PROBLEMS.
THREE PHASE POWER KVA-AMPERS AND WIRE SIZE.
KM3P MOTOR BRUSH CONTAMINANT FIX (COVER).
MACHINE INPUT VOLTAGE AND AIR REQUIREMENTS.
MISSING SURGE SUPPRESSOR BMC 10-15.
MISCOUNTS ON KM3 DUE TO SHIELDS MISSING.
BMC AXIS BELT TENSION.
USING DISTRIBUTOR STOCK.
TAPE READER PROBLEMS TM5.
RANDTRONICS CHASSIS WIRING PROBLEMS.
OVER RATED HEATER ON BMC 15 CHIP CONVEYOR.
TOOL CHANGER LIMIT SWITCH PROBLEM BMC 20.
ULTIMAX LOCKUPS.
BRAKE PACK PROBLEMS WITH MD1 AND MD3.
MB3 SERVOMATE/RANDTRONIC TRANSFORMER.
BX MISCOUNTING ON KNEE MILLS.
DELTRON POWER SUPPLY ADJUSTMENT.
CUSTOM CPU JUMPER CAUSES RS232 RS 232 PROBLEM.
SOLENOID EXHAUST FILTERS CLOG MD3 THRU BMC 15.
REV. C
PAGE 2 OF 5
FSBINDEX.DOC 9-May-97
FSB NUMBER
1099
1100-A
1101
1102
1103
1104
1105
1106
1107
1108
1109
1110
1111
1112
1113
1114
1115
1116
1117
1118
1119
1120
1121
1122
1123
1124
1125
1126
1127
1128
1129
1130
1131
1132
1133
1134
1135
1136
1137
1138-B
1139
1140
1141
1142
1143
1144
1145
1146-A
1147
1148
1149
1150
1151
DESCRIPTION
BMC 10/10L TOOL SUPPORT PROBLEM.
BMC 20 THRU 50 GIBS AND AXIS CURRENT ADJUSTMENT.REVISED 1/25/93
TM5 Z AXIS BOUNCING AT Z PLUS LIMIT SWITCH.
SPIETH LOCKNUT INSTALLATION INSTRUCTIONS.
MAX2 RS232 HARNESS MISSWIRE.
SOFTWARE FOR YASKAWA MD3 MACHINES.
ORIENT PROBLEM WITH YASKAWA RETROFIT.
KMC3P PALL CHUCK REPLACEMENT.
BMC AUTO LUBE WIRING IMPROPER SHIELDING.
INSTALLATION OF THRUST BEARING'S.
NONVOLATILE CPU/MEMORY PCB FOR ULTIMAX 1.
TOOL CHANGER HEIGHT WITH 06F SOFTWARE.
BMC DRAW ADJUSTMENT.
BMC CLUTCH NOISE.
BMC 20 THRU 50 GIB WEAR.
AXIS END CAP PROBLEM KM3 MILLS.
CONTROL RELAY PANEL PCB MAX 2 MACHINES.
DELTRON POWER SUPPLY CHECK OUT.
CONTROL GROUNDING IN ULTIMAX.
RS232 CABLE HURCO REQUIREMENTS.
PARAJUST A BRAKE BOARD REPLACEMENT.
MISSWIRE ON YASKAWA RETROFIT.
WRONG SPINDLE OVERLOADS ON KM3 TYPE MACHINES.
GROUNDING OF INDUSTRIAL SERVO DRIVES.
FANUC SPINDLE SPEED SENSOR INSTALL AND TROUBLINGSHOO
DECKEL IND. SERVO DRIVE MODIFICATIONS.
DELTRON POWER SUPPLY PROBLEMS.
FERRITE BEADS AND TRANSIENT VOLTAGE PROTECTORS.
BMC ATC JAMING (BUSHING PROBLEM)
LEADSCREW MAPPING 7.24 BMC 20/50
CHIP DOOR INTERLOCK PROBLEM 7.24 SOFTWARE
TAPPING T1 TRANSFORMER (BMC STAND ALONE)
MAGAZINE JAMMED ERROR (ELECTRICAL)
BIJUR WAY LUBE PUMP ADJUSTMENT
MAX2 MEMORY BOARDS (DALLAS RAM)
ENCODERS SHAFT MOUNT
SPINDLE FIRMWARE FOR MD3 WITH YASKAWA DRIVE
YASKAWA SPINDLE DRIVE RETROFIT KIT
BMC20 V2 Z AXIS LUBRICATION LINE MISSROUTE
DISK DRIVE RETROFIT, & FLOPPY DISK CONFIGURATION Revised 8/3/94 REV A
VERTICLE HEAD LUBE RELAY ON DECKEL/MAX
TURKITE DAMAGE
BMC30 STRIKER PLATE SCREW PROBLEM
YASKAWA SPINDLE DRIVE DOCUMENTATION PROBLEM
GROUNDING IN ULTIMAX CONTROL CONSOLE
GIB ADJUSTMENTS. Refer to FSB 1100-A
REPLACING HURCO AMPS WITH SERVOMATE
YASKAWA ORIENT MODIFICATION
ATC STRIKER PLATE HOLD-DOWN SCREWS
ATC MAGAZINE AIR CYLINDER SET SCREW
ATC MAGAZINE AIR CYLINDER SET SCREW
CONTROL RESIDENT DIAGNOSTICS (MAX)
FLOOD FILTER (5 GAL)
PAGE 3 OF 5
FSB NUMBER
1152
1153
1154
1155
1156
1157
1157-A
1158
1159
1160
1161
1162
1163
1164
1165-B
1166
1167
1168
1169
1170
1171
1172-A
1173
1174-A
1175
1176
1177
1178-A
1179
1180
1181
1182
1183
1184-A
1185
1186
1187
1188
1189-B
1190
1191
1192
1193-A
1194
1195
1196
1197
1198
1199
1200
1201
1202
1203
DESCRIPTION
REPLACEMENT OF KNEE MILL MOTORS/ENCODERS (MTE ASSY)
TRANSIENT ELIMINATOR (LINE POWER PROBLEMS)
DUAL AXIS PCB (DAC OFFSET PCB)
COUNTER WEIGHT RETROFIT BMC40 IP
ISOLATION TRANSFORMER (BMC 20-50)
CRT RELIABILITY IMPROVEMENT
CRT GROUNDING
BACKLASH MEASURING
CIRCUIT PCB CLEANING
FIELD SERVICE ACCURACY STANDARD
OIL COOLER CONTACTOR MIS-WIRE (BMC 30-50)
BEARING TORQUE SETTINGS
TOOL RETENTION FORCES (ATC)
SERVICE CALL CHECK LIST
FUTABA CMK PARAMETER SETTINGS (EDM) Revised 3/3/92
REV. A
KM5P DRAWBAR
KM5P AXIS PULLEY LOCKING ELEMENTS
KM5P DRAWBAR
ROTARY TABLE ERRORS (BMC 20-50)
YASKAWA SPINDLE DRIVE RETROFIT KIT (MB2-MD3)
FAST FILL PROBLEMS TRM21 (EDM)
CONTACTOR SUPPRESSION (BMC KM5P)
LEADSCREW MAPPING INITIALIZATION v8.5
ULTIMAX SECRET (HIDDEN) SCREENS. Revised 3/17/93
BMC 20-50 SPINDLES
CRT CONTROLER PCB, 26 PIN EDGE CONNECTOR
VMC900 ORBITING UNIT (EDM)
NOISE SUPPRESSION TRM21 W/ VMC 900 (EDM)
ISOLATION TRANSFORMER KM5P
UNCLAMP LIMIT SWITCH BMC 25-30K
RS232 CABLES
AXIS MISWIRE KM3/P
MACHINE CONFIGURATION PROBLEMS (BCM 20-50 8.5 OR LATER)
CRT CONTROLLER PCB-2. Revised 6/23/93
MAX 400 AMPLIFIER MODIFICATION.
LEAD SCREW MAP INITIALIZATION v8.51 (BMC 20-50).
CHAIN ROLLER, COUNTER WEIGHT (BMC 20-50.
PARAJUST DIGITAL REVERSING PCB. (SPINDLE DRIVES)
Z AXIS CRT ASSY. Revised 6/22/93 REV. A
REV. C
KNEE MILL PULLY CLUTCH SHAFT RETRO-FIT KIT. KM3/P
UNCLAMP PUSH STUD LOCKNUT, LOCKTITE, BMC 20-50
SHAPE ELECTRONICS TRANSFORMER FUSES.
MODIFICATION TO VOLTAGE DIVIDER PCB. ( TRM21/TRM39 )
TRANSFORMER COVER ( BMC 40SLV ).
LUBE MODIFICATION KM5P.
TYPE 1 ATC MODIFICATION FOR MAGAZINE OVERSHOOT.
COUNTER WEIGHT NOISE ELIMINATION (BMC20-50 40SLV).
ULTIMAX 3 DC POWER SUPPLY, REV. "C" NEW TERMINAL STRIP.
CRP3 PCB MODIFICATION. BMC 20-50.
OIL COOLER REPLACEMENT. BMC 30-50. 8-11-93
MAX 3 KEY BOARD BUTTON REPLACEMENT CHART. 10-29-93
CLAIREX SWITCH USED ON KM1/HM1 LIMIT SWITCHES. 1-4-94
TOOL RELEASE / KNOCK OUT LENGTH ON BMC'S.
PAGE 4 OF 5
FSB NUMBER
1204
1205
1206
1207
1208
1209
1210
1211
1212
1213
1214
1215
1216
1217
1218-A
1219
1220
1221
1222
1223
1224
1225
1226-A
1227
1228
1229
1230
1231
1232
1233
1234-A
1235
1236
1237
1238
1239
1240
1241
1242
1243
1244
1245
1246
1247
1248
1249
1250
DESCRIPTION
KM5D INPUT POWER, SOURCE FOR TRANSFORMER.
KM3/3P MTE REMOVAL REPLACEMENT PROCEDURE.
HAWK 5D MACHINE CONTROL PARAMETERS.
HAWK 5D JO-BLOCK PROCEDURE FOR BACKLASH & LEADSCREW COMP.
HAWK 5D SERVO AMP SET-UP PROCEDURE.
HAWK 5D LIMIT SWITCH SET-UP PROCEDURE.
HAWK 5M AUTO SPEED CONTROL PROM UPDATE.
HAWK 5M I/O & CANBUS MAPPING.
HAWK 5M SERVO AMP SET-UP.
HAWK 5M PARAMETERS.
HAWK 5M MONO CRT SETTINGS. REV. A
HAWK 5M ADVANCED CMOS SET-UP.
HAWK 5M LEAD SCREW MAP SET-UP.
HAWK 5M & ISA HARD DRIVE SET-UP.
YASKAWA AC SERVO SET-UP, MAX-2 & MAX-32 DUAL AXIS
ACROLOC COOLANT PUMP LOW VOLUME
HAWK 5M V1.51 HURCO.LDR FILE
BMC SPINDLE HANDLING PRECAUTIONS
HAWK 5M AXIS CURRENT SETUP
ACCURACY STANDARD PROCEDURE
HAWK 5M/5D TABLE T-SLOT ALIGNMENT
HAWK 5M/5D DRAWBAR SET-UP
KURT POWER DRAWBAR HAWK 5M/5D
FLOOD COOLANT LEAKS
POWER CABINET COOLANT LEAKS
INCORRECT PARAMETER FOR WINDING CHANGE
SERVO DYNAMICS DRIVE TUNE PROCEDURE
DIGITAL SPINDLE CONTROLLER PCB MODIFICATIONS
UPGRADE OF REMOTE SHUTDOWN RELAY (RSR)
UPGRADE OF RS232C CABLES (COM1, COM2)
KURT POWER HEADS & DRAWBAR SETUP
RETROFIT OF DRIVE SPINDLES TO ACCEPT 18MM PROXIMITY SWITCHES
MAX32 HARD DRIVES
FRAME A FRL UNITS
FRAME A Z AXIS CABLE DAMAGE
ISA CARDRACK FAN REPLACEMENT
ACROLOC 1540, 3030 OILING PROBLEMS
BMC4020 NOISE PROBLEMS
ISA CARDRACK TIPS
30SSM DAC SHIELD
WORKLIGHT SUPPRESSION MODIFICATIONS
SPINDLE AGREE FAULTS DURING RIGID TAP FUNCTIONS
HARNESS BRACKET INSTALLATION ON BMC40/20 MACHINES.
CANBUS CONTROLLER MODIFICATION
SIEMENS DRIVE WIRING MODIFICATION
COOLANT/OIL SEPARATOR RETROFIT
SIEMENS FAST STOP SIGNAL MIS-WIRE
PAGE 5 OF 5
FSB NUMBER
1251
1252
1253
1254
1255
1256
1257
1258
1259
1260
1261
1262
1263
1264
1265
1266
1267
1268
1269
1270
1271
1272
1273
1274
1275
1276
1277
1278
1279
1280
1281
1282
1283
1284
1285
1286
1287
1288
1289
1290
1291
1292
1293
1294
1295
1296
1297
1298
1299
1300
1301
DESCRIPTION
V2.00 PARAMETER CHANGES
M Code Mods for Frame "A"
SPINDLE DRIVE FAULTS NOT REPORTED TO CONTROL
FULL ENCLOSURE DOOR SLIDES 410-5001-002
AIR REQUIREMENTS / BMC3017, BMC4020
HAWK5M SERVO INHIBIT
VERSION 2.0 PARAMETER CHANGES, BMC 4020
BMC3017SSM MODIFICATIONS MN3996
PAGE 6 OF 7
FSBINDEX.DOC 26-Jun-97
HURCO FIELD SERVICE BULLETIN
DATE:
AUGUST 24, 1981
ISSUE NUMBER:
SUBJECT:
TOOL CHANGER ALIGNMENT
PRODUCT LINE: MB1
1001
SUPERSEDES NUMBER: 102
PAGE
1 OF 7
NOTE: DURING TC SET-UP, ENSURE TORQUE LIMITER NUT IS FULLY LOOSE UNTIL ALL OTHER
ADJUSTMENTS ARE MADE. THIS PREVENTS THE ARM FROM SWINGING.
SHOT PIN ADJUSTMENT
1.
2.
3.
4.
APPLY BLUEING TO LOWER SPINDLE COUPLING.
ROTATE THE SPINDLE SO THE NOTCH IS NOT ALIGNED WITH THE SHOT PIN.
ENERGIZE SHOT PIN MANUALLY, AND ROTATE SPINDLE.
THE SHOT PIN SHOULD CONTACT LOWER SPINDLE COUPLING EVENLY. IF NOT, ADJUST
SHOT PIN BRACKET AND REPEAT PROCEDURE.
SHOT PIN LIMIT SWITCH ADJUSTMENT
1.
INSTALL THE LIMIT SWITCH MOUNTING BRACKET USING LOCKTITE 242 ON THE B.H.C.S.
NOTE: PLACE A TIE WRAP AROUND THE LIMIT SWITCH TO HOLD THE PLASTIC IN PLACE.
2.
ROTATE THE SPINDLE UNTIL IT'S NOTCH IS DIRECTLY IN FRONT OF THE SHOT PIN
CYLINDER.
3.
ENERGIZE THE SHOT PIN MANUALLY (VALVE IN UPPER RIGHT SIDE OF SPINDLE HEAD
CASTING).
4.
WATCH FOR LIMIT SWITCH TO BE ACTUATED WHEN THE SHOT PIN IS ENERGIZED.
5.
ORIENT THE SPINDLE TO THE POSITION WHERE THE SHOT PIN NOTCH IS NOT IN FRONT
OF THE SHOT PIN.
6.
ENERGIZE THE SHOT PIN. MAKE SURE THE SWITCH IS NOT ACTUATED, IF IT DOES,
ADJUST THE LIMIT SWITCH, THEN REPEAT STEPS 3 AND 4.
NO TOOL IN SPINDLE P.C. BRD MOUNTING AND ADJUSTMENT
1.
ENSURE THE P.C. BOARD IS CORRECTLY COATED WITH HUMISEAL (BOTH SIDES.
2.
INSTALL THE BOARD IN HEAD, USING B.H.C.S & LOCKTITE #242.
3.
WATCH OPTICAL SWITCH WHILE ALTERNATING CLAMPING AND UNCLAMPING ENSURE
THAT OPTICAL SWITCH DOES NOT RUB ON THE RING.
4.
FINAL ADJUSTMENT IS MAKE AFTER THE OTHER LIMIT SWITCH ADJUSTMENTS ARE
COMPLETE.
ORIGINATOR:
REVISED BY:
WAYNE E. HAWKINS
R. BRYANT
TC ARM SET UP
1. POSITION A PIECE OF WOOD PERPENDICULAR TO THE LEFT END OF THE TABLE. SET A
SMALL HYDRAULIC JACK ON THE WOOD AND PLACE A BLOCK OF WOOD ON TOP OF THE JACK.
RAISE JACK TO SUPPORT TC ASSEMBLY.
2. LOOSEN FOUR M12 S.H.C.S ADJUST JACK UNTIL TC ASSEMBLY IS LEVEL. POSITION LEVEL ON
ARM WHEN ARM IS HALFWAY BETWEEN FULLY RETRACTED AND FULLY FORWARD. TIGHTEN
SCREWS, REMOVE THE JACK, AND CHECK ARM AT FULLY RETRACTED, HALFWAY AND NEAR
SPINDLE. THE ARM SHOULD NOT SWING BY ITSELF IN EITHER DIRECTION UPON RELEASE.
3. MOVE TC ARM UNDER SPINDLE AND RECHECK LEVEL.
4. MOVE ARM BACK, REMOVE SHOCK ABSORBER AND SCREW MECHANICAL STOP INTO ARM.
5.
INSERT TOOL HOLDER IN SPINDLE. JOG Z-AXIS TO ALLOW THE TOOL CHANGER FINGERS
TO ENGAGE THE TOOL HOLDER. DEPRESS THE EMERGENCY STOP. USING A TAPE MEASURE,
MEASURE FROM THE LOWER SURFACE AT Z BALLNUT TO MATING AXIS STOP SURFACE. MB-1
MILLS REQUIRE 13.75". IF SLIGHTLY LESS, 13.6" OR GREATER, RAISE ARM FROM LEVEL POSITION
A SMALL AMOUNT. RECHECK.
6. DEPRESS POWER ON TO RELEASE BRAKE. WHILE ACTIVATING SHOT PIN SOLENOID, ROTATE
SPINDLE UNTIL SHOT PIN ENGAGES, DEPRESS EMERGENCY STOP. (THIS PROCEDURE WILL ALIGN
THE TOOL HOLDER FOR A TOOL CHANGE ORIENTATION.
7.
ENSURE THE GENEVA DRIVE ACTIVATES THE LIMIT SWITCH IN THE TOOL CAROUSEL
THROUGHOUT THIS ADJUSTMENT PERIOD. POSITION TC ARM UNDER THE SPINDLE TO CHECK
THE ALIGNMENT OF TC FINGER TO TOOL HOLD V SLOT. LOOK FOR DEFLECTION OF EACH
FINGER. IF MISALIGNED, ADJUST FOUR M10 JACK SCREWS ON TC MOUNDING BRACKET SCREWS
AND TIGHTENING M12A. BY ADJUSTING A SMALL AMOUNT AT A TIME, THE CORRECT
ADJUSTMENT CAN BE DETERMINED. WHEN THE GENEVA DRIVE HAS EQUAL CW AND CCW
MOTION, THE ARM IS CORRECTLY ADJUSTED. (ROTATING THE GENEVA DRIVE BY HAND WILL
FORCE THE CAROUSEL TO ROTATE SLIGHTLY CW AND CCW UNTIL THE TOOL FINGERS TOUCH
AGAINST IT'S NEIGHBORING FINGER. THE PHYSICAL AMOUNT OF GENEVA CW AND CCW MOTION
SHOULD BE EQUAL FOR CENTER ADJUSTMENT.)
8.
THE "CAROUSEL IN POSITION SWITCH-SHOULD BE ADJUSTED INTO ], (AND AS CLOSE AS
POSSIBLE TO) THE GENEVA DRIVE TO ENSURE THE DRIVE STOPS ON THE FLAT READER PORTION.
THIS SWITCH NOT ONLY ALLOWS TOOL POSITION TO BE READ, BUT MOST IMPORTANTLY
COMMANDS THE TOOL CAROUSEL ROTATE MOTOR TO STOP ROTATING. THERE IS A SLIGHT
MOTOR COASTING, SO THE SOONER THE SWITCH IS MADE THE SOONER THE MOTOR WILL STOP.
(THE COASTING SHOULD LEAVE THE GENEVA DRIVE "FLAT" ON THE CENTER OF THE SWITCH.
9. WHEN ADJUSTMENTS ARE COMPLETE, USE LOCTITE # 242 ON ALL MOUNTING SCREWS. BY
REMOVING AND LOCTITING ONE SCREW AT A TIME, THE ADJUSTMENTS WILL HOLD POSITION.
TC ENCODER P.C. BOARD ADJUSTMENT
1. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN SPINDLE, ACTIVATE THE SHOT
PIN AND ROTATE THE SPINDLE UNTIL THE SHOT PIN ENGAGES THE NOTCH.
2. ROTATE CAROUSEL UNTIL TOOL #9 LINES UP WITH THE TOOL HOLDER IN THE SPINDLE.
3. DEPRESS THE EMERGENCY STOP.
4. POSITION ARM SO FINGERS ENGAGE THE TOOL HOLDER.
NOTE: ENSURE THE GENEVA DRIVE ACTUATES THE LIMIT SWITCH.
5. THE NUMBER 9 SHOULD APPEAR ON THE CRT BESIDE COORDINATES.
6. IF NOT, ADJUST TC ENCODER BY LOOSENING THE BRACKET AND EITHER TURNING OR
RAISING/LOWERING UNTIL #9 IS DISPLAYED. BY ROTATING THE PC BRD, THE # 8 WILL APPEAR IN
ONE DIRECTION, AND #1 IN THE OTHER. ADJUST THE BOARD TO THE CENTER OF THIS BAND.
7. WHILE FINGERS ENGAGE THE TOOL HOLDER, GENTLY ROTATE GEAR IN BOTH DIRECTIONS TO
THE PHYSICAL LIMIT. DEPRESS THE LIMIT SWITCH AT EACH LIMIT AND ENSURE #9 STILL
APPEARS ON THE SCREEN. ID NOT, FINE ADJUST THE ENCODER BOARD. 8. MOVE THE ARM AWAY
FROM THE TOOL. ROTATE GENEVA GEAR BY HAND TO ENSURE THE ENCODER BOARD PHOTO
EYES DO NOT RUB ON THE ENCODER RINGS.
9. POWER ON, DEPRESS CHECK, OPERATE, ROTATE, AND WATCH THE SCREEN FOR EACH
CORRECT TOOL NUMBER.
10. IF NO TOOL NUMBER IS DISPLAYED AS THE CAROUSEL MOVES INTO POSITION, THEN ADJUST
TOOL CAROUSEL IN-POSITION LIMIT SWITCH.
NOTE: IT MAY BE NECESSARY TO ADJUST THE TC ENCODER BOARD FOR ALL TOOL NUMBERS TO
BE DISPLAYED.
11. IF THE WRONG TOOL NUMBER IS DISPLAYED, FINELY ADJUST THE TOOL CHANGER ENCODER
BOARD.
12. USE LOCTITE #242 ON ALL MOUNTING SCREWS, REMOVING THEM ONE AT A TIME.
MECHANICAL STOP ADJUSTMENT
1. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN THE SPINDLE. ACTIVATE SHOT
PIN AND ROTATE THE SPINDLE UNTIL SHOT PIN ENGAGES NOTCH. RELEASE THE SHOT PIN
WITHOUT ROTATING THE SPINDLE.
2. DEPRESS THE EMERGENCY STOP. LOOSEN TORQUE LIMITER NUT.
3. MOVE ARM UNTIL FINGERS FULLY ENGAGE THE TOOL HOLDER.
4. ADJUST MECHANICAL STOP TO JUST "TOUCH OFF" THE STOP BLOCK.
5. TIGHTEN LOCKNUT (8mm) USING LOCTITE # 242.
SHOCK ABSORBER INSTALLATION
1. INSTALL THE SHOCK ABSORBER IN THE ARM, SCREWING IN UNTIL BODY IS EVEN WITH THE
ARM SURFACE. NOTE: DO NOT TIGHTEN LOCKNUT AT THIS TIME.
2. FINAL ADJUSTMENT WILL BE MADE IN LATER STEPS.
TC HEIGHT ADJUSTMENT
1. DEPRESS POWER ON, CHECK OPERATE, TOOL CAL.
2. BRING THE HEAD DOWN WITH THE TOOL HOLDER CLAMPED IN THE SPINDLE TO PROPER
ALIGNMENT WITH THE T/C FINGERS. (WHEN THE CAROUSEL IS MOVED INTO CONTACT WITH
THE TOOL HOLDER). OBSERVE CAREFULLY THAT THE FINGERS ENGAGE THE "V" FLANGE OF THE
HOLDER CENTRALLY UP AND DOWN AND RADIAL SO BOTH FINGERS OPEN APPROXIMATELY
EQUALLY.
3. MOVE THE CAROUSEL BACK OUT OF THE WAY. IN DATE BLOCK "0", TOOL CALIBRATE, MOVE
THE HEAD UP 2.4 INCHES. ADJUST THE ENCODER DISK ROTATION SO THE MARKER IS NOW
ALIGNED AT THIS POINT.
4. YOU SHOULD NOW HAVE THE HEAD APPROXIMATELY .100 INCHES BELOW TOP LIMIT
SWITCH SETTING. THIS .100 INCH MAY VARY AS THE T/C POSITION IS DETERMINED FROM THE
FIRST MARKER PULSE/ ADJUST THE TOP LIMIT SWITCH UP OR DOWN AS NECESSARY TO STAY IN
THE RANGE OF .075 TO .125.
5. USE LOCTITE #242 ON ALL MOUNTING SCREWS.
6. CHECK FOR Z TRAVEL (-16.050" TO -16.150".
EMERGENCY STOP ARM DEFLECTION LIMIT SWITCH ADJUSTMENT.
1. MOUNT VEE BLOCK. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN THE
SPINDLE. ACTIVATE THE SHOT PIN AND ROTATE THE SPINDLE UNTIL SHOT PIN ENGAGES THE
NOTCH. 2. DEPRESS THE EMERGENCY STOP. LOOSEN THE TORQUE LIMITER NUT.
3. MOVE THE ARM IN, UNTIL FINGERS ENGAGE THE TOOL HOLDER.
4. THIS STEP IS VERY IMPORTANT! ADJUST THE VEE BLOCK SO ANY ARM MOVEMENT
INTERRUPTS THE SWITCH.
5. TEST ADJUSTMENT BY PERFORMING 10 TOOL CHANGES WITH NO TOOLS IN THE CAROUSEL.
(NO TOOLS WILL ALLOW THE ARM TO FORWARD WITH MAXIMUM FORCE. IN SHOULD NOT TRIP
SWITCH,) 6. USE LOCTITE #242 ON ALL MOUNTING SCREWS.
ARM FORWARD LIMIT SWITCH ADJUSTMENT
1. POWER ON TO RELEASE THE BRAKE. INSERT TOOL HOLDER IN THE SPINDLE. ACTIVATE THE
SHOT PIN AND ROTATE THE SPINDLE UNTIL THE PIN ENGAGES THE NOTCH.
2. DEPRESS THE EMERGENCY STOP. LOOSEN THE TORQUE LIMITED NUT.
3. MOVE THE ARM IN, UNTIL FINGERS FULLY ENGAGE THE TOOL HOLDER.
4. ADJUST ARM FORWARD SWITCH SO IT HAS JUST BEEN ACTIVATED. SWITCH SHOULD
ACTIVATE SLIGHTLY BEFORE DESIRED FORWARD POSITION TO KEEP ARM FROM BANGING AT
STOP.
5. USE LOCTITE # 242 ON SET SCREWS.
ARM RETRACT
1. THE ARM RETRACT SWITCH IS ADJUSTED SO THE "COASTING" ACTION LEAVES THE ARM IN A
SAFETY-RELATED POSITION, ALLOWING CLEARANCE FROM THE TC CARROUSEL TO THE HEAD
OF THE MILL AND FROM THE CONDUIT TO CHAIN. (THERE IS NO MECHANICAL STOP IN THE
RETRACT POSITION.)
2. USE LOCTITE # 242 ON SET SCREWS.
CHAIN ADJUSTMENT
1. ADJUST CHAIN BY MOVING THE MOTOR BRACKET BACKWARDS OR FORWARD ON ITS SLOTS.
2. SLACK SHOULD BE TAKEN OUT, BUT THERE SHOULD BE NO PRESSURE APPLIED THROUGH
CHAIN. THE DRIVE PACKAGE SHOULD BE HORIZONTAL, NOT AT AN ANGLE.
3. USE LOCTITE #242 ON ALL MOUNTING SCREWS AND SET SCREWS.
TORQUE LIMITER ADJUSTMENT
1. MATE-IN THE TORQUE LIMITER BY TIGHTENING TO APPROXIMATELY FINAL TIGHTNESS,
THEN ADDITIONAL 1/8 TURN. REQUEST TC WHILE HOLDING ARM STATIONARY. ALLOW THE
LIMITER TO SPIN FOR 60 SECONDS. LOOSEN AND PROCEED. 2. USE A SMALL AMOUNT OF GREASE
BETWEEN THE NUT AND LOCK WASHER TO PREVENT DAMAGE TO THE LOCK WASHER.
3. TIGHTEN THE NUT UNTIL THE ARM MOVEMENT BECOMES STIFF BY HAND.
4. DURING AN AUTOMATIC TOOL CHANGE, THE CLUTCH SHOULD SLIP APPROXIMATELY 1/4
TURN WHEN THE TOOL IS AT SPINDLE.
5. BEND TAB ON THE LOCK WASHER FULLY INTO GROOVE IN THE NUT TO PREVENT THE NUT
FROM LOOSENING. DRY RUN THE CT WITH NO TOOL HOLDERS.
SHOCK ADJUSTMENT
1. ADJUST SHOCK ABSORBER SO THE ARM HAS A SMALL AMOUNT OF "SLOW DOWN" WHEN TC
FINGER ENGAGE THE TOOL HOLDER. BANGING NOISE SHOULD NOT OCCUR. AS MUCH OF THE
SHOCK TRAVEL AS POSSIBLE SHOULD BE USED (APPROXIMATELY 3/4 " TO 7/8".)
2. TIGHTEN LOCKING NUT.
TOOL IN CAROUSEL LIMIT SWITCH
NOTE: ENSURE ACTUATORS ARE LUBRICATED WITH OIL OR GREASE.
1. PLACE A TOOL IN EACH POSITION IN THE TOOL CAROUSEL.
2. ROTATE CAROUSEL AND STOP AT EACH POSITION.
3. ENSURE TOOL IN-CAROUSEL SWITCH IS ACTUATED AND THAT THE LIMIT SWITCH IS NOT
ACTUATED WHEN THE TOOL IS REMOVED.
NO TOOL IN-SPINDLE LIMIT SWITCH ADJUSTMENT
WARNING: PLACE YOUR HAND NEAR THE EMERGENCY STOP BUTTON.
1. INSTALL TOOL HOLDER IN SPINDLE AND TOOL IN #1 SLOT IN CAROUSEL. IN DATA BLOCK 0,
PROGRAM CUR TOOL 0 AND ATTEMPT TOOL CHANGE. CRT SHOULD READ ES TC ERROR.
2. OPTICAL SWITCH SHOULD BE MADE WITH NO TOOL IN SPINDLE AND NOT MADE WITH THE
TOOL IN THE SPINDLE. ADJUST ACCORDINGLY. THE OPTIC SWITCH SHOULD NOT RUB THE
ENCODER RING.
3. USE LOCTITE #242 ON THE MOUNTING SCREWS.
FINE ADJUSTMENTS MAY BE REQUIRED THROUGHOUT TC, AS THE FIRST FEW AUTOMATIC TOOL
CHANGES ARE MADE.
HINT: ADJUSTING IN SMALL INCREMENTS AIDS IN FIND TUNING.
SPINDLE ORIENT RPM
1. THE ORIENT RPM SHOULD BE 1 REVOLUTION PER 2 SECOND PERIOD.
2. JOG Z AXIS BELOW TOOL CHANGE HEIGHT (-2.4"0. CHANGE TOOL "VIA" DATA BLOCKS "0"
AND DEPRESS MOTION HOLD BEFORE -2.4" IS REACHED. THE SPINDLE WILL TURN AT ORIENT
SPEED AND R40 ON THE ISOLATION INTERFACE BOARD CAN BE ADJUSTED FOR THE CORRECT
RPM RESEAL R40.
Z AXIS TOOL CHANGER CURRENT LIMIT ADJUSTMENT
1. Z AXIS MUST RUN AT 250 IPM TOOL CHANGE SPEED.
2. TO ADJUST, RUN A LOOP DRILL FUNCTION, TOOL CAL AT 3.00", Z UP AND Z DOWN DIMENSION
OF "0" INCHES. Z AXIS WILL THEN POSITION UP AND DOWN AT 250 IPM. INSTALLING A
TEMPORARY JUMPER WIRE FROM +24 TO TB9-3 AND ANOTHER TEMPORARY JUMPER FROM IJ3-5
TO GROUND WILL ACTIVATE THE API RELAY AND THE 10K OHM POT, ON THE ATC RELAY PANEL
WILL CONTROL THE Z AXIS CURRENT LIMIT. ADJUST THE Z AXIS CURRENT LIMIT POT ON THE
ATC PANEL SO THE Z AXIS WILL JUST RUN RELIABLY. USE GLYPTOL ON THE POT. STEM TO HOLD
IT'S POSITION.
3. PLACE PROTECTIVE STOCK BOX UNDER SPINDLE AND TC AREA TO SHIELD TABLE SURFACES
FROM FALLING TOOLS. INSERT TOOL HOLDER IN SPINDLE. ATTEMPT AUTOMATIC TOOL CHANGE
CAUTIOUSLY, BEING PREPARED TO DEPRESS EMERGENCY STOP OR MOTION HOLD.
HINT: BY LOWERING THE RAPID TRAVERSE SPEED IN DATA BLOCK 0.1 TO 10 IPM, ANY TOOL
DEFLECTION CAN BE SEEN AS THE TOOL IS RELEASED AND THE Z GOES UP, OR, WHEN Z AXIS
COMES DOWN AND THE TOOL ENGAGES SPINDLE.
BEFORE TC CYCLES
1.
2.
3.
4.
RUN EACH TOOL POSITION AT LEAST TWICE IN AUTO TC.
ENSURE TANG IS BENT TO LOCK NUT ON TORQUE LIMITER.
ENSURE LOCKNUT IS TIGHT ON SHOCK ABSORBER.
ENSURE SHOT PIN MOUNTING BOLTS ARE TIGHT.
5. ENSURE MOUNTING BOLTS FOR TOOL CHANGER ARM ARE TIGHT.
6. ENSURE LOCKNUT ON MECHANICAL STOP IS TIGHT.
7. ENSURE E.S. ARM DEFLECTION SWITCH IS CORRECTLY ADJUSTED AND OPERABLE. 8.
ENSURE CHAIN HAS BEEN ADJUSTED.
9. ENSURE ALL MOUNTING SCREWS AND SET SCREWS HAVE BEN LOCTITED WITH #242.
10. ENSURE ALL TOOL HOLDERS TO BE USED FOR TC CYCLE DO NOT CONTAIN TOOLS.
11. PROCEED WITH CYCLING
12. AT LEAST THE LAST 250 TOOL CHANGES MUST HAVE THE COMPLETE COVERS MOUNTED
DURING CYCLES.
TOOL CHANGER PINNING
THERE ARE TWO HOLES NEAR THE ARM MOUNTING BOLTS. DRILL THROUGH THESE HOLES INTO
THE FRAME TO A DEPTH OF 3/4". DRILL SIZE Q, REAM SIZE IS .374" AND PIN SIZE IS PULL DOWEL
3/8 X 1 3/4 (HURCO PN 112-0013-001).
SHOT PIN PINNING
THERE ARE TWO HOLES NEAR THE MOUNTING BOLTS ON THE SHOT PIN BRACKET.
DRILL INTO THE HEAD THROUGH THESE HOLES TO A DEPTH OF .50". USE DRILL SIZE 3/16" AND
3/16" X 1 1/4 SPRING PIN.
DATE: DEC. 22, 1981
ISSUE NUMBER: 1002
SUBJECT: RELIABILITY IMPROVEMENT B INTERFACE BRD SUPERSEDES NUMBER:
117
PRODUCT LINE: ALL B CONTROL MILLS
PAGE 1 OF 1
THIS MODIFICATION SHOULD BE MADE WHEN A MACHINE EXHIBITS MANUAL JOG
HAND WHEEL RESPONSE PROBLEMS. THIS MODIFICATION SHOULD BE
ACCOMPLISHED PRIOR TO ORDERING A REPLACEMENT INTERFACE BOARD.
REFERENCE SCHEMATIC AND PICTORIAL ATTACHED:
1. CUT LAND TO PIN 6 OF 14035 AT THE POINT SHOWN ON SHEET TWO
WHICH IS MARKED BUY THE X.
2. ADD JUMPERS AS SHOWN ON THE NON COMPONENT SIDE OF THE
BOARD,
INSTALL ONE JUMPER FROM PIN 24 TO PIN 10 OF THE 7400.
3. ADD A 2K OHM RESISTOR FROM PIN 8 TO PIN 14 OF THE 7400 ON THE
COMPONENT SIDE OF THE BOARD AS SHOWN ON SHEET THREE.
PARTS REQUIRED:
1. ONE 2K OHM 1/4 WATT RESISTOR 407-0007-030.
2 EIGHT INCHES OF 28-30 GAUGE SOLID INSULATED WIRE.
SHEET FIVE SHOWS THE SCHEMATIC OF THE INTERFACE BOARD.
SHEET FOUR SHOWS THE MODIFICATION AS IT APPEARS ELECTRICALLY.
ORIGINATOR: WAYNE HAWKINS
REVISED BY: R BRYANT
DATE: JANUARY 5, 1982
ISSUE NUMBER: 1003
SUBJECT:NUISANCE SHEAR PINNING ON PARAJUST B SUPERSEDES NUMBER: 119
PRODUCT LINE: ALL B AND BX BED MILLS
PAGE 1 OF 1
WE HAVE RECENTLY FOUND THAT NUISANCE SHEAR PINNING IS NOT CAUSED BY
THE ACTUAL SHEAR PIN CIRCUITRY BUT IS CAUSED BY THE SHEAR PIN RESET
CIRCUITRY. THIS CIRCUIT DRAWN BELOW IS COMPOSED OF NORMALLY CLOSED
SET OF K1 CONTACTS, CAPACITOR C12 ON THE FREQUENCY CONTROL BOARD
AND K5 RELAY ON THE VOLTAGE CONTROL BOARD. WHENEVER WE TURN THE
DRIVE OFF WE DROP OUT THE K1 RELAY WHICH IN TURN CLOSES THE K1
CONTACTS ALLOWING CURRENT TO FLOW THROUGH THE K5 RELAY COIL. THE K5
WILL THEN PICK UP AND SHOULD STAY PICKED UP UNTIL CAPACITOR C12
CHARGES AT WHICH POINT K5 THEN DROPS OUT. THIS IS THE REASON WHY,
WHENEVER WE DO A TOOL CHANGE, IT APPEARS THAT WE GET A SHEAR PIN
INDICATION. IF WE DISABLE THE CIRCUIT BY CLIPPING CAPACITOR C12 OUT THE
NUISANCE SHEAR PIN WILL GO AWAY. WE CAN ALSO ATTRIBUTE THE K5
STICKING RELAY PROBLEM TO THIS SAME CIRCUIT IF CAPACITOR C12 IS LEAKY
IT MIGHT ALLOW ENOUGH CURRENT TO FLOW EVEN WHEN CHARGED TO HOLD
THE K5 RELAY ON. THIS WOULD BE SEEN AS A STUCK RELAY AND TAPPING THE
RELAY USUALLY DROPS IT OUT. IF YOU SHOULD RUN INTO THIS PROBLEM TRY
CLIPPING C12 AND RUNNING THE MACHINE TO SEE IF THE PROBLEM GOES AWAY.
IF IT DOES NOT GO AWAY WHEN IT IS AN ACTUAL SHEAR PIN AND SHOULD BE
INVESTIGATED TO FIND THE CAUSE OF THE PROBLEM.
REVISED BY:
ISSUE NUMBER: 1004
SUBJECT:
ENCODER INSTALLATION
PRODUCT LINE: KM1
PAGE 1
OF 1
REMOVAL
1. ACCESS THE ENCODER FOR THE Z AXIS BY REMOVING THE FIBERGLASS HALF- COVER,
FOR THE X AXIS THE MOTOR COVER AND FOR THE Y AXIS, THE COVER ON THE Y MAIN
FRAME.
2. REMOVE THE BLACK PLASTIC ENCODER CAP.
3. UNPLUG THE ENCODER. PULL APART THE PLUG BODIES ONLY. DO NOT PULL ON THE
WIRES GOING INTO THE PLUGS.
4. REMOVE THE TWO SCREWS HOLDING THE ENCODER BODY TO THE LIMIT SWITCH
BRACKET. REMOVE THE BODY BY PULLING IT AT A RIGHT ANGLE AWAY FROM THE DISK
SHAFT.
5. LOOSEN THE TWO SCREWS HOLDING THE DISK TO THE SHAFT AND REMOVE THE DISK.
THESE SET SCREWS MAY BE EITHER BRISTOL SPINE OR HEX.
CAUTION: THE DISK CAN BE EASILY CHIPPED CRACKED OR SCRATCHED AND
SHOULD BE HANDLED WITH CARE.
INSTALLATION
1. CLEAN AREA ON LIMIT SWITCH ASSEMBLY BRACKET WHERE ENCODER MOUNTS.
2. PLACE THE ENCODER DISK ON THE ENCODER SHAFT. DO NOT TIGHTEN SET SCREWS.
3. CAREFULLY PLACE THE ENCODER BODY AROUND THE DISK, BEING CAREFUL NOT TO
SCRATCH THE DISK. SCREW THE ENCODER BODY TO THE LIMIT SWITCH BRACKET.
CAUTION: USE A THIN-BLADED SCREWDRIVER WHEN TIGHTENING THE
MOUNTING SCREWS, A LARGE BLADED SCREWDRIVER CAN DAMAGE THE DISK BECAUSE
OF THE PROXIMITY OF THE DISK EDGE TO THE SCREW HEAD.
4. INSERT THE .008" SHIM BETWEEN THE DISK AND THE READING HEAD ON THE
ENCODER BODY. ADJUST THE DISK TO THE SHIM AND THE BODY AND TIGHTEN THE SET
SCREWS. REMOVE THE SHIM. THE .008" DIMENSION IS THE CORRECT DISK-TO-READING
HEAD GAP.
5. PLUG IN THE NEW ENCODER.
6. IF POSSIBLE SET UP A DUAL TRACE OSCILLOSCOPE TO PINS 1 AND 2 OF SJ 3,4 OR 5 ON
THE SERVO CONTROL BOARD. JOG THE AXIS AT 50 INCHES PER MINUTE TO ENSURE THAT
BOTH PHASES ARE CHANGING AND 90 DEGREES SHIFTED.
ORIGINATOR: UNKNOWN
REVISED BY: R. BRYANT
DATE:FEBRUARY 10, 1982
ISSUE NUMBER: 1005
SUBJECT: POWER DOWN MEMORY CIRCUIT
PRODUCT LINE: B CONTROL MILLS
PAGE 1
OF 2
THIS BULLETIN IS TO CLARIFY THE BATTERY PROTECTION CIRCUIT USED IN THE B
CONTROL MILLS.
FIGURE 1 SHOWS THE BASIC HARDWIRING CIRCUIT BETWEEN THE DC POWER SUPPLY
AND THE MPU AND THE MEMORY BOARDS. THIS DRAWING DOES NOT SHOW ALL THE
WIRING, BUT ONLY THOSE INVOLVED WITH THE MEMORY BACKUP SUPPLY FOR POWER
DOWN CONDITIONS. ALL MILL SUPPLIES ARE BASICALLY THE SAME, THE ONLY
DIFFERENCE WOULD BE THAT OF SPECIFIC WIRE LOCATIONS. REFER TO THE OWNER'S
MANUAL OF THE PARTICULAR MACHINE YOU ARE WORKING ON.
FIGURE 2 SHOWS THE ACTUAL POWER CIRCUIT WHICH EXISTS ON THE MPU BOARD AND
TIED TOGETHER WITH THE MEMORY BOARDS BY THE BACKPLANE CABLE J1-50. THE
BATTERY PRESENTLY IS USED UP TO 3.7 VDC AND SLOWLY BLEED OFF POWER UNTIL IT
REACHES APPROXIMATELY 2.0 VDC BELOW THIS LEVEL THE HARDWARE ON THE
MEMORY BOARDS (U1, U3, U12) IS NOT RATED TO PERFORM AND A MEMORY FAILURE
MAY OCCUR.
IN TROUBLE-SHOOTING A SYSTEM, IT IMPERATIVE TO ASSURE ALL BOARDS HAVE THE
CORRECT VOLTAGES PRESENT DURING A POWER DOWN CONDITION. UNTIL YOU DO THIS,
BY MEASURING THE BOARDS PLUS VERIFYING WIRING, YOU CAN NOT ASSUME YOU
HAVE A MEMORY OF MPU BOARD FAILURE.
ORIGINATOR: JERRY MC CLATCHEY
DATE: MARCH 30, 1982
ISSUE NUMBER: 1006
SUBJECT: PROPER AXIS CURRENT DRAW FOR KMB-1
PRODUCT LINE: KMB-1
PAGE 1
OF 1
IT APPEARS THERE IS SOME CONFUSION WITH AXIS CURRENT READINGS AND
ADJUSTMENT FOR THE KMB-1 X, Y AND Z AXIS. THE MACHINES ARE SET UP ON THE
MANUFACTURING FLOOR TO DRAW BETWEEN 4.5 AND 5.5 AMPS AT 50 IPM. THIS
ACCOMMODATES THE PRE-LOAD SETTINGS OF THE BEARING'S AND ALLOWS THE
RIGIDITY OF THE MACHINE TO PASS SQUARENESS AND GEOMETRY TESTS. THE CURRENT
DRAW IS NOT TAKEN INTO CONSIDERATION ON THE LAST ONE INCH OF POSITIVE Y AXIS
TRAVEL BECAUSE OF THE CONSTRUCTION OF THE SADDLE ASSEMBLY AND THE FACT
THAT THE WAYS HAVE A SLIGHT OUTWARD BOW BUILT INTO THEM. ALSO, THE LAST
ONE INCH OF THE NEGATIVE X AXIS TRAVEL IS NOT CONSIDERED BECAUSE OF THE
MOTOR MOUNTING BRACKET AND THE CRITICAL ALIGNMENT OF BALL SCREW.
MANUFACTURING IS ALLOWING UP TO 7 AMPS INTERMITTENTLY ON THE AXIS WHEN
THE MACHINE HAS THE MODERN STYLE BALL NUT. THE WAY YOU CAN TELL THE
DIFFERENCE BETWEEN THE MODERN STYLE AND THE OLD NUT IS BY LOOKING AT THE
BALL NUT ITSELF. THE MODERN NUT HAS TWO METAL BANDS IN PLACE AROUND BALL
RETURN TUBES. ALSO, THESE RETURN TUBES ARE MUCH MORE PRONOUNCED ON THE
MODERN BALL NUT, WHEREAS, THE OLD ONES WERE CONSTRUCTED WITHIN THE NUT
ITSELF. THE NUT EASILY ACCESSIBLE ON THE Y AXIS BY SIMPLY REMOVING THE METAL
PLATE ON THE RIGHT SIDE OF THE KNEE. TO GET TO THE X AXIS TO DETERMINE WHICH
STYLE IT IS SIMPLY RUN THE X AXIS TO THE FULL POSITIVE POSITION, THEN LOOK
UNDERNEATH THE TABLE AT THE NUT ITSELF. THE Z AXIS IS ACCESSIBLE BY JUST
REMOVING THE FRONT
COVER ON THE HEAD AND LOOKING IN AT THE NUT. TO ELIMINATE ANY CONFUSION
INSETTING THESE CURRENTS, A NORMAL CURRENT DRAW IS TO BE BETWEEN 4.5 AND 5.5
AMPS ON THE OLD AS WELL AS THE NEW BALL NUT THE MODERN NUT CAN DRAW UP TO
7 AMPS INTERMITTENTLY.
THESE CURRENT READINGS SHOULD BE TAKEN FROM THE FULL LIMITS OF AXIS TRAVEL
WITH THE EXCEPTION OF THE LAST ONE INCH IN THE X AXIS AND THE LAST ONE INCH IN
THE Y AXIS. THE READINGS SHOULD BE CONSISTENT OVER THE WHOLE LENGTH OF
TRAVEL. WHEN THE AXIS IS STILL THE STANDING CURRENT IS TO BE A MAXIMUM OF 2.5
AMPS. TYPICAL STANDING CURRENT IS 1 TO 1.5 AMPS.
ORIGINATOR: RANDALL RENNEKAMP
ISSUE NUMBER: 1007
SUBJECT: MB1 SHOT PIN LIMIT SWITCH
PRODUCT LINE: MB1 MILL
PAGE 1
OF 2
IN THE PAST WE HAVE EXPERIENCED MANY PROBLEMS WITH THE SHOT PIN LIMIT
SWITCH ON THE MB1 MACHINES. THE NEW STYLE LIMIT SWITCH DESIGN THAT IS USED
ON THE MB1H MACHINE SEEMS TO BE FAR SUPERIOR. THEREFORE IF YOU RUN INTO A
MACHINE WITH PROBLEMS RELATED TO THE SHOT PIN LIMIT SWITCH, IT MAY BE A
GOOD IDEA TO RETROFIT THE NEW STYLE PROXIMITY SWITCH. THIS CAN BE
ACCOMPLISHED QUITE EASILY AND REQUIRES ONLY A FEW PARTS.
1) 802-0914-001
2) 117-0001-015
3) 101-0001-005
4) 110-1005-001
5) 423-1005-001
6) 406-2523-001
7) 406-0801-006
8) 406-0801-002
BRACKET
1
4-40 HEX NUT
2
4-40 X 3/4 SHCS
2
4 INTERNAL STARWASHER
PROXIMITY SWITCH 1
20 GA RED WIRE
MOLEX PINS
3
MOLEX BODY
1
2
12"
PROCEDURE
1. REMOVE POWER FROM THE MACHINE.
2. REMOVE BROWN AND WHITE WIRES FROM THE EXISTING SHOT PIN LIMIT SWITCH.
THESE WILL BE USED LATER SO DO NOT CUT THEM OFF.
3. REMOVE OLD LIMIT SWITCH AND BRACKET BY REMOVING THE TWO BUTTON HEAD
SCREWS. SAVE THESE SCREWS FOR FUTURE USE.
4. MOUNT NEW PROXIMITY SWITCH ONTO NEW BRACKET USING THE TWO STAR
WASHERS AND THE TWO #4-40X3/4 SOCKET HEAD CAP SCREWS AND THE TWO 4-40 HEX
NUTS.
5. MOUNT THE NEW SWITCH AND THE BRACKET TO THE SHOT PIN ASSEMBLY USING THE
BUTTON HEAD SCREWS, WHICH WERE REMOVED IN STEP 2.
6. ATTACH A MOLEX PIN TO EACH OF THE BROWN AND THE WHITE WIRES, WHICH WERE
REMOVED IN STEP 1. ALSO ATTACH A MOLEX PIN TO ONE END OF THE RED WIRE.
7. INSERT THE THREE MOLEX PINS INTO THE MOLEX BODY SUCH THAT PIN 1 IS RED, PIN 2
IS WHITE AND PIN 3 IS BROWN. WHEN THE SWITCH IS PLUGGED INTO THIS CONNECTOR,
THE RED WIRES SHOULD CONNECT, THE WHITE WIRE SHOULD CONNECT TO THE BLACK
WIRE FROM THE SWITCH AND THE BROWN WIRE SHOULD CONNECT TO THE WHITE WIRE
FROM THE SWITCH.
8. CONNECT THE OTHER END OF THE RED WIRE TO PIN 1 OF THE TOOL IN SPINDLE PHOTO
CELL SWITCH ASSEMBLY. THIS SHOULD SUPPLY +5VDC TO THE SWITCH.
9. UNPLUG THE PROXIMITY SWITCH AND APPLY POWER. CHECK FOR +5 WITH A METER
AT THE MOLEX PLUG YOU JUST INSTALLED, FROM PIN 1 (RED WIRE) TO PIN 2 (WHITE
WIRE).
10. PLUG THE PROXIMITY SWITCH IN AND LOAD THE MASTER TAPE. SELECT LANGUAGE
AND PUT THE CONTROL IN EMERGENCY STOP. PUSH POWER ON BUTTON TO RELEASE
SPINDLE BRAKE. MONITOR PIN 2 OF THE MOLEX CONNECTOR.
11. ROTATE SPINDLE BY HAND UNTIL NOTCH IN SPINDLE IS DIRECTLY IN FRONT OF SHOT
PIN CYLINDER.
12. ENERGIZE SHOT PIN AIR VALVE IN UPPER RIGHT SECTION OF HEAD. WATCH SIGNAL
FOR A LOW INDICATION WHEN THE SHOT PIN IS ENERGIZED. IF NOT LOW INDICATION
APPEARS, ADJUST THE SWITCH UNTIL A LOW SIGNAL IS OBTAINED.
13. ROTATE THE SPINDLE UNTIL THE NOTCH IS NOT IN FRONT OF THE SHOT PIN
CYLINDER.
14. ENERGIZE THE SHOT PIN AIR VALVE AND WATCH THE SIGNAL. A LOW INDICATION
SHOULD NOT APPEAR. ID A LOW SIGNAL IS SEEN, ADJUST THE SWITCH UNTIL THE LOW
SIGNAL IS NOT PRESENT.
15. REPEAT STEPS 11-14 UNTIL THE PROPER ADJUSTMENT ID OBTAINED. A LOW
INDICATION SHOULD ONLY BE SEEN WHEN THE SHOT PIN IS IN THE NOTCH ON THE
SPINDLE.
16. ONCE PROPER ADJUSTMENT IS OBTAINED. REMOVE THE BUTTON HEAD MOUNTING
SCREWS ONE AT A TIME AND APPLY LOCTITE # 242 AND RE-INSTALL THE SCREWS.
17. SET THE MACHINE AND RUN AN AUTO TOOL CHANGE TO BE SURE THAT THE SWITCH
IS WORKING PROPERLY.
18. THIS COMPLETES THE RETROFIT AND THE LAST STEP IS TO NOTE ON YOUR SERVICE
REPORT THAT THIS RETROFIT HAS BEEN DONE.
NOTE: THE MOUNTING BRACKET IS TAPPED FOR M2.5X.45 SCREWS SO IT MAY BE
NECESSARY TO ENLARGE THE HOLES IN ORDER TO GET THE 4-40 SCREWS THROUGH.
REVISED BY:
DATE: APRIL 16, 1982
ISSUE NUMBER: 1008
SUBJECT:
PARAJUST B CHOPPER BOARDS
PRODUCT LINE: ALL BED MILLS USING B PARAJUST
PAGE 1
OF 1
RECENTLY WE HAVE BEEN MADE AWARE THAT THERE IS SOME CONFUSION
PERTAINING TO THE CHOPPER BOARS FOR A PARAJUST B UNIT.
THE QUESTION WAS ASKED IF THE MBII STYLE CHOPPER BOARD AND THE MBIH
STYLE CHOPPER BOARD WERE THE SAME. THE MBII 10 AND 15HP PARAJUST UNITS USE A
CHOPPER BOARD WITH THE PART NUMBER 402-6005-009; THE MBIH 7 1/2 HP PARAJUST
UNITS USE A CHOPPER WITH PART NUMBER 402-5004-005. THE ONLY DIFFERENCE
BETWEEN THESE TWO CHOPPER BOARDS IS THE VALVE OF RESISTOR R2. FOR 10HP AND
15 HP UNITS THE VALUE SHOULD BE 2.. OHMS, FOR THE 7 1/2 HP UNITS R2 VALUE IS 390
OHMS. IF YOU ARE IN THE FIELD AND SHOULD HAPPEN TO RECEIVE A CHOPPER BOARD
FOR REPLACEMENT INTO A MACHINE IT MAY BE A WISE IDEA TO VERIFY THE VALUE OF
R2, JUST TO BE SURE THAT YOU HAVE THE CORRECT CHOPPER BOARD FOR THE MACHINE
YOU ARE WORKING ON. ALSO, IF YOU RECEIVE ONE STYLE BOARD AND FIND THAT R2 IS
NOT WHAT YOU REALLY NEED YOU CAN SIMPLY CHANGE THE VALUE OF R2 TO MAKE
THE CHOPPER WORK IN YOUR PARTICULAR MODEL OF MACHINE.
REVISED BY:
DATE: MAY 3, 1982
ISSUE NUMBER: 1009
SUBJECT:
PARAJUST A SETUP
PRODUCT LINE: ANY MILL USING PARAJUST A
PAGE 1
OF 3
MATERIALS REQUIRED:
DIGITAL TACHOMETER
OSCILLOSCOPE
DIGITAL MULTI-METER
1. TURN ODD DISCONNECT SWITCH TO REMOVE POWER.
2. CHECK ALL TERMINAL STRIPS FOR TIGHT SCREWS AND GOOD CRIMP CONNECTIONS.
3. VERIFY THE FOLLOWING.
A. CAUTION HIGH VOLTAGE LABELS IN PROPER PLACE.
B. GROUND WIRE FROM PARAJUST CHASSIS TO ITS, MECCA GROUND ASSEMBLY
C. GROUND WIRE FROM SPINDLE MOTOR TO PARAJUST CABINET.
D. POLARITY OF WIRING CORRECT .015 OHM CURRENT SENSE RESISTOR. (BLACK ON
TOP, WHITE OR CLEAR ON BOTTOM).
E. INSURE SLIDE SWITCH S1 ON THE ANALOG BOARD IS IN THE L POSITION.
F. INSURE SLIDE SWITCH S2 ON THE ANALOG BOARD IS IN THE 5HP POSITION.
G. INSURE ALL TERMINALS ON THE DC BUSS CAPACITORS ARE SOLDERED.
H. INSURE RESISTANCE ON THE DYNAMIC BRAKE BOARD OUTPUT RESISTORS IS
BETWEEN 11 AND 13 PHMS, AND WIRE INTO THE PARAJUST PROPERLY.
4. THE RESISTANCE MEASURED BETWEEN THE ISOLATION INTERFACE BOARD TERMINAL
# 11 AND TERMINAL # 14 MUST BE GREATER THAN 19 MEG OHM.
5. INSURE THAT THE DIODES MARE MOUNTED CORRECTLY ON THE DYNAMIC BRAKING
BOARD, (DIODES ARE IN5626 PART NUMBER 417-0001-017. NOTE DIODES MAY BE PREWIRED ON THE BRAKING BOARD).
TWO LEADS OF THE DIODES COME FROM TB7-1, THE TOP DIODE HAS THE BANDED
END COMING FROM TB7-1 THE BOTTOM AWAY FROM TB7-1
THE OTHER END OF THE TOP DIODE GOES TO TB6 NEG TERMINAL.
THE OTHER END OF THE BOTTOM DIODE THE BANDED END GOES TO TB6
POSITIVE TERMINAL.
ORIGINATOR: RANDAL RENNEKANP
DYNAMIC BRAKING BOARD DIODES:
6. SET THE FOLLOWING POTS AS SPECIFIED:
ANALOG BOARD
ACC/DEC
V/HZ
BOOST
SHEAR PIN
BRAKE BOARD
FULL CW
50%
THRESHOLD
FULL CCW
FULL CW
GAIN
FULL CCW
FULL CCW,CW 1/4 T
7. THE RESISTANCE BETWEEN TB1-10 AND TB1-11 MUST BE 0 OHMS.
8. CONFIRM THAT THE PARAJUST BRAKE BOARD C3 IS A .56 UFD 200 VDC CAPACITOR.
9. ISOLATION INTERFACE BOARD SETUP PROCEDURE:
A. POSITION THE AUTO-MANUAL SWITCH TO THE AUTO POSITION.
B. ROTATE R65 TO ITS' MAXIMUM CCW POSITION.
C. APPLY POWER. MEASURE AC INPUT TO THE PARAJUST 218 TO 253 VAC.
D. CHECK FOR 2.2 VDC INPUT AT TERMINAL #12 WITH RESPECT TO TERMINAL #13 WITH
AN INPUT COMMAND OF 896 RPM ON THE CRT. (READ A JUST THE DAC INPUT ON THE CNC
INTERFACE IF NEEDED).
SEAL POT WITH TORQUE SEAL (HURCO PART NUMBER 348-0001-001).
E. COMMAND AN INPUT OF 208 RPM ON THE CRT AND ADJUST R27 UNTIL THE SPINDLE
RPM MEASURES 230-235 ON THE DIGITAL TACH.
F. COMMAND AN INPUT OF 3408 RPM ON THE CRT AND ADJUST R26 UNTIL THE SPINDLE
RPM MEASURES 3400 TO 3415.
G. RE-CHECK 208 AND 3408 RPM AND INSURE BOTH ARE WITHIN THE TOLERANCE
SPECIFIED. IF OUT OF SPECIFICATION, REPEAT STEPS E AND F.
H. CHECK THE FOLLOWING RPM,S.
PROGRAM
ACCEPTABLE RANGE
144
163-175
240
250-270
496
500-530
1008
1000-1070
2016
1995-2110
3600
3540-3620
IF THE RPM FALLS BELOW 3540, SUBSTITUTE THE FOLLOWING VALUES FOR 18K RESISTOR
R9 AND R17 ON THE ISOLATION INTERFACE BOARD.
R9 - 13K
R18 - 15K
THESE WILL WORK ON 9 OUT OF TEN BOARDS. THE REMAINING BOARDS WILL REQUIRE
DECADE BOXES TO TRIM.
I. IF A TOOL CHANGER IS PRESENT, COMMAND A TOOL CHANGE AND ADJUST R40 UNTIL
THE PROPER ORIENT SPEED ID REACHED. THIS IS TO BE 1 REVOLUTION /2 SECONDS. IN
MOST CASES.
J. CHECK TO SEE IF THE SCREWDRIVER ADJUSTMENT OF R56 AND R51 HAVE BEEN
SEALED. IF THEY HAVE NOT. PROCEED THRU A-H IF THEY HAVE GOTO STEP 12
A. WITH A DIGITAL VOLTAGE METER, ADJUST R56 UNTIL PIN 3 OF IC12 EQUALS 5.4 VDC
WITH RESPECT TO PHASE B. (OUTPUT SIGNAL COMMON, PIN 5 ISOLATION INTERFACE
BOARD).
B. REMOVE POWER.
C. IMPORTANT TEMPORARILY REMOVE THE LEADS COMING FROM THE CURRENT SENSE
RESISTOR INPUT TERMINALS NUMBER 6 AND 7.
D. TEMPORARILY SHORT INPUT TERMINALS 5 AND 6 TOGETHER.
E. TEMPORARILY CLIP LEAD INPUT TERMINAL # 7 TO PIN 3 OF IC8 AND SHORT OUT VRS.
F. WHEN POWER IS NOW REAPPLIED THERE SHOULD EXIST AN INPUT OF ABOUT .138 VDC
BETWEEN TERMINALS 6 AND 7.
G. MONITORING PIN 6 OF IC11 WITH RESPECT TO PHASE B (OUTPUT SIGNAL COMMON, PIN
#5 ISOLATION INTERFACE BOARD) WITH A DIGITAL VOLTMETER, ADJUST R51 UNTIL PIN 6
MEASURES 10.47 TIMES THE VDC BETWEEN TERMINALS 6 AND 7.
H. REMOVE ALL CLIP LEADS, TEMPORARY SHORTS AND RECONNECT THE CURRENT
SENSE RESISTOR TO INPUT TERMINALS 6 AND 7. CAREFULLY NOTING POLARITY. (WHITE
OR CLEAR PIN 6, BLACK PIN 7). SEAL THE ADJUSTMENTS OF ALL POTS ON P.C. BOARD
WITH TORQUE SEAL (HURCO PART NUMBER 348- 0001-001).
12. DISCONNECT POWER, BE SURE THAT THE LARGE FILTER CAPACITORS INSIDE THE
PARAJUST ARE DISCHARGED.
13. POSITION THE AUTO/MANUAL SWITCH OF ISOLATION INTERFACE BOARD THE
MANUAL POSITION. POSITION R38 FULL CCW THEN TURN CW 6 TURNS
14. RE-APPLY POWER. MEASURE AC INPUT TO PARAJUST, 218 TO 253 VAC.
15. ENERGIZE SPINDLE.
A. POSITION R38 UNTIL SPINDLE RPM FALLS BETWEEN 200-208 RPM'S READING FROM THE
DIGITAL TACH. ADJUST THE PARAJUST BOOST UNTIL THE SPINDLE MEASURES 72.2 TO
43.4 VDC ON THE DC BUSS CAPACITORS (BOTH LELAND AND G.E. MOTORS).
16. POSITION R38 UNTIL THE SPINDLE RPM FALLS BETWEEN 896-900 RPM ON THE DIGITAL
TACH. ADJUST PARAJUST V/HZ POTENTIOMETER UNTIL PARAJUST DC BUSS VOLTAGE
MEASURES 278 TO 282 VDC. (BOTH LELAND AND G.E. MOTORS)
17. REPEAT STEPS 15 AND 16 UNTIL NO FURTHER ADJUSTMENTS ARE NECESSARY.
18. ADJUST R38 UNTIL THE SPINDLE SPEED IS 2000 RPM, ON THE DIGITAL TACH, WILE
SWITCHING THE AUTO-MANUAL SWITCH BETWEEN OFF AND MANUAL, SET THE RAMP UP
AND DOWN WITH THE ACCEL/DECEL POTS, WHILE THE OSCILLOSCOPE IS CONNECTED AT
TB1-12 AND TB1-13 (PARAJUST COMMON) FOR A RAMP OF 3 SECONDS FOR LELAND
MOTOR AND A RAMP OF 1.4 SECONDS FOR A G.E. MOTOR NOTE: IF THIS ADJUSTMENT
CANNOT BE SET LESS THAN OR EQUAL TO 3 SECONDS FOR LELAND MOTOR, CHECK THE
SIZE OF C7 ON THE ANALOG BOARD AND REPLACE WITH A 10 UFD 25V CAPACITOR IF
NEEDED.
CAUTION: THE RED WIRE OF THE CAP BANK CAN BE FLOATING AT 300 VOLTS ABOVE
CHASSIS. THE SCOPE CHASSIS WILL ALSO BE AT THIS POTENTIAL WHEN THE GROUND IS
CONNECTED TO THE PARAJUST SIGNAL COMMON. DO NOT HAVE THE SAFETY GROUND
ON THE SCOPE HOOKED UP ALSO THE METAL OF THE SCOPE WILL BE AT THIS VOLTAGE
DO NOT TOUCH.
THIS RAMP DOWN AND RAMP UP REFERS TO THE MAXIMUM SPINDLE MOTOR
ACCELERATION FROM 9 TO 2000 RPM AND A MAXIMUM SPINDLE MOTOR DECELERATION
FROM 2000 TO 0 RPM.
DATE: MAY 7, 1982
ISSUE NUMBER: 1010
SUBJECT: CHATTER ON KMB-IM & KMB-I MILLS
PRODUCT LINE: KONDIA STYLE KNEEL MILLS
PAGE 1
OF 1
WHEN CUTTING FAIRLY MILD CUTS IN ALUMINUM OR STEEL, SOME MACHINES
SEEM TO SHOW EXCESSIVE CHATTER IN THE SPINDLE. WHEN THERE IS A PROBLEM, THE
NOISE IS USUALLY MORE PREVALENT WHEN AN AXIS IS MILLING IN ONE DIRECTION,
WHILE THE OTHER DIRECTION SEEMS MUCH SMOOTHER. CHECK TO SEE ID THERE IS A
GAP BETWEEN THE SPINDLE NUT AND THE QUILL. THE SPINDLE NUT HOLDS THE SPINDLE
UP IN THE QUILL AND PUTS THE PRELOAD ON THE OUTER RACES OF THE SPINDLE
BEARING'S. IF THERE IS NO GAP THIS MEANS THE QUILL NUT IS BOTTOMED OUT AND
THERE PROBABLY WON'T BE SUFFICIENT PRELOAD ON THE BEARING'S. THE MINIMUM
GAP IS .010 INCH. WE DON'T WANT A LARGE GAP BECAUSE IT COULD BE A CHIP TRAP
AND DRAG CHIPS INTO THE BORE.
IF YOU HAVE A MACHINE WHICH HAS NO CLEARANCE. THE NUT MUST BE
REMOVED AND TURNED DOWN ON A LATHE. TO REMOVE THIS NUT YOU MUST FIRST
REMOVE THE ERICHSON OR UNIVERSAL SPINDLE NUT. THEN LOOSEN THE ALLEN HEAD
SCREW ON THE BACK OF THE QUILL (IT MAY BE COVER WITH PUTTY TO KEEP CHIPS OUT)
THEN TURN THE NUT OFF THE QUILL. AFTER REINSTALLING THE NUT AND THE SET
SCREW RE-PUTTY THE SET SCREW HOLE TO KEEP THE CHIP OUT OF THE BORE.
NOTE: IF YOU HAVE TOO MUCH CLEARANCE THE THREADED PART OF THE NUT MUST BE
TURNED DOWN.
ORIGINATOR: RANDAL RENNEKAMP
DATE: MAY 13, 1982
ISSUE NUMBER: 1011
SUBJECT: FRONT PANEL BOARD MODIFICATIONS
PRODUCT LINE: ANY B CONTROL MILL
PAGE 1
OF 1
IF YOU SHOULD RUN INTO A MACHINE THAT HAS BENDING OF THE VIDEO AT THE TOP
OF THE SCREEN, THE FOLLOWING MODIFICATION TO THE FRONT PANEL BOARD SHOULD
CURE THE PROBLEM.
STEP 1
CUT THE LAND BETWEEN PIN 5 AND PIN 5 OF IC 33 (7430).
STEP 2
ADD A JUMPER FROM PIN 6 OF IC 33 (7430) TO PIN 24 OF IC 28 (MCM66710P).
STEP 3
REPLACE R80 WITH A 100 OHM 1/4 WATT 5 PERCENT RESISTOR.
THIS MODIFICATION WILL MORE CLOSELY MATCH THE INPUT REQUIREMENTS OF THE CRT BY
DECREASING THE VERTICAL SYNC SIGNAL TO 500 MICRO SECONDS AND DECREASING
COMPOSITE VIDEO OUTPUT TO 1 VOLT PEAK TO PEAK.
REVISED BY:
DATE: MAY 26, 1982
ISSUE NUMBER: 1012
SUBJECT:
MILL AUTO LUBE OIL TYPE
PRODUCT LINE: MILLS
PAGE 1
OF 1
THE TYPE OF OIL WE RECOMMEND FOR USE IN OUR MACHINES IS MOBIL VACTRA 2 OR
EQUIVALENT. HERE IS A SMALL CROSS LIST OF MANUFACTURERS.
ALLUBE
AMERICAN INDUSTRIAL
AMERICAN INDUSTRIES INC.
AMERICAN LUBRICANTS CO.
AMOCO OIL CO.
ANDERSON OIL & CHEMICAL CO.
ASHLAND OIL INC.
ATLANTIC RICHFIELD CO.
BEL-RAY CO. INC.
BROOKS TECHNOLOGY CO.
CATA OIL & GREASE CO.
CHEVRON USA INC.
CITIES SERVICE CO.
CONTINENTAL OIL CO.
DARMEX INDUSTRIAL CORP.
DAVIS HOWLAND OIL CORP
DUBOIS CHEMICALS
EXXON CO. USA
FISKE BROS. REFININHG CO.
GEORGE-CAROLINA OIL CO.
GETTY REFINING & MARKETING
GRAPHITE PRODUCTS CORP.
GULF OIL CORP
IMPERIAL OIL * GREASE CO.
KENDALL REFINING CO.
MOBIL OIL CORP.
UNION OIL CO. OF CALIFORNIA
MOLY SHIELD WAY OIL 315
REXLUBE #20
516 WAY LUBES #20
ALUCO MOLY WAY LUBE #40
WAYTAC OIL #31
WINSOR WAY OIL 1L
WAULUBE W-30
TRUSLIDE S-315
RAYLENE EP OIL #2
BARCOTE 961
MED. HVY OIL FOR SLIDEWAYS
CHEVRON OIL 68
CITGO SLIDERITE NO. 2
HD WAY LUBE 31
DARMEX 1050
WAY OIL 80
MPO-30
FEBIS K68
NO. 3-V
G-C PRESS MEDIUM
VEEDOL ATLINE 20
GP #350 WO
GULFWAY 52
MOLUB-ALLOY M.W.O. 20
KENDALL 965
VACTRA NO. 2
WAY OIL HD 315
ORIGINATOR: RANDAL RENNEKANP
DATE: MAY 27, 1982
ISSUE NUMBER: 1013
SUBJECT:
MBII SPINDLE SHOT PIN LIMIT SWITCH
OPTIMUM SETTING
PRODUCT LINE:
MB 2
PAGE 1
OF 2
TO CLARIFY ANY MISCONCEPTIONS AND AS A REMINDER, THE FOLLOWING PROCEDURE
SHOULD BE USED FOR ADJUSTING THE SPINDLE SHOT PIN (IN) LIMIT SWITCH FOR AN
OPTIMUM SETTING:
1. PLACE CONTROL IN EMERGENCY STOP CONDITION.
2. MANUALLY ACTIVATE SHOT PIN IN SOLENOID AIR VALVE SO THAT THE SHOT PIN IS
RIDING ON THE OUTSIDE OF THE ORIENTATION COLLAR.
3. THE PROPER "GAP" SHOULD BE BETWEEN .80 " TO .100" JUST AS THE SWITCH IS BEING
MADE, OR STATED ANOTHER WAY, THE LOGIC "0) LEVEL IS DETECTED ACROSS THE
SWITCH WIRES. IF THE .080" TO .100" GAP IS NOT CORRECT ADJUST THE L.S. ACTUATING
DOG TO OBTAIN IT AND REMEMBER TO LOCKTITE THE ACTUATING DOG SET SCREW
WHEN FINAL ADJUSTMENTS AREÿMADE.
NOTE: SEE ATTACHED DRAWING FOR DETAILS.
ORIGINATOR: H.D. HUNT
REVISED BY:
DATE: JUNE 3, 1982
ISSUE NUMBER: 1014
SUBJECT:
VARIDRIVE BELT REPLACEMENT
PRODUCT LINE: KONDIA VARIDRIVE MACHINES
PAGE 1
OF 1
WHEN IN A SERVICE CALL TO A CUSTOMER WHO IS HAVING PROBLEMS WITH THE
VARIDRIVE BELT. WE NEED TO CHECK THE VARIDRIVE PULLEYS FOR PITTING CAUSED
BY RUST IN SHIPMENT FROM KONDIA TO HURCO IT IS POSSIBLE THAT THESE PULLEYS
CAN ACQUIRE A SMALL RUST DEPOSIT ON THEM. THIS RUST CAN BECOME DEPOSITED IN
THE VARIDRIVE BELT, AND CAUSE IT TO WERE OUT EXCESSIVELY FAST. IF ARE ON A
CALL AND THE BELT IS WORN OR NEEDS REPLACING, MAKE SURE ANY RUST OR PITTING
IS REMOVED FROM THE VARIDRIVE PULLEYS BEFORE THE NEW BELT IS INSTALLED. THIS
CAN BE DONE BY SIMPLY RUBBING THE PULLEYS WITH STEEL WOOL AND MAKING SURE
THEY ARE CLEAN.
ORIGINATOR: R. RENNEKAMP
DATE: JUNE 9, 1982
ISSUE NUMBER: 1015
SUBJECT:
MBII ATC LIMIT SWITCH & AIR VALVE
SETTINGS
PRODUCT LINE: MB2
PAGE 1
OF 1
AS AN ENDEAVOR TO OPTIMIZE THE MB-II ATC LIMIT SWITCHES AND AIR FLOW
CONTROL VALVE SETTINGS, THE FOLLOWING SHOULD BE OBSERVED:
PUSH BUTTON LIMIT SWITCH SHOULD HAVE .050 ADDITIONAL TRAVEL WHEN
ACTIVATED BEFORE MECHANICAL STOP; ROLLER PUSH ACTUATE LIMIT SWITCHES
SHOULD HAVE .100" TO .125" ADDITIONAL TRAVEL BEFORE MECHANICAL STOP.
THE ATC AIR FLOW CONTROL VALVE ADJUSTMENT SCREWS SHOULD BE SET AS
FOLLOWS:
HI SPINDLE GEAR
1/2 TURN FROM CLOSED POSITION.
