Charmilles Robofil 190 290P 310P 510P 1-2 Maintenance Manual

ROBOFIL 190 • 290P • 310P • 510P
Maintenance manual
205 964 540/E/08.2000 ver. B
Part 1/2
205 946 940/E/09.08.2000

ATTENTION
Les illustrations contenues dans ce manuel se rapportent aux machines ROBOFIL de

taille 510P, mais restent valables pour les machines ROBOFIL de taille 190/290P/
310P.
Les procédures de maintenance et de dépannage sont valables pour les deux tailles
de machines.
ATTENTION
The illustrations in this manual refer to ROBOFIL machines of sizes 510P but are also
valid for ROBOFIL machines of sizes 190/290P/310P.
The maintenance and trouble-shooting procedures are valid for the two sizes of
machine.
ACHTUNG
Die in diesem Handbuch enthaltenen Abbildungen beziehen sich auf die ROBOFIL-
Maschinen der Grösse 510P, aber sie sind auch für die ROBOFIL-Maschinen der
Grösse 190/290P/310P gültig.
Die Wartungs- und Entstörungsverfahren gelten für beide Maschinengrössen.
ATTENZIONE
Le illustrazioni contenute in questo manuale si riferiscono alle macchine ROBOFIL

modelli 510P, ma restano valide per le macchine ROBOFIL modelli 190/290P/
310P.
Le procedure di manutenzione e di riparazione sono valide per tutti I modelli di
macchine.
ATENCIÓN
Las ilustraciones que contiene este manual se refieren a las máquinas ROBOFIL de
tamaño 510P, pero siguen válidas para las máquinas ROBOFIL de tamaño 190/
290P/310P.
Los procedimientos de mantenimiento y reparación son válidos para todos los
tamaños de máquinas.
CHARMILLES TECHNOLOGIES 205 915 200/FEDIEs/08.10.1999 1

2 CHARMILLES TECHNOLOGIES 205 915 200/FEDIEs/08.10.1999
1. Period maintenance procedures
2. List of error messages
3. Location of units
4. Troubleshooting
5. On-board diagnostic
Maintenance manual
6. Installation
ROBOFIL
190/290P 7. Set of diagrams
310P/510P
IMPRESSUM
Document designed and written by N. Fujisé and F. Zaslawski, CTSA-Geneva.
DTP by IRL-Lausanne.
The technical data is from our R&D department, CTSA-Geneva.
Our thanks for their collaboration go to: Messrs. Bouchoud, Brachet and Argese,
CTSA-Geneva. Table of
Printed by IRL-Lausanne. contents
CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000 0.1

Table of
contents
0.2 CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000

General table of contents
Period maintenance procedures 1.1.1
List of periodic maintenance operations 1.1.3
Log book 1.2.1
List of error messages 2.1
Introduction 2.3
Error message numbering 2.3
Error message alphabetic identification 2.3
Run Time Errors 2.4
Location of machine units 3.1
Introduction 3.1.3
ROBOFIL 290P/310P/510P:
Overall view of machine (front view) 3.1.4
Overall view of machine (rear view) 3.1.5
Alphabetical index of units 3.1.16
ROBOFIL 190:

Table of
Alphabetical index of units 3.1.26 contents

Location of units of electrical cabinet 3.2
Overall view 3.2.3

Identification of components 3.2.3
Troubleshooting procedures 4.1
Alarm messages
073 4.23
642 4.17
648 4.15/16/18/19
649 4.20
660 4.22
666 4.23
703 4.17
717 4.21
719 4.20
720 4.20
735 4.19
746 4.20
747 4.18
851 4.18
904 4.27
905 4.27
906 4.27
907 4.27
910 4.26
911 4.26
912 4.27
913 4.27
914 4.27
915 4.27
916 4.4
917 4.4
Problem
Automatic rethreading 4.20
Automatic threading 4.18/19
Axis 4.5
Brake 4.22
Broken wire 4.15/16
Deionisation 4.8
Dielectric cooling 4.6
Filtering 4.7
General when machining 4.24/25
High pressure injection 4.9
Measurement precision 4.23
Table of Polluted clean water tank 4.10
Pump 4.11
contents

Screen 4.3
Wire cutting 4.17
With dielectric function functional component 4.12/14
Checks and adjustments

Compressed air pressure 4.29
Power supplies 4.28
Suction jet 4.31
Threading jet 4.30
Torque limiter (16 kg spools) 4.33
Wire evacuation roller pressure 4.32
Replacement, removal and installation