LO SPINDLE GEAR
"
"
TOOL ARM UP
"
"
TOOL POT FORWARD 1 1/4 TO 1 1/2 TURNS FROM CLOSED POSITION.
TOOL POT BACK
"
"
"
"
SPINDLE SHOT PIN OUT
"
"
"
"
CAROUSEL LOCATE IN
"
"
"
"
CAROUSEL LOCATE OUT
"
"
"
"
TOOL POT CLAMP
"
"
"
"
TOOL POT UNCLAMP "
"
"
"
VERIFY AIR REGULATOR IS SET BETWEEN 5.5 AND 6.0 KG/CM2 AND DOES NOT DROP
MORE THAN .5 KG/CM2 DURING AN AUTO TOOL CHANGE CYCLE.
ORIGINATOR: H.D. HUNT
DATE: AUGUST 31, 1982
ISSUE NUMBER: 1016
SUBJECT:
GROUND ROD USE IN HURCO MILLS
PRODUCT LINE: ALL MILL LINES
PAGE 1
OF 1
IN THE PAST HURCO SUPPLIED GROUND RODS FOR THE CUSTOMER TO USE WITH
THEE MILL. THIS PRACTICE WAS DISCONTINUED WITH THE ULTIMAX LINE OF CONTROL.
IT WAS FOUND WITH THE GROUND ROD INSTALLED THE MACHINE WAS ACTING AS THE
GROUNDING POINT FOR ALL MACHINES IN THE SHOP. CAUSING PROBLEMS WITH THE
HURCO OF COURSE. SO DO NOT HAVE AN ULTIMAX CONTROL HOOKED TO A GROUND
ROD.
WITH THE B OR BX CONTROL THEY SHOULD BE HOOKED TO THE GROUND ROD
THAT WAS SUPPLIED WITH THE MACHINE.
ORIGINATOR: R. BRYANT
REVISED BY:
DATE: SEPTEMBER 3, 1982
ISSUE NUMBER: 1017
SUBJECT:
SNOW ON CRT
PRODUCT LINE: MB1H
PAGE 1
OF 1
THE FOLLOWING MODIFICATION SHOULD BE MADE TO ALL MB1H MACHINES TO
ELIMINATE SNOW ON THE CRT. THIS SNOW IS CAUSED BY NOISE FROM THE SERVO
SYSTEM. THE NOISE REACHES THE CRT VIA THE FRONT PANEL TO CONTROL WIRING
HARNESS WHICH RUNS NEXT TO THE SERVO SYSTEM.
MODIFICATION:
1. SPLICE THE TWO WHITE WIRES TOGETHER AT THE CRT CONNECTOR. THIS TIES
THE VIDEO COMMON TO THE POWER SUPPLY COMMON.
2. MACHINES SHIPPED AFTER 6/2/82 SHOULD ALREADY HAVE THIS MODIFICATION
DONE.
REVISED BY:
DATE: FEBRUARY 24, 1983
ISSUE NUMBER: 1018
SUBJECT:
SHEAR PIN DURING TAP ON PARAJUST B
PRODUCT LINE: ALL MILLS USING PARAJUST B UNITS
PAGE 1
OF 1
IT HAS BEEN DISCOVERED THAT THE REVERSE RELAY CIRCUITY FOR THE PARAJUST CAN
CAUSE A SHEAR PIN CONDITION DURING TAP. THIS WILL SHOW UP AS AND EMERGENCY
STOP NO RPM AT THE BOTTOM OF A TAP. THIS CONDITION IS CAUSED BY A RELAY WITH
EXCESSIVE BOUNCE.
WE CAN PERFORM A SIMPLE MODIFICATION TO REMOVE THE REVERSE RELAY, AND
TRIGGER THE PARAJUST WITH A DIRECT CONNECTION TO THE OPTO-ISOLATOR THAT
CONTROLS THE REVERSE RELAY.
THIS MODIFICATION WILL ONLY WORK ON PARAJUST B UNITS AND SHOULD NOT BE
ATTEMPTED ON PARAJUST A UNITS.
MODIFICATION:
1. REMOVE WIRE AT TB8-13.
2. REMOVE WIRE AT TB9-6.
3. SPLICE THESE TWO WIRE TOGETHER.
4. REMOVE REV RELAY.
TRY DOING THIS MODIFICATION IF YOU RUN INTO A MACHINE THAT HAS HAD THIS
PROBLEM BEFORE TRYING ANYTHING ELSE. ALL MACHINES BEING BUILT AFTER 2/15/83
WILL HAVE THIS MODIFICATION DONE. A SIMILAR SOLUTION IS BEING INVESTIGATED
FOR MACHINES WITH PARAJUST A.
AGAIN I REPEAT.
DO NOT PERFORM THIS MODIFICATION ON PARAJUST A UNITS.
REVISED BY:
DATE: MAY 2, 1983
SUBJECT:
ISSUE NUMBER: 1019
MISS-WIRED CONTROL TRANSFORMER (T2) SUPERSEDES NUMBER: 155
PRODUCT LINE: MB3
PAGE 1
OF 1
ON A MB3 INSTALLATION IT WAS DISCOVERED THAT THE PRIMARY SIDE OF THE
T2 CONTROL TRANSFORMER WAS MISS-WIRED. THE 230 VAC INPUT SHOULD BE
CONNECTED TO EITHER H1-H3 OR H1-H4. IN NO CASE SHOULD THE INPUT BE CONNECTED
TO H1-H2. TO DETERMINE WHICH PRIMARY TAPS TO USE (H1-H3 OR H1- H4), MONITOR THE
SECONDARY VOLTAGE AND WIRE THE PRIMARY TO ACHIEVE AS CLOSE TO THE 120 VAC
AS POSSIBLE.
NOTE: THE CONTROL MAGNETICS SCHEMATIC (DRAWING # 002-1653-001) IN THE MB3
OWNER'S MANUAL IS MISS-WIRED. STEPS ARE BEING TAKEN TO GET THAT CORRECTED.
ORIGINATOR:
REVISED BY:
DATE: OCTOBER 28, 1983
ISSUE NUMBER: 1020
SUBJECT:
HIGH SPEED SPINDLE
PRODUCT LINE: MILLS WITH HSS
PAGE 1
OF 1
HIGH SPEED SPINDLE MACHINE ARE NOW BEING PRODUCED AND THERE ARE SOME
DIFFERENCES THAT YOU NEED TO BE AWARE OF.
1. A TAG IS BEING PLACED ON THE INSIDE OF THE PARAJUST DOOR TO HELP IDENTIFY A
HSS MACHINE.
2. THE LETTERS "HSS" ARE BEING STAMPED ON THE IDENTIFICATION PLATE AFTER THE
SERIAL NUMBER.
3. ONLY HSS MASTER TAPES SHOULD BE USED IN HSS MACHINES.
4. THE FREQUENCY BOARD OR ANALOG BOARD IS MODIFIED.
5. THE SETUP PROCEDURE IS SLIGHTLY DIFFERENT.
6. THE SPINDLE MOTOR IS DIFFERENT AND THE NEW PART NUMBER IS 401-6001- 613
7. THE SPINDLE ASSEMBLY IS ALSO DIFFERENT.
REVISED BY:
ISSUE NUMBER: 1021
SUBJECT:
BX RETROFIT TO TOOLMASTERS CONTROLS
PRODUCT LINE: MB1
PAGE 1
OF 1
WE WERE RECENTLY ABLE TO SOLVE POSITIONING PROBLEM AT TWO DIFFERENT
CUSTOMERS BY RE-ROUTING THE MOTOR WIRES AWAY FROM THE 5VDC CIRCUITRY AT
TB7-X-Y-Z. IN BOTH CASES THE WIRES WERE RE-ROUTED ALONG THE RIGHT HAND SIDE
OF THE POWER CABINET AWAY FROM THE 5VDC CIRCUITS.
IF YOU ARE EXPERIENCING A POSITIONING PROBLEM WITH A BX RETROFIT TOOLMASTER
CONTROL, TRY RE-ROUTING THE MOTOR WIRES.
REVISED BY:
ISSUE NUMBER: 1022
SUBJECT:
SET-UP OF BX SERVO CONTROL BOARD
PRODUCT LINE: BX MILLS
PAGE 1
OF 1
ALIGNMENT PROCEDURE OF BX SERVO CONTROL BOARD
THE SERVO CONTROL BOARD HAS ONLY THREE ADJUSTMENTS. THE +10 VOLT
REFERENCE LEVEL, ADJUSTMENT R15 THE -10 VOLT REFERENCE LEVEL ADJUSTMENT,
R16 THE +5 VOLTAGE REFERENCE ADJUSTMENT R14. THE LAST TWO ADJUSTMENTS ARE
DEPENDENT IN THE +10 VOLTAGE ADJUSTMENT, THUS THE +10 VOLTAGE REFERENCE R15
SHOULD BE ADJUSTED FIRST.
ADJUSTMENT PROCEDURE
1. APPLY +15, -15, AND +5 VOLTS TO THE SERVO CONTROL BOARD.
2. MONITORING THE VOLTAGE ON PIN 6 OF U33 ADJUST R15 FOR +10 VOLTS +- .01 VOLTS.
3. WILE MONITORING THE VOLTAGE ON PIN 14 OF U32 ADJUST R16 FOR -10 VOLTS +- .01V.
4. MANUALLY JOG AND AXIS AND TURN THE OVERRIDE POT TO FULL CW AND ADJUST
R14 TO ACHIEVE A FEEDRATE OF 150.8.
THE VOLTAGE ADJUSTMENTS NEED NOT BE DONE AGAIN AS LONG AS NOT IC,S ARE
REPLACED ON THE BOARD. THE VOLTAGES WILL REMAIN STABLE EVEN IF THE +-15 V
CHANGE AS WOULD BE THE CASE WHEN THE SERVO BOARD IS PLACED IN A DIFFERENT
MILL.
REVISED BY:
DATE:
JANUARY 12, 1984
ISSUE NUMBER: 1023
SUBJECT:
PARAJUST 280VDC BUSS VOLTAGE PROBLEM
PRODUCT LINE: PARAJUST B MILLS
PAGE 1
OF
1
IF IN THE FIELD YOU FIND IT DIFFICULT TO OBTAIN 280VDC @ 900 RPM
(PER MFG. DOCUMENT NO. 757-1001-003), THEN REMOVE TRIM RESISTOR R19. T
R19 TRIM RESISTOR IS USED TO SET THE POINT ON THE DC HOLD ADJUSTMENT
WHERE THE DC HOLD IS FIRST REALIZED. SINCE DC HOLD IS NOT USED IN OUR
APPLICATION, REMOVING R19 WILL HAVE NO ADVERSE AFFECT ON THE OPERATION
REVISED BY:
ISSUE NUMBER: 1024
SUBJECT:
RS232 DATA CARRIER LOSS BX MPU BRD
PRODUCT LINE: BX CONTROL MILLS
PAGE 1
OF 2
IF YOU ARE WORKING ON A BX MILL USING RS232 AND GETTING DATA CARRIER LOST
ERRORS TRY REMOVING RESISTORS R10 AND R6 330 OHM ON THE BX MPU. INPUTS J5-5,8
COULD BE ALLOWING NOISE TO BE RECEIVED. THIS MODIFICATION SHOULD ELIMINATE
THIS PROBLEM.
ISSUE NUMBER: 1025
SUBJECT: MOD TO X5 MOTHER BRD FOR MIS POSITIONING
PRODUCT LINE: MB3/MD3
PAGE 1
OF 2
THIS MODIFICATION WILL HELP ELIMINATE NOISE FROM PHASE A AND B OF LINEAR
SCALES.
ADD 4 (407-0001-058) 10PF CAPACITORS TO NON COMPONENT SIDE OF X 5 MOTHER BOARD
KEEP LEAD LENGTH SHORT (1/4" OR LESS).
ADD CAPACITORS BETWEEN:
1. J1-1 AND J1-2 GROUND AND 5 VOLTS.
4. TB1-5 AND TB1-6 GROUND AND 5 VOLTS.
VERIFY MACHINE CALIBRATION AND POSITIONING AFTER MODIFICATION.
REVISED BY:
DATE: May 9, 1984
ISSUE NUMBER: 1026
SUBJECT:
SPLINE COUPLING REPLACEMENT
PRODUCT LINE: KMB-I /KMBX-I
PAGE 1
OF 1
Before any spline coupling is replaced, the following steps need to be followed.
1) Put ample grease on spline shaft and spline coupling.
2) Re-tram head.
3) Re-align "Z" axis ballscrew assembly.
Then if noise persists, it can be determined that the spline coupling is bad and indeed should be replaced.
When new spline coupling is received, make sure there is a good fit between it and the spline shaft by
following the procedure outlined in Manufacturing Document #757-3012-011. If the fit is not good, a
new spline coupling should be ordered.
ORIGINATOR: Wayne E. Hawkins
REVISED BY:
DATE: MAY 30, 1084
ISSUE NUMBER: 1027
SUBJECT: SERVO AMP BRD AND DIODE PUMP SETUP
PRODUCT LINE: 425, 900, AND 1450 EDM,S
PAGE 1
OF 2
RETRACT TIME ADJUSTMENTS STEPS 1-8
1. REMOVE ALL MATERIALS AND/OR FIXTURES FROM THE SURFACE OF THE WORK
TABLE.
2. REMOVE ELECTRODE AND/OR HOLDER.
3. REMOVE DIAL INDICATOR AND MICROMETER FROM Z AXIS DEPTH GAGE RAIL.
4. TURN ON MAINS AT REAR OF MACHINE AND ON FRONT PANEL GENERATOR.
5. RELEASE FRONT PANEL EMERGENCY STOP. SELECT HEAD LOCK. USING FAST
APPROACH CONTROL KNOB. CONFIRM PROPER AMOUNT OF Z AXIS TRAVEL ADJUST IF
NECESSARY.
425 = Approximately 6" or 152mm
900 = Approximately 11" or 280mm
1450 = Approximately 11.8" or 300mm
6. PRESET COARSE FEED POT TO 0.
PRESET FIND FEED POT TO 5 OR MID RANGE ON THE 425E.
PRESET SENSITIVITY POT TO FULL "-" POSITION.
7. USING THE FAST APPROACH CONTROL KNOB POSITION THE Z AXIS ON THE MINUS
LIMIT SWITCH.
A.
RELEASE HEAD LOCK AND START TIMING Z AXIS OVER FULL TRAVEL. RETRACT
TIME SHOULD BE AS FOLLOWS.
425E & 425 MARK II
2 MINUTES + OR - 10 SEC.
900 MARK II 4 MINUTES + OR - 10 SEC.
1450 MARK II 4 MINUTES 30 + OR -10 SEC.
8. IF THE RETRACT TIMES ARE INCORRECT, CORRECTIONS SHOULD BE MAKE BY
ADJUSTING THE AMPLIFIER GAIN POT MOUNT ON THE AMP CHASSIS ASSEMBLY.
FIRST LOOSEN THE JAM NUT.
A. CW TO REDUCE.
B. CCW TO INCREASE TIME.
DIODE PUMP OR SERVO GAIN ADJUSTMENTS 9-17
9. PRESET FINE FEED POT TO 5 (MID-RANGE ON THE 425E), COARSE FEED TO 0,
SENSITIVITY POT TO MID RANGE.
10. REMOUNT DIAL INDICATOR ON Z AXIS DEPTH GAUGE RAIL.
11. APPLY HEAD LOCK, USING FAST APPROACH KNOB MOVE Z AXIS APPROXIMATE
MIDDLE OF TRAVEL.
12. ZERO DIAL INDICATOR.
13. SELECT MAXIMUM CURRENT ( AMP, 50 AMP, OR 25 AMP DEPENDING ON MODEL OF
GENERATOR.
14. TURN ON THE DIELECTRIC PUMP, ALLOW IT TO RUN UNTIL THE DIELECTRIC IS
FLOWING ACROSS THE TABLE. CONFIRM THAT GENERATOR ON WILL LATCH ON. TURN
GENERATOR OFF.
15. SELECT EDGE, FIND RELEASE HEAD LOCK AND ADJUST COARSE FEED POT TO
BALANCE Z AXIS (NO MOVEMENT ON DIAL INDICATOR)
16. APPLY HEAD LOCK, DISENGAGE EDGE FIND, TURN ON GENERATOR. RELEASE HEAD
LOCK. ADJUST HIGH CURRENT TRIM POT, TO BALANCE Z AXIS. NO MOVEMENT DIAL
INDICATOR.
17. REPEAT STEPS 12 THROUGH 17 ON THE LOW CURRENT RANGE. USE LOW CURRENT
TRIM POT TO BALANCE Z AXIS.
ORIGINATOR: B.J. STINSON
REVISED BY:
DATE: MAY 29, 1984
ISSUE NUMBER: 1028
SUBJECT: OPTITRON TRIP POINT SETTING ADJUSTMENTS
PRODUCT LINE: EDM'S
PAGE 1
OF
1. JUMPER PINS S AND P ON THE RF BOARD (FIGURE 2).
2. APPLY POWER TO GENERATOR AND RELEASE EMERGENCY STOP AND ADJUST THE
EFFICIENCY METER TO THE RED TRIP POINT GRADUATION.
3. WHILE WATCHING THE THRESHOLD RELAY (MOUNTED ON THE BIAS SUPPLY BOARD,
FIGURE 1) ADJUST THE THRESHOLD POT ON THE RF BOARD (FIGURE 2) SO THE RELAY
JUST PICKS UP.
REVISED BY:
DATE: JUNE 1, 1984
ISSUE NUMBER: 1029
SUBJECT: SERIAL NUMBER ID ON HURCO PRODUCTS
SUPERSEDES NUMBER 18
PRODUCT LINE: ALL HURCO PRODUCTS
PAGE 1
OF
15
SCOPE:
All products, systems, etc., identified by Hurco serial number
are to be marked according to the method prescribed in this
specification. Information required for identification labels
included.
I. Serial Numbering Plan
1.
Format
Number each product line and each sub-assembly type sequentia
as follows:
All products are to use the same format with appropriate
prefixes and suffixes. Sub-assemblies which are to have seri
numbers will not use prefix letters.
Ö-----------------Ú-----°
°
°
°
XXXX7
NNN
MM8X
°°°°
°°°
°° °
Product Line Prefix --ÙÙÙì
ÛÙÀ
°° Û----(Letter(s) as listed
°
°°
in Table #1)
°
°°
°
ÛÙ------°
Consecutive numbering -------------ì
of products beginning
each month (by major
product line).
Year
Major Revision
suffix from
Table #2
Month
First M is zero
for numbers less
than 10
B 1029 SERIAL NUMBER OF HURCO PRODUCTS
TABLE #1
Serial Number Prefix Letters - Product Identification
--------------------------------Ú-----------------------Ú-----------°Serial Numbers Are At- °
Ass
Table #1 (Part 1) - CNC Mills°tached to Power Cabinet° Location &
------Ú-------Ú-----------------Ù-----------------------é-------Ú---°
°
°Indpls.°Read
ITEM° MODEL °
DESCRIPTION
°U.S.A. °Engl
------é-------é-----------------------------------------é-------é---____1_°KM-1___°Bridgeport_Knee_Mill_____________________°____B__°___-_
____2_°KMB-1__°Kondia_Knee_Mill_________________________°____K__°__KM__
____3_°KMB-1s_°Short_Axis_Travel_KMB-1__________________°___KS__°___-_
____4_°KMB-1m_°Manual_Spindle_Speed_KMB-1_______________°___KM__°__MK_
____5_°KMBX-1_°KMB-1_w/BX_Control_______________________°___KX__°___-_
____6_°KMBX-1m°KMB-1_w/BX_Control_&_Manual_Spindle_Speed°__KMX__°___-_
____7_°_______°_________________________________________°_______°_____
____8_°_______°_________________________________________°_______°_____
____9_°M1_____°Toyama___________________________________°____H__°___M_
___10_°MB-1___°M1-Improved_Size_&_Strength______________°___HB__°__MB_
___11_°MB-1S__°MB-1_With_Short_Axis_Travel______________°__MBS__°___-_
___12_°MB-1H__°Greater_Spindle_Power_MB-1_______________°___MH__°___-_
___13_°MBX-1__°BX_Control_on_MB-1H______________________°___MX__°___-_
___14_°MD-1___°Toyama___________________________________°___MD__°___-_
___15_°_______°_________________________________________°_______°_____
___16_°M2_____°Toyama___________________________________°____T__°___-_
___17_°MB-2___°M2_With_Greater_Travel_&_Power___________°___TB__°___-_
___18_°_______°_________________________________________°_______°_____
___19_°_______°_________________________________________°_______°_____
___20_°MBX-3__°Toyama___________________________________°___JB__°___-_
___21_°_______°_________________________________________°_______°_____
___22_°MD-3___°Toyama___________________________________°___JD__°___-_
___23_°_______°_________________________________________°_______°_____
___24_°TM-5___°T-Bed_Mill_______________________________°__HTA__°___-_
___25_°TMC-5__°T-Bed_Mill_ATC___________________________°__HTB__°___-_
___26_°KM-3___°SM1_CNC_MAX______________________________°__SDA__°___-_
___27_°KM-3___°SM1_CNC_MAX_SSC__________________________°__SDB__°___-_
___28_°KMC-3__°SM1_CNC_MAX_ATC_SSC______________________°__SDC__°___-_
___29_°KM-3___°SM1_CNC_BX_______________________________°__SXA*_°___-_
___30_°KM-3___°SM1_CNC_BX_SSC___________________________°__SXB__°___-_
___31_°KMC-3__°SM1_CNC_BX_ATC_SSC_______________________°__SXC__°___-_
___32_°KM-3P__°KMB1m_MAX________________________________°__KDA__°___-_
___33_°KM-3P__°KMB1m_MAX_SSC____________________________°__KDB__°___-_
___34_°KMC-3P_°KMB1m_MAX_ATC_SSC________________________°__KDC__°___-_
___35_°KM-3P__°KMB1m_BX_________________________________°__KXA__°___-_
___36_°KM-3P__°KMB1m_BX_SSC_____________________________°__KXB__°___-_
___37_°KMC-3P_°KMB1m_BX_ATC_SSC_________________________°__KXC__°___-_
TABLE #1
--------------------------------Ú-----------------------Ú-----------°Serial Numbers Are At- °
Ass
Table #1 (Part 1) - CNC Mills°tached to Power Cabinet° Location &
------Ú-------Ú-----------------Ù-----------------------é-------Ú---°
°
°Indpls.°Read
ITEM° MODEL °
DESCRIPTION
°U.S.A. °Engl
------é-------é-----------------------------------------é-------é---___38_°BMC-10_°Toyama_Bed_Mill_10HP_4000________________°___BA__°_____
___39_°BMC-10_°Toyama_Bed_Mill_10HP_6000________________°___BB__°_____
___40_°BMC-10L°Toyama_Bed_Mill_10HP_4000________________°__BLA__°_____
___41_°BMC-10L°Toyama_Bed_Mill_10HP_6000________________°__BLB__°_____
___42_°BMC-15_°Toyama_Bed_Mill_15HP_4000________________°___BF__°_____
___43_°BMC-30_°Taiwan_Bed_Mill_10HP_4000_(OEM_&_V1)_____°___BC__°_____
___44_°BMC-40_°Taiwan_Bed_Mill_10HP_4000_(OEM_&_V1)_____°___BD__°_____
___45_°BMC-50_°Taiwan_Bed_Mill_15HP_3000_(OEM_&_V1)_____°___BE__°_____
___46_°BMC-30_°Taiwan_Bed_Mill_10,000_RPM_(OEM_&_V1)____°___BG__°_____
___47_°BMC-20_°Taiwan_Bed_Mill___________(OEM_&_V1)_____°___BH__°_____
___48_°FP3A___°Deckel_Universal_Mill_4000_RPM___________°__DHA__°_____
___49_°FP4A___°Deckel_Universal_Mill_4000_RPM___________°__DHB__°_____
___50_°BMC-20_°Bed_Mill_BMC-20_V2_______________________°___BJ__°_____
___51_°BMC-30_°Bed_Mill_BMC-30_V2_______________________°___BK__°_____
___52_°BMC-40_°Bed_Mill_BMC-40_V2_______________________°___BL__°_____
___53_°BMC-50_°Bed_Mill_BMC-50_V2_______________________°___BM__°_____
*Was SDX Suffix B (Rigidram); therefore, SDX Suffix B (Rigidram) and S
TABLE #1
Table #1 (Part 2) - Standard Mills
Ö-------Ú---------Ú-------------------------------------------Ú-----°
°
° CN
DESCRIPTION
° PREFIX °PREFIX°
û-------é---------é-------------------------------------------é------1
° Standard 9 X 42 Table, Standard Ways
°
SA
° -- °
û-------é---------é-------------------------------------------é------1
° Kondia
9 X 42 Table, Hardened Ways
°
SB
° SBX °
û-------é---------é-------------------------------------------é------1
° Kondia
12 X 42 Table, Standard Ways
°
SC
° -- °
û-------é---------é-------------------------------------------é------1
° Kondia
°
SD
° SDX °
û-------é---------é-------------------------------------------é------1
° Kondia
12 X 48 Table, Standard Ways
°
SE
° -- °
û-------é---------é-------------------------------------------é------1
° Kondia
°
SF
° -- °
û-------é---------é-------------------------------------------é------2
° Kondia
°
SG
° -- °
Û-------Ù---------Ù-------------------------------------------Ù------Table #1 (Part 3) - Other Products
Ö-------Ú---------Ú-------------------------------------------Ú-----°
1
° DTP-1
° Desk Top Programmer
°
D
û-------é---------é-------------------------------------------é-----°
2
° DTP-2
° Desk Top Programmer, Level 2
°
D2
Û-------Ù---------Ù-------------------------------------------Ù-----Table #1 (Continued) - Serial Number Prefix Letters
Table #1 (Part 4) - **Autobend 4 Gauges - Place Serial Numbers on P
Mechanical Gauges
Ö----Ú---------Ú----------------------------Ú----Ú-------------------°
°
°
°PRE-°
°ITEM° MODEL °
DESCRIPTION
°FIX °
SPECIAL INST
û----é---------é----------------------------é----é-------------------°_1__°SD_______°Single_Drive_ABIV___________°__A_°_1)_The_prefix_"N"_i
°_2__°DS_______°Dual_Drive_ABIV_____________°__C_°____units_with_diagn
°_3__°DS/2_____°1/2_Dual_Drive______________°__C_°_____________________
°_4__°--_______°Two_Axis_Drive______________°__E_°_____________________
°_5__°P2_______°Plate_Gauge_________________°__G_°_____________________
°_6__°S1_______°Shear_Gauge_________________°__I_°_____________________
°_7__°SDHD2A___°Single_Drive_Hydraulic______°_AE_°_2)_Combination_of_u
°____°_________°___2_Axis_ABIV______________°____°____have_a_two,_thre
°_8__°DSHD2A___°Dual_Drive_Hydraulic________°_CE_°____letter_prefix_to_
°____°_________°___2_Axis_ABIV______________°____°____system.__Example
°_9__°SDPM2A___°Single_Drive_Promecam_______°_AE_°____a)_Single_drive_
°____°_________°___2_Axis_ABIV______________°____°____b)_Single_drive_
°_10_°SD/DS____°Front/Rear,_Dual_Front-_____°__F_°_______front/rear____
°____°_________°___Single_Rear______________°____°____c)_Dual_drive/2_
°_11_°SD/DSHD2A°Front/Rear,_Hyd._2_Axis_____°_FC_°_______rear_with_dia
°____°_________°___Dual_Fnt.,_Dual_Rear_ABIV°____°____Use_2,_3_or_4_le
°_12_°DSPM2A___°Dual_Drive_Promecam_________°_CE_°____to_describe_syst
°____°_________°___2_Axis_ABIV______________°____°_____________________
°_13_°SDM2A____°Single_Drive_Mech._Stop_____°_AE_°_____________________
°____°_________°___2_Axis_ABIV______________°____°_____________________
°_14_°DSM2A____°Dual_Drive_Mech._Stop_______°_CE_°_____________________
°____°_________°___2_Axis_ABIV______________°____°_____________________
** Vertical Control Unit (Autobend 2 Axis) requires the following:
a)
b)
c)
Serial Number
- Identical to that of the Autobend Power Box
Assembly Number - Hurco drawing number for the vertical control
Contact Ratings - Maximum continuous current rating and voltage
Relay Contacts if relay is used. (5A @ 240 VA
Table #1 (Continued) - Serial Number Prefix Letters
Ö--------------------------------------------------------------------° Table #1 (Part 5) - Autobend 5 Gauges
Û--------------------------------------------------------------------Ö-----Ú------------------Ú-------------------------------------------°ITEM °
MODULE
°
DESCRIPTION
û-----é------------------é-------------------------------------------°__1__°_Power_Cabinet____°_Main_Power_Cabinet__________________________
ntrol_Head_____°_Main_Control_Console___________________________°___AB_
l_#1_°_Smart_Control_for_S4_Type_Gauge________________°___AC___° °__4__
Type_Gauge__________________________________°___AD___° °__5__°_S7_Gaug
_Type_Gauge_______________________°___AG___° °__6__°_H7_Gauge_________
________________________°___AH___° °__7__°_MDS______________°_Multiple_
______________°___AI___° °__8__°_Multibend________°_Multibend__________
____°___AJ___° °__9__°_Vert._Ctl._(Std.)°_Hydraulic_and_Mechanical_Stop
___° °_10__°_Vert._Ctl._(Up)__°_Promecam,_PRM_400,_Amada,_Adira,_SMT_P
_°_Vert._Drive_(1)__°_Promecam_______________________________________°_
rive_(2)__°_Promecam_(400)_________________________________°___AN___°
°_Amada__________________________________________°___AP___° °_14__°_Ve
_______________________________________°___AQ___° °_15__°_Vert._Drive_
_____________________________°___AR___° °_16__°_S6,_S8_Gauge_____°_Sin
em_________________°___AS___°
Ö-------------------------------------------------------------------° Table #1 (Part 6) - E.D.M.'s
Û-------------------------------------------------------------------Ö------Ú----------------Ú-------------------------------------------° ITEM °
MODEL
°
DESCRIPTION
û------é----------------é-------------------------------------------°
1 °
425E
° Combined Spark Unit & 30 Amp Generator
û------é----------------é-------------------------------------------°
2 °
425
° Spark Unit (for 25 Amp)
û------é----------------é-------------------------------------------°
3 °
425
° Spark Unit (for 50 Amp)
û------é----------------é-------------------------------------------°
4 °
900
° Spark Unit (No Side Servo)
û------é----------------é-------------------------------------------°
5 °
900
° Spark Unit (Side Servo)
û------é----------------é-------------------------------------------°
6 °
1450
° Spark Unit
û------é----------------é-------------------------------------------°
7 °
25 AMP
° Generator, 25 Amp (for 425 or 400)
û------é----------------é-------------------------------------------°
8 °
50 AMP
° Generator, 50 Amp (for 425 or 900)
û------é----------------é-------------------------------------------°
9 °
50 AMP
° Generator, 50 Amp (for 1450)
û------é----------------é-------------------------------------------° 10 °
100 AMP
û------é----------------é-------------------------------------------° 11 °
100 AMP
û------é----------------é-------------------------------------------° 12 °
CEC 200
° Machine Tool (for 60 Amp)
û------é----------------é-------------------------------------------° 13 °
CEC 200
° Filter Unit (for 60 Amp)
û------é----------------é-------------------------------------------° 14 °
CEC 200
° Electronics Cabinet (for 60 Amp)
û------é----------------é-------------------------------------------° 15 °
425E
° Optitron Minor
û------é----------------é-------------------------------------------° 16 ° OPTIONAL EXTRA ° Programmable Digital Oscillator
°
°
° (MK1 Generators Only)
Û------Ù----------------Ù--------------------------------------------
Ö-------------------------------------------------------------------° Table #1 (Part 6) - E.D.M.'s
Û-------------------------------------------------------------------Ö------Ú----------------Ú-------------------------------------------° ITEM °
MODEL
°
DESCRIPTION
û------é----------------é-------------------------------------------° 17 °
30/10
° Generator
û------é----------------é-------------------------------------------° 18 °
60/10
° Generator
û------é----------------é-------------------------------------------° 19 °
330
° Spark Unit
û------é----------------é-------------------------------------------° 20 °
900 NC
° Spark Unit
û------é----------------é-------------------------------------------° 21 °
1450 NC
° Spark Unit
û------é----------------é-------------------------------------------° 22 ° 1450/900 NC
° Spark Unit
Û------Ù----------------Ù-------------------------------------------Table #1 (Continued) - Serial Number Prefix Letters
Ö-------------------------------------------------------------------° Table #1 (Part 6) - E.D.M.'s
Û-------------------------------------------------------------------Ö------Ú----------------Ú-------------------------------------------° ITEM °
MODEL
°
DESCRIPTION
û------é----------------é-------------------------------------------° 17 °
30/10
° Generator
û------é----------------é-------------------------------------------° 18 °
60/10
° Generator
û------é----------------é-------------------------------------------° 19 °
330
° Spark Unit
û------é----------------é-------------------------------------------° 20 °
900 NC
° Spark Unit
û------é----------------é-------------------------------------------° 21 °
1450 NC
° Spark Unit
û------é----------------é-------------------------------------------° 22 ° 1450/900 NC
° Spark Unit
Û------Ù----------------Ù--------------------------------------------
Table #2 - Serial Number Suffix Letters
Ö-------------------------------Ú------------------------------------° Table #2 (Part 1) - CNC Mills °
Major Change Notes
Û-------------------------------Ù------------------------------------Ö----Ú-----------------Ú--------Ú------------------------------------°ITEM°
MODELS
° SUFFIX °
CHANGE & DATE ENTERED IN PRODUCT
û----é-----------------é--------é------------------------------------° 1 ° KMB-1, KMB-1m, °
A
° Change to Randtronics Servo Amp. (3/
û----é-----------------é--------é------------------------------------°
° MB-1H, MB2
°
A
° Change to Randtronics Servo Amp. (3/
û----é-----------------é--------é------------------------------------° 2 ° KMB-1
°
B
° Brake Board Change (3/82)
û----é-----------------é--------é------------------------------------° 3 ° KMB-1m
°
B
° Support Cost Change (3/82)
û----é-----------------é--------é------------------------------------° 4 ° KMB-1
°
C
° Rigid Overarm (3/82)
û----é-----------------é--------é------------------------------------° 5 ° MB-1H, MB-2,
°
B
° Change to HURCO FET Servo Amp
û----é-----------------é--------é------------------------------------°
° MB-3
°
B
û----é-----------------é--------é------------------------------------° 6 ° KMB-1m
°
C
û----é-----------------é--------é------------------------------------° 7 ° KMB-1
°
D
° Rigid Overarm - HURCO FET Servo Amp
û----é-----------------é--------é------------------------------------° 8 ° KMB-1m
°
E
° Moveable Overarm - HURCO FET Servo Am
û----é-----------------é--------é------------------------------------° 9 ° KMB-1
°
F
° Moveable Overarm - HURCO FET Servo Am
û----é-----------------é--------é------------------------------------° 10 ° KMB-1
°
G
° Rigid Overarm - HURCO FET Servo Amp
û----é-----------------é--------é------------------------------------° 11 ° KMB-1
°
H
° Moveable Overarm - Randtronics Servo
û----é-----------------é--------é------------------------------------° 12 ° KMB-1
°
J
° Rigid Overarm - Randtronics Servo Amp
û----é-----------------é--------é------------------------------------° 13 ° MB-1
°
C
° HURCO FET Servo Amp High Speed Spind
û----é-----------------é--------é------------------------------------° 14 ° MB-1
°
D
° Randtronics Servo Amp High Speed Spi
û----é-----------------é--------é------------------------------------° 15 ° SM1-CNC
°
A
° SM1-CNC With NSK Ballscrews
û----é-----------------é--------é------------------------------------° 16 ° MD-1, MD-3
°
A
° Randtronics Servo Amp Low Speed Spin
û----é-----------------é--------é------------------------------------° 17 ° MD-1
°
B
° Randtronics Servo Amp High Speed Spi
Û----Ù-----------------Ù--------Ù-------------------------------------
Table #2 (Continued) - Serial Number Suffix Letters
Major Change Notes
Û-------------------------------Ù------------------------------------Ö----Ú-----------------Ú--------Ú------------------------------------°ITEM°
MODELS
° SUFFIX °
û----é-----------------é--------é------------------------------------° 18 ° MD-3
°
B
° HURCO FET Servo Amp
û----é-----------------é--------é------------------------------------° 19 ° MD-1
°
C
° HURCO FET Servo Amp Low Speed Spindl
û----é-----------------é--------é------------------------------------° 20 ° MD-1
°
D
° HURCO FET Servo Amp High Speed Spind
û----é-----------------é--------é------------------------------------° 21 ° TM-5
°
A
° HURCO Hybrid Servo Amp
û----é-----------------é--------é------------------------------------° 22 ° TM-5
°
B
° HURCO FET Servo Amp
û----é-----------------é--------é------------------------------------° 23 ° SM1-CNC
°
B
° Rigid Overarm - (December 17, 1984)
û----é-----------------é--------é------------------------------------° 24 ° BMC-10(L) & 15 °
A
° Original Release
û----é-----------------é--------é------------------------------------° 25 ° KMC-3P
°
D
° Has Kondia Tool Changer w/SSC
û----é-----------------é--------é------------------------------------° 26 ° KM-3P
°
D
° Has Kondia SSC
û----é-----------------é--------é------------------------------------° 27 ° KM-3
°
C
° K Interface (Kondia Magnetics)
û----é-----------------é--------é------------------------------------° 28 ° KM-3
°
D
° K Interface - Left Hand Ball Screws
û----é-----------------é--------é------------------------------------° 29 ° BMC20-50
°
A
° Triple Axis Servo (One Piece Unit)
û----é-----------------é--------é------------------------------------° 30 ° BMC20-50
°
B
° Single Axis Servo
û----é-----------------é--------é------------------------------------° 31 ° BMC30-50
°
C
° Triple Axis Servo (Max 2)
û----é-----------------é--------é------------------------------------° 32 ° BMC20
°
C
° HURCO Built Tool Changer
û----é-----------------é--------é------------------------------------° 33 ° BMC30-50
°
D
° HURCO Built Pneumatics
û----é-----------------é--------é------------------------------------° 34 ° BMC20
°
D
° V1 Control AC 2 Motor
û----é-----------------é--------é------------------------------------° 35 ° BMC30-50
°
E
° V1 Control
û----é-----------------é--------é------------------------------------° 36 ° KM-3, KM-3P
°
E
° MAX 2 Control
Û----Ù-----------------Ù--------Ù-------------------------------------
Major Change Notes
Û-------------------------------Ù------------------------------------Ö----Ú-----------------Ú--------Ú------------------------------------°ITEM°
MODELS
° SUFFIX °
û----é-----------------é--------é------------------------------------° 37 ° BMC-20
°
E
° OEM AC3S Spin Motor 4000 RPM
û----é-----------------é--------é------------------------------------° 38 ° BMC-20
°
F
° OEM AC3S Spin Motor 6000 RPM
û----é-----------------é--------é------------------------------------° 39 ° BMC-20
°
G
° V1 AC3S Spin Motor 4000 RPM
û----é-----------------é--------é------------------------------------° 40 ° BMC-20
°
H
° V1 AC3S Spin Motor 6000 RPM
û----é-----------------é--------é------------------------------------° 41 ° BMC-30-40
°
F
° OEM 18P Spin Motor 4000 RPM
û----é-----------------é--------é------------------------------------° 42 ° BMC-30-40
°
G
° OEM 18P Spin Motor 6000 RPM
û----é-----------------é--------é------------------------------------° 43 ° BMC-30-40
°
H
° V1 18P Spin Motor 4000 RPM
û----é-----------------é--------é------------------------------------° 44 ° BMC-30-40
°
J
û----é-----------------é--------é------------------------------------° 45 ° BMC-50
°
F
° OEM 22P Spin Motor
û----é-----------------é--------é------------------------------------° 46 ° BMC-50
°
G
û----é-----------------é--------é------------------------------------° 47 ° FP3A, FP4A
°
A
° Original Release (MAX II With Disk S
û----é-----------------é--------é------------------------------------° 48 ° BMC-50
°
H
û----é-----------------é--------é------------------------------------° 49 ° BMC-20-30
°
A
° V2 Yaskawa 6000 RPM (Standard)
û----é-----------------é--------é------------------------------------° 50 ° BMC-40-50
°
A
° V2 Yaskawa 4000 RPM (Standard)
û----é-----------------é--------é------------------------------------° 51 ° BMC-20-40
°
B
° V2 Yaskawa 10000 RPM (Optional)
û----é-----------------é--------é------------------------------------° 52 ° BMC-30
°
C
û----é-----------------é--------é------------------------------------° 53 ° BMC-40
°
C
û----é-----------------é--------é------------------------------------° 54 ° KM-3, KM-3P
°
F
° MAX 2 Control, Personality 2
û----é-----------------é--------é------------------------------------° 55 ° BMC-20
°
J
° V1 AC3S Spin Motor 4000 RPM, Persona
Û----Ù-----------------Ù--------Ù-------------------------------------
Major Change Notes
Û-------------------------------Ù------------------------------------Ö----Ú-----------------Ú--------Ú------------------------------------°ITEM°
MODELS
° SUFFIX °
û----é-----------------é--------é------------------------------------° 56 ° BMC-20
°
K
û----é-----------------é--------é------------------------------------° 57 ° BMC-30-40
°
K
° V1 18P Spin Motor 4000 RPM, Personal
û----é-----------------é--------é------------------------------------° 58 ° BMC-30-40
°
L
û----é-----------------é--------é------------------------------------° 59 ° BMC-50
°
J
û----é-----------------é--------é------------------------------------° 60 ° BMC-50
°
K
û----é-----------------é--------é------------------------------------° 61 ° FP3A, FP4A
°
B
° MAX II With Disk Standard, Personali
û----é-----------------é--------é------------------------------------° 56 ° BMC-20
°
K
û----é-----------------é--------é------------------------------------° 57 ° BMC-30-40
°
K
û----é-----------------é--------é------------------------------------° 58 ° BMC-30-40
°
L
û----é-----------------é--------é------------------------------------° 59 ° BMC-50
°
J
û----é-----------------é--------é------------------------------------° 60 ° BMC-50
°
K
û----é-----------------é--------é------------------------------------° 61 ° FP3A, FP4A
°
B
° MAX II With Disk Standard, Personali
Û----Ù-----------------Ù--------Ù------------------------------------Table #2 (Part 2) - Autobend
Ö-------------------------------Ú------------------------------------° Table #2 (Part 1) - Autobend °
Major Change Notes
û----Ú-----------------Ú--------é------------------------------------°ITEM°
MODELS
° SUFFIX °
û----é-----------------é--------é------------------------------------° 1 ° Left Gauge
°
L
° Identifies left half of an S5 gaugin
û----é-----------------é--------é------------------------------------° 2 ° Right Gauge
°
R
° Identifies right half of an S5 gaugi
û----é-----------------é--------é------------------------------------° 3 ° 1/2 Dual Drive °
R
° Identifies drive for reference purpo
Û----Ù-----------------Ù--------Ù------------------------------------II. Special Identifying Features
Autobend IV
1)
2)
3)
Rear Gauge, Dual Drive, Left/Right Identification - Stand at
mounts to the press brake (opposite the motor end) and look t
left gauge is to the left hand and the right gauge is to the
Front Gauge, Dual Drive, Left/Right Identification - Use the
above.
One half dual drive - treat this as a right gauge.
III. Obsolete Serial Numbering System (for reference only)
A.
Autobend (Numbering used until near 2nd half of 1978)
Ö-----------------Ú------YEAR
7
XXXX
X 8
Consecutive numbering ----------ì
°
of gauges from the 1st
Û----Month
gauge ever manufactured.
This may be a one
required to defin
B.
CNC Mills (Numbering used until near beginning of 1980)
Ö-----------------Ú------YEAR
7
XXXX
X 8
Consecutive numbering ----------ì
°
of mills from the 1st
Û----Month
day of each new year.
This may be a one
required to defin
IV.
General Information & Warning Label Data (Information to be Adde
°
Interrupt - Maximum short circuit overload current at which
breaker may be expected to blow in a failsafe co
for CNC Mills; 500 Amps for Autobend and DTP Pro
Diagram Number - Hurco part number of the pertinent Owner's M
the power cabinet assembly number for Autob
Serial Number - Serial number derived from Standard (#715-40
AMPS:
a)
F.L. - Maximum continuous system operating current at nom
voltage; Full load. (Product Standard 715-0000-0
b)
Largest Motor - Maximum continuous operating current supp
motor having the greatest current requir
AC VOLTS - Nominal machine supply voltage as designated by t
consistent with Product Standard 715-0000-001.
HZ - Supply voltage frequency as designated by the customer
with Product Standard 715-0000-001.
Table #3 - Largest Motor Currents (Full Load)
Ö--------------------------------------------------------------------° CNC MILLS û--------------------------------------------------------------------° KMB-1
G. E. Spindle Motor - 11 Amps
°
° KMB-1
Leland Spindle Motor - 12.6 Amps
°
° MB-1
°
° MB-1
Leland Spindle Motor - 12.6 Amps
°
° MB-1H
Leland Spindle Motor - 14 Amps
°
° MB-2
°
° MB-3
°
° KMB-1m
Kondia Spindle Motor - 8.9 Amps
°
° KM-3P
°
° KM-3P
°
° KMC-3P
û--------------------------------------------------------------------° Autobend °
° All Mills
û--------------------------------------------------------------------° TMD-5
Custom Spindle Motor - 15.5 Amps
°
° MD-1
Custom Spindle Motor - 14 Amps
°
° MD-3
°
° BMC-10(L)
Yaskawa - 43 Amps @ 200 VAC
°
° BMC-15
Yaskawa - 74 Amps @ 200 VAC
°
° KM-3
Kondia Spindle Motor - 8.9 Amps (SM1-CNC)
Û---------------------------------------------------------------------
DATE: JULY 10, 1984
ISSUE NUMBER: 1030
SUBJECT:
OIL LUBE AIR REGULATOR
PRODUCT LINE: KMB-I KMBX-I KMB-Im
PAGE 1
OF 1
WE HAVE DISCOVERED THAT THE SET-UP PROCEDURE FOR OIL LUBE AIR
REGULATOR THERE ARE NO SPECIFIC INSTRUCTIONS TO LOCK THE ADJUSTMENT KNOB.
THIS OVERSIGHT HAS BEEN CORRECTED IN HOUSE.
WHEN SERVICING A MILL THAT UTILITIES AN OIL LUBE REGULATOR A ROUTINE
CHECK SHOULD BE MADE TO CONFIRM THE FOLLOWING:
1. THE LUBE REGULATOR IS SET TO 30 POUNDS PSI.
2. THE MAIN REGULATOR IS SET TO 80 POUNDS PSI.
3. THE ADJUSTMENT KNOBS ARE LOCKED IN PLACE.
THERE ARE TWO TYPES OF OIL LUBE AIR REGULATORS. THEY ARE THE
WILKERSON REGULATOR AND THE WATTS REGULATOR. THE WILKERSON IS LOCKED
WITH A LOCKING RING THAT SNAPS UP AGAINST THE ADJUSTMENT KNOB. THE WATTS
REGULATOR IS LOCKED BY TIGHTENING THE PHILLIPS HEAD SCREW ON TOP OF THE
ADJUSTMENT KNOB.
DATE: Unknown
ISSUE NUMBER: 1031
SUBJECT: Control Transformer Replacement
SUPERSEDES NUMBER:
PRODUCT LINE: SM 1 CNC
PAGE 1 OF 1
CONTROL MAGNETIC ASSEMBLY "002-2431-001
The current servo power transformer in the SM1- CNC is a single voltage input transformer. A PIN is in
process to change this transformer to a 240 or 480/60 HZ input, 60V output. The part # for the new XFMR. is
413-0003-075. The new XFMR will be used in the KM1 (bridgeport), SM1 CNC. This transformer will
enable a service engineer to change the taps of the XFMR to accommodate the customers power as opposed to
ordering a new transformer.
ORIGINATOR: Joe Stinson
REVISED BY:
PROPRIETARY INFORMATION
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE
MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
DATE: JULY 19, 1984
ISSUE NUMBER: 1032
SUBJECT:
ATC DECODER PINS MOVING
PRODUCT LINE: MD1 / MBX1
PAGE 1
OF 1
WE HAVE SEEN SEVERAL TOOL CHANGER FAILURES IN THE FIELD CAUSED BY THE
DECODING PINS IN THE TOOL CHANGER ASSEMBLY. THESE PINS NOT ONLY GIVE THE
COUNT ON THE TOOL POSITION BUT ALSO HOLD THE FINGERS IN THE CAROUSEL. AS THE
FINGERS WORK BACK AND FORTH WITH THE TOOLS BEING PUT IN THE SPINDLE THE PINS
CAN MOVE DOWN. THIS INCREASES THE GAP BETWEEN THE PINS AND THE SENSORS
CAUSING A TOOL MISCOUNT. THE FIX FOR THIS PROBLEM IS TO FIRST
TAP THE PINS BACK TO THE RIGHT HEIGHT, (A GAP OF .01 TO .02") BETWEEN THE
SENSORS AND THE PINS. THEN HAVE SPACERS MADE THAT WILL FIT UNDER THE PINS
BETWEEN THE PINS AND THE BOTTOM PLATE OF THE TOOL CHANGER (THE PLATE THAT
HOLDS THE FINGERS ON. THIS WILL KEEP THE PINS FROM WORKING DOWN AND IS A
PERMANENT FIX DO NOT TRY TO LOCKTITE THE PINS IT DOES NOT HOLD.
DATE: July 7,1984
ISSUE NUMBER: 1033
SUBJECT: Oil Flow Indicator Retrofit
SUPERSEDES NUMBER:
PRODUCT LINE: MII Gen I & II
PAGE 1 OF 4
The oil pump for MII Machines Generations I and II is driven by the spindle motor via a belt. If
the belt brakes there is no signal to the control to shut off. Nor is there any alarm signal to
warn the operator of the failure. With no lubrication to the gears in the head severe damage
will occur.
To correct this potential problem we are installing an OIL FLOW INDICATOR to notify the
operator in the event of a failure with the oil flow system.
The Assembly is available in a retrofit kit. For MII Generation 1 the part # for the kit is 0022059-001.
For generation II the part # is 002-2059-002. The difference between the two kit is the 001 has
an adapter plate and two 10/24 x 1.5" shcs. Page 2 thru 4 of this FSB will assist in the
installation of this retrofit.
ORIGINATOR: BJ STINSON
REVISED BY: L. Leffew 12/16/96
DATE:JULY 23, 1984
ISSUE NUMBER: 1034
SUBJECT:ORIENT TIME-OUT ERR IN LOW GEAR
PRODUCT LINE: MBII MBXII MB3
PAGE 1
OF
1
If a MBII, MBXII MB3 is getting an intermittent orient time out
error during a tool change in low gear. Add a 18 gauge Green and
Yellow wire from power supply terminal strip TB4-21 to power
cabinet mecca ground. Also add a 18 gauge green and yellow wire
from Parajust terminal strip TB7-4 to the Parajust cabinet mecca
ground lug. This should reduce the ground potential between mecca
ground and the dac return. Do several tool changes in low gear to
confirm that problem has been resolved.
ORIGINATOR:
REVISED BY:
JOE STINSON
DATE: JULY 31, 1984
ISSUE NUMBER: 1035
SUBJECT:
40V TOOL CHANGER
PRODUCT LINE: HMBX1 / MD1 40V MACHINES
PAGE 1
OF 2
It has been determined that the spring tension of the die spring that supports the carousel is insufficient.
This is especially evident if heavy tools are put in one side of the carousel. The carousel will tilt toward
the heavier tools causing tool changer errors and or damage to the sensor switches. A PIN is being
implemented to resolve this problem in house. The PIN consist of 1) Shorting the spacer from 2" to 1.700"
to increase the die spring tension. 2) Readjusting the carousel in limit switch. 3) Readjusting the carousel
down limit switch. 4) Readjusting the physical stop setscrew. The procedure for making these changes and
adjustments in
the field are as follows.
1) Remove all tools from the carousel
2) Remove all covers from the tool changer
3) Confirm that the setscrew and jam nut are tight (item #12 and #57).
4) While supporting the carousel remove the M6-10 x 65 mm bolt (item #9)
NOTE!! The setscrew (item #12) should hold the carousel in position with the mounting bolt removed
but care should be taken that the carousel doesn't drop down.
5) Remove the bearing cup, Spacer, and Spring (item #8,#10, and #105)
6) The spacer should be cut down from 2" to 1.7". NOTE!! do not discard the short piece of spacer it will
be needed for reassembly..
7) Use a lathe and a facing tool to clean and square the rough edge of each spacer.
8) Reassemble using the short piece of spacer as a washer against the head of the bolt. (use locktite #271
on the threads of the bolt)
9) With the carousel all the way back in home position adjust the Carousel down limit switch for a gap of
.200" to .220". (FIGURE 1)
10) Clamp a tool in the spindle. Go into data block 0 program current tool
#1. Command the computer to get tool #2. When Z axis gets to tool change height depress
motion hold then hit Emergency stop.
11) Manually run the carousel in and adjust the carousel in limit switch to actuate .100" before physical
stop. (FIGURE 2)
12) Run the carousel in so the fingers are engaging the tool. Adjust the
physical stop setscrew to touch the rest button on the carousel
support casting. Lock down the setscrew locknut confirm that the
setscrew is still touching the rest button with fingers fully engaging
the tool. Apply loctite #271 to the setscrew threads.
13) Fill the carousel up with tools. Use a few heavy tools (Shell mill,
large drills, etc). Run a minimum of 50 tool changes to confirm tool
changer operation.
ORIGINATOR: J.B. STINSON
REVISED BY: R.BRYANT
ISSUE NUMBER: 1036
SUBJECT: INTERMITTENT PROBLEMS DUE TO POWER
SUPPLY TRANSFORMER
PRODUCT LINE: ALL B AND BX MILLS
PAGE 1
OF 2
RECENTLY ON THREE DIFFERENT SERVICE CALLS ON MILLS THAT WERE DISPLAYING
INTERMITTENT PROBLEMS, THE FINAL SOLUTION TO CORRECT THESE PROBLEM WAS
CHANGING THE TAPS OF THE PRIMARY DC POWER SUPPLY TRANSFORMER. THIS FSB IS
TO:
1, ALERT OUR SERVICE ENGINEERS OF THIS POTENTIAL PROBLEM.
2, A FEW OF THE SYMPTOMS TO LOOK FOR.
3, VOLTAGE MEASUREMENTS TO MAKE, THAT WILL HELP DETERMINE IF CHANGING
TAPS SHOULD BE IMPLEMENTED.
UNDER IDEAL CONDITIONS (MACHINE IS WIRE FOR 230 INPUT AND CUSTOMER POWER IS
230). THE INPUT VOLTAGE TO THE POWER SUPPLY TRANSFORMER IS 115 VAC. MILLS ARE
SHIPPED FROM HURCO WITH THE PRIMARY OF THE POWER SUPPLY TRANSFORMER
TAPPED FOR 115 VAC. IN THE CASE WERE A CUSTOMERS POWER IS LOW, SAY 218 VAC OR
DURING TIMES OF PEAK USAGE THE CUSTOMERS POWER DROPS FROM 230 TO 218. THE
INPUT TO THE POWER SUPPLY TRANSFORMER WILL BE REDUCED TO APPROXIMATELY
109 VAC. WITH 109 VAC INPUT ON THE 115V PRIMARY TAP THE SECONDARY CAN BE
UNDER POWERED. THIS IN TURN REDUCES THE DC POTENTIAL APPLIED TO THE
REGULATORS OF THE DC POWER SUPPLY. A FEW OF THE SYMPTOMS A MACHINE MIGHT
DISPLAY ARE:
1, INTERMITTENT LOCKUPS.
2, LOSING THE MASTER PROGRAM FOR NO APPARENT REASON.
3, LOSING INFORMATION FROM THE PART PROGRAM.
4, MILLS WITH MANUAL SPINDLES (KMI, KMB1M), THESE SYMPTOMS MAY SEEM TO
OCCUR WHEN THE SPINDLE IS STARTED.
FOR SCHEMATICS AND PHYSICAL LAYOUTS SEE POWER SUPPLY SCHEMATICS OF
SECTIONS 6 AND 7 OF THE CUSTOMER'S OWNER MANUAL.
THE VOLTAGE MEASUREMENTS YOU SHOULD MAKE TO DETERMINE IS CHANGING THE
INPUT TAPS ARE:
1, MEASURE THE CUSTOMER'S INPUT POWER TO THE MACHINE. CONFIRM THE MAIN
INPUT TRANSFORMER IS WIRED ACCORDINGLY. THE INPUT POWER SHOULD BE + OR - 10%
OF WHAT THE MACHINE IS WIRED FOR.
2, CONFIRM WHICH PRIMARY TAPS ARE BEING USED, 110, 115 OR 120.
3, MEASURE THE AC INPUT VOLTAGE TO THE PRIMARY TAP THAT IS BEING USED.
4, MEASURE THE DC POTENTIAL ACROSS THE FILTER CAPACITOR "C1" OF THE DC POWER
SUPPLY AND WRITE IT DOWN.
5, IF THE 115V PRIMARY TAP IS BEING USED AND THE INPUT VOLTAGE IS 113 TO 118 VAC
IT SHOULD BE OKAY. IF THE INPUT VOLTAGE IS ABOVE 118 VAC OR BELOW 113 PROCEED
WITH STEPS 6 AND 7.
6, IF THE MACHINE VOLTAGE IS 118.1 VAC TURN OFF THE MAIN POWER TO THE
MACHINE. CHANGE THE PRIMARY TAP TO THE 120 VAC INPUT. TURN POWER ON AND
MEASURE THE DC POTENTIAL ACROSS C1, COMPARE IT TO THE FIRST
MEASUREMENT, YOU SHOULD SEE A SMALL DECREASE.
7, IF THE INPUT VOLTAGE IS 103.5 TO 112.9 VAC. TURN OFF MAIN POWER TO THE
MACHINE. CHANGE THE PRIMARY TAP TO THE 110 V TAP. TURN POWER BACK ON,
MEASURE THE DC POTENTIAL ACROSS C1, COMPARE IT TO THE FIRST MEASUREMENT,
YOU SHOULD SEE A SMALL INCREASE.
IF THE INPUT POWER TO THE PRIMARY TAPS IS BELOW 103.5 OR_ABOVE 1126.5
THERE IS A PROBLEM WITH THE INPUT POWER.
IT SHOULD BE NOTED THAT THIS FIX IS NOT THE ANSWER TO ALL INTERMITTENT
MACHINE PROBLEMS. HOWEVER, IT IS SOMETHING YOU NEED TO KNOW ABOUT AND
HOW TO LOOK FOR THE PROBLEM. IF YOU MAKE THIS CHANGE TO A MACHINE,
DOCUMENT IT ON PAGE TWO OF THE SERVICE REPORT.
ORIGINATOR: J.B. STINSON
REVISED BY:
ISSUE NUMBER: 1037
SUBJECT:
TAPE READER ADJUSTMENT
PRODUCT LINE: B AND BX MILLS
PAGE 1
OF 1
Tape Reader adjustment is no longer approved by HURCO. Research conducted by our
Manufacturing Engineering Department has shown that there is no way that we can adjust them as
accurately as Raymond. Raymond uses calibrated test tapes and test equipment that is calibrated and
verified by the National Bureau of Standards. They only use their test tapes ten times before replacing
them and their test equipment has a strict calibration schedule. Raymond says that if we do try to adjust
them, then we can probably get them to read tapes but the tape drive will not be within specification. The
more times we adjust them, the farther off the drive gets. If it then becomes necessary to replace the drive,
the new drive will not read tapes written on the old drive. I admit that we did allow adjustment in the past
but Raymond proved that we were causing more problems than we were correcting.
If you run into a situation where there is incompatibility between tape readers then I recommend the
following action.
1) Verify that the customer is using the latest software in all of his machines. The latest software
utilizes an adaptive read program which is less susceptible to speed variations by adapting itself to the
timing of the tape. A retry should always be performed if a tape fails to read in order to give the adaptive
feature a second chance. This feature has been in all software released since the B series, C3 version.
2) If problems are still present, format a new tape on one of the
units and write a part program on the tape. Then try to read the
tape into one of the other units.
3) If trouble persists, then a tape reader replacement is in order and a determination must then be made
whether one or all need replacement.
In all cases the customer should be made aware of the fact that tapes are not going to last forever and the
more a tape is used, the shorter its life will be. It should be common practice to make backup copies of all
parts programs and periodic replacement of the working copy is necessary. Under no condition should you
ever again adjust a tape reader.
ORIGINATOR: WAYNEHAWKINS
REVISED BY:
ISSUE NUMBER: 1038
SUBJECT: VOLTAGE CONVERSIONS
SUPERSEDES NUMBER: 206B
PRODUCT LINE: SM1-CNC / KM3
PAGE 1 OF 1
DATE: NOVEMBER 1, 1984
ISSUE NUMBER: 1039
SUBJECT: MEMORY PCB BATTERY LED'S STAYING ON
PRODUCT LINE: ALL ULTIMAX ONE MILLS
PAGE 1
OF 1
A PROPERLY FUNCTIONING 415-0168-001 128K MEMORY BOARD OR A 414-0168-002 256 K
MEMORY BOARD SHOULD NOT BE REPLACED OR CONSIDERED MARGINAL IF ONLY ONE
OR TWO LED'S (LED1, LED2, LED3) STAY ON AFTER ONE HOUR OF RECHARGE TIME.
IF ANY BATTERY LED IS OFF, THE MEMORY BOARD WILL PROVIDE A MINIMUM OF 72
HOURS OF POWER OFF MEMORY PROTECTION. THIS IS POSSIBLE DUE TO THE AMOUNT OF
REDUNDANCY IN THE BATTERY BACKUP CIRCUIT AS IT APPLIES TO HURCO'S RETENTION
SPECS. IT SHOULD BE NOTED THAT EACH OF THE THREE BATTERIES CONTAIN THREE
SEPARATE CELL CONNECTED IN SERIES. ALTHOUGH, IT WOULD BE MARGINAL, JUST TWO
OF THESE CELLS COULD MEET HURCO'S 72 HOUR REQUIREMENT . A BATTERY LED WILL
STAY ON IF ONE OR MORE OF THE INDIVIDUAL CELLS SHORT; THEREFORE, THEN ALL
THREE LED'S STAY ON THE MEMORY BOARD HAS NO GUARANTEE OF BATTERY BACKUP
PROTECTION.
BY THE WAY, LED4 INDICATES THAT THE CARD RACK COULD BE SUPPLYING LESS THAN
4.6 VDC. IF THE BOARD VOLTAGES ARE OKAY, THEN AN INTERNAL PROBLEM EXISTS ON
THE MEMORY BOARD AND THE BOARD SHOULD BE REPLACED. TYPICAL BATTERY
VOLTAGE RANGE SHOULD MEASURE 3.6 TO 4.2 VDC.
IF A RED LED IS LIT ON THE HYBRID MPU/MEM BRD THE BATTERY IS DEAD
IS WILL SHUT THE BOARD DOWN AND THE BATTERY AT LEAST MUST BE REPLACED.
IF THE MPU BATTERY BOARD IS THE TWO BATTERY TYPE REPLACE THE BOARD IF
IT IS A ONE BATTERY TYPE REPLACE THE BATTERY.
REPLACEMENT BATTERIES FOR 128K BOARDS ARE 413-8001-008
REPLACEMENT BATTERIES FOR 256K BOARDS ARE 413-8001-009
REPLACEMENT BATTERIES FOR THE HYBRID MPU/MEM BOARDS ARE 450-0001-266
ORIGINATOR: MARK WHITCOMB
ISSUE NUMBER: 1040
SUBJECT: PARAJUST VOLTAGE CONTROL BOARD
PRODUCT LINE: BED MILLS WITH PARAJUST B
PAGE 1
OF 1
THE LATEST VERSION OF A PARAJUST B VOLTAGE CONTROL MODULE, 402-6005-021, CAN
BE IDENTIFIED BY THE FACT THAT IT HAS A SOLDER MASK ON THE NON- COMPONENT
SIDE OF THE BOARD. IN THIS LATEST VERSION, PARAMETRICS HAS MISTAKENLY LEFT IN
TWO COMPONENT THAT IS SUPPOSED TO BE JUMPIER OUT IN THE HURCO VERSION.
THE FIRST COMPONENT IS CAPACITOR C20, LOCATED NEAR PIN 5 OF MC9, ) LOWER RIGHT
HAND QUARTER OF THE BOARD). C20 NEEDS TO BE REMOVED AND A JUMPER SOLDERED
IN ITS PLACE. THE SECOND COMPONENT IS R25 A 3.3 K OHM RESISTOR LOCATED
ADJACENT TO C20. R25 ALSO NEEDS TO BE REMOVED. WITH OUT THESE MODIFICATION,
INTERMITTENT SHEARPINS COULD OCCUR DURING EITHER ACCEL OR DECELL.
SPECIFICALLY ON ULTIMAX SERIES MACHINES, A FLICKERING SHEARPIN LAMP AT DRIVE
AT DRIVE TURN OFF ONLY IS NOT A PROBLEM ACCORDING TO PARAMETRICS. IF THIS
OCCURRENCE RESULTS IN A CRT MESSAGE OF SPINDLE DRIVE FAULT DETECTED THEN A
PROBLEM DOES EXIST.
REVISED BY:
ISSUE NUMBER: 1041
SUBJECT:
Z AXIS TRAVEL
PRODUCT LINE: SM1-CNC
PAGE 1
OF 1
WE HAVE RECENTLY EXPERIENCED OCCASIONS WHEN THE Z AXIS LIMIT SWITCHES
HAVE BEEN ADJUSTED TO PROVIDE 4.75 INCHES OF Z AXIS TRAVEL AND WE HAVE OVER
RUN THE SWITCH TO THE HARD STOP. THIS OVERRUN HAS CAUSED MACHINE DAMAGE IN
AT LEAST TWO INSTANCES.
THE Z AXIS TRAVEL SPECIFICATION HAS BEEN CHANGED TO 4.5 INCHES AND ALL
PRODUCTION MILLS ARE ADJUSTED TO THIS DIMENSION. DO NOT, UNDER ANY
CIRCUMSTANCES, ADJUST THE Z AXIS LIMIT SWITCH TO ANYTHING GREATER THAT 4.5
INCHES TRAVEL.
WHEN THE Z AXIS HITS THE HARD STOP IT CAN CAUSE THE LOWER BEARING TO BREAK
THRU THE HEAD CASTING. THIS CAN HAPPEN IN A AXIS RUNAWAY AS WILL TO FIX THE
MACHINES THAT HAVE THIS PROBLEM A KIT HAS BEEN CREATED. THIS
KIT HAS A STEEL INSERT AND NEW AXIS THRUST BEARING'S. THE PART NUMBER IS 0022482-001
ORIGINATOR: DAVE ROCH
DATE: DECEMBER 17, 1984
ISSUE NUMBER: 1042
SUBJECT:
TAPE FORMATTING PROBLEM
PRODUCT LINE: ULTIMAX ONE MD1/MD3
PAGE 1
OF 1
THE PROBLEM WITH FORMATTING A TAPE APPEARS TO BE A RESULT OF RUNNING THE
TAPE CONTROLLER BOARD AT TOO HIGH A CLOCK RATE. (I.E., THE 8085 AND 8255
PARALLEL CHIP ARE SPEC'ED AT A MAXIMUM CLOCK FREQUENCY OF 6 AND 3 , MHZ
RESPECTIVELY. WITH THE 6.144 MHZ CRYSTAL IN THE CURRENT CONFIGURATION, THEY
ARE RUNNING AT 6.144 AND 3.072 MHZ. THIS RESULTS IN NON-EXECUTION OF CERTAIN
INSTRUCTIONS IN THE 8085 AND NOT-LATCHING OF DATA ON THE 8255 THAT
INTERFACES TO THE TAPE DRIVE SYSTEM. THE REPLACEMENT CRYSTAL IS A
4.9152 MHZ PART NUMBER 407-0016-009 IF YOU FIND ANY THAT NEED CHANGING
PLEASE DO SO WITH THIS NUMBER.
ORIGINATOR: DAVID PLATTS
ISSUE NUMBER: 1043
SUBJECT: SERVICE OF PARAMETRICS SPINDLE DRIVES
PRODUCT LINE: ALL MILLS USING PARAJUST DRIVES
PAGE 1
OF 1
DRIVER MODULES
DRIVER MODULES SHOULD ALWAYS BE REPLACED IN PAIRS THE PAIR BEING THE TWO
SERIES-CONNECTED DRIVER MODULES. AS THE PAIR IS A SERIES CIRCUIT, FAILURE OF
ONE DRIVE WILL ALWAYS OVERSTRESS THE REMAINING DRIVER MODULE IN THAT LEG.
THIS OVERSTRESS MAY LEAD TO LATENT EFFECTS AND SUBSEQUENT RELIABILITY
PROBLEMS IN THE DRIVER AND OR CHOPPER BOARD AREAS.
CHOPPER BOARDS
CHOPPER BOARDS SHOULD ALWAYS BE REPLACED IN PAIRS ON THE LARGE PARAJUST B
DRIVERS/ AS THE PAIR OF CHOPPERS IS A PARALLEL CIRCUIT FAILURE OF ONE CHOPPER
WILL ALWAYS OVERSTRESS THE REMAINING CHOPPER. THIS OVERSTRESS MAY LEAD TO
LATENT DEFECTS AND SUBSEQUENT RELIABILITY PROBLEMS IN THE DRIVE UNIT.
POWER MONITOR FAULTS
IF THE POWER MONITOR FAULT REOCCURRS AFTER REPLACEMENT OF THE OF THE
POWER MONITOR BOARD AN INCOMING POWER LINE EVALUATION SHOULD BE DONE AD
SOON AS POSSIBLE, POWER MONITOR FAULTS OCCUR WHEN THE POWER LINE IS OUT OF
THE HURCO SPECIFIED RANGE. OPERATION OF THE MILL WHEN POWER MONITOR FAULTS
REPEATABLTY OCCUR MAY CAUSE SERIOUS RELIABILITY PROBLEMS WITH THE
PARAMETRICS DRIVE AND WITH OTHER PARTS. (POWER MONITOR FAULTS MAY OCCUR
AT THE INSTANT THE MAIN DISCONNECT IS TURNED ON, AND DURING THIS MANUAL
TURN-ON ARE NOT A VALID FAULT. AFTER TURN-ON, FAULTS ARE ALWAYS CAUSE FOR
CONCERN.)
ORIGINATOR: RICK GUNYON
REVISED BY:
ISSUE NUMBER: 1044
SUBJECT:
Y AXIS BALLSCREW
PAGE 1
OF 1
THE NEW SM1-CNC RIGID RAM COULD HAVE LEFT OR RIGHT HAND BALL SCREWS IN THE
Y AXIS. THIS WILL NOT CAUSE ANY PROBLEMS WITH THE MACHINE OPERATION BUT, IF
WE EVER REPLACE ONE WITH THE OTHER, THEN THE MOTOR AND TACH WIRES WILL
HAVE TO BE REVERSED TO MAKE THE AXIS MOVE IN THE RIGHT DIRECTION. THE
ENCODER PHASE A AND B ALSO WILL NEED TO BE REVERSED.
ORIGINATOR: WAYNE E. HAWKINS
REVISED BY:
ISSUE NUMBER: 1045
SUBJECT:
MISSWIRED SPINDLE DAC
PRODUCT LINE: MD1
PAGE 1
OF 1
A WIRING LIST ERR HAD MACHINES SHIPPING WITH THE DAC SHIELD WIRE BEING TIED
TO THE DAC OUTPUT. THIS COULD CAUSE INTERMITTENT SPINDLE FAULTS.
REMOVE DAC SHIELD WIRE FROM TB14-1 AND ATTACH TO TB14-13.
REVISED BY:
ISSUE NUMBER: 1046
SUBJECT: RANDTRONICS AUX BRIDGE SC LED
SUPERSEDES NUMBER:
PRODUCT LINE: MD3
PAGE 1
OF 1
MD3 ONLY
OLD STYLE (ARTWORK AUX BRIDGE PCB'S WILL FALSELY SURGE CURRENT TRIP DUE TO
A TEMPERATURE SENSITIVITY. IF THE CRT DISPLAYS SERVO AMP FAULT AND THE Z AXIS
STATUS LED ON AC2 IS OUT, IN ADDITION TO THE AUX BRIDGE SC LED LATCHING ON,
THEN THE OLD STYLE AUX BRIDGE NEEDS TO BE REPLACED WITH THE NEW STYLE.
OLD STYLE IDENTIFICATION:
COMPONENTS C10, R26 AND D16 ARE LOCATED JUST BELOW S1, THE HEAT
SENSOR FOR THE PCB'S HEATSINK.
NEW STYLE INDENTIFICATION:
COMPONENTS C10, R26 AND A16 ARE LOCATED TO THE LEFT OF Q10 (LOCATED IN
THE BOTTOM RIGHT HAND CORNER OF THE PCB).
*NOTE: RANDTRONIC PCB PART NUMBER, REVISION LETTER OR SERIAL NUMBERS
DO_NOT IDENTIFY OLD OR NEW STYLES IN ANY WAY!
REVISED BY:
ISSUE NUMBER: 1047
SUBJECT:
MAIN INPUT TRANSFORMER WIRING
PRODUCT LINE: ALL MILLS
PAGE 1
OF 1
WE RECENTLY EXPERIENCED EXCESSIVE HURCO SERVO AMP PROBLEMS ON AN MB3.
BETWEEN AUGUST 20, 1984 AND DECEMBER 4, 1984 WE MADE TEN SERVICE CALLS. WE
REPLACED 12 SERVO AMPS, 3 SERVO AMP POWER SUPPLIES, 2 BRIDGE RECTIFIERS AND
THE COMPLETE SERVO AMP CHASSIS.
AFTER REVIEWING THE HISTORY, WE NOTICED THAT THE MAIN INPUT TRANSFORMER
HAD BEEN REWIRED ON A PREVIOUS SERVICE CALL. THE OUTPUT VOLTAGE MEASURED
233 VAC BUT THE TRANSFORMER WAS NOT WIRED PER THE VOLTAGE CONVERSION
PRINT. ON DECEMBER 4, 1984, THE TRANSFORMER WAS REWIRED PER PRINT. AND THE
OUTPUT VOLTAGE MEASURED 218 VAC. WE HAVE HAD NO FURTHER PROBLEMS WITH
THIS MACHINE.
FROM KNOW ON, WE SHOULD MAKE SURE THAT WE DO NOT WIRE A TRANSFORMER ANY
WAY OTHER THEN TO PRINT.
DATE:
FEBRUARY 12, 1985
ISSUE NUMBER: 1048
SUBJECT:
SERVO DYNAMIC SET-UP PROCEDURE
PRODUCT LINE: MILLS USING WESTAMP
PAGE 1
OF 1
DIRECT REPLACEMENT OF -006 WESTAMPS
WHEN PLUGGING THE J1 CONNECTOR ONTO THE SERVO DYNAMICS BOARD, ENSURE PIN
J1 CONNECTOR PLUGS INTO PIN 1 ON J1 CONNECTOR OF THE NEW BRD.
THE J2 CONNECTOR IS NOT USED ALSO NOTE THE PINS 12,13,15 ARE NOT USED ON THE J1
CONNECTOR.
PRESETS
1: USING AN OHM METER, BETWEEN STATED POINTS, MAKE THESE PRESET
ADJUSTMENTS PRIOR TO INSTALLING THE BOARD.
ADJUST
AUX POT: TP2 TO TP1 =
SIG POT: TP3 TO TP1 =
TAC POT: TP4 TO TP1 =
*CMP POT: TP5 TO TP1 =
0.00K OHM.
2.67K OHM.
7.45K OHM.
.72K OHM.
*NOTE: START WITH POT FULL CW AND TURN CCW FOR DESIRED READING.
CL POT: J3-1 TO J3-3 = 0.87K OHM
RMS POT: MAX C.W. (SHOULD BE PRESET ALREADY)
POWER UP SETTINGS
2: POWER SERVOS UP, ADJUST SIG TO ACHIEVE .9 VDC B SERIES (.000") .65 VDC BX
SERIES (.0000") OF DAC AT 25 IMP IN EITHER DIRECTION. IF AN IMBALANCE OF
VOLTAGE OCCURS, ADJUST BAL TO GET BOTH DIRECTIONAL VOLTAGES WITHIN .050
VDC OF EACH OTHER.
3: NOW ZERO AXIS AND FINE TUNE BAL POT TO ACHIEVE CRT READINGS OF .0000.
ORIGINATOR: TERRY ROSENKOTTTER
REVISED BY:
ISSUE NUMBER: 1049
SUBJECT: CIRCLE & POSITIONING ACCURACY
PAGE 1
MACHINE TYPE
³ SM1 CNC / KM3 ³ MD1 / KM3P
MD3
³
OF 1
³BMC 10 THRU 50³
POSITIONING ACCURACY ³+/-.001 INCH ³+/- .0005 INCH ³+/-.0004 INCH ³
REPEATABILITY
³+/-.0005 INCH ³+/- .0003 INCH ³+/-.0002 INCH ³
CIRCLE T.I.R. .002 T.I.R. ³ .0015 T.I.R. ³ .0010 T.I.R³
THE MACHINED CIRCLE SHOULD BE ROUND WITHIN THE T.I.R SPECIFICATION FOR THAT
MACHINE TYPE.
THE TRUE MEASURED CENTER OF A CIRCLE SHOULD FALL WITHIN THE ACCURACY
SPECIFICATION FOR EACH MACHINE TYPE.
VERIFICATION PROCEDURE:
SWEEP THE MACHINED CIRCLE WITH AN INDICATOR INSERTED INTO THE SPINDLE. FIND
THE TRUE CENTER OF THE CIRCLE BY MANUALLY JOGGING X AXIS TO OBTAIN EQUAL
READINGS AT THE 3:00 AND 9:00 POSITIONS.
MANUALLY JOG THE Y AXIS TO OBTAIN EQUAL READINGS AT THE 12:00 AND THE 6:00
POSITIONS. IDEALLY THE READINGS AT 12:00, 3:00, 6:00 AND 9:00 SHOULD BE EQUAL.
ONCE THE CENTER IS ESTABLISHED, ZERO THE INDICATOR AT THE 12:00 POSITION,
SWEEP THE CIRCLE AND RECORD THE READINGS AT VARIOUS POINTS. THE TOTAL
INDICATOR READING (T.I.R.) SHOULD NOT EXCEED THE T.I.R. SPECIFICATION FOR THE
MACHINE TYPE BEING CHECKED.
NOTE: DO NOT USE AUTOMATIC POSITIONING TO DETERMINE TRUE CENTER AS
ADDITIONAL POSITIONING VARIABLES MAY CAUSE GREATER THAN SPECIFIED T.I.R.
READINGS. IT SHOULD ALSO BE NOTED THAT MACHINING PRACTICES CAN CAUSE
EXCESSIVE T.I.R. READINGS. ID THE READINGS ARE ALL PLUS OR ALL MINUS, THE T.I.R. IS
THE LARGEST MEASURED DEVIATION FROM INDICATOR ZERO. IF SOME READINGS ARE
PLUS AND SOME ARE MINUS, THE T.I.R IS THE SUM OF THE LARGEST PLUS READING AND
THE LARGEST MINUS READING IGNORING THE SIGNS.
(THEIR ABSOLUTE VALUES.)
ISSUE NUMBER: 1049A
SUBJECT:
CIRCLE & POSITIONING ACCURACY
PAGE 1
OF 1
DO NOT QUOTE THESE SPECIICATIONS TO CUSTOMERS
MACHINE TYPE
³ SM1 CNC / KM3 ³ MD1 / KM3P ³BMC 10 THRU 50³
³
³
³ MD3
³
POSITIONING ACCURACY ³+/-.001 INCH ³+/- .0005 INCH ³+/-.0004 INCH ³
REPEATABILITY
³+/-.0005 INCH ³+/- .0003 INCH ³+/-.0002 INCH ³
CIRCLE T.I.R.
³ .002 T.I.R. ³ .002 T.I.R. ³ .002 T.I.R ³
THE MACHINED CIRCLE SHOULD BE ROUND WITHIN THE T.I.R SPECIFICATION FOR THAT
MACHINE TYPE. CIRCLE TIR IN MOST CASES CAN BE SUBSTANTIALLY IMPROVED OVER
THE ABOVE SPECIFICATIONS.
THE TRUE MEASURED CENTER OF A CIRCLE SHOULD FALL WITHIN THE ACCURACY
SPECIFICATION FOR EACH MACHINE TYPE.
VERIFICATION PROCEDURE:
SWEEP THE MACHINED CIRCLE WITH AN INDICATOR INSERTED INTO THE SPINDLE. FIND
THE TRUE CENTER OF THE CIRCLE BY MANUALLY JOGGING X AXIS TO OBTAIN EQUAL
READINGS AT THE 3:00 AND 9:00 POSITIONS.
MANUALLY JOG THE Y AXIS TO OBTAIN EQUAL READINGS AT THE 12:00 AND THE 6:00
POSITIONS. IDEALLY THE READINGS AT 12:00, 3:00, 6:00 AND 9:00 SHOULD BE EQUAL.
ONCE THE CENTER IS ESTABLISHED, ZERO THE INDICATOR AT THE 12:00 POSITION,
SWEEP THE CIRCLE AND RECORD THE READINGS AT VARIOUS POINTS. THE TOTAL
INDICATOR READING (T.I.R.) SHOULD NOT EXCEED THE T.I.R. SPECIFICATION FOR THE
MACHINE TYPE BEING CHECKED.
NOTE: DO NOT USE AUTOMATIC POSITIONING TO DETERMINE TRUE CENTER AS
ADDITIONAL POSITIONING VARIABLES MAY CAUSE GREATER THAN SPECIFIED T.I.R.
READINGS. IT SHOULD ALSO BE NOTED THAT MACHINING PRACTICES CAN CAUSE
EXCESSIVE T.I.R. READINGS. ID THE READINGS ARE ALL PLUS OR ALL MINUS, THE T.I.R. IS
THE LARGEST MEASURED DEVIATION FROM INDICATOR ZERO. IF SOME READINGS ARE
PLUS AND SOME ARE MINUS, THE T.I.R IS THE SUM OF THE LARGEST PLUS READING AND
THE LARGEST MINUS READING IGNORING THE SIGNS.
(THEIR ABSOLUTE VALUES.)
REVISED BY: MIKE GARLICK
DATE: APRIL 8, 1985
ISSUE NUMBER: 1050
SUBJECT: SPINDLE HARDWARE FAULT
SUPERSEDES NUMBER: 228/233
PRODUCT LINE: MD3
PAGE 1
OF 1
DURING A RECENT SERVICE CALL ON AN MD3 WHICH WAS DISPLAYING INTERMITTENT
SPINDLE HARDWARE FAULTS, WE FOUND THAT THE CLAMPING AND /OR UNCLAMPING
OF THE SPINDLE CAUSED A TEMPORARY LOSS OF AIR PRESSURE TO THE SHOT PIN. THE
SHOT PIN OUT STATE IS DRIVEN BY A SPRING. THIS TEMPORARY LOSS OF AIR ALLOWS
THE SHOT PIN TO BACK OFF THE SHOT PIN LIMIT SWITCH CAUSING A SPINDLE HARD
WARE FAULT.
THIS PROBLEM WAS CORRECTED BY READJUSTING THE AIR FLOW RESTRICTORS FOR THE
SPINDLE CLAMP AND UNCLAMP CYLINDERS. PRESET ADJUSTMENT IS, TURN THE
RESTRICTOR ADJUSTMENT SCREWS ALL THE CW THEN BACK 1 1/2 TURNS CCW. RUN
SEVERAL TOOL CHANGES, OBSERVE OPERATION OF THE SPINDLE CLAMP, UNCLAMP,
AND SPINDLE SHOT PIN. IF ANY PROBLEMS WITH CLAMP OR UNCLAMP ARE NOTED
ADDITIONAL ADJUSTMENTS OF 1/2 TURN CCW MAY BE REQUIRED.
SHOT PIN IN LIMIT SWITCH ADJUSTMENT
1. ORIENT SPINDLE SO SHOT PIN IS ENERGIZED BUT NOT INTO SPINDLE SLOT.
(ORIENTED SLOT)
2. PLACE SHIM OF .100 " THICKNESS BETWEEN SHOTPIN IN SWITCH AND ADJUSTABLE
ACTUATOR DOG..
3. ADJUST DOG UNTIL SWITCH IS JUST MADE. LOCK INTO POSITION.
4. ACTUATE SHOTPIN OUT-VALVE AND ADJUST DOG UNTIL SHOTPIN OUT-SWITCH IS
MADE RELIABLY.
5. CYCLE 200 TOOL CHANGES AND OBSERVE PROPER OPERATION.
6. LOCKTITE ALL ADJUSTMENTS.
DATE: April 16, 1985
ISSUE NUMBER: 1051
SUBJECT: FAULT LOGIC BOARD 402 – 5001 – 035
SUPERSEDES EUXBER: 234
PRODUCT LINE: MD3
PAGE 1 OF 1
HURCO RECENTLY MADE A PURCHASE OF FAULT LOGIC BOARDS FROM
RANDTRONICS WHICH HAD A DIFFERENT 3 PHASE RECTIFIER THAN WE HAD
ORIGINALLY USED.
THIS NEW AND IMPROVED MODEL, WHICH HAS BEEN UNSUCCESSFUL, MUST BE
REPLACED AND REPLACED AS A BOARD ASSEMBLY SINCE HURCO DOES NOT
STOCK ONLY THE RECTIFIER.
THE DEFECTIVE UNIT IS A SILICON POWER CUBE AND LOOKS EXACTLY LIKE A
SQLID STATE RELAY. IT SAYS SILICON POWER ON THE UNIT. THE CORRECT
RECTIFIER IS A BLACK AND SILVER CANISTER AND ONLY HAS NUMBERS ON IT
AND IS CLEARLY LARGER THAE THE SILICON POWER TYPE.
THIS MUST BE REPLACED. YOU MUST CHECK OUT EVERY MD3 YOU INSTALL
MANUFACTURED IN FEBRUARY, MARCH AND APRIL. IT WOULD ALSO BE
ADVISABLE TO DOUBLE CHECK ANY YOU SERVICE AND NOTE ON YOUR REPORT
IF THE MACHIEE HAS THE CORRBCT RECTIFIER.
REVISED BY:
DATE: MAY 13, 1985
ISSUE NUMBER: 1052
SUBJECT: DOOR LATCH INTERFACE
PAGE 1 OF 1
THE ONE AC TRANSFORMER HAS BEEN FOUND TO INTERFERE VITH THE
OPERATION OF THE DOOR LATCH ON SOME CONTROL CABINETS.
THE SOLUTION IS TO MOVE THE ONEAC 3/'8" TQ 1/2" TOWARD THE REAR OF THE
POWER CABINET BY DRILLIEG NEW HOLES IN THE ONE AC.
THE INTERFERENCE ALLOWS THE LATCH HANDLE TO BE OPERATED WITHOUT
OPERATING THE SCREW-DRIVER SLOT.
ALL SMI-CNC'S SHOULD BE CHECKED FOR PROPER OPERATION OF THE LATCH
AND REWORKED IN THE FIELD WHEN IMPROPER LATCH OPERATION IS FOUND.
ALL SMI CNC MILLS SHIPPED VITH ONEACS PRIOR TO 3/ 30/'85 ARB BELIEVED TO
REQUIRE THE REWORK.. ON 3/30/85 A MANUFACTURING NOTICE WAS ISSUED
REQUIRING THIS RBWORK PRIOR TO SHIPMENT.
REVISED BY:
DATE: MAY 15, 1985
ISSUE NUMBER: 1053
SUBJECT: LUBRICATION OF SPLINE COUPLING:
PRODUCT LINE: KMB1, KMBX1, KMBX1 – ATC
PAGE 1 OF 1
THE SPLINE COUPLING AND THE SPLINED AREA OF THE SPINDLE SHOULD BE
PERIODICALLY LUBRICATED TO PREVENT THE OCCURRENCE OF EXCESSIVE
NOISE DURING MACHINING OPERATIONS AND TO PROMOTE A LONGER LIFE
EXPECTANCY.
FREQUENCY OF LUBRICATION IS DEPENDENT UPON SEVERITY OF OPERATION
AND AMOUNT OF MACHINE USE. (A GENERAL GUIDE MAY BE APPROXIMATELY
EVERY 250 MACHINE HOURS.
APPLY A LIGHT COATING OF N.L.G.I. #2 GENERAL PURPOSE LITHIUM-BASED HIGH
TEMPERATURE GREASE TO THE SPLINED AREA OF THE SPINDLE AT BOTH SIDE OF
THE COUPLING. DO NOT APPLY EXCESSIVE AMOUNTS OR GREASE THAT MAY BE
SLUNG INTO THE DRIVE BELT AS THIS MAY CAUSE BELT SLIPPAGE.
A LABEL HAS BEEN MADE AVAILABLE FOR FIELD RETROFIT. THE PART NUMBER
IS 703-1005-297.
ORIGINATOR: FRANK PARROTT
DATE: JULY 9, 1985
ISSUE NUMBER 1054
SUBJECT: HONING QUILL BORES
PRODUCT LINE: KNEE MILLS
PAGE 1 OF 1
THERE ARE (2) HONES LOCATED IN THE HURCO TOOL CRIB, HOWEVER ONLY ONE
IS SUITABLE FOR USE IN HONING QUILLS IN KMB1-M THRU KM3 TYPE MACHINES.
BECAUSE OF THE SLOT IN THE FRONT OF THE QUILL BORE, USE THE SUNNEN
BRAND HONE. IT HAS STONES SPACED SO THIS SLOT WILL BE SPANNED AND THE
STONES WILL NOT FALL INTO THE SLOT, REGARDLESS OF THE HONE RPM.
DO NOT USE THE AMMCO HONE FOR THESE MACHINES. IT IS OKAY TO USE THE
HONE FOR KMB1 TYPE QUILL BORES AS THEY ARE FULLY ROUND, WITH NO SLOT.
ORIGINATOR: JACK NANCE
REVISED BY:
HURCO
ISSUE NUMBER: 1055
SUBJECT: SPINDLE REBUILDS
PRODUCT LINE: SPINDLE REBUILD KNEE MILLS
PAGE 1 OF 1
IF AT ALL POSSIBLE WHEN RETURNING SPINDLES FOR REBUILD, RETURN THE
QUILL ALSO. THIS WILL ALLOW MANUFACTURING TO ASSURE THE SPINDLE IS
PROPERLY SIZED FOR THE QUILL. IN SOME CASES SPINDLE BEARING'S HAVE BEEN
LOOSE INSIDE THE QUILL DUE TO INTERNAL QUILL WEAR. IF THE QUILL IS
RETURNED, MANUFACTURING CAN ASSURE A TIGHT FIT BETWEEN SPINDLE
BEARING'S AND THE I.D. OF THE QUILL.
ORIGINATOR: R.J. JOHNSON
REVISED BY:
DATE: JULY 10, 1985
SUBJECT: MISCOUNTS DUE TO WIRING IN X5 BOX
ISSUE NUMBER: 1066
PRODUCT LINE: MILLS USING HEIDENHEIN SCALES PAGE 1 OF 2
MISCOUNTS MAY OCCUR IF THE WIRE PAIRS FOR J4, J5, J6 TO TB4, TB5 AND
TB6 WITHIN THE X5 BOX ARE NOT TIGHTLY TWISTED. TWIST AS MANY TURNS AS
POSSIBLE WHILE ALLOWING CONNECTION TO WAGOS TB4-6. DO NOT TWIST TO
THE POINT OF DOUBLE LEVELS OF TWIST, A SINGLE TIGHT TWIST IS REQUIRED.
MILLS BEING INSTALL OR SERVICED SHOULD BE INSPECTED AND REWORKED TO
THE ABOVE. MILLS NOT COMPLYING WITH THE ABOVE MAY BE EXPECTED T.O
MISCOUNT SLIGHTLY, OR MAY NOT MISCOUNT AT ALL.
REVISED BY:
DATE:JULY 11, 1985
ISSUE NUMBER: 1057
SUBJECT: AIR LINE FITTINGS POPPING OFF
PRODUCT LINE: KMB1, MB1, MD1
PAGE 1 OF 1
THE FITTINGS BELOW CAN BE USED TO REPLACE THE FITTINGS
SHIPPED WITH THE MILL ORIGINALLY TO REDUCE THE POSSIBILITY OF AIR LEAKS
DUE TO AIR LINES POPPING OFF.
506-5060-002 FREE SWIVEL ELBOW O.D. 1/'4 PIPE THREAD 1/'4.
506-0002-013 STRAIGHT MALE CONNECTOR O.D. 1/2 THREAD 1/2
506-0002-014 STRAIGHT MALE CONNECTOR O.D. 1/'4 THREAD 1/8.
506-3012-016 UNION TEE TUBE O.D. 1/'4.
506-3009-036 MALE ELBOW O.D. 1/4 THREAD 1/4.
506-3009-037 MALE ELBOW O.D. 1/4 THREAD 1/8.
ORIGINATOR: ROBERT JOHNSON
DATE: JULY 23, 1985
ISSUE NUMBER: 1058
SUBJECT: CHIP REMOVAL FROM BENEATH SADDLE SUPERSEDES NUMBER: 255/253
PRODUCT LINE: MD1
PAGE 1 OF 1
REMOVAL OF THE CHIP BUILD-UP BENEATH THE SADDLE (AROUND THE BALL
LEADSCREW) IS TO BE PERFORMED ON WEEKLY BASIS. THIS TO PREVENT THE
POSSIBILITY OF BINDING And/or UNDUE WEAR ON THE LEADSCREW AND IMPROVE
THE RETURN FLOW OF THE COOLANT.
A STICKER PART NUMBER 703-1005-296 SHOULD BE INSTALLED ON THIS MACHINE
TO INFORM THE CUSTOMER ABOUT THE CHIP REMOVAL.
ORIGINATOR: JACK NANCE
DATE: JULY 23, 1985
SUBJECT: Y AXIS LEADSCREW COVER
PRODUCT LINE: MD1
ISSUE NUMBER: 1059
PAGE 1 OF 1
WHEN THE WIDE Y AXIS WAY COVERS WERE ADDED TO THE MD1 MILLS, THE Y
AXIS BALL SCREW COVER WAS DELETED. A BALLSCREW COVER IS AVAILABLE
TO
PROTECT THE BALL SCREW FROM CHIPS WHICH MAY GET UNDER THE SADDLE BY
FALLING BEHIND THE TABLE.
THE FOLLOWING PARTS ARE REQUIRED:
1, BALLSCREW COVER
902-0434-002 1
2, SPACER BAR
802-1661-001 2
3, M6 C 12 S.H.C.S
101-5008-003 2
A NOTCH MUST BE CUT IN THE SLIDIHG WAY COVER TO ALLOW CLEARANCE. SEE
ATTACHED DRAWING FOR CUTOUT DIMENSIQNS. 802-1655-001,
NOTE: ALL HOLES REQUIRED ARE ALREADY DRILLED AND TAPPED FOR THE
BALLSCREW COVER, SPACER BAR ETC..
ORIGINATOR: ROBERT JOHNSON
REVISED BY:
DATE: JULY 24, 1985
ISSUE NUMBER: 1060
SUBJECT: QUILLS FOR KONDIA MILLS
PRODUCT LINE: ALL SM1-CNC KILLS
PAGE 1 OF 1
A)
FIRST (21) SMI-CNC RETROFITS, MANUAL MILL TO CNC HAD KMB1M
HEADS.
THIS PART NUMBER IS 713-0016-001. QUILL TO BORE CLEARANCE IS .0008
TO . 0010" .
B)
UNTIL JANUARY 85, SM1 – CNC MILLS WERE ALL SMI MANUAL MILLS
CONVERTED
TO CNC MILLS; THEREFORE WE TOOK MANUAL MILL, QUILLS PART NUMBER 7130012-108 RACK GEAR TYPE, AND MODIFIED IT, THUS NUMBER S01-1350-001.
NOTE: THIS APPLIES ONLY TO CONVERTED SM1'S HURCO STYLE CNC CLEARANCE
FOR QUILL TO BORE .0008-.0012".
C)
ON SM1-CNC'S BEGINNING WITH BUILDS IN JANUARY 1985, WE RECEIVED
AND USED KONDIA'S RIGID OVERARM MODEL. THIS USED QUILL PART NUMBER
713- 0012-330. THIS WAS CHROME PLATED GROUND AND POLISHED QUILL.
CLEARANCE WAS .0008-. 0010".
D)
IN FEBRUARY 1985, WE INSTITUTED AN INDUCTION HARDENED QUILL.
THIS WAS THE SAME QUILL AS IN C BUT THE FINISH WAS CHANGED FROM
CHROME INDUCTION HARDENED, GRIND AND POLISH FINISH. TO NO CHROME.
HURCO PART NUMBER 713-0012-330. THESE QUILLS IN MILLS HAVE JUST ARRIVED
THIS MONTH. CLEARANCES IS . 0004-.0006".
E)
REPLACEMENT QUILLS FOR ALL SMI-CNC'S WITH THE RIGID OVERARM
ONLY SHOULD USE THIS LAST QUILL, AND THIS CLEARANCE. IN THE CASE OF
OVERSIZE QUILLS, USE HARDENED QUILLS AHD CHROME PLATE AND GRIND TO
OBTAIN THE DESIRED FIT OF .0004-.0006".
F)
REPLACEMENT QUILLS FOR THE EARLIER SM1-CNC'S HURCO STYLE,
SHOULD USE QUILLS AS IN B ABOVE.
ORIGINATOR: DAVE ROCH
REVISED BY:
ISSUE NUMBER: 1061
SUBJECT: PARAJUST B WIRE DRESSING
PRODUCT LINE: MD1-MD3 MILLS
PAGE 1 OF 1
IT HAS BEEN FOUND THAT A PROBLEM COULD OCCUR IF THE PARAJUST WIRING IS
NOT CORRECT. THE WIRING FROM THE PARAJUST CABINET TO THE PARAJUST
DOOR (TB-1 AND THE BRAKE BOARD) CAN BECOME NICKED OR SEVERED IF IT IS
NOT PROTECTED AND DRESSED PROPERLY. IT CAN ALSO CAUSE PROBLEMS
CLOSING THE DOOR. THE PROPER DRESS SHOULD INCLUDE APPROXIMATELY 12"
OF 1/'2" SPIRAL WRAP OVER THIS AREA OF WIRING FOR PROTECTION. IT SHOULD
BE DRESSED SO AS TO PROTECT WIRING AND PARAJUST CIRCUIT BOARDS WHEN
OPENING AND CLOSING PARAJUST DOORS.
THE PART NUMBER FOR SPIRAL WRAP IS 406-6241-001.
ORIGINATOR: K. PERKINS
REVISED BY:
ISSUE NUMBER: 1062
SUBJECT: ADJUSTABLE SPINDLE ORIENT SPEED
PRODUCT LINE: MD1-3
PAGE 1 OF 1
D SERIES MILLS WITH A06 OR LATER SOFTWARE HAVE AN ADJUSTABLE ORIENT
SPEED. SWITCH BLOCK S2 ON THE X SPINDLE DUAL AXIS BOARD. NORMAL
SETTING IS S2 POSITIONS 1 TO 5. SPEED ADJUSTMENTS ARE AS FOLLOWS:
LSB (BIT 1) POSITION 5
(BIT 2) 4
(BIT 3) 3
MSB (BIT 4)
2
SIGH BIT
1 FASTER = OPEN OR OFF/' SLOWER = CLOSED OR ON.
THE SPEED ADJUSTMENT IS +- 50 '/ OF NOMINAL FOR MACHINE TYPE
NOMINAL=40 RPM.
SW2 POSITION 1 OPEN, AND 2 THRU 5 CLOSED = 50'/ FASTER.
SW2 POSITION 1 CLOSED, AND 2 THRU 5 CLOSED = 50/ SLOWER.
ANY COMBINATION MAY BE USED TO GET A WORKING ORIENT SPEED.
AFTER ADJUSTING, CYCLE THE TOOL CHANGER USING HIGH AND LOW GEAR
(RANGE) AND ENSURE RELIABLE OPERATION. FINE TUNE SPEED UNTIL HIGH AND
LOW GEAR (RANGE) ARE BOTH RELIABLE. AFTER COMPLETION OF SETTING
ORIENT SPEED,
CYCLE THIS TOOL CHANGER 200 TIMES USING FULL RANGE OF RPM'S AND BOTH
CW AND CCW ROTATION,
ORIGINATOR: KEITH PERKINS
REVISED BY:
HURCO FIELD SRRVICE BULLETIN
ISSUE NUMBER: 1063
SUBJECT: TAPE TRANSPORT GROUNDING
PRODUCT LINE: ULTIMAX ONE
PAGE 1 OF 2
ENSURE THAT THE CARTRIDGE GROUNDING CLIP IS PROPERLY INSTALLED IN THE
TAPE TRANSPORT. THE GROUND CLIP SHOULD PROTRUDE THROUGH THE BOTTOM
OF THE TRANSPORT SO AS TO TOUCH THE BOTTOM SO AS TO TOUCH THE
BOTTOM OF THE CARTRIDGE WHEN INSERTED INTO THE TRAESPORT. NOTE : CLIP
CAN BE SEEN TO THE RIGHT SIDE OF THE TAPE HEAD IN THE BQTTOM OF THE
TRANSPORT AS VIEWED THROUGH THE CARTRIDGE QPENING. THERE IS ANOTHER
GROUND WIRE TO BE CQNNECTED TO THE GRQUND LUG OH THE TAPE
TRANSPORT. BOTH GROUND WIRES ARE TO BE CONNECTED ON THE OPPOSITE
END TO THE CONSOLE GROUND AREA. LOCATED AT THE UPPER LEFT SIDE OF THE
CABLE CONNECT BOARD ON THE BOTTOM OF THE ENCLOSURE. SEE THE
ATTACHED DRAWING FOR THE LOCATION OF THE GROUND LUGS AND THE
GROUND CLIP.
NOTE: SOME EARLY TAPE TRANSPQRTS HAD A INFERIOR QUALITY GROUND CLIP
THAT GETS CAUGHT ON THE BOTTOM OF THE TAPE CARTRIDGE AND WOULD GET
BENT CAUSING THE TAPE NOT TO EJECT FULLY FROM THE TRANSPORT. IF THIS
CONDITION IS SEEN, THE TAPE TRANSPORT SHOULD BE REPLACE WITH A NEW
ONE OR A CURRENT PRODUCTION STYLE GROUND CLIP INSTALLED.
REVISED BY:
ISSUE NUMBER: 1064
SUBJECT: LUBE PRESSURE SWITCH SETUP
PRODUCT LINE: MD3
PAGE 1 OF 2
WITH A06 OR LATER SOFTWARE THAT MONITORS THE LUBE PRESSURE SWITCH.
THE SWITCH SET UP IS AS FOLLOWS.
1. CONNECT VOLTMETER ACROSS LUBE PRESSURE SWITCH CONTACTS (N.O.) THE
METER SHOULD BE IN THE 20 VDC SCALE.
2. SWITCH SHOULD BE OPEN (APPROXIMATELY 5 VDC READING). IF NOT, LOOSEN
LUBE PRESSURE JAM NUT AND TURN ADJUSTMENT SCREW.
3. MANUALLY ACTIVATE LUBE SOLENOID. SWITCH SHOULD CLOSE
(APPROXIMATELY 0 VDC). IF NOT ADJUST LUBE SWITCH.
4 MANUALLY ACTIVATE AND DEACTIVATE THE LUBE SOLENOID. VERIFY SWITCH
CLOSES WHEN LUBE PUMP ACTIVATES AND THE SWITCH OPENS WHEN THE
SOLENOID IS DEACTIVATED.
5. TIGHTEN LUBE SWITCH ADJUSTMENT JAM NUT BEING CAREFUL NOT TO ALTER
SCREW SETTING.
6. RECHECK TO VERIFY CORRECT SWITCH ADJUSTMENT.
7. TO SIMULATE A SOFTWARE CONTROLLED OPERATION OF THE LUBE PUMP
TURN
OFF / ON POWER TO THE MILL. UPON POWER UP AND ENERGIZING SERVOS LUBE
PUMP SHOULD BE ACTIVATED, FIRING SOLENOID AND CLOSING SWITCH. VERIFY
NO ERROR IS REPORTED ON THE CRT SCREEN INDICATING "LUBE PRESSURE
FAILURE".
NOTE: SEE ATTACHED PAGE FOR LOCATION OF THE LUBE PRESSURE SWITCH AND
SOLENOID.
REVISED BY:
DATE: November 2, 1992
ISSUE NUMBER: 1065-B
SUBJECT: Ultimax Power Supply Adjustments.
SUPERSEDES NUMBER: 1065-A
PRODUCT LINE: Ultimax Machines
PAGE 1 OF 4
On Ultimax 1 thru 3 power supplies check at locations per type on the following pages.
Output to be within the following spec.:
5 VDC
24 VDC
- 12 VDC
+ 12 VDC
=
=
=
=
+5.2 - 5.3 VDC
+24.5 - 25.0 VDC
-12.5 - -13 VDC
+12.5 - +13 VDC
ALSO NOTE: THE 24 VOLT SUPPLY OUTPUT FROM THE POWERTEC IS ADJUSTABLE BUT
NOT FOR THE POWERMATE.
ALL ULTIMAX 1 THRU 2, SUPPLIES WILL BE REPLACED WITH THE DELTRON IF THEY ARE
BAD, SO YOU MAY HAVE TO MOVE SOME WIRES AROUND TO MATCH HOOKUPS.
SEE ATTACHED PAGES FOR DRAWINGS OF POWER SUPPLIES.
ORIGINATOR: Randall Bryant
REVISED BY: Randall Bryant
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE
RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
230VAC
G
R
O
U
N
D
Powermate DC Switching power supply
Hurco part number 413-0008-001
+5VDC
All Pots are Interacting and should be verified after setup.
Caution: Use Non-metallic adjusting tool. As legs of pot
-12VDC
10 9
G +
R 5
O V
U D
N C
D
8
G
R
O
U
N
D
7
+
24
V
D
C
6
G
R
O
U
N
D
5
+
5
V
D
C
+12VDC
4
12
V
D
C
3
G
R
O
U
N
D
2
G
R
O
U
N
D
are very near adjustment screw.
1
+
12
V
D
C
NONADJUSTABLE
Powertec Power Supply
Hurco Part number 413-0008-006
+5VDC
+24VDC
-12VDC
+12VDC
1
2
3
4 5 6
7
8
G V V + + - C
R A A 12 24 12 O
O C C V V V M
U
D D D M
N
C C C O
N
D
C
O
M
M
O
N
9 10 11
C
O
M
M
O
N
+
5
V
D
C
+
5
V
D
C
FSB 1065B Page 2 of 4
+12VDC
-12VDC
+24VDC
Deltron Power supply
+5VDC
All Pots are Interacting and should be verified after
setup.
Caution: Use Non-metallic adjusting tool. As legs of
pot are very near adjustment screw.
1
2
3
4 5 6
7
8
G V V + - + C
R A A 12 12 24 O
O C C V V V M
U
D D D M
N
C C C O
D
N
C
O
M
M
O
N
9 10 11
C
O
M
M
O
N
+
5
V
D
C
+
5
V
D
C
Fan
Ground
Common
5VDC
-12VDC
12VDC
120 VAC
Common
24VDC
Ultimax 3 DC Power Supply. "REV A or B"
Hurco Part number
413-0008-013
NOTE: refer to FSB 1198 for wiring code.
Ultimax 3 DC Power Supply. "REV C"
Hurco Part number
413-0008-013
FSB XXX Page 4 of 4
DATE: December 7, 1993
ISSUE NUMBER: 1065-C
SUBJECT: Ultimax Power Supply Adjustments Mod's.
SUPERSEDES NUMBER: 1065-B
PRODUCT LINE: Ultimax Machines
PAGE 1 OF 5
Revised Added Page 2 and Notes
See page 2 for modification information.
On Ultimax 1 thru 3 power supplies check at locations per type on the following pages.
Output to be within the following spec.:
5 VDC
24 VDC
- 12 VDC
+ 12 VDC
=
=
=
=
+5.2 - 5.3 VDC
+24.5 - 25.0 VDC
-12.5 - -13 VDC
+12.5 - +13 VDC
ALSO NOTE: THE 24 VOLT SUPPLY OUTPUT FROM THE POWERTEC IS ADJUSTABLE BUT
NOT FOR THE POWERMATE.
ALL ULTIMAX 1 THRU 2, SUPPLIES WILL BE REPLACED WITH THE DELTRON IF THEY ARE
BAD, SO YOU MAY HAVE TO MOVE SOME WIRES AROUND TO MATCH HOOKUPS. SEE PAGE 2
FOR MORE INFORMATION ON REPLACEMENT SUPPLIES.
SEE ATTACHED PAGES FOR DRAWINGS OF POWER SUPPLIES.
REVISED BY: L. Leffew
The MAX 2 Deltron supply has been replaced by a modified MAX 3 Deltron supply. This new
supply is stocked under the old part number (413-0008-011).
The modifications are for mounting only. This supply will mount in place of the original unit,
except on KM3/3P machines that had the supply mounted behind the card rack. In this case the
supply is moved to the left hand side wall. All cabling involved will reach to the new position.
The 12 position Wago connector (406-4005-067) and directions on making the connections are
included with the new supply.
On early machines,(MD1's and MD3's possibly early OEM's) the supply was setup to
operate on 230 vac, the new supply can not be changed to operate at this voltage.
To install this new supply on a machine that is at 230 vac you will need to move the input voltage,
to the power conditioner, from 230 vac to the 115 vac. Consult the wiring diagrams for proper
connection points.
The following information is supplied as an example only. It is not intended to be used to
make wiring changes to the machine.
On the MD1 the power conditioner is supplied from the primary side of T2 control voltage
transformer. Locate the lines feeding the conditioner and move them to the secondary side of T2.
FSB 1065C Page 2 of 5
G
R
O
U
N
D
230VAC
Powermate DC Switching power supply
Hurco part number 413-0008-001
+5VDC
-12VDC
10 9
G +
R 5
O V
U D
N C
D
8
G
R
O
U
N
D
7
+
24
V
D
C
6
G
R
O
U
N
D
5
+
5
V
D
C
+12VDC
4
12
V
D
C
3
G
R
O
U
N
D
2
G
R
O
U
N
D
1
+
12
V
D
C
NONADJUSTABLE
Powertec Power Supply
+5VDC
+24VDC
-12VDC
+12VDC
1
2
3
4 5 6
7
8
G V V + + - C
R A A 12 24 12 O
O C C V V V M
D D D M
U
C C C O
N
N
D
C
O
M
M
O
N
9 10 11
C
O
M
M
O
N
+
5
V
D
C
+
5
V
D
C
FSB XXX Page 4 of 5
+12VDC
-12VDC
+24VDC
Deltron Power supply
+5VDC
All Pots are Interacting and should be verified after
setup.
Caution: Use Non-metallic adjusting tool. As legs of
pot are very near adjustment screw.
1
2
3
4 5 6
7
8
G V V + - + C
R A A 12 12 24 O
O C C V V V M
U
D D D M
N
C C C O
D
N
C
O
M
M
O
N
9 10 11
C
O
M
M
O
N
+
5
V
D
C
+
5
V
D
C
Fan
Ground
Common
5VDC
-12VDC
12VDC
120 VAC
Common
24VDC
Ultimax 3 DC Power Supply. "REV A & B"
5V Adj
+24 V Adj
+-12V Adj
Ultimax 3 DC Power Supply. "REV C"
Hurco Part number
413-0008-013
DATE:
MARCH 23, 1989
ISSUE NUMBER: 1066
SUBJECT: DIP SWITCH SETTINGS ON ULTIMAX MILLS SUPERSEDES NUMBER: 267
PRODUCT LINE: ALL ULTIMAX MILLS CONTROLS
PAGE 1
OF 9
INTENT: TO PROVIDE UNIFORMITY IN SETTING SWITCH POSITIONS ON ALL ULTIMAX
CONTROL MACHINES.
INDEX
A. 128K MEMORY BOARD (415-0168-001)
B. 256K MEMORY BOARD (415-0168-002)
C. X/Y DUAL AXIS BOARD (415-0176-00X)
D. Z/SPINDLE DUAL AXIS BOARD (415-0176-00X)
E. MACHINE PERSONALITY BOARD (415-0176-001/002)
F. CRT CONTROLLER BOARD (415-0174-001/002)
G. MICRO MEMORY BOARD MAX II
H. CONTROL RELAY PANEL
NOTE: CONTROL MUST BE RESET (POWER DISCONNECTED) TO DETECT A CHANGE IN
SWITCH CONFIGURATION.
ORIGINATOR:
A. 128K MEMORY BOARD: 415-0168-001 SWITCH AND JUMPER CONFIGURATION.
FOR ANY BOARD WITH IT'S ADDRESS STARTING ABOVE 256K, A JUMPER MUST BE
PRESENT BETWEEN E1 AND E2.
Battery Select
Brd 1
thru 4
0 = OPEN
S1
Configurations
6
5
4 3
2
1
1 = CLOSED
Battery Select
A. #1 CLOSED, #2 OPEN = MEMORY SUPPORTED BY +5V SUPPLY AND NOT BATTERY
VOLTAGE BOARD
B. #1 OPEN, #2 CLOSED = MEMORY SUPPORTED BY BATTERIES FOR DATE
RETENTION. (NORMAL SETTING)
Board #
#1
#2
#3
#4
Switch Position
6 5 4 3
1 1 1 1
0 1 1 1
1 1 1 1
0 1 1 1
Jumper E1 to E2
Jumper E1 to E2
B. 256K MEMORY BOARD 415-0168-002
NOTE:
SWITCH #
1= CLOSED = ON
O= OPEN = OFF
FUNCTION
SW1
BANK SELECT
SW2
READ TIME CLOCK (RTC) SELECT
SW3
UPPER LIMIT BLOCK A
SW4
LOWER LIMIT BLOCK A
SW5
UPPER LIMIT BLOCK B
SW6
LOWER LIMIT BLOCK B
SW7 (1 THRU 3) BATTERY ENABLES
SW7 (4)
RTC WRITE PROTECT
SW7 (5)
+4 VDC RACK TO RAM ARRAY
SW7 (6)
VBB (BATTERIES) TO RAM ARRAY
SW9
RTC SELECT
COMMON SWITCH SETTINGS (ALL 256K BOARDS)
SWITCH #
SETTINGS
SW1
SW2
SW9
SW7 #1
SW7 #2
SW7 #3
SW7 #4
SW7 #5
SW7 #6
1 THRU 4 = CLOSED
1 THRU 5, 7, 8 = CLOSED; 6= OPEN
1 THRU 4 = CLOSED
CLOSED BATTERY 1 IN CIRCUIT
CLOSED HARDWARE WRITE PROTECTED
OPEN +5V FROM BUS DISABLED
CLOSED BATTERY VOLTAGE TO RAM
COMMON WIRE JUMPERS (256K BOARDS)
WIRE JUMPER
FUNCTION
REMOVE E28 TO E 27
REMOVE E24 TO E35
INSTALL E31 TO E32
INSTALL E29 TO E30
INSTALL E21 TO E22
DISABLES INTIALIZATION GEN. BY +5 MONT
NEEDED FOR 16 BIT OPERATION
XACK DELAY AT 310 NSEC
SWITCH SETTINGS TO MAKE PER BOARD
FIRST 256K (MEMORY PCB #1) 0-3FFFF TOTAL
SW3
1 2 3 4 5 6
0 0 0 1 1 1
SW4
1 2 3 4
1 1 1 1
5
1
6
1
SW5
1 2
0 0
3
0
4
0
5
1
6
1
SW6
1 2
1 1
3
1
4 5 6
0 1 1
6
1
SW6
1 2
1 1
3
1
4 5 6
0 0 1
SECOND 256K (MEMORY PCB #2) 4000-7FFFF
SW3
1 2 3 4 5 6
0 0 0 1 0 1
SW4
1 2 3 4
1 1 1 1
5
0
6
1
SW5
1 2
0 0
3
0
4
0
5
0
WARNING: SW7 POSITIONS 1,2,3 MUST BE OPEN BEFORE PCB BATTERY OR
BATTERY FUSES ARE DESOLDERED!
C. DUAL AXIS BOARD (X/Y) 415-0176-00X FOR ALL ULTIMAX MILLS
S1 NOTE: 1 = ON = CLOSED, O = OFF = OPEN
BOARD ADDRESS
STANDARD CONFIGURATION
1,2 AND 3 OPEN
4 CLOSED
1
2
3 4
On
Off
LEADSCREW ERROR IS COMPENSATED OVER 20".
SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
S2
S3
MSB
1
2
3
4
LSB
5
6
7
8
MSB
1
3
4
5
6
7
8
Scale/Encoder
On = Rotary Encoder
Off = Scale
Sign Bit
On = Shorten Travel
Off = Lengthen Travel
Y axis Leadscrew Comp.
Y axis Backlash Comp.
S4
S5
MSB
1
2
LSB
2
3
4
LSB
5
6
7
8
Sign Bit
On = Shorten Travel
X axis Leadscrew Comp.
MSB
1
2
3
4
LSB
5
6
7
8
Scale/Encoder
On = Rotary Encoder
Off = Scale
X axis Backlash Comp.
SCALES = .000039" PER BIT (MD3, BMC 10 THRU 15)
ROTARY ENCODERS = .00005" PER BIT (MD-1, KM3 & KM3P)
ROTARY ENCODERS = .0000197 PER BIT (BMC 20-50)
NOTE: BMC 10 THRU 15 USE A ROTARY ENCODER BUT ARE SET AT SCALE VALUES.
SET SWITCHES IN BINARY CONFIGURATION FOR TOTAL ERROR COMPENSATION.
FOR SCALES :
ENCODERS :
BMC 20-50 Max 1 & 2 until 7.24
POSITION 8 = .000039"
8 = .00005"
8 = .0000197"
7 = .000078"
7 = .00010"
7 = .0000394"
6 = .000156"
6 = .00020"
6 = .0000788"
5 = .000312"
5 = .00040"
5 = .0001576"
4 = .000624"
4 = .00080"
4 = .0003152"
3 = .001248"
3 = .00160"
3 = .0006304"
2 = .002496"
2 = .00320"
2 = .0012608"
EXAMPLE: MD1 HAS .0005" OF BACKLASH. TO STRAP. FOR THIS YOU WOULD TURN ON
POSITIONS 7 AND 5. FOR A DIFFERENT VALUE TURN ON OTHER SWITCHES. THE BIT
VALUE ADDS AS THE SWITCHES ARE TURNED ON.
NOTE: ON BMC 20-50, YOU MAY HAVE A TWO TO ONE PULLEY RATIO
AND THE VALUES HAVE TO BE CUT IN HALF.
D. DUAL AXIS BOARD (Z/SPINDLE) 415-0176-001 USED IN MD1, MD3, BMC10 & 15
S1 NOTE: 1 = ON = CLOSED, O = OFF = OPEN
BOARD ADDRESS
STANDARD CONFIGURATION
1 2
3 4
1,2 AND 3 OPEN
On
4 CLOSED
Off
LEADSCREW ERROR IS COMPENSATED OVER 20".
S2
On HSS
Off LSS
On=Shot pin enabled S3
Off = Shot pin disabled
With 1 turned On 8-4 speeds up dwell.
1 turned Off 8-4 Slows down dwell.
LSB
1 2 3 4 5 6 7 8
Orient Speed
Adjust
1 2 3 4 5 6 7 8
Mill type
On=MD3
Off=MD1
8=LSB 4=MSB with a
Max 70% Change with 4-8 on
Spindle Type/Shotpin Select
Tap / Dwell
SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
S4
S5
MSB
LSB
MSB
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Sign Bit
On = Shorten Travel
Scale/Encoder
On = Rotary Encoder
Off = Scale
Z axis Leadscrew Comp.
LSB
Z axis Backlash Comp.
SCALES = .000039" PER BIT (MD3, BMC 10/15)
ROTARY ENCODERS = .00005" PER BIT (MD-1, KM3 & KM3P)
ROTARY ENCODERS = .0000197 PER BIT (BMC 20-50)
NOTE: BMC 10 /15 USE A ROTARY ENCODER BUT ARE SET AT SCALE VALUES.
SET SWITCHES IN BINARY CONFIGURATION FOR TOTAL ERROR COMPENSATION.
FOR SCALES :
POSITION 8 = .000039"
7 = .000078"
6 = .000156"
5 = .000312"
4 = .000624"
3 = .001248"
2 = .002496"
ENCODERS :
8 = .00005"
7 = .00010"
6 = .00020"
5 = .00040"
4 = .00080"
3 = .00160"
2 = .00320"
BMC 20-50 Max 1 & 2 until 7.24
8 = .0000197"
7 = .0000394"
6 = .0000788"
5 = .0001576"
4 = .0003152"
3 = .0006304"
2 = .0012608"
NOTE: ON BMC 20-50, YOU MAY HAVE A TWO TO ONE PULLEY RATIO
AND THE VALUES WILL HAVE TO BE CUT IN HALF.
E. MACHINE PERSONALITY BOARD 415-0177-00X
NOTE:
1 = ON = CLOSED
O = OFF = OPEN
S1
TO CHANGE A ULTIMAX ONE PERSONALITY
BOARD TO A ULTIMAX TWO BOARD,
REMOVE THE JUMPER ON TB 6 AND INSTALL
IT TO PINS 4 AND 9. REMOVE THE JUMPER ON
TB7 AND INSTALL IT TO PIN 12 ONLY.
CHANGE THE PART NUMBER FROM 415-0177001 TO 415-0177-002.
Note: To turn off the
Auto Spindle for a
KM3P reverse pos#
Language
English
German
French
Spanish
3 on S1
Machine
Auto Spindle MD1
MD3
MD1 Manual Spindle
Training Console
BMC 10
BMC 10 L
BMC 15
BMC 10N
BMc 10NL
KM3 Auto Spindle Speed
KM3P Auto Spindle Speed
KMC3P
KM3
KM3P Manual Spindle
Pos
0
1
0
1
Pos
0
0
1
1
Pos
0
0
0
1
1 2 3 4 5 6 7 8
Not used
Spindle Type
On = Hss
Off= Standard
Tool Changer
On = Enabled
Off = Disabled
Pos:1
0
1
0
1
0
1
0
1
0
1
0
0
1
0
Pos:2
0
0
0
1
1
1
0
0
1
0
1
0
0
1
Pos:3
0
0
0
1
0
0
1
1
1
0
0
1
1
1
Pos:4
0
0
1
1
0
0
0
0
0
1
1
1
1
1
S2
Not used
1 2 3 4 5 6 7 8
A Axis Select
On = Present
Off=Disable
Not used
B Axis Select
On = Present
Off=Disable
S3
STANDARD CONFIGURATION: POSITIONS 1 THRU 7 =OFF, POSITION 8 = ON
F. CRT CONTROLLER ONE BOARD (415-0174-001) SWITCH CONFIGURATIONS
S1
Not used
1 2 3 4 5 6 7 8
1,2&3 OFF
Baud rate 9600
Normal / Local Mode
On =Normal
Off = Local or Test mode
50/60 Hz On = 60 Hz
Off = 50 Hz
Not used
NOTE: POSITIONS 4,6,7 ARE NOT CURRENTLY USED.
CRT CONTROLLER TWO BOARD (415-0174-002) SWITCH CONFIGURATIONS
Jumper X1B is jumpered1-2 = Normal mode, Jumper removed = local or test mode.
Jumper X1A 1-2 = 60 Hz, Jumper removed = 50 Hz
G. MICRO MEMORY BOARD FOR MAX2
NOTE: 1 = CLOSED = ON
O = OPEN = OFF
Switch
1
2
3
SW1
1
1
1
SW2
1
1
0
SW3
0
0
1
SW4
0
0
0
4
1
1
1
0
5
1
1
1
1
6
1
1
1
1
7
1
1
1
1
8
1
1
1
1
Memory
BLOCK A LO = $00000
BLOCK B LO = $40000
BLOCK A HI = $3FFFF
BLOCK B HI = $FFFFF
H: CONTROL RELAY PANEL
SW1
Frame type
BMC 30
BMC 40
BMC 50
BMC 20
S1
0
0
1
1
S2
0
1
0
1
ATC type
20 Station
24 Station
30 Station
16 Station
SW2
Spindle Speed
4000 RPM
6000 RPM
10000 RPM
3000 RPM
S3
0
0
1
1
S4
0
1
0
1
SW3
S1
0
0
1
1
S2
0
1
0
1
ATC Solenoid type
Single ended
Double ended
SW4
Rotary Axis Resolution
4000 Ticks/Degree
2000 Ticks/Degree
S1
0
1
Spindle Clutch
Enable
Disable
ATC Enable/Disable
0
1
Up
Center
Down
Enabled
Disabled
Enable
S2
0
1
ISSUE NUMBER: 1067
SUBJECT: LUBRICATION PROBLEMS
PAGE 1 OF 1
THE BALL NUT LUBE LINE OF SM1-CNC MACHINE MAY HAVE BEEN SUPER GLUED
TO THE BALL NUT. THE GLUE MAY CAUSE A BLOCKAGE IN THE LUBE LINE WHICH
WOULD CAUSE THE X AND Y AXIS BALL NUTS TO RUN DRY.
WHEN PERFORMING SERVICE ON SM1-CNC'S THE X AXIS BALL SCREW SHOULD BE
CHECKED FOR SIGNS OF LUBRICATION. IF THE SCREW LOOKS DRY OR HAS A DULL
COLOR AND FEELS STICKY THIS COULD INDICATE IMPROPER LUBRICATION. IF
THIS IS THE CASE, SLIDE THE TABLE AWAY AND VISUALLY VERIFY THE
OPERATION OF THE LUBE SYSTEM.
IF THE LINE APPEARS CLOGGED IT CAE BE CLEARED WITH EITHER A STOUT
SAFETY PIN OR A SMALL DIAMETER DRILL. WHEN THE LINE HAS BEEN CLEARED,
SUPER GLUE THE LINE BACK TO THE BALL NUT AND VERIFY PROPER OPERATION
BY CYCLING THE LUBE PUMP.
ORIGINATOR: UNKNOWN
REVISED BY:
ISSUE NUMBER: 1068
SUBJECT: CRTs SHORTING OUT
PRODUCT LINE: ULTIMAX ONE CONTROLS
PAGE 1 OF 1
RECENT INFORMATION FROM SERVICE INDICATES FAILURE OF TEXT AND
GRAPHICS CRTs. IF THE FAILURE SYMPTOM IS NO DISPLAY, ONE OF THE CAUSE'S
MAY BE THE PART LEADS OF THE CRTS ARE SHORTING TO THE MOUNTING PLATE
THAT FORMS THE BACK OF THE CONSOLE. THIS COULD BE A RESULT OF
INADVERTENTLY PRESSING THE CRT BOARD.
IF THIS OCCURS THERE IS A FUSE ON BOTH THE TEXT AND GRAPHICS BOARDS
WHICH CAN BE REPLACED. THE FUSE IS A 2 AMP PICO 125 VOLT, LOCATED AT
F401 (PART NUMBER 409-1001-074).
IN ORDER TO REDUCE THE POSSIBILITY OF LEADS SHORTING OUT ALL CRT
BOARDS ARE BEING CLIPPED PRIOR TO MOUNTING. ADDITIONAL ACTION IS
BEING PLANNED TO MINIMIZE THIS PROBLEM.
TO REDUCE THE POSSIBILITY OF LEADS SHORTING OUT FOR FIELD MACHINES #4
NYLON WASHERS CAN BE INSTALLED BETWEEN THE CRT BOARDS AND THE
MOUNTING PLATE STANDOFFS (PART NUMBER 220-0085-001), 7 WASHERS ARE
NEEDED PER BOARD, OR 14 PER MACHINE.
REVISED BY:
ISSUE NUMBER: 1069
SUBJECT: ENCODER DAMAGE DUE TO COUPLING
SUPERSEDES NUMBER: 2 76
PRODUCT LINE: ALL MILLS WITH ENCODER COUPLINGS
PAGE 1 OF 1
COMPRESSING OR TENSIONING THE FLEX COUPLING BETWEEN THE ENCODER
AND THE SERVO MOTOR CAN CAUSE PREMATURE FAILURE OF THE ENCODER
BEARING'S. RATHER THAN COMPRESSING THE FLEX COUPLING TO RESOLVE
MISCOUNTS, YOU SHOULD REPLACE THE COUPLING WITH THE NEW ONE
DESIGNED FOR DAMPENING TO ASSURE "CLEAN" OUTPUT OF PHASE A AND PHASE
B. (NUMBER 205-0010-006 1/4" X 1/2" SHAFT DIAMETER),
ALL SM1-CNC MILLS SHIPPED AFTER APRIL 1985 HAVE THE NEW COUPLING. 1/'4" X
1/4") ALL KMB1M (UK) MILLS SHIPPED AFTER SEPTEMBER 1985 HAVE THE NEW
DAMPENED COUPLING (1/4" X 1/'2".
ORIGINATOR: R.J JOHNSON
REVISED BY:
ISSUE NUMBER: 1070
SUBJECT: HEIDENHEIN 3P BOARDS
PRODUCT LINE: MBX2 MB3 MD3
PAGE 1 OF 1
HEIDENHEIN HAS REDESIGNED THE X5 BOARD TO IMPROVE RELIABILITY.
HOWEVER, THE NEW BOARDS ARE TALLER AND WILL NOT FIT INTO THE
ENCLOSURE AND STILL ALLOW THE COVER TO BE REPLACED.
IN ORDER TO OVERCOME THIS PROBLEM PERFORM THE FOLLOWING:
1.
REMOVE THE MOTHBR BOARD FROM THE E1%CLOSURE SAVING
THE SCREWS AND THE STANDOFFS.
2.
REMOVE THE ELECTRICAL PANEL.
3.
REMOVE THE ENCLOSURE FROM THE WALL OF THE POWER CABINET.
4.
USING THE ELECTRICAL PANEL AS A TEMPLATE DRILL FOUR HOLES IN
THE BACK OF THE ENCLOSURE FOR THE FOUR HOLES IN THE MOTHER
BOARD.
5.
REMOUNT THE MOTHER BOARD TO THE BACK OF THE ENCLOSURE USING
SCREWS AND STANDOFFS FROM 1 ABOVE.
ASSURE ALL WIRING IS RETURNED TO THE ORIGINAL CONDITION.
REMEMBER WIRING IS RUNNING FROM THE MOTHER BOARD TO THE
LINEAR SCALE CABLES INSIDE THE ENCLOSURES SHOULD HAVE A
MINIMUM OF SIX TURNS.
6.
PART NUMBERS FOR OLD AND NEW X5 BOARDS ARE:
PART NUMBER
415-0152-001 OLD X5 BOARD
415-0152-002 NEV X 5 BOARD
ORIGINATOR: R.J JOHNSON
REVISED BY:
DESCRIPTION DIMENSIONS
2. 5" X 2. 75"
2. 5" X 2. 87"
ISSUE NUMBER: 1071
SUBJECT: PARAJUST MAINTENANCE
PRODUCT LINE: ANY MILLS WITH PARAJUST
PAGE 1 OF 2
THE FOLLOWING IS A LIST OF PREVENTIVE MAINTENANCE ITEMS WHICH CAN
IMPROVE THE RELIABILITY AND REDUCE PART FAILURES TO THE PARAJUST
SPINDLE SPEED DRIVE.
1. APPLY RTV ADHESIVE TO THE ORANGE CAPACITORS ON THE DRIVE MODULES
TO REDUCE THE EFFECT OF VIBRATION.
2. DRESS THE CABLE LEADING FROM THE DQOR TO THE VOLTAGE CONTROL
BOARD SUCH THAT IT DOES NOT PUSH AGAINST THE VOLTAGE CONTROL BOARD.
WRAP SPIRAL BAND AROUND THE CABLE TO PREVENT ABRASION AND PINCHING
THE CABLE IN THE DOOR.
3. TIGHTEN THE FEMALE PINS ON ALL MOLEX CONNECTORS TO ASSURE GOOD
CONNECTION . EXAMINE THE MOLEX CONNECTOR (MC95) ON THE CHOPPER
BOARD FOR BROWN COLOR. IF IT IS BROWN, IT IS A HIGH RESISTANCE POINT AND
NEEDS TO BE CORRECTED. (LOOSE CONNECTIONS MAY ALSO BE FOUND BY
WIGGLING THE CONNECTOR BODY AND NOTING TIGHTNESS.)
4. TIGHTEN ALL SCREWS ON BUSS CAPACITOR. IF SCREWS BOTTOM OUT,
ADD WASHERS TO ASSURE TIGHTNESS.
5. TIGHTEN SCREWS ON ALL TERMINALS AND CONNECTION POINTS.
6. WIGGLE RING TONGUES TO ASSURE TIGHTNESS.
7. EXAMINE SOLDER JOINTS AROUND CONNECTORS TO ASSURE GOOD CONTACT
AND NO COLD JOINTS. THIS WILL REDUCE THE EFFECT OF VIBRATION.
8. ASSURE THAT THE SHEAR PIN SENSE WIRE IS NOT COUPLED WITH THE BUS
POWER VIRES. THIS IS APPLICABLE TO M-2 THROUGH MD-3 DRIVES.
9. ASSURE FANS ARE CLEAN AND OPERATIONAL FOR GOOD AIR FLOW.
10. ASSURE SCREW TERMINALS AND NUTS ARE TIGHT ON MAIN INPUT FUSES.
11. ASSURE MAIN INPUT FUSE CLIPS ARE TIGHT. THIS IS APPLICABLE TO M-1
THROUGH MD-1 DRIVES.
REVISED BY:
.
12. ASSURE EXTERNAL HEAT EXCHANGER SHEET METAL COVERS ARE IN PLACE
THIS INCLUDES PERFORATED AND "L" SHAPED COVERS ON M-2 THROUGH MD-3
DRIVES.
FSB1071 PARAJUST MAINTENANCE
13.
CLEAN CHIPS OFF THE TOP OF THE PARAJUST ENCLOSURE BEFORE
OPENING DOOR. CLEAN CHIPS OFF ANY INTERNAL COMPONENTS.
14.
EXAMINE THE BACK SIDE OF THE FREQUENCY AND VOLTAGE CONTROL
MOTHER BOARDS FOR COLD SOLDER JOINTS OR CRACKED SOLDER TO THE
MOLEX PLUGS MOUNTED TO THE BOARDS.
15.
A CORRECTION IS NECESSARY REGARDING BRAKE BOARD ADJUSTMENT
ON B DRIVES: ALL B DRIVES <EXCEPT 6000 RPM VERSION) ADJUST THE GAIN POT
SO WHEN THE BRAKE IS ON THE OUTPUT HAS A 60'4 DUTY CYCLE. THE OUTPUT
MUST NOT SWITCH ON AND REMAIN LOCKED TO THE BUS VOLTAGE.
ALL B DRIVE WITH 6000 RPM VERSION MILLS,
ADJUST THE GAIN POT SO WHEN THE BRAKE IS ON THE OUTPUT IS AT MAXIMUM
AND THE BRAKE VOLTAGE REMAINS AT BUSS LEVEL FOR AS LONG AS POSSIBLE
BEFORE PWM OCCURS.
16.
SHEAR PINS ON DECEL AND OR BLOWN DRIVER AND CHOPPERS CAN
RESULT FROM
BREAKING RESISTOR BOX PROBLEM SUCH AS POOR SOLDER JOINTS, LOOSE
CONNECTION, FAULTY RESISTORS.
17.
JUST A REMINDER... THE INPUT VOLTAGE AT THE PARAJUST (NOT THE
MAIN POWER TRANSFORMER) SHOULD NOT EXCEED 253 VAC. IF THE
INPUT VOLTAGE AT THE PARAJUST IS AT 253 VAC OR SLIGHTLY LESS, NORMAL
LINE POWER FLUCTUATIONS MAY EXCEED THE 253 LIMIT AND DOWNWARD
ADJUSTMENT IS REQUIRED.
18.
INSURE THE DC HOLD POT IS FULL CCW ESPECIALLY ON REPLACEMENT
BOARDS. IMPROPERLY ADJUSTED DC HOLD POTS WILL CAUSE PREMATURE
CHOPPER BOARD FAILURE.
ISSUE NUMBER: 1072
SUBJECT: GROUND FAULT ON HURCO AMPS
PRODUCT LINE: ANY MILL USING HURCO AMPS
PAGE 1 OF 1
THE PURPOSE OF THIS FSB IS TO CLARIFY THE MEANING OF A GROUND FAULT
INDICATION ON THE HURCO FET SERVO AMP. A GROUND FAULT ON ANY AXIS
INDICATES THAT THERE IS A GROUND FAULT SOMEWHERE IN THE TOTAL SERVO
SYSTEM, NOT NECESSARILY THE AXIS IT IS INDICATED ON. FOR EXAMPLE, A
GROUND FAULT IN THE Y AXIS MOTOR COULD FAULT THE X AXIS SERVO BOARD,
THE Z AXIS SERVO BOARD OR ANY COMBINATION THEREOF, DEPENDING ON
WHICH CIRCUITS HAPPEN TO BE MORE SENSITIVE, ONE CANNOT ASSURE THAT
BECAUSE THE X AXIS INDICATED A GROUND FAULT CONDITION AND Y AND THE
Z DO NOT, THE PROBLEM IS IN THE X AXIS. THE FAULT COULD BE IN THE Y OR Z
AXIS ALSO.
ORIGINATOR: JOE BARESTEAD
REVISED BY:
ISSUE NUMBER: 1073
SUBJECT: FRL PLASTIC BOWLS CRACKING
PAGE 1 OF 2
PLASTIC BOWL FAILURES (CRACKS IN BOWL) MAY OCCUR DUE TO INCOMPATIBILITY WITH
MATERIALS IN THE COMPRESSED AIR LIME (INCLUDING CERTAIN COMPRESSOR OILS) OR
MATERIALS USED TO CLEAN THE FRL BOWL OR USED NEAR THE BOWL.
METAL BOWLS ARE AVAILABLE FROM THE FRL MANUFACTURE IN THE VENT OF
REPEATED BOWL FAILURES OCCURRED OCCUR AND INCOMPATIBLE MATERIAL CANNOT BE
ELIMINATED.
THE MANUFACTURER'S STATEMENT REGARDING THESE MATERIALS IS LISTED BELOW:
"CERTAIN COMPRESSOR OILS, CHEMICALS, HOUSEHOLD CLEANERS, SOLVENTS,
PAINTS AND FUMES WILL ATTACK PLASTIC BOWLS AND CAN CAUSE BOWL FAILURE. DO NOT
USE HEAR THESE MATERIALS. WHEN BOWL BECOMES DIRTY REPLACE BOWL OR WIPE ONLY
WITH A CLEAN DRY CLOTH. REINSTALL METAL BOWL GUARD OR BUY AND INSTALL A METAL
BOWL GUARD. IMMEDIATELY REPLACE ANY CRAZED, CRACKED,
DAMAGED OR HOLED PLASTIC BOWL WITH A METAL BOWL OR A new PLASTIC BOWL AND
METAL GUARD."
SOME OF THE MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS:
ACETALDEHYDE
ACETIC ACID (CONC.)
ACETONE
ACRYLONITRILE
AMMONIA
AMMONIUM FLUORIDE
AMMONIUM HYDROXIDE
AMMONIUM SULFIDE
CRESOL
CYCLOHEXANOL
CYCLQHEXANONE
CYCLOHEXNE
DIMETHLY FORMANIDE
DIOXANE
ETHANE TETRACHLORIDE
ETHYL ACETATE
REVISED BY:
METHYLENE SALICYLATE
MILK OF LIME (CaOH)
NITRIC ACID (CONC.)
NITEOBENZENE
NITROCELLULOSE LACQUER
PHENOL
PHOSPHOROUS HYDROXY CHLORIDE
PHOSPHOROUS TRICHLORIDE
ANTIFREEZE
BE]BENZENE
BENZOIC ACID
BENZYL ALCOHOL
BRAKE FLUIDS
BROMOBENZENE
BUTYRIC ACID
CARBOLIC ACID
CARBON DISULFIDE
TERAHYDRONAPHTHALENE
CARBON TETRACHLORIDE
CAUSTIC POTASH SOLUTION
CAUSTIC SODA SOLUTION
CHLORBENZENE
CHLOROFORM
ETHYL ETHER
ETHLAMINE
ETHYLENE CHLOROHYRIN
ETHLENE DICHLORIDE
ETHYLENE GLYCOL
FORMIC ACID (CONC.,)
FREON
GASOLINE
HYDRAZINE
PROPIONIC ACID
PYRIDINE
SODIUM HYDROXIDE
SODIUM SULFIDE
STRENE
SULFURIC ACID (CONC.)
SULPHURAL CHLORIDE
TANNERGAS
HYDROCHLORIC ACID
LACQUER THINNER
METHYL ALCOHOL
METHYLENE CHLORIDE
PERCHLORETHYLENE
THIOPHENE
TOLUENE
TURPENTINE
XYLENE
TRADE NAMES OP SOME COMPRESSOR, OILS RUBBER COMPOUNDS AND OTHER
MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS:
ATLAS "PERMA GUARD"
BUNA N
CELLULUBE 4150 AND 4220
CRYLEX t5 CEMENT
EASTMAN 910
GARLOCK # 98403
HASKEL 4568 023
HILGARD CO,'S HIL PHENE
HOUGHTON 5 CO, OIL 0 1120, 1130,1055
HOUTOSAFE 1000
KANO KROIL
KEYSTONE PENETRATING OIL #2
MARVEL MYSTERY OIL
MINN. RUBBER 366Y
NATIONAL COMPOUND #N11
NYLOCK VC 3
PARCO 4' 1306 NEOPRENE
PETRON PD287
PRESTONE
PYDRAUL AC
SEARS REGULAR MOTOR OIL
SINCLAIR OIL "LILY WHITE"
SOME LOCTITE COMPOUNDS
STAUFFER CHEMICAL FYRQUEL #150
STILLMAN 4SR 269 75
STILLMAN OSR513 70
TELAR
TENNECO ANDER #495 AND #'500 OILS
TITON
ZEREX
DATE: JANUARY 14, 19S6
ISSUE NUMBER: 1074
SUBJECT: OPERATION OF LUBE SYSTEMS
PRODUCT LINE: ALL MILLS USING AUTOLUBE
PAGE 1 OF 1
BELOW IS A SUMMARY OF THE WAY LUBE OPERATION BY MACHINE TYPE:
MD3:
20 MINUTES OFF TIME.
PUMP ACTUATION IS ON FOR 5 SECONDS, THEN OFF FOR 5 SECONDS, THEN ON FOR
20 SECONDS AND CHECK FOR LUBE PRESSURE.
TIMER CONTROLLED WHEN SERVOS ARE TURNED ON RESETS AND CYCLES, IF
THE OFF TIME IS GREATER THAN 20 MINUTES. THE ERROR MESSAGE IS LUBE
PRESSURE FAILURE.
BMC 10-15:
RUN PUMP FOR 60 SECONDS AND CHECK FOR LUBE SWITCH MADE AT LEAST TWO
TIMES. THE TIMER CONTROL IS THE SAME AS THE MD3 BUT USING 30 NOT 20
MINUTES.
BMC 20-50:
12 MINUTES OFF TIME CONTROLLED BY AT TIMER BUILT INTO THE PUMP.
PUMPS 3 TO 6 CC AND IS ADJUSTABLE.
KM3:
ON FOR 8 SECONDS; NO SWITCH CHECKED.
IT TURNS ON PUMP WHENEVER THE SERVOS ARE TURNED ON AND RESETS TIMER.
PRE-ULTIMAX:
USED A 15 MINUTE MOTOR DRIVEN CAM THAT IN SOME CASES TURNS ON
THE PUMP AND IN OTHERS TURNED ON THE LUBE TIMER IN THE RELAY PANEL.
THAT TIMED THE ON TIME. IN THE TYPE THAT DID NOT HAVE A DELAY RELAY
THE ON TIME WAS CONTROLLED BY THE SPACING OF THE GAP IN THE CAM.
ISSUE NUMBER: 1075
SUBJECT: ATC ERROR, CAROUSEL
PRODUCT LINE: BMC-15 MILLS
PAGE 1 OF 1
DURING RE-LAYOUT OF THE EXISTING ARTWORK FOR THE CONTROL RELAY PCB
IT WAS NOTICED THAT SU1, LOCATED JUST BELOW J3, SHOULD BE A IN4002 DIODE
NOT A SUPPRESSOR. REMOVE SU1 AND REPLACE IT WITH A 417-0001-003. FOR
POLARITY SEE THE FIGURE BELOW:
REVISED BY:
ISSUE NUMBER: 1076
SUBJECT: INDEX OPTION ULTIMAX
PRODUCT LINE: KM3 KM3P
PAGE 1 OF 1
THE WIRING FOR THE INDEX OPTION INSIDE THE KM3 ULTIMAX POWER CABINET
MAY BE WIRED INCORRECTLY. IF THE BLUE WIRE FOR ICR IS IN TB4-2, MOVE THIS
WIRE TO TB6-2 LOCATED ON THE FAR RIGHT HAND SIDE OF TB6.
SCHEMATICALLY, THE FOLLOWING WIRING SHOULD EXIST:
INDEX CONNECTOR "B" TO TB6-2.
TB6-2 TO MP-P3-25.
PLEASE CHECK WIRING WHEN SERVICING ANY KM-3 ULTIMAX MACHINE.
ORIGINATOR: TERRY ROSENKOETTER
REVISED BY:
DATE: 9/11/96
ISSUE NUMBER: 1077
SUBJECT: HI-LO GEAR SWITCH PROBLEM
SUPERSEDES NUMBER:
PRODUCT LINE: MD3-BMC15
PAGE 1 OF 1
THE SWITCHES USED FOR THE HI/LO GEAR CHANGE (404-5202-005) ON THE MD3 AND
BMC 10-15 MACHINES HAVE PROVED TO BE INTERMITTENT DURING HIGH VIBRATION
CUTS. THE CONTACT ON THE CLOSED SWITCH MIGHT OPEN BRIEFLY CAUSING THE
SPINDLE AXIS STATUS LIGHT TO GO OUT. IF SWITCH ADJUSTMENT DOES NOT SOLVE
THE PROBLEM, PLACE A PIECE OF RUBBER APPROXIMATELY .125" THICK BETWEEN
THE SWITCH AND IT'S MOUNTING BRACKET. THIS WILL ELIMINATE MUCH OF THE
VIBRATION THAT THE SWITCH IS FEELING. BE SURE TO LOCKTITE THE MOUNTING
SCREWS
DAVID PRICE
Revived by L.Leffew & Wayne Kline
ORIGINATOR: Lonnie Leffew
REVISED BY:
ISSUE NUMBER: 1078
SUBJECT: MIS-WIRE OF RS232 PORTS
SUPERCEDES NUMBER: 307
PRODUCT LINE: KM TYPE KNEEMILLS
PAGE 1 OF 1
DUE TO A ERROR IN THE WIRING LIST SOME KM3 MILLS WITH ULTIMAX
CONTROLS MAY HAVE SHIPPED WITH THE RS232 PORTS (1 AND 2) REVERSED.
VERIFY PORT WIRING IS AS SHOWN BELOW. IF PORT 1 AND 2 ARE REVERSED ALL
YOU NEED DO IS REMOVE THE PORT RECEPTACLES FROM THE MAIN ELECTRICAL
CABINET AND SWITCH THEM.
REVISED BY:
ISSUE NUMBER: 1079
SUBJECT: MULTI-LOAD MASTERS ON CRT
SUPERSEDES NUMBER: 3 06
PRODUCT LINE: BX MILLS
PAGE 1 OF 1
THIS FRONT PANEL BOARD MODIFICATION ELIMINATES MULTI-LOAD MASTER
ON BX CRT'S AT POWER-UP. CONNECT A 20 Pf (CAPACITOR HURCO P/'N
407-0005-007) TO R76 (INPUT TO 7400) AND THE GROUND LAND NEAR R76.
REVISED BY:
ISSUE NUMBER: 1080
SUBJECT: SPEED SENSE SWITCH WIRING
SUPERSEDES NUMBER: 309 / 310
PRODUCT LIES: KMC3P
PAGE 1 OF 1
ENSURE THERE IS A SHIELDED CABLE FROM THE SWITCH THAT SENSES SPINDLE
RPM (4PRS) TO THE AUTOMATIC SPEED CONTROL PCB. THE SHIELD MUST BE
CONNECTED TO GROUND AT THE TERMINAL BLOCK IN THE REMOTE STATION
BOX.
WIRE NUMBERS 194,195 AND 196 ARE 194 TO GROUND, 195 SIGNAL AND 196 TO +
VCC. IF THE WIRING IS NOT DONE WITH SHIELDED CABLE, REMOVE AND REPLACE
WITH BELDEN #' 8771 3 CONDUCTOR 20 AWG SHIELDED (HURCO PART
NUMBER 406- 1441-001) THIS ELIMINATES NOISE THAT CAUSE ERRATIC ASC
FUNCTION.
IT IS IMPERATIVE THAT CORRECT INPUT LINE PHASING BE APPLIED TO THE KMC3P CONTROL BEFORE THE TOOL CHANGER IS CYCLED. VERIFY THE CORRECT
PHASING BY RUNNING THE SPINDLE AND OBSERVE CORRECT ROTATION. (NOTE:
REMEMBER THAT WHEN YOU RUN THE SPINDLE IN MANUAL THE CONTROL
ASSUMES THAT YOU ARE IN HIGH GEAR SO CHECK TO MAKE SURE.) THE
INCORRECT PHASING WILL CAUSE
THE CLAMP/'UNCLAMP MOTOR TO JAM RESULTING IN DISASSEMBLY FOR REPAIR.
ORIGINATOR: T. ROSENKOETTER
REVISED BY:
DATE: APRIL 3, 1986
ISSUE NUMBER: 1081
SUBJECT: THREE PHASE POWER SERVICE
PAGE 1 OF 2
THE FOLLOWING CHART PROVIDES A CROSS REFERENCE BETWEEN THREE PHASE
KVA AND LINE CURRENT IN AMPERES. THIS IS USEFUL BECAUSE ELECTRICAL
SERVICE REQUIREMENTS ARE RATED IN TERMS OF KVA, AS IN THE CASE OF
HURCO MACHINES. OCCASIONALLY, SERVICE REQUIREMENTS ARE RATED IN
TERMS OF SUPPLY AMPERES. USING THIS CHART AND / OR THE FORMULA
ALLOWS YOU TO CROSS BETWEEN THE TWO UNITS OF MEASURE. THE LAST
CHART SHOWS THE MINIMAL WIRE SIZE BY CURRENT.
FSB1081 THREE PHASE POWER SERVICE
DATE: MAY 8, 1986
ISSUE NUMBER: 1082
SUBJECT: MOTOR COVER
PRODUCT LINE: KM3P, KMC3P
PAGE 1 OF 1
A COVER HAS BEEN DESIGNED TO ENSURE THAT THE Y AXIS MOTOR AND TACH
BRUSHES ON THE KMP TYPE MACHINES CANNOT BE CONTAMINATED WITH OIL.
THIS COVER ALONG WITH 0-RINGS UNDER THE BRUSH CAPS PROVIDED ON THE
MOTOR WILL ELIMINATE THE CHANCE OF OIL ON THE BRUSHES.
PART NUMBERS FOR KIT ARE:
602 – 0002 – 008
HOSE CLAMP
802-1774 – 001 MOTOR COVER 8/ /2" X 81/'2" COVER NEOPRENE.
REVISED BY:
DATE: MAY 20, 1986
ISSUE NUMBER: 1083
SUBJECT: INPUT VOLTAGE AND AIR PRESSURE
PAGE 1 OF 2
ORIGINATOR: DAVID PRICE
DATE: JULY 1, 1986
ISSUE NUMBER: 1084
SUBJECT: MISSING SURGE SUPPRESSORS
PRODUCT LINE: BMC 10 THRU 15
PAGE 1 OF 1
RECENTLY A SURGE SUPPRESSOR WAS FOUND MISSING FROM THE CONTROL
RELAY PANEL ON A BMC 10. THE LACK OF THIS SUPPRESSER CAN CAUSE
INTERMITTENT TOOL CHANGER ERRORS WHEN THE FLOOD COOLANT TURNS ON
AND OFF. QE EVERY SERVICE CALL, CHECK TO BE SURE SU15 IS PRESENT ON THE
CONTROL RELAY PANEL.
THE SUPPRESSOR IS ORANGE, ABOUT THE SIZE OF A TWO WATT RESISTOR, AND IS
LOCATED NEAR THE BOTTOM LEFT HAND CORNER OF THE BOARD. IF THE
SUPPRESSOR IS NOT PRESENT, INSTALL A 417-6001-012 SUPPRESSOR AS SOON AS
POSSIBLE.