Of spool drive motor toothed belt 4.48
Of wire drive motor toothed belt 4.37/49
Of bottom head height 4.46
Of printed circuit boards (PCB's) 4.35
Of the X, Y, U or V motor belts 4.38/50
Of wire evacuation rollers 4.42
Of curling pinions 4.44
Greasing of bottom head gears 4.47
Draining of tanks 4.40
On-board diagnostic 5.1
Introduction 5.3
Definition and role of the Diagnostic 5.3
Field of application 5.4
Startup Diagnostic 5.4
Console 2 Diagnostic 5.4
Utilities 5.4
Safety regulations 5.5
Protection against electrostatic discharges 5.6
Identification and quality control of faulty items 5.7
How to communicate to Geneva the problems encountered
when using the diagnostic 5.7
STARTUP DIAGNOSTIC 5.8

Introduction 5.8
Startup sequence of the machine 5.9
Significance of the statuses of test results 5.10
Startup with no defect detected 5.10
Startup with no defect detected with Diagnostic requested 5.11
Startup with defect detected on coprocessor 80187
of the CCU Com board 5.14
Startup with defect detected on coprocessor 80187
of the CCU Com board and without the CCU Exe board 5.15
Table of
contents

Console 2 DIAGNOSTIC 5.18
Introduction 5.18
Preparation of the machine prior to the tests 5.18
For a ROBOFIL 5X0, 3X0, 290 5.18
Structure of the machine equipped with a Csl2 5.19
Structure of Csl2 5.19
Detailed structure of the machine with Csl2 5.19
Software version 5.20
Startup sequence of the machine 5.21
Parameters of the test execution modes 5.23
Console module tests 5.25
Communication module tests 5.28
Execution module tests 5.31
Pilot module tests 5.35
Reporting 5.43
Utilities 5.47
Introduction 5.47
How to use the different utilities 5.47
How to execute the different utilities 5.48
List of error messages 5.49
System Board 5.49
Memory Test 5.57
Hard Drive Test 5.59
Floppy Disk Drive Test 5.61
Keyboard Test 5.63
Video Test 5.64
Installation 6.1
Introduction 6.3
Transport and handling 6.4

Storage prior to placing in service 6.4
Precaution to be taken before unpacking 6.5
Transporting and unpacking 6.6
Choice of working premises 6.7

Site dimension - Bulk 6.7
The floor 6.11
Atmosphere 6.11
Location 6.11
Equipping the premises (Outside connections) 6.12

Electrical mains 6.12
Compressed air 6.12
Automatic filling 6.12
Thermostabilization of dielectric 6.13
Table of
contents

Machine installation check list 6.14
Choice and equipment of premises 6.14
Packing +Transport 6.14
Data sheet ROBOFIL 190 6.15
Data sheet ROBOFIL 290P 6.17
Set of diagrams 7.1
Functional diagrams
CONTROL Functional diagram 7.3
POSITION Functional diagram 7.5
DIELECTRIC Functional diagram - ROBOFIL 190/290P 7.7
DIELECTRIC Functional diagram - ROBOFIL 310P/510P 7.9
WIRE CHANGE Functional diagram 7.11
ERODE Functional diagram 7.13
Electrical diagrams
400/110/24V power supply cabinet 8 314 950
Interconnection + machine electrical equipment 8 315 210
Axis diagrams ROBOFIL 190 130 001 872
I/O diagrams ROBOFIL 190 130 001 873
Mechanical diagrams
Dielectric diagram ROBOFIL 190 130 000 414
Dielectric diagram ROBOFIL 290P 130 003 081
Dielectric diagram ROBOFIL 290P AWT 130 003 082
Dielectric diagram ROBOFIL 310P/510P 422 130
Table of
contents

Table of
contents

1.1 Period maintenance
Period maintenance procedures
procedures
1.2 Log book
ROBOFIL
190/290P
310P/510P
Period maintenance procedures
Table of
List of periodic maintenance operations 1.1.3 contents
CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000 1.1.1

1.1.2 CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000
List of periodic maintenance operations
ROBOFIL 290P
ROBOFIL 310P
ROBOFIL 510P
ROBOFIL 190
Checks before machining
Check :
– filtering circuit pressure (replacement of filters) p. 1.1. 8 4 6
– the deionisation value (replacement of deionisation bottle resins) p. 1.1. 14 12 10
– wire, quality and storage p. 1.1. 16
– presence of minimum top and bottom injection p. 1.1. 20 18
– presence of top and bottom wetting contact p. 1.1. 24 22
– correct attachment of bonding braids and current feeders p. 1.1. 28 26
– wire unwinding stability p. 1.1. 30
– state of top machining contact p. 1.1. 68 66
Weekly checks
Check :
– wire tension p. 1.1. 32
– the top and bottom high pressure injection bearings p. 1.1. 36 34
– the condition of the wire drive rollers (wear and surface) p. 1.1. 42
– the quality, cleanliness and tightening of the top and bottom wire guides p. 1.1. 70
– appearance quality of injection nozzles p. 1.1. 72
Monthly servicing or number of machine hours servicing