ORIGINATOR: DAVID PRICE
REVISED BY:
DATE: JULY 7, 1986
ISSUE NUMBER: 1085
SUBJECT: MIS-WIRE ON KM3 BX TYPE MILLS
PRODUCT LINE: KM3 BX TYPE
PAGE 1 OF 2
DURING A REVISION TO SERVO CONDUIT HARNESSES ON THE BX KNEE MILLS IT
WAS DISCOVERED THAT SHIELDS FOR THE MOTOR AND TACH. WERE NOT
DOCUMENTED TO BE GROUNDED. THIS ERROR CAN FOUND ON KNEE MILLS WITH
REMOVABLE SERVO CONDUIT HARNESSES. WITH THE SHIELDS NOT GROUNDED
THE PROBABILITY FOR MISCOUNTING IS EVIDENT.
THE CORRECTION TO THIS PROBLEM INVOLVES THE MOTOR SHIELDS TO GROUND
AT THE RANDTRONICS TERMINAL STRIP (RTB1) AND CONNECTING THE TACH.
SHIELDS TO TACH. RETURN AT RTB1. (THIS IS HOW THE ULTIMAX CONTROL IS
WIRED.)
PARTS NEEDED:
HURCO PART NUMBER
406-4005-003
406-2005-029
406-6481-004
406-6481-006
DESCRIPTION
GREEN /' YELLOW WAGO TERMINAL
16 AWG WHITE WIRE
SHRINK SLEEVE 1/'4"
SHRINK SLEEVE 1/'2"
QUANTITY
1
18"
3"
3"
1. INSTALL ONE (1) ADDITIONAL GREEN/YELLOW WAGO TERMINAL ADJACENT TO
EXISTING GREEN/'YELLOW TERMINAL AT RTB1-MGT.
2. USE 18 AWG WHITE WIRE TO CONNECT MOTOR SHIELD TO GREEN/YELLOW
TERMINAL. SOLDER WHITE WIRE TO SHIELD AND USE 1/'2" SHRINK SLEEVE
TO COVER CONNECTION. COMPLETE THIS ON X,Y AND Z.
3. CONNECT TACH. SHIELD TO TACH. RETURN AT RTB1. SOLDER BLACK WIRE
(TACH, RETURN) TO SHIELD AND USE 1/'4" SHRINK SLEEVE TO COVER
CONNECTION THIS CAN BE ACCOMPLISHED BY STRIPPING INSULATION OF BLACK
WIRE ENOUGH TO ATTACH SHIELD, YET ALLOWING INSULATION TO REMAIN
ALONG WIRE TO RTB1. COMPLETE THIS ON X,Y AND Z.
ORIGINATOR: T. ROSENKOETTER
X AXIS (EXAMPLE):
ISSUE NUMBER: 1086
SUBJECT: AXIS DRIVE BELT TENSION
PRODUCT LINE: BMC MILLS
PAGE 1 OF 1
DUE TO THE BELT DRIVE SYSTEM FOR THE AXIS ON THE BMC 30, 40, AND 50 THE
AMOUNT OF MOTOR BELT TENSION ON EACH AXIS AFFECTS THE BACKLASH IN
THAT AXIS. AFTER THE LASER TEST HAS BEEN PERFORMED AND THE BACKLASH
IS VERIFIED, THE GAP BETWEEN THE BELT HOUSING AND THE MOTOR MOUNTING
PLATE WILL BE MEASURED WITH A FEELER GAUGE AND THAT VALUE WILL BE
WRITTEN ON THE INSIDE OF THE POWER CABINET DOOR BELOW THE LASER
COMPENSATION VALUES.
WHEN INSTALLING MOTORS AT INSTALL, POSITION THE MOTOR TO ACHIEVE THE
SAME GAP BETWEEN THE MOTOR MOUNTING PLATE AND THE BELT HOUSING
THAT IS WRITTEN ON THE INSIDE OF THE CABINET.
ORIGINATOR: TIM CLOUD
REVISED BY:
ISSUE NUMBER: 1087
SUBJECT: USING DISTRIBUTOR STOCK PARTS
PAGE 1 OF 1
IF AND WHEN AN EMERGENCY SITUATION ARISES WHERE WE HAVE TO REMOVE
PARTS FROM A DISTRIBUTORS STOCK MACHINE, THE FOLLOWING PROCEDURE
MUST BE FOLLOWED.
1. THE DISTRIBUTOR MUST FIRST AUTHORIZE THE REMOVAL OF THE ITEMS AS
THESE MACHINE ARE THE DISTRIBUTOR'S PROPERTY!
2. THE SERVICE ENGINEER MUST ENSURE THAT THE MACHINE IS NOT SCRATCHED
OR DAMAGED IN ANY WAY AND THE CONDITION MUST BE NOTED ON THE
SERVICE REPORT.
3. THE SERVICE ENGINEER MUST ORDER REPLACEMENT PARTS BEFORE LEAVING
THE DISTRIBUTOR'S PLANT.
4. A SERVICE REPORT MUST BE FILLED OUT AND SIGNED BY THE AUTHORIZED
INDIVIDUAL AT THE DISTRIBUTOR'S OFFICE. A NOTE ON THE SERVICE
REPORT MUST BE MADE AS TO THE REPLACEMENT OF THE PARTS. NOTE WHO
IS RESPONSIBLE FOR REPLACING THE PARTS AND IF WE HAVE TO RETURN TO
DO IT; THE SCHEDULER FOR THE AREA MUST BE NOTIFIED SO A FOLLOW-UP
CALL CAN BE MADE.
5. TO ELIMINATE ANY FUTURE CONFUSION; A DISTRIBUTOR AHD HIS STOCK
MACHINE IS TO BE TREATED EXACTLY LIKE A CUSTOMER.
ORIGINATOR: RANDY RENEKAMP
REVISED BY:
DATE: FEBRUARY 5, 1987
ISSUE NUMBER: 1088
SUBJECT: TAPE READER PROBLEMS
PRODUCT LINE: TM5
PAGE 1 OF 1
Upon investigation of the TM5 Tape Reader problems, a design error was
found on the Front Panel Cable Connect PCB Serial LED Driver circuit
(This PCB , 415-0201-001, is only used on the TM5.) The circuit that
controls the LED brightness was incorrectly designed. A maximum current
specification for this circuit is 750 micro amps. The circuit was
operating with 850 micro amps causing the Serial LED Driver to operate
extremely hot (140 degrees F.) The heat caused the reset line from the
Serial LED Driver to operate incorrectly. This reset signal is received
by the Tape Transport and CRT Controller PCB.
The problem is solved by replacing R4, currently a 10K resistor, with a
39.2K resistor. This drops the worst case operating temperature to 109
degrees F. (this also dims the LED's , but not objectionably.) To
further enhance this circuit, add a heat sink to the Serial LED Driver.
The retrofit to field mills is two fold.
1) Replace R4 on the Front Panel Cable Connect PCB, (clearly marked and
currently a 10K resistor) with a 39.2K resistor (HURCO P/M 407-0035441. )
2) Mount a heat sink to U6 on the Front Panel Cable Connect PCB. This
heat sink (HURCO P/N 420-0002-015) can be attached with a good thermal
conductive cement such as Thermalbond Thermally Conductive Epoxy
Adhesive.
This fix will significantly improve the Tape Reader issue.
ORIGINATOR: T. ROSENKOETTER, W HAWKINS
REVISED BY:
DATE: February 9, 1987
ISSUE NUMBER: 1089
SUBJECT: RANDTRONICS CHASSIS WIRING
PRODUCT LINE: Mills
PAGE 1 OF 1
Some wiring problems have recently been discovered on the production
floor with the Randtronics chassis wiring. These wiring problems have
been in the Wago terminal strip wires which are done by Randtronics.
In some cases the wires have not been stripped sufficiently to make a
good connection. In other cases the wires were inserted into the Wago
too far and the connection was through the insulation.
The floor techs are watching out for this now but some may have gotten
out into the field and might cause problems at a later date. Be aware
of this possibility and check the wires going into the Wago terminal
strip on the Randtronics chassis when on a service call whether it is
for a servo related problem or not. Hopefully this will prevent a
service call in the future if we can correct the wiring errors before
they cause a problem.
ORIGINATOR: Wayne Hawkins
REVISED BY:
ISSUE NUMBER: 1090
SUBJECT: CHIP CONVEYOR MOTOR HEATER
PRODUCT LINE: BMC 15
PAGE 1 OF 1
IT HAS BEEN DETERMINED THAT THE HEATER FOR BMC 15 CHIP MOTOR IS
NOT THE CORRECT VALUE. IT HAS AN ADJUSTABLE RANGE OF 1.6 TO 2.5 AMPS.
THIS IS MUCH TOO HIGH SINCE THE MOTOR IS ONLY RATED AT 200 VAC. WHEN
SERVICING A BMC 15 THIS SHOULD BE REPLACED.
THE CORRECT HEATER HAS A RANGE OF .38 TO .62 AMP. THE HURCO PART
NUMBER IS 403-5501-015. THE GE PART NUMBER IF CR4G1WD.
IF THIS IS NOT REPLACED WITH THE CORRECT VALUE HEATER MOTOR DAMAGE
COULD OCCUR IF THE MOTOR BECAME STALLED.
ADJUST HEATER TO .5 TO .6 AMP AND ENSURE THAT CUSTOMER IS AWARE OF
WHERE TO CHECK THIS IF HIS MOTOR STALLS.
REVISED BY:
ISSUE NUMBER: 1091
SUBJECT: TOOL CHANGE LIMIT SWITCH
PAGE 1 OF 1
ON ALL BMC 30 MILLS PRIOR TO BC8005096B THE WIRE GOING TO THE HOME
POSITION LIMIT SWITCH IS IN DANGER OF BEING CAUGHT ON THE SWITCH DOG
AND TORN FROM THE MICRO SWITCH. TO PREVENT THIS DAMAGE SECURE THE
WIRE WITH A JIFFY-CLAMP. THERE IS CURRENTLY AN M5 THREADED HOLE WHICH
MAKES THE LOCATION AND MOUNTING OF THE JIFFY-CLAMP VERY EASY. IF YOU
DO NOT HAVE THE PARTS AVAILABLE TO PERFORM THIS MODIFICATION, HERE
ARE THE HURCO PART NUMBERS.
1
2
3
108-5003-003
110-0061-004
408-7501-009
M5 X.OBX10 BHSS
#10 EXTERNAL STAR WASHER
#125 JIFFY-CLAMP
THE JIFFY-CLAMP MODIFICATION WILL BE IN EFFECT UNTIL LEADVELL HAS
PROVIDED THE NEW THROUGH HOLE.
LEADWELL HAS BEEN NOTIFIED TO DRILL A THROUGH HOLE BESIDE THE MICRO
SWITCH TO ROUT THE WIRE THROUGH; THEREFORE PREVENTING THE
POSSIBILITY OF DAMAGE TO THE MICRO SWITCH WIRES.
ORIGINATOR: ERIC HUDSON
REVISED BY:
ISSUE NUMBER: 1092
SUBJECT: ULTIMAX LOCKUP
PRODUCT LINE: ULTIMAX MILLS
PAGE 1 OF 1
1. IT HAS BEEN DISCOVERED THAT INCORRECT ROUTING OF THE J-1 CABLE IN
THE ULTIMAX CONSOLE CAN CAUSE MACHINE LOCKUPS. ROUTING THE CABLE
ACROSS THE TOP OF THE CRT CONTROLLER BOARD IS NO LONGER ACCEPTABLE
THIS CAN CAUSE THE CABLE TO BE PINCHED WHEN THE CARD CAGE IS
SLID BACK INTO ITS NORMAL POSITION. ROUTE THE J1 CABLE TO THE SIDE OF
THE CARD RACK TO ELIMINATE THIS PROBLEM.
2. RAPID BUTTON PUSHING AND MODE CHANGES HAVE BEEN KNOWN TO CAUSE
LOCK-UPS. ENCOURAGE THE CUSTOMER TO USE ONLY ONE HAND WHILE
PROGRAMMING THE MACHINE.
3. EMERGENCY STOP DEPRESSED WHILE IN THE TOOL SETUP MODE, THEN TRYING
TO ACCESS PART PROGRAMMING MODE, WILL LOCKUP THE CONTROL VIRTUALLY
EVERY TIME.
4. SWITCHING BETWEEN AUTO MODE AND SINGLE CYCLE MODE WILL LOCK THE
CONTROL ON THE 20 MODE CHANGE . WE ARE NOT CLEARING THE BUFFER, THIS
WILL BE FIXED
ORIGINATOR: RANDY RENNEKAMP, M. GARLICK
REVISED BY: R, BRYANT
DATE: APRIL 1, 1987
ISSUE NUMBER: 1093
SUBJECT: TOOL CHANGERS
PRODUCT LINE: MD1 MD3
PAGE 1 OF 1
IT HAS BEEN NOTED THAT ON SOME CONTROL RELAY PANELS, 415-0189-001 AND
415-0189-002 THAT THE BRAKE PACK SOCKET HAS BEEN SOLDERED ONTO THE
BOARDS INCORRECTLY.
PLEASE NOTE WHEN AT A CUSTOMERS PLANT; THAT THE BRAKE PACK IS
INSTALLED CORRECTLY. IF PIN NUMBER 1 OF THE BRAKE PACK SOCKET DOES
NOT LINE UP WITH THE PCB SILKSCREEN NUMBER 1, REMOVE THE SOCKET AND
CORRECT THE PROBLEM.
IF THIS SITUATION IS FOUND, THE BRAKE PACK (PART NUMBER 412-0003-001)
WILL REQUIRE REPLACEMENT DUE TO DAMAGE FROM BEING INCORRECTLY
INSTALLED.
ORIGINATOR: RANDY RENNEKAMP
REVISED BY:
DATE: APRIL 6, 1987
ISSUE NUMBER: 1094
SUBJECT: SERVOMATE TRANSFORMER MIS-WIRED
PRODUCT LINE: MB3
PAGE 1 OF 1
A PROBLEM HAS BEEN DISCOVERED IN THE FIELD WHICH NEEDS TO BE WATCHED
FOR WHEN SERVICING THE MB3 MACHINES.
THE 72 VAC INPUT TRANSFORMER CAN BE TAPPED FOR EITHER 72 VAC OR 88 VAC.
THE CORRECT VOLTAGE FOR THE MH3 RANDTRONICS AMPLIFIERS IS 72 VAC.
IF A MACHINE IS FOUND WITH A TRANSFORMER WIRED 88 VAC, PROMPTLY
REWIRE IT FOR 72.
THIS PROBLEM WILL NOT BE VERY VIDE SPREAD, BUT PLEASE LOOK FOR IT WHEN
ALREADY ON AN MB3 CALL.
ORIGINATOR: RANDY RENNEKAMP
REVISED BY:
DATE: April 6,1967
ISSUE NUMBER: 1095
SUBJECT: BX Miscounting On Knee Mills
PRODUCT LINE: BX Kneemills
PAGE 1 OF 1
On some BX knee mills in the field we have been able to eliminate
miscounting by adding a jumper from pin sixteen in the motor junction
box to ground. The machine must have the new style servo conduits for
this jumper to have a chance of working. The ground that we used was
the head of the screw which holds the junction box to the motor.
Ensure that the threads have no black paint in them so proper
connection is made. The part number for this jumper is 423-6092-002
and has been released on P.I.N. 9335. This modification may cause the
miscount to increase on some mills; however, on the majority of
machines it corrected miscounting.
ORIGINATOR: Eric Hudson
REVISED BY:
DATE: JUNE 11, 1987
ISSUE NUMBER: 1096
SUBJECT: Deltron Power Supplies
PRODUCT LINE: All ULTIMAX MILLS
PAGE 1 OF 1
Effective with the June Mill Shipments, we will begin using a new
Deltron switching power supply instead of the Powertec. The Deltron
has Hurco part number 413-OOOB-010 and has the same mounting holes as
the Powertec. The main difference is in the wiring, pins 5 and 6 on
the Deltron are opposite the Powertec. Pin 5 on the Deltron is minus
12VDC and pin 6 is plus 24VDC. Pin 5 on the Powertec is plus 24VDC and
pin 6 is minus 12VDC. If you are replacing a Powertec with a Deltron,
make sure the wiring is correct before applying power. A sheet of
paper with the wiring difference is being shipped with each Deltron.
The Deltron is easily identified because it is gold in color and the
Powertec is black. The adjustment pots are indicated below.
DATE: JULY 29, 1987
ISSUE NUMBER: 1097
SUBJECT: Custom CPU / Memory PCB
PRODUCT LINE: All Ultimax Mills
PAGE 1 OF 1
It has been found that Custom CPU / Memory PCB's (415-0194-001,002,004)
may have been shipped with a jumper installed that should have been
removed if a Dual RS-232 PCB was installed. The jumper runs from
J1-12 to J1-17. It is located on the non-component side of the PCB.
If this jumper is installed the RS-232 PCB will not function. Note
that the Schematic for the CPU/Memory PCB shows this jumper and refers
to its removal on page 9 note 12 (REF. 415-0194-001,002,004 Rev.F).
When making a Service call on a machine that has a Custom CPU/'Memory
PCB make sure that this jumper has been removed if a RS-232 PCB is
installed.
ORIGINATOR: Keith Perkins
REVISED BY:
DATE: August 8, 1987
ISSUE NUMBER: 1098
SUBJECT: Solenoid Exhaust Filters
PRODUCT LINE: MB3, MD3, BMC10, BMC15
PAGE 1 OF 1
It has been found that if the solenoid exhaust filters become clogged
that when the spindle clamp/unclamp cylinder operates back pressure
can allow the shot pin to also move. This can cause an error since the
shot pin may move enough to come off of the limit switch.
To eliminate the problem will require one of the following;
1) Remove and clean filter.
2) Replace filter.
3) Remove filter from the pneumatic system.
ORIGINATOR: K. Perkins
REVISED BY:
DATE: September 14,1987
ISSUE NUMBER: 1099
SUBJECT: BMC 10 and 10L Tool Support
PRODUCT LINE: BMC10, BMC10L
PAGE 1 OF 2
The BMC series of machines from Toyama utilize plastic tool support
slides rather than the metal ones like the M2 and M3 series of
machines. The BMC10L uses a clear plastic support (713-0008-320) which
is the same size as the M2 and M3 support. The BMC10 uses a black
plastic support (713-0008-696) which is quite a bit thicker. We have
had several occurrences of breakage on these plastic tool supports.
The breaks occur in the corner of the tool support where the roll pin
is located.
If you should find this condition on a BMC10L machine in the field, you
need to order the following parts for each broken support.
Qty
Description
Part Number
1
MD3 Steel Tool Support
713-0006-005
2
Roll Pin, 2 X 8
713-0008-313
If you should find this condition on a BMC10 machine in the field, you
need to order the following retrofit kit.
Qty
1
Description
BMC10 Tool Support Repair Kit
Part Number
002-3133-001
Tool Support Repair Plate
M3 X .5 X 10MM FHSCS
M3 X .5 Std. Hex Nut
M3 Int Teeth Lockwasher
802-2118-001
102-5001-003
117-5009-001
110-0067-004
This kit includes:
24
48
48
48
This will give you enough parts to repair all 24 tool supports. See
the attached drawing for attaching these plates.
If any of the springs and balls are needed, their part numbers are,
713-0005-205 for the spring and 713-0008-299 far the ball.
DATE: September 14, 1987
ISSUE NUMBER: 1099
SUBJECT: BMC 10 and 10L Tool Support
SUPERSEDES NUMBER:
PRODUCT LINE: BNC10, BMC10L
PAGE 2 OF 2
1) Remove the cover from the tool changer carousel.
2) Remove the tool support from the tool holder by removing the roll 1
pin from the corner of the tool support and sliding it out of the
tool holder. Make sure you do not lose the steel ball or spring.
3) Drill two 9/64" holes through the end of the tool support. One
hole should be 5/16" from the side with the tab and 3/16" up from
the bottom. The other hole should be 13/16" from the side with the
tab and 3/16" up from the bottom.
4) Slide the tool support back through the tool holder making sure the
spring and steel ball are reinstalled.
5) Attach the repair plate to the tool support using two N3 X .5 X
10MM FHSCS, two M3 internal tooth lockwashers and two M3 X .5
standard hex nuts.
6) After all tool supports have been modified, rotate the carousel to
each tool position and move each tool holder in and out of the
holding station to make sure the repair plates clear all obstacles.
In some cases, some of the ribs on the holding station casting will
need to be ground down a small amount.
7) Reinstall the tool changer carousel cover.
ORIGINATOR: WAYNE E. Hawkins
REVISED BY:
DATE: January 25, 1993
ISSUE NUMBER: 1100 A
SUBJECT: AXIS AMPERAGE
SUPERSEDES NUMBER: 1100 & 1144
PRODUCT LINE: BMC 20 / 50
PAGE 1 OF 2
It has been found that the gib adjustment screws on BMC mills can come loose in shipment and during
normal use. It is important that these be checked on install as well as on service calls.
Most BMC machines have tapered gibs with screws at both ends of the gib, one to adjust the gib
pressure and one to lock the gib. Over tightening of these screws can damage the gib. The adjusting
screws are on the top for the Z axis, the left hand end of the table for the X axis and the front of the
saddle for the Y axis. The BMC 40/50 have gibs at both ends of X axis and do not have the lock
screws.
NOTE: The maximum rated current of the servo amplifiers must not be exceeded.
The rated current for BMC 20/30 OEM/V1, FANUC MODEL 0/5, =
10 AMPS Peak.
The rated current for BMC 40/50 OEM/V1, FANUC MODEL 10, =
15 AMPS Peak.
The rated current for BMC 20 V2, (pre LR) YASKAWA AMPS, =
11 AMPS Peak.
The rated current for BMC 20 LR/25/30 V2,YASKAWA AMPS, =
17 AMPS Peak.
The rated current for BMC 40/50 V2, YASKAWA AMPS, =
42 AMPS Peak.
The ULTIMAX 3 machines use the same amps as MAX 2 V2 machines.
SEE PAGE 2 FOR DETAILS ON GIB ADJUSTMENTS.
REVISED BY: Wayne E. Hawkins
REVISED BY: KEITH PERKINS
Revised by Lonnie Leffew 3-17-1993
THE PROCEDURE FOR MONITORING FANUC AXIS CURRENT IS AS FOLLOWS:
1
2
3
4
5
6
Connect a DVM positive lead to CH 10, 11, OR 12.
Note: There are three sets of test points L, for X axis M for Y axis & N for Z axis.
Connect negative lead to CH3.
Set meter for VAC.
Jog the axis at 100 IPM.
The voltage reading on the meter is a VOLTS/AMP reading.
EXAMPLE: The meter reads .255 VAC. This is equal to 2.55 AMPS of current.
The axis being checked should be run full travel in both directions.
Note The lowest and highest readings seen.
X axis
Y axis
Z+ axis
Z- axis
BMC 20
2.5 to 3.5
2.5 to 3.5
4 to 5
3 to 4
BMC 20 LR
1 to 2
1 to 2
2 to 3
1 to 2
BMC 25/30
2 to 4
2 to 4
2 to 4
1 to 2
BMC 40/50
3 to 5
3 to 5
4 to 6
2 to 4
YASKAWA AXIS CURRENT CHECKS
1.
2.
3.
Check Axis Setup per Eng Doc # 757-4001-092. Check all axis.
To check axis current draw, Connect a DVM with the positive lead to TM3-4 and the negative
lead on the 0V of the appropriate axis amplifier.
Note: Check all axes in both directions at 100 ipm over the full travel of the axis.
Divide the meter reading by the appropriate value listed below.
1 amp on aBMC 20 = .789
BMC 20 LR / 25 / 30=.484 VDC
BMC 40/50=.200 VDC
Acceptable values are:
BMC 20: X&Y=
BMC 20: +Z=
BMC 20: -Z=
2.5-3.5 A
4-5 A
3-4 A
1.973 - 2.762 VDC
3.156 - 3.945 VDC
2.367 - 3.156 VDC
BMC 20LR: X&Y=
BMC 20LR: +Z=
BMC 20LR: -Z=
1-2 A
2-3 A
1-2 A
0.484 - 0.968 VDC
0.968 - 1.936 VDC
0.484 - 0.968 VDC
BMC 25/30 X&Y=
BMC 25/30 +Z=
BMC 25/30 -Z=
2-4 A
2-4 A
1-2 A
0.968 - 1.936 VDC
0.968 - 1.936 VDC
0.484 - 0.968 VDC
BMC 40/50 X&Y=
BMC 40/50 +Z =
BMC 40/50 -Z =
3 - 5 A 0.6 - 1.0 VDC
4 - 6 A 0.8 - 1.2 VDC
2 - 4 A 0.4 - 0.8 VDC
When adjusting gibs on any mill use caution. Do not tighten them too much. The BMC 20 box way
machines may not be able to reach the currents specified. If you can not adjust for the recommended
currents, ensure that you have gib pressure by loosening the gibs until you have the minimum current (no
further drop) then tighten gibs to obtain an increase in current draw. Be sure to verify axis operation by a
cutting test, ETC.
RECORD THE INFORMATION ON THE SERVICE REPORT.
FSB 1100A Page 2 of 2
ISSUE NUMBER: 1101
SUBJECT: Z AXIS BOUNCING AT LIMIT SWITCH
PRODUCT LINE: TM5
PAGE 1 OF 1
MOST IF NOT ALL TM5 MILLING MACHINES EXHIBIT THE PROBLEM OF BOUNCING
ON AND OFF THE Z PLUS LIMIT SWITCH. THE REASON FOR THIS IS, LIKE OTHER
MACHINES, THE AMP IS SHUT OFF ON A LIMIT. THE DIFFERENCE ON THE TM5 Z
AXIS IS, THAT EXCEPT FOR THE BALL SCREW BRAKE WHICH IS ONLY ON WHEN
THE S.E.R. RELAY IS OFF), THE AMP IS THE ONLY THING HOLDING THE Z AXIS UP.
WHEN THE AMP IS SHUT OFF ON THE LIMIT SWITCH IT FALLS. WHEN IT FALLS OFF
THE SWITCH, IT RESTARTS AND JUMPS BACK UP TO THE SWITCH. THIS CAUSES AN
ANNOYING BOUNCING ON MOST MACHINES. THIS IS SOLVED BY CLIPPING THE
WIRE J10-9 ON THE HURCO AMPLIFIER MOTHER BOARD AND J4-9 ON THE I/O
BOARD THIS ALLOWS THE AMP TO REMAIN ENERGIZED WHILE ON THE Z PLUS
LIMIT SWITCH.
ORIGINATOR: PAUL CHAMBERS
REVISED BY:
ISSUE NUMBER: 1102
SUBJECT: Knee Mill Bearing Locknut
PRODUCT LINE: KM3, KM3P, KMC3, KMC3P
PAGE 1 OF
The new axis bearing locknuts used on the Knee Mills now should be
installed in the following manner.
1) Loosen all clamp screws on the locknut.
2) Screw the locknut onto the Leadscrew until its contact face is
approximately .1" from the mating face.
3) Uniformly tighten the clamp screws evenly and diagonally while
turning the locknut until the thread clearance is removed as
indicated by an increase in thread friction. The center line of the
locknut is now in line with the center line of the Leadscrew and the
locknut contact face is square with the common centerline of the
locknut and the Leadscrew.
4) Tighten the locknut with the spanner wrench to 35 ft/'lbs.
5) Secure the position of the locknut by tightening the clamp screws to
25 in/lbs.
ASSEMBLY HINTS
1) Clamp screws should never be tightened before locknut is fully
engaged on its mating male thread to avoid distortion.
2) During the disassembly process, it is important to loosen all clamp
screws evenly and diagonally to prevent clamp screw jamming.
ORIGINATOR: Wayne Hawkins
REVISED BY:
DATE: October 1, 1987
ISSUE NUMBER: 1103
SUBJECT: New MAX2 RS232 Harness
PRODUCT LINE: All MAX2 Controls
PAGE 1 OF 1
It has been discovered that some of the RS232 Harnesses are not
correctly wired. Steps have been taken to assure that they will be
wired correctly from now on. Unfortunately some of the harnesses have
already been shipped and will require checking in the field. On MAX2
controls prior to October of 1987, these harnesses need to be checked
and corrected. The correct wiring is shown below.
ORIGINATOR:
Wayne E. Hawkins
ISSUE NUMBER: 1104
SUBJECT: MD3 SOFTWARE FOR YASKAWA. DRIVE
PRODUCT LINE: MD3 MILLS
PAGE 1 OF l
IT HAS BEEN FOUND THAT THE SPINDLE EPROM THAT IS INCLUDED WITH THE
RETROFIT KIT DOES NOT WORK WITH SOFTWARE PRIOR TO D06E LEVEL. ANY
MACHINE THAT RECEIVE THE YASKAWA DRIVE SHOULD HAVE VERSION D06E OR
LATER SOFTWARE. THERE IS A PROBLEM WITH CUSTOMERS THAT USE NC
SOFTWARE.
CURRENTLY THE ONLY RELEASED VERSION OF NC SOFTWARE IS A06.
SOFTWARE IS WORKING ON A VERSION THAT WILL WORK WITH THE YASKAWA
SPINDLE PROM. ANY CUSTOMERS THAT HAVE THE YASKAWA ON THEIR MD3 AND
THAT NEED THE NC SOFTWARE SHOULD WAIT FOR THE NEXT RELEASE (NOTE DO
NOT ORDER 06F VERSION IT HAS A BUG IN IT THAT CAUSES MORE PROBLEMS
THAN IT FIXES)
ISSUE NUMBER: 1105
SUBJECT: ORIENT PROBLEM WITH
YASKAWA RETROFIT
PRODUCT LINE: MB2, MB3, MD3
PAGE 1 OF 1
A RANDOM PROBLEM HAS BEEN SEEN WITH SOME MACHINE, PARTICULARLY
MACHINE WITH LELAND SPINDLE MOTORS. THE PROBLEM IS BEING ABLE TO
OBTAIN SMOOTH ORIENTATION IN BOTH OPERATING RANGES. THE MACHINE
WILL OCCASIONALLY MISS THE SHOT PIN DUE TO CAMMING ACTION. ONE WAY
TO ELIMINATE THIS IS TO RESET ONE OF THE SWITCH'S ON THE YASKAWA DRIVE.
SWITCH 68 POSITION 1 IS NORMALLY SET TO ON. THIS SHOULD BE RESET TO OFF.
THIS WILL ENABLE DYNAMIC BRAKING WHEN THE SPINDLE RAMPS DOWN TO
l / 40 OF MAXIMUM FREQUENCY. TO MAKE THIS CHANGE FIRST TURN THE
MACHINE POWER OFF CHANGE 68-1 FROM ON TO OFF THEN TURN MACHINE
POWER BACK ON. SEVERAL TOOL CHANGES SHOULD BE RAN TO ENSURE
CORRECT ORIENTATION IM BOTH LOW AND HIGH RANGES AND WITH BOTH CW
AND CCW SPINDLE ROTATION. ORIENT SPEED MAY NEED TO BE READJUSTED.
REVISED BY:
ISSUE NUMBER: 1106
SUBJECT: BALL CHUCK REPLACEMENT
PRODUCT LINE: KM3CP
PAGE 1 OF 2
THE BALL CHUCK SHOULD BE REPLACED IN THE FOLLOWING MANNER.
1. REMOVE MOTOR/CLUTCH ASSEMBLY, THIS CAN BE DONE WITH LESS STRAIN
ON CABLES IF THE Z AXIS IS MOVED TO THE MINUS LIMIT SWITCH.
2. CALIBRATE THE Z AXIS AFTER REMOVING MOTOR/CLUTCH ASSEMBLY.
3. REMOVE SNAP RING FROM SPINDLE SHAFT AND INSPECT FOR DAMAGE, IF
DAMAGED REPLACE WITH PART NUMBER 113-0002-030.
4. UNSCREW QUILL DETECTOR FROM THE SPINDLE SHAFT (ITEM 019, PAGE 2)
AND REMOVE, CHECK FOR DAMAGE, I.E. CRACKS OR BAD THREADS.
5. INSERT BALL CHUCK INTO SPINDLE TAPER WITH SPECIAL TOOL, TURN
SPINDLE SHAFT CW TWO TURNS TO HOLD, INSERT DEPTH GAGE INTO TAPER
AND ADJUST DISTANCE BETWEEN BALL CHUCK AND SPINDLE FACE TO 2.204"
BY TURNING SPINDLE SHAFT CW.
6. WHEN 2.204H IS ACHIEVED REINSTALL QUILL DETECTOR AND TURN SPINDLE
SHAFT CW 1 TURN, INSERT A TOOL HOLDER INTO SPINDLE AND CLAMP BY
TURNING SPINDLE SHAFT BY HAND.
7. TURN SPINDLE SHAFT CCW UNTIL TOOL HOLDER IS RELEASED AND QUILL
DETECTOR IS IN POSITION TO ACTIVATE THE UNCLAMP LIMIT SWITCH.
8. IT MAY BE NECESSARY TO ADJUST THE UNCLAMP LIMIT SWITCH TO SEE THE
QUILL DETECTOR. IF THE LIMIT SWITCH IS DEFECTIVE REPLACE WITH
PART NUMBER 713-0012-365.
9. REINSTALL SNAP RING AND MOTOR/CLUTCH ASSEMBLY.
10. CLAMP AND UNCLAMP A TOOL HOLDER USING MANUAL SWITCHES PRIOR TO
RUNNING TC IN AUTO MODE. RUN 50-100 TOOL CHANGES IN THE AUTO MODE
FOR FINAL CHECKOUT.
ORIGINATOR: FRED RAES
REVISED BY:
ISSUE NUMBER: 1107
SUBJECT: BMC Auto Lube Wiring
SUPERSEDES NUMBER: 400B
PRODUCT LINE: BMC 20-50 (OEM)
PAGE 1 OF 1
It has been discovered that the wiring to the auto lube pump has not
been properly shielded. This can cause intermittent false low lube
errors. All machines shipping in May and some in April will have
properly shielded wiring. If you wish to correct one in the field, the
existing wiring will need to be replaced. You will need approximately
15 feet each of a three conductor non shielded 20 AWG cable (HURCO P/N
406-1247-007) and a two conductor with shield 22 AWG cable (HURCO P/N
406-1242-004).
1) Remove the 4 conductor cable to the auto lubricator.
BMC 20
2) Add 3 conductor cable.
BLACK 41 from Rly 16-5 to Lube -1.
BLACK P2 from Rly 16-8 to Lube -2.
YELLOW / GREEN from MECCA ground to Case Ground of the lube pump.
CLEAR / SHIELD from T25 to Lube -3.
BLACK from T26 to Lube -4.
BMC 30 – 50
YELLOW / GREEN from MECCA ground to Case Ground of the lube pump.
with 10MA control (schematic 002-3210-004)
BLACK f2 from Rly 9-6 to Lube -2.
with OMA control (schematic 002-3210-006)
BLACK #2 from Rly 8-6 to Lube -2.
with HURCO 24VDC pneumatic (schematic 002-3210-055)
CLEAR/SHIELD from T25 to Lube -3.
BLACK from T24 to Lube -4.
REVISED BY: Wayne E. Hawkins
ISSUE NUMBER: 1108
SUBJECT: INSTALLATION OF THRUST BEARING'S
SUPERSEDES NUMBER: 391A
PAGE 1 OF 2
PURPOSE: TO PROVIDE A DEFINITIVE STATEMENT ON THE
INSTALLATION OF THE AXIS THRUST BEARING'S IN HURCO
MILL PRODUCTS.
IN BRIEF THE AXIS BEARING'S IN ALL HURCO MILLS WILL BE MOUNTED
IN THE DB NODE. IN THE PAST WE WERE MOUNTING THE QUAD SETS IN THE BMC
40 AND 50 MACHINES IN THE DF MODE, THIS WILL NO LONGER BE THE PRACTICE.
THE MANUFACTURING FLOOR WILL START INSTALLING THE BEARING'S IN DB
MODE FROM THIS DATE FORWARD. ALSO ANY MACHINE FROM THIS DATE
FORWARD THAT MUST HAVE THE THRUST BEARING'S REPLACED WILL HAVE
THEM INSTALLED IN THE DB MODE,
DB (BACK TO BACK)
IN THE DB MODE THE STAMPED SIDES
OR "BACKS" OF THE BEARING' S ARE
MOUNTED TOGETHER. A GAP IS THEN
LEFT BETWEEN THE INNER RINGS.
TIGHTENING THE LOCK NUT ON THE
BALL SCREW SHAFT CLOSES THIS
GAP AND BRINGS THE BEARING'S INTO
CONTACT WITH THE RACES UNDER A
PREDETERMINED LOAD, AND THUS
PRELOAD'S THE BEARING'S. BECAUSE
THE LOAD LINES DIVERGE ON THE SHAFT
THIS ARRANGEMENT PROVIDES EXCELLENT
RIGIDITY WITH A MINIMAL AMOUNT OF
BACKLASH IN THE SYSTEM.
ORIGINATOR: RANDALL BRYANT
REVISED BY: RANDALL BRYANT
ISSUE NUMBER: 1109
SUBJECT: Nonvolatile CPU / Memory PCB
PRODUCT LINE: Ultimax I Mills
PAGE 1 OF 2
The Nonvolatile CPU/Memory PCB (415-0194-70X) includes a completely
redesigned power down and battery circuit which utilizes the latest
technology in power down devices and Lithium energy sources. This new
design requires an external voltage source which will provide an early
warning that power is going down. This early warning will cause the
microprocessor to: 1) complete the cycle it is on; 2) put everything away in memory;
3) deselect the memory devices; 4) reset the system; and 5) switch the memory devices over to the
lithium energy source before power is too low for reliable operation. This new circuitry is located
on a piggy-back board which is installed on the CPU board where the
NiCad battery used to be. The external voltage is provided by the CCPU
NMI Power Supply (002-3410-001) which is a black cylinder with two 2
conductor cables coming out of it. One of the cables is terminated with
ring tongues and the other cable is terminated with a small connector.
To install the new board and the external voltage source please follow
these steps: (Remember to use the Static Safe Wrist strap)
1) Turn off main power to the Mill and remove the old CPU board and
place it on an anti-static work area.
2) Remove the Graphics and RS-232 boards from the old CPU board by
removing the nylon screws from the non-component side of the CPU
board.
3) Unpack the new Nonvolatile CPU and place it on the anti-static
work area. Note the location of the new piggy-back board and. the
empty connector on the piggy-back board.
4) Install the Graphics and RS-232 boards onto the new CPU board.
5) Install the new CPU board into the card rack in the same location
that the old board was in.
6) Take the CCPU MMI Power Supply and connect the cable with the ring
tongues to a 115 VAC source in the control cabinet. This 115 VAC
source can be found at the DC Switching Power Supply input on all
Mills except MD1 and MD3. On ND1 and MD3 Mills the 115 VAC source
can be found on the secondary of the T2 control transformer.
ISSUE NUMBER: 1109
SUBJECT: Nonvolatile CPU / Memory PCB
SUPERSEDES NUMBER:
PRODUCT LINE: Ultimax I Mill PAGE - OF 2
7) Turn on main power to the mill and check the voltage on the other
cable of the CCPU NMI Power Supply. There should be approximately
50 VDC between the white and black wire with the black wire being
positive.
8) Turn off main power to the mill and plug the connector into the
empty connector on the piggy-back board of the new CPU board.
9) Dress the cables neatly and attach the CCPU MMI Power Supply to the
cabinet by removing the paper from the double sided tape and
sticking the power supply to the cabinet.
10) Installation is now complete. Turn on main power to the mill and
load the master tapes.
DATE: May 12, 1988
ISSUE NUMBER: 1110
SUBJECT: Tool Change Height and 06F
PRODUCT LINE: BMC 30, 40, 50 MAX1
PAGE 1 OF 2
With the 06F version of Ultimax software, the Tool Change Height is
handled with switch block Sl on the machine personality board instead of
the EEPROM on the custom CPU board. This makes the tool change height
handling the same as with MAX2.
When updating to 06F software, you must set the tool change height on Sl.
To obtain the correct height, enter the machine diagnostic mode using a
tape version other than 06F. Use the ENTER, 4, 8, 8, ENTER sequence to
read the correct height value and record it. After the value is
recorded, turn the machine power off and set switches 1 through 6 of Sl
o match the recorded value. The switches are a binary input with Sl-1
being the least significant bit and Sl-6 being the most significant with
each bit representing 0.01 inches. The number must be rounded to the
nearest 0.01 inch. See example below. After the switches are set
correctly, load in the 06F version tape. The Tool Change Height now set
on Sl will be the value that the machine will use for automatic tool
changes.
REVISED BY:
ATC HEIGHT SETUP FOR BMC 20 TO 50 (INCLUDING BMC 25)
(L06F Software h MAX 2 Machines to V8.0)
++++ NOTE +++~
Always use WRIST STRAP When working with any thing inside
the Cabinet or Control Head on any HURCO PRODUCT.
1. Power up machine, Remove tool from spindle and from magazine tool
load position. (You may need to remove tools from either side For
visibility.)
2. Go to Manual Mode" Calibrate axis, & Tool Changer, Lock Spindle,
Start ATC Diagnostics, move Magazine right. Enter the "Secret
Code" by pressing Enter Button" 4,8,8"Enter Button.
3. Carefully move "Z" axis (HEAD), with the Jog Hand Wheel, down to
achieve a gap of .5000" between the bottom of the "V" Flange and
the bottom of the spindle. BMC 25 has fingers 5 reference the same.
4. Record Z axis position from CRT display as shown ie.
(z axis) 0.0000"
5. Press EXIT soft key then move the Magazine left" press EM STOP.
6. Turn MAIN BREAKER off & pull Personality Board from computer card
rack. The Personality Board can be identified by three cables that
extend from its top , it is the first. board in the tall section.
7. Locate the block of switches labeled Sl (see Fig.1) Turn on the
switches that add up to the value recorded in step 4.
Example. Recorded value = .1834" Set switches # 5 and #2 to on
8. Reinstall board, power up machine and test Tool Changer for proper
operation. Observe the Tool Changer as it engages the tool, if it
pulls up increase SW1 settings by . .0100" and retry. Also if it. moves
down decrease SW1 by . .0100" and retry Continue until TC engages
as smoothly as possible.
DATE: JUNE 10, 1988
ISSUE NUMBER: 1111
SUBJECT:
DRAW BAR ADJUSTMENT
PAGE 1 OF 2
It has been discovered that in most cases the draw bar lock nuts have
been backing off causing the tool to be held loosely in the spindle. These
are identified as item #26 on the attached sheet. To determine if these are
maladjusted remove the front cover from the head. Looking in from the
right hand side, between the bottom of the knock out cylinder and the top
of the RPM sensor switch mounting bracket, You will see the two lock nuts
in question. If these are set properly you should see one half to one turn
of thread showing above the top lock nut. To adjust these two nuts it is
necessary to loosen the top nut by turning it CCW and then tighten the
bottom nut by turning it CW. Then re-tighten the top nut to see if you have
at least one half to one complete turn of thread showing above the tap lock
nut.
To insure the proper adjustment, this procedure may have to be repeated
several times. After the proper adjustment has been achieved tighten the
top nut down to maintain locking effect.
See attached sheet for draw bar nut location.
DATE: JULY 16, 1988
ISSUE NUMBER 1112
SUBJECT:
CLUTCH NOISE
PRODUCT LINE: BMC MILLS WITH 2 SPEED BOX
PAGE 1 OF 1
In the BMC 30-50 two speed box clutch (a two part unit) we
have found some cases of the guide pins out of true location.
This can cause a bind or pinch when the two halves try to mesh.
This binding can cause a loud popping noise when the machine tries
to change gears. To determine if this has accrued look at the
clutch where it meshes it will look like it is cocked to one side.
If you are getting the popping sound you will have this problem.
Some of the other symptoms are a grinding noise or spindle errors,
(no RPM) due to both clutches engaged at the same time.
At this time the only fix is to replace the clutch or the two
speed box.
Dana Abshier
Service Engineer
Randall Bryant
Technical Specialist BMC
DATE: JULY 16, 1988
ISSUE NUMBER: 1113
SUBJECT: GIB WEAR
PAGE 1 OF 1
Information has been gathered by Barny Lewis that there are
cases of excessive Gib wear in the BMC 40-50 machines. This
is caused by a lack of lubrication to the Z axis, [due to
long lube lines], The solution for this problem is in
installing a separate lubrication system for the Z axis. This
is done by interrupting the oil lines coming from the
original oil pump and installing a 2nd oil pump for the z
axis, The motor is paralleled off the first pumps wiring and
installed above or below the original pump. The following
part numbers are needed to perform this modification.
713-0020-091
713-0020-102
713-0020-551
Lube pump
T junction
Flex hose
REVISED BY:
DATE: DECEMBER. 12, 1988
ISSUE NUMBER: 1114
SUBJECT:
X AXIS BED CAP
PRODUCT LINE: KM3P
PAGE 1 OF 1
A PROBLEM WITH THE X AXIS END CAP HAS BEEN IDENTIFIED BY
MANUFACTURING. WE BELIEVE THIS TO BE A ISOLATED PROBLEM AND
DON'T EXPECT IT TO SHOW UP IN THE FIELD. HOWEVER THE CAP
SHOULD BE INSPECTED IF WORKING ON A KM3P WITH HIGH X AXIS
CURRENT. THE CAPS FLANGE MAY BE TO LONG, APPLYING UNWANTED
PRELOAD ON THE AXIS BEARING, CAUSING HIGH AXIS CURRENT AND
PREMATURE BEARING FAILURE. IF THE FLANGE IS CONTACTING THE
BEARING THE FLANGE LENGTH SHOULD BE SHORTENED, OR REMOVED
COMPLETELY, THIS CAP IS USED AS A COVER ONLY IN OUR
APPLICATION. IF BEARING WAS DAMAGED REPLACE WITH 211-0009-007
ORIGINATED BY: FRED RABS
DATE: DECEMBER 30,1988
ISSUE NUMBER: 1115
SUBJECT: CONTROL RELAY PANEL PCB
PRODUCT LINE: BMC 20-50/' FP3A/4A MAX 2
PAGE 1 OF 1
BETWEEN THE MONTHS OF AUGUST 1988 AND NOVEMBER 1986 AN
INCORRECT PART MAY HAVE BEEN USED ON THE RELAY CONTROL PANEL,
PCB NUMBER 415-0224-001. THE CORRECT PART IS AN MID400 OPTOCOUPLER, PN 417-0004-015, USED IN THE U1 POSITION. THE INCORRECT
PART, HCPL2531 WILL NOT WORK IN OUR APPLICATION. THIS OPTO IS
USED FOR THE INDEX OPTION; SO IF WORKING ON ANY PROBLEM WITH
INDEXER OPTION YOU MAY WANT TO CHECK U1 FIRST. IT IS BELIEVED
THAT ALL BAD OPTOS WERE REPLACED, BUT THERE IS A POSSIBILITY
THAT SOME MAY HAVE GOTTEN OUT THE DOOR. IF THE WRONG OPTO IS
FOUND ,REPLACE WITH THE PN LISTED ABOVE.
REVISED BY:
ISSUE NUMBER: 1116
SUBJECT: Deltron Power Supply
PRODUCT LINE: All Mills
PAGE 1 OF 1
Recently there has been an increasing number of Deltron Power supplies
being returned from the field with no problem found. Deltron has
informed us that starting immediately they will charge Hurco $75.00 per
supply that is return to them and tests good. As you know the outputs
of these supplies float and need to have a load on them to make them
stable.
If one of the outputs from the power supply is low try to make sure that
it is definitely because of the supply and not something in the system
which is pulling it down. If you need to check the power supply with
the outputs disconnected it is necessary to place a load on the output
while testing. Below are the recommended resistor values needed to put
a full load on each of the outputs.
5 VOLTS ----> .25
12 VOLTS ---> 3.3
24 VOLTS ---> 8
OHM 100 WATT
OHM 48 WATT
OHM 72 WATT
ORIGINATOR: MIKE GARLICK
REVISED BY:
ISSUE NUMBER: 1117
SUBJECT: GROUNDING IN CONTROL CONSOLE
PRODUCT LINE: ALL ULTIMAX MILLS
PAGE 1 OF 1
There are two grounding studs provided in the control
console. However because the nutserts are glued into bottom
of the console it is possible to have a large difference in
potential or no continuity at all between them. If the two
Mecca ground wires are installed on one stud and the board
grounds are installed on the other it is possible that the
boards will not be grounded. This has been traced as a cause
of "lock-ups" on several machines. In the future when
installing the console put all the grounds onto the same
stud. On existing machines check to make sure this has been
done and correct it if it has not.
ORIGINATOR: MIKE GARLICK
REVISED BY:
ISSUE NUMBER: 1118
SUBJECT: RS232 CABLE
PRODUCT LINE: MILLS
PAGE 1 OF 1
TO CLEAR UP SOME QUESTIONS ON THE SIZE AND LENGTH OF RS232
CABLES I AM PASSING ON THIS INFORMATION AS RECOMMENDED CABLE SIZE
FROM HURCO MANUFACTURING.
1: SIX CONDUCTOR SHIELDED CABLE
2: 22 GAUGE STRANDED WIRE, AS THE MINIMAL WIRE SIZE.
3: 50 FEET OR LESS CAN BE SINGLE SHIELDED.
4: OVER 50 FEET THE CABLE MUST BE MULTI-SHIELDED.
5: A MAXIMUM OF 100 FEET POSSIBLE BUT 80 FEET OR LESS IS BEST.
6: DO NOT RUN THESE CABLES NEAR FLUORESCENT LIGHTING FIXTURES OR
OTHER POSSIBLE ELECTRICAL NOISE SOURCES. EXP. POWER CABLES,
CONTACTORS, TRANSFORMERS, ETC., ETC.
7: THE CABLE SHIELDS SHOULD BE CONNECTED AT ONE CONNECTOR DO NOT
GROUND BOTH ENDS.
THE HURCO PART NUMBER FOR SIX WIRE RAW CABLE IS 406-1244-002.
REVISED BY:
ISSUE NUMBER: 1119
SUBJECT:
PARAJUST A BRAKING BOARDS
PRODUCT LINE: ALL MILLS WITH PARAJUST A
PAGE 1 OF 1
THERE HAS BEEN SOME CONFUSION ON REPLACING OLD STYLE BRAKING
BOARDS (402-6002-007/'013) WITH THE NEW STYLE BOARD (402-6002-016), IT IS
NOT NECESSARY TO UPGRADE TO THE NEW STYLE BOARD. HOWEVER IT CAN BE
USED TO REPLACE THE OLD STYLE BOARDS. INSTALL THE NEW STYLE AS YOU
WOULD THE OLD, THEN WIRE TB-6 AND TB-7 AS THEY WERE ON THE OLD BOARD,
THEN WIRE TB-8 IN THE FOLLOWING MANNER.
1) REMOVE THE RED JUMPER WIRE FROM TERMINAL 1 OF DRIVER MODULE
#2 THAT JUMPS TO TERMINAL 1 DRIVER MODULE #4
2) CONNECT THE SINGLE CONDUCTOR BLUE WIRE FROM TERMINAL 1 OF THE
DRIVER MODULE # 2 TO TERMINAL 1 OF TB-8 ON THE NEW BRAKING BOARD.
3) CONNECT THE SINGLE CONDUCTOR RED WIRE FROM TERMINAL 1 OF
DRIVER MODULE # 4 TO TERMINAL 2 OF TB-8 ON NEW STYLE BRAKING BOARD.
4) USE TIE WRAPS TO SECURE THE NEW WIRES TO THE EXISTING HARNESS.
5) FOLLOW NORMAL BRAKING BOARD SETUP.
***NOTE*** DIODES FOUND BETWEEN TB-6 AND TB-7 ON SOME OLD STYLE
BOARDS SHOULD NOT BE INSTALLED ON THE NEW STYLE BRAKING BOARD.
REVISED BY:
ISSUE NUMBER: 1120
SUBJECT: MIS-WIRE OF YASKAWA
RETROFIT
PRODUCT LINE: MB2 MB3
PAGE 1 OF 1
DURING TWO MB2 YASKAWA RETROFITS, WE FOUND THAT A MISTAKE WAS
MADE ON THE INTERNAL WIRING OF THE YASKAWA. THE 1 K OHM RESISTOR
FEEDING THE 100 OHM LOW AND HIGH GEAR ORIENT POTS WERE PARALLEL
SOLDERED ON THE 5V FEED WIRE BUT THE WIRE WAS NOT CUT OUT (FIGURE 1)
WHEN INSTALLING THE MB2 / 3 RETROFITS THIS SHOULD BE CHECK AND THE
WIRE CUT OUT AS SHOWN IN FIGURE 2.
ALSO ON ANY SERVICE CALL CHECK THIS RESISTOR TO MAKE SURE THE
RESISTOR IS WIRED IN RIGHT.
THIS WILL GIVE FULL ADJUSTMENT POTENTIAL TO THE ORIENT POTS. IF YOU
HAVE MADE THIS RETROFIT AND HARD TIME ADJUSTING THESE POTS THIS MAY
HAVE BEEN YOUR PROBLEM, PLEASE ADVISE YOUR REGIONAL MANAGER IF YOU
RECALL ANY YASKAWA INSTALLS WHERE THIS WAS A PROBLEM. FOLLOW UP
WILL BE REQUIRED.
REVISED BY:
DATE: MAY 19, 1988
ISSUE NUMBER: 1121
SUBJECT: SPINDLE MOTOR OVERLOAD
PRODUCT LINE: KM3 AND KM3P
PAGE 1 OF 1
RECENTLY WE HAVE DISCOVERED THAT SOME MACHINES HAVE BEEN SHIPPED
WITH THE WRONG SPINDLE MOTOR OVERLOAD. IN ORDER TO PREVENT ANY
PREMATURE SPINDLE MOTOR FAILURES, IT IS IMPORTANT FOR YOU TO CHECK
ALL KM3 AND KM3P'S WHEN YOU ARE IN ON INSTALL OR WORKING ON
MACHINES. IF THE MACHINE IS WIRED FOR 230 VAC ADJUST EXISTING
OVERLOADS FOR THE 10 AMP SETTING.
IF THE MACHINE IS WIRED FOR 480 VAC AND HAS A 10-16 AMP OVERLOAD,
REPLACE IT WITH A 6..3 TO 10 AMP OVERLOAD, PART NUMBER 403-5501-013 AND
ADJUST FOR 6.3 AMP SETTING.
REVISED BY:
ISSUE NUMBER: 1122
SUBJECT: INDUSTRIAL DRIVES GROUNDING
PRODUCT LINE: DECKEL FP3A/'4A
PAGE 1 OF 1
"EFFECTIVE IMMEDIATELY"
ALL INDUSTRIAL DRIVES SERVO AND SPINDLE DRIVES MUST HAVE A GROUND
WIRE FROM THE MOTOR GROUND TERMINAL ON EACH DRIVE BACK TO THE
SPARE GROUND TERMINAL ON THE PSR3 POWER SUPPLY (INDUSTRIAL DRIVE
POWER SUPPLY). THE WIRE FOR THIS APPLICATION IS 12 AWG GREEN / YELLOW.
WHEN INSTALLING THE ADDITIONAL GROUND VIRES ON THE DRIVES BE SURE
THE MOTOR GROUND WIRE AND ADDED GROUND WIRE ARE TIGHT IN THE
TERMINAL! THE ADDITION OF THESE WIRES IS NECESSARY FOR TO REASONS.
1. INDUSTRIAL DRIVES RECENTLY STARTED PAINTING ALL OF THEIR DRIVES
AND THE UNITS ARE NO LONGER ADEQUATELY GROUNDED VIA THE CHASSIS
MOUNTING HARDWARE.
2. THE ADDITION OF THE GROUND WIRES WILL HELP ELIMINATE THE
POSSIBILITY OF MISCELLANEOUS DRIVE FAULTS WHICH COULD OCCUR
WITHOUT PROPER GROUNDING.
ORIGINATOR: TOM MURDEN
REVISED BY:
DATE: MARCH 1, 1989
ISSUE NUMBER: 1123
SUBJECT: ORIENTATION SENSOR REPLACEMENT
PRODUCT LINE: BMC 20-50
PAGE 1 OF 3
THERE HAS BEEN SOME QUESTION ON HOW TO TROUBLESHOOT AND REPLACE
THE MAGNETIC SENSOR FOR FANUC SPINDLE DRIVES. WHEN ORIENTATION
PROBLEMS OCCUR, THE FOLLOWING SHOULD BE CHECKED.
1. CONNECT A DUAL TRACE OSCILLOSCOPE TO OBSERVE THE MAGNETIC SENSOR
OUTPUTS WHICH ARE SIGNAL A (MSA) AND SIGNAL B (LSA) ON THE ORIENT
BOARD.
2. START THE SPINDLE AND RUN AT 120 RPM. (NOTE YOU MAY HAVE TO
INCREASE THE RPM'S SO IT CAN BE SEEN ON THE SCOPE.)
3. IF THE MAGNETIC SENSOR AND MAGETIZER ARE MOUNTED CORRECTLY AS IN
FIG. 2 THE OUTPUT WAVEFORMS SHOULD MATCH THE WAVEFORMS IN FIG. 1.
4. IF NOT REFER TO THE TROUBLESHOOTING TABLE ON PAGE 2 OF THIS
BULLETIN.
NOTE: WHEN INSTALLING A NEW SENSOR, LINE UP THE SLOT IN THE
SENSOR HEAD AND THE REF HOLE ON THE MAGNETIZER . ALSO THEY
SHOULD BE ON THE LOWER SIDE IN OUR SYSTEM, DO NOT HAVE THEM
POINTED UP AS THE FANUC MANUAL TELLS YOU.
ISSUE NUMBER: 1124
SUBJECT: INDUSTRIAL DRIVE
PRODUCT LINE: DECKEL FP3A, FP4A
PAGE 1 OF 1
ANY INDUSTRIAL DRIVES AXIS OR SPINDLE AMPLIFIER ORDERED FROM HURCO
STOCK BEFORE MARCH 1, 1989 AS A REPLACEMENT UNIT WILL NEED
MODIFICATIONS IN HOUSE BEFORE SHIPMENT AS NOTED BELOW. THESE
MODIFICATIONS SHOULD ALSO BE VERIFIED UPON RECEIPT OF THE
REPLACEMENT PART IN THE FIELD.
402-6003-007 X, Y AXIS DRIVE.
THE ACS3 COMP1 BOARD NEEDS THE FOLLOWING CHANGES.
X AXIS REMOVE THE 332K OHM R 60 AND REPLACE WITH A 226K OHM RESISTOR.
Y AXIS REMOVE THE 332K OHM R 60 AND REPLACE WITH A 226K OHM RESISTOR.
ALSO REMOVE JUMPER AT J-10 AND INSTALL A JUMPER AT J11.
403-6003-006 Z AXIS DRIVE.
THE ACS3-COMP1 BOARD NEEDS THE FOLLOWING CHANGES.
REMOVE THE TO 100PF CAPACITOR AT C25. REPLACE WITH TO 4700PF
CAPACITORS.
402-6003-010 SPINDLE DRIVE.
ALL DECKEL MACHINES SHOULD HAVE THE R/'D FLYER BOARD ON THE SPINDLE
DRIVE REPLACED WITH THE OLD STYLE ANALOG DEVICES R/'D CERAMIC
PACKAGE. THE R/'D FLYER BOARD IS LABELED ACS3-RDA1 AND IS LOCATED AT
THE TOP OF THE AC3-MC2 BOARD. THE CERAMIC PACKAGE IS LABELED
AP1750/'0416, 1524/'560.
DATE: APRIL 21, 1988
ISSUE NUMBER: 1125
SUBJECT: PROBLEMS CAUSED BY VIBRATION IN
DELTRON, POWER SUPPLY.
PRODUCT LINE: ALL ULTIMAX MILLS
PAGE 1 OF 1
A PROBLEM WITH SOME DELTRON POWER SUPPLIES HAS BEEN IDENTIFIED;
HURCO P/'N 413-0008-011. DUE TO A MANUFACTURING ERROR BY DELTRON,
VIBRATION MAY CAUSE THE POWER SUPPLY TO DE-ENERGIZE MOMENTARILY.
THIS IS CAUSED BY A FASTENER ON THE BACK OF THE CHASSIS CONTACTING THE
ELECTRICAL CIRCUITRY. THIS PROBLEM MAY BE PRESENT IN ANY POWER SUPPLY
MANUFACTURED BEFORE DECEMBER, 1987.
THIS DOES NOT IMPLY THAT ALL PRE-DECEMBER SUPPLIES ARE DEFECTIVE.
TO UNDER STAND WHAT HAS OCCURRED THE FOLLOWING EXPLANATION IS
OFFERED.
IN LATE 1987, DELTRON FOUND THAT A CLEARANCE HOLE FOR THE FASTENER IN
QUESTION WAS COUNTERSUNK TO DEEP ALLOWING THE FASTENER TO CONTACT
THE MAIN PRINTED CIRCUIT BOARD. THEY HAVE INCORPORATED AN INSULATOR
ON ALL POWER SUPPLIES SINCE DATE CODE 5087 (5 WEEK OF 1987) TO ENSURE
THAT THIS WILL NOT HAPPEN IN THE FUTURE. IT IS A FLAT SHEET OF MATERIAL
THAT IS VISIBLE BETWEEN THE BASE AND THE MAIN CIRCUIT BOARD. ALTHOUGH
THIS PROBLEM COULD EXIST ON ANY PRE-DECEMBER POWER SUPPLIES IT IS
MOST PROBABLE TO EXIST IN ONLY A FEW. WE WILL BE WATCHING RETURNS
CLOSELY.
PLEASE BE AWARE OF THIS SITUATION WHEN TROUBLESHOOTING LOCK-UP
PROBLEMS OF INTERMITTENT COMPUTER RESET. THE PROBLEM CAN BE
INDUCED AND PROVEN BY TAPPING ON THE WAY OF THE POWER CABINET
USED TO MOUNT THE POWER SUPPLY. IF THE PROBLEM OCCURS, REPLACE THE
POWER SUPPLY.
REVISED BY:
DATE: MAY 11, 1989
ISSUE NUMBER: 1126
SUBJECT: FERRITE BEADS AND TRANSIENT
VOLTAGE PROTECTORS
SUPERSEDES NUMBER:
PRODUCT LINE: ALL PRODUCT
PAGE 1 OF 3
IN RESPONSE TO RECENT INTEREST IN THIS SUBJECT, HERE IS A SHORT
DISCUSSION OF THESE COMPONENTS AND HOW THEY CAN BE USED ON
THE ATTACHED PAGES.
ORIGINATOR: RICK GUNYON,
WAYNE E. HAWKINS
FERRITE BEADS AND TRANSIENT VOLTAGE PROTECTORS.
AS DISCUSSED IN THE RECENT SERVICE MEETING, THE ENGINEERING AND
SERVICE GROUPS ARE PRESENTLY IN THE PROCESS OF DECIDING IF
FERRITE BEADS WILL BE PLACED IN THE PRODUCTS AS A " STANDARD" PART. IN
THE INTERIM FERRITE BEADS HAVE PROVEN EFFECTIVE, ON BOTH MILL AND
AUTOBEND PRODUCTS, AT A NUMBER OF CUSTOMER SITES WHEN NOISE HAS
CAUSED SYSTEM RELIABILITY PROBLEMS AND NORMAL " PREREQUISITE" STEPS
HAVE NOT TOTALLY RESOLVED THE FAILURES.
WHEN WIRE IS RAN THRU A FERRITE BEAD, THE BEAD WILL BLOCK OR ABSORB
ELECTRICAL SIGNALS OF CERTAIN FREQUENCY RANGES AT THAT POINT IN THE
WIRE. THIS CHARACTERISTIC CAN BE USED TO REDUCE NOISE AND
INTERFERENCE THAT IS CONDUCTED INTO A CIRCUIT FROM THE EXTERNAL
CABLES OR OTHER CIRCUITS.
FERRITE BEADS ARE SPECIFIED BY DESCRIBING TWO MAIN CHARACTERISTICS,
SIZE AND MATERIAL. BEADS MADE OF DIFFERENT COMPOSITIONS OF FERRITE
MATERIALS WILL ABSORB DIFFERENT FREQUENCY RANGES. DC SIGNALS AND
LOW FREQUENCY ( < 1mHZ) ARE NOT EFFECTED. FOR THE PURPOSE OF
ABSORPTION OF ELECTROMAGNETIC INTERFERENCE (EMI OR NOISE), THE RISE
TIME OF THE NOISE SHOULD BE CONSIDERED AS THE FREQUENCY WHICH NEEDS
ATTENUATION; FOR MOST NOISE, THE MATERIAL ABSORBING THE HIGHER
FREQUENCIES IS DESIRED. THE BEAD DOES NOT NEED TO FIT THE WIRE
DIAMETER TIGHTLY; A GUIDELINE – THE OPEN INTERNAL DIAMETER IN THE
FERRITE BEAD CAN BE UP TO 5 TIMES THE CONDUCTOR DIAMETER AND STILL BE
100% EFFECTIVE.
HIGHER LEVELS OF NOISE ATTENUATION CAN BE GAINED BY PASSING THE WIRE
THRU THE BEAD MORE THAN ONCE; JUST LOOP THE WIRE AROUND THE BEAD,
EACH TIME IT PASSES THROUGH THE BEAD IS LIKE ADDING ONE MORE BEAD SO,
FOR EXAMPLE, 3 TURNS IS 3 TIMES THE ATTENUATION AS A SINGLE BEAD/SINGLE
TURN.
CABLES ARE TREATED JUST LIKE A SINGLE WIRE, IN THAT THE ENTIRE CABLE
CAN PASS THROUGH A BEAD AND EACH WIRE IN THE CABLE WILL RECEIVE THE
ATTENUATION JUST AS IF EACH WIRE RAN THROUGH IT'S OWN BEAD. WE HAVE
USED "SPLIT BEADS" (FERRITE BEADS CUT IN HALF DURING THE
MANUFACTURING PROCESS) SO THEY CAN BE PLACED AROUND A PRE-EXISTING
CABLE AND IT'S CONNECTORS EASILY. EACH HALF OF THE SPLIT BEAD IS THEN
TAPED TOGETHER TO FORM A WHOLE BEAD AND SECURED IN PLACE WITH A TIEWRAP. THESE SPLIT BEAD ARE AVAILABLE FOR ROUND CABLES AND FLAT LAY
CABLES. MAXIMUM EFFECT IS GAINED WHEN THE BEAD IS PLACED AT THE POINT
THE SIGNAL ENTERS THE PCB CIRCUITRY, AFTER THE EXTERNAL CABLING HAS
PICKED UP ALL NOISE DUE TO ANTENNA EFFECT, AND BEFORE THE PCB
PROCESSES THE SIGNALS FROM THE CABLE. ON MULTIPLE PCB SYSTEMS, A BEAD
AT EACH PCB NAY BE NEEDED.
WE HAVE SOLVED PROBLEMS DUE TO EMI FROM OTHER INDUSTRIAL EQUIPMENT
SUCH AS WELDERS; FROM CB RADIOS ON FORK TRUCKS IN THE PLANT, AND
PROBLEMS DUE TO VARIOUS UNKNOWN SOURCES OF NOISE. IT IS IMPORTANT TO
STRESS THAT THIS TECHNOLOGY IS NOT A CURE-ALL AND DOES NOT TAKE THE
PLACE OF PROPER DESIGN AND INSTALLATION TECHNICS.
TRANSIENT VOLTAGE PROTECTORS
THE BRAND OF DEVICE ME PRESENTLY USE IS A TRANSZORB, MADE BY GENERAL
SEMICONDUCTOR DEVICES. THESE ARE LIKE A FAST ACTING ZENER DIODE AND
DESIGNED SPECIFICALLY FOR QUENCHING NOISE TRANSIENTS. THEY ARE
INSTALLED FROM +5 VDC TO GROUND ON THE PCB TO BE PROTECTED, OR CAN BE
INSTALLED ON INDIVIDUAL INPUT AND/OR OUTPUT LINES TO QUENCH NOISE AT
THESE POINTS.
THESE DEVICES ARE FOUND ON THE PERSONALITY 2 PCB ON MILL PRODUCTS
AND HAVE BEEN ADDED TO EACH AUTOBEND PCB SINCE MARCH OF 1988,
INCLUDING PCB'S RE-TESTED AND REPAIRED FROM CUSTOMER SITES.
THESE DEVICES ARE OPEN AT THEIR OPERATING VOLTAGE (AVAILABLE IN 5.0
VOLT TO 45 VOLT MODELS) AND TURN ON TO CLAMP TRANSIENT SPIKES DURING
THE TIME THE SPIKE IS SOMEWHAT ABOVE THIS OPERATING VOLTAGE. (FOR
EXAMPLE, THE 5.0 VOLT TRANSZORB CLAMPS AT A 7.8 VOLT LEVEL.) THE
CLAMPING ACTION TAKES PLACE IN LESS THAN 1 X 10 -12 SECONDS AND SO IS
QUICK ENOUGH TO KNOCK DOWN EMI BEFORE THE CIRCUITRY ON THE PCB CAN
REACT TO IT. THESE DEVICES ALSO HAVE A POWER RATING, AND IF THE
EFFECTIVE POWER IN THE NOISE EXCEEDS THIS POWER RATING, THE DEVICE
MILL INITIALLY FAIL SHORT AND TRIP THE SYSTEMS CIRCUIT BREAKER OR FUSE.
IF THIS FAILS TO TRIP, AFTER SOME TIME THE DEVICE WILL OPEN DUE TO
INTERNAL HEATING. THE DEVICES WE SPECIFY ARE RATED AT 1500 WATTS OF
PEAK PULSE POWER AND 200 AMPS OF FORWARD SURGE CURRENT.
DURING OUR TESTING TO DEFINE OUR ADDITION OF THESE DEVICES, WE
COMPLETED TESTS IN OUR PLANT AND IN THE FIELD. AS A TYPICAL EXAMPLE OF
THE RESULTS, AT A CUSTOMER SITE WE MEASURED 7 VOLT NOISE SPIKES ON THE
5.0 VOLT POWER AT THE PCB, WITH THE SYSTEM LOCKING UP, DATA CHANGING,
ETC. DUE TO THIS NOISE. AFTER ADDING TRANSZORB ( NO OTHER CHANGES), THE
MEASURED NOISE DECREASED TO A MAXIMUM OF .7 VOLTS AND ALL FAILURES
WERE ELIMINATED. AGAIN, THESE TRANSZORBS ARE NOT A CURE-ALL BUT ONE
MORE EFFECTIVE MEASURE WITHIN A RELIABLE SYSTEM DESIGN.
ISSUE NUMBER: 1127
SUBJECT: BMC TOOL MAGAZINE JAMMING
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 40/50
PAGE 1 OF 3
We have found that the brass thrust ring at the top of the tool
magazine is spinning on the aluminum of the magazine causing the
brass and aluminum to burr. This causes drag, to correct this situation the thrust ring must be pinned to the magazine and an oil
groove added. This is only to be done on BMC 40/50, please notify
technical specialist of this problem on a BMC 20/30. The procedure
for pinning and grooving the thrust ring is as follows
1) Remove all tools from the magazine.
2) Remove the fiber glass covers on the tool changer and
magazine.
3) Remove the black cover on the bottom of the magazine shaft.
4) Remove the Geneva drive assembly at this time.
5) Secure magazine with a hoist or jacks and then remove the bearing
retainer plate on the bottom of the magazine shaft.
(Caution: The bottom bearing is a three piece assembly,
the lower and middle parts may fall out at this
time. The shims should be removed at this time.)
6) Lover the magazine until it clears the shaft.
7) Remove and modify the thrust bearing at this time as per the
enclosed drawings. You will need three roll pins (3/16x
1 1/2 inch) to pin it.
8) Pin the thrust ring to the magazine and reinstall the
magazine on the shaft after it is well greased.
(Caution: Place the pins as straight as possible so they
can later be removed if needed.)
9) Install the bottom bearing and the shims, then the
bearing retainer cap. The magazine should turn at this
point with some resistance. if the magazine spins free or
one man can't turn it you must re-shim it.
ORIGINATOR: R.ARTHUR
10) Replace the Geneva drive and check that the flywheel to
magazine you can just insert a .001" shim.
11) Check tool change rotation in both directions. If it
rotates correctly install tools and do 25 tool changes.
If no problems, now LOCTITE the bolts one at a time on
the bearing retainer cap and the Geneva drive assembly.
12) Load and run 200 tool changes at this time.
13) Replace covers and run 50 tool changes.
DATE: JUNE 20, 1989
ISSUE NUMBER: 1128
SUBJECT: Leadscrew Mapping 7.24
BMC 20\30\40\50 only
SUPERSEDES NUMBER:
PAGE.1..... OF.1.....
On the BMC 20/30/40/50 series machines the new 7.24 software
includes Leadscrew mapping.
Machines that were shipped with 7.24 software were Leadscrew
mapped at the factory and this» mapping will have to be loaded
back into the memory whenever a memory board is changed.
This can be done from the secret screen (642) by loading it
from the mapping disk sent with each machine or manually
through the keyboard using the MANUAL DATA ENTRY Softkey and
the mapping charts in each machine. If this is not done no
compensation will be taken into account.
Because 7.24 software no longer looks to the dual axis boards
for Leadscrew compensation on the current line of bed mil1s,
machines using earlier versions of software will have to have
the dip switch settings transferred into memory. This is
done once again from the secret screen by selecting the DUAL
AXIS DEFAULTS Softkey. This automatically takes the
information stored in the dual axis boards and stores it in
memory.
The following procedure should be followed whenever a memory
board with 7.24 or later software is installed.
1) Power up after installing the new board.
2) Use the EXIT Softkey to get out of- the machine
configuration screen.
3) Select manual.
4) Turn on servo power and CALIBRATE the machine.
5) Go to the leadscrew setup screen by pressing:
ENTER 6 4 2 ENTER from the tool change diagnostics screen.
6) If information is to be loaded from a disk select LOAD
DATA FROM DISK Softkey. (The current storage device needs
to be drive A selected under the AUXILIARY menu)
7) If data is to be transferred from the dual axis boards
select the DUAL AXIS DEFAULTS Softkey.
Backlash continues to be compensated for on the dual axis
boards.
ORIGINATOR: Mike Garlick
DATE: JUNE 21, 1989
ISSUE NUMBER: 1129
SUBJECT: CHIP DOOR INTERLOCK 7.24 SOFTWARE
SUPERSEDES NUMBER:
PRODUCT LINE: BMC-20/30/40/50
PAGE 1 OF 1
With version 7.24 software or later the chip door interlock is now
looked at as a normally closed contact. When machines are upgraded to
7.24 1t will be necessary to install a jumper betveen terminals
9 and 10 of TB-3 on the Control Relay Panel.
If this is not done a CHIP DOOR OPEN error will be displayed when the
machine is put into AUTO mode and the program will be aborted.
ORIGINATOR: Hike Garlick
REVISED BY:
DATE: JUNE 21, 1989
ISSUE NUMBER: 1130
SUBJECT: TAPPING T1 TRANSFORMER
(STAND ALONE)
SUPERSEDES NUMBER
PAGE 1 OF 1
IT HAS CAME TO MY ATTENTION THAT SOME OF THE BMC 20 THRU 50
MACHINES HAY HAVE' HAD THE T1 TRANSFORMER TAPPED FOR TOO HIGH A
SECONDARY VOLTAGE OUTPUT. THIS MAY IN TURN CAUSE PREMATURE FAILURE
OF THE FANUC AXIS AND SPINDLE DRIVE SYSTEM.
IF THE VOLTAGE IS RUNNING ON THE HIGH SIDE OF THIS RANGE OR IF IT
IS OVER THE LIMITS TRY MOVING THE OUTPUT TO THE 190VAC TAPS. REMEMBER
THE RANGE IS FROM 180 TO 220VAC AND THE 190 IS CLOSER TO THE MIDDLE OF
THIS RANGE WHEN THE INCOMING VOLTAGE IS ON THE HIGH SIDE. BE SURE TO
CHECK ALL VOLTAGE LEVELS BEFORE AND AFTER MOVING THE TAPS.
FROM THIS TIME ON, PLEASE CHECK ALL TRANSFORMERS ON ANY MACHINES
YOU MAY BE WORKING ON THIS MAY SAVE A TRIP LATER TO REPLACE THE
SPINDLE OR AXIS DRIVES. IF YOU HAVE ANY QUESTIONS PLEASE CALL ME DON'T
GUESS BE SURE.
ORIGINATOR: RANDALL BRYANT, KEN BORGMEYER
REVISED BY:
DATE: 06/21/89
ISSUE NUMBER: 1131
SUBJECT: MAGAZINE JAMMED ERROR
SUPERSEDES NUMBER:
PRODUCT LINK: BMC-20/30/40/50
PAGE 1 OF 1
THIS BULLETIN SHOULD BE USED IN CONJUNCTION WITH FSB 1127 TO PROPERLY
TROUBLE SHOOT AND CORRECT THE "MAGAZINE JAMMED" ERROR.
We are beginning to get more and more reports of MAGAZINE JAMMED errors
on machines in the field. FSB 1127 deals with the mechanical causes of
this problem. However it is felt that the problem could also be caused
by arcing in the ROTATE ENABLE (RE) and/or the TOOL MAGAZINE COUNTER
CLOCKWISE (TMCC) relays.