Check :
– cleanliness of electrical equipment cabinet air filters and wire conditions p. 1.1. 38
– condition of annealing contacts 250 hs p. 1.1. 40
– condition of bottom contact brushes (wear, surface) 250 hs p. 1.1. 42
– brake belt wear 250 hs p. 1.1. 44
– spool drive belt wear 250 hs p. 1.1. 44
– wire calibration (size) by running a "WIRE SET-UP" cycle 250 hs p. 1.1. 54
– top head block cleanliness 250 hs p. 1.1. 58 56 57
– removal of top head blocks p. 1.1. 58 56 57
– suction nozzle cleanliness 250 hs p. 1.1. 61
– top injection chamber 250 hs p. 1.1. 62
– top injection chamber guide sleeve condition 250 hs p. 1.1. 63
– condition of blade and backing blade 250 hs p. 1.1. 64
– quality and cleanliness of threading nozzle 250 hs p. 1.1. 72
– rethreading unit wire rejection cylinder 250 hs p. 1.1. 74
Also :
– clean the X, Y, U, V and Z axis drives On appearance of alarms
A050 ou F051 p. 1.1. 48 46
Six-monthly or more servicing

Check :
– general cleanliness of dielectric
– clean the heat exchanger and electrovalve Y24 (option) p. 1.1. 52 50
– the geometry of the guide sleeves, sapphires and wire guides 1000 hs p. 1.1. 55
– the condition of the distributor unit guide sleeve p. 1.1. 61

Filtering circuit pressure check and filter replacement
ROBOFIL 290P
Frequency When error message «E715 - Clean water level too low» message appears.
When the filtering circuit pressure is greater than 3.5 bars.
Procedure/ Check the condition of the wires and replace if necessary.

Adjustment The filters are replaced when pump M13 is stopped (Q13 tripped).
• Trip circuit-breaker Q13 of pump (1).
• Unscrew cover (4) from filter body (8) using thumbwheel (5).
• Replace filter (9).
• Check seal (7); replace if necessary.
• Repeat this operation for the other four or five filters.
• Restart the filtering pump; engage circuit-breaker Q13.
• On starting the circuit, check that there is no leakage from the covers.
If leakage occurs, shut off the circuit again and repair the seal.
!
When disposing of filters, comply with the anti-pollution standards in force.
List of wear parts
No. Description Charmilles No. Qty. per machine Supplier
3 Circlips 209 227 224 4

5 Thumbhweel 100 433 158 1
6 O-ring seal 200 448 164 4
7 O-ring seal 200 448 165 4
9 Cartridge filter 100 343 117 4

;;;
;;;
;;;
;;;
;;;
;;;
4052
(1)
(5)
1777
(6)
(3)
(4)
(7)
(8)
(9)
1773

Filtering circuit pressure check and filter replacement
ROBOFIL 310P/510P
Frequency When error message «E715 - Clean water level too low» appears.
Procedure/ Check the condition of the filters and replace them if necessary.
Adjustment It is possible to replace filters without stopping the machine (310P/510P).
Simply stop one of the circuits and allow the other to operate as shown on the label located behind
the machine.
• Select one of the circuits by turning control valve (2) to the right or left.
• Unscrew cover (4) from the filter body (8) using thumbwheel (5).
• Repeat this operation for all the filters.
• Set the three-channel control valve (2) to the centre position.
• On restarting the circuit, check that there is no leakage from the covers. If leakage occurs, stop
the circuit involved and repair.
! It is preferable to replace the filters of both batteries simultaneously. When disposing of

filters, comply with the anti-pollution standards in force.
List of wear parts
N° Description N° Charmilles Qty. per machine Supplier
3 Circlips 209 227 224 8/10

5 Thumbhweel 100 433 158 1
6 O-ring seal 200 448 164 8/10
7 O-ring seal 200 448 165 8/10
9 Cartridge filter 100 343 117 8/10

(5)
1777
(6)
(3)
(4)
(7)
(8)
(9)
1773
1st circuit 2nd circuit
(2)
1491
(1) Pump
6 1
7 2
ROBOFIL 510P: 5 filters 8 3 5 filters
ROBOFIL 310P: 4 filters (4 filters)
9 4
10 5
Filtering pump
M13
Middle (medium)
10 filters (8 filters)
4051
Dirty water tank Clean water tank
5 filters 5 filters
(4 filters) (4 filters)
1546

Check of the filtration circuit pressure and replacement of filters
ROBOFIL 190
Frequency When error message «E715 - Clean water level too low» message appears.
Procedure/
Adjustment Check the condition of the wires and replace if necessary.
Adjustment The filters are replaced when pump M13 is stopped (Q13 tripped).
• Trip circuit-breaker Q13 of pump (1).
• Unscrew cover (4) from filter body (8) using thumbwheel (5).
• Repeat this operation for the other four or five filters.
• Restart the filtering pump; engage circuit-breaker Q13.
• On starting the circuit, check that there is no leakage from the covers.
If leakage occurs, shut off the circuit again and repair the seal.
Note: With the 8 filters option it is possible to change the filters during machining.
Select a circuit of filters (2) according to the label.
! It is preferable to replace the filters of the two batteries simultaneously.