The BMC-20 appears to be the most susceptible to this arcing problem
On newer V1 machines and all V2 machines the suppression in the Magazine
motor circuit has been increased substantially. There are now 6 arc
suppressors in the circuit which has helped reduce the arcing of the
relay contacts.
On older machines it may be necessary to place suppressors across the
following contacts:
ROTATE ENABLE (RE)
6-9
3-9
TOOL MAGAZINE COUNTER CLOCKWISE (TMCC)
9-3
9-6
8-5
8-2
It would be wise to replace the relays when the suppressors are
installed as the contacts will probably have been badly pitted.
PART NUMBER FOR SUPPRESSORS: 417-6001-010
PART NUMBER FOR RELAYS: 403-2001-013
REVISED BY:
DATE: 06/28/89
ISSUE NUMBER: 1132
SUBJECT: BIJUR LUBE PUMP ADJUSTMENT
SUPERSEDES NUMBER:
PRODUCT LINE: BMC-20/30/40/50
PAGE 1 OF 1
The BIJUR lube pump adjustment procedure sent out to the field recently
is incorrect. Please use the following procedure.
1) Remove the locking screw found inside the center of the manual hand
pump to get to the adjusting screw. This could be a slotted or hex
head set screw.
2) Using a depth micrometer measure the distance from the top of the
pump handle to the top of the adjusting screw. This dimension should
be set for .95 inches to allow 3cc of flow per cycle. However it may
be necessary to use a different setting on some machines. Refer to
the following chart for dimensions and outputs.
INCHES
DISCHARGE
1.03
2.5 cc
.95
3.0 cc
.87
3.5 cc
.79
4.0 cc
.71
4.5 cc
.63
5.0 cc
Each .080 of ad9ustment is equal to .5 cc.
3) Re-install locking screw.
REVISED BY:
DATE: 8/3/89
ISSUE NUMBER: 1133
SUBJECT: MAX 2 MEMORY BOARDS
SUPERSEDES NUMBER:
PRODUCT LINE: ALL MAX 2 MILLS
PAGE 1 OF 1
THE NON VOLATILE STATIC RAM SITES ON THE MAX 2 MEMORY
BOARDS WERE DALLAS DS1235 IC'S. THOSE DEVICES ARE TEMPORARILY
UNAVAILABLE. THE RAM SITES MUST BE REWORKED BY OUR Vendor TO USE
SMART SOCKETS AND STANDARD STATIC RAM IC'S.
PREVIOUS TO THIS REWORK IT WAS POSSIBLE TO REMOVE THE
DALLAS RAMS FROM A DEFECTIVE MEMORY BOARD AND INSTALL THEM INTO A
NEW MEMORY BOARD. THIS WAS NORMALLY DONE TO SAVE A CUSTOMERS
PROGRAMS WHEN THE MACHINE WASN'T EQUIPPED WITH THE DISK OPTION. THIS
WILL NOT BE POSSIBLE WITH THE REWORKED MEMORY BOARDS.
REVISED BY:
DATE: 8-18-89
ISSUE NUMBER: 1134
SUBJECT: SHAFT MOUNT ENCODERS
SUPERSEDES NUMBER:
PRODUCT LINE: ALL
PAGE 1 OF 1
ORIGINALLY, THE USE OF SHAFT MOUNT ENCODERS CAME ABOUT FOR
TWO REASONS.
1) HIGH DEGREE OF DIFFICULTY IN ADJUSTING ENCODERS TO ACHIEVE
PROPER QUADRATURE.
2) ENDPLAY IN SERVO MOTORS EXCEEDING ENCODER AIR GAP RESULTING
IN A DAMAGED ENCODER DISK.
ALL SHAFT MOUNT ENCODERS ARE ADJUSTED THEN SEALED BY OUR
VENDOR. SERVICE ENGINEERS SHOULD NEVER DEFEAT THE FACTORY SEAL
ON ANY SHAFT MOUNT ENCODER. IF THE MACHINE IS OUT OF WARRANTY
REPLACE THE ENCODER, IF THE MACHINE IS STILL UNDER A PART
WARRANTY ,THE MTE ASSEMBLY MUST BE REPLACED.
ORlGINATOR: FREDRICK RAES
REVISED BY:
ISSUE NUMBER: 1135
SUBJECT: Spindle Firmware
SUPERSEDES NUMBER:
PRODUCT LINE: MD3 with Yaskawa Spindle Drive
PAGE 1 OF 1
A new Spindle EPROM has been released for the MD3 type machines with
the Yaskawa Spindle Drive (002-2060-001). The new EPROM is a 450-3001501 and replaces the 450-3001-439 EPROM.
The changes in this new EPROM allow separate adjustments for Spindle
Orient speed based upon the Spindle Gear Range (High or Low). Orient
adjustments for this EPROM are listed below.
Z / SPINDLE DUAL AXIS PCB
SWITCH BLOCK 2: LOW GEAR SPEED ADJUST
POSITION
( S1 on D / A2 )
1
2
3
4
5
6
7
8
ON = SLOWER OFF = FASTER
MOST SIGNIFICANT BIT
SPEED ADJUSTMENT
SPEED ADJUSTMENT
LEAST SIGNIFICANT BIT
NOT USED
ON = SHOT PIN ENABLED OFF SHOT PIN DISABLED
ON = MD3 MACHINE TYPE OFF
OFF = MD1 MACHINE TYPE
SWITCH BLOCK 3: HIGH GEAR SPEED ADJUSTMENT
POSITION (S2 on D/A2 )
1
2
3
4
5.
6
7
8
ON = SLOWER
OFF = FASTER
MOST SIGNIFICANT BIT
SPEED ADJUSTMENT
SPEED ADJUSTMENT
LEAST SIGNIFICANT BIT
NOT USED
NOT USED
NOT USED
ORIGINATOR: K. PERKINS
REVISED BY:
DATE: Auqust 11, 1989
ISSUE NUMBER: ll36
SUBJECT: Yaskawa Spindle Drive Retrofit Kits
SUPERSEDES NUMBER:
PRODUCT LINE: MD3, MB2/3 (002-2060-001i002)
PAGE 1 OF 2
Effective September, 1989 the Yaskawa Retrofit Kits (002-2060-001,002)
will change to different braking resistors. The new resistors eliminate
the "Over Voltage" problem that has been seen during deceleration from
a high RPM by providing more braking torque.
The new resistors can be installed into existing drives in the field to
eliminate the "OV" fault that could occur during deceleration from a
high RPM. The new resistors have a part number of 407-0043-001. This.
part number is for both the left and right hand resistor bank so only
order a quantity of one (1) for each machine The resistors mount in
the same location that the Yaskawa resistors did, but do not have
overload contacts and connect in series as opposed to the parallel
wiring of the Yaskawa resistors.
Installation instructions are below:
1) Remove thermal overload wiring from the drive cabinet at TB8,
positions 1 THRU 4 (blue and white vires).
2) Remove the resistor shields, save the BHCS for reuse.
3) Remove the cover plates from the Yaskawa resisters.
4) Disconnect the braking wires (black) from the Yaskawa resistors.
5) Remove the Yaskawa resistors, along with the overload wiring that
was disconnected from TB8. Also remove the resistor spacers that are
between the cabinet and the resistors. Save the BHCS for reuse.
6) Remove the conduit from the bottom of the Yaskawa resistors.
7) Mount the Post Glover resistors to the cabinet as the Yaskawa
resistors were except do not install the spacers.
8) Connect the two (2) black braking wires to the posts on the new
resistors.
9) Since these resistors connect in series, not parallel, remove one
of the brake wires going to the drive at terminal "P" and one from
terminal "B3".
10) At this point you should have a wire from one resistor bank to drive terminal "P" and one
wire from the other bank to drive terminal "B3".
11) Connect the other two black wires, one from each resistor bank,
to each other inside the drive cabinet. Use either a butt splice or
wire nut to connect the wires. Assure a sound connection, and that the
connection is not exposed and that the wiring is dressed neatly.
12) The total resistance of the two brake resistor units connected in
series is 14 Ohms.
l3) Power up the machine and program a series of spindle operations
using both CW and CCW spindle rotations and both High and Low gear
ranges. Also verify proper Orientation.
14) Verify the resistors are functioning properly by measuring the
voltage being transferred to the resistors, during deceleration,
from the drive at terminals "P" and "B3".
15) Re-install the brake shields and update the customers Yaskawa
manual with the wiring changes that you have made.
16) If desired the accel and decel ramps of the drive can be set for a
minimum time duration, (i.e. < 4 seconds) so as to confirm that the drive will follow the
DAC ramps.
DATE: 09/07/89
ISSUE NUMBER: 1137
SUBJECT: Z AXIS LUBRICATION LINES
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 V2
PAGE 1 OF 2
ON SOME BMC 20,S THAT HAVE RECENTLY SHIPPED THE Z AXIS
BALLSCREW NUT LUBRICATION LINE WAS ROUTED INCORRECTLY.
ALL MACHINES NEED. TO BE CHECKED ON INSTALL AND ON SERVICE
CALLS.
IT MUST BE REPLACED IF WRONG!
THIS IS THE RIGHT WAY.
TO CHECK YOU MOST LOOK IN THE COLUMN, BEHIND THE SPINDLE MOTOR
AT THE OIL DISTRIBUTION BLOCK. THERE SHOULD BE A HOLE FOR THIS
OIL LINE TO PASS THRU AND ATTACH TO THE Z AXIS BALL NUT.
THIS IS THE WRONG WAY!
IF THE LINE IS ROUTED OVER THE TOP OF THE Z AXIS ASSY AND NOT
THROUGH THIS HOLE, THE LINE CAN BE SHEARED OFF. IF THIS IS NOT
NOTICED THIS CAN CAUSE SEVERE DAMAGE TO THE BALLSCREW.
TO CORRECT THIS PROBLEM THE FOLLOWING PARTS WILL BE NEEDED:
1.
2.
3.
4.
5.
6.
METER UNIT 713-0020-093
.2 COMPRESSION SLEEVES
713-0020-098
1 TUBE CLIP 713-0021-268
.10" 4MM TUBING
713-0021-269
COMPRESSION NIPPLE
713-0020-099
COMPRESSION NUT 713-0020-097
ORIGINATOR: BROCK REXING
RANDALL BRYANT
REVISED BY:
ISSUE NUMBER: 1138-A
SUBJECT: Floppy Disk Drives, Max2/32/3
PRODUCT LINE: All Ultimax Controls
PAGE 1 OF 6
Revised and added Configuration of Max3 and Max32 HD (1.44 Mbyte) Floppy drives.
Max2
NEC has got out of the business of making disk drives. We will therefore be using Teac and Sony drives
in the future. However the pinout on these drives is located further to the right than on the NEC drives.
Due to the shortness of the cable between plugs it will require replacing both drives in the event of one
failing. A new part number has been issued for these drives. 426-0056-903.
The 902 and 901 drives are still available in limited quantities and these should be used up before going
to the 903 style.
-If a machine has 901 style drives and one goes bad both drives will need to be replaced with two
002-3303-005 retrofit kits.
-If a machine has 902 style drives and one goes bad both drives will have to be replaced with the 903
style. The physical size of these drives is the same so the retrofit kit is not needed.
Max3 or 32
Teac has obsoleted two of the orginal Floppy drives used in the Max3 and 32 controls. Although the
part number (426-0056-007) has remained unchanged, we have several different Teac drive
configurations.
The following 5 pages show the pinout and switch / jumper configuration of each of the drives and the
retrofit kit.
REVISED BY: Brock Rexing
FSB 1138-A Page 2 of 6
SIZE
C
DRAWING
002-3303-005
SHT.
1
OF
1
REV.
B
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR
DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT
THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
1
2
3
FRONT
SIDE
4
BOTTOM
1
4
4
1
802-2300-039
101-0001-003
110-0002-022
426-0056-003
QTY.
PART NUMBER
4
3
2
1
ADAPTER PLATE, DISK DRIVE
4-40 X 1/2 SHCS
WASHER #4
DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, CFG#2
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
CN
127
B 10378
A 10072
REV
P.I.N.
NO.
ITEM 1 WAS 426-0056-002
RELEASE
REVISION DESCRIPTION
17
FWG AUG
89
23
FWG JAN
89
REV DATE CHK DATE APPD DATE DF
BY
BY
BY
FIRST USED ON
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00 ±.0150
.000 ±.0050
.0000 ±.0005
ANGULAR ± 0ANGULAR °30' DRAWN
BREAK ALL
SHARP EDGES
SCALE
THIRD ANGLE
ASSY, 3.5 INCH FLOPPY DRIVE RETROFIT KIT
F. GROSS
PROJECTION
DISK OPTION
HURCO MANUFACTURING COMPANY, INC.
INDIANAPOLIS, IN U.S.A.
R
1.25=1
UNIT OF MEAS.
PC
DATE
CHECKED
DATE
APPROVED
DATE
23JAN89
SIZE
C
DRAWING
SHT.
1
002-3303-005
OF
1
REV.
B
SIZE
D
DRAWING
426-0056-003
SHT.
1
OF
1
REV.
A
1.000
FRONT
4.000
ACTUAL APPEARANCE OF THE FRONTS MAY VARY BETWEEN VENDORS.
HOWEVER, THE DIMESIONS OF THE BEZEL REMAIN 4" X 1" FOR
ALL VENDORS UNDER THIS HURCO PART NUMBER.
SIGNAL PINOUT
PIN 2
PIN 1
TEAC FD-235
SONY MP-F11W-50L
BACK
MS
IR
RY
DC
D1
D0
FG
TOP
SIDE
SHUNT CONFIGURATION
DRIVE A
SWITCH CONFIGURATION
DRIVE B
MS
MS
IR
IR
RY
RY
DC
DC
D1
D1
D0
D0
DRIVE A
3
2
1
DRIVE B
0
3
2
1
0
1
DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, PINOUT #2
426-0056-903
QTY.
PART NUMBER
1
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
FIRST USED ON
CN
129
A 10378 REL.
REV
P.I.N.
NO.
FWG
17
AUG
89
BY
BY
BY
HURCO,DECKEL
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
ANGULAR ± 0ANGULAR °30'DRAWN
BREAK ALL
F. GROSS
SHARP EDGES
R
3.5" MICROFLOPPY DISK DRIVE, 1" BEZEL
THIRD ANGLE
PROJECTION
SCALE
1.25=1
UNIT OF MEAS.
EA.
DATE
CHECKED
DATE
APPROVED
DATE
25JAN89
SIZE
D
DRAWING
SHT.
1
426-0056-002
OF
1
REV.
A
SIZE
D
DRAWING
426-0056-001
SHT.
1
OF
1
REV.
A
PROPRRIETARY INFORMATION
MODEL FD1036A
NEC
MODEL FD1036A
NEC
MODEL FD1036A
NEC
P/N 134-500105-004-0
P/N 134-500105-004-0
P/N 134-500105-004-0
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1
MODEL FD1037A NEC
P/N 134-500474-954-0
TOP
SIGNAL PINOUT
PIN 1
PIN 2
MODEL FD1036A
NEC
MODEL FD1036A
NEC
MODEL FD1036A
NEC
P/N 134-500105-012-0
P/N 134-500105-012-0
P/N 134-500105-012-0
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1
BACK
SWITCH SETTINGS FOR DRIVE CONFIGURATION
Pos. 1
Drive A
Pos. 2
Drive B
Pos. 3
Pos. 4
NOT USED
1
426-0056-901
QTY.
DISK DRIVE, 3.5" FLOPPY, 1.25" BEZEL
PART NUMBER
1
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
FIRST USED ON
CN
130
A
10378
REV
P.I.N.
NO.
ORIG. ISSUE
FWG
17
AUG
89
BY
BY
BY
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
SHARP EDGES
SCALE
THIRD ANGLE
R
3.5" MICROFLOPPY DISK DRIVE
FWG
PROJECTION
FULL
UNIT OF MEAS.
DATE
CHECKED
DATE
APPROVED
DATE
17AUG89
SIZE
D
DRAWING
426-0056-001
SHT.
1
OF
1
REV.
A
SIZE
D
DRAWING
426-0056-002
SHT.
1
OF
1
REV.
A
NEC FD1037A-154
1.000
FRONT
BACK
4.000
DRIVE A
DRIVE B
SIGNAL PINOUT
PIN 2
PIN 1
1
2
3
4
1
2
3
4
1
426-0056-902
QTY.
PART NUMBER
1
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
FIRST USED ON
CN
131
17
FWG AUG
89
A 10378 RELEASE
REV
P.I.N.
NO.
REV DATE CHK DATE APPD DATE
BY
BY
BY
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
F. GROSS
SHARP EDGES
SCALE
THIRD ANGLE
PROJECTION
DF
HURCO,DECKEL
R
1.25=1
UNIT OF MEAS.
EA.
DATE
CHECKED
DATE
APPROVED
DATE
17AUG89
SIZE
D
DRAWING
SHT.
1
426-0056-002
OF
1
REV.
A
SIZE
SHT.
DRAWING
D
1
426-0056-007
OF
REV.
1
Teac FD 235HF-201
Teac FD 235HF-3201 /S
Teac FD-235HF-4429
E
D
C
B
A
G
F
E
D
C
B
A
2 1
4 3 2 1
NOTES:
Teac FD-235HF-5429
Jumper configuration for various HD Floppy Drives
used on Ultimax 3 and Max32
DS
0 1
SURFACE TREATMENT
~
~
HEAT TREATMENT
CN
XXXX-X
FIRST USED ON
A XXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
REV
P.I.N.
NO.
X
XX/XX
X
XX
BY
BY
BY
Ultimax 3
Max 32
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
SHARP EDGES
R
1.44 HD FLOPPY DRIVE CONFIGURATION
B.R.R.
THIRD ANGLE
PROJECTION
SCALE
NONE
UNIT OF MEAS.
PC
DATE
CHECKED
DATE
APPROVED
DATE
12/8/93
SIZE
D
DRAWING
SHT.
1
426-0056-007
OF
1
REV.
SUBJECT: Floppy Disk Drives, Max2/32/3
PRODUCT LINE: All Ultimax Controls
PAGE 1 OF 6
Revised and added Configuration of Max3 and Max32 HD (1.44 Mbyte) Floppy drives. (Rev A, 12-12-93)
Revised Page 3 of 6, Add Sony MPF420-2 Max2 720K Floppy Drive Configuration (Rev B, 8-3-94)
Max2
NEC has got out of the business of making disk drives. We will therefore be using Teac and Sony drives
in the future. However the pinout on these drives is located further to the right than on the NEC drives.
Due to the shortness of the cable between plugs it will require: 1) ordering another 34 pin connector
(406-0802-047) to add to the existing disk control cable, or, 2) replacing both drives (426-0056-903)
when one fails. Once both drives are the new -903 style they can be replaced individually.
The 902 and 901 drives are still available in limited quantities and these should be used up before going
to the 903 style.
-If a machine has 901 style drives and one goes bad both drives will need to be replaced with two
002-3303-005 retrofit kits.
-If a machine has 902 style drives and one goes bad both drives will have to be replaced with the 903
style. The physical size of these drives is the same so the retrofit kit is not needed.
Max3 or 32
Teac has obsoleted two of the orginal Floppy drives used in the Max3 and 32 controls. Although the
part number (426-0056-007) has remained unchanged, we have several different Teac drive
configurations.
The following 5 pages show the pinout and switch / jumper configuration of each of the drives and the
retrofit kit.
FSB 1138-A Page2 of 6
SIZE
C
DRAWING
002-3303-005
SHT.
1
OF
1
REV.
B
1
2
3
FRONT
SIDE
4
BOTTOM
1
4
4
1
802-2300-039
101-0001-003
110-0002-022
426-0056-003
QTY.
PART NUMBER
4
3
2
1
ADAPTER PLATE, DISK DRIVE
4-40 X 1/2 SHCS
WASHER #4
DISK DRIVE, 3.5" FLOPPY, 1" BEZEL, CFG#2
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
CN
127
B 10378
A 10072
REV
P.I.N.
NO.
ITEM 1 WAS 426-0056-002
RELEASE
17
FWG AUG
89
23
FWG JAN
89
BY
BY
BY
FIRST USED ON
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00 ±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
SHARP EDGES
SCALE
THIRD ANGLE
ASSY, 3.5 INCH FLOPPY DRIVE RETROFIT KIT
F. GROSS
PROJECTION
DISK OPTION
R
1.25=1
UNIT OF MEAS.
PC
DATE
CHECKED
DATE
APPROVED
DATE
23JAN89
SIZE
C
DRAWING
SHT.
1
002-3303-005
OF
1
REV.
B
SIZE
DRAWING
SHT.
REV.
1
D
426-0056-003
OF
1
A
SONY MPF420-0
1.000
FRONT
4.000
BACK
SHUNT CONFIGURATION
SIGNAL PINOUT
"A" Drive
"B" Drive
PIN 2
PIN 1
15
TEAC FD-235
SONY MP-F11W-50L
15
10
5
14
9
13
5
15
15
10
5
4
14
9
4
8
3
13
8
3
12
7
2
12
7
2
11
6
1
1
11
6
1
1
426-0056-903
5
BACK
MS
IR
RY
11
DC
D1
11
1
D0
FG
TOP
SIDE
SHUNT CONFIGURATION
DRIVE A
DRIVE B
MS
MS
IR
IR
RY
RY
DC
DC
D1
D1
D0
D0
DRIVE A
3
2
1
DRIVE B
0
3
2
1
0
QTY.
PART NUMBER
1
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
~
HEAT TREATMENT
FIRST USED ON
CN
129
17
A 10378 REL.
REV
P.I.N.
NO.
89
REV DATE CHK DATE APPDDATE
BY
BY
BY
IN INCHES
DF
HURCO,DECKEL
HURCO
TOLERANCE
R
.0
Ç.0300
.00
Ç.0150
.000
Ç.0050
.0000
Ç.0005
ANGULAR Ç 0•30'
DESCRIPTION
3.5" MICROFLOPPY DISK DRIVE, 1" BEZEL
DRAWN
DATE
F. GROSS
25JAN89
SCALE
SIZE
CHECKED
DATE
APPROVED
DATE
BREAK ALL
SHARP EDGES
THIRD ANGLE
PROJECTION
FWGAUG
ALL DIMENSIONS
DECIMAL
1.25=1
UNIT OF MEAS.
EA.
D
DRAWING
SHT.
REV.
1
426-0056-002
OF
1
A
SIZE
D
DRAWING
426-0056-001
SHT.
1
OF
1
REV.
A
PROPRRIETARY INFORMATION
MODEL FD1036A
NEC
MODEL FD1036A
NEC
MODEL FD1036A
NEC
P/N 134-500105-004-0
P/N 134-500105-004-0
P/N 134-500105-004-0
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1
MODEL FD1037A NEC
P/N 134-500474-954-0
TOP
SIGNAL PINOUT
PIN 1
PIN 2
MODEL FD1036A
NEC
MODEL FD1036A
NEC
MODEL FD1036A
NEC
P/N 134-500105-012-0
P/N 134-500105-012-0
P/N 134-500105-012-0
FACTORY DEFAULT
CONFIGURED DRIVE 0
CONFIGURED DRIVE 1
BACK
SWITCH SETTINGS FOR DRIVE CONFIGURATION
Pos. 1
Drive A
Pos. 2
Drive B
Pos. 3
Pos. 4
NOT USED
1
426-0056-901
QTY.
DISK DRIVE, 3.5" FLOPPY, 1.25" BEZEL
PART NUMBER
1
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
FIRST USED ON
CN
130
A
10378
REV
P.I.N.
NO.
ORIG. ISSUE
FWG
17
AUG
89
BY
BY
BY
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
SHARP EDGES
SCALE
THIRD ANGLE
R
3.5" MICROFLOPPY DISK DRIVE
FWG
PROJECTION
FULL
UNIT OF MEAS.
DATE
CHECKED
DATE
APPROVED
DATE
17AUG89
SIZE
D
DRAWING
426-0056-001
SHT.
1
OF
1
REV.
A
SIZE
D
DRAWING
426-0056-002
SHT.
1
OF
1
REV.
A
NEC FD1037A-154
1.000
FRONT
BACK
4.000
DRIVE A
DRIVE B
SIGNAL PINOUT
PIN 2
PIN 1
1
2
3
4
1
2
3
4
1
426-0056-902
QTY.
PART NUMBER
1
ITEM DESCRIPTION
ITEM
PARTS LIST
SURFACE TREATMENT
~
~
HEAT TREATMENT
FIRST USED ON
CN
131
17
FWG AUG
89
A 10378 RELEASE
REV
P.I.N.
NO.
BY
BY
BY
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
F. GROSS
SHARP EDGES
SCALE
THIRD ANGLE
PROJECTION
DF
HURCO,DECKEL
R
1.25=1
UNIT OF MEAS.
EA.
DATE
CHECKED
DATE
APPROVED
DATE
17AUG89
SIZE
D
DRAWING
SHT.
1
426-0056-002
OF
1
REV.
A
SIZE
SHT.
DRAWING
D
1
426-0056-007
OF
REV.
1
Teac FD 235HF-201
Teac FD 235HF-3201 /S
Teac FD-235HF-4429
E
D
C
B
A
G
F
E
D
C
B
A
2 1
4 3 2 1
NOTES:
Teac FD-235HF-5429
Jumper configuration for various HD Floppy Drives
used on Ultimax 3 and Max32
DS
0 1
SURFACE TREATMENT
~
~
HEAT TREATMENT
CN
XXXX-X
FIRST USED ON
AXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
REV
P.I.N.
NO.
X
XX/XX
X
XX
BY
BY
BY
DF
Ultimax 3
Max 32
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
DESCRIPTION
.00
±.0150
.000 ±.0050
.0000 ±.0005
BREAK ALL
SHARP EDGES
SCALE
THIRD ANGLE
R
1.44 HD FLOPPY DRIVE CONFIGURATION
B.R.R.
PROJECTION
NONE
UNIT OF MEAS.
PC
DATE
CHECKED
DATE
APPROVED
DATE
12/8/93
SIZE
D
DRAWING
SHT.
1
426-0056-007
OF
1
REV.
ISSUE NUMBER: 1139
SUBJECT: Vertical head lube relay
SUPERSEDES NUMBER:
PRODUCT LINE: FP3A/FP4A Ultimax 2
PAGE 1 OF 1
Effective immediately all FP3A and FP4A Ultimax machines should be
checked f or proper wiring and. operation of the vertical head lube relay
and solenoid.
1.) The wire from R101 pin 4 should connect to RLY4 terminal 6. This
wire may currently be connected to RLY4 terminal 8 making the
Vertical head lube solenoid non-functional. If the wire has been
incorrectly connected to terminal 8, remove the wire from the
relay and all wireways back to connector R101. The wire should be
long enouqh to route up the riqht hand wireway and across to the
top of RLY4 terminal 6. see 002-3730-012 +24VDC Unregulated
Schematic for additional information. If RLY4 was mis-wired
proceed to step 02. If RLY4 was correctly wired proceed to step
03.
Remove the Vertical head lube solenoid connector and cover and
inspect the wiring and diode connection. Terminal 01 should
contain the black wire and the cathode end of the suppression
diode. Terminal #2 should contain the clear wire and the anode
end of the suppression diode. After checkinq wiring verify +24vdc
on terminal 01 and qround on terminal 02 by manually requestinq a
machine lube cycle. The solenoid is energized four times in
succession following the way lube cycle. After verifyinq the
proper wiring and voltage install the connector and proceed to
step #3.
3.) Remove Vertical head lube line at the head connection and cover
end of lube line with shop towel. Manually request a machine lube
cycle and check for four shots of oil, one for each time the
solenoid is energized. If no oil is present repeat machine lube
Cycle until oil is seen in four shots for each manual lube cycle.
Reconnect the oil line to the head and tighten fittings.
REVISED BY:
DATE: 9/29/89
ISSUE NUMBER: 1140
SUBJECT: Turcite damage
SUPERSEDES NUMBER:
PRODUCT LINE: BMC. full enclosure machines
PAGE 1 OF 1
A number of machines have had damage done to the turcite on the X-Axis
way surfaces. This is. being cause by the way cover extension brackets
being mounted with the top edge above the way surface. The sharp edge
of. the bracket peels the turcite from the underside of the table as it
rides out over the end of the way.
Due to the tact that all BMC-20 machines come with way extensions we
have seen the problem mostly on this series machine. However it is
possible for this to happen on any full enclosure machine old or new and
has.
It would be vise to check any of the above mentioned machine
configurations for any damage that may have occurred. On BMC-30\40
full enclosure machines the extensions can and should be pinned to stop
this from happening. The OEM BMC-50's the extensions were pinned and
should not be a problem however they should be checked.
The BMC-20 design does not allow pinning. Because it is mounted flat to
the way surface any weight out on the way cover could cause the sharp
edge of the extension to raise up and dig into the turcite as it passes
under it. The only suggested solution is to remove the extensions and
out a radius on the top edge of them where they mount to the casting.
This will stop it from digging into the turcite. In some cases the
extensions are physically to thick and when in place will be higher than
the way surface. If this is found they will need to be ground down to be
flush or lower than the way.
This fix although not perfect can be done on a belt sander and needs to
be done on all BMC-20's with slide ways covers. It does not take very
long to do and could save weeks of down for a customer and a 3 to 4 day
service call.
If turcite is found to be damaged it will need to be repaired. However
in most cases the damaged area can be cut out and the high spots stoned
to allow the customer to at least run the machine until it can be
repaired. As long as there is some turcite left it should not be a
problem.
REVISED BY:
DATE: 9/28/89
ISSUE NUMBER: 1141
SUBJECT: STRIKER PLATE HOLD-DOWN SCREWS
SUPERSEDES NUMBER:
PRODUCT LINE: BMC-30 V1 ATC
PAGE 1 OF 1
The shock absorbers on the BMC-30 Vl ATC make contact with
steel "striker plates" to avoid direct contact with the soft
aluminum casting. These are currently attached with quantity (4)
102-5003-002 FHSCS M5x0.8xlO which does not provide a sufficient
depth of engagement. In the future these plates will be attached with
quantity 4) 102-5003-004 SHCS M5x0.8xl6. these longer screws can
be used for field service replacement and should work even if the
first two or three threads are stripped in the aluminum casting.
ORIGINATOR: MICHAEL WATSON
REVISED BY: RICHARD ARTHUR
ISSUE NUMBER: 1142
SUPERSEDES NUMBER:
PRODUCT LINE: MD3, MB3, MB2
PAGE 1 OF 1
Recently some changes were to have been made to the Yaskawa
Spindle Drive retrofit kits (002-2060-001, 002). These changes
included changing the vendor for the Braking Resistors that are used
from Yaskawa to Post Glover. This change eliminates the problem that
was seen as an "OV" Fault during deceleration from a high RPM.
The Post Glover resistors connect in series and do not have
internal overload contacts, as opposed to the Yaskawa resistors that
connected in parallel and had these contacts that connected thru the
drive fault circuitry.
Due to these differences. the interface schematics and Wago
terminal layout of the spindle drive cabinet also changed, as did the
manuals for these kits.
The actual change to the Post Glover resistors has not yet been
implemented because we are still waiting for the Post Glover
resistors to arrive, but the manuals, schematics, etc. have been
changed.
Until the drive configuration is changed over to the Post Glover
resistors the potential exists for the wrong documentation to be sent
with the kit, or you may receive the new documentation and not be
aware of which revision of the schematic matches what drive
configuration.
The past dive configuration is with the Yaskawa resistors, and
you should use the REV. B schematics (002-2063-001 or -002). The
Manuals for these kits have gray covers with a part number of 7040001-364 for MD3 and 704-0001-365 for NB2/3 and are dated April, 89.
The new configuration, with the Post Glover resistors, will be
implemented within the next two months or so, and for these you
should use the REV. C schematics. The new manuals carry the same part
number, are dated Sept. 89 and have blue plastic covers.
'The Yaskawa Braking resistors have a tan color enclosure and will
have a pair of black vires along with a blue and white twisted pair
connected to them. The Post Glover resistors are in a perforated
aluminum enclosure and will not have the blue and white twisted pair.
The Yaskawa resistors, when connected properly will have a
resistance of 25 Ohms. The Post Glover resistors, when connected
properly will have a resistance of 14 Ohms.
ORIGINATOR: K. Perkins
DATE: 11/9/89
ISSUE NUMBER: 1143
SUBJECT: GROUND ON ULTIMAX
CONTROL CONSOLE
SUPERSEDES NUMBER:
PRODUCT LINE: ALL ULTIMAX CONTROLS
PAGE 1 OF 1
Over the years We have had some problems vita the control locking
up, jog buttons controlling the wrong axis and other various problems
which are related to the CRT controller board. This board is in the
process of being redesigned. but until this happens We must try to
limit the situation as much as possible. The main cause of the Board
being damaged is static electricity. The static and noise problem is
made worse by the poor grounding found in the control head. To help
solve this problem from now on any Ultimax control you are working on
add a 5umper from the top half to the bottom half of the control head.
This should be done on both sides of the control head. Use 2 small self
tapping screws and a short piece of wire with two eyelets on the ends to
insure the halves are conducting. Then run a wire to the main grounding
post on the left hand side of the console.
REVISED BY:
DATE: 11/9/89
ISSUE NUMBER: 1144
SUBJECT: Gib Adjustment
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20,30,40,50 V2 machine
PAGE 1 OF 1
In writing the BMC V2 Install Sheet I used the Engineering
Document to find the information about adjusting the Gibs. Since that
time I have found the current setting in the Engineering Document was
wrong. and all the machines that have gone out have been adjusted to the
wrong values. From this time on any time you are working on a BMC V2
machine adjust the Gibs for a current draw of 2 to 3 amperes on the BMC
20 and 30, and 3 to 4 amperes on the BMC 40 and 50 machines.
REVISED BY:
DATE: 11/10/89
ISSUE NUMBER: 1145
SUBJECT: Replacing Hurco Amps with SERVOMATE
SUPERSEDES NUMBER:
PRODUCT LINE: Kmbx-1 Hmbx
PAGE 1 OF 4
At times we must Replace the Hurco amplifier chassis with SERVOMATE
amplifier chassis. Whether this replacement is done due to the cost
of the replacements or to improve the reliability of the machine. The
following is a guide line we have used to make this replacement.
The part number for the small SERVOMATE chassis is 402-5001-920.
1:
Jog all axis to mid travel.
2:
Power off, Remove the three Hurco amplifiers from the chassis.
3:
Mark the motor leads and remove from TB1.
4:
Mark the J connectors and unplug (P11-Z, P8-Y & P9-X).
(TACH DAC LS + -) example Dwg #1 connection below.
5:
Remove 115 VAC and 60 VAC red vires.
Dwg. #1 Hurco Amplifier J connectors. (P11-Z P8-Y & P9-X)
Pin 1 is at the top with wires exiting to the right.
6:
Unbolt the Hurco amplifier chassis and install the SERVOMATE
chassis. Removing the boards makes this an easier Sob.
7:
On Hurco Chassis get the vires for 115 VAC from T1, 5 6 T1,1; and
the Buss voltage vires from FLB 2 & 4.
Use Large Female spade terminals for (4) #10 awg vires and attach
to the Fault logic board on J5 pins 1 E 2 (AC Servo Buss Voltage).
The red and the white vires go to J4 1 E 2 {115 VAC).
ORIGINATOR: Brock Rexing E Randall Bryant
Replacement of Hurco amplifiers with SERVOMATE.
8: Working with one axis at a time connect the wiring to match the
SERVOMATE TB strip shown in DWG #2.
DWG #2. SERVOMATE Terminal buss.
9:
Add jumpers from TACH – to DAC – (9 to 12 for Z, 17 to 20 for Y,
25 to 28 for X).
Amplifier ad1ustments: Note: Attempt to adjust only one amplifier at a
time. Disconnect the other amplifiers as
they all interact.
1:
Starting with the X axis amplifier follow the standard BX pot
presets.
SIG 20 CW then CCW 5 turns
Aux 20 CCW turns
TACH 20 CW turns
BAL 20 CW then 10 CCW turns
GAIN 20 CW the 5 CCW turns
CLM 20 turns
2:
Verify correct motor lead polarity, power up, load the master.
Push, Power On, Check, Enter and Operate with your hand on the
Estop button in case of axis runaway.
Helpful Hints:
If the axis runs away try reversing the motor leads.
If the axis Oscillates try reversing TACH leads.
All machines may not be wired the same way, so you may have to
find the correct combination of, TACH, DAC, and Motor wires. Note
if the DAC is + the TACH is A – Voltage they oppose each other.
Use and Ohm meter to verify the polarity of the DAC wire to the
servo control board J2-X J3-Y J4-Z pins 8 and 9 of each plug.
3:
Before proceeding with the amplifiers fine tuning, verify that
when the PLUS + LS is displayed on the CRT that the axis will move
in the MINUS – direction. Use a screwdriver to actuate the LS.
Then check the LS for PLUS + movement only when the MINUS – LS is
shown. If this is not correct reverse LS +- at the SERVOMATE RTB.
4:
Proceed with the standard BX SERVOMATE setup procedure, adjust the
gain pot until axis oscillation starts the back off three to five
turns, (use o'scope on the motor vires).
5:
Adjust the SIG pot to measure .65vdc on pins 8 and 9 of SJ2-3-4.
at 25ipm. Note you may have to adjust the TACH pot if you are
are unable to achieve .65vdc with the SIG pot alone.
DATE: 12-01-89
ISSUE NUMBER: 1146A
SUBJECT: Yaskawa Orient Modification
SUPERSEDES NUMBER:1146
PRODUCT LINE: All V2-BMC Mills
PAGE 1 OF 5
In order to better monitor "Orient End" and prevent accidental damage to the machine or injury to the
operator the following modifications should be made.
Modification of the orient card will change the pull-up resistor on the "In Position" signal to a pull-down,
allowing the spindle drive to recognize problems caused by intermittent connections between the orient
sensor and the drive, or displacement of the spindle by the operator.
A spindle axis firmware change is also required to continuously monitor the "Orient End" (ORE) signal.
This firmware will correct the problem in BMC-50's when making a tool change from 600RPM. The
dual winding machines will now orient in both high and low winding, requiring that the orient card setup
be changed.
To prevent the possibility of switching the cables for the spindle encoder (3CN) and the orient amplifier
(5CN), a key will be added to the 5CN connector.
Before starting this modification please verify that the ORIENT CARD has not been modified previously
or is not the new style. See page 4 to determine if new style board.
Parts required to complete this modification:
1 Spindle Axis PROM
450-3001-512
1 Resistor, 30.1K 1/4W 1% 407-0035-430
2" Heatshrink, 1/8"
406-6481-002
1 Contact, Male (Honda)
406-0811-008
Special Tools required:
Honda Pin Extractor
REVISED BY:
Documentation Required:
Spindle Drive Setup
757-4001-093 Rev. C
What to do
1. Power off the machine and remove the Orient PCB from the spindle drive. Cut off R123 (located near
5CN - See drawing Page 5) from the PCB. Install a 30.1K Ohm, 1/4 Watt, 1%, "Metal Film" resistor
to the solder side of the PCB from pin 16 of 5CN to the center pin of S23. Insure the leads are insulated
with 1/8" heatshrink.
2. To distinguish modified boards, change the PCB number and type at
the top of the PCB with a permanent marker as follows.
"TYPE" JPAC-C345 change to JPAC-C345-YA
"CODE NO." ETC008611 change to ETC503070
3. Remove the cover from connector 5CN, extract the female pin 13 (this pin should not have a wire in
it) and replace it with a male pin (406-0811-008). Note that the mating pin on the PCB has already been
cut off by Yaskawa.
4. Replace cover on connector and reinstall orient PCB.
5. Install new spindle axis firmware (450-3001-512).
6. Power on machine and follow the "Orient Setup" in the attached spindle drive setup (757-4001-093
Rev. C).
Note: Check all drive Parameters (CN01 though CN40) to ensure they
are correct. Power the machine off/on after changes have been
made, to reload the Nonvolatile RAM.
7. Cycle the ATC (50 changes minimum) using several tools with the RPM set for both high and low
winding ranges. Ensure that the orient position is correct for both windings.
The new style Orient board looks very similar to the original board. The differences are, the new board
has a shunt just above U38. U38 is in the lower right section of the board. See drawing "B" on page 4 of
5 and there is a resistor in the old R123 location. Also the identification numbers on the board have been
changed. See below.
"TYPE" JAPC-C345 and "CODE" ETC008612
FSB XXX Page 2 of 5
There are some boards that have been modified by the manufacturers. These boards can be identified by
R123 having been removed and by the type and code as listed below.
"TYPE" JAPC-C345YA and "CODE" ETC503080
If you have problems or question please call me. EXT 2640
ORIGINATOR: Dale Clark
REVISED BY: Lonnie Leffew
DATE: MARCH 31,1991
FSB XXX Page 3 of 5
FSB xxxx Page 4 of 5
FSB XXX Page 5 of 5
DATE: 12/12/89
ISSUE NUMBER: 1147
SUBJECT: ATC STRIKER PLATE
HOLD-DOWN SCREWS
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30 V1 ATC
PAGE 1 OF 1
The shock absorbers on the BMC-30 V1 ATC make contact with steel
"striker plates" to avoid direct contact with the soft aluminum casting.
These are currently attached with quantity (4) 102-5003-002 M5 X .8 X 10
which does not provide a sufficient length of thread. In the future
these plates will be attached with quantity (4) 102-5003-004 FHSCS M5 X
.8 X 16. These longer screws can be used for Field Service replacement
and should work even if the first two or three threads are stripped in
the aluminum casting.
ORIGINATOR: RICHARD ARTHUR
TECHNICAL SPECIALIST
REVISED BY:
DATE: 12/11/89
ISSUE NUMBER: 1149
SUBJECT: TOOL CHANGER MAGAZINE
AIR CYLINDER SET SCREW
SUPERCEDES NUMBER 1148
PAGE 1 OF 2
It has come to my attention that we use (3) different set screws on
the BMC 30 tool magazine air cylinders. this is to try and clarify these
different set screws.
P/N8022324006: This 3 inch set screw has a counterbore and 1s used
on any BMC ATC with an 8 inch stroke cylinder, prior to the V2 model
tool changer. The V2 model tool changer will use the part number
80223244 001 three inch set screw.
P/N8022324001: This 4 inch set screw is for Field Service use only
and is used on tool changer with 7 1/2 inch stroke cylinder.
P/N8022324001: This 3 inch set screw is currently used on the BMC 20
tool changer and does not have the counterbore.
I, also am including 1nstructions for adjusting the cushions with
this set screw. I hope this clarifies the confusion, if you have any
questions please contact Technical Support.
ORIGINATOR: RICHARD ARTHUR
REVISED BY:
DATE: 01/18/90
ISSUE NUMBER: 1150
SUBJECT: CONTROL RESIDENT DIAGNOSTICS
SUPERSEDES NUMBER:
PRODUCT LINE: ALL ULTIMAX II MILLS
PAGE 1 OF 2
PURPOSE: The Control Resident Diagnostics Executive vas designed to
execute within the normal operation of the ULTIMAX control.
However, the Control Resident Diagnostics may only be accessed in
mills with ULTIMAX II controls with version 8.00 or greater.
This Field Service Bulletin explains how to use the Control Resident
Diagnostics Executive in all other ULTIMAX II mills.
Supplied with the Control Resident Diagnostics Field Service Kit
(P/N 002-3417-002) are the following items:
l.
2.
3.
4.
5.
6.
7.
8.
9.
10a.
10b.
Control Resident Diagnostics Manual
RS-232 MIL Circle Test Connector
RS-232 DB-25 Test Connector
I/O Test Cable, MP/J1 to MP/J3
Dual Axis Test Cable
25-pin Breakout Board
37-oin Breakout Board
50-pin Breakout Board
BMC 20-50 (VC) Axis Firmware
BMC 20-50 STD/GER Memory Board
BMC 20-50 STD/GER EPROM's
704-0001-545
423-9000-001
423-9000-002
423-9000-003
423-9000-004
415-0196-001T
415-0197-001T
415-0198-001T
450-3001-vvv
415-0168-xxx
450-3002-yyy
through zzz
Note 1: Items 9, 10a, and 10b, Part Numbers are not completely provided
because they will change with each new release of ULTIMAX II Software.
Note 2: Items 10a and 10b can be used in any machine with an Ultimax II
Control, but only to use the Control Resident Diagnostics.
The Control Resident Diagnostics Manual provides instruction using the
Test Connectors, the Test Cables and the Breakout Boards, but assumes that
the control already has the Diagnostics resident in the Executive.
To set up a mill with the Control Resident Diagnostics Executive, power
the mill to off and remove the MM8800C Memory PCB from the card rack. If
the BMC 20-50 Memory Board (item 10a above) is provided, install the BMC
20-50 Memory Board in place of the current Memory Board. If the BMC 20-50
EPROM's (item 10b) are provided, remove the current Memory Board and
replace the V65-V76 EPROM's with the BMC 20-50 EPROM's U65-U76; reinstall
the Memory Board.
CAUTION: Item 10a or 10b nay be installed in any other Ultimax II mill
for the execution of the Control Resident Diagnostics only;
remove the item from the Control when testing is complete.
CONTROL RESIDENT DIAGNOSTICS FIRMWARE SETUP
Within the Interactive Diagnostics of Control Resident Diagnostics are
tests for the Dual Axis Boards and the Display of System Switch Settings;
these tests require the new Axis Firmware. Since only one Firmware EPROM
is provided, only one axis may be tested at any time. Remove the
appropriate Dual Axis Board and replace the current Axis Firmware EPROM
with the BMC 20-50 Axis Firmware EPROM (item 9) using the following Axis
Chart :
ZS DUAL axis PCB
U45
U48
XY DUAL AXIS PCB
Spindle Axis
Z Axis
AB DUAL AXIS PCB
Y Axis
X Axis
B Axis
A Axis
The BMC 20-50 Axis Firmware EPROM may also be used in place of the Spindle
Axis Firmware EPROM.
For the Display of System Switch Settings test, only one axis of the Dual
Axis Board with the BMC 20-50 Axis Firmware EPROM installed will display
the switch settings properly. Switch blocks S2 and S3 of the Dual Axis
Board correlate to the U45 Axis Firmware EPROM while Switch blocks S4 and
S5 correlate to the U48 Firmware EPROM.
Note: When installing the BMC 20-50 Axis Firmware EPROM,
make sure that all of the other current Firmware EPROM's are
installed.
Caution: Item 9 may be installed in any other ULTIMAX II mill type to
execute the Dual Axis Tests only of the Control Resident Diagnostics;
remove the item from the Control when testing is complete.
ORIGINATOR: DAVE SKRZYCZAK
DATE: 1-12-90
ISSUE NUMBER: 1151
SUBJECT: 5 GALLON FLOOD FILTER
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20-50 V2
PAGE 1 OF 1
There have been some instances where the new style 5 gallon flood
filters have caused the system to loose prime. If this occurs it
will be necessary to verify that the filtering element is not
clogged, that the PVC piping within the filter has been glued
together properly, and the lid/fittings are sealed proper. A thin
film of an oil based lubricant around the lid gasket, v111 aid in
prolonging the life of the gasket and improve an air tight seal.
Part no. 617-0008-002 Filter
If the system looses prime and the flood pump is allowed to run for a
long period of time, the shaft seals on this pump may become damaged.
If this happens the motor/pump will need to be replaced.
Part no. 509-0002-001 Motor/pump
If the need arises to replace an older flood motor/pump use
Part no. 002-3915-006 on the parts list doc.
This is a field service replacement KIT for the early OEM system
converting to the current production style.
ORIGINATOR: Brock Rexing
REVISED BY:
DATE: 1-11-90
ISSUE NUMBER: 1152
SUBJECT: REPLACEMENT OF KNEE MILL MOTORS
AND ENCODERS
PRODUCT LINE: KM3/3P
PAGE 1 OF 1
As of Oct. 1988 Electrocraft is supplying Hurco with an MTE ASSY.
incorporatlnq an industrial qrade BEI encoder. To identify this motor,
it has a Blue Label with a part no. 002-2490-005 on it. The encoder
shaft is the coupling, there are no stand offs as the rear cover mounts
directly to the back of the encoder.
While customers are under WARRANTY, and the need arises to replace
either the motor or encoder, use an MTE Assemblie. 002-2490-008 as this is
the ONLY way HURCO can return the parts to Electrocraft per our
warranty agreement with them.
As the machines go out of warranty, and the need arises to replace
only the Industrial BEI encoder use part no. 002-2490-007.
The early style motor used on the KM3/3P, can be identified by a RED
label and used an instrument qrade Litton, Datametrics, or BEI encoder.
And has stand offs for the rear motor cover, a separate coupling, and
a housing mounting bracket to attach the encoder to the motor.
The Part Number for this encoder remains the same 002-2490-002.
Be advised that we have two MTE assemblies in stock, both of which will have
an Industrial grade BEI encoder in the assy.
1.) CUSTOMER REPLACEMENT ONLY* 002-2490-003R
comes with a black pin pusher and a removal / installation procedure.
2.) SERVICE ENGINEER REPLACEMENT 002-2490-008
MTE ASSY as the service engineer has a pin pusher in his tool kit.
DATE: 1/30/90
ISSUE NUMBER: 1153
SUBJECT: CUSTOMER SUPPLY POWER
RELATED PROBLEMS
SUPERSEDES NUMBER:
PAGE 1 OF 1
We have found that many ongoing problems with some mills are
actually related to incoming power problems. These problems may show up
as intermittent servo/spindle faults, computer lockups, and an unusual
number of board failures. In the past we sent a serviceman in with a
Dranetz Line Analyzer which vas installed, then we had to return to
disconnect the device and evaluate the chart.
In the future we will send the customer a Transient Suppression Unit
with the understanding that he may try it for thirty days. If he does
not feel it corrected the situation he may return it for a full refund.
At the time the order is placed we will need a purchase order number. We
do not consider this part of the machine warranty since the customer is
responsible for furnishing acceptable power.
We have two different Transient Eliminates devices, the first is a
three phase unit and will normally be used with bed mills. This devise
should be suggested if besides control lockups and unusual amount of
board failures you also get axis and spindle drive failures. This unit
is designed to protect the entire machine. The other device is a single
phase unit and is used to protect the DC supply, this devise is
suggested if you see constant control lockups or an unusual amount of
PC board failures. this device is suggested for any mill.
If you feel that power protect is advised, please consult with any
Technical Specialist so the machine may be monitored as to the
effectiveness of the devise.
Listed are the Hurco part numbers and a description of each device.
P/N 417-5001-017 Transient Eliminator TE110JR is a single phase 110
device used to protect the DC power supply. This is suggested for all
knee mills and for bed mills that show control problems, but display no
axis or spindle drive problems.
P/N 417-5001-018 Transient Eliminator TE600 is a three phase device
which should only be suggested for bed mills display axis and spindle
drive problems in addition to control problems.
ORIGINATOR: RICHARD E. ARTHUR
DATE: 11 January, 1990
ISSUE NUMBER: 1154
SUBJECT: DAC Offset PCB Failures
SUPERSEDES NUMBER:
PRODUCT LINE: Dual Axis Board with DAC Offset
PCB attached
PAGE 1 OF 1
The Test and Repair department has reported a number of Dual Axis boards
(equipped with the DAC Offset PCB) returned to them as failed boards.
The problem with most was simply that the DAC Offset "Piggyback" board
was loose. The assemblies were repaired by reseating this attached
board. Please be aware of this and check the integrity of the
connection before ordering or replacing this board when a failure is
indicated.
The machines this effects are BMC V2 Mills and all Deckel mills
equipped with Ultimax controls. Also soon, this will include the OEM
and Vl mills that have 8.0 software incorporated.
ORIGINATOR: Paul Chambers
REVISED BY:
DATE: 4/20/90
ISSUE NUMBER: 1155
SUBJECT: COUNTER WEIGHT (UPPER)
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 40 IP
PAGE 1 OF 3
Procedure to add an upper weight to the existing counter weight on BMC 40
IP machines.
Note: All of these machines currently in the field have been flagged and
each customer with a BMC-40-IP will receive this weight over the course
of the next few weeks,
THIS IS THE ONLY PROCEDURE TO FOLLOW AS DEVIATION TO THIS PROCEDURE
MAY CAUSE DAMAGE TO THE MACHINE AND OR PERSONAL INJURY.
All directions are called out as if standing in the front, facing the
Machine, as the operator would.
1. Jog the "Z" axis down to the minus limit switch, place a "steel" bar
into the access hole located on the lower left side of the column,
slowly jog the "Z" axis up until the counter weight will rest on the
bar, see attached DWG, pg. 3.
2. Place support (wood 2X4) between the rear of the counter weight and
the inside of column to support the counter weight from shifting
during the next few steps, see attached DWG, pg. 4.
**NOTE*
At this point make certain that the chains are still taught and the
weight is resting on the bar. If the existing counter weight has an eye
bolt, remove it.
3. Locate and remove the left bolt on the support bracket, {used to
support the counter weight during shipment), pivot this bracket out
of the way and reinstall same bolt using lock-tight 271, see attached
DWG, pg. 4.
4. Remove the other (right) bolt holding the support bracket, discard
bracket and bolt. From this point, remove and discard bolt located
diagonally holding the plate to the counter weight, clean this
surface, see attached DWG, pg. 4.
DATE: 5/24/90
ISSUE NUMBER: 1156
SUBJECT: NEW ISOLATION TRANSFORMER
SUPERSEDES NUMBER:
PAGE 1 OP 3
BED MILLS ARE PRESENTLY BEING BUILT WITH A NEW TRANSFORMER MOUNTED
TO THE CABINETS. SHAPE TRANSFORMER MODEL Z-1321, 413-0003-1071
IS FOR BMC 20 AND MODEL Z-1322, 413-0003-1081 IS FOR BMC 30-50.
SHAPE TRANSFORMER MODEL Z-1332i 413-0003-109i IS FOR ASIAN MACHINES
WITH 380 AND 415VAC TAPS.
REFER TO THE DRAWING NOTES FOR CONNECTIONS USING THE APPROPRIATE
PRIMARY TAPS AND 208VAC SECONDARY TAPS. THE COOLANT PUMP MOTOR
WILL BE CONNECTED TO THE 208VAC TAP.
ORIGINATOR: MATT WARNER
REVISED BY:
DATE: 6/18/90
ISSUE NUMBER: 1157A
SUBJECT: CONSOLE CRT GROUNDING
PRODUCT LINE: BMC20-50, MILLS, FP3A/4A
PAGE 1 OF 1
Effective immediately, modifications to separate the console CRT
grounds from their respective CRT PCB ground are to be discontinued
(refer to original issue of FSB 1577 released 5/25/90).
Separation of these grounds will result in any or all of the
following problems, flyback circuit instability, increased console DC
voltage noise levels, and masking of possible CRT defects caused during
vendor manufacturing processes or through improper shipping and
handling procedures.
The CRT's should be wired as follows.
The ground wire connected at the back of the tube should be
connected to the CRT PCB at J401. The ground wire that connects to the
console door ground stud between the CRT PCB's should be connected to
CRT PCB J104.
All Field Service engineers are requested to report customer
names, machine types, and if possible serial numbers of machines on
which this modification vas implemented. This information must be
given to Hurco Indianapolis, Field Service schedulers.
In addition, on any new machine shipped in April, May, and June
console CRT wiring should be checked to insure that it is wired per the
above instructions.
If you have any questions concerning this bulletin please call the
Field Service Technical Specialists.
ORIGINATOR:
REVISED BY: TOM MURDEN
DATE: 06/01/90
ISSUE NUMBER: 1158
SUBJECT: Measuring Backlash
SUPERSEDES NUMBER:
PAGE 1 OF
In order to establish a common method assuring the axes
backlash the following is set forth as the only service approved
standard for backlash measurement.
Required Equipment:
.0001 inch indicator.
Tool holder for indicator.
A flat surface (i.e. vise).
Definition:
Backlash is the difference in axis travel that occurs when an axis
direction is changed. This is usually do to mechanical looseness in
the axis (i.e. worn thrust bearings or ballscrews).
Remove all backlash strapping from the machine.
It is required that you write a program of position blocks to do the
test. Bring the indicator against the flat surface. Zero the
indicator, then zero the machine reference at this point. Bring the
indicator up from the surface and position the axis .5 inch further
in the same direction. Reverse the travel and bring the axis back to
the machine zero. Lower the indicator. The difference on the
indicator is the backlash. Repeat this process four time and average
the readings. This is the backlash in the axis. Use strapping charts
to adjust the backlash to the new value.
REVISED BY:
DATE: 06/04/90
ISSUE NUMBER: 1159
SUBJECT: Board Cleaning
SUPERSEDES NUMBER:
PAGE 1 OF 2
One of the most important operations in a good preventive maintenance
program is regular and thorough cleaning of the system. In any system
dust builds up. Any smoke or other particulate or chemical matter that
is in the environment is drawn into the system and collects on
everything.
This dust and garbage buildup can cause severe problems in a system if
allowed to go unchecked. The dust layer acts as an insulator to heat,
which prevents proper cooling of the system and may cause a system to
overheat and damage components.
The dust may contain other chemicals. These chemicals can conduct
electricity, causing minor current shorts and electrical signal paths
where they should not be. The chemicals also rapidly accelerate
corrosion on any of the components in the system that are installed in
sockets or where boards plug into slots. Cable connectors also can be
affected by this corrosion. Floppy disk drives are another location
where contamination can cause damage.
To properly clean the system you need several items and tools.
Beyond the tools that are normally required you will need the following.
Freon TF or Isopropyl alcohol.
The cleaning material must be moisture and
residue free. Pure Freon TF is best.
Small brush.
Gold wipes for cleaning the edge connectors.
* Antistatic kit.
* Vacuum cleaner.
* 3.5 inch disk drive "wet" cleaning kit.
Foam swabs
REVISED BY:
Reseating Socketed Chips:
One of the primary preventive maintenance functions is to undo the
effects of "chip creep." As the system heats and cools, it also
expands and contracts. This physical expansion and contraction causes
any components plugged into sockets to gradually work their way out of
those sockets. For this reason, you need to find all the socketed
components in the system and properly reseat them.
Cleaning the Boards:
The next step is to clean the boards and all connectors in the
system. The first thing to do is clean the dust and debris off the board
itself and then clean the edge connectors on the board. To clean the
boards, first use the brush to gently wipe the boards, loosening and
removing any dust and debris. You use the brush because simply blasting
the board with compressed air does not remove all the dirt and dust
There is also the possibility that you could drive the debris under the
components. After you loosen the dirt and dust you can then use the
"vacuum" to remove the debris.
CAUTION: BE Careful OF STATIC WEAR THE STATIC STRAP AND USE ALL STATIC
PRECAUTIONS.
If at this point you still find dirt or debris on the board use the
liquid cleaning solution and swabs to remove it. Then use the "Gold
Wipes" to clean the edge connectors.
Cleaning Connectors and Contacts:
On the backplane you will want to clean the slot connectors. First
vacuum the dirt and debris from the boards or cable. Then use the "Gold
Wipes" or a swab with solution on it, to wipe the connector clean.
Do not use a pink eraser to clean the board connectors as it removes
the gold from the contact and this will then cause the contact to
corrode faster. This in turn causes the contact to need cleaning more
often.
On the cable connectors use "Gold Wipes" where you can, then use the
swabs to clean the other pins and places where the wipes will not reach.
Disk Drives:
Use the brush to clean dust and debris from the drive then use the
wet head cleaner kit to clean the disk heads. Don't forget to clean the
cable plugs on the drives.
Note: The Anti Static Vacuums will come after we have started the
maintenance program, so use the brush to clean the boards.
DATE: 6/04/90
ISSUE NUMBER: 1160
SUBJECT: New Field Service Accuracy Standard
SUPERSEDES NUMBER:
PRODUCT LINE: All Mill
PAGE 1 OF 1
You will soon be receiving a metal bar that has been measured on the
CMM here at Hurco for its length. This dimension will be stamped into
the metal. This standard will allow us to quickly and easily check a
machine for accuracy. The length will be slightly over 13 inches. This
size will allow you the ability to see the Leadscrew compensation in the
older machines and still be small enough for use on the knee mills.
To use the standard first allow it to reach the same temperature as
the machine, this could take up to one hour. Take the time don't hurry!
Place the standard perpendicular to the axis. It must be within .0001"
from end to end. Using your indicator reference the part Zero on the
end that does not have the tab (A). Program the axis to move the
distance marked on the standard. Indicate the inside of the tab (B) the
distance shown moved on the control should be the same as the distance
marked on the standard taking into account the tolerances for the
machine type.
REVISED BY:
DATE: 08/06/90
ISSUE NUMBER: 1161
SUBJECT: Oil Cooler Contactor Mis-wire
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30 Thru 50 IP
PAGE 1 OF 4
We have recently changed from GE to Square D starter and heaters on BMC mills. Two
problems must be corrected.
Problem 1: On all mills with Square D (FCS A OCS) parts prior to August shipment the
115vac control line to the coil is connected at "A1" (white wire) and "96" (Red wire). 7he Red
wire must be moved to "95" To provide over current protection.
To correct first find the cable from TB1-4,8,10 to OCS-1 (L1), 3 (L2),
5 (L3) (on machines with MRP & ARP boards TB 1 - 3,6,8 ) Remove the red
wire at both ends – – insulate and leave in wireway, in case of 3
phase oil cooler replacement in the future. Connect white to OCS-1 (L1),
black to OCS-3 (L2). Add 14 AWG black wire from OCS-5 (L3) to OCS-4 (T2).
Connect cable to chiller, white OCS-2 (T1), black to OCS-6 (T3). Connect
cable to suppressor board as follows, white to OCS-2 (T1), Black to OCS6 (T3), again leave the red wire in wireway. At the suppressor board TB
30-6 remove the red wire, black should be connected at TB 30-9 and white
at TB 30-8.
Originator: Dale Clark
DATE: 13 SEPTEMBER 1990
ISSUE NUMBER: 1162
SUBJECT: TORQUE SETTINGS FOR AXIS BEARINGS
SUPERSEDES NUMBER:
PRODUCT LINE: ALL HURCO MILLS
PAGE 1 OF 1
The following is a listing of all torque settings for axis bearings on
the Hurco Milling machines:
MACHINE TYPE
AXIS
SETTING IN FT / LBS.
KM-1, KMB-1, – 1m,
KM-3/3P, SM1-CNC,
MB-1, BMC-20, MD-1
ALL
45-50
MB-2, MB-3, MD-3,
BMC-10, BMC-30
ALL
65
BMC-15, BMC-40,
BMC-50
ALL
85-90
40 SLV
ALL
55
REVISED BY:
DATE: 13 SEPTEMBER 1990
ISSUE NUMBER: 1163
SUBJECT: TOOL RETENTION FORCES
SUPERSEDES NUMBER:
PRODUCT LINE: BMC MILLS
PAGE 1 OF 2
The following tool retention force specifications have been agreed
to with LEADWELL. This applies to both Hurco Inc. and Hurco Ltd.
MACHINE TYPE
MAXIMUM
MINIMUM
BMC-20
3.91 Kn.
3. 6 Kn.
BMC-25
8.12 Kn.
7.3 Kn.
BMC-30
8.12 Kn.
7.3 Kn.
BMC-40
8. 12 Kn.
7.3 Kn.
BMC-50
13.7 Kn.
12.3 Kn.
Specification may be exceeded slightly but must unclamp at 90 PSI.
Settings must NOT be below minimum.
Use the following formula to convert Kn. to Foot Lbs. 224.754 * Kn. = Ft. Lbs.
REVISED BY:
MEASURING RETENTION FORCE
1. Release the automatic draw in mechanism
2. Insert the DELTA CONTROL measuring system into the spindle by hand and
operate the automatic draw-in mechanism.
3- Read off the draw-in force and record the figure.
4. Grip the DELTA CONTROL measuring system by hand and release the automatic
draw-in mechanism.
5. Repeat the measurement in the 180 degree opposite position.
6. Repeat steps 2 to 5 another 3 times so that an average value can be obtained
and any irregularities in the draw-in mechanism can be discovered.
7. Remove and clean the DELTA CONTROL measuring system after use and place it
in its wooden box.
DATE: 01/09/89
ISSUE NUMBER: 1164
SUBJECT: Service call check list
SUPERSEDES NUMBER:
PRODUCT LINE: All Machines
PAGE 1 OF 3
The following items should be checked on a machine on every
service call whether they relate to the problem you were
called in for or not. By doing these checks you may be able
to save a future service call by spotting a potential
problem.
SOFTWARE
Check to make sure the correct and latest software and
firmware is installed in the machine.
VOLTAGE CHECKS
1) Incoming Power. +/-10%
2) 115U supply voltage. 110-130
3) Power supply voltages
4) Servo Bus supply voltage
5) Spindle and Servo drive voltages (BMC)
On the BMC 20/50 series machines verify that the voltage to
the spindle drive is as close to 200V as possible. Retap the
main input transformer if necessary. Check the servo
transformer for correct output voltage and correct if
necessary.
CONNECTIONS
1) Check cabling to the card rack, relay panels and terminal
strips for tightness.
2) Make sure all relays are properly seated.
3) Check all external wiring for looseness and or damage.
On KM style machines verify that the cable clamps have been
installed.
SETUP PROCEDURES
Go through the complete amplifier setup procedure. Verify
smooth axis operation. Amplifiers which are out of
adjustment can cause positioning and motion error problems.
MECHANICAL
1) Visually inspect the machine for excessive dirt and chip
buildup. If the machine looks unkept and not properly
maintained bring it to the customers attention and document
it on your service report. Instruct the customer \ operator on
critical areas to keep clean if this does not appear to be
being done. (I.e. around limit switches, way covers, tool
changer and ballscrews.)
2) Check all machine covers for damage or binding.
3) Verify all fans are running and check filters to make sure
they are being regularly cleaned and changed.
LUBRICATION
1) Inspect all oiled surfaces for adequate lubrication.
2) Inspect all grease points for new and clean grease.
(especially M1\MB1\MD1)
3) Check lube reservoir level and the type of oil they are
using. Verify oiler and timer operation.
AIR
1) Verify correct air pressure to the machine.
2) Check air lube reservoir for oil.
3) Check water bowl for excessive water in air lines.
All tool changers on Hurco machines almost exclusively use
air pressure for tool changer operation. It is important to
verify that the machine has a large volume of clean dry air
supplied to it. It is the responsibility of the customer to
provide this to the machine. If there is a problem with the
air bring it to the customers attention and document it.
AIR HOSES
Hurco does not recommend the use of air hoses to clean chips
from the machine. High pressure air can lodge chips in areas
of the machine which can cause excessive damage. We can not
stop customers from using them on the machines but we can
recommend alternative methods. (vacuum systems). If you see
situations where operators are blowing chips indiscriminately
explain to them the problems which can arise from such action
and instruct them to blow chips away from areas where the
most damage can be done.
FINAL CHECK
Before turning a machine over to a customer it is important
to verify proper machine operation. The only way to do this
is to program the machine and allow it to run for a while in
automatic mode. A simple program including drill, tap and
mill routines with multiple tools, speeds and feeds will
exercise all axis, the spindle, tool changer and control.
Watch for smooth tool changer operation.
After cycling for a while position the table to machine zero
and verify positioning accuracy with the marker.
SUBJECT: Futaba Pulscale CMK Parameters
PRODUCT LINE: Eltee TRM21/39 EP300CP
PAGE 1 OF 2
Parameter settings for the Futaba CMK DRO in current production.
Default settings
1. Hold down the Xo key, then turn on the power. Ready will appear on
the display. Press Enter and the counter will take three steps to
write-in the default settings. These steps are called Pass-1,
Pass-2, and Pass-3 on the display.
Changing a parameter setting
1. Hold the Unit key and turn power on. The display flashs SP.
Press Xo key and the parameter data is displayed. Depressing the
Xo key switches the display from Parameter #(ie..SP01) to
Parameter Data(00000000).
2. With SP01 displayed depress 2, enter, and Parameter #2 is
displayed.
3. To change data in a parameter, use the 0-9 keys and press Enter.
Note:For SP#1,6,7,37, and 49 select the proper axis before
keying in the data.
4. Data settings for steps 2-3 can be verified with chart on page 2.
5. Turn the power off/on. Parameter change is effective on power up.
REVISED BY: Richard Arthur
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY
THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
2
TRM21
PARAMETERS
00001001 X
00001001 Y
00001001 Z
0.000
TRM39
PARAMETERS
00001001 X
00001001 Y
00001001 Z
0.000
4
0.000
0.000
5
0.000
0.000
+105.0000 X
+100.0000 Y
+160.0000 Z
-105.0000 X
-100.0000 Y
-160.0000 Z
00000000 X
00000000 Y
00000001 Z
00000000
00000000
+148.250 X
+101.600 Y
+108.000 Z
-148.250 X
-101.600 Y
-108.000 Z
00000000 X
00000000 Y
00000001 Z
00000000
00000000
00100000
01111000
01000010 X
00000000 Y
00000000 Z
01001001
00000000
00100000
01111000
01000010 X
00000000 Y
00000000 Z
01001001
00000000
00000000 X
00000000 Y
00000000 Z
00000000 X
00000000 Y
00000000 Z
SP#
1
6
7
30
31
34
35
36
37
38
40
49
PARAMETER
DESCRIPTION
SCALE RESOLUTION
NOTES
00001000=.5um
00001100=10um
00001001= 1um
00001101=25um
00001011= 5um
00001110=50um
REFERENCE POINT
SHIFT
EDGE SENSOR
SHIFT
LOST MOTION
COMPENSATION
+ SOFTWARE
LIMITS
MUST SET FOR EACH AXIS SCALE
- SOFTWARE
LIMITS
SCALE POLARITY
NOTE Z POLARITY
SMOOTHING
PRINTER
INTERFACE
RS-232 BAUD
RS-232C MODE
DIRECTION TO
RETURN POINT
DATA IS SET IN X AXIS
MODE/EDM DISPLAY
POWER LOSS
MEMORY
INCH/MM
OPERATION
00000010= MM ONLY OPERATION
00000000= INCH/MM OPERATION
DATE: March 3, 1992
SUBJECT: Futaba Pulscale CMK Parameters
SUPERSEDES NUMBER:1165 & 1165A
PRODUCT LINE: Eltee TRM21/39 EP300CP
PAGE 1 OF 2
Parameter settings for the Futaba CMK DRO in current production.
Default settings
1. Hold down the Xo key, then turn on the power. Ready will appear on
the display. Press Enter and the counter will take three steps to
write-in the default settings. These steps are called Pass-1,
Pass-2, and Pass-3 on the display.
Changing a parameter setting
1. Hold the Unit key and turn power on. The display flashs SP.
Press Xo key and the parameter data is displayed. Depressing the
Xo key switches the display from Parameter #(ie..SP01) to
Parameter Data(00000000).
2. With SP01 displayed depress 2, enter, and Parameter #2 is
displayed.
3. To change data in a parameter, use the 0-9 keys and press Enter.
Note:For SP#1,6,7,37, and 49 select the proper axis before
keying in the data.
4. Data settings for steps 2-3 can be verified with chart on page 2.
5. Turn the power off/on. Parameter change is effective on power up.
2
TRM21
PARAMETERS
00001001 X
00001001 Y
00001001 Z
0.000
TRM39
PARAMETERS
00001001 X
00001001 Y
00001001 Z
0.000
4
0.000
0.000
5
0.000
0.000
+105.0000 X
+100.0000 Y
+160.0000 Z
-105.0000 X
-100.0000 Y
-160.0000 Z
00000000 X
00000000 Y
00000001 Z
00000000
00000000
+148.250 X
+101.600 Y
+108.000 Z
-148.250 X
-101.600 Y
-108.000 Z
00000000 X
00000000 Y
00000001 Z
00000000
00000000
00100000
01111000
01000010 X
00000000 Y
00000000 Z
01001001
00000000
00100000
01111000
01000010 X
00000000 Y
00000000 Z
01001001
00000000
00000000 X
00000000 Y
00000000 Z
00000000 X
00000000 Y
00000000 Z
SP#
1
6
7
30
31
34
35
36
37
38
40
49
PARAMETER
DESCRIPTION
SCALE RESOLUTION
NOTES
00001000=.5um
00001100=10um
00001001= 1um
00001101=25um
00001011= 5um
00001110=50um
REFERENCE POINT
SHIFT
EDGE SENSOR
SHIFT
LOST MOTION
COMPENSATION
+ SOFTWARE
LIMITS
- SOFTWARE
LIMITS
SCALE POLARITY
NOTE Z POLARITY
SMOOTHING
PRINTER
INTERFACE
RS-232 BAUD
RS-232C MODE
DIRECTION TO
RETURN POINT
DATA IS SET IN X AXIS
MODE/EDM DISPLAY
POWER LOSS
MEMORY
INCH/MM
OPERATION
00000010= MM ONLY OPERATION
00000000= INCH/MM OPERATION
DATE: 06 NOV. 90
ISSUE NUMBER: 1166
SUBJECT: DRAWBAR
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P
PAGE 1 OF 1
Manufacturing discovered that the Drawbar in the KM5P will create
a loud noise and possible failure when in low gear. On two occasions
the tool holder came loose during cutting. The Drawbar was almost to
a complete stop with the spindle in motion when the loud noise was
observed.
The loud noise vas corrected by removing the nylon bushing from the
Drawbar. Topwell uses a nylon bushing on the manual Drawbar;
therefore, the power Drawbar was designed to use a nylon bushing.
Engineering determined that the nylon bushing is not needed; moreover,
Drawbar performance is increased when the nylon bushing is removed.
Machines in the field that shipped prior to 31 0CT. 90 need to have the
nylon bushing removed from the Drawbar.
ORIGINATOR: Gregg A. Wallace
REVISED BY:
DATE: 11/30/90
ISSUE NUMBER: 1167
SUBJECT: AXIS PULLEY LOCKING ELEMENTS
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P
PAGE 1 OF 1
All KM5P machines need to have split locking elements in the axis
pulleys. Some of the early machines were shipped with solid locking
elements which will permit the pulley to slip on the ballscrew. As of
September 28, 1990 all KM5P machines have split locking elements No.
219-0001-027.
Two sets of split locking elements are needed for each of the three
axis pulleys. The X-axis and Y-axis pulleys are easy to service;
although, the head needs to be removed to service the Z-axis pulley.
ORIGINATOR: Gregg Wallace
REVISED BY:
DATE: 12/11/90
ISSUE NUMBER: 1168
SUBJECT: KM5P DRAWBAR
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P
PAGE 1 OF 2
The KM5P drawbars are not piloting into the spindle shaft. The
pilot diameter (.705 inches dia.) on the drawbar is not long
enough which can lead to unthreading of the tool holder.
The pilot diameter has been lengthened from .38 to .51 inches on
PIN No. 11094. This revision effects the next order which will
be seen on September 1991 machines for 5/8-11 threaded drawbars. This
revision will be seen on March 1991 machines for M16x2 threaded drawbars.
Until the new revision is shipped the drawbars will be modified
for correct piloting. The bottom shoulder will be turned back
.05 inches which will change the head length from 6.500 to 6.450
inches (shoulder to shoulder).
The drawbar setup height (distance from the top of the drawbar
spline to the top of the head casting bearing plate) will now be
.95/.90 inches compared to the factory setting of 1.00/.95
inches.
The following machines need to have the drawbars modified:
1.
KT9003090A
2.
KT9005090A
3.
KT9001080A
4.
KT9001100A
5.
KT9002100A
6.
KT9003100A
7.
KT9004100A
8.
KT9005100A
9.
KT9006100A
ORIGINATOR: Gregg A. Wallace
REVISED BY:
DATE: 12/14/90
ISSUE NUMBER: 1169
SUBJECT: NUISANCE V2 ROTARY ERRORS DURING
PARK MACHINE
SUPERSEDES NUMBER:
PRODUCT LINE: V2 BMC20-50 NON MRP/ARP
WITH 4TH AXIS ROTARY OPTIONS
PAGE 1 OF 1
The following applies to all V2 BMC machines with rotary
options which have the rotary interface terminal strip and brake
relay mounted on the DIN rail next to the machine relays.
When a park machine command is executed and 24 VDC switched is
dropped out a rotary clamp/unclamp may occur. This error is
caused by the rotary brake changing state due to the loss of
24VDC switched and software detecting an unclamp state without a
command being given to unclamp.
This error may be a nuisance for some machine operators and
can be eliminated by making a simple wiring change.
Remove the 18 awg blue wire that runs from brake relay
terminal "A" to brake relay terminal "9". Connect an 18 awg blue
wire from brake relay terminal "9" to 24VDC at the TB4 terminal
strip.
This will power the rotary table brake on unswitched 24 VDC
and should eliminate the nuisance unclamp error.
REVISED BY:
DATE: 01/07/91
ISSUE NUMBER: 1170
SUPERSEDES NUMBER:
PRODUCT LINE: 002-2060-001, 002
PAGE 1 OF 1
Effective this month the inverter being used for these retrofit kits
will appear slightly different. We are now receiving two styles of the
inverter, both of which are functionally the same. The difference in the
new style is in how the brake module and resistors connect to the
-inverter. The connection is as shown below:
NOTE: The Buss voltage was measured on P-n on old style drive on the new
is now measured on +,–.
REVISED BY:
DATE: 1-10-91
ISSUE NUMBER:1171
SUBJECT: FAST FILL
SUPERSEDES NUMBER:
PRODUCT LINE: TRM21
PAGE 1 OF 2
It has come to our attention that the fast fill on some recent TRM21'S
has no effect on filling the work tank. Upon further investigation it was
found that a plug, in the plumbing, in the dielectric unit is missing.
All TRM21'S produced after 09/01/90 will need to be check for this
problem. Approx. 12 machines.
To check, pull up the gate in the work tank, turn on the dielectric unit
and open the fill valve completely, press the fast fill button on the power
supply, there should be a noticeable difference in the rate at which the
work tank is filled, if not, proceed with the following steps.
1. Utilizing the following diagram locate the hose from the filter tank to
a 1 1/4" to 3/4" reducing coupling (T). View of the dielectric tank with
the top cover removed on page 2 of this FSB. This nipple is for support
only and should contain a plug. If the plug is not in the nipple order part
number 804-0024-001 and install in place of current nipple. This will
restrict the flow to the 3/8" hose and thus allow the fast fill solenoid to
function properly see page 3 for flow diagram.
2. Check for proper wiring of pump motor, jumper configuration is supplied
on page 2.
REVISED BY:
ISSUE NUMBER: 1172
SUBJECT: Contactor suppression
SUPERSEDES NUMBER:
PRODUCT LINE: KM-5P, BMC
PAGE 1 OF 1
The contactors used in the KM-5P and BMC lines have a build in
suppression circuit for the coil. We have found that this varistor is
marginal at best. The problem has become a major issue on the KM-5P,
causing run away problems in the Z axis WHEN the spindle motor
contactors turn off or on.
Testing done at Hurco shows that the black 238v stranded lead
suppressors carried by stores did the best job of noise suppression.
All new KM-5P's and BMC's will have these suppressors installed across
the coils of all contactors during assembly.
We need to start placing these devices on all KM-5P and BMC machines in
the field. It is critical that we get all the KM-5P's as soon as
possible as this can cause serious damage. The BMC's we can work on as
we come across them. Order some of these suppressors for your kits.
HURCO PART NUMBER – 417-6881-818
ISSUE NUMBER: 1173
SUBJECT: Lead Screw Mapping initialization V8.5
SUPERSEDES NUMBER:
PAGE 1 OF 1
DESCRIPTION: It has been recommended upon upgrading a customer to
version 8.58 Executive software that the CLEAR RAMDISK (NVRAM)
softkey in Interactive Diagnostics be selected to ensure that all
of the battery-backed RAM is in a known state. However, as a
result, the structure size for the Lead Screw Map is also cleared.
Though the new Mapping data can be entered for both the Forward and
Reverse Lead Screw Maps for each axis and the Memory will be
retained, writing the Map to diskette will not record the
information properly (even though no error message is displayed) so
that subsequent readings of the Map from that diskette will corrupt
the battery-backed RAM, including non Lead screw Map data.
SOLUTION: With the version 8.58 Executive, the only way to reinitialize the Lead Screw Map is to load a previous Executive
version's Lead Screw Map, either version 7.24 or 8.88.
For machine's that are only receiving the version 8.58 upgrade and
are not being LASER recertified, simply loading the existing Lead
Screw Map diskette will properly initialize the Lead Screw Map and
load the data properly into the Forward and Reverse Maps. If the
machine does not have a Lead Screw Mapping diskette then selecting
the DUAL AXIS DEFAULTS softkey in Lead Screw Setup will suffice;
no Mapping diskette is to be made unless the machine is Laser
certified.
For machine's that are receiving both the version 8.58 upgrade and
LASER certification, the old Lead Screw Map diskette must be loaded
before beginning the LASER runs but after the battery-backed RAM is
cleared. After loading the original Lead Screw Map data, selection
of the DUAL AXIS DEFAULTS softkey will then overwrite zeros into
the initialized Lead Screw Map. LASER certification can then begin.
The STORE DATA ON DISKETTE softkey will then function properly in
writing the Lead Screw Map data on the diskette.
Always reload the Lead Screw Map from the Lead Screw Mapping
diskette immediately after clearing the battery-backed RAM.
ORIGINATOR: David J. Skrzypczak
REVISED BY:
SUBJECT: Ultimax secret screens
PRODUCT LINE: Ultimax II, 32, 3 Machines
PAGE 1 OF 1
The following is a listing of the secret screens found in the Ultimax II control and the screens they are
reached from. Some machine types and software versions do not have all of these screens. ie: knee
mills and Deckels do not have the mapping screen.
Old
Access
Code
639
488
642
**
527
**
Function/ Description
Machine Configuration Edit
Tool Changer Height, Axis &
Spindle setup
Leadscrew Map setup
8.60T Axis Accel Setup
(Matrix 4 Axis Tune
Diagnostics Max 32/3)
Interactive Diagnostice
8.60T Manual Axis
Initialization
Access Screen
New
Access
Code
Configuration Screen or
(Auxillary Screen Max 32/3)
100
Tool changer diagnostic Screen
Tool change diagnostic Screen
101
102
103
Auxilary Screen
200
300
REVISED BY: Brock Rexing 3/17/93
ISSUE NUMBER: 1175
SUBJECT: BMC SPINDLES
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 – 50
PAGE 1 OF 1
All BMC 20 through 50 spindles now have a Hurco part number. This
includes OEM machines. There is no longer any reason to disassemble
spindles in the field to match pulleys. Spindles and pulleys are
balanced as an assembly and the drawbar is installed and set prior to
being shipped to a customer. By changing pulleys we run the risk of
throwing the new spindle out of balance and possibly shortening its
life span.
Although there are only a few different spindles used in the BMC line,
there are numerous configurations of spindle RPM ranges. To ensure a
correct spindle is ordered for a customer it is important to take this
into account. It may require the measurement of the spindle pulley and
spindle length to select the correct one. Before ordering a spindle,
part numbers should be verified with a Technical Specialist as they have
the necessary information to help select the correct one.
Spindle part numbers called out in manuals should not be assumed to be
correct as they call out a standard number which may or may not match the
actual spindle in the machine. A great deal of effort has gone into
identifying and correcting problems with spindles. By making sure the
correct spindle is ordered the failures seen in the past due to vibration
will be eliminated.
REVISED BY:
DATE: 3-4-91
ISSUE NUMBER:1176
SUBJECT: Connector, card edge 26 pos.
SUPERSEDES NUMBER:
PRODUCT LINE: All Max II controls
PAGE 1 OF 1
Item 406-0803-492 is an "AMP" 499560-5 card edge connector, 26
position that is connected to the CRT controller board. "AMP"
changed their design from a high tension connector to a low tension
connector without informing us. Because of the low tension
connector, the Max II control may appear to be locked-up. If you
have a machine that appears to be locked-up please check for the
low tension "AMP" connector 111109-5 on the CRT controller board
before determining other faults. A new vendor is being sourced but
in the mean time you may order the 406-0803-492 in high tension
form to fix any bad connection problems.
ORIGINATOR: Bill Baitinger
REVISED BY:
ISSUE NUMBER: 1177
SUBJECT: VCM900 Orbiting Unit
SUPERSEDES NUMBER:
PRODUCT LINE: TRM21 EP300CP
PAGE 1 OF 1
In the event you find problems with the, VMC900 Orbiting Unit, that
is loose in one axis or the other, check the following areas:
1.) On the diagram below locate item number 41, these are cone
point set screws (CPSHSS) that hold the leadscrew nut
(item 37) in place. Check for tightness, if loose, remove
and apply LOCTITE 609 and re-install the set screws.
NOTE: The 3R chuck and the orbital unit will need to be removed
to gain access to these screws.
2.) It is also possible that the locknut (item 47) has backed off.
ISSUE NUMBER: 1178A
SUBJECT: VMC 900 Noise Suppression
PRODUCT LINE: TRM21 TRM39 EP300CP
With VMC 900
PAGE 1 OF 1
In an effort to reduce the noise susceptibility throughout the machine
the following modification may need to be performed.
On all machines.
1. Adding four . 022uf Caps ( PART NUMBER ECH009 ) from TB1 pins 3
thru 6 to the ground plane on the circuit board. This can be
accomplished by removing the PCB and soldering the caps from pins
TB1-3 thru TB1-6 on the back side of the PCB. The solder mask
around this connector is the ground plane of the board. This will
need to be checked and verified on every machine as service is
performed.
Verify all connections and screw terminals are securely fastened. Secure
the D04 diodes, CR6-CR8, (FR4D3R), on the Power Distribution PCB. If
diodes are loose, remove nut, apply LOCTITE 242 to thread and reinstall.
Verify FSB 1193 has been performed to machine.
Optional VMC900 only
2. For machines that have the Optional VMC900 Control, and are
experiencing noise related problems such as, the Z axis position
on the Futaba DRO and Z axis position on the VMC do not
correspond to the same value, or the machine is experiencing
communication errors, i.e.. ERROR 15. Order and install a new
cable assy ( PART NUMBER 423-0311-002 ) . This new cable is a
field service replacement part. It is only 60 inches long and
utilizes improved shielding properties. When installing cable,
ensure to route it away from the Gap Power leads on side panel.
3. If after installing new cable, the machine is still experiencing
similar problems as described above, perform the following
modification to the System PCB. Install a .01 Uf 100V ceramic
capacitor on pin 49 (U18 68180) to DC common
SUBJECT: Isolation Transformer
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P
PAGE 1 OF 3
There have been two transformers used on the KM5P's. The original
was part number 413-0003-105. This transformer supplied spindle
motor power from taps on the secondary windings. This was soon
discovered to cause the secondary voltage to sag approximately
50VAC. The cure was to change the transformer to another style.
This new transformer is auto wound on its primary windings. This
gives a constant 220VAC for the spindle motor. The part number is
413-0003-115.
All machines shipped should have the 413-0003-115 transformer. If
you are on a service call on a KM5P, please check the transformer
part number. If it is incorrect, you will need to do one of two
things. First determine their incoming power. If incoming power is
220/230VAC, then rewire so that the spindle is powered from line
voltage. If the customer's power is some other voltage level, i.e.
208 or 460 VAC, order the correct transformer and replace it.
Please take a look at the attached drawings. They show the
transformers in question. Drawing number 002-4022-001 REV A is the
control voltage schematic using the 413-0003-105 transformer. (NOTE
this drawing is currently in the KM5P manual). This drawing shows
one set of secondary leads from T1. When in reality there are two
different voltage outputs, 200VAC and 220VAC. Drawing number 4130003-105 shows how the unit is wound. It also gives the connections
for the different inputs voltages possible.
For the correct information, use drawings 002-4022-001 REV B and
413-0003-115. The control voltage schematic shows the correct
wiring. The terminal connections are also given. The spindle is
powered from 220VAC and the rest of the machine is powered from
230VAC. Drawing 413-0003-115 shows how it is wound. The motor power
is derived from taps on the primary side of the unit. If you
suspect a bad transformer, please consult the wiring diagram while
checking the resistance of the windings. A low resistance between
the non isolated secondary and the primary is to be expected.
REVISED BY:
ISSUE NUMBER: 1180
SUBJECT: Unclamp Switch
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 25 & 30K
PAGE 1 OF 1
As most of you know we have a new style tool changer on the BMC
25 and 30K lines. This new tool changer uses a plastic tool
finger. On occasion these have been known to break if the tool
should stick in the spindle taper. As part of the solution to
this problem engineering has created a three stage unclamp
cylinder. This will knock the tool free of the taper.
This revised set up procedure is a further precaution against
breakage. To perform this set up you will need a shell end mill
or similar large tool Insure that all cutters have been removed
from the tool before you start. You will also need a piece of
wood sturdy enough to support the head. (A 4" square block
should do).
Start by gaining access to the unclamp cylinder. Insert tool in
to spindle then jog head down until tool rests on the wood
block. You will have some pressure on the wood but do not let
motion error activate. Then in ATC DIAGNOSTICS command the
spindle to unclamp. This should simulate a stuck tool
condition. If the unclamp cylinder lifts the head reduce the
air pressure until it no longer lifts the head. You may have to
bypass the air pressure switch to allow the servos to remain on.
Once the machine is in a stuck tool condition set the unclamp
switch so that it is on the edge of closing.
Test the unclamp switch adjustment several times to insure that
the switch does not close if tool is stuck. You can do this by
commanding clamp and unclamp from ATC DIAGNOSTICS screen while
monitoring the switch. When you are satisfied that adjustments
are correct, return Machine to its normal operating condition.
Be certain that the air pressure switch and regulator are set
correctly.
Ken Borgmeyer
REVISED BY:
DATE: MAY 16, 1991
ISSUE NUMBER: 1181
SUBJECT: RS232
SUPERSEDES NUMBER:
PRODUCT LINE: ALL
PAGE 1 OF 1
We have had several reports of RS232 cables having been plugged in the
wrong direction.
Gentlemen when HURCO ships a new machine the cables are disconnected from
the printed circuit boards. This is done to prevent any undo strain on
the boards during shipment to their new homes. When you are doing the
install please insure that all connectors are plugged in correctly. Most
are "D" style connectors and can not be installed backwards. This is not
the case on the graphics and text CRT connectors nor the RS232 connector.
The two CRT connectors will be obvious if they are wrong. You get blank
displays. The RS232 will not function if in backwards. You will not
know this until some one needs to use the communication feature.
When you install a machine or are in on a service call please check to
see if the RS232 is correct. If you examine the connector you will see
an arrow on the pin 1 end of the plug and on the jack. These arrows will
need to be aligned. This should help prevent problems if the customer
decides to use his serial ports at a later date.
DATE: JUNE 6, 1991
ISSUE NUMBER: 1182
SUBJECT: AXIS MISWIRE
SUPERSEDES NUMBER:
PRODUCT LINE: KM3/P
PAGE 1 OF 2
A wiring mistake has been found on some of the machines made in the first half of this year.
Please note not all machines have this problem, but the number that do is not known. If you have a
machine that is miscounting over a long run of parts and it was made this year then this is more
than likely what's wrong. In other cases check wile you are in the shop to ensure the wiring is
correct.
What happened was the shielding was not terminated correctly.
Note: this only applies to the machine with the new max 400 amplifiers.
Please check and or do the following as needed:
1: At the amplifier (all three)
a:
At P1-1 (VCS+) The shield wire was hooked to P1-1, Disconnect the
shield at this end and shorten and dress the cable.
b:
P3-1 (TG-)
P3-2 (TG+) tachometer,
P3-4 (MT-)
P3-5 (MT+) Motor,
Strip the cable jackets and solder the shield drain wire from both cables to an
white wire. Connect the new drain wire to P3-3 (com).
18 ga
REVISED BY:
2:
At TB6:
a: Remove the GRN/YEL wires. that go to TB7 as shown.
TB6-1 to TB7-7
TB6-13 to TB7-6
TB6-26 to TB7-5
b: Add gray 14ga wires as shown.
TB6-1 to TB4-34
TB6-13 to TB4-35
TB6-25 to TB4-36
c: Add two Wago jumpers to TB4-34-35-36 (part number 406-4006-003)
FSB1182 page 2 o
DATE: JUNE 13, 1991
SUBJECT: MACHINE CONFIGURATION PROBLEMS
PRODUCT LINE: BMC 20-50 WITH 8.5 OR LATER
ISSUE NUMBER: 1183
SUPERSEDES NUMBER:
PAGE 1 OF 1
It has been found in manufacturing that if power is applied to
the machine with the J1 connector for the personality board
disconnected, the control will re-configure itself incorrectly.
On power-up the control looks to the switch settings on the CRP
board for verification of some of the parameters it has stored
in memory. If it does not see these switches, ie. the cable to
the CRP board is disconnected, it will configure the machine for
just about any possible combination of machine options. In most
cases when the cable is re-connected the control will NOT return
to the correct configuration.
To stop this from happening always make sure the cable from J1
on the personality board to J2 on the CRP board is connected
prior to applying power to the machine. If it is necessary to
disconnect this cable for trouble shooting purposes make sure
you check the machine for correct configuration after
reconnecting.
REVISED BY:
DATE: June 23, 1993
SUBJECT: CRT Controller PCB 2
PRODUCT LINE:
PAGE 1 OF 1
The CRT Controller PCB 1 (415-0174-001) when failing, is being replaced with the CRT Controller PCB 2
(415-0174-002). All connectors will correspond the same, except for the power supply "J4".
You will also need to order this 6 Position Wago Plug PN 406-4005-061.
To install:
1.) Cut the AMP female plug from the power supply harness.
2.) Strip 1/4" from each of the six wires.
3.) Insert the wires into the Wago terminal , as follows:
PIN
WIRE COLOR
SIGNAL
1
2
3
4
5
6
Gray
Yellow
Blue
Brown
Orange
Gray
GND
+5V
RST
+12V
-12V
GND
Note: below is the jumper configuration. bold is standard configuration. EXAMPLE To go to "Local
Mode" remove jumper 1-2 on X1B jumper.
Mode
X1B jumper
Line
Local
1-2
1-*
Mode
X1A jumper
60Hz
50Hz
1-2
1-*
ORIGINATOR: Fred Gross
DATE: July 18, 1991
ISSUE NUMBER: 1185
SUBJECT: Max 400 Servo Amp
SUPERSEDES NUMBER:
PRODUCT LINE: KM3/P & Rebuilt machines
PAGE 1 OF 2
All amps in the field, including all KM3/P machines shipped
between 12/90 thru 6/91 and also several of the rebuilt machines
should be checked for this modification when making a service
call.
The mod is to remove C12 and C13 from the Power Amp PCB to
correct a problem with output FETs ringing thus resulting in the
amp blowing.
All drives in machines shipped from July '91 have the lastest
changes.
Note that the current output signal (MCO) that is used to
display the axis load bar on the CRT is not scaled properly.
This problem is being investigated and will be corrected once a
resolution has been found.
REVISED BY: Matt Warner
FSB 1185 PAGE 2 of 2
DATE: July 29, 1991
ISSUE NUMBER: 1186
SUBJECT: Lead Screw Map Initialization, v8.51
SUPERSEDES NUMBER:
DESCRIPTION:
PAGE 1 OF 1
A modification was made to the lead screw map
structure in version 8.51. This change altered
the lead screw map structure stored in memory.
An upgrade to v8.51, therefore invalidates the
v8.50 or earlier lead screw map stored in memory.
The maximum axis travel supported by the lead
screw map follow:
X = 54"
Y = 30"
Z = 28"
NOTE - AXIS TRAVEL SHOULD NOT EXCEED THE LEAD
SCREW MAP LIMITS.
SOLUTION:
- Verify that you have a valid lead screw map on
diskette. Compare the lead screw map with a
hard copy printout. If one is not available
make one from the current lead screw map
residing on the machine.
- Load lead screw map from disk, if it loads ok
then you have a valid disk. Verify that the
loaded map matches the printout made earlier.
If the lead screw map does not load, then you
will have to enter map manually after upgrade.
- Install version 8.51.
- If this is a new memory board then CLEAR RAM
DISK
- Load map from disk if valid or enter it
manually. Verify that the loaded map matches
printout.
- Write lead screw file onto disk and update
label with date, "V8.51", and name of person.
ORIGINATOR: Mark L. Kolp
REVISED BY:
DATE: JULY 26 1991
ISSUE NUMBER: 1187
SUBJECT: Chain Roller
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 to 50
PAGE 1 OF 2
Gentlemen,
I have received several questions and suggestions dealing with
chain roller failures. We have found a problem with some of the
shafts used on BMC machines. These shafts have been determined
to be "soft". They should be hardened to a ROCKWELL C 50 - 55.
If you experience a failure of these shafts you should replace
all four shafts and the needle bearings. Also check for damage
to the chain rollers. Replace them if necessary. Part numbers
can be found in the manuals. If not, then call service.
I have received several suggestions to add a grease fitting to
the chain roller shafts. Although engineering feels that it is
not necessary, we can add grease fittings if the customer wants
them. Please follow the instructions on the drawing below.
REVISED BY:
DATE: July 30, 1991
ISSUE NUMBER: 1188
SUBJECT: Parametrics Digital Reversing Card
SUPERSEDES NUMBER:
PRODUCT LINE: All with parametrics
PAGE 1 OF 1
We are currently using a new style digital reversing card in the
parajust drives as the original style is no longer available.
There has been some confusion on the proper installation of
these new style boards. To help clarify this situation please
refer to the following when replacing this card.
1.
2.
3.
4.
5.
6.
Remove jumper between terminal 4 and 5 of TB-6.
Remove white jumper on terminal 3 of TB-6.
Adjust potientiometer R4 to full CW position.
Connect reversing wire to terminal 2 of TB-6.
If spindle runs backwards swap two motor output wires.
Program several tap cycles and verify proper operation.
This will help clarify proper installation of the digital
reversing card. Please note the following part numbers
for reference:
402-6002-006
402-6005-006
Parajust "A"
Parajust "B"
(5 HP)
(7.5/10 HP)
ORIGINATOR: Mark G. Bullington
REVISED BY:
DATE: May 18, 1993
ISSUE NUMBER: 1189A
SUBJECT: Z AXIS CRT ASSEMBLY
SUPERSEDES NUMBER: FSB 1189
PRODUCT LINE: ALL MAX 2 CONTROLS
PAGE 1 OF 2
TIN 1007
Hurco now uses a new supplier for the 12 inch CRT's used in the Max 1 and 2 controls. The CRT's can be
identified by a large rear panel, this will accommodate the Z Axis assembly. The part number for this larger rear
CRT panel is 002-3994-004, and must be used with the Display Technology CRT's as well as the Z Axis CRT's.
The part numbers for the Z Axis CRT's are as follows.
TEXT CRT
GRAPHICS CRT
425 0001 013
425 0001 014
If the control has Z Axis CRT's they may be adjusted using the following procedure.
R-101
Contrast.
R-304
Vert. Size-
Adjust the display open and close vertically.
R-307
Vert. Sizes-
Adjust vertical size of the characters at top and bottom of the display.
R-401
Horz. Width-
Adjust the width of Horizontal position. This is a coil not a pot.
R-406
Horz. Cent-
Adjust the horizontal position of the display. This is fine adj.
R-410
Horz. Freq-
Adjust the horizontal position of the display. This is the coarse
adjustment.
R-421
Focus-
Focus adjust.
R-425
Bright-
Adjust the brightness.
ORIGINATOR: Richard Arthur
The only other difference is the Z Axis CRT has it's ribbon cable soldered on the PC board using the
existing cable. Route the wires from the top of the board, through the holes and solder at the bottom.
The following is the wire color code for the Z Axis CRT.
1) Red
2) n/c
3) n/c
4) n/c
5) Yellow
6) Violet
7) Brown and Orange (2 wires)
8) Green
9) White
10) Gray
Remove the black and blue wires and attach them to the center stud as ground wires. The ribbon
cable is attached to the PC board with a tie wrap, using the two holes at right side of the board.
CRT
DATE: June 22, 1993
ISSUE NUMBER: 1189B
SUBJECT: Z AXIS CRT ASSEMBLY
SUPERSEDES NUMBER: FSB 1189A
TIN 1007
PRODUCT LINE: ALL MAX 2 CONTROLS
PAGE 1 OF 2
The Max 1 & 2 Text and Graphics CRT's are now shipping with a 10 Pos Header Socket (P3) on the circuit
PCB. In the past Customers and Field Service were instructed to cut the exsisting 10 Pin Plug from the ribbon
cable and solder the wires direct to the CRT. This is no longer in effect with the new CRT's.
If a Z-Axis CRT fails, and the wires were soldered to the PCB, you will need to order the customer a ribbon
cable along with a replacement CRT. This allows for a relative simple removal and installation process in the
future.
423-6141-001
423-6139-002
425 0001 013
425 0001 014
Note:
Ribbon cable Assy, Text CRT to CRT Cnt'l PCB
Ribbon Cable Assy, Graphics CRT to FPCC PCB
Text CRT
Graphics CRT
If replacing an orginal Elston CRT, you will need to order the Back Plate Mounting Assy Kit to
accomodate the Z-Axis CRT into the console. Part Number 002-3994-004,
The Z-Axis CRT's may be adjusted using the following procedure and diagram on the following page.
R-101
Contrast.
R-304
Vert. Size-
R-307
Vert. Lines-
L-401
Horz. Width-
R-406
Horz. Phase-
Adjust the horizontal position fine adj.
R-410
Horz. Freq.-
Adjust the horizontal position coarse adjustment.
R-421
Focus-
Focus adjust.
R-425
Bright-
R406
R421
P4
R410
R307
R304
F101
L401
P2
R425
1
P3
R101
** NOTE PIN #1
NOTE: The Brown wire on the Ribbon cable is oriented to Pin 1 (J3).
WARNING
Ensure Proper Connection and Orientation of Ribbon Cables. Damage may occur if cables
are not plugged in properly!
NOTE: Before turning on Power, check the other end of the Ribbon Cable, to ensure
proper orientation, Brown to Pin 1.
Text CRT J3 to CRT Controller PCB P1. Brown to Pin 1 each end. !
Graphics CRT J3 to Front Panel Cable Connect (FPCC) PCB P55. Brown to Pin 1 each end !
FSB 1189-B Page 2 of 2
ISSUE NUMBER: 1189C
SUBJECT: Z Axis CRT Assembly
SUPERSEDES NUMBER:1189B/A
&TIN 1007
PAGE 1 OF 3
PRODUCT LINE: All Max 2 controls
The Max 1 & 2 Text and Graphics CRT's are now shipping with a 10 Pos Header Socket (P3) on the circuit
PCB. In the past Customers and Field Service were instructed to cut the exsisting 10 Pin Plug from the ribbon
cable and solder the wires direct to the CRT. This is no longer in effect with the new CRT's.
If a Z-Axis CRT fails, and the wires were soldered to the PCB, you will need to order the customer a ribbon
cable along with a replacement CRT. This allows for a relative simple removal and installation process in the
future.
423-6141-001
423-6139-002
425 0001 013
425 0001 014
Note:
Ribbon cable Assy, Text CRT to CRT Cnt'l PCB
Ribbon Cable Assy, Graphics CRT to FPCC PCB
Text CRT
Graphics CRT
If replacing an orginal Elston CRT, you will need to order the Back Plate Mounting Assy Kit to
accomodate the Z-Axis CRT into the console. Part Number 002-3994-004, this kit now contains
ground wire to be added per print on page 3 of this FSB.
The Z-Axis CRT's may be adjusted using the following procedure and diagram on the following page.
R-101
Contrast.
R-304
Vert. Size-
R-307
Vert. Lines-
L-401
Horz. Width-
R-406
Horz. Phase-
Adjust the horizontal position fine adj.
R-410
Horz. Freq.-
Adjust the horizontal position coarse adjustment.
R-421
Focus-
Focus adjust.
R-425
Bright-
R406
R421
P4
R410
R307
R304
F101
L401
P2
R425
1
P3
R101
** NOTE PIN #1
NOTE: The Brown wire on the Ribbon cable is oriented to Pin 1 (J3).
WARNING
Ensure Proper Connection and Orientation of Ribbon Cables. Damage may occur if cables
are not plugged in properly!
NOTE: Before turning on Power, check the other end of the Ribbon Cable, to ensure
proper orientation, Brown to Pin 1.
Text CRT J3 to CRT Controller PCB P1. Brown to Pin 1 each end. !
Graphics CRT J3 to Front Panel Cable Connect (FPCC) PCB P55. Brown to Pin 1 each end !
SIZE
C
DRAWING
002-3822-051
SHT.
1
OF
REV.
1
UPPER HALF
CONSOLE
REAR PANEL
BLACK
Add Wire's
TO POWER CABINET
LOWER HALF
CONSOLE
(SINGLE POINT)
BLACK
NOTES:
1. ALL CHASSIS GROUND CONNECTIONS ARE GREEN/YELLOW WIRE EXCEPT WHERE NOTED.
2. CHASSIS GROUND CONNECTIONS APPLY TO THE FOLLOWING ASSEMBLIES:
a. 002-3994-004
b. 002-3301-012
c. 002-3301-011
d. 002-3301-010
e. 002-3301-009
MACHINE CONTROL PCB
PROGRAM ENTRY PCB
SURFACE TREATMENT
~
~
HEAT TREATMENT
FIRST USED ON
CN
7103
A
12836
REV
P.I.N.
NO.
EXCEPT AS NOTED:
ALL DIMENSIONS
HURCO
IN INCHES
TOLERANCE
DECIMAL
.0
±.0300
.00 ±.0150
DESCRIPTION
.000 ±.0050
.0000 ±.0005
ANGULAR ± 0ANGULAR °30'
DRAWN
BREAK ALL
SHARP EDGES
SCALE
THIRD ANGLE
PROJECTION
SCHEMATIC, MAX 2 CONSOLE GROUNDING
FWG
NONE
RELEASE
BY
BY
BY
MAX 2
R
UNIT OF MEAS.
PC
DATE
CHECKED
DATE
APPROVED
DATE
21SEP93
SIZE
C
DRAWING
SHT.
1
002-3822-051
OF
1
REV.
ISSUE NUMBER: 1190
SUBJECT: Knee mill pulley clutch shaft retrofit kit
SUPERSEDES NUMBER:
PRODUCT LINE: Knee mills
PAGE 1 OF 1
There are two styles of "timing belts" used in the head of knee
mills. The old style belt has square groove teeth and the latest
style belt is an HTD style (small round teeth). Because of the
difference in belts, the pulley clutch shaft and timing pulley
also have to match the tooth style. Since the only style pulley
clutch shaft we can get is the HTD style, I have come up with a
retrofit kit to convert the square groove machines to HTD (high
torque drive). We will continue to sell square groove belts and
square groove pulleys separately if a customer wants them but,
we can not supply the square groove pulley clutch shaft # 7130016-042.
If you are trying to order a 713-0016-042 pulley clutch shaft
(square groove) a cross reference will tell you to order 0022542-001 ass'y K-mill timing belt retrofit kit. This kit
contains the following
713-0016-145 Pulley clutch shaft
713-0016-146 Timing belt pulley
713-0016-147 Timing belt
HTD
HTD
HTD
FYI: The HTD (high torque drive) belt is a positive drive belt
with better power transmission characteristics and longer life.
That is the reason our supplier only makes the HTD style now.
ORIGINATOR: Bill Baitinger
REVISED BY:
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTIONDISCLOUSURE
OR
OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO
ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
ISSUE NUMBER: 1191
SUBJECT: Push Stud
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 to 50
PAGE 1 OF 1
Gentlemen:
Recently we have had several cases where the Push Stud and Lock
Nut have come loose during operation of the spindle. When this
happens the stud will work its way down against the top of the
spindle and weld itself to the spindle. This then necessitates
changing the draw bar and occasionally the spindle cartridge.
Please locktite the pushstud into knock out cylindar shaft and
locktite the locknut to the pushstud any time you are working on
the head or doing an install of a machine. Record this in your
service report
REVISED BY:
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO
ISSUE NUMBER: 1192
SUBJECT: Transformer fuses
SUPERSEDES NUMBER:
PRODUCT LINE: As noted in text
PAGE 1 OF 1
The Shape Electronics transformer, Z1301, p/n 413-0003-104 has
three fuses on the output side. There have been reports of
intermittent losses of power due to poor contact between the
fuse and the contact point at the bottom of the fuse holder.
Manufacturing is removing the springs and stretching them in
order to increase the life of a good contact. It is recommended
that the same be done on the machines with this type of
transformer. Engineering will pursue a correction with the
vendor.
This unit is found in:
CNC cabinets with MRP & ARP boards
BMC/MAX 3 CNC cabinets
BMC 40SX Prototype
BMC 40SLV Power cabinets
KM5P CNC cabinets
MB-2 Rebuilds
MB-1S to MD-1 Reworks
MB-1 Rework
ORIGINATOR: Matt Warner
REVISED BY:
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOUSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO
DATE: March 6, 1992
SUBJECT: Modification to Voltage Divider PCB E2104016
PRODUCT LINE: TRM21 TRM39 EP300CP EDM
PAGE 1 OF 2
The following inspection and modifications to the Voltage Divider PCB
(E2104016) is to completed on ALL TRM21 / TRM39 EP300CP EDM machines with
serial number prefix of PC or PE.
This modification shall be preformed on the EDM machines as service is
required.
Refer to page 2 for the artwork layout of pcb.
Add 2 links ( jumpers ) to either the front or back side of PCB as shown
on page 2.
REVISED BY:
ISSUE NUMBER: 1194
SUBJECT: Transformer Cover
SUPERSEDES NUMBER:
PRODUCT LINE: SLV 40
PAGE 1 OF 1
Recently a potential problem was discovered with the cover plate
used on the SLV 40 transformer. There is a notch cut into the
cover to allow the power cord to pass. This notch needs to be
widened to approximately 2" for good clearance.
At your first opportunity please correct this on the SLV40's in
your area. Inspect the wiring for damage, and take corrective
action as needed. As always please note the work done on a
service report. This will be done on all machines under
construction at HURCO MFG.
REVISED BY:
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOUSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO
ISSUE NUMBER: 1195
SUBJECT: Lube Modification
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P
PAGE 1 OF 1
The checking function of the meter units to the head assembly is
not working properly. Therefore, it will be necessary to install
an additional check valve to the line that feeds the head. Remove
the line from the three port junction, at the left side of the
machine base, that goes into the base to the head area. A
compression nut and sleeve will be required in order to make the
connection to the check valve.
It has also been found that an excess of lube from the Z ballsleeve
for the shift lever will wash the grease from the spindle bearings.
It has been decided to remove the ballsleeve lube line from the
five port manifold in the head and plug it. This plug has a
standard thread that should thread into the manifold. The correct
plug is metric and more costly. Use it if the stock on the other
is depleted.
Parts list:
502-0130-006
713-0020-097
713-0020-098
506-3023-005
713-0021-323
check valve
compression nut
compression sleeve
closure plug
closure plug (metric)
ORIGINATOR: Matt Warner
REVISED BY:
DATE: June 9 1992
ISSUE NUMBER: 1196
SUBJECT: TYPE 1 ATC OVER SHOOT FIX
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 25 TO 30 and SLV 40
PAGE 1 OF 1
Some HURCO machines have experienced an overshoot problem on the
magazine rotation on TYPE 1 ATC's. The Type 1 ATC has plastic
fingers and no vertical movement of magazine. Engineering has a
solution for this problem.
The solution to this problem is as follows;
1.
Install new motor to new bracket with (2) M5 x 45 SHCS, (2) M5
nuts, and lock washers.
2.
Mount motor and bracket assembly to plate and Geneva drive
using existing hardware and coupling. Use new drive key
supplied with motor.
3.
Replace
4.
Remove brake pack and cover socket with label.
5.
Connect motor white wire to white wire of supply. This is
common lead. Connect motor red wire to red wire of supply.
Connect motor black wire to black wire of supply.
If magazine runs backwards reverse red and black wires.
12 mfd capacitor with 7.5 mfd cap.
6.
Make a note on their ATC Relay PCB V2 Schematic of the changes.
Include capacitor value, brake pack removal, and motor wire
colors.
Part Number of Retrofit Kit
002-4107-003
Part numbers (listed for reference only).
ATC gear motor
401-3002-002
Bracket for new motor
802-2602-023
Capacitor 7.5 MFD
401-3002-003
REVISED BY:
Label No brake Pack required
703-1005-379
FSB XXX Page 2 of 3
DATE: June 23, 1992
ISSUE NUMBER: 1197
SUBJECT: Counterweight Noise
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 20 to 50, SLV40
PAGE 1 OF 2
On occasion a HURCO machining center counterweight will "BANG" against the column as the head
travels. This is caused by the counterweight not hanging parallel to the column walls and as the head
moves the weight will start swinging. To solve this problem you will need to determine which way
the weight is out of parallel with the column; either left to right, front to back, or possibly both.
Follow the appropriate instructions below.
LEFT to RIGHT.
With the weight out left to right the preferred solution is to adjust the length of the chains to bring it
square to column. This can be done with the "adjusting bolt" which attaches the chain to the top of
the head. You must have as much of the adjusting bolt threaded into the head casting as possible. If
this does not allow enough adjustment bring it as close as possible, and test the machine to see if a
problem still exists. If it does, then follow the "rail mod" instructions on page two.
FRONT to BACK.
If the counterweight is out front to back, determine if it is hitting at the front or the back of column.
If it hits at the front of the column then change the rear chain roller sprocket to the next larger
diameter sprocket. This will move the counterweight assembly about one quarter inch to the rear.
If the weight is hitting at the rear of the column then follow the "rail mod" instructions on page two.
REVISED BY:
RAIL MODIFICATIONS
After you have determined where the counterweight is hitting and the instructions given above do not
cure the problem, then fabricate guide rails for the counter weight.
First measure the inside height of the column. You will need two pieces (per side that needs the
guides) of flat bar stock of this length. This stock needs to be thick enough to prevent the
counterweight from swinging but not cause it to bind up. This stock is normally .25" - .375" thick
and 1.5" or more wide. You will also need a 2" long piece of the same material per rail to attach
these rails to the top of the column. Drill and tap two holes in one end of each rail. Drill two holes in
the small pieces to attach them to the long rails. These pieces are attached at 90 degrees. Also drill
two holes in the small pieces to attach the assembly to the top of the column. Don't forget to drill and
tap the column top also. Insert the assemblies between the weight and the side of the column and bolt
them in place. The rails need to be placed so that they guide the counterweight and prevent it from
banging into the column or rails. Test the changes thoroughly.
As with any work done on the machines include the information in the service report.
FSB 1197 Page 2 of 2
DATE: July 27, 1992
ISSUE NUMBER: 1198
SUBJECT: Ultimax 3 DC Power Supply
SUPERSEDES NUMBER:
PRODUCT LINE: BMC20-50
PAGE 1 OF 1
Starting in August, the Deltron power supply (413-0008-013), used in all Ultimax 3 machines, will have
a Wago connector in place of the screw terminals for the DC outputs. This version of the supply will be
Rev. "C".
When replacement of a Rev. "A" or "B" supply must be made using a Rev. "C" supply, the mating Wago
connector will be required to modify the harness in that machine. Assembly 002-4107-004 has been
created for Field use, this kit contains the power supply 413-0008-013 and one 12 position Wago
connector 406-4005-067. Please see drawing 423-6807-003 page 2 for pin out information.
ORIGINATOR: Dale Clark
REVISED BY:
DATE: July 21, 1993
ISSUE NUMBER: 1199
SUBJECT: CRP3 PCB Modification
SUPERSEDES NUMBER:
PAGE 1 OF 1
On February 22, 1993 Manufacturing Notice 3788 reworked the CRP3 relay boards to revision E.
This modification tied pin 1 of M2, M4, and M6 to 24 VDC return on pin 19 of M2, M4, and M6. It was
later discovered that this induced an offset during the axis balance setup. On March 13, 1993
Manufacturing Notice 3792 came out with a new modification for CRP3 and rescinded Manufacturing
Notice 3788. Basically the new modification removes 24 VDC return from the ground side of the load
monitor input and instead ties the 12 VDC isolated voltage return in its place.
Note, the revision letter for the 415-0224-004 CRP3 board was marked revision E for both modifications.
Any MAX3 machines with erratic load meters and especially those shipped in February or March
1993 which are experiencing load meter problems or axis balance problems with a large offset should have
the CRP modifications checked and reworked. This modification corrects an oversight from the original
CRP3 board design. Functionally the CRP3 load meter circuit will be identical to CRP2 with the addition of
this modification.
Modification:
1.
2.
3.
4.
5.
Use approximately 1/2" of wire wrap wire and solder pin 3 of U4 to C36 pin 2 (top). Tack Pack the
wire to the PCB as required.
Ensure that pins 1 and 19 of M2, M4 and M6 are not tied together as described on Manufacturing
Notice 3788.
Change the revision level to "E".
ORIGINATOR: Tom Murden
REVISED BY:
ISSUE NUMBER: 1200
SUBJECT: Replacement of Spindle Oil Cooler
SUPERSEDES NUMBER:
PAGE 1 OF 1
The following parts are needed for field installation of the new design oil cooler:
ItemDescription
1) Fitting, 90 degree elbow (3/8T-1/4 M.P.)
2) Tubing, 3/8 O.D.
3) Oil Cooler
4) Brace, splash guard
Part Number
506-3009-039
508-2001-005
504-5001-005
802-2618-004
Quantity
4 ea.
25 feet
1 ea.
1 ea.
Field replacement of the new oil cooler requires the following steps:
1. The original mounting plate needs to be drilled to facilitate the new oil cooler. Due to
inconsistency in hole location, it is best to set the new oil cooler in and mark the hole pattern from
it. Then drill the original base and bolt on the new oil cooler. You may use your discretion on the
mounting bolts.
2. The original oil lines will be of insufficient length and must be replaced. Fittings and tubing are
listed with the parts above.
3. The original wiring should be of sufficient length and may be used. The new design oil unit is
wired to receive 220 VAC single phase. On most of our machines 208 VAC single phase is the
actual voltage supplied and is sufficient for this application.
4. The splash guard brace should be installed from the column to the splash guard using the one bolt
hole end to any available screw on the column, as close to the level of the original brace as
possible. The splash guard will need to have holes drilled to accommodate the two screws at its end
of the brace.
REVISED BY:
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE MADE
BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
ISSUE NUMBER: 1201
SUBJECT: Max3 Keyboards
SUPERSEDES NUMBER:
PRODUCT LINE: Ultimax 3 Controls
PAGE 1 OF 1
Replacement keytops are now available for repairing Ultimax 3 keyboards. This will eliminate the need
for a complete keyboard replacement when any of the keys break off. The part numbers for ordering the
specific keytops required are listed below. Please note that when these keytops break, the plastic tang
(shaped like an “+”) usually breaks off flush with the pushbutton actuator. This will require taking a
needle and heating the tip so it can be inserted at an angle into the center of the broken “+” tang. When
the needle cools the broken tang should easily pull out with the needle. Carefully snap the new keytop
into place to complete the repair.
PART NUMBER
DESCRIPTION
PART NUMBER
609-0514-001
609-0514-002
609-0514-003
609-0514-004
609-0514-005
609-0514-006
609-0514-007
609-0514-008
609-0514-009
609-0514-010
Keytop, Enter (1.25 x2) Dk.Gray
Keytop, “0” (Zero)
Keytop, (1 x 2) Dk.Gray
Keytop, (1 x 2) Lt. Gray
Keytop, “8”
Keytop, “7”
Keytop, “6” or “9”
Keytop, “5”
Keytop, “4”
Keytop, “3”
609-0514-011
609-0514-012
609-0514-013
609-0514-014
609-0514-015
609-0514-016
609-0514-017
609-0514-018
609-0514-019
609-0514-020
DESCRIPTION
Keytop, “2”
Keytop, “1”
Keytop, “.” (Decimal Point)
Keytop, “X” (Multiply Sign)
Keytop, “/” (Divide Sign)
Keytop, “-” (Minus Sign)
Keytop, “+” (Plus Sign)
Keytop, (Arrow)
Keytop, (1 x 1) Dk.Gray
Keytop, (1 x 1) Lt. Gray
ORIGINATOR: Mark Bullington
REVISED BY:
ISSUE NUMBER: 1202
SUBJECT: Clairex Switch
SUPERSEDES NUMBER:
PRODUCT LINE: KM1/HM1
PAGE 1 OF 1
The Clairex optical switch (418-0003-001) used on KM1/HM1 machines is no longer available. This
switch was used for axis over travel and marker inputs on the KM1 machine, and for over travel on the
M1.
The only switches that are required for the machine to function are the marker switches and a switch for
each axis to calibrate, (Z+, X-, Y-). If you encounter a machine that needs the switch replaced the
following two (2) options exist.
1. Use one of the existing switches on the machine that are not required for machine operation, (Z-,
X+, Y+).
2. A possible replacement that may be used is the magnetic proximity switch (418-5002-004) that was
used on KMB1’s thru KM3’s. In order for this switch to be used an alternate mounting bracket and
switch dog will need to be fabricated. Wire the switch as follows:
SWITCH WIRE
BLACK (-)
COMMON
RED (+)
5VDC
WHITE
(LOAD)
KM1 LS PCB
D OR E
M1 LS HARNESS
P12-4
A OR B
P12-5
C
P12-2(+LS) OR P12-3(-LS)
NOTE: IF OPTION 2 IS DONE, PLEASE FORWARD A COPY OF THE BRACKET AND
SWITCH DOG DESIGN BACK TO HURCO, SO THAT WE MAY OFFER THIS AS PART
OF A KIT IN THE FUTURE.
REVISED BY:
DATE: Jan. 4, 1994
1203
SUBJECT:
SUPERSEDES NUMBER:
PRODUCT LINE:
PAGE 1 OF 1
Tool release knock out " tool push out " can be measured and adjusted per the following information.
Push Out Amount.
BMC 20 LR, 30, 40, 50.
OEM 20 LR, 30, 40, 50
BMC's with the "TYPE 1" tool changer
.080" to .100 "
If the machine is working correctly with its present setup there is no need to adjust it.
Push out should be checked with an indicator. The air blast through the spindle will need to be
disconnected and plugged during the check and adjustment. Do not forget to reconnect the air blast
afterwards.
ORIGINATOR: L. Leffew
REVISED BY:
ISSUE NUMBER: 1204
SUBJECT: KM5D Input Power
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk KM5D
PAGE 1 OF 1
The new Knee Mill, KM5D “HAWK” can only be ordered from the factory as 230 VAC 3 Phase, 60
Hz. If your customer has a different incoming service, the distributor or customer needs to supply a
9KVA transformer that will convert their 3 phase plant line voltage to 230 VAC/3 Phase/60 Hz. Hurco
suggests using a local supply suorce as an economical alternative. Example: G.E. Supply #9T21A4015.
G.E. can be reached at 1-800-273-7313. Hurco will not be stocking any transformers for this purpose.
REVISED BY:
704-0001-589
ISSUE NUMBER: 1205
SUBJECT: MTE Removal/Replacement
SUPERSEDES NUMBER:
PRODUCT LINE: KM3/3P
PAGE 1 OF 2
KM3/3P MOTOR/TACH/ENCODER REPLACEMENT PROCEDURE
1.
If possible, move axis to a position providing easy access to the motor being removed.
2.
Switch the Main Disconnect Switch to OFF.
3.
Remove the servo conduit cable connector from the motor assembly. (Refer to Figure 1 for
the location of the various components.)
4.
Remove the motor junction box cover.
5.
Locate pins “L”, “S”, “K”, and “H” on the motor receptacle. (Refer to Figure 1, View
AA.)
6.
Using the pin extraction tool, remove the pins from the motor receptacle, being careful to
note the color of the wire, and which location of the receptacle it was removed from. Also
be extremely careful not to damage the pin or wire during removal.
7.
Remove the cord grip lock nut that secures the cord grip to the motor junction box.
8.
Carefully remove the cable from the junction box.
9.
Remove the motor.
10.
Install the new motor.
REVISED BY:
11.
Install the limit switch cable and cord grip to the motor junction box, and tighten the cord
grip lock nut.
12.
Using a small screwdriver to facilitate installation, insert the pins that were removed in step
6, into the motor receptacle. Be sure that the wire colors match the correct locations.
13.
Replace the junction box cover and reconnect the servo conduit cable to the motor.
14.
Switch the Main Disconnect Switch to ON.
15.
Check the motor, encoder, and limit switches for proper operation by SLOWLY jogging the
axis to each switch.
FIGURE 1
MOTOR CONNECTOR RECEPTACLE
A
JUNCTION BOX
A
CORD GRIP
VIEW A-A
L
A
K
B
M
J
S
N
C
20-16
H
R
P
D
E
G
F
END VIEW
DATE: March 30, 1994
ISSUE NUMBER: 1206
SUBJECT: Hawk 5D Machine Control Prameters
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5D
PAGE 1 OF 35
The following table shows the default parameters for the 10M control when used for the Hawk 5D Knee
Mill.
Reference Part 3 of the Dynapath Installation Guide for Delta 10M/20M Computer Numerical
Controls for Multi-Axes Milling Machines and Machining Centers for parameter descriptions and
editing information.
REVISED BY:
Addr
Hex
0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
000A
000B
000C
000D
000E
000F
0010
0011
0012
0013
0014
0015
0016
0017
0018
0019
001A
001B
001C
001D
001E
001F
0020
0021
0022
0023
0024
0025
0026
0027
0028
0029
002A
002B
002C
002D
002E
002F
00F0
00F1
Value
Byte
03
00
01
01
00
01
01
01
02
03
10
50
01
01
01
12
02
50
01
00
00
50
01
00
02
03
20
00
05
10
00
FF
02
50
01
00
00
50
01
00
02
03
20
00
05
10
00
FF
FF
FF
Addr
Hex
0030
0031
0032
0033
0034
0035
0036
0037
0038
0039
003A
003B
003C
003D
003E
003F
0040
0041
0042
0043
0044
0045
0046
0047
0048
0049
004A
004B
004C
004D
004E
004F
0050
0051
0052
0053
0054
0055
0056
0057
0058
0059
005A
005B
005C
005D
005E
005F
0121
0122
Value
Byte
01
50
01
00
00
50
01
00
04
06
40
00
05
10
00
FF
00
04
00
01
01
01
00
01
00
00
00
00
00
00
00
00
01
00
40
00
40
00
80
00
80
00
00
50
01
00
00
01
00
00
Addr
Hex
0060
0061
0062
0063
0064
0065
0066
0067
0068
0069
006A
006B
006C
006D
006E
006F
0070
0071
0072
0073
0074
0075
0076
0077
0078
0079
007A
007B
007C
007D
007E
007F
0080
0081
0082
0083
0084
0085
0086
0087
0088
0089
008A
008B
008C
008D
008E
008F
0152
0153
Value
Byte
00
31
02
00
10
00
02
00
00
00
02
00
10
13
77
00
00
00
02
00
10
06
02
00
00
00
10
00
10
00
10
00
00
00
10
00
10
00
10
00
00
00
10
00
10
00
10
00
00
00
Addr
Hex
0090
0091
0092
0093
0094
0095
0096
0097
0098
0099
009A
009B
009C
009D
009E
009F
00A0
00A1
00A2
00A3
00A4
00A5
00A6
00A7
00A8
00A9
00AA
00AB
00AC
00AD
00AE
00AF
00B0
00B1
00B2
00B3
00B4
00B5
00B6
00B7
00B8
00B9
00BA
00BB
00BC
00BD
00BE
00BF
0183
0184
Value
Byte
00
00
01
00
00
00
FF
FF
FF
FF
FF
FF
01
50
FF
FF
18
00
01
00
00
50
07
20
00
10
00
00
10
10
00
00
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
00
00
Addr
Hex
00C0
00C1
00C2
00C3
00C4
00C5
00C6
00C7
00C8
00C9
00CA
00CB
00CC
00CD
00CE
00CF
00D0
00D1
00D2
00D3
00D4
00D5
00D6
00D7
00D8
00D9
00DA
00DB
00DC
00DD
00DE
00DF
00E0
00E1
00E2
00E3
00E4
00E5
00E6
00E7
00E8
00E9
00EA
00EB
00EC
00ED
00EE
00EF
01B4
01B5
Value
Byte
00
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
00
00
FF
00
00
00
00
25
FF
FF
FF
FF
00
00
00F2
00F3
00F4
00F5
00F6
00F7
00F8
00F9
00FA
00FB
00FC
00FD
00FE
00FF
0100
0101
0102
0103
0104
0105
0106
0107
0108
0109
010A
010B
010C
010D
010E
010F
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
011A
011B
011C
011D
011E
011F
0120
01E5
01E6
01E7
01E8
01E9
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
01
00
00
00
00
01
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0123
0124
0125
0126
0127
0128
0129
012A
012B
012C
012D
012E
012F
0130
0131
0132
0133
0134
0135
0136
0137
0138
0139
013A
013B
013C
013D
013E
013F
0140
0141
0142
0143
0144
0145
0146
0147
0148
0149
014A
014B
014C
014D
014E
014F
0150
0151
0216
0217
0218
0219
021A
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0154
0155
0156
0157
0158
0159
015A
015B
015C
015D
015E
015F
0160
0161
0162
0163
0164
0165
0166
0167
0168
0169
016A
016B
016C
016D
016E
016F
0170
0171
0172
0173
0174
0175
0176
0177
0178
0179
017A
017B
017C
017D
017E
017F
0180
0181
0182
0247
0248
0249
024A
024B
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0185
0186
0187
0188
0189
018A
018B
018C
018D
018E
018F
0190
0191
0192
0193
0194
0195
0196
0197
0198
0199
019A
019B
019C
019D
019E
019F
01A0
01A1
01A2
01A3
01A4
01A5
01A6
01A7
01A8
01A9
01AA
01AB
01AC
01AD
01AE
01AF
01B0
01B1
01B2
01B3
0278
0279
027A
027B
027C
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
01B6
01B7
01B8
01B9
01BA
01BB
01BC
01BD
01BE
01BF
01C0
01C1
01C2
01C3
01C4
01C5
01C6
01C7
01C8
01C9
01CA
01CB
01CC
01CD
01CE
01CF
01D0
01D1
01D2
01D3
01D4
01D5
01D6
01D7
01D8
01D9
01DA
01DB
01DC
01DD
01DE
01DF
01E0
01E1
01E2
01E3
01E4
02A9
02AA
02AB
02AC
02AD
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
01EA
01EB
01EC
01ED
01EE
01EF
01F0
01F1
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF
0200
0201
0202
0203
0204
0205
0206
0207
0208
0209
020A
020B
020C
020D
020E
020F
0210
0211
0212
0213
0214
0215
02DA
02DB
02DC
02DD
02DE
02DF
02E0
02E1
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
14
00
00
01
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
021B
021C
021D
021E
021F
0220
0221
0222
0223
0224
0225
0226
0227
0228
0229
022A
022B
022C
022D
022E
022F
0230
0231
0232
0233
0234
0235
0236
0237
0238
0239
023A
023B
023C
023D
023E
023F
0240
0241
0242
0243
0244
0245
0246
030B
030C
030D
030E
030F
0310
0311
0312
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
024C
024D
024E
024F
0250
0251
0252
0253
0254
0255
0256
0257
0258
0259
025A
025B
025C
025D
025E
025F
0260
0261
0262
0263
0264
0265
0266
0267
0268
0269
026A
026B
026C
026D
026E
026F
0270
0271
0272
0273
0274
0275
0276
0277
033C
033D
033E
033F
0340
0341
0342
0343
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
027D
027E
027F
0280
0281
0282
0283
0284
0285
0286
0287
0288
0289
028A
028B
028C
028D
028E
028F
0290
0291
0292
0293
0294
0295
0296
0297
0298
0299
029A
029B
029C
029D
029E
029F
02A0
02A1
02A2
02A3
02A4
02A5
02A6
02A7
02A8
036D
036E
036F
0370
0371
0372
0373
0374
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
02AE
02AF
02B0
02B1
02B2
02B3
02B4
02B5
02B6
02B7
02B8
02B9
02BA
02BB
02BC
02BD
02BE
02BF
02C0
02C1
02C2
02C3
02C4
02C5
02C6
02C7
02C8
02C9
02CA
02CB
02CC
02CD
02CE
02CF
02D0
02D1
02D2
02D3
02D4
02D5
02D6
02D7
02D8
02D9
039E
039F
03A0
03A1
03A2
03A3
03A4
03A5
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
02E2
02E3
02E4
02E5
02E6
02E7
02E8
02E9
02EA
02EB
02EC
02ED
02EE
02EF
02F0
02F1
02F2
02F3
02F4
02F5
02F6
02F7
02F8
02F9
02FA
02FB
02FC
02FD
02FE
02FF
0300
0301
0302
0303
0304
0305
0306
0307
0308
0309
030A
03CF
03D0
03D1
03D2
03D3
03D4
03D5
03D6
03D7
03D8
03D9
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0313
0314
0315
0316
0317
0318
0319
031A
031B
031C
031D
031E
031F
0320
0321
0322
0323
0324
0325
0326
0327
0328
0329
032A
032B
032C
032D
032E
032F
0330
0331
0332
0333
0334
0335
0336
0337
0338
0339
033A
033B
0400
0401
0402
0403
0404
0405
0406
0407
0408
0409
040A
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
01
00
00
10
01
00
00
10
01
00
0344
0345
0346
0347
0348
0349
034A
034B
034C
034D
034E
034F
0350
0351
0352
0353
0354
0355
0356
0357
0358
0359
035A
035B
035C
035D
035E
035F
0360
0361
0362
0363
0364
0365
0366
0367
0368
0369
036A
036B
036C
0431
0432
0433
0434
0435
0436
0437
0438
0439
043A
043B
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
0375
0376
0377
0378
0379
037A
037B
037C
037D
037E
037F
0380
0381
0382
0383
0384
0385
0386
0387
0388
0389
038A
038B
038C
038D
038E
038F
0390
0391
0392
0393
0394
0395
0396
0397
0398
0399
039A
039B
039C
039D
0462
0463
0464
0465
0466
0467
0468
0469
046A
046B
046C
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FF
FF
FF
FF
FF
FF
FF
FF
01
01
01
03A6
03A7
03A8
03A9
03AA
03AB
03AC
03AD
03AE
03AF
03B0
03B1
03B2
03B3
03B4
03B5
03B6
03B7
03B8
03B9
03BA
03BB
03BC
03BD
03BE
03BF
03C0
03C1
03C2
03C3
03C4
03C5
03C6
03C7
03C8
03C9
03CA
03CB
03CC
03CD
03CE
0493
0494
0495
0496
0497
0498
0499
049A
049B
049C
049D
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FF
00
00
00
00
FF
FF
FF
FF
FF
FF
03DA
03DB
03DC
03DD
03DE
03DF
03E0
03E1
03E2
03E3
03E4
03E5
03E6
03E7
03E8
03E9
03EA
03EB
03EC
03ED
03EE
03EF
03F0
03F1
03F2
03F3
03F4
03F5
03F6
03F7
03F8
03F9
03FA
03FB
03FC
03FD
03FE
03FF
04C4
04C5
04C6
04C7
04C8
04C9
04CA
04CB
04CC
04CD
04CE
04CF
04D0
04D1
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FF
FF
FF
FF
FF
FF
FF
01
00
10
00
10
00
10
040B
040C
040D
040E
040F
0410
0411
0412
0413
0414
0415
0416
0417
0418
0419
041A
041B
041C
041D
041E
041F
0420
0421
0422
0423
0424
0425
0426
0427
0428
0429
042A
042B
042C
042D
042E
042F
0430
04F5
04F6
04F7
04F8
04F9
04FA
04FB
04FC
04FD
04FE
04FF
0500
0501
0502
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
50
49
43
043C
043D
043E
043F
0440
0441
0442
0443
0444
0445
0446
0447
0448
0449
044A
044B
044C
044D
044E
044F
0450
0451
0452
0453
0454
0455
0456
0457
0458
0459
045A
045B
045C
045D
045E
045F
0460
0461
0526
0527
0528
0529
052A
052B
052C
052D
052E
052F
0530
0531
0532
0533
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
00
01
00
01
00
01
FF
FF
FF
FF
45
45
44
20
54
4F
20
42
45
20
52
45
46
45
046D
046E
046F
0470
0471
0472
0473
0474
0475
0476
0477
0478
0479
047A
047B
047C
047D
047E
047F
0480
0481
0482
0483
0484
0485
0486
0487
0488
0489
048A
048B
048C
048D
048E
048F
0490
0491
0492
0557
0558
0559
055A
055B
055C
055D
055E
055F
0560
0561
0562
0563
0564
00
01
00
00
01
01
00
00
00
FF
FF
FF
FF
FF
FF
00
00
FF
FF
18
00
01
00
00
50
07
20
00
10
00
00
10
10
00
00
FF
FF
FF
20
50
52
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111A
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114A
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115A
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122A
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118A
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128C
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11FA
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120A
120B
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120D
120E
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124A
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42
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126A
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127A
127B
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127D
127E
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1280
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128A
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12A0
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4C
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20
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1301
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130A
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130D
130E
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1313
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134A
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135A
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1366
1367
1368
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136A
136B
136C
136D
136E
136F
1370
1371
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1373
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1375
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1378
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137A
137B
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137D
137E
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144A
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20
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138C
138D
138E
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1397
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139A
139B
139C
139D
139E
139F
13A0
13A1
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13A8
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20
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54
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13EA
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1400
1401
1402
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140A
140B
140C
140D
140E
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1410
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20
31
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20
20
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54
141E
141F
1420
1421
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142A
142B
142C
142D
142E
142F
1430
1431
1432
1433
1434
1435
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143A
143B
143C
143D
143E
143F
1440
1441
1442
1443
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150A
150B
150C
150D
150E
150F
1510
1511
1512
1513
1514
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20
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54
42
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54
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144F
1450
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145E
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1460
1461
1462
1463
1464
1465
1466
1467
1468
1469
146A
146B
146C
146D
146E
146F
1470
1471
1472
1473
1474
1475
153A
153B
153C
153D
153E
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54
42
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1480
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148A
148B
148C
148D
148E
148F
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1495
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149A
149B
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149D
149E
149F
14A0
14A1
14A2
14A3
14A4
14A5
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156B
156C
156D
156E
156F
1570
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54
42
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54
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42
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14B1
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14D0
14D1
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14D3
14D4
14D5
14D6
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159C
159D
159E
159F
15A0
15A1
15A2
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20
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42
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1500
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15D0
15D1
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42
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54
53
41
47
45
20
4E
55
4D
42
45
52
20
31
1516
1517
1518
1519
151A
151B
151C
151D
151E
151F
1520
1521
1522
1523
1524
1525
1526
1527
1528
1529
152A
152B
152C
152D
152E
152F
1530
1531
1532
1533
1534
1535
1536
1537
1538
1539
15FE
15FF
1600
1601
1602
1603
1604
1605
1606
1607
1608
1609
160A
160B
160C
160D
45
52
20
31
31
35
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
1547
1548
1549
154A
154B
154C
154D
154E
154F
1550
1551
1552
1553
1554
1555
1556
1557
1558
1559
155A
155B
155C
155D
155E
155F
1560
1561
1562
1563
1564
1565
1566
1567
1568
1569
156A
162F
1630
1631
1632
1633
1634
1635
1636
1637
1638
1639
163A
163B
163C
163D
163E
4C
54
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
31
37
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
47
45
20
4E
55
4D
42
45
52
20
31
32
34
20
20
20
1578
1579
157A
157B
157C
157D
157E
157F
1580
1581
1582
1583
1584
1585
1586
1587
1588
1589
158A
158B
158C
158D
158E
158F
1590
1591
1592
1593
1594
1595
1596
1597
1598
1599
159A
159B
1660
1661
1662
1663
1664
1665
1666
1667
1668
1669
166A
166B
166C
166D
166E
166F
20
31
31
38
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
31
39
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
15A9
15AA
15AB
15AC
15AD
15AE
15AF
15B0
15B1
15B2
15B3
15B4
15B5
15B6
15B7
15B8
15B9
15BA
15BB
15BC
15BD
15BE
15BF
15C0
15C1
15C2
15C3
15C4
15C5
15C6
15C7
15C8
15C9
15CA
15CB
15CC
1691
1692
1693
1694
1695
1696
1697
1698
1699
169A
169B
169C
169D
169E
169F
16A0
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
32
30
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
20
4E
55
4D
42
45
52
20
31
32
37
20
20
20
20
4D
15DA
15DB
15DC
15DD
15DE
15DF
15E0
15E1
15E2
15E3
15E4
15E5
15E6
15E7
15E8
15E9
15EA
15EB
15EC
15ED
15EE
15EF
15F0
15F1
15F2
15F3
15F4
15F5
15F6
15F7
15F8
15F9
15FA
15FB
15FC
15FD
16C2
16C3
16C4
16C5
16C6
16C7
16C8
16C9
16CA
16CB
16CC
16CD
16CE
16CF
16D0
16D1
32
31
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
32
32
20
20
58
20
41
58
49
53
2D
20
58
20
41
58
49
53
2B
20
160E
160F
1610
1611
1612
1613
1614
1615
1616
1617
1618
1619
161A
161B
161C
161D
161E
161F
1620
1621
1622
1623
1624
1625
1626
1627
1628
1629
162A
162B
162C
162D
162E
16F3
16F4
16F5
16F6
16F7
16F8
16F9
16FA
16FB
16FC
16FD
16FE
16FF
1700
1701
1702
1703
1704
1705
41
47
45
20
4E
55
4D
42
45
52
20
31
32
33
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
54
48
20
41
58
2D
20
34
54
48
20
41
58
2B
20
35
54
48
20
163F
1640
1641
1642
1643
1644
1645
1646
1647
1648
1649
164A
164B
164C
164D
164E
164F
1650
1651
1652
1653
1654
1655
1656
1657
1658
1659
165A
165B
165C
165D
165E
165F
1724
1725
1726
1727
1728
1729
172A
172B
172C
172D
172E
172F
1730
1731
1732
1733
1734
1735
1736
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
32
35
20
20
20
20
54
31
34
30
49
4E
53
52
54
31
34
31
49
4E
53
52
54
31
34
1670
1671
1672
1673
1674
1675
1676
1677
1678
1679
167A
167B
167C
167D
167E
167F
1680
1681
1682
1683
1684
1685
1686
1687
1688
1689
168A
168B
168C
168D
168E
168F
1690
1755
1756
1757
1758
1759
175A
175B
175C
175D
175E
175F
1760
1761
1762
1763
1764
1765
1766
1767
45
20
4E
55
4D
42
45
52
20
31
32
36
20
20
20
20
4D
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
45
31
34
36
49
4E
53
52
54
31
34
37
49
4E
53
52
54
31
34
38
16A1
16A2
16A3
16A4
16A5
16A6
16A7
16A8
16A9
16AA
16AB
16AC
16AD
16AE
16AF
16B0
16B1
16B2
16B3
16B4
16B5
16B6
16B7
16B8
16B9
16BA
16BB
16BC
16BD
16BE
16BF
16C0
16C1
1786
1787
1788
1789
178A
178B
178C
178D
178E
178F
1790
1791
1792
1793
1794
1795
1796
1797
1798
54
42
20
46
41
55
4C
54
20
4D
45
53
53
41
47
45
20
4E
55
4D
42
45
52
20
31
32
38
20
20
20
20
2B
20
35
32
49
4E
53
52
54
31
35
33
49
4E
53
52
54
31
35
34
49
16D2
16D3
16D4
16D5
16D6
16D7
16D8
16D9
16DA
16DB
16DC
16DD
16DE
16DF
16E0
16E1
16E2
16E3
16E4
16E5
16E6
16E7
16E8
16E9
16EA
16EB
16EC
16ED
16EE
16EF
16F0
16F1
16F2
17B7
17B8
17B9
17BA
17BB
17BC
17BD
17BE
17BF
17C0
17C1
17C2
17C3
17C4
17C5
17C6
17C7
17C8
17C9
59
20
41
58
49
53
2D
20
59
20
41
58
49
53
2B
20
5A
20
41
58
49
53
2D
20
5A
20
41
58
49
53
2B
20
34
38
49
4E
53
52
54
31
35
39
49
4E
53
52
54
31
36
30
49
4E
1706
1707
1708
1709
170A
170B
170C
170D
170E
170F
1710
1711
1712
1713
1714
1715
1716
1717
1718
1719
171A
171B
171C
171D
171E
171F
1720
1721
1722
1723
17E8
17E9
17EA
17EB
17EC
17ED
17EE
17EF
17F0
17F1
17F2
17F3
17F4
17F5
17F6
17F7
17F8
17F9
17FA
17FB
17FC
17FD
41
58
2D
20
35
54
48
20
41
58
49
4E
53
52
54
31
33
38
49
4E
53
52
54
31
33
39
49
4E
53
52
49
4E
53
52
54
31
36
35
49
4E
53
52
54
31
36
36
49
4E
53
52
54
31
1737
1738
1739
173A
173B
173C
173D
173E
173F
1740
1741
1742
1743
1744
1745
1746
1747
1748
1749
174A
174B
174C
174D
174E
174F
1750
1751
1752
1753
1754
1819
181A
181B
181C
181D
181E
181F
1820
1821
1822
1823
1824
1825
1826
1827
1828
1829
182A
182B
182C
182D
182E
32
49
4E
53
52
54
31
34
33
49
4E
53
52
54
31
34
34
49
4E
53
52
54
31
34
35
49
4E
53
52
54
4E
53
52
54
31
37
31
49
4E
53
52
54
31
37
32
49
4E
53
52
54
31
37
1768
1769
176A
176B
176C
176D
176E
176F
1770
1771
1772
1773
1774
1775
1776
1777
1778
1779
177A
177B
177C
177D
177E
177F
1780
1781
1782
1783
1784
1785
184A
184B
184C
184D
184E
184F
1850
1851
1852
1853
1854
1855
1856
1857
1858
1859
185A
185B
185C
185D
185E
185F
49
4E
53
52
54
31
34
39
49
4E
53
52
54
31
35
30
49
4E
53
52
54
31
35
31
49
4E
53
52
54
31
53
52
54
31
37
37
49
4E
53
52
54
31
37
38
49
4E
53
52
54
31
37
39
1799
179A
179B
179C
179D
179E
179F
17A0
17A1
17A2
17A3
17A4
17A5
17A6
17A7
17A8
17A9
17AA
17AB
17AC
17AD
17AE
17AF
17B0
17B1
17B2
17B3
17B4
17B5
17B6
187B
187C
187D
187E
187F
1880
1881
1882
1883
1884
1885
1886
1887
1888
1889
188A
188B
188C
188D
188E
188F
1890
4E
53
52
54
31
35
35
49
4E
53
52
54
31
35
36
49
4E
53
52
54
31
35
37
49
4E
53
52
54
31
35
52
54
31
38
33
49
4E
53
52
54
31
38
34
49
4E
53
52
54
31
38
35
49
17CA
17CB
17CC
17CD
17CE
17CF
17D0
17D1
17D2
17D3
17D4
17D5
17D6
17D7
17D8
17D9
17DA
17DB
17DC
17DD
17DE
17DF
17E0
17E1
17E2
17E3
17E4
17E5
17E6
17E7
18AC
18AD
18AE
18AF
18B0
18B1
18B2
18B3
18B4
18B5
18B6
18B7
18B8
18B9
18BA
18BB
18BC
18BD
18BE
18BF
18C0
18C1
53
52
54
31
36
31
49
4E
53
52
54
31
36
32
49
4E
53
52
54
31
36
33
49
4E
53
52
54
31
36
34
54
31
38
39
49
4E
53
52
54
31
39
30
49
4E
53
52
54
31
39
31
49
4E
17FE
17FF
1800
1801
1802
1803
1804
1805
1806
1807
1808
1809
180A
180B
180C
180D
180E
180F
1810
1811
1812
1813
1814
1815
1816
1817
1818
18DD
18DE
18DF
18E0
18E1
18E2
18E3
18E4
18E5
18E6
18E7
18E8
18E9
18EA
18EB
18EC
18ED
18EE
18EF
18F0
18F1
18F2
18F3
18F4
18F5
36
37
49
4E
53
52
54
31
36
38
49
4E
53
52
54
31
36
39
49
4E
53
52
54
31
37
30
49
31
39
35
49
4E
53
52
54
31
39
36
49
4E
53
52
54
31
39
37
49
4E
53
52
54
31
182F
1830
1831
1832
1833
1834
1835
1836
1837
1838
1839
183A
183B
183C
183D
183E
183F
1840
1841
1842
1843
1844
1845
1846
1847
1848
1849
190E
190F
1910
1911
1912
1913
1914
1915
1916
1917
1918
1919
191A
191B
191B
191C
191C
191D
191D
191E
191E
191F
191F
1920
1920
33
49
4E
53
52
54
31
37
34
49
4E
53
52
54
31
37
35
49
4E
53
52
54
31
37
36
49
4E
30
31
49
4E
53
52
54
32
30
32
49
4E
53
52
52
54
54
32
32
30
30
33
33
49
49
1860
1861
1862
1863
1864
1865
1866
1867
1868
1869
186A
186B
186C
186D
186E
186F
1870
1871
1872
1873
1874
1875
1876
1877
1878
1879
187A
192D
192E
192F
1930
1931
1932
1933
1934
1935
1936
1937
1938
1939
193A
193B
193C
193D
193E
193F
1940
1941
1942
1943
1944
1945
49
4E
53
52
54
31
38
30
49
4E
53
52
54
31
38
31
49
4E
53
52
54
31
38
32
49
4E
53
32
30
35
49
4E
53
52
54
32
30
36
49
4E
53
52
54
32
30
37
49
4E
53
52
54
32
1891
1892
1893
1894
1895
1896
1897
1898
1899
189A
189B
189C
189D
189E
189F
18A0
18A1
18A2
18A3
18A4
18A5
18A6
18A7
18A8
18A9
18AA
18AB
195E
195F
1960
1961
1962
1963
1964
1965
1966
1967
1968
1969
196A
196B
196C
196D
196E
196F
1970
1971
1972
1973
1974
1975
1976
4E
53
52
54
31
38
36
49
4E
53
52
54
31
38
37
49
4E
53
52
54
31
38
38
49
4E
53
52
31
31
49
4E
53
52
54
32
31
32
49
4E
53
52
54
32
31
33
49
4E
53
52
54
32
31
18C2
18C3
18C4
18C5
18C6
18C7
18C8
18C9
18CA
18CB
18CC
18CD
18CE
18CF
18D0
18D1
18D2
18D3
18D4
18D5
18D6
18D7
18D8
18D9
18DA
18DB
18DC
198F
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
199A
199B
199C
199D
199E
199F
19A0
19A1
19A2
19A3
19A4
19A5
19A6
19A7
53
52
54
31
39
32
49
4E
53
52
54
31
39
33
49
4E
53
52
54
31
39
34
49
4E
53
52
54
37
49
4E
53
52
54
32
31
38
49
4E
53
52
54
32
31
39
49
4E
53
52
54
32
32
30
18F6
18F7
18F8
18F9
18FA
18FB
18FC
18FD
18FE
18FF
1900
1901
1902
1903
1904
1905
1906
1907
1908
1909
190A
190B
190C
190D
19C0
19C1
19C2
19C3
19C4
19C5
19C6
19C7
19C8
19C9
19CA
19CB
19CC
19CD
19CE
19CF
19D0
19D1
19D2
19D3
19D4
19D5
19D6
19D7
19D8
19D9
19DA
19DB
39
38
49
4E
53
52
54
31
39
39
49
4E
53
52
54
32
30
30
49
4E
53
52
54
32
49
4E
53
52
54
32
32
34
49
4E
53
52
54
32
32
35
49
4E
53
52
54
32
32
36
49
4E
53
52
1921
1921
1922
1922
1923
1923
1924
1924
1925
1925
1926
1926
1927
1927
1928
1928
1929
1929
192A
192A
192B
192B
192C
192C
19F1
19F2
19F3
19F4
19F5
19F6
19F7
19F8
19F9
19FA
19FB
19FC
19FD
19FE
19FF
1A00
1A01
1A02
1A03
1A04
1A05
1A06
1A07
1A08
1A09
1A0A
1A0B
1A0C
4E
4E
53
53
52
52
54
54
32
32
30
30
34
34
49
49
4E
4E
53
53
52
52
54
54
4E
53
52
54
32
33
30
49
4E
53
52
54
32
33
31
49
4E
53
52
54
32
33
32
49
4E
53
52
54
1946
1947
1948
1949
194A
194B
194C
194D
194E
194F
1950
1951
1952
1953
1954
1955
1956
1957
1958
1959
195A
195B
195C
195D
1A22
1A23
1A24
1A25
1A26
1A27
1A28
1A29
1A2A
1A2B
1A2C
1A2D
1A2E
1A2F
1A30
1A31
1A32
1A33
1A34
1A35
1A36
1A37
1A38
1A39
1A3A
1A3B
1A3C
1A3D
30
38
49
4E
53
52
54
32
30
39
49
4E
53
52
54
32
31
30
49
4E
53
52
54
32
53
52
54
32
33
36
49
4E
53
52
54
32
33
37
49
4E
53
52
54
32
33
38
49
4E
53
52
54
32
1977
1978
1979
197A
197B
197C
197D
197E
197F
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
198A
198B
198C
198D
198E
1A53
1A54
1A55
1A56
1A57
1A58
1A59
1A5A
1A5B
1A5C
1A5D
1A5E
1A5F
1A60
1A61
1A62
1A63
1A64
1A65
1A66
1A67
1A68
1A69
1A6A
1A6B
1A6C
1A6D
1A6E
34
49
4E
53
52
54
32
31
35
49
4E
53
52
54
32
31
36
49
4E
53
52
54
32
31
52
54
32
34
32
49
4E
53
52
54
32
34
33
49
4E
53
52
54
32
34
34
49
4E
53
52
54
32
34
19A8
19A9
19AA
19AB
19AC
19AD
19AE
19AF
19B0
19B1
19B2
19B3
19B4
19B5
19B6
19B7
19B8
19B9
19BA
19BB
19BC
19BD
19BE
19BF
1A84
1A85
1A86
1A87
1A88
1A89
1A8A
1A8B
1A8C
1A8D
1A8E
1A8F
1A90
1A91
1A92
1A93
1A94
1A95
1A96
1A97
1A98
1A99
1A9A
1A9B
1A9C
1A9D
1A9E
1A9F
49
4E
53
52
54
32
32
31
49
4E
53
52
54
32
32
32
49
4E
53
52
54
32
32
33
54
32
34
38
49
4E
53
52
54
32
34
39
49
4E
53
52
54
32
35
30
49
4E
53
52
54
32
35
31
19DC
19DD
19DE
19DF
19E0
19E1
19E2
19E3
19E4
19E5
19E6
19E7
19E8
19E9
19EA
19EB
19EC
19ED
19EE
19EF
19F0
1AB5
1AB6
1AB7
1AB8
1AB9
1ABA
1ABB
1ABC
1ABD
1ABE
1ABF
1AC0
1AC1
1AC2
1AC3
1AC4
1AC5
1AC6
1AC7
1AC8
1AC9
1ACA
1ACB
1ACC
1ACD
1ACE
1ACF
1AD0
1AD1
1AD2
1AD3
54
32
32
37
49
4E
53
52
54
32
32
38
49
4E
53
52
54
32
32
39
49
32
35
34
49
4E
53
52
54
32
35
35
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1A0D
1A0E
1A0F
1A10
1A11
1A12
1A13
1A14
1A15
1A16
1A17
1A18
1A19
1A1A
1A1B
1A1C
1A1D
1A1E
1A1F
1A20
1A21
1AE6
1AE7
1AE8
1AE9
1AEA
1AEB
1AEC
1AED
1AEE
1AEF
1AF0
1AF1
1AF2
1AF3
1AF4
1AF5
1AF6
1AF7
1AF8
1AF9
1AFA
1AFB
1AFC
1AFD
1AFE
1AFF
1B00
1B01
1B02
1B03
1B04
32
33
33
49
53
4E
52
54
32
33
34
49
4E
53
52
54
32
33
35
49
4E
00
99
99
01
00
00
50
00
01
00
99
99
FF
FF
01
07
20
00
01
01
01
01
01
00
02
00
00
02
00
00
01
1A3E
1A3F
1A40
1A41
1A42
1A43
1A44
1A45
1A46
1A47
1A48
1A49
1A4A
1A4B
1A4C
1A4D
1A4E
1A4F
1A50
1A51
1A52
1B17
1B18
1B19
1B1A
1B1B
1B1C
1B1D
1B1E
1B1F
1B20
1B21
1B22
1B23
1B24
1B25
1B26
1B27
1B28
1B29
1B2A
1B2B
1B2C
1B2D
1B2E
1B2F
1B30
1B31
1B32
1B33
1B34
1B35
33
39
49
4E
53
52
54
32
34
30
49
4E
53
52
54
32
34
31
49
4E
53
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1A6F
1A70
1A71
1A72
1A73
1A74
1A75
1A76
1A77
1A78
1A79
1A7A
1A7B
1A7C
1A7D
1A7E
1A7F
1A80
1A81
1A82
1A83
1B48
1B49
1B4A
1B4B
1B4C
1B4D
1B4E
1B4F
1B50
1B51
1B52
1B53
1B54
1B55
1B56
1B57
1B58
1B59
1B5A
1B5B
1B5C
1B5D
1B5E
1B5F
1B60
1B61
1B62
1B63
1B64
1B65
1B66
35
49
4E
53
52
54
32
34
36
49
4E
53
52
54
32
34
37
49
4E
53
52
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1AA0
1AA1
1AA2
1AA3
1AA4
1AA5
1AA6
1AA7
1AA8
1AA9
1AAA
1AAB
1AAC
1AAD
1AAE
1AAF
1AB0
1AB1
1AB2
1AB3
1AB4
1B79
1B7A
1B7B
1B7C
1B7D
1B7E
1B7F
1B80
1B81
1B82
1B83
1B84
1B85
1B86
1B87
1B88
1B89
1B8A
1B8B
1B8C
1B8D
1B8E
1B8F
1B90
1B91
1B92
1B93
1B94
1B95
1B96
1B97
49
4E
53
52
54
32
35
32
49
4E
53
52
54
32
35
33
49
4E
53
52
54
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1AD4
1AD5
1AD6
1AD7
1AD8
1AD9
1ADA
1ADB
1ADC
1ADD
1ADE
1ADF
1AE0
1AE1
1AE2
1AE3
1AE4
1AE5
1BAA
1BAB
1BAC
1BAD
1BAE
1BAF
1BB0
1BB1
1BB2
1BB3
1BB4
1BB5
1BB6
1BB7
1BB8
1BB9
1BBA
1BBB
1BBC
1BBD
1BBE
1BBF
1BC0
1BC1
1BC2
1BC3
1BC4
1BC5
1BC6
1BC7
1BC8
1BC9
1BCA
1BCB
FF
00
00
10
00
01
00
00
50
00
10
00
00
40
96
00
10
10
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1B05
1B06
1B07
1B08
1B09
1B0A
1B0B
1B0C
1B0D
1B0E
1B0F
1B10
1B11
1B12
1B13
1B14
1B15
1B16
1BDB
1BDC
1BDD
1BDE
1BDF
1BE0
1BE1
1BE2
1BE3
1BE4
1BE5
1BE6
1BE7
1BE8
1BE9
1BEA
1BEB
1BEC
1BED
1BEE
1BEF
1BF0
1BF1
1BF2
1BF3
1BF4
1BF5
1BF6
1BF7
1BF8
1BF9
1BFA
1BFB
1BFC
50
00
18
00
00
18
00
00
01
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1B36
1B37
1B38
1B39
1B3A
1B3B
1B3C
1B3D
1B3E
1B3F
1B40
1B41
1B42
1B43
1B44
1B45
1B46
1B47
1C0C
1C0D
1C0E
1C0F
1C10
1C11
1C12
1C13
1C14
1C15
1C16
1C17
1C18
1C19
1C1A
1C1B
1C1C
1C1D
1C1E
1C1F
1C20
1C21
1C22
1C23
1C24
1C25
1C26
1C27
1C28
1C29
1C2A
1C2B
1C2C
1C2D
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1B67
1B68
1B69
1B6A
1B6B
1B6C
1B6D
1B6E
1B6F
1B70
1B71
1B72
1B73
1B74
1B75
1B76
1B77
1B78
1C3D
1C3E
1C3F
1C40
1C41
1C42
1C43
1C44
1C45
1C46
1C47
1C48
1C49
1C4A
1C4B
1C4C
1C4D
1C4E
1C4F
1C50
1C51
1C52
1C53
1C54
1C55
1C56
1C57
1C58
1C59
1C5A
1C5B
1C5C
1C5D
1C5E
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1B98
1B99
1B9A
1B9B
1B9C
1B9D
1B9E
1B9F
1BA0
1BA1
1BA2
1BA3
1BA4
1BA5
1BA6
1BA7
1BA8
1BA9
1C6E
1C6F
1C70
1C71
1C72
1C73
1C74
1C75
1C76
1C77
1C78
1C79
1C7A
1C7B
1C7C
1C7D
1C7E
1C7F
1C80
1C81
1C82
1C83
1C84
1C85
1C86
1C87
1C88
1C89
1C8A
1C8B
1C8C
1C8D
1C8E
1C8F
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1BCC
1BCD
1BCE
1BCF
1BD0
1BD1
1BD2
1BD3
1BD4
1BD5
1BD6
1BD7
1BD8
1BD9
1BDA
1C9F
1CA0
1CA1
1CA2
1CA3
1CA4
1CA5
1CA6
1CA7
1CA8
1CA9
1CAA
1CAB
1CAC
1CAD
1CAE
1CAF
1CB0
1CB1
1CB2
1CB3
1CB4
1CB5
1CB6
1CB7
1CB8
1CB9
1CBA
1CBB
1CBC
1CBD
1CBE
1CBF
1CC0
1CC1
1CC2
1CC3
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1BFD
1BFE
1BFF
1C00
1C01
1C02
1C03
1C04
1C05
1C06
1C07
1C08
1C09
1C0A
1C0B
1CD0
1CD1
1CD2
1CD3
1CD4
1CD5
1CD6
1CD7
1CD8
1CD9
1CDA
1CDB
1CDC
1CDD
1CDE
1CDF
1CE0
1CE1
1CE2
1CE3
1CE4
1CE5
1CE6
1CE7
1CE8
1CE9
1CEA
1CEB
1CEC
1CED
1CEE
1CEF
1CF0
1CF1
1CF2
1CF3
1CF4
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1C2E
1C2F
1C30
1C31
1C32
1C33
1C34
1C35
1C36
1C37
1C38
1C39
1C3A
1C3B
1C3C
1D01
1D02
1D03
1D04
1D05
1D06
1D07
1D08
1D09
1D0A
1D0B
1D0C
1D0D
1D0E
1D0F
1D10
1D11
1D12
1D13
1D14
1D15
1D16
1D17
1D18
1D19
1D1A
1D1B
1D1C
1D1D
1D1E
1D1F
1D20
1D21
1D22
1D23
1D24
1D25
FF
FF
FF
FF
FF
FF
FF
FF
FF
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FF
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FF
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FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1C5F
1C60
1C61
1C62
1C63
1C64
1C65
1C66
1C67
1C68
1C69
1C6A
1C6B
1C6C
1C6D
1D32
1D33
1D34
1D35
1D36
1D37
1D38
1D39
1D3A
1D3B
1D3C
1D3D
1D3E
1D3F
1D40
1D41
1D42
1D43
1D44
1D45
1D46
1D47
1D48
1D49
1D4A
1D4B
1D4C
1D4D
1D4E
1D4F
1D50
1D51
1D52
1D53
1D54
1D55
1D56
FF
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FF
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FF
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1C90
1C91
1C92
1C93
1C94
1C95
1C96
1C97
1C98
1C99
1C9A
1C9B
1C9C
1C9D
1C9E
1D63
1D64
1D65
1D66
1D67
1D68
1D69
1D6A
1D6B
1D6C
1D6D
1D6E
1D6F
1D70
1D71
1D72
1D73
1D74
1D75
1D76
1D77
1D78
1D79
1D7A
1D7B
1D7C
1D7D
1D7E
1D7F
1D80
1D81
1D82
1D83
1D84
1D85
1D86
1D87
FF
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1CC4
1CC5
1CC6
1CC7
1CC8
1CC9
1CCA
1CCB
1CCC
1CCD
1CCE
1CCF
1D94
1D95
1D96
1D97
1D98
1D99
1D9A
1D9B
1D9C
1D9D
1D9E
1D9F
1DA0
1DA1
1DA2
1DA3
1DA4
1DA5
1DA6
1DA7
1DA8
1DA9
1DAA
1DAB
1DAC
1DAD
1DAE
1DAF
1DB0
1DB1
1DB2
1DB3
1DB4
1DB5
1DB6
1DB7
1DB8
1DB9
1DBA
1DBB
FF
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FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1CF5
1CF6
1CF7
1CF8
1CF9
1CFA
1CFB
1CFC
1CFD
1CFE
1CFF
1D00
1DC5
1DC6
1DC7
1DC8
1DC9
1DCA
1DCB
1DCC
1DCD
1DCE
1DCF
1DD0
1DD1
1DD2
1DD3
1DD4
1DD5
1DD6
1DD7
1DD8
1DD9
1DDA
1DDB
1DDC
1DDD
1DDE
1DDF
1DE0
1DE1
1DE2
1DE3
1DE4
1DE5
1DE6
1DE7
1DE8
1DE9
1DEA
1DEB
1DEC
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1D26
1D27
1D28
1D29
1D2A
1D2B
1D2C
1D2D
1D2E
1D2F
1D30
1D31
1DF6
1DF7
1DF8
1DF9
1DFA
1DFB
1DFC
1DFD
1DFE
1DFF
1E00
1E01
1E02
1E03
1E04
1E05
1E06
1E07
1E08
1E09
1E0A
1E0B
1E0C
1E0D
1E0E
1E0F
1E10
1E11
1E12
1E13
1E14
1E15
1E16
1E17
1E18
1E19
1E1A
1E1B
1E1C
1E1D
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1D57
1D58
1D59
1D5A
1D5B
1D5C
1D5D
1D5E
1D5F
1D60
1D61
1D62
1E27
1E28
1E29
1E2A
1E2B
1E2C
1E2D
1E2E
1E2F
1E30
1E31
1E32
1E33
1E34
1E35
1E36
1E37
1E38
1E39
1E3A
1E3B
1E3C
1E3D
1E3E
1E3F
1E40
1E41
1E42
1E43
1E44
1E45
1E46
1E47
1E48
1E49
1E4A
1E4B
1E4C
1E4D
1E4E
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1D88
1D89
1D8A
1D8B
1D8C
1D8D
1D8E
1D8F
1D90
1D91
1D92
1D93
1E58
1E59
1E5A
1E5B
1E5C
1E5D
1E5E
1E5F
1E60
1E61
1E62
1E63
1E64
1E65
1E66
1E67
1E68
1E69
1E6A
1E6B
1E6C
1E6D
1E6E
1E6F
1E70
1E71
1E72
1E73
1E74
1E75
1E76
1E77
1E78
1E79
1E7A
1E7B
1E7C
1E7D
1E7E
1E7F
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1DBC
1DBD
1DBE
1DBF
1DC0
1DC1
1DC2
1DC3
1DC4
1E89
1E8A
1E8B
1E8C
1E8D
1E8E
1E8F
1E90
1E91
1E92
1E93
1E94
1E95
1E96
1E97
1E98
1E99
1E9A
1E9B
1E9C
1E9D
1E9E
1E9F
1EA0
1EA1
1EA2
1EA3
1EA4
1EA5
1EA6
1EA7
1EA8
1EA9
1EAA
1EAB
1EAC
1EAD
1EAE
1EAF
1EB0
1EB1
1EB2
1EB3
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1DED
1DEE
1DEF
1DF0
1DF1
1DF2
1DF3
1DF4
1DF5
1EBA
1EBB
1EBC
1EBD
1EBE
1EBF
1EC0
1EC1
1EC2
1EC3
1EC4
1EC5
1EC6
1EC7
1EC8
1EC9
1ECA
1ECB
1ECC
1ECD
1ECE
1ECF
1ED0
1ED1
1ED2
1ED3
1ED4
1ED5
1ED6
1ED7
1ED8
1ED9
1EDA
1EDB
1EDC
1EDD
1EDE
1EDF
1EE0
1EE1
1EE2
1EE3
1EE4
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1E1E
1E1F
1E20
1E21
1E22
1E23
1E24
1E25
1E26
1EEB
1EEC
1EED
1EEE
1EEF
1EF0
1EF1
1EF2
1EF3
1EF4
1EF5
1EF6
1EF7
1EF8
1EF9
1EFA
1EFB
1EFC
1EFD
1EFE
1EFF
1F00
1F01
1F02
1F03
1F04
1F05
1F06
1F07
1F08
1F09
1F0A
1F0B
1F0C
1F0D
1F0E
1F0F
1F10
1F11
1F12
1F13
1F14
1F15
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1E4F
1E50
1E51
1E52
1E53
1E54
1E55
1E56
1E57
1F1C
1F1D
1F1E
1F1F
1F20
1F21
1F22
1F23
1F24
1F25
1F26
1F27
1F28
1F29
1F2A
1F2B
1F2C
1F2D
1F2E
1F2F
1F30
1F31
1F32
1F33
1F34
1F35
1F36
1F37
1F38
1F39
1F3A
1F3B
1F3C
1F3D
1F3E
1F3F
1F40
1F41
1F42
1F43
1F44
1F45
1F46
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1E80
1E81
1E82
1E83
1E84
1E85
1E86
1E87
1E88
1F4D
1F4E
1F4F
1F50
1F51
1F52
1F53
1F54
1F55
1F56
1F57
1F58
1F59
1F5A
1F5B
1F5C
1F5D
1F5E
1F5F
1F60
1F61
1F62
1F63
1F64
1F65
1F66
1F67
1F68
1F69
1F6A
1F6B
1F6C
1F6D
1F6E
1F6F
1F70
1F71
1F72
1F73
1F74
1F75
1F76
1F77
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1EB4
1EB5
1EB6
1EB7
1EB8
1EB9
1F7E
1F7F
1F80
1F81
1F82
1F83
1F84
1F85
1F86
1F87
1F88
1F89
1F8A
1F8B
1F8C
1F8D
1F8E
1F8F
1F90
1F91
1F92
1F93
1F94
1F95
1F96
1F97
1F98
1F99
1F9A
1F9B
1F9C
1F9D
1F9E
1F9F
1FA0
1FA1
1FA2
1FA3
1FA4
1FA5
1FA6
1FA7
1FA8
1FA9
1FAA
1FAB
FF
FF
FF
FF
FF
FF
FF
00
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1EE5
1EE6
1EE7
1EE8
1EE9
1EEA
1FAF
1FB0
1FB1
1FB2
1FB3
1FB4
1FB5
1FB6
1FB7
1FB8
1FB9
1FBA
1FBB
1FBC
1FBD
1FBE
1FBF
1FC0
1FC1
1FC2
1FC3
1FC4
1FC5
1FC6
1FC7
1FC8
1FC9
1FCA
1FCB
1FCC
1FCD
1FCE
1FCF
1FD0
1FD1
1FD2
1FD3
1FD4
1FD5
1FD6
1FD7
1FD8
1FD9
1FDA
1FDB
1FDC
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
1F16
1F17
1F18
1F19
1F1A
1F1B
1FE0
1FE1
1FE2
1FE3
1FE4
1FE5
1FE6
1FE7
1FE8
1FE9
1FEA
1FEB
1FEC
1FED
1FEE
1FEF
1FF0
1FF1
1FF2
1FF3
1FF4
1FF5
1FF6
1FF7
1FF8
1FF9
1FFA
1FFB
1FFC
1FFD
1FFE
1FFF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
FF
EA
00
80
FF
FF
FF
FF
FF
1F47
1F48
1F49
1F4A
1F4B
1F4C
FF
FF
FF
FF
FF
FF
1F78
1F79
1F7A
1F7B
1F7C
1F7D
FF
FF
FF
FF
FF
FF
1FAC
1FAD
1FAE
FF
FF
FF
1FDD FF
1FDE FF
1FDF FF
ISSUE NUMBER: 1207
SUBJECT: Hawk 5D JO-BLOCK PROCEDURE
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5D Knee Mill
PAGE 1 OF 7
The following procedure will provide a standardized procedure for testing and compensating for the
leadscrew and backlash error for the Hawk 5D Knee Mill. Note that the programs are designed for use
with a 19.5” Jo Block for the X axis and a 10” Jo Block for the Y axis. The tables are designed to be
used as the indicator reads. (EXAMPLE: If the indicator reads minus error, then you would use the
minus table).
EQUIPMENT
Obtain the following equipment required to perform Jo Block test:
19.5 inch Jo Block
10 inch Jo Block
3 End Blocks
2 Toe Clamps
2 Tee Nuts
2 Bolts
Tool Holder
Dial Indicator
X AXIS PROCEDURE
1. Load program XJB. Reference program listed below:
N0000.5(9)E1$
N0001(0)X0Y0Z0$
N0002(1)X.03F5C0G0$
N0003(1)Y-.25F5C0G0$
N0004(1)X4.03F100C0G0$
N0005(1)X.03F100C0G0$
N0006(1)Y0F5$
N0007(0)X0$
N0008(1)X.03F5$
REVISED BY:
1
N0009(1)Y-.25F5C0G0$
N0010(1)X4.03F100C0G0
N0013(0)X0Y0Z0$
N0014(1)X.03F5C0G0$
N0015(0)X19.5Z1$
N0016(1)Z0F100C0G0$
N0017(1)X19.53F5C0G0$
N0018(0)X0Z1$
N0011(1)X.03F100C0G0$
N0019(1)Z0F100C0G0$
N0020(1)X.03F5C0G0$
N0021(0)X19.5Z1$
N0022(1)Z0F100C0G0$
N0023(1)X19.53F5C0G0$
N0024(0)X0Y0Z1$
N0025(1)Z0F100C0G0$
N0026(1)X.03F5C0G0$
N0027(0)Z2$
N0028(9)M0E0$
N0029(9)M30$
2.
3.
Reference the machine.
Mount the 19.5 inch Jo Block with end blocks attached in the center slot using the toe
clamps to hold the Jo Block in place.
4. Install the tool holder and indicator in the spindle.
5. Zero the indicator on the outside left surface of the left end block, centered
1/8 inch from top of block.
6. Back X off of the block 0.0030 inches and ZERO SET X, Y, and Z.
7. Run the program in Single Event. (The first part of the program is backlash)
8. Press CYCLE START until the indicator touches the Jo Block and check the
indicator for zero.
9. Continue with the program until the indicator touches the Jo Block again. Take the
first reading and record it.
___________________inches
10. Continue with the program. Backlash is rechecked for verification.
11. Continue with the program until the indicator touches the right end block.. Take
and record the reading. This reading is the leadscrew error.
___________________inches
12. Continue with the program. The program repeats to verify the reading.
13. Load presets per Table 1.
14. Load the compensation into the parameters. (Table 2)
15. Load backlash into the parameters. (Table 4)
14. Repeat the procedure to verify compensation is accurate.
Y AXIS PROCEDURE
1. Load program YJB. Reference program listed below:
N0000.5(9)E1T1$
N0001(0)X0Y0Z0$
N0002(1)Y.03F5C0G0$
2
N0003(1)X-.25F5C0G0$
N0004(1)Y4.03F100C0G0$
N0005(1)Y.03F100C0G0$
N0006(1)X0F5$
N0007(0)Y0$
N0008(1)Y.03F5$
N0009(1)X-.25F5C0G0$
N0010(1)Y4.03F100C0G0$
N0011(1)Y.03F100C0G0$
N0012(1)X0F5C0G0$
N0013(0)X0Y0Z0$
N0014(1)Y.03F5C0G0$
N0015(0)X0Y10Z1$
N0016(1)Z.2F100C0G0$
N0017(1)Y10.03F5C0G0$
N0018(0)X0Y0Z1$
N0019(1)Z0F100C0G0$
N0020(1)Y.03F5C0G0$
N0021(0)Y10Z1$
N0022(1)Z.2F100C0G0$
N0023(1)Y10.03F5C0G0$
N0024(0)X0Y0Z1$
N0025(1)Z0F100C0G0$
N0026(1)Y.03F5C0G0$
N0027(0)Z2$
N0028(9)M0E0$
N0029(9)M30$
2.
3.
Reference the machine.
Mount the 10 inch Jo Block, with one end block attached, in the center of the table
situated with the end block toward the column and 1/2 inch of the Jo Block extending
over the front table pad. Use the toe clamp to hold the Jo Block in position.
4. Zero the indicator on the front surface of the Jo Block, centered 1/8 inch from top of
block.
5. Back Y off of the block 0.0030 inches and ZERO SET X, Y, and Z.
6. Run the program in Signal Event. (The first part of the program is backlash)
7. Press CYCLE START until the indicator touches the Jo Block and check the
indicator for zero.
8. Continue with the program until the indicator touches the Jo Block again. Take the
first reading and record it.
___________________inches
9. Continue with the program. Backlash is rechecked for verification.
10. Continue with the program until the indicator touches the end block. Take and
record the reading. This reading is the leadscrew error.
___________________inches
11. Continue with the program. The program repeats to verify the reading.
12. Load the compensation into the parameters. (Table 3)
13. Load backlash into the parameters. (Table 4)
3
14. Repeat the procedure to verify compensation is accurate.
LOADING PARAMETERS
1. Depress EMERGENCY STOP.
2. Toggle the WRITE PROTECT SWITCH on the Processor PCB to the DOWN position to
enable the EEPROMs.
NOTE:
3.
4.
5,
ANY DATA THAT IS CHANGED WILL AFFECT THE OPERATION OF
THE MACHINE. BE EXTREMELY CAREFUL WHEN SELECTING THE
ADDRESS TO BE CHANGED.
Press RESET, "P" to enter the Parameter mode.
Select the address to be changed by typing "A", then the address number, ENTER.
NEXT EVENT will move to the next address.
After all parameters are changed, toggle the WRITE PROTECT SWITCH to the UP
position. Press RESET, then release the EMERGENCY STOP BUTTON.
TABLE #1 - Presets:
ADDR.
0005
0047
100
101
102
103
104
105
200
201
202
203
204
205
DATA
01
01
00
00
00
02
54
00
35
60
00
02
54
00
TABLE #4: BACKLASH
AXIS ADDR
X
0048
0049
Y
004A
004B
DATA
NOTE: Values are
loaded in millimeters
Example: 0.014mm
X
0048
00
0049
14
4
TABLE # 2: X AXIS
Error is in ten thousandths of an inch (0.0001)
ADDR
0106
0107
0108
0109
010A
010B
010C
010D
010E
010F
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
011A
011B
011C
011D
011E
011F
0120
0121
0122
0123
+1
00
00
00
00
11
00
00
00
00
11
00
00
00
00
11
00
00
00
00
11
00
00
00
00
11
00
00
00
00
11
+2
00
11
00
00
11
00
11
00
00
11
00
11
00
00
11
00
11
00
00
11
00
11
00
00
11
00
11
00
00
11
+3
00
11
11
00
11
00
11
11
00
11
00
11
11
00
11
00
11
11
00
11
00
11
11
00
11
00
11
11
00
11
+4
00
11
11
11
11
00
11
11
11
11
00
11
11
11
11
00
11
11
11
11
00
11
11
11
11
00
11
11
11
11
+5
00
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
12
+6
00
11
11
11
12
11
11
11
11
12
11
11
11
11
12
11
11
11
11
12
11
11
11
11
12
11
11
11
12
12
+7
00
12
11
11
12
11
12
11
11
12
11
12
11
11
12
11
12
11
11
12
11
12
11
11
12
11
12
11
12
12
+8
00
12
12
11
12
11
12
12
11
12
11
12
12
11
12
11
12
12
11
12
11
12
12
11
12
11
12
12
12
12
+9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
11 12 12 12 12 13 13 13 13 13 14 14 15 15 14 15 16
12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
12 12 12 12 13 13 13 13 13 14 14 15 14 14 15 15 15
12 12 12 12 12 13 14 13 13 13 14 14 14 14 15 15 15
12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 14 16
12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15
11 12 12 12 12 12 13 13 13 13 14 14 14 14 14 15 16
12 12 12 13 13 13 14 13 14 14 14 14 14 15 15 15 15
12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 15 16
12 12 12 13 13 13 13 13 14 14 14 15 14 15 15 15 15
12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
12 12 12 12 12 13 13 14 13 14 14 14 15 14 15 15 15
12 12 13 13 13 13 14 14 14 14 14 14 15 15 15 15 15
12 12 12 12 12 13 13 13 14 13 14 14 14 15 14 15 16
12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15
12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
TABLE # 2: X AXIS (continued)
ADDR
0106
0107
0108
0109
010A
010B
010C
010D
010E
010F
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
011A
011B
011C
011D
011E
011F
0120
0121
0122
0123
-1
00
00
00
00
01
00
00
00
00
01
00
00
00
00
01
00
00
00
00
01
00
00
00
00
01
00
00
00
00
01
-2
00
01
00
00
01
00
01
00
00
01
00
01
00
00
01
00
01
00
00
01
00
01
00
00
01
00
01
00
00
01
-3
00
01
01
00
01
00
01
01
00
01
00
01
01
00
01
00
01
01
00
01
00
01
01
00
01
00
01
01
00
01
-4
00
01
01
01
01
00
01
01
01
01
00
01
01
01
01
00
01
01
01
01
00
01
01
01
01
00
01
01
01
01
-5
00
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
02
-6
00
01
01
01
02
01
01
01
01
02
01
01
01
01
02
01
01
01
01
02
01
01
01
01
02
01
01
01
02
02
-7
00
02
01
01
02
01
02
01
01
02
01
02
01
01
02
01
02
01
01
02
01
02
01
01
02
01
02
01
02
02
-8
00
02
02
01
02
01
02
02
01
02
01
02
02
01
02
01
02
02
01
02
01
02
02
01
02
01
02
02
02
02
-9
00
02
02
02
02
01
02
02
02
02
01
02
02
02
02
01
02
02
02
02
01
02
02
02
02
02
02
02
02
02
-10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
02 02 02 02 03 03 03 03 03 04 04 05 05 04 05 06
02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
02 02 02 03 03 03 03 03 04 04 05 04 04 05 05 05
02 02 02 02 03 04 03 03 03 04 04 04 04 05 05 05
02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
03 02 02 02 02 03 03 03 03 03 04 04 04 04 04 06
02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05
02 02 02 02 02 03 03 03 03 04 04 04 04 04 05 06
02 02 03 03 03 04 03 04 04 04 04 04 05 05 05 05
02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
03 02 02 02 02 03 03 03 03 03 04 04 04 04 05 06
02 02 03 03 03 03 03 04 04 04 05 04 05 05 05 05
02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
02 02 02 02 03 03 04 03 04 04 04 05 04 05 05 05
02 03 03 03 03 04 04 04 04 04 04 05 05 05 05 05
02 02 02 02 03 03 03 04 03 04 04 04 05 04 05 06
02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05
02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
FSB XXX Page 6 of 7
TABLE # 3: Y AXIS
ADDR
0206
0207
0208
0209
020A
020B
020C
020D
020E
020F
0210
0211
0212
0213
0214
+1
00
00
00
11
00
00
00
00
11
00
00
00
00
11
00
+2
00
11
00
00
11
00
00
11
00
00
11
00
00
11
00
+3
00
00
11
00
11
11
00
11
00
11
11
00
11
11
00
+4
00
11
11
11
00
11
11
11
00
11
11
11
00
11
11
+5
00
11
11
11
11
00
11
11
11
00
11
11
11
11
11
+6
00
11
11
11
11
11
11
12
11
11
11
11
11
11
11
+7
00
11
11
12
11
11
12
11
11
12
11
11
12
11
11
+8
00
12
11
11
12
11
12
11
11
12
11
12
11
11
12
+9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
12 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15
11 12 12 12 13 13 13 13 13 14 14 14 14 14 14 15 14
12 12 12 13 12 12 13 13 13 13 14 13 14 14 14 14 15
12 12 12 12 12 13 12 13 13 13 13 14 13 14 14 14 14
11 11 12 12 12 12 13 12 13 13 14 14 14 14 15 15 15
12 12 12 12 13 13 13 13 13 13 13 13 14 14 14 14 14
11 12 12 13 12 12 12 13 13 14 13 14 14 14 14 14 15
12 12 12 12 12 13 13 13 13 13 14 13 13 14 14 14 14
12 11 12 12 13 12 13 12 13 13 13 14 14 14 15 15 15
11 12 12 12 12 13 12 13 13 13 13 14 14 14 14 14 14
12 12 12 12 12 12 13 13 13 14 14 13 14 14 14 14 15
12 12 12 13 12 13 13 13 13 13 13 14 13 14 14 14 14
11 12 12 12 13 12 12 13 13 13 14 13 14 14 14 15 15
12 12 12 12 12 13 13 13 13 13 13 14 14 14 14 14 14
ADDR
0206
0207
0208
0209
020A
020B
020C
020D
020E
020F
0210
0211
0212
0213
0214
-1
00
00
00
01
00
00
00
00
01
00
00
00
00
01
00
-2
00
01
00
00
01
00
00
01
00
00
01
00
00
01
00
-3
00
00
01
00
01
01
00
01
00
01
01
00
01
01
00
-4
00
01
01
01
00
01
01
01
00
01
01
01
00
01
01
-5
00
01
01
01
01
00
01
01
01
00
01
01
01
01
01
-6
00
01
01
01
01
01
01
02
01
01
01
01
01
01
01
-7
00
01
01
02
01
01
02
01
01
02
01
01
02
01
01
-8
00
02
01
01
02
01
02
01
01
02
01
02
01
01
02
-9
00
02
01
02
02
01
02
01
02
02
01
02
02
01
02
-10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
02 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05
02 02 02 03 03 03 03 03 04 04 04 04 04 04 05 04
02 02 03 02 02 03 03 03 03 04 03 04 04 04 04 05
02 02 02 02 03 02 03 03 03 03 04 03 04 04 04 04
01 02 02 02 02 03 02 03 03 04 04 04 04 05 05 05
02 02 02 03 03 03 03 03 03 03 03 04 04 04 04 04
02 02 03 02 02 02 03 03 04 03 04 04 04 04 04 05
02 02 02 02 03 03 03 03 03 04 03 03 04 04 04 04
01 02 02 03 02 03 02 03 03 03 04 04 04 05 05 05
02 02 02 02 03 02 03 03 03 03 04 04 04 04 04 04
02 02 02 02 02 03 03 03 04 04 03 04 04 04 04 05
02 02 03 02 03 03 03 03 03 03 04 03 04 04 04 04
02 02 02 03 02 02 03 03 03 04 03 04 04 04 05 05
02 02 02 02 03 03 03 03 03 03 04 04 04 04 04 04
FSB XXX Page 7 of 7
ISSUE NUMBER: 1208
SUBJECT: Hawk 5D Servo Amplifier Setup Procedure
SUPERSEDES NUMBER:
PAGE 1 OF 1
The following procedure will assist in the adjustment and setup of the Servo Dynamics DC servo drives
used in the Hawk 5D Knee Mill.
AMPLIFIER PRE-SETS
1)
Assure control power is OFF and that the J1 connector has been removed from the servo amp
that is to be adjusted.
2)
Connect an Ohm meter between TP1 and TP3 (Reference Servo Dynamics manual for location
of test points).
3)
Adjust the SIGNAL pot for a reading of ≅ 2.5 Kohms.
4)
Connect the meter between TP1 and TP4 and adjust the TACH pot for a reading of
≅ 4Kohms.
5)
AUX. pot - Set full CCW.
6)
CMP. pot - Set full CCW, then 10 turns CW.
7)
CL. pot - Set full CW
8)
BALANCE pot - Set mid-range (20 turn pot).
9)
Reconnect the J1 connector.
FINAL SETTINGS
1)
Enable the Servos and adjust the CMP pot CW till the motor starts to oscillate, then CCW
until the oscillation stops, and then an additional 3 turns CCW.
2)
Enable the LAG display on the control (axis setup screen), and then select Medium Jog speed
with the override set at max. This will jog the axis at 15 IPM.
3)
Adjust the SIGNAL pot to achieve 0.0150” of Lag.
4)
Adjust the BALANCE to minimize the difference between the lag when the jog direction is
changed.
5)
Motion Hold, and adjust the BALANCE for 0.0000” of Lag.
6)
Run a program to move all the axes at rapid, full travel to assure that no errors occur.
REVISED BY:
ISSUE NUMBER: 1209
SUBJECT: Hawk 5D Limit Switch Setup Procedure
SUPERSEDES NUMBER:
PAGE 1 OF 2
The following procedure will assist in the setup of the Axis Limit Switches on the Hawk 5D Knee
Mill.
Z AXIS
1)
Move the Z axis so that the Quill extends ≈ 1 inch (as measured between the bottom of the
Head casting and the top of the Quill locknut ring).
2)
Adjust the Reference Switch to be made at this point. Note that the switch activates off the
top of the dog.
3)
Home Z or jog it to ZERO.
4)
Adjust the Z Reference Switch so that the DRAW BAR height is 0.90” to 1.00” as
measured from the top of the DRAW BAR to the Bearing surface, when Z is at ZERO.
5)
Set the Over Travel switches for 0.100” of over travel. In order to do this you will need to
open up the software travel limits.
Z (+) = 0.100”
Z (-) = (-) 6.100”
6)
Set software travel limits to:
Z (+) = 0.020”
Z (-) = (-) 6.020”
7)
Set Z Home for 0.0000”.
Y AXIS
1)
Reference the Y axis.
2)
E-Stop to disable the servos.
3)
Move the Y axis by hand, noting the position display on the control, until the Y is at the
positive hard stop.
4)
Set the Reference switch dog for ≈ 0.300” from the Y ZERO.
5)
Set the Over Travel switches for 0.100” of over travel.
Y (+) = 0.100”
Y (-) = (-) 14.100”
REVISED BY:
FSB 1209 PAGE 2 OF 2
6)
7)
Set the software limits to:
Y (+) = 0.020”
Y (-) = (-) 13.77”
Set Y Home for (-) 1.000”
X AXIS
1)
Reference the X axis.
2)
Jog to near each hard stop and then E-Stop and verify that there is a minimum of 0.300” on
both ends, to hard stop.
3)
Adjust the Reference Switch dog to achieve this.
4)
Set the Over Travel switches for 0.100” of over travel.
X (+) = 31.100”
X (-) = (-)0.100”
5)
Set the software limits for:
X (+) = 31.020”
X (-) = 0.020”
6)
Set Home for (+) 1.000”
For all axes, assure that the axis will run full travel at rapid without hitting a over travel
switch.
For Z axis, assure that the Draw Bar functions properly.
DATE: July 7, 1994
ISSUE NUMBER: 1210
SUBJECT: Auto Speed Control Prom Update
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P/KM5M
PAGE 1 OF 1
There has been a new ASC Prom released for the KM5P or KM5M machines that fixes two problems.
The part number is 450-3010-104.
The first problem effects the 5M only. During tapping extraneous interrupts were processed as real
commands and would be seen as a speed change command at the top and bottom of the tap cycle. The
new Prom uses Switch 2 position 2 to enable a 130msec delay for each new command.
The second problem effects all machine types and would cause the speed control to runaway to hard
stop.
With this Prom, in order to maintain compatibility with older versions of executive software, the
debounce switch can be switched ON/OFF. Switch 2-2 controls the debounce enable. The chart below
details the switches and their functions:
ASC SWITCH
2
POSITION 1
POSITION 2
OPEN
CLOSED
BYPASS SOFTWARE LIMITS
USE SOFTWARE
LIMITS
NO DEBOUNCE **
ENABLE 130mSEC
DEBOUNCE *
* - Use with Max 32, Max 3 version 1.51 or above software
** - Use with all Max 2 and Max 32, Max 3 version 1.50 or below software.
REVISED BY:
DATE: May 13, 1994
ISSUE NUMBER: 1211
SUBJECT: Hawk 5M I/O & CANbus Mapping
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5M
PAGE 1 OF 1
INPUTS
FUNCTION
CRP4
WAY LUBE LEVEL
J1-45
INDEXER IN POSITION
J1-29
CHIP ENCLOSURE INTERLOCK #1 J1-44
CONTROL POWER STATUS
J1-28
SPINDLE OVERLOAD TRIP
J1-43
SPINDLE SPEED CONTROL 0
J1-27
J1-42
J1-26
CHIP ENCLOSURE INTERLOCK #2 J1-41
AXIS FAULT (X/Y/Z/a/b)
J1-40
AXIS MOTOR OVERTEMP
J1-24
OUTPUTS
FUNCTION
CRP4
AXIS ENABLE RELAY
J1-17
SPINDLE ENABLE RELAY
J1-16
INDEXER COCK RELAY
J1-15
FLOOD COOLANT RELAY
J1-32
MIST COOLANT SOLENOID
J1-49
SPINDLE FWD. STARTER
J1-48
SPINDLE REV. STARTER
J1-47
SPINDLE BRAKE SOLENOID
J1-46
CONTROL ON RELAY
J1-2
SPINDLE SPEED CHANGE ENABLE J1-35
SERVO FAULT RELAY
J1-34
AUTO MODE RELAY
J1-33
I/O INTERFACE
J1-45
J1-29
J1-44
J1-28
J1-43
J1-27
J1-42
J1-26
J1-41
J1-40
J1-24
I/O INTERFACE
J1-17
J1-16
J1-15
J1-32
J1-49
J1-48
J1-47
J1-46
J1-2
J1-35
J1-34
J1-33
CANBUS
J3-1
J3-2
J3-3
J3-4
J3-6
J3-7
J3-8
J3-9
J3-11
J3-13
J3-14
CANBUS
J3-17
J3-18
J3-19
J3-20
J3-22
J3-23
J3-24
J3-25
J3-31
J3-32
J3-33
J3-34
REVISED BY:
DATE:
May 13, 1994
SUBJECT: Servo Drive Setup
SUPERSEDES NUMBER:
PAGE 1 OF 3
The following procedure will assist in the adjustment and setup of the Servo Dynamics DC drives
used in the Hawk 5M Knee Mill.
AMPLIFIER PRE-SETS
1. Ensure that the (2) 0 Ohm shunts labeled W1 and W2 have been removed from the drive (only
required on a replacement drive installation & setup). Reference the Figure shown below for
location.
W1 & W2
2. Assure that the machine is in Emergency Stop.
3. Remove the J1 connector from the drive to be adjusted.
REVISED BY: David Skrzypczak
4. Connect an Ohm meter between TP1 and TP3 on the drive and adjust the SIGNAL pot for a
reading of ≅ 5,000 Ohms.
5. Connect the Ohm meter between TP1 and TP4 and adjust the TACH pot for a reading of ≅ 7,000
Ohms.
6. Adjust the CMP pot full CCW, then 10 turns CW.
7. Adjust the CL pot full CW.
8. Adjust the BAL pot mid-range (20 turn pot).
9. Reconnect the J1 connector to the drive.
AXIS BALANCE ADJUSTMENTS
1. Set the RAPID DETENT parameter on the control for:
1016 mmpm for X or Y axis adjustment
635 mmpm for Z axis adjustment
2. Jog the axis to be adjusted to mid-travel.
3. Connect a DVM set to DC Millivolts to J1-1 with respect to J1-2 of the drive to be adjusted.
4. Enable the servo power by depressing Manual Mode, Power ON, Start.
5. Enter the “101” screen and enable the LOAD BAR DISPLAY, FOLLOWING ERROR
DISPLAY, and ACTUAL POSITION DISPLAY.
6. Select AXIS BALANCE, then depress “Motion Hold”, select the Softkey for the axis to be
adjusted, and depress “Start”.
7. Do not adjust the pots on the Matrix 4 DSP board (if the pots are not sealed then use TIN 1074
to null the DSP boards before balancing the amplifiers). Adjust the BAL pot of the respective
drive until a reading of 0.0 Millivolts is obtained.
8. Verify the balance by observing the Encoder Count display (the right-most column) with Motion
Hold depressed; a properly balanced axis will not be counting. Do not balance by the Most
Positive and Most Negative Count displays.
9. Once the servo drive has been balanced, exit the axis balance test and return to the Manual Mode
screen.
10. Jog the axis at rapid (1016 mmpm for X or Y axis, 635 mmpm for Z) and adjust the SIGNAL pot
on the drive to obtain a reading of ≅ 0.95 VDC. This reading must be .95 or less.
11. Program a 45 degree vectored move for XY of 300 mm length at 5000 mmpm velocity. The
following error should be ≅ 0.700 mm with no more than a difference between X and Y of
0.06 mm.
DIGITAL SPEED CONTROLLER BALANCE ADJUSTMENTS
1. Connect a DVM set to DC Millivolts to TB1-1 (DAC IN) with respect to TB1-2 (DAC RTN) of
the Digital Speed Controller Board.
2. Enter the “101” screen and select AXIS BALANCE, then depress “Motion Hold”; select
SPINDLE and depress “Start”.
3. Adjust the VR4 pot on the DSP Board...
DATE: May 13, 1994
ISSUE NUMBER: 1213
SUBJECT: HAWK 5M PARAMETERS
SUPERSEDES NUMBER:
PRODUCT LINE: HAWK 5M
PAGE 1 OF 15
The following figures show the default parameters for the Hawk 5M Knee Mill and should be used to aid
in the machine configuration.
Access the “secret” screens as follows:
Function/Description
Machine Configuration &
Axis/Spindle Setup
Axis Balance
Leadscrew Mapping
Matrix 4 DSP Axis Tune
Interactive Diagnostics
Access Screen
Power-Up Configuration
or from Auxiliary Mode
Manual Mode
ATC Diagnostics
Manual Mode
ATC Diagnostics
Manual Mode
ATC Diagnostics
Auxiliary Mode
Access Code
“ENTER”,“100”,“ENTER”
REVISED BY:
The figures shown are as follows:
Figure 1 Machine Configuration screen in Metric as seen at machine power-up
Figure 2 Machine Configuration screen in Inch as seen during power-up
(Note “100” access code entered)
Figure 3 Machine Configuration screen seen after “100” code and “ENTER” depressed
Figure 4 X Axis Physical Parameters
Figure 5 X Axis Vertical Parameters
Figure 6 Y Axis Physical Parameters
Figure 7 Y Axis Vertical Parameters
Figure 8 Z Axis Physical Parameters
Figure 9 Z Axis Vertical Parameters
Figure 10 - Spindle Physical Parameters
Figure 11 - More Spindle Physical Parameters
Figure 12 - Spindle Vertical Parameters
Figure 13 - Configuration Parameter Screen for Machine Parameters & Tool Changer Parameters
Figure 14 - Machine Parameters
Figure 15 - Tool Changer Parameters
Figure 16 - System Parameters screen as seen in Auxiliary Mode
Figure 17 - Text Color Parameters for Mono CRT
Figure 18 - Graphics Color Parameters for Mono CRT
Figure 19 - Storage Functions Color Parameters for Mono CRT
Figure 20 - ATC Diagnostics Screen
Figure 21 - ATC Diagnostics Screen showing “103” code to access Axis Tuning for DSP
Figure 22 - Axis Tune Screen after entry of “103” code
Figure 23 - X Axis Tuning Parameters
Figure 24 - Y Axis Tuning Parameters
Figure 25 - Z Axis Tuning Parameters
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 8
FIGURE 9
FIGURE 10
FIGURE 11
FIGURE 12
FIGURE 13
FIGURE 14
FIGURE 15
FIGURE 16
FIGURE 17
FIGURE 18
FIGURE 19
FIGURE 20
FIGURE 21
FIGURE 22
FIGURE 23
FIGURE 24
FIGURE 25
DATE: May 13, 1994
ISSUE NUMBER: 1214
SUBJECT: Monochrome CRT Settings
SUPERSEDES NUMBER:
PAGE 1 OF 2
The color settings on a Monochrome system must be set properly in order for the information to be seen
on the CRT’s. It is very easy to change these parameters from the default settings and get the control
into a state in which you can not see anything on the CRT’s. If this occurs there are two ways to get
back the default settings.
1)
2)
Reload the machine configuration parameters from the backup disk (assuming you can see
enough on the CRT to do this).
Know the keystrokes for the color parameters to get back to the default settings.
Below are listed the Softkey strokes required from a machine power-up state to reset the color settings.
F8
EXIT
AUXILIARY MODE
F4
MACHINE CONFIGURATION
F3
SET COLOR PARAMETERS
F1
TEXT COLOR PARAMETERS
F1
BLACK
F7
MORE
F2
LIGHT GRAY
F7
MORE
F7
MORE
F4
WHITE
F7
MORE
F7
MORE
F4
WHITE
F7
MORE
F7
MORE
F4
WHITE
F7
MORE
F7
MORE
REVISED BY:
F4
F7
F7
F4
F7
F7
F4
F8
F2
F7
F7
F4
F4
F7
F2
F7
F2
F7
F7
F4
F7
F7
F4
F7
F7
F4
F8
F3
F7
F2
F7
F7
F4
F1
F7
F7
F4
F1
F7
F7
F4
F7
F2
F7
F2
F1
F8
WHITE
MORE
MORE
WHITE
MORE
MORE
WHITE
EXIT
GRAPHICS COLORS
MORE
MORE
WHITE
CYAN
MORE
LIGHT GRAY
MORE
LIGHT GRAY
MORE
MORE
WHITE
MORE
MORE
WHITE
MORE
MORE
WHITE
EXIT
STORAGE FUNCTION COLORS
MORE
LIGHT GRAY
MORE
MORE
WHITE
BLACK
MORE
MORE
WHITE
BLACK
MORE
MORE
WHITE
MORE
LIGHT GRAY
MORE
LIGHT GRAY
BLACK
EXIT
DATE:
January 23, 1997
SUBJECT: Monochrome (and Color) CRT Settings
PRODUCT LINE: Ultimax 3
PAGE 1 OF 2
The color settings on a Monochrome system must be set properly in order for the information to be seen on the
CRTs. Early software versions enabled the SET COLOR PARAMETER softkey. This was removed in V1.52
to prevent customers from inadvertently changing colors on a monochrome system; however, V1.61 has
reenabled this softkey (due to the incorrect setting of some of the monochrome colors during a software
upgrade, the softkey now allows the customer to reset the colors to their default).
COLOR PARAMETER DEFAULTS
A. TEXT COLOR PARAMETERS
1. Background Color
2. Reverse Background Color
3. Data Display Area
4. Prompt Area Color
5. Softkey Label Color
6. Softkey Text Color
7. Softkey Line Delimiter
8. Cursor Color
Monochrome
Black
Light Gray
White
White
White
White
White
White
Color
Black
Light Gray
White
Light Red
Light Red
Light Cyan
White
Blue
NOTE: Reverse Background Color is also used for the Cursor Color in the NC Part Program editor.
B. GRAPHICS COLORS
1. Part Path Color
2. Cutter Path Color
3. Rapid Path Color
4. Axes Color
5. Character Color
6. Box Color
7. Pointing Device Cursor Color White
Monochrome
Light Gray
White
White
White
White
White
Color
Light Cyan
Light Red
Yellow
Light Green
White
Light Cyan
Yellow
REVISED BY: David Skrzypczak
8. DXF Line Color
9. DXF Highlight Color
10. DXF Branch Color
11. DXF Calculator Display Color
12. DXF Calculator Buttons Color
13. DXF Calculator Grid Color
C. STORAGE FUNCTION COLORS
1. Directory Background Color
2. Highlighted Directory Color
3. Unhighlighted Directory Color
4. Current Directory Color
5. File Background Color
6. Highlighted File Color
White
7. Unhighlighted File Color
8. Line Border Color
9. Page Up/Page Down Arrow Color
Light Gray
White
White
White
White
Light Gray
Green
Yellow
Red
Light Green
White
Green
Monochrome
Light Gray
White
Black
White
Black
Color
Red
White
Black
Yellow
Blue
White
Light Gray
Light Gray
Black
Light Gray
Light Gray
Black
If the monochrome colors are all changed then there are several ways to get back the default settings:
1. Delete the SYSINT.SYS file from the C:\CONFIG\V1.xx directory (this will force the software to reload
the default color settings).
2. Reload the Machine Configuration parameters from the Machine Configuration Disk (assuming that enough
of the CRT can be seen to do this).
3. Boot the Executive from floppy disk and allow the default Machine Configuration to be loaded. Then copy
the SYSINT.SYS file created on the last Executive disk to C:\CONFIG\V1.xx
4. If the screen is completely blank and it is suspected that the colors have been changed, enter the following
keystrokes to restore enough of the screen to set the remaining defaults. After machine power up, press:
F8
(EXIT)
Auxiliary Mode
F4
(MACHINE CONFIGURATION)
F3
(SET COLOR PARAMETERS)
F1
(TEXT COLOR PARAMETERS)
F1
(BLACK for Background Color)
F7
(MORE)
F2
(LIGHT GRAY for Reverse Background Color)
F7 twice
(MORE)
F4
(WHITE for Data Display Area)
F7 twice
(MORE)
F4
(WHITE for Prompt Area Color)
F7 twice
(MORE)
F4
(WHITE for Softkey Label Color)
F7 twice
(MORE)
F4
(WHITE for Softkey Text Color)
F7 twice
(MORE)
F4
(WHITE for Softkey Line Delimiter Color)
F7 twice
(MORE)
F4
(WHITE for Cursor Color)
F8
(EXIT; required to activate color settings)
FSB 1214-A, Page 2 of 2
DATE: May 13, 1994
ISSUE NUMBER: 1215
SUBJECT: Hawk 5M Advanced CMOS Setup Options
SUPERSEDES NUMBER:
PAGE 1 OF 3
The following tables list the default settings for the AMI BIOS Setup for the ISA control used on the
Hawk 5M Knee Mill.
In order to access the BIOS Setup Utilities you will need to connect a standard AT keyboard to the
keyboard connector located on the bottom of the ISA Card Rack. Then reboot the control and depress
the (DEL) key during the power-up. This will bring up the screen shown below:
AMI BIOS SETUP PROGRAM - AMI BIOS SETUP UTILITIES
© 1992 American Megatrends, Inc., All Rights Reserved
STANDARD CMOS SETUP
ADVANCED CMOS SETUP
ADVANCED CHIPSET SETUP
AUTO CONFIGURATION WITH BIOS DEFAULTS
ADVANCED PERIPHERAL SETUP OPTIONS
CHANGE PASSWORD
HARD DISK AUTO DETECT
HARD DISK UTILITY
WRITE TO CMOS AND EXIT
DO NOT WRITE TO CMOS AND EXIT
Advanced CMOS Setup for configuring System Options
ESC: EXIT
ßáàâ: SEL
F2/F3: COLOR
F10: Save and Exit
REVISED BY:
The following tables list the settings for:
1)
2)
3)
ADVANCED CMOS SETUP
ADVANCED CHIPSET SETUP
ADVANCED PERIPHERAL SETUP
TABLE 1: ADVANCED CMOS SETUP
Typematic Rate Programming
Disabled
Typematic Rate Delay (msec.)
500
Typematic Rate (Char/Sec)
15
Above 1MB Memory Test
Disabled
Memory Test Tick Sound
Disabled
Memory Parity Error Check
Enabled
Hit <DEL> Message Display
Enabled
Hard Disk Type 47 RAM Area
0:300
Wait For <F1> If Any Error
Enabled
System Boot-Up Num Lock
On
Numeric Processor Test
Enabled
Weitek Processor
Absent
Floppy Drive Seek At Boot
Enabled
System Boot-Up Sequence
A:, C:
System Boot-Up CPU Speed
High
External Cache Memory
Enabled
Internal Cache Memory
Enabled
Fast Gate A20 Option
Enabled
Turbo Switch Function
Enabled
Password Checking Option
Setup
Video ROM Shadow C000, 16K
Enabled
Video ROM Shadow C400, 16K
Enabled
Adapter ROM Shadow C800, 16K
Disabled
Adapter ROM Shadow CC00, 16K
Disabled
Adapter ROM Shadow D000, 16K
Disabled
Disabled
Disabled
Adapter ROM Shadow DC00, 16K
Disabled
Adapter ROM Shadow E000, 16K
Disabled
Disabled
Disabled
Adapter ROM Shadow EC00, 16K
Disabled
System ROM Shadow E000, 64K
Disabled
System ROM Shadow F000, 64K
Enabled
Boot Sector Virus Protection
Disabled
Table 2: ADVANCED CHIPSET BIOS SETUP
Hidden Refresh
Enabled
Slow Refresh
Disabled
Single ALE Enable
No
Keyboard Reset Control
Disabled
Master Mode Byte Swap
Disabled
AT Cycle Wait State
Enabled
AT Cycle Between I/O Cycles
3
AT Bus Clock Selection
CLKI/5
Fast Decode Enable
Disabled
Memory Read Wait State
2 W/S
Memory Write Wait State
3 W/S
Cache Read Cycle
3-2-2-2
Cache Write Wait State
1 W/S
Non-Cacheable Block-1 Size
Disabled
Non-Cacheable Block-1 Base
0 KB
Non-Cacheable Block-2 Size
Disabled
Non-Cacheable Block-2 Base
0 KB
Cacheable RAM Address Range
64 MB
Video BIOS Area Cacheable
Yes
Table 3: ADVANCED PERIPHERAL SETUP
Programming Option
Auto
On-Board Floppy Drive
Disabled
On-Board IDE Drive
Disabled
First Serial Port Address
Disabled
Second Serial Port Address Disabled
Parallel Port Address
Disabled
IRQ Active State
High
Parallel Port Mode
Normal
DATE: May 16, 1994
ISSUE NUMBER: 1216
SUBJECT: Lead Screw Mapping
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5M Knee Mill
PAGE 1 OF 8
In order to compensate for leadscrew and backlash error the control incorporates a forward and reverse
map for each axis. This map will allow compensation in millionths of an inch (i.e. 0.0001 inches = 100
millionths of an inch) for each inch of axis travel, for full travel of the axis. It will also allow a single
backlash entry that will alter the reverse map data by the back lash value entered. Refer to Figures 9
thru 12.
The method you will use to enter the error values will depend upon the method used to check the
accuracy of the axis.
If you are using a Laser Interferometer or a Webber bar that will allow you to check the axis every inch
full travel, then you can simply enter the error seen in millionths of an inch in the forward map screen,
and the errors seen on the return run in the reverse screen.
If you are using a JO-Block of a given dimension as a standard, you will then need to determine the
error per inch in millionths of an inch and calculate the values to be entered into the table. The same
values will need to be entered into both the forward and reverse map and then the backlash value
could be entered in to alter the reverse map. Refer to Figures 9 thru 12.
Figure 1 shows the screen you will see when you enter Machine Diagnostics, which you will need to go
to access the mapping screens. Note the “102” at the bottom of the screen. This is the secret code to
access the mapping screens. The key sequence once you have entered the diagnostics screen is
“ENTER”, “102”, “ENTER”. This will then display the screen shown in Figure 2.
Figure 2 is the main screen for mapping. From this screen you can: 1) Manually enter compensation, 2)
Load axis mapping from disk (floppy or hard disk) that was previously saved, 3) Load defaults (Note
that this will reset all map data to zero’s, i.e. no mapping information), 4) Save mapping
compensation to disk (floppy or hard drive)
REVISED BY:
Figures 3 thru 8 show typical forward and reverse screens for the X, Y, and Z axes.
Example:
The X axis was checked using a JO-Block that was 19.5 inches long. The error seen at 19.5 inches was
0.0002925 inches (292.5 millionths). The error per inch would be 0.0002925 ' 19.5 which would equal
0.000015 inches (15 millionths). This error per inch was then entered for each entry in the
forward table (Figure 3) and the reverse table. Prior to the back lash value being entered the screens
had the same values entered for both forward and reverse mapping. The backlash error was 0.0003
inches (300 millionths) and this was added as a single entry using the reverse compensation softkey, to
the reverse compensation and the result displayed in the reverse table shown in Figure 4.
The Y axis was checked with a 10 inch JO-Block. The error was (-) 0.0004 inches (400 millionths) and
the backlash was 0.0008 inches (800 millionths). Refer to Figures 5 and 6.
The Z axis screens (Figures 7 and 8) show 0.00001 inches (10 millionths) per inch error and 0.0001
inches (100 millionths) of backlash.
Figures 9 and 10 show an example of a Z axis prior to entering backlash compensation. The Z axis
leadscrew error is 0.0001 inches (100 millionths of an inch) per inch. Figure 11 shows entering 100
millionths (0.0001 inches) of backlash compensation. Figure 12 shows the result of the backlash
compensation on the reverse map.
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 8
FIGURE 9
FIGURE 10
FIGURE 11
FIGURE 12
Once the mapping is completed and all data is entered and confirmed valid, you should save the
leadscrew map to both the hard drive and to the customer’s configuration floppy disk. Note that as with
all types of accuracy checks that the axes should be allowed to warm up to minimize the effect of
thermal expansion and that the more accurate the measuring device the more accurate the machine will
perform.
The accuracy and repeatability specs for the 5M are:
Accuracy ) 0.0005 inches Repeatability ) 0.0003 inches
DATE: May 20, 1994
ISSUE NUMBER: 1217
SUBJECT: ISA HARD DISK SETUP
SUPERSEDES NUMBER:
PAGE 1 OF 2
The following steps are required to setup a hard drive to boot the Ultimax software. It is assumed that
the drive will be low level formatted from the manufacturer.
1)
You must have a DOS bootable floppy disk with the following files:
FDISK.EXE, FORMAT.COM, BOOTMERG.EXE, AND BOOTSTRP.BIN.
NOTE: It is also handy to have some form of disk utility such as NU.EXE from the Norton Utilities.
2)
Create the “C:” and “D:” partitions by using FDISK.EXE and setup the primary partition
for 10 megabytes, and make this the active (boot) partition. The second partition (D:)
should use the remainder of the space on the drive.
3)
Use FORMAT.COM and format the C: drive. Enter EXECUTIVE_1 as the volume label.
Format the D: partition, no volume label is needed.
4)
Put the Hurco bootstrap on the boot sector of the drive by typing the following:
bootmerg bootstrp.bin c:
NOTE THE SPACES, SYNTAX IS EVERYTHING
REVISED BY:
5)
Copy the HURCO.LDR file onto “C:”
NOTE: This must be the first file copied onto the “C:” partition. The reason is that the
HURCO.LDR must start at cluster 2 and must be contiguous. It must be the first or second
entry in the root directory, the volume label is the other. The bootstrap is a small program that
assumes that these conditions exist. The Norton utilities are useful for checking these conditions.
NU.EXE can be used to look at the root directory and verify that the volume label and the
hurco.ldr are the first two entries. Also check the start cluster for hurco.ldr and make sure it is 2.
Then select the FAT and verify that the chain of clusters is contiguous.
6)
Copy all other files in any order to C:
7)
Reboot the control by cycling the power OFF and ON.
DATE: July 29, 1994
SUBJECT: Yaskawa AC Servo Set-up, Max 2 & Max32 Dual Axis SUPERSEDES NUMBER:
PRODUCT LINE: BMC20-50, KM5
PAGE 1 OF 5
Revised Engineering Doc 757-4002-092:
To reflect KM5 & BMC20LR X & Y Axis Jumper setting on SW2
SUBJECT:
Ultimax II BMC 20-50 IP/V2 and KM5 Yaskawa Servo
Amplifier Set-up Procedure
II. APPLICABILITY:
Applicable to all Ultimax II and Max 32 BMC 20/50 IP/V2 Machine Centers and KM5 Knee Mills. This procedure to be
used by Manufacturing during build process and by Customer Service when installing or servicing the above machine
types.
III. INDEX:
Page 2
Page 2Page 3
Page 4
Page 5
-
Servopack Configuration ** INFORMATION ADDED **
DAC Offset PCB Adjustment procedure
Linear Axis Servo Setup procedure
Yaskawa Servopack PCB layout Diagram
Amplifier Information and Fault Codes
Tools Required:
Digital Volt Ohm Meter (DVM)
Small Screwdriver
REVISED BY:
IV. LINEAR AXIS YASKAWA SERVOPACK CONFIGURATION:
NOTE:
Normally the factory settings of VR1 thru VR6 will not need to be altered.
A)
Verify that the Yaskawa Servopack for each Axis is configured as follows:
LINEAR AXES Refer to Page 4 for location
Shunt
SW1
SW2
SW3
SW4
Pot’s
VR1
VR3
VR4
VR5
VR6
Settings
Jumpers on 4 & 8
Jumpers on 2 thru 8
1:2 Ratio/ All BMC
Jumpers on 1 thru 8
1:1 Ratio BMC20LR X & Y Axis Direct Drive
Jumpers on 3 thru 8
1:4 Ratio KM5
Jumpers on 1 & 4. Add jumper to #7 if machine exhibits an axis
oscillation in manual and / or automatic. Will be heard as a rumble.
Jumpers on 1 thru 4 & 8
IN-B
ZERO
FINE
CUR
LOOP
Setting
Mid range
Mid range
Mid range
Full CW
Mid range
Scale
5 of 10 Scale
5 of 10 Scale
5 of 10 Scale
10 of 10 Scale
5 of 10 Scale
V. DAC FLYER PCB SETUP PROCEDURE:
AXIS CONTROLLER ONE (AC1)
Top pot
Z axis DAC offset adjustment
Bottom pot Spindle DAC offset adjustment (Used on KM5 Only)
AXIS CONTROLLER TWO (AC2)
Top pot
X axis DAC offset adjustment
Bottom pot Y axis DAC offset adjustment
A)
Ensure machine is Calibrated and the Axis are positioned to center of travel.
B)
Depress the “Change Tool or Diagnostics” Softkey then “ATC & Machine Diagnostics” softkey,
to display the diagnostic screen. Depress “Enter”, “488”, “Enter”, (Note: may be “101” on later
software versions) to display the Spindle/Servo Diagnostic Setup screen.
C)
Depress “Axis Balance Adjustment” softkey. This commands an open-loop routine that outputs
four bits of DAC, both plus and minus, at a three second duty cycle. This will produce an
approximate +/- 9.7mVDC command signal to the servo amplifier.
D)
Use the “Axis Jog” buttons to select the axis to adjust, then depress the “Start” button.
E)
Connect a Digital Volt Meter, set on the Millivolt DC scale, to TM3-2 (Positive Lead) and 0V
(Negative lead) of the approiate servo amplifier.
F)
Adjust the approiate DAC Offset Adjustment pot to obtain a symmetrical reading within 0.0001
VDC (0.1mVDC). Note the actual voltage value may vary slightly from one Dual Axis PCB
to another, however it will usually be around +/- 9.7mVDC.
G)
Return the axis to the closed-loop servo mode by depressing the “Exit” softkey and the Manual
Mode key.
FSB XXX Page 2 of 5
VI. LINEAR AXIS SERVO SETUP PROCEDURE:
1.
A)
B)
C)
Confirm the Control is in Metric Mode” and enter the following programs for the Axis to be
adjusted:
X Axis:
Part Setup:
X = 0, Y = 0, Z = 0
Tool Setup:
Tool 1 = Any type, Any Diameter, Length = 0, RPM = 100.
Program Parameters: Rapid Traverse = 1016 mm/Min.
Part Program:
Data block 1 = Pattern Loop Rectangular, 10 x 10 with no offsets.
Data block 2 = Position Tool 1 to X of 0, Y of 0.
Data Block 3 = Position Tool 1 to X of 100 mm, Y to 0 mm.
Data Block 4 = Pattern End.
Y Axis:
Same as above except exchange X and Y coordinates in Data Block 3.
Z Axis:
Part and Tool Setup same as above.
Program Parameters same as above.
Part Program:
Data Block 1 = Drill Holes with Tool 1, Z Start and Z Bottom = -100 mm,
Feed = 1016 mm/Min., RPM = 100. Bolt Circle of 100 holes with 0 Radius.
2.
Connect DVM to Yaskawa TM3-2 (Positive Lead), and 0V (Negative lead) of the axis to be
setup. Set Meter on 2 VDC scale.
3.
While running the correct program for the axis being set, adjust VR1 to obtain .945 to .955 VDC
in both directions. Use VR3 to minimize difference in signal when changing direction of the
axis. Adjust VR4 to obtain .950 to .952 VDC in both directions.
4.
After VR4 is set for .950 to .952 VDC in both directions depress Motion Hold button. Verify that
signal is 0.000 VDC. If not adjust VR3 for 0.000 VDC or as close as possible to zero.
5.
Repeat above steps for All Axes.
6.
Calibrate Axes and observe position display on CRT. CRT should display 0.000MM for all axes
and Marker Dot should be either on solid or flashing on & off. If not, fine tune VR3 for the
selected Axis.
7.
Run Axes thru a few short position moves, then recheck the axis balance by Calibrating Axes as
in step above.
8.
Program Full Travel, Rapid Traverse moves of 10160 mm/Min. and verify axes run smoothly
and that no Motion Error occurs. Repeat this ten times.
FSB XXX Page 3 of 5
CACR-SRCA
REV B
OV
TM5
TM3
TM4
1
1
1
SW1
T
O
T
O
8
8
T
O
8
1
T
O
SL4
8
SW4
RESET PUSHBUTTON
1
T
O
TROUBLE LED INDICATION
(7-SEGMENT)
8
SW2
VR9
IN
1
VR2
P
T
O
VR10
MP
8
VR11
VR12
5VP
VR13
IN-B
SW3
1
LOOP
T
O
ZERO
8
VR7
CUR
VR4
8 TO 1
VR8
TM2
8 TO 1
2CN
SL6
SL7
TM1
SL5
1CN
FSB XXX Page 4 of 5
MAX TWO V2 AXIS AMPLIFIER INFORMATION
GREEN LED STATUS
INDICATORS
LED NAME
MP
ILLUMINATED INDICATION
MAIN BUS INPUT VOLTAGE IS PRESENT.
(AXIS BUS STARTER [ABS] IS ACTIVATED)
P
AMPLIFIER CONTROL VOLTAGE IS PRESENT.
(INTERNAL +5VDC)
IN
A DAC COMMAND IS CURRENTLY APPLIED.
AXIS AMPLIFIER SEVEN-SEGMENT LED
DISPLAY
LED
-
INDICATION
BASE CURRENT
IS BLOCKED
NORMAL
OPERATION
1
4
GOES ON AFTER THE START
PUSH BUTTON IS DEPRESSED.
AXES ARE READY TO MOVE.
GOES ON WHEN THE MAIN
DISCONNECT IS TURNED ON.
DEFECTIVE AMPLIFIER CONTROL CIRCUIT
BOARD (1 PWB).
GOES ON WHEN THE START
PUSH BUTTON IS DEPRESSED
AND MCCB DOES NOT TRIP.
DEFECTIVE CURRENT FEEDBACK CIRCUIT.
DEFECTIVE MAIN CIRCUIT TRANSISTOR
MODULE.
PUSH BUTTON IS DEPRESSED
AND MCCB DOES TRIP.
DEFECTIVE MOTOR GROUNDING.
DEFECTIVE MAIN CIRCUIT TRANSISTOR
MODULE.
GOES ON WHEN THE AXIS
STARTS OR SLOWS DOWN.
BOARD (1 PWB).
BOARD (1 PWB).
DEFECTIVE MAIN CIRCUIT THYRISTOR
DIODE MODULE.
BOARD (1 PWB).
DEFECTIVE REGEN TRANSISTOR OR REGEN
RESISTOR.
DEFECTIVE REGEN CIRCUIT.
DEFECTIVE REGENERATIVE CIRCUIT.
MOTOR/ENCODER CONNECTION ERROR
OR MOTOR/ENCODER FAILURE.
PROTECTOR
TRIPPED
3
PROBABLE CAUSE
MACHINE IS IN EMERGENCY STOP.
OVERCURRENT
CIRCUIT
2
TIME OF INDICATION
REGENERATIVE
TROUBLE
OVERVOLTAGE
5
OVERSPEED
6
VOLTAGE DROP
DEFECTIVE MAIN CIRCUIT THYRISTOR
DIODE MODULE.
BOARD (1 PWB).
RESULT OF POSSIBLE OVERHEAT, ALLOW
SYSTEM TO COOL FOR 30 MINUTES.
GOES ON DURING MACHINE
OPERATION.
CONTINUOUS MACHINE OPERATION ABOVE
100% RATED LOAD.
RESULT OF POSSIBLE OVERHEAT, ALLOW
SYSTEM TO COOL FOR 30 MINUTES.
OPERATION.
CONTINUOUS MACHINE OPERATION ABOVE
100% RATED LOAD.
BOARD (1 PWB).
BOARD (1 PWB).
MOTOR STARTS MOMENTARILY,
THEN C. ERROR GOES ON.
MOTOR/ENCODER CONNECTION ERROR
OR MOTOR/ENCODER FAILURE.
BOARD (1 PWB).
MISSING THREE PHASE INPUT SOURCE.
CHECK AXIS BUS STARTER (ABS).
OPERATION.
BOARD (1 PWB).
7
A
b
C
F
OVERLOAD
OVERHEAT
A/D ERROR
OVERRUN
PROTECTION
OPEN
PHASE
CPU ERROR
ERROR STATUS IS RELEASED BY PRESSING THE AMPLIFIER RESET BUTTON
703-0006-169 Rev.A
FSB XXX Page 5 of 5
ISSUE NUMBER: 1219
SUBJECT: Low Volume from Coolant Pumps.
SUPERSEDES NUMBER:
PRODUCT LINE: Acroloc 1540, 1550, 3030 Twin Spindles
PAGE 1 OF 1
This FSB covers any Acroloc 1540, 1550, or 3030 Twin Spindle with the 200 gallon coolant reservoir.
The low coolant volume that we are experiencing has been found to be caused by a filter screen directly
in front of the coolant pump. To rectify this problem, remove the screen from in front of the pump. The
filter basket is sufficient to keep chips and debris from damaging the Pump. This could also be why we
are experiencing such a high rate of Coolant Pump failures, as the motor must work harder to pump
coolant.
ORIGINATOR: Don Schmedake
REVISED BY:
ISSUE NUMBER: 1220
SUBJECT: Executive Disk V1.51
SUPERSEDES NUMBER:
PAGE 1 OF 1
The Executive Diskettes V1.51 that were shipped with all Hawk 5M machines have a defective
HURCO.LDR file. The control will not be able to boot off of these floppy diskettes, as the control will
continually reboot. Also, do not attempt to execute an UPGRADE EXECUTIVE with these diskettes as
this will transfer the defective HURCO.LDR file to the Hard Drive. This will result in the control
continuously rebooting. If a customer needs to use the Executive Diskettes, a new V1.51 (or a V1.52
with a new Software Protection Key) will be required.
REVISED BY:
ISSUE NUMBER: 1221
SUBJECT: Spindle Handling Precaution
SUPERSEDES NUMBER:
PRODUCT LINE: All BMC’S (Cartridge Type)
PAGE 1 OF 1
HURCO MANUFACTURING has had our spindle rebuilders investigate the causes for failures. One
cause for failures is supporting the weight of the spindle cartridge assembly on the spindle nose instead
of the cartridge mounting flange. This will lead to premature bearing failure.
Whenever you are replacing the spindle cartridge in any machine that has a cartridge assembly. the
weight of the assembly is to be supported by the mounting flange. This can be accomplished by using
wood blocks of sufficient height and width to keep the spindle nose clear of the table. As always use
caution when moving heavy objects.
After installing but, before running the new spindle, be sure to completely check it out.
Do the following geometry checks and procedures.
1. Verify machine is level. Correct as necessary.
2. X to Z, Y to Z & X to Y squareness. Correct as necessary. You may have to sacrifice level to
obtain proper squareness
3. Check table flatness. (The preceding three (3) items can cause an apparent spindle problem.)
4. Check spindle sweep. Correct as necessary.
5. Set drive belt tension per engineering document # 757 4001 117 rev B.
6. Perform Spindle Run In per engineering document # 757 4001 118 rev A.
REVISED BY:
ISSUE NUMBER: 1222
SUBJECT: Proper Axis Current Set-Up
SUPERSEDES NUMBER:
PAGE 1 OF 1
The proper axis currents for the Hawk 5M mill are as follows:
1)
The X/Y Axis current should be between 3 to 6 Amps; in both plus and minus directions.
2)
The Z Axis current should be between 1.5 to 3 amps; in both plus and minus directions.
The axis currents are to be set by adjusting Gib tension per normal procedure.
REVISED BY:
R
DATE:
January 16, 1995
ISSUE NUMBER: 1223
SUBJECT:
Accuracy Standard Procedure
PRODUCT LINE:
All Mills
PAGE 1 OF 5
INTENT:
To have a standard procedure in using the accuracy standard to setup the leadscrew
compensation and backlash on all machines. Following is a step by step procedure to assist you in this
endeavor:
1. Allow the 13.1 inch standard to reach the same temperature as the machine, which could take up to
one hour or more depending on the initial temperature of the standard.
2. Stone the table to remove small nicks in order to provide a smooth surface.
3. Level the machine and check geometry to insure the machine is within specifications.
4. Place the standard on the table parallel to the axis you intend to measure. The standard should be
directly over the leadscrew and not to one side of the table. If it is off to one side, a small kick in
the table will affect the outcome of your measurements. Align the standard with a .0001” indicator
in order to ensure absolute parallelism with the axis, usually .0001” from end to end. If the standard
has a slight bow, align the ends and disregard the center. Placing a magnetic base along side the
standard is sufficient to hold the standard in place. If you must use clamps to hold the standard, DO
NOT over tighten; if debris is under the standard or the table is not flat then the standard may be
damaged.
5. Refer to the following Fig. 1 and the program ACCRCSTD.HD3 in checking the machine. The Part
Zero and Tool Zero is at Position 1 and should be near the center of the tab. Data Block 1 is a
Parameter Block to slow the Rapid Traverse, setup Retract Clearance, and increase Drill Dwell. By
using a Data Block for the parameters, it allows you to jog at normal feedrates in the manual mode.
Data Block 2 sets up a loop for a continuous run. Data Blocks 3 and 4 provides for Drill Positions
1 through 6. Please note that Z Start in Data Block 4 is at a -.5000”. A similar program can be
written for the B/BX machines.
ORIGINATOR: Ken Borgmeyer
REVISED BY:
Pos. 2
Pos. 1 & 3
Pos. 4 & 6
Pos. 5
13.1 INCH STANDARD
FIG. 1
6. The program should be ran in the Dry Run of Test Mode with a Minimum Z of -0.5000”. On the
B/BX, a Dry Run is done by depressing Operate, Auto On, Check, Start, and Head Down for each
movement. The Spindle On and Auto tool Change are not used. A couple of runs should be done
to check the measurements to insure that the Standard is not moving and that the indicator is giving
good readings. For example, the reading at Position 3 should be the same on all runs.
7. The difference between Position 3 and Position 4 is the leadscrew error. The difference between
Positions 1 and 3 is the backlash at that position. Likewise, the difference between Positions 4 and
6 is the backlash at that end of the Standard. Record this information.
8. Leadscrew error should be corrected first, thus making the backlash checks easier. To compute
leadscrew error, take the difference between Positions 3 and 4 and divide by 13.1”. Round off the
result to the nearest ten-millionths and add to each inch value in the Forward Map. For example, if
you have a difference of 0.0008” (or 800 millionths) between Positions 3 and 4, dividing by 13.1
results in 61.07 millionths which is rounded to 60 millionths per inch. In the Forward Map (102
screen), enter the following numbers:
0 inch
1 inch
2 inch
3 inch
4 inch
0
60
120
180
240
and so on. In the Reverse Map, enter the same numbers in each location. For the above example, 0
inch will be 0, 1 inch will be 60, etc. Note: this is before you enter any backlash in the Reverse
Map! The program should be run again to verify the leadscrew error has been corrected and only
then should the backlash error be recorded.
9. If the backlash is approximately the same on bothe readings, an average can be used. For example,
if the differences between Positions 1 and 3 is 0.0004” and Positions 4 and 6 is 0.0006” then
0.0005” would be sufficient to bring the machine into specification. In this case, 500 millionths
would be added to all locations in the Reverse Map. If the backlash varies over the lenght of the
leadscrew, different backlash can be added at those locations.
FSB1223.DOC
Page 2 of 5
10. The numbers in the Leadscrew Compensation screen corresponds to the machine location from table
zero. If you have large differences in backlash from one inch to the next (greater than 0.0002”) then
you have a serious problem with the leadscrew or other major problems.
This procedure should allow you to setup a machine to specification. If the customer insists the
machine be setup under closer standards then a laser must be done.
FSB1223.DOC
Page 3 of 5
HURCO ULTIMAX PART PROGRAM
ACCRCSTD.HD3
INCH
STANDARD
PART SETUP
PART ZERO
OFFSET
X
Y
Z
1.2345
6.7890
0.0000
SAFETY WORK REGION
Z TOP (+)
99.0000
Z BOTTOM (-)
-99.0000
X LEFT (-)
-99.0000
X RIGHT (+)
99.0000
Y FRONT (-)
-99.0000
Y BACK (+)
99.0000
GENERAL PARAMETERS
RETRACT CLEARANCE
RAPID TRAVERSE
PECK CLEARANCE PLANE
CHORD ERROR
DEPLETION RETRACT
99.0000 IN
400.0 IPM
0.0500 IN
0.0001 IN
0.0050 IN
HOLES PARAMETERS
BORE ORIENT RETRACT
DRILL DWELL
BORE DWELL
0.0200 IN
0.5 SEC
1.0 SEC
MILLING PARAMETERS
BLEND OFFSET
BLEND OVERLAP
FINISH FEED
FINISH SPEED
FINISH XY
FINISH Z
MILLING DIRECTION
POCKET OVERLAP
CUTTER COMP PARAMETER
0.1250 IN
0.1250 IN
100 %
100 %
0.0100 IN
0.0050 IN
CLIMB
10 %
INSERT ARC
PROGRAM PARAMETERS
OVERRIDE LOCKOUT
PROGRAM PROTECT
TOOL CHANGE POSITION
OFF
PARTIAL
NO
TOOL SETUP
1
TYPE
DIAMETER
ZERO CALIBRATION
SPEED (RPM)
COOLANT
CW
DRILL
0.1000
12.3456
0
OFF
FSB1223.DOC
Page 4 of 5
DATA BLOCKS
1
CHANGE GENERAL PARAMETERS
RETRACT CLEARANCE
RAPID TRAVERSE
PECK CLEARANCE PLANE
CHORD ERROR
DEPLETION RETRACT
HOLES PARAMETERS
BORE ORIENT RETRACT
DRILL DWELL
BORE DWELL
MILLING PARAMETERS
BLEND OFFSET
BLEND OVERLAP
FINISH FEED
FINISH SPEED
FINISH XY
FINISH Z
MILLING DIRECTION
POCKET OVERLAP
2
PATTERN LOOP RECTANGULAR
X NUMBER
10
Y NUMBER
10
X DISTANCE
0.0000
Y DISTANCE
0.0000
3
HOLES
DRILL
TOOL
Z START
Z BOTTOM
PLUNGE FEED
SPEED (RPM)
PECK DEPTH
PECK TYPE
LOCATIONS
1
2
3
1
0.0000
0.0000
5.0
0
0.0000
STANDARD
X
Y
0.0000
0.0000
-1.0000
0.0000
0.0000
0.0000
HOLES
DRILL
TOOL
Z START
Z BOTTOM
PLUNGE FEED
SPEED (RPM)
PECK DEPTH
PECK TYPE
LOCATIONS
1
2
3
1
-0.5000
-0.5000
5.0
0
0.0000
STANDARD
X
Y
13.1000
0.0000
14.1000
0.0000
13.1000
0.0000
4
5
0.5000 IN
40.0 IPM
0.0500 IN
0.0001 IN
0.0050 IN
0.0200 IN
1.0 SEC
1.0 SEC
0.1250 IN
0.1250 IN
100 %
100 %
0.0100 IN
0.0050 IN
CLIMB
10 %
PATTERN END
FSB1223.DOC
Page 5 of 5
DATE: March 24, 1995
ISSUE NUMBER: 1224
SUBJECT: Table T-Slot Alignment
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5M / Hawk 5D
PAGE 1 OF 1
The T-Slot parallel alignment to X Axis is measured from the center to each end of the table, not from
one end to the other. This measurement should be 15 inches from center in each direction and the
tolerance is 0.0008 inches over 12 inches of travel. The center T-Slot is the only one measured or
specified. See diagram below.
15”
15”
15”
REVISED BY:
DATE: JUNE 13, 1995
ISSUE NUMBER: 1225
SUBJECT: HAWK 5M/5D DRAWBAR SETUP
SUPERSEDES NUMBER:
PRODUCT LINE: HAWK 5M/5D
PAGE 1 OF 1
The following is the procedure for setting the drawbar height on all HAWK 5 machines.
There have been several reports of power heads failing in the field and the possible cause
could be inproper drawbar setup.
1) Calibrate machine.
2) Remove cover and power head assembly.
.
3) Measure from top of retainer cap to top of drawbar and set to .950” to 1.00”
with machine at home position
4) Adjust Z+ limit switch if necessary to achieve .950” to 1.00”.
ORIGINATOR: KOSTAS EVDOKIOU
REVISED BY:
ISSUE NUMBER: 1226
SUBJECT: Kurt Power Drawbars-Hawk 5 M and Hawk 5 D SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5 M-5D
PAGE 1 OF 1
It has been discovered that some of the Kurt Power Drawbars were supplied to HURCO with out the
O-ring being greased. This results in the Kurt Power drawbar either not engaging every time or not
returning to the normal disengaged position (It sticks in the down position.).
TO RESOLVE THIS PROBLEM; GREASE THE O-RING
1) Remove Kurt power head from machine.
2) Remove power cover (4 screws).
3) Remove the spring clip and snap the collet out.
4) This exposes the O-ring, coat with a lithium grease
5) Preload the spring clamp tension
6) Replace the power cover.
7) Mount Power Head back on machine and verify that Kurt Power Head engages and disengages the
cleanly every time.
NOTE: IF THE TOP OF THE DRAW BAR IS DAMAGED THE DRAWBAR MUST BE
REPLACED ALSO. PART #802-2706-001 The washer part number if needed is 604-0742-013.
The part # for the Kurt Power Drawbar is 002-4005-001
ORIGINATOR: Steven Artz
REVISED BY:
DATE: July 21, 1995
ISSUE NUMBER: 1227
SUBJECT: Flood Coolant Leaks
SUPERSEDES NUMBER:
PRODUCT LINE: Frame "A" Machines
PAGE 1 OF 2
The Frame “A” machines described below need to have the wipers and covers for the Y-axis
checked for wear, gaps and excessive weld build up which can cause wiper failure.
Machines 1-73 were modified per the Frame “A” machine addendum and will not have the
wiper shown in figure 1. Machines 74 and later must be inspected and corrected. Any machine with
a May 1995 or later serial number falls into this group. Frame numbers are located on the lower right
when viewing from the back of the machine.
Please review the following drawings for locations of points to be inspected.
REVISED BY:
figure 1
The neoprene wiper seen here against the Y-axis cover may have become damaged by
running back and forth over heavy welding . Inspect the Y-axis with a flashlight from the back of the
machine. Black rubber flakes on the Y-axis cover indicates further inspection of the wipers should be
done.
During your inspection watch for gaps during axis movement over the full travel of Y.
Some mounting bolts may need to be loosened to adjust the covers up or down to eliminate gaps.
But to not bind the way covers when the Y- axis moves to the negative limit.
IF YOU HAVE ANY QUESTIONS CALL HURCO TECHNICAL SERVICE.
ISSUE NUMBER: 1228
SUBJECT: Power Cabinet Coolant Leaks.
SUPERSEDES NUMBER:
PAGE 1 OF 1
Gentlemen;
The purpose of this FSB is to notify you of a possible invasion of coolant into the Power Cabinet. We
have had 3 incidents where coolant has leaked into the Power Cabinet past the mounting bolts for the
transformer located on top of the Power Cabinet and shorting out either the Servo Dynamics axis drive,
or the I/O board and Backplane in the ISA Card Rack. After close inspection of the mounting flange on
the transformer, it appears that the only way to resolve the problem is to silicone the threads of the
bolts, the nutsert, and between the mounting flange and Power Cabinet. ( Due to the slotted holes on 1
side of the transformer mounting bracket.)
If you have a Hawk 5M in your territory, it will be necessary to resolve this problem before any damage
can occur. You can find a 4.7 oz. tube of silicone under the Hurco part number 702-0001-004. We do
have this silicone in stock at this time.
REVISED BY:
ISSUE NUMBER: 1229
SUBJECT: Incorrect parameter for Winding Change
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/HT/D
PAGE 1 OF 1
We have had some instances of BMC 30/HT/D machines not changing windings in the field due to an
incorrect parameter being installed. Please check to make sure that the BMC 30/HT/D Machines in your
region changes windings at your next visit to the customers facility.
The symptoms of this problem would be lack of torque, and difficulty setting up Rigid Tapping as the
spindle is always in high gear.
To check to see if your machine is changing windings is to simply program a spindle speed of 1999 rpm,
and than a spindle speed of 2003 rpm. Since the winding change occurs at 2001 rpm, you should hear
the Dual Winding contactor change states and also see the Load Meter jump at the same time.
If you determine that this problem does exist, follow the procedure in the Dynapath Delta 20 Installation
Guide to access parameters, and verify that parameter address 4AE is set to 04. Change this parameter
to a value of 05. If this parameter is set to a value other than mentioned, please call Technical Support
for further instructions. This parameter is used to turn on options located in the PIC Ladder
Instructions, so it must be set correctly.!!!
REVISED BY:
ISSUE NUMBER: 1230
SUBJECT: Servo Dynamics Drive Tune Procedure.
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/D, Hawk 5D, Hawk 5M
PAGE 1 OF 1
If it becomes necessary to change a Servo Dynamics Drive Board or Drive Chassis Assembly, use the
following procedure to assure proper tuning of the replacement board or boards.
1. Disconnect all plugs from the board or boards.
2. Attach the common of your volt meter to TP1 on a good drive Board.
3. Measure and document the Ohms between TP1 (common) and TP2, (Aux Pot) TP3, (Sig Pot) TP4.
(Tach Pot) and TP5 (Cmp Pot).
4. Adjust the Potentiometers on the new Drive Board to match your documented readings from the
good board. This will tune the new board to the correct specifications.
5. Double check your Axis Balance and Axis Lag before leaving and adjust as necessary.
REVISED BY:
DATE: Nov. 28, 1995
ISSUE NUMBER: 1231
SUBJECT: Digital Spindle Controler PCB Modifications
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk 5 ssm
PAGE 1 OF 1
This modification is to remedy the spindle not at speed error on the SINGLE SCREEN MAX Hawk
5’s.
On the digital speed controller (415-0252-901)solder a 330 ohm 1/4w resistor in parallel with the
resistor element at RN1 pin 5.
All new boards should have a 270 ohm resistor pack (407-0010-070) not the 2.2 K resistor pack.
Machines shipped after Jan 01, 1996 should already have this modification done. Machines shipped
in 1995 may not have had board modified. PLEASE CHECK.
RESISTOR, 330 OHM 1/4 W 5%
..........
RN 1
SOLDER SIDE
ORIGINATOR: J. Steven Artz
REVISED BY:
DATE: Jan. 16, 1996
ISSUE NUMBER: 1232
SUBJECT: Upgrade of Remote Shutdown Relay. (RSR)
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/D, BMC 30/HT/D
Delta 20 and Delta 40 Controls
PAGE 1 OF 1
The purpose of this FSB is to upgrade the Remote Shut Down Relay to enable the Servo Dynamics
Drive to brake the Axis to a stop when Emergency Stop is depressed. To perform this upgrade, it will be
necessary to order a Hurco Part Number # 407-0002-078 50 VDC., 220 Micro Farrad Radial Polarized
Capacitor, and install it across the coil of Remote Shutdown Relay. This will cause the Servo Dynamics
Drive to remain ready long enough after the DAC Signal is cut off to allow braking before the Drive is
Inhibited. Remember to observe the Polarity of the Capacitor. Keep in mind that the Silver Stripe on the
Diode is the plus side of the relay coil.
REVISED BY:
DATE: Jan. 24, 1996
ISSUE NUMBER: 1233
SUBJECT: Upgrade of RS232C Cables. (Com 1, Com 2 )
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30/M, BMC 30/HT/M
PAGE 1 OF 1
The purpose of this FSB is to upgrade the Com 1, Com 2 RS232C cables located on the back door of
the Electrical Cabinet. To do this upgrade you will need to order 2 of a part # 423-4405-080, and 4
threaded stand-offs, part # 110-0134-051. Remove the existing Ribbon Cable Harness going to Com 1
and Com 2, taking care to note where Com 1 and Com 2 plug into the ISA Card Rack, so as not to
unintentionally swap the two ports. Attach the new shielded Cables to their respective ports on the ISA
Card Rack, and secure the Female ends of the Cables to the back door of the Electrical Cabinet using
the Thumb Screws already in the new cable assembly and the Female Stand Offs to secure it to the Com
Panel, using Loctite 601 to prevent these from coming loose.
This is being done to solve a noise problem that occurs during long transfers of files VIA RS232C.
REVISED BY:
DATE: 02/21/96
ISSUE NUMBER: 1234
SUBJECT: Kurt Power Heads & Drawbar Set-up
SUPERSEDES NUMBER:
PRODUCT LINE: KM5P, Hawk 5M, Hawk 5D, & Hawk 5SSM PAGE 1 OF 2
DISASSEMBLY OF CHICAGO PNEUMATIC OR KURT POWER DRAWBAR VOIDS THE ONE
(1) YEAR MANUFACTURER’S WARRANTY. If suspected failure and under warranty then replace.
Complete Power Drawbar Assemblies (Powerhead, with base plate,switches, & fittings, Drawbar, and
Head Cover) can now be ordered.
PART NUMBER
002-4208-003
002-4208-004
002-4208-005
002-4208-006
DESCRIPTION
Metric Power Drawbar Assy.
Inch Power Drawbar Assy.
Metric Power Drawbar Assy.
Inch Power Drawbar Assy.
DRAWBAR PART #
802-2906-003
802-2906-002
802-2706-002
802-2706-001
WHERE USED
Current Hawk Mills
Current Hawk Mills
KM5P & Early Hawk Mills
KM5P & Early Hawk Mills
PROBLEMS TO BE ADDRESSED
1. Washer coming loose from mounting plate and hanging up on drawbar.
Solution: Insure that tool change height is set to 1.00” to 0.95” (FSB 1225)
Set-up: Need 0.050” to 0.100” clearance between top of drawbar shoulder and bottom of
thrust washer.
2. Air ratchet catching and binding up when moving up/down.
Solution: Fill (there is a level check plug on rear of air ratchet and this is where you fill the air ratchet)
with air tool oil (5wt) when installing a new machine or power drawbar head.
Check to make sure that the guide rods are straight and parallel. NOTE: If Chicago
Pneumatic Air Ratchet is under or over oiled, the ratchet loses power.
3. Air ratchet coming loose from mounting base.
Solution: Loc Tite the 4 bolts holding the head to plate. This is to be done any time servicing or
replacing unit.
ORIGINATOR:Steven Artz
REVISED BY:
4. Top end of drawbar being chewed up.
Solution: Make sure height set correctly.
5. Tools coming loose in spindle.
Solution: Refer to FSB 1166, 1168, 1225, TIN 1024A, & 1065.
6. Air motor starts before head is down in spline.
Solution:#1 Check spring (Spring-Plunger) inside powerhead (REF. Page 15 Item # 18 in Kurt
manual) it maybe weak and need replaced. ONLY DISASSEMBLE IF NON-WARR.
#2 FSB 1226
#3 Guide rods are not parallel. Replace unit.
7. Air motor runs in one direction only or doesn’t run at all.
Solution: #1 Disconnect the 2 air lines (1/4”) from powerhead that come from IN/OUT valve and
make sure air is coming through each line when appropriate button selected. If no air, check
button assembly (Page 11 of Kurt Manual)
#2 Disassemble upper block (Page 5 in Kurt Manual) and check “O- Rings” items #3 & #7
#3 Check Mist Lube Unit to make sure that we are not over lubing and causing valve in
powerhead to stick. If this is the case adj. the mist lube unit and cycle the powerhead to
free up. ONLY DISASSEMBLE IF NON-WARRANTY.
8. Powerhead Assembly Sticks in down position.
Solution: #1 Check drawbar spline for damage. If damaged replace and set-up correctly.
#2 Check drawbar/head alignment (float in if needed).
#3 FSB 1226A (O-Ring not greased Item # 18, page 5 in Kurt Manual)
#4 Air lines binding in cover. Reroute, open slot in cover and reapply protective edging.
#5 Spring to weak or adjusted incorrectly (No preload). Ref. Item #13 on page 5 of Kurt
Manual.
#6 Air Line Retro (TIN 1024), use 3/8” line @80psi (Head needs minimum of 70 psi)
#7 Guide rods bent.
HURCO SERVICE ENGINEERS ARE NOT TO CALL KURT MFG FOR TECHNICAL
SUPPORT
FSB XXX Page 2 of 4
DATE: March 3, 1996
ISSUE NUMBER: 1235
SUBJECT: Retro-fit of Drive Spindles to
accept 18 MM Proximity Switches.
SUPERSEDES NUMBER:
PRODUCT LINE: Acroloc 15-32, 15-40 Machining
Centers
PAGE 1 OF 1
Our current supplier of 300-577 14 mm Proximity Switches has notified us that they are discontinuing
these switches. We have no choice but to go to a larger diameter switch as they were the only ones who
manufactured this switch. The replacement switch will be part # 418-5002-016, and has a diameter of
18mm.
The Acroloc machines that will be most affected by this change will be the 1980 to 1990 15-32 and 1540 machines with the following controls: Fanuc 6 M to 11 M, Yasnac MX 1, GE Mark 2000, and
Siemens 810 Controls.
To perform this retro-fit when replacing this switch, it will be necessary to remove and disassemble the
drive spindle, remove and disassemble the orient plunger assembly, and drill out existing switch holes
with a 15.5 mm drill, and than tap these holes with an 18 x 1 mm tap.
When resetting the proximity switches in the drive spindle, be sure to leave enough clearance for the
button head screw in the orient sensing ring to clear the switch. (When the head of the button head
screw just clears the proximity switch, back the switch off 1 full turn before locking it into place.)
REVISED BY:
R
DATE:
Feb. 08, 1996
ISSUE NUMBER: 1236
SUBJECT:
Max32 Hard Drives
PRODUCT LINE:
All Max32 machines
PAGE 1 OF 1
There have been several reported problems with Max32 upgrades not allowing the
servos to power up. The following is to be done to all Max32 Snooper PCBs.
When doing a Max32 upgrade to any machine with any Hard Drive type(Ex. Conner,
Seagate, Quantum...) you must make sure that the Hard Drive is mounted on the back side
of the Snooper PCB. Reroute the power cable if needed. You might have to unsolder the cable
from the front side and solder to the back side to make it work being careful not to cross any
wires. Also, you must reroute the ribbon cable for the Hard Drive to make it work.
When reinstalling the Hard Drive into the card rack be sure that the Snooper PCB
is nearest to the Personality Board and the Hard Drive is facing the CPU. All Snooper PCB
assemblies in Max32 kits will be modified this way at Hurco Mfg Co starting in May96.
Please verify any Snooper PCB that you install in a Max32 machine is done this
way.
ORIGINATOR: K. Evdokiou
REVISED BY:
DATE: April 4 1996
ISSUE NUMBER: 1237
SUBJECT: FRL Units
SUPERSEDES NUMBER:
PRODUCT LINE: All 30 “A” Frames
PAGE 1 OF 1
Gentleman;
The purpose of this FSB is to remind you that the Water Trap Filter on the FRL Units is NOT an
Automatic Self Dumping Unit. There has been some confusion as to which type of Water Trap Filter is
being used, as some of the documentation implies, but does not specifically say that it is or is not an
Automatic Dumping Unit. The current Water Trap Filter must be drained periodically to insure that no
water is able to infiltrate the Machine air system. This is done by squeezing the two tabs located on the
bottom of the Water Trap Filter Bowl. Please instruct your customers at install or your next Service Call
to drain this unit daily, to prevent damage to the air driven tool change motor, valves, and pneumatic
cylinders, thus preventing down time. We are currently trying to source a Self Dumping Water Trap
Filter replacement for the Manual units. We will offer this replacement as a Non Warranty replacement
Option if the customer prefers the Automatic Self Dumping Unit.
REVISED BY:
DATE:
April 29, 1996
ISSUE NUMBER:
SUBJECT:
Z AXIS Cable Damage
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 30M/ HTM/ D
1238
PAGE 1 OF 1
This bulletin is to correct machines that have had damage to some of the cables going to the HEAD
area. These cables run through the Z AXIS CABLE HOUSING and into the Z AXIS CABLE
CARRIER. As it passes from the housing to the carrier it rubs on a rough edge of the housing.
HURCO’S sub-contract manufacturer’s will start adding a plastic conduit to protect the cables with
their MARCH shipments. This is an “interim” fix. The long term correction will be for manufacturer’s
to weld a round bar at the rough edge to give a smooth surface to protect the cables.
Manufacturing has been adding a NEOPRENE SHEET to protect the cables. This should be done in
the field to any machine that has not been remedied yet. You should be able to purchase NEOPRENE
at a local industrial supply house, i.e.( W.W. GRAINGERS ).
The Z AXIS CABLE HOUSING can be seen from the right side. It is between the cabinet and the Z
AXIS CABLE CARRIER (flexible metal tube). It has two access plates on it.
REVISED BY:
DATE: June 17, 1996
ISSUE NUMBER: 1239
SUBJECT: Fan Replacement / ISA Card Racks
SUPERSEDES NUMBER:
PRODUCT LINE: All ISA machines
PAGE 1 OF 1
Card rack with integrated power supply:
To replace fans on this ISA card rack you will need to order one piece of 002-4428-017 for
each new 24VDC fan.
1.
2.
3.
4.
Power off the machine.
Remove the fan housing screws.
Carefully remove the plastic fasteners that are holding each fan.
Unplug and replace with the new fan or fans and reassemble.
Card rack with power distribution board:
If you are working on the old style card rack with the power distribution pcb on the side you
will need to convert the fan wiring from 12VDC to 24VDC when replacing the fans. Order two of the
002-4428-017 fans and proceed as follows.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Power off the machine.
Remove the four mounting screws holding each fan.
Unplug and replace with the new fans and reassemble.
Locate the 423-4400-009 ISA Fan /Backplane power harness. This harness is internal to
the card rack and the J1 end of the harness plugs through the card rack and into the back
side of the power distribution board at TB7.
Locate the 12VDC brown wire on J1-10.
Remove this wire from the J1 wago connector.
Remove a blue 24VDC wire from either J1-11, or J1-12.
Splice the brown fan wire to the 24VDC wire and insert back into the respective J1
terminal.
This completes the modification. You should now have 24VDC supplied to the new fans.
REVISED BY:
ISSUE NUMBER: 1240
SUBJECT: Oiling Problems
SUPERSEDES NUMBER:
PRODUCT LINE: Acroloc 1540, 3030
PAGE 1 OF 1
This bulletin is to inform you to inspect the oil line which goes across the y-axis ways on all Acroloc
1540 and 3030 machines. This oil line can be found inside the saddle, and goes across the y-axis
ballscrew. One of the x-axis telescopic covers must be pulled back to inspect.
Some machines had the oil line stretched too tight at assembly. Some of the oil lines are pulling out of the
compression nut and ferrule. When re-installing oil line leave slack in the line, but ensure that the oil line is clear
of the y-axis ballscrew rotation.
Recommended parts for correction:
1. 350112
2. 508-2001-001
Ferrule
5/32 Bijur Tubing
Qty 2
Qty 3 ft.
ORIGINATOR: Tim Cloud
REVISED BY:
ISSUE NUMBER: 1241
SUBJECT: Possible Noise Problems
SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020/HT/M, BMC4020SSM
PAGE 1 OF 2
The purpose of this FSB is to prevent potential noise problems to the ISA Control caused by the close
proximity of the Commutation Reactor wiring harness and the main Wire Way located in the center of the
Electrical Cabinet.
To correct this problem, you will need to remove the Commutation Reactor harness from the Wire Way,
unfasten the Commutation Reactor from the back wall of the cabinet, and rotate the reactor 180 deg., so that
the harness is going out towards the Siemens Drive Package. Secure the wires to the back wall of the cabinet
using cable ties and self adhesive tie downs. (See attached drawing for details. )
If after doing this procedure, the machine is still experiencing noise related anomaly’s , (control lock ups, tool
change errors etc. ) try to move as many of the of the wires from the main wire way to the smaller wire way
located on the left side of the cabinet, as cable length will allow. Also verify that all required suppressers and
diodes are installed.
REVISED BY:
FSB xxxx Page 3 of 2
DATE: Sept. 6, 1996
ISSUE NUMBER: 1242
SUBJECT: ISA CARD RACK DIAGNOSTIC TIPS
SUPERSEDES NUMBER:
PRODUCT LINE: ALL ISA MACHINES
PAGE 1 OF 2
This document was created to help diagnose problems within the ISA card rack. This document
will be updated when additional helpful information is available. If you discover a unique way to
diagnose a card rack problem, write detailed steps down and it will be reviewed for validity and
possibly added to this document.
1.
Don’t hesitate to SCAN the hard drive for a virus before trying any other tests on a card
rack you may save yourself a lot of frustration.
2.
CMOS settings and motherboard jumpers are also crucial. I wouldn’t recommend making
any changes before consulting your documentation first; don’t guess.
3.
If your card rack boots and the Ultimax screens come up and you suspect an I/O and or
peripheral or functional type problem; Install your ISA test harnesses and run the ISATEST
diagnostic software which came with the harness kit (refer to your blue ISA manual for
instructions). Don’t forget that there are some interactive diagnostic functions available through
the Auxiliary screen using “Enter, 200, Enter”.
4.
If you are having video problems i.e. no video displayed: Power off the rack, remove the
Canbus controller card and power up the rack again. The Canbus controller has been known to
cause video problems. You may have to wait 30-45 seconds before the screens come up if you
are booting the executive.
5.
For intermittent problems such as rebooting. Check the power connections at the
motherboard and the Power Good (PG) signal. Especially on the old style racks the power
connector on the motherboard has one pin with two wires crimped in it. This is the 12VDC for
REVISED BY:
the Power Good chip. If this wire is loose and intermittent the rack will reboot.
6.
Check the fans on the card rack for slow movement or no movement. If needed replace the
fans. If you are replacing 12VDC fans refer to FSB1239. If the fans are OK, and you have a new
style rack remove the power supply cover and check for loose connections. Also, check the fuse
block connections in the integrated power switch. If you have the old style card rack with the
separate power supply, check the fan on the power supply. Is it moving slowly or not at all? If
the fan on the supply isn’t working replace the power supply. While you are at the power supply
don’t forget to check the supply voltages.
7.
If you suspect an I/O Interface, DC I/O, or Canbus controller board lockup, go into the
machine diagnostic screen from manual mode and try running the ATC functions, unclamp, etc.
Try jogging the axis. Try spindle on in manual mode. If some of these functions don’t work,
your I/O interface, D/C I/O, or Canbus controller may be locked up. Try cycling power on the
machine. If this clears up the problem, you need to try all diagnostics functions one at a time.
Also, check the washdown and coolant functions. One of these is probably improperly
suppressed.
8.
If the rack won’t boot the Executive software and displays errors like missing loader etc.
Try booting a DOS disk. You can remove all the boards except the Video card and the Floppy
Drive Transceiver board if you need to and still boot the card rack with a DOS bootable disk.
Then diagnose the hard drive etc.
Page 2 of 2
ISSUE NUMBER: 1243
SUBJECT: Spindle twitch @ Null setup.
SUPERSEDES NUMBER:
PRODUCT LINE: BMC30SSM
PAGE 1 OF 2
The first group of production BMC30 SSM bedmills (from Quaser) were affected by a spindle noise problem
not seen in previous, similar Frame A bedmills. The severity of the noise varied from machine-to-machine,
and manifested itself as a “twitchy” spindle at 0 rpm conditions, during the spindle balance portion of the
machine acceptance test.
Depending on the machine, it was difficult to null the spindle. Once (an unstable!) null was established, it
then became more difficult to adjust the spindle’s high speed parameters so that our set up specifications could
be met. A few machines with noise symptoms that were not as prevalent , were able to be set up satisfactorily
and shipped, and must now be repaired in the field.
This problem is created by having the DAC shield tied at both ends, and also having the DAC cable stripped
back too far at the TB1 strip. The suggested repair is to remove the shield ground from the S1CN connector,
Pin 2 at the spindle drive, and to remove the excess DAC wire inside the wire way at the TB1 strip. In some
cases, there was found to be as much as 3 Ft. of unshielded wire on either side of the TB1 connector. Please
trim this and any harness back so that no more than 4 inches of DAC wires are left outside of the cable.
Please refer to Drawing # 423-4401-073 for details.
REVISED BY:
Drawing Number 423-4401-073
Remove
Page 2 of 2
ISSUE NUMBER: 1244
SUBJECT: Work Light Suppresser Modification
SUPERSEDES NUMBER:
PRODUCT LINE: BMC30SSM, BMC30/M with Siemens,
BMC4020/HT/M, BMC4020SSM
PAGE 1 of 2
The purpose of this FSB is to make you aware of a problem that we are experiencing with the Work
Light on off switch located on the Communications panel.
If the Work Light is turned on or off there is a chance that the control will lock up, making it necessary
to reboot the control.
To rectify this problem, you will need (2) # 417-6001-010 Surge suppressers. Refer to the attached
schematic and install a Part Number 417-6001-010 surge suppresser across each ballast and work light.
REVISED BY:
417-6001-010
417-6001-010
ISSUE NUMBER: 1245
SUBJECT: Spindle Agree Faults during Rigid Tap Functions
SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020HT/M, BMC4020SSM, BMC30HT/M
(Siemens Drive Only)
PAGE 1 OF 1
We have been experiencing “Spindle Agree Fault” errors during Rigid Tap Functions on
BMC4020/HT/M, BMC4020SSM, and BMC30/HT/M mills that use the Siemens Drive package.
Changing the following Parameters in the Ultimax 3 ISA control and the Siemens Spindle Drive module
will prevent these errors from occurring.
1) Tap Deceleration, on the 103 screen will be decreased from 120,000 rev/min/min to
80,000 rev/min/min.
2) Siemens Spindle Drive Parameter # P-027, will be increased from 20 RPM to 30 RPM.
REVISED BY:
ISSUE NUMBER: 1246
SUBJECT: Harness Bracket Installation
SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020/HT/M, BMC4020/SSM
PAGE 1 OF 2
The purpose of this FSB is to install bracket assemblies on the harness coming into the bottom the
electrical cabinet, and on the wire harness exiting the cattrack above the electrical cabinet.
This modification will remove the foam insulation currently packed in around these harness entry / exit
locations, and must be done to help seal the cabinet from external contamination. (Coolant, oil, dust,
etc.)
Enclosed in the kit you will find assorted grommets, a 7. inch piece of H channel, (8) M5 x 12 mm
screws and flat washers, and (2) two piece brackets that need to be installed according to the attached
pictures.
The grommets will have to be cut in one place in order to fit over the cables. This will prevent having to
remove the cable ends.
Note: Use the H channel to seal between the holes in the 2 piece plate.
REVISED BY:
Cattrack Harness Installation
Cabinet Bottom Installation
ISSUE NUMBER: 1247
SUBJECT: Canbus Controller Modification
SUPERSEDES NUMBER:
PRODUCT LINE: All ISA machines
PAGE 1 OF 1
This modification may help eliminate some lock-up situations on 486 based systems especially
during screen updates. The modification is mandatory for all Pentium based systems to correct
an ISA bus conflict, caused by the I/F circuit responding to non-specific addressing.
Modification: U36, pin 1 is to be cut at the PCB and pulled out perpendicular to the side of the
IC. Using ¾” 30 GA. Wire (insulated wirewrap wire), solder one end to the
floating pin 1 on U36, and the other end to the via as shown below. Change the
revision letter from B to C.
Verification: Continuity between gold finger A11(AEN) and U36 pin 1, and no continuity
between U36 pin 1 and ground.
U36
U37
Pin 1
Ground
REVISED BY:
ISSUE NUMBER: 1248
SUBJECT: Siemens Drive wiring change.
SUPERSEDES NUMBER:
PRODUCT LINE: BMC4020/HT/M, BMC4020/SSM
PAGE 1 OF 3
The purpose of this FSB is to initiate a wiring change to the Enable circuits of the Siemens Drive
Package to leave "Pulse Enable" active at Emergency Stop for a greater time period to allow for
regeneration of axis motor voltage, and proper braking of the axis.
The symptoms that would lead to this wiring change would be a slight drift of the of the axis after
Emergency Stop is depressed.
In order to make this modification, you will need to do the following steps.
1) Remove the Wago jumper bar between TB2 - 50 and TB2 - 51.
( This TB strip is located at the back wall of the control cabinet, on the left side. If in doubt as
to the location, please refer to the cabinet lay out drawing, number 003-2007-002 and
003-2007-003 located in the BMC4020 manual, part # 704-0001-748.)
2) Disconnect the wires that run from CRP4 TB1 - 5, and X321 Pin 663 on the dual axis drive module,
and X321 Pin 663 on the Single axis drive module.
3) Add a jumper wire (24AWG) between X321 Pin 663 and Pin 9 on the dual axis drive module
and on X321 Pin 663 and Pin 9 on the single axis drive module.
This change will keep the Pulse Enable Signal on till the regeneration for braking is complete.
4) Add a wire (18AWG) from CRP4 / TB1 - 5 to TB2 - 50. This is for the Axis Enable Relay signal.
REVISED BY:
Please Reference Sheet 8 of 12 on Drawing # 003-2022-002 in the BMC4020 Manual, Rev "A", Part # 704-0001-748 for
more detail.
Please Reference Sheet 9 of 12 on Drawing # 003-2022-002 in the BMC4020 Manual, Rev "A", Part # 704-0001-748 for
more detail.
FSB 1248 Page 3of 3
ISSUE NUMBER: 1249
SUBJECT: Coolant/Oil Separator Modification
SUPERSEDES NUMBER:
PRODUCT LINE: 30D/HT/M/SSM, 4020SSM/HTM
PAGE 1 OF 3
There are a few Frame A machines still having problems with coolant run off from the back of the
machine casting. In order to try to correct this problem a replacement Coolant/Oil Separator Tank
has been designed. This design replaces the current separator tank and will catch any run off from
almost the entire width of the machine base. This should correct any of the problem machines we still
have in the field. This new design can also be retrofitted to the new 4020 machines if necessary. This
modification should only be done if FSB1227 has been completed and the machine still has coolant
leakage.
Retrofit Parts:
003-1008-012 Assembly Coolant/Oil Separator (consists of parts listed below).
1pc
9pc
9pc
6ft.
24in.
1pc
1pc
4pc
803-1049-004 Tank Coolant/Oil Separator
101-5008-003 SHCS, M6 X 1.0 P X 12 LG
110-0046-007 Lockwasher, M6 Helical Spring
507-0001-002 Low Pressure Hose ¾” I.D.
507-1203-002 Low Pressure Hose ½” I.D.
702-0001-004 RTV, 4.7oz Clear
506-5008-003 Plug 3/8”
602-0002-006 Clamp, #16 Aeroseal
Retrofit procedure:
1. Remove the existing Coolant/Oil separator tank from the back of the machine frame.
2. Using the old tank and wooden blocks etc., locate the new tank centered on the back of the
machine frame to transfer the mounting holes. Locate the tank approximately ¼” down from the
Y axis servo motor (this will allow for easier motor removal and belt adjustment). See figure 1.
3. Transfer the top right and top left hole locations from the tank and drill and tap these two holes
first. Temporarily mount the tank with two fasteners and transfer the remaining holes.
REVISED BY:
4. Thoroughly clean the back of the machine frame to help bond the RTV sealant used on the tank
mounting flange.
5. Apply a generous bead of RTV to the tank mounting flange and install the tank with the fasteners
provided.
6. Remove any excess RTV.
7. Remove the old drain tube and fitting from the flood coolant tank and install the 3/8” plug into the
flood coolant tank. See figure 2.
8. Drill and tap ¾”PT holes in the flood motor mounting plates (locations are approximate). See
figure2.
9. Install the ¾’ elbow fittings in each of the two holes.
10. Install ¾” hose between each of the flood coolant fittings and each side of the new Coolant/Oil
separator tank (use hose clamps provided).
11. Install ½” hose between Coolant/Oil separator tank and oil catch tank (use hose clamps from old
Coolant/Oil separator tank).
12. Run washdown system and check for leaks.
Rear view of machine base
Figure 1
Top view of machine.
Figure 2
ISSUE NUMBER: 1250
SUBJECT: Re-Wire of Fast Stop signal to Siemens Drive
SUPERSEDES NUMBER:
PRODUCT LINE: BMC30/HT/M, BMC4020/SSM, BMC4020/HT/M
PAGE 1 OF 2
There is a chance that Frame "A" mills with Siemens Drive packages (BMC30/HT/M's and BMC4020's
) have a mis-wire in the Fast Stop circuit.
Fast Stop has been found to be tied into the Spindle Purge Relay, ( RLY 2 ) at Pin 7, instead of being
attached to TB10, Pin 3, on the CRP4 Brd. as shown in the current electrical schematics, causing the
Drive to be disabled when Spindle Purge times out, and causing the following alarm message. "Spindle
Fault Agree Error", when the machine is put back in cycle or programmed with a spindle speed.
Please do not hesitate to check the Fast Stop circuit if your customer notifies you of this symptom on
their Siemens driven mill.
Please reference the following page for correct wiring information.
REVISED BY:
HURCO MANUFACTURING COMPANY
One Technology Way
Indianapolis, IN 46268-0180
R
DATE:
June 26, 1997
ISSUE NUMBER: 1251
SUBJECT:
PRODUCT LINE:
ULTIMAX 3 ISA
PAGE 1 OF 4
PURPOSE: To correct parameters that were incorrectly listed on the Engineering Documents and the
Machine Parameter Diskettes issued with V2.00 Field Installation Software Kit, 007-4123-009.
DESCRIPTION: Please update the following Engineering Documents in the V2.00 Field Installation
Software Kit (these documents will be distributed upon their release):
757-4002-125 Rev B, Ultimax V2.xx Software Field Installation Procedure
page 7, step 21, change the Machine S/N Prefix for 427-0004-014 from B3M to B3HM
change the Machine S/N Suffix for 427-0004-014 from B to C
change the Machine S/N Prefix for 427-0004-015 from B3HM to B3M
change the Machine S/N Suffix for 427-0004-015 from C to B
757-4005-001 Rev A, Parameters for BMC30SSM (Siemens Spindle) with Ultimax 3 ISA Software V2.X
757-4005-002 Rev A, Parameters for BMC30SSM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X
757-4005-003 Rev A, Parameters for BMC30M (Siemens Spindle) with Ultimax 3 ISA Software V2.X
757-4005-004 Rev A, Parameters for BMC30HTM (Siemens Spindle) with Ultimax 3 ISA Software V2.X
757-4005-005 Rev A, Parameters for BMC30M (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X
757-4005-006 Rev A, Parameters for BMC30HTM (Yaskawa Spindle) with Ultimax 3 ISA Software V2.X
757-4005-007 Rev A, Parameters for BMC4020SSM with Ultimax 3 ISA Software V2.X
757-4005-008 Rev A, Parameters for BMC4020HTM with Ultimax 3 ISA Software V2.X
page 6, General Parameters, change Configuration Parameter Units from Inch to Metric
General Parameters, change Max. Programmable Contour Feedrate from 300.0 to 7620.0
page 5, Axes, Physical Parameters, change Distance per Revolution from 0.4724in to 12.0mm for
X, Y, and Z Axes
NOTE: This corrects an axis misposition problem in which the Inch value of 0.4724 was being
being converted to 11.99896mm; the correct value is 12.0mm or 0.47244095in.
ORIGINATOR: David Skrzypczak
REVISED BY:
page 5, Axes, Vertical Parameters, change Plus Direction Travel Limit from 30.0in to 762.0mm
for X Axis
Axes, Vertical Parameters, change Plus Direction Travel Limit from 18.0in to 432.0mm
for Y Axis
Axes, Vertical Parameters, change Minus Direction Travel Limit from -24.0in to -609.0mm
for Z Axis
page 5, Axes, Physical Parameters, change Maximum Feedrate from 500.0ipm to 12700.0mmpm
for Z Axis
Axes, Physical Parameters, change Maximum Feedrate from 590.0ipm to 15000.0mmpm
for X and Y Axes
page 11, change N95:211 from 0 to 1
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
page5, Spindle, Physical Parameters, change Maximum DAC Volts from 9.350 to 9.500
NOTE: this change is required for initial startup only; it will be reset for Spindle Balance
FSB1251.DOC
Page 2 of 4
for X Axis
for Y Axis
for Z Axis
for Z Axis
for X and Y Axes
INSTRUCTIONS: Please update the following Machine Parameters Diskettes in the V2.00 Field
Installation Software Kit:
Machine Parameters Diskette, BMC 30SSM Siemens Spindle, 427-0004-011
1. Using DOS Edit (or other ASCII editor), load the INTCFG.SYS file from the 30SSMS.MCD directory.
2. Search for N95:211; the line will read “N95:211= SPINDLE DRIVE TYPE = 0”.
3. At the end of the line, change the 0 to 1.
4. Exit and save the file.
The following steps must be done at a machine for the following diskette:
1. After V2.00 has been loaded with the correct parameters per the Installation Procedure, access the
Integrator Support Services screen from Auxiliary by pressing <Enter> 100 <Enter>.
2. Select the CNC CONFIG PARAMETERS softkey.
3. Select the SPINDLE softkey
4. Select the VERTICAL PARAMETERS softkey.
5. Select the GEAR TABLE PARAMETERS softkey.
6. Change the Minimum RPM from 100 to 1.
7. Select the EXIT softkey (may require multiple selections) to return to the Integrator Support Services
screen..
8. Select the MISCELLANEOUS SERVICES softkey.
9. Select the YES softkey to change the D: Drive Access Enable.
10. Select the EXIT softkey(may require multiple selections) to return to Auxiliary mode.
11. Select the STORAGE FUNCTIONS softkey.
12. Select the DISK OPERATIONS LIST DIRECTORY softkey.
13. Select the SELECT CURRENT STORAGE DRIVE softkey.
14. Select the HARD DRIVE D softkey.
15. Highlight the 30SSMS.MCD directory and select the CHANGE TO DIRECTORY softkey.
16. Highlight the SPINDLE.SYS file and select the COPY PROGRAM softkey.
17. Insert the 427-0004-011 diskette into the floppy disk drive (make sure the disk is not Write Protected).
18. Enter “A:” to copy the file to the Machine Parameters Diskette.
19. Reenter Integrator Support Services and disable the D:Drive Access Enable.
20. In Auxiliary, backup the modified parameters to the Ultimax 3 Version 2.xx Parameter Backup diskette.
The following steps must be done at a machine for each of the following diskettes:
FSB1251.DOC
Page 3 of 4
Machine Parameters Diskette, BMC 30HTM Siemens Spindle, 427-0004-012
Machine Parameters Diskette, BMC 30SSM Yaskawa Spindle, 427-0004-013
Machine Parameters Diskette, BMC 30M Siemens Spindle, 427-0004-014
Machine Parameters Diskette, BMC 30M Yaskawa Spindle, 427-0004-015
Machine Parameters Diskette, BMC 30HTM Yaskawa Spindle, 427-0004-016
Machine Parameters Diskette, BMC 4020SSM Siemens, 427-0004-017
Machine Parameters Diskette, BMC 4020HTM Siemens, 427-0004-018
3. Select the SPINDLE softkey.
4. Change the Maximum DAC Volts from 9.35 to 9.5 volts.
5. Select the EXIT softkey.
6. Select the GENERAL PARAMETERS softkey.
7. Change the Configuration Parameter Units from Inch to Metric.
8. Enter the Max. Programmable Contour Feedrate as 7620.0.
10. Select the X AXIS softkey.
11. Enter the Distance per Revolution as 12.0.
12. Enter the Maximum Feedrate per the revised Engineering Document for each machine type.
14. Enter the Plus and Minus Direction Travel Limit for each machine type.
15. Repeat steps 10-14 for the Y and Z Axes.
16. Select the EXIT softkey to return to the Integrator Support Services menu.
24. Highlight the appropriate .MCD directory and select the CHANGE TO DIRECTORY softkey.
25. Highlight the SYSFIX.SYS file and select the COPY PROGRAM softkey.
26. Insert the 427-0004-01x diskette into the floppy disk drive (make sure the disk is not Write Protected).
28. Reenter Integrator Support Services and disable the D: Drive Access Enable.
Network: The correct INTCFG.SYS, SPINDLE.SYS, and SYSFIX.SYS files for each of the machine
types are located on the service network in the following subdirectory:
\COMMON\SERVICE\EXEC\MAX3_OEM\PARAM
There is one zip file for every machine type which contains the replacement Configuration files discussed in
this FSB.
FSB1251.DOC
Page 4 of 4
One Technology Way
R
DATE:
June 26, 1997
ISSUE NUMBER: 1251b
SUBJECT:
PRODUCT LINE:
ULTIMAX 3 ISA
PAGE 1 OF 4
PURPOSE: To correct parameters that were incorrectly listed on the Engineering Documents and the
Machine Parameter Diskettes issued with V2.00 Field Installation Software Kit, 007-4123-009.
DESCRIPTION: Please update the following Engineering Documents in the V2.00 Field Installation
Software Kit (these documents will be distributed upon their release):
757-4002-125 Rev B, Ultimax V2.xx Software Field Installation Procedure
page 7, step 21, change the Machine S/N Prefix for 427-0004-014 from B3M to B3HM
change the Machine S/N Suffix for 427-0004-014 from B to C
change the Machine S/N Prefix for 427-0004-015 from B3HM to B3M
change the Machine S/N Suffix for 427-0004-015 from C to B
page 6, General Parameters, change Configuration Parameter Units from Inch to Metric
General Parameters, change Max. Programmable Contour Feedrate from 300.0 to 7620.0
page 5, Axes, Physical Parameters, change Distance per Revolution from 0.4724in to 12.0mm for
X, Y, and Z Axes
NOTE: This corrects an axis misposition problem in which the Inch value of 0.4724 was being
being converted to 11.99896mm; the correct value is 12.0mm or 0.47244095in.
REVISED BY: Tom Murden
for X Axis
for Y Axis
for Z Axis
NOTE: Changing travel limits on existing V2.00 machines will erase the leadscrew map for that axis.
On upgrades from V1.XX to V2.00 use the travel limits from V1.XX (write them down before doing
the upgrade).
for Z Axis
for X and Y Axes
page 11, change N95:211 from 0 to 1
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
for Z Axis
for X and Y Axes
page5, Spindle, Physical Parameters, change Maximum DAC Volts from 9.350 to 9.500
NOTE: this change is required for initial startup only; it will be reset for Spindle Balance
FSB1251.DOC
Page 2 of 4
for X Axis
for Y Axis
for Z Axis
for Z Axis
for X and Y Axes
INSTRUCTIONS: Please update the following Machine Parameters Diskettes in the V2.00 Field
Installation Software Kit:
1. Using DOS Edit (or other ASCII editor), load the INTCFG.SYS file from the 30SSMS.MCD directory.
2. Search for N95:211; the line will read “N95:211= SPINDLE DRIVE TYPE = 0”.
3. At the end of the line, change the 0 to 1.
4. Exit and save the file.
The following steps must be done at a machine for the following diskette:
3. Select the SPINDLE softkey
5. Select the GEAR TABLE PARAMETERS softkey.
6. Change the Minimum RPM from 100 to 1.
7. Select the EXIT softkey (may require multiple selections) to return to the Integrator Support Services
screen..
15. Highlight the 30SSMS.MCD directory and select the CHANGE TO DIRECTORY softkey.
16. Highlight the SPINDLE.SYS file and select the COPY PROGRAM softkey.
17. Insert the 427-0004-011 diskette into the floppy disk drive (make sure the disk is not Write Protected).
19. Reenter Integrator Support Services and disable the D:Drive Access Enable.
The following steps must be done at a machine for each of the following diskettes:
FSB1251.DOC
Page 3 of 4
Machine Parameters Diskette, BMC 30HTM Siemens Spindle, 427-0004-012
Machine Parameters Diskette, BMC 30SSM Yaskawa Spindle, 427-0004-013
Machine Parameters Diskette, BMC 30M Siemens Spindle, 427-0004-014
Machine Parameters Diskette, BMC 30M Yaskawa Spindle, 427-0004-015
Machine Parameters Diskette, BMC 30HTM Yaskawa Spindle, 427-0004-016
Machine Parameters Diskette, BMC 4020SSM Siemens, 427-0004-017
Machine Parameters Diskette, BMC 4020HTM Siemens, 427-0004-018
3. Select the SPINDLE softkey.
4. Change the Maximum DAC Volts from 9.35 to 9.5 volts.
6. Select the GENERAL PARAMETERS softkey.
7. Change the Configuration Parameter Units from Inch to Metric.
8. Enter the Max. Programmable Contour Feedrate as 7620.0.
10. Select the X AXIS softkey.
11. Enter the Distance per Revolution as 12.0.
12. Enter the Maximum Feedrate per the revised Engineering Document for each machine type.
14. Enter the Plus and Minus Direction Travel Limit for each machine type.
15. Repeat steps 10-14 for the Y and Z Axes.
16. Select the EXIT softkey to return to the Integrator Support Services menu.
22. Select the CHANGE PROGRAM MASK softkey and change to *.*.
25. Highlight the appropriate .MCD directory and select the CHANGE TO DIRECTORY softkey.
26. Highlight the SYSFIX.SYS file and select the COPY PROGRAM softkey.
27. Insert the 427-0004-01x diskette into the floppy disk drive (make sure the disk is not Write Protected).
29. Reenter Integrator Support Services and disable the D: Drive Access Enable.
Network: The correct INTCFG.SYS, SPINDLE.SYS, and SYSFIX.SYS files for each of the machine
types are located on the service network in the following subdirectory:
\COMMON\SERVICE\EXEC\MAX3_OEM\PARAM
There is one zip file for every machine type which contains the replacement Configuration files discussed in
this FSB.
FSB1251.DOC
Page 4 of 4
ISSUE NUMBER: 1252
SUBJECT: M-CODE MODIFICATIONS
SUPERSEDES NUMBER:
PRODUCT LINE: YASKAWA ISA BEDMILLS
PAGE 1 OF 8
The M-Code modifications that were incorporated into V2.01 on production machines may
be required by customers when upgrading their older ISA bedmills to V2.XX. The following MCode modifications can be added to either older Yaskawa ISA bedmills or older Siemens ISA
bedmills that don’t have terminal strips.
**If a customer has probing on the machine that is to be upgraded to V2.XX and he wants
the M-Code modifications, then a second DC I/O board will need to be added to the card rack. If the
customer has Probing and also has a Rotary Table option, then the M-Code modification can be
added to their existing second DC I/O board.
A.
M-Code modifications for Siemens ISA machines without TB1, TB2 terminal strips.
Materials required:
1 PC 20 position terminal strip (406-4005-323).
2 PC 5 conductor 24 AWG cable 30 inches in length (406-1325-008).
1.
Mount the 20 position terminal strip on the main panel near the cardrack.
2.
Modify the following terminations of the DCI/O J2 Harness, 423-4401-068:
a)
At the DC I/O J2-22 remove the gray wire. Heatshrink and fold back.
b)
At the DC I/O J2-37 remove the blue wire. Heatshrink and fold back.
Install the first piece of 5-conductor cable as show below.
c)
Black wire to DC I/O J2-22 (OUT 9).
d)
Brown wire to DC I/O J2-6 (OUT 10).
e)
Red wire to DC I/O J2-38 (OUT 11).
f)
Green wire to DC I/O J2-23 (OUT 23).
REVISED BY:
g)
h)
i)
j)
k)
l)
White wire to DC I/O J2-37 (OCOM 3).
Also add a jumper from DC I/O J2-37 to DC I/O J2-7 (+24 VDC).
Terminate the other end of this cable at the new terminal strip as follows:
White wire to new terminal strip at terminal 11 and jumper to 12,13,14, and 15
(+24VDC).
Black wire to terminal 16 (AUX OUT 1).
Brown wire to terminal 17 (AUX OUT 2).
Red wire to terminal 18 (AUX OUT 3).
Green wire to terminal 19 (AUX OUT 4).
3.
Modify the following terminations of the I/O to Infeed I/R Module Harness, 423-4405-077:
a)
Remove the wires attached to Siemens drive X141 connector terminal 15 and R.
Trace the wires back into the wireway to the 2 position mate n loc connector
disconnect and discard.
b)
Install the clear wire of the new 2 conductor cable at X141-R.
c)
Install the black wire of the new 2 conductor cable at X141-15.
Continue termination of the other end of the two conductor cable in step 4.
4.
Modify the following terminations of the I/O IF J1 Harness, 423-4401-065:
a)
Remove the wire at I/O IF J1-48, heatshrink and fold back. Install the other end of the
new 2 conductor clear wire at I/O IF J1-48.
b)
Install the other end of the new 2 conductor black wire and shield at I/O IF J1-7. You
will need to splice into the wire currently at I/O IF J1-7.
5.
Modify the following terminations of the DC I/O J1 Harness, 423-4401-067.
Install the second 5-conductor cable as show below.
a)
Black wire to DC I/O J1-39 (GND). You will need to splice into the wire currently at
DC I/O J1-39. This wire should already be tied to ground.
b)
Brown wire to DC I/O J1-24 (INP13).
c)
Red wire to DC I/O J1-8 (INP14).
d)
Green wire to DC I/O J1-40 (INP15).
e)
White wire to DC I/O J1-25 (INP16).
f)
Black wire to new terminal strip at terminal 5 and jumper to 4,3,2, and 1.
g)
Brown wire to terminal 6 (AUX OUT 1 OFF).
h)
Red wire to terminal 7 (AUX OUT 2 OFF).
i)
Green wire to terminal 8 (AUX OUT 3 OFF).
j)
White wire to terminal 9 (AUX OUT 4 OFF).
B.
M-Code modifications for Yaskawa ISA machines without TB1, TB2 terminal strips.
Materials required:
1 PC 20 position terminal strip (406-4005-323).
1.
Mount the 20 position terminal strip on the main panel near the cardrack
2.
Install the first piece of 5-conductor cable as show below.
a)
Black wire to DC I/O J2-22 (OUT 9).
b)
Brown wire to DC I/O J2-6 (OUT 10).
c)
Red wire to DC I/O J2-38 (OUT 11).
d)
Green wire to DC I/O J2-23 (OUT 23).
e)
Remove the existing wire at DC I/O J2-37. Heatshrink and fold back. Install the
White wire to DC I/O J2-37 (OCOM 3). Also add a jumper from DC I/O J2-37 to DC
I/O J2-7 (+24 VDC).
f)
White wire to new terminal strip at terminal 11 and jumper to 12,13,14, and 15
(+24VDC).
g)
Black wire to terminal 16 (AUX OUT 1).
h)
Brown wire to terminal 17 (AUX OUT 2).
i)
Red wire to terminal 18 (AUX OUT 3).
j)
Green wire to terminal 19 (AUX OUT 4).
3.
Modify the following terminations of the DC I/O J1 Harness, 423-4401-067.
Install the second 5-conductor cable as show below.
a)
Black wire to DC I/O J1-39 (GND). ). You will need to splice into the wire currently
at DC I/O J1-39. This wire should already be tied to ground.
b)
Brown wire to DC I/O J1-24 (INP13).
c)
Red wire to DC I/O J1-8 (INP14).
d)
Green wire to DC I/O J1-40 (INP15).
e)
White wire to DC I/O J1-25 (INP16).
f)
Black wire to new terminal strip at terminal 5 and jumper to 4,3,2, and 1.
g)
Brown wire to terminal 6.
h)
Red wire to terminal 7.
i)
Green wire to terminal 8.
j)
White wire to terminal 9.
C.
M-Code modifications for current production BMC30, and BMC4020 machines with TB1 and
TB2 terminal strips
1.
Modify the following terminations of the I/O to Infeed I/R Module Harness, 423-4405-077:
a)
Find the two conductor shielded cable that runs from TB2-45, 55, and 56 to the
Siemens I/R module at X141-15, and R. Remove the wires from TB2-45, 55, and 56
and reroute the cable in the wireways to go to TB1-55, and 56.
b)
Connect the wire from I/R module X141-R to TB1-55.
c)
Connect the wire from I/R module X141-15 and the cable shield to TB1-56.
This removes the I/R Module reset at the DC I/O board and makes TB2-45
available as M-code output 1.
d)
Update Harness Revision to C.
2.
Modify the following terminations of the I/O IF J1 Harness, 423-4401-065:
a)
Delete OUTP6 (spare) signal from I/O IF/J1-48 to CRP4/J1-48. Remove the Honda
pin from I/O IF/J1-48 with a pin pusher or unsolder the wire and fold back and
heatshrink.
b)
Using a piece of 24 AWG blue wire externally route a new connection from I/O IF J148 to TB1-55. This reconnects the I/R module reset at the I/O IF board.
c)
Update Harness Revision to C.
3.
a)
Find the wire from DC I/O J2-5 to TB2-55 bottom. Move the wire end at DC I/O J25 to DC I/O J2-23. Move the other end that was at TB2-55 bottom to TB2-35
bottom. This sets up OUTP12 at TB2-35 and disconnects the GND reference from
OCOM3 at TB2-55.
b)
The OCOM3 output source for outputs 9,10,11, and 12 is currently connected from
DC I/O J2-37 to TB2-55. Move the TB2-55 end to TB2-52. This sets up the outputs
to send out 24V when active.
c)
Find OUTP24 which is connected from DC I/O J2-44 to TB2-47. Move the DC I/O
J2-44 end to DC I/O J2-38. This sets up OUTP11 at TB2-47 and does away with the
old probe reset.
d)
Modify Harness Revision to D.
4.
Using the 24AWG Blue Wire and two Ferrules, add a MGND signal from TB1-7 to TB1-56
bottom. This reconnects the ground reference between the I/O IF board and the Seimens I/R
module.
D.
Version 2.00 Specifications for Auxiliary M-Codes
Overview
Hurco has defined 4 outputs and 4 inputs as auxiliary M-Code functions. These active high
I/O points will aid in eliminating noise related problems. The operator may use Hurco defined
M-Codes to perform unique machine functions from within a part program. The operator
may use these M-Codes in NC or conversational part program. The configuration table
allows the integrator to define the M-Codes, assign an average time to the function for
estimated run time purposes, and to display a string on the auto screen when the M-Code is
executed.
I/O Specifications
Outputs (LH1510 device):
• 24VDC solid state relays with SPST normally
open outputs.
• Absolute maximum continuous load: IL = 150mA.
• Damage to outputs will occur if operated
200mA ≤ IL < 360mA.
• Current limit: ILMT = 360mA.
• Current limit at > 360mA will cause current
foldback condition.
• Absolute maximum voltage: VL = 200VDC.
• On-resistance: 10Ω at load current 50mA.
Off-resistance: 3,300GΩ
• The outputs are configured as a bank of 4, active
high 24VDC.
• 24VDC supply maximum load: Isupply = 500mA.
• Outputs are disabled at power-up and in case of
embedded E-Stop condition (Host Watchdog Time-out)
Inputs (PS2505 device):
• Inputs are Bi-directional optocouplers with a
24VDC +/-10% signal range.
• Maximum input source current: Isource = 2mA.
• The inputs are configured as a bank of 4, active
high 24VDC.
External Signal Conditioning
If the integrator chooses to incorporate external devices such as relays, solenoids, contactors, etc.
diodes and surge suppressors must be placed in the integrators circuit (typically across relay,
contactor, or solenoid coils) to protect the I/O boards from any high voltage spikes and/or noise
conditions.
Predefined M-Codes
Each of the Aux Outputs are controlled by a pair of pre-defined M-Code functions, as follows:
M52
M53
M54
M55
Enables Aux Output 1
M62
M63
M64
M65
Disables Aux Output 1
Connection of Physical I/O
Connection points for utilizing M-Codes on machines with TB1 and TB2 terminal strips installed at
the factory.
Outputs
Aux Out 1
Aux Out 2
Aux Out 3
Aux Out 4
Confirmation Inputs
Aux In 1
Aux In 2
Aux In 3
Aux In 4
I/O Description
OUT09
OUT10
OUT11
OUT12
I/O Description
INP13
INP14
INP15
INP16
Terminal Block
TB2 - 45
TB2 - 46
TB2 - 47
TB2 - 35
Terminal Block
TB2 - 21
TB2 - 22
TB2 - 23
TB2 - 24
Connection points for utilizing M-Codes on machines with field installed 20 position M-Code
terminal strip.
Outputs
Aux Out 1
Aux Out 2
Aux Out 3
Aux Out 4
I/O Description
OUT09
OUT10
OUT11
OUT12
Terminal Block
TB1 - 16
TB1 - 17
TB1 - 18
TB1- 19
Confirmation Inputs
Aux In 1
Aux In 2
Aux In 3
Aux In 4
I/O Description
INP13
INP14
INP15
INP16
Terminal Block
TB1 - 6
TB1 - 7
TB1 - 8
TB1 - 9
In addition to the inputs and outputs above, +24 VDC is available for inputs at TB1-11,12,13,14, and
15. VDC Return is also available at TB1-1,2,3,4, and 5 (field installed terminal strip only).
Configuration of M-Code Parameters
The integrator defined M-Codes are found in Integrator Support Services under:
• F1 - CNC Configuration Parameters
• General Parameters
• M-Code Table
• Page Down
M Code Table (0-255)
Status
Time (sec)
52
53
54
55
62
63
64
65
Integrator Defined
Integrator Defined
Integrator Defined
Integrator Defined
Integrator Defined
Integrator Defined
Integrator Defined
Integrator Defined
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Program Operation
Label
Aux Out #1
Aux Out #2
Aux Out #3
Aux Out #4
Aux Out #1 Off
Aux Out #2 Off
Aux Out #3 Off
Aux Out #4 Off
In the fields of the table you can put the time required for each specific M-Code and this time will be
added in the program estimated run time. Also, The Program Operation Label can be edited. The
text will be displayed on the screen when the M-Code is called in the program (conversational only).
The M-Code confirmation enable is found in the Integrator Support Services under:
• F2 - Integrator Configuration parameters
• F2 - Integer parameters
• F1 - Jump to parameter 250
Integer Parameters
N95:250
Description
Aux Output CF Enable
Value
0
To make use of the Aux Inputs, the Auxiliary M-Code Confirmation Enable Mask parameter
(N95:250 in the Integrator Config Parameters) must be set. The value to be entered in for N95:250 is
determined as follows:
Aux Input 1
Aux Input 2
Aux Input 3
Aux Input 4
2
4
8
16
(Value to activate this input only)
For more than one Aux Input in use, simply add the value for the respective Aux Inputs (for example,
using Aux Inputs 1, 2, and 3, enter 14 for N95:250). If the Auxiliary M-Code Confirmation Enable
Mask is set then every occurrence of an Aux Output will require a corresponding Aux Input
confirming that the Aux Output request is completed.
Examples of M-Code Use
Example without Confirming input:
A simple configuration would be to wire a relay to one of the Aux Outputs. If the coil of a relay were
wired to the Aux Output 1 then commanding an M52 will enable the relay and an M62 will disable the
relay. The Aux Inputs are not used in this configuration because the Confirmation parameter is not
set. If the user needs a time delay for the M52 (or M62) function to be completed then a dwell would
have to be added to the program (in NC, use G04).
Example with Confirming input:
The following example uses Aux Output 1, Aux Input 1, with N95:250 set to 2. Commanding an
M52 will enable Aux Output 1; this will stop the program until the Aux Input 1 is TRUE (or high)
before proceeding with the program. The Aux Output 1 will stay enabled until an M62 is
commanded; this will then disable Aux Output 1 and will stop the program until the Aux Input 1 is
FALSE (or low) before proceeding with the program. You may have to wire a set of normallyopened contacts from the relay with the Finish signal input so that when the Aux Output is disabled
with the M62, the Aux Input will be disabled.
In this example, the user may also want to define the Time (in sec) in the M-Code Table (in General
Parameters of CNC Config Parameters) that is required for the Aux Input 1 to be active (with an
M52) or inactive (with an M62). Note that these times are only for computing estimated run-time
and will not control any delay in program execution of the respective M-Codes.
IMPORTANT: If you are using a relay, solenoid, contactor, etc with the Aux Outputs, be sure to use
diodes or surge suppressors in the circuit to protect the DC I/O board from any high voltage spikes
and/or noise conditions.
Documentation Reference for M-Code changes
003-2022-004 (CAD 8385 REV. C) Interconnect Diagram, BMC4020 with Siemens
003-2022-002 (CAD 8278 REV. E) Electrical Diagrams for BMC4020 with Siemens
003-1022-016 (CAD 8397 REV. C) Interconnect Diagram, BMC30HT/M with Siemens
003-1022-014 (CAD 8277 REV. E) Electrical Diagrams for BMC30HT with Siemens
003-1022-013 (CAD 8401 REV. D) Interconnect Diagram, BMC30M with Siemens
003-1022-007 (CAD 8399 REV. D) Electrical Diagrams for BMC30M with Siemens
003-1022-018 (CAD 8477 REV. D) Interconnect Diagram, BMC30/SSM with Siemens
003-1022-017 (CAD 8476 REV. E) Schematics, Electrical, BMC30/SSM with Siemens
423-4401-065 (CAD 8337 REV. C)
423-4401-067 (CAD 8339 REV. D)
423-4401-068 (CAD 8340 REV. D)
423-4405-077 (CAD 8298 REV. C)
Harness, I/O IF J1
Harness, DC I/O J1
Harness, DC I/O J2
Harness, I/O to Infeed I/R Module
ISSUE NUMBER: 1253
SUBJECT: Spindle Drive Faults not reported to Control
SUPERSEDES NUMBER:
PRODUCT LINE: BMC 40/50, BMC 50/50
PAGE 1 OF 3
Due to an error in the DC I/O harness wiring some BMC40/50 and BMC50/50 machines may
not be reporting spindle drive faults. If you suspect a machine has this problem inspect the 423-4405035 DC I/O J1 harness. There should be jumpers between pins 3, 35, and 37 at the DC I/O J1 end of
the harness (SEE the attached drawings, 423-4405-035, 002-4122-044 Pg. 3 of 6).
The problem with most of the machines is DC I/O pin 37 has not been tied to +24vdc with pin
3 and 35. This supplies the reference voltage for the spindle fault input.
REVISED BY:
ISSUE NUMBER: 1254
SUBJECT: Full Enclosure Door Slides 410-5001-002
SUPERSEDES NUMBER:
PRODUCT LINE: BMC40, BMC50
PAGE 1 OF 2
Due to limited availability and higher cost the C3301-27 full enclosure door slide is no longer
being used. It has been replaced with the C3301-28 under the same Hurco part number. This door slide
is one inch longer than the original and may require some mounting modifications. See sheet two which
shows mounting hole locations.
REVISED BY:
ISSUE NUMBER: 1255
SUBJECT: Air Requirements
SUPERSEDES NUMBER:
PRODUCT LINE: All BMC30 and BMC40/20
PAGE 1 OF 1
It is the customers responsibility to assure the following air requirements are met and maintained.
1. A continuous supply of 5 CFM @ 80-100 PSI (0.14 CMM @ approximately 5.5-7.0 bar).
2. The air pressure drop during an ATC cycle must not exceed 10 PSI (approximately 0.75 bar).
3. The minimum air supply line ID is 0.5 in (12mm). Do not use quick connect fittings due to their
restrictive nature.
Note 1: Service representatives should assure that the Low Air Pressure Switch is set at 60 PSI
(approximately 4 bar).
Note 2: V1.XX software will disable Control Power if a Low Air Pressure fault is detected. The
operator must correct the error and enter ATC Diagnostics to clear the error message.
Note 3: V2.0X software will activate the Interrupt Cycle Mode if a Low Air Pressure fault is
detected. The error prompt will be automatically cleared when the error is corrected. If the fault
occurs during an ATC cycle, then the control will complete the ATC cycle (if possible) before
beginning the Interrupt Cycle. The program can be resumed when the Air Pressure is restored and
the operator selects Auto and presses Start.
Note 4: V2.1X will work the same as V2.0X except the error message will not be cleared until the
operator selects another operation or selects auto to resume the program.
REVISED BY:
ISSUE NUMBER: 1256
SUBJECT: Hawk5M Servo Inhibit
SUPERSEDES NUMBER:
PRODUCT LINE: Hawk5M W/Wago Servo Dynamic
PAGE 1 OF 3
In the event of an unexpected power failure the Hawk5M machines may exhibit axis movement of ¼” to
½” while the servo bus capacitor discharges. This problem can be corrected by using the AER signal to
control the servo inhibit inputs as well as the solid state relay that enables the bus voltage.
This problem was corrected on the redesigned Hawk5M. The machines which can benefit from this
modification are the early Hawk5M machines. These machines were all dual screen with the transformer
on top of the power cabinet and orange Wago connectors on the servo drives. If you have trouble
determining whether a machine is a candidate for this modification Call the Hurco Service Department.
Material needed:
3 pc
20 in.
2.7K ohm ¼ watt resistors 407-0035-331 or 407-0036-079
20 awg wire
Modification:
1. Locate Q15 on each servo drive board (see figure 1). Carefully unsolder and remove Q15 from the
component side of the board. Install the 2.7K resistor (at old Q15 location) as shown in figure 1 on
the component side of the board. Keep the resistor leads short to prevent shorting out on the
heatsink/ mounting bracket.
2. Install wire jumpers to tie each drive together at J1 pin 9 (Wago connector). Install an additional
jumper from the X axis servo board J1 pin 9 and tie to the Servo drive chassis TB201 pin 1 or CRP4
TB1-5 (AER 24VDC enable signal, see figure 2). This will enable and disable the servo drives with
the enable signal.
REVISED BY:
FSB 1256 2 of 3
FSB 1256 3 of 3
One Technology Way
DATE:
October 15, 1997
ISSUE NUMBER: 1257
SUBJECT:
V2.00 Parameter Changes
PRODUCT LINE:
BMC 4020SSM
PAGE 1 OF 1
PURPOSE: To recommend a change to one of the Siemens Spindle parameters to correct a problem
where the Spindle could orient with the magazine in the right position.
DESCRIPTION: For BMC4020SSM Machining Centers running V1.64 Executive software, the Siemens
Spindle parameter P-149, Startup parameter C axis/position, is set to 29H per Engineering Document 7574002-097. This sets the orient direction to unidirectional so that when an orient is required, the Spindle will
always orient in the same direction.
However during an Auto Tool Change operation when the Tool Magazine is in the Right position and the
Head is in the Down position completing the tool change sequence, the Spindle is clamped which re-enables
Spindle Enable Relay (SER). As the Tool Magazine moves back to the Left position, if SER has not yet
been energized to hold the Spindle in orient position, it is possible for the movement of the magazine to
rotate the Spindle slightly. Once SER is energized, the Spindle Drive senses that the Spindle is no longer
oriented so it reissues an Orient command. This occurs in a fraction of a second, before the Tool Magazine
has fully disengaged from the Head on its way left. With the P-149 parameter set to 29H, the Spindle could
orient one full revolution thereby damaging the Spindle Key or the Tool Fingers.
Testing has shown that the proximity switch for sensing Orient Position on BMC4020SSM Machining
Centers is capable of handling a bidirectional orient command (that is, the orient will take the shortest
direction to reach Orient Position). Changing P-149 to 21H for BMC4020SSM Machining Centers
establishes bidirectional orient so that in the above scenario, the Spindle will still orient to the Orient
Position but will not do a full revolution asit will take the shortest path.
MATERIALS:
Siemens I/R Module, Servo Drive, and Spindle Drive Setup Procedure with Ultimax 3 ISA Control.
Applicable Machining Centers: BMC30M, BMC30HT, BMC30SSM, BMC4020HT and BMC4020SSM.
Engineering Document 757-4002-097
INSTRUCTIONS: Modify Engineering Document, 757-4002-097, Attachment B, BMC4020SSM,
change P149 from 29H to 21H. Also modify section XVI, paragraph A, step 1 from 29H to 21H.
REVISED BY:
ISSUE NUMBER: 1258
SUBJECT: BMC30SSM Modifications MN3996
SUPERSEDES NUMBER:
PRODUCT LINE: BMC30SSM
PAGE 1 OF 1
In June of 1996 Manufacturing Notice #3996 was released. This document specifically documented
several changes needed on the early machines which would be added in the field and integrated into
manufacturing as new machines were built. Recently we have found that some of these changes are
still not being included on the new production machines. Please review the following list of changes
on any BMC30SSM and verify that these changes have indeed been added to each machine. The
frames which we know need to be checked are Q376-Q379, Q392-Q399, and Q404-Q415. Newer
machines should be checked during any service call. Some of these machines may have been
upgraded to dual screen (Be sure to check frame and serial numbers).
CHECKLIST:
1. Servo Dynamics amplifiers not modified. Check Q15, it should have been removed and replaced
with a resistor and the amplifiers should have several white opto-couplers on the boards. Also,
these amplifiers should be labeled as SDFPO 1525 type drives (402-5001-087) and a Shunt
Regulator assemble, (402-5001-074) should be mounted to the chassis near the bus capacitor.
2. There should be a 16 AWG green/yellow ground wire from the cabinet ground bus bar to the ISA
cardrack wing nut.
3. The keyboard port harness located on the SSM console assemble is incorrectly wired. Please
verify wiring per drawing 423-4401-064.
4. TB1 and TB2 terminal strips sag in the middle. Double sided tape should be added to the back of
this assembly to correct this problem. Later production units used an aluminum mounting rail to
correct this problem.
REVISED BY:
5. The Flood coolant contactor was installed without the overload relay. Install the overload relay
#403-5503-010 and adjust for 1 amp.
6. The Flood coolant contactor is also missing noise suppressors (417-6001-010). Add suppressors
to the coil and from phase to phase on the overload. The suppressors should be implemented
at frame #Q566.
7. The CB3 20A and CB4 32A circuit breakers for the primary (220 VAC) and secondary (90VAC)
windings of the Control transformer (Servo Dynamics taps) should be replaced due to nuisance
tripping caused by high inrush current. These changes should be implemented on frame
#Q578.
a) The new CB3 breaker (20A) is a 404-9081-059 Klockner Moeller #FAZN C20-2, or ABB
S272-K20.
b) The new CB4 breaker (40A) is a 404-9081-058 Klockner-Moeller # FAZN C40-2, or ABB
S272-K40
8. In addition at the release of V2.00 the Z axis rapid was increased from 394 ipm (10008 mmpm) to
500 ipm (12700 mmpm).
a) It is important that the DAC is reset to 0.950 @ 50 ipm on the Z axis drive when the rapid has
been increased to 500 ipm.
b) Since this change could affect Rigid Tapping it would be beneficial to check Z and
Spindle axis parameters and verify that Rigid Tapping functions correctly (refer to
parameter document 757-4005-001, CAD DP0001 REV D).

field service bulletin index

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