When disposing of the filters, comply with the anti-pollution regulations in force.
List of wear parts
N° Description Charmilles No. Qty. per machine Supplier
7 Toroidal sealing ring 2/4

9 Cartridge filter 100 343 117 4/8

+4 filters: OPTION
4 filters: STANDARD
(8)
Clean water reservoir
(2)
(1)
Polluted water reservoir
4654
4680
(7)
(4)
(2x 9)
(5)
4655
Filter remover
(3)
4656

Checking and replacement of deionisation resins
ROBOFIL 310P/510P
Frequency In the INFO mode, the indication shall be equal to the setpoint ± 2 µS/cm. Replace the resins when
the deionisation test no longer drops to the setpoint value: mode EXE, «USER PARAMETERS» Deio.
Procedure/ To stop the water flowing in the bottle, give a high value to parameter Deio (EXE mode: «USER
Adjustment PARAMETERS»), e.g.: 25 µS/cm.
Bottle (7):
• Disconnect the bottle and place the tubes in a bucket.
• Unscrew cap (4) under the bottle using wrench (6).
• Roughly drain off the resins.
• Fill the bottle with dry resins from the bottom.
• Fit cap (4).
• Connect the bottle, respecting the direction of the arrows (see drawing).
• Set parameter Deio to 5 µS/cm.
• Check that the water flows correctly at the bottle outlet.
• Set parameter Deio to approximately 15 µS/cm.
Bottle (9):
• Disconnect the bottle and place the tubes in a bucket.
• Unscrew cap (10) and the control valve (11).
• Drain the resins coarsely.
• Fill the bottle with dry resins from the top.
• Fill the bottle with water.
• Fit control valve (11) and cap (10).
• Connect the bottle, respecting the direction of the arrows.
• Check that the water flows correctly from the bottle.
• Reset parameter Deio to approximately 15 µS/cm.
! When disposing of resins, comply with the local anti-pollution standards in force.
Refer to manufacturer's material safety data sheet (MSDS) for safe handling instructions.
List of wear parts
1 Bend LH 3/4" 200 445 009 2

3 Coupling and plate 200 290 852
5 Complete cover 200 290 863
6 Special bottle key 100 431 851 1
7 Complete bottle 100 342 272 1
8 Resins (Load of 25 l) 100 342 355

IN OUT
1464
! Respect the arrow directions
(7)
7 (1)
1 (3)
3 (1)
1
Flow outlet to clean tank Yv18

Inlet flow
OUT IN
(5)
5
(10)
(8)
8
(11)
(9)
4075
(6)
6
(4)
4
953
952

Checking and replacement of deionisation resins
ROBOFIL 290P
Procedure/ For the water to stop flowing in the bottle, give a high value to parameter Deio (EXE mode, «USER
Adjustment PARAMETERS»), e.g.: 25 µS/cm.
• Disconnect the bottle.
• Remove ring (1), remove base (2) and empty the bottle.
• Rinse the inside of the bottle and filters (3) and (4).
• Insert a resin charge.
• Replace the bottom and tighten ring (1).
• Reconnect the tubes, inlet at (A) and outlet at (B).
• Check that the water flows correctly from the bottle outlet.
• Reset parameter Deio to 15 µS/cm.
List of wear parts
1 Snap fastener 200 290 949 2

2 Base 200 290 948 1
3 Filter and tube 200 290 950 1
4 Filter 200 290 963 1
5 Cover and couplings 200 290 947 1
6 Cover and base seal 200 290 946 2
Resins (Load of 25 L) 100 342 355

;;;
;;;
;;;
;;;
;;;
;;; (1)
4052
(7)
(1)
(2)
2613
(6)
Inlet (4)
2614
(5) Outlet (B) (A) Inlet
Outlet (3)
2615

Check and replacement of deionization resins
ROBOFIL 190
Procedure/
Adjustment For the water to stop flowing in the bottle, give a high value to parameter Deio (EXE mode, «USER
PARAMETERS»), e.g.: 25 µS/cm.
• Disconnect the bottle.
• Remove ring (1), remove base (2) and empty the bottle.
• Rinse the inside of the bottle and filters (3) and (4).
• Insert a resin charge.
• Replace the bottom and tighten ring (1).
• Reconnect the tubes, inlet at (A) and outlet at (B).
• Check that the water flows correctly from the bottle outlet.
• Reset parameter Deio to 15 µS/cm.
List of wear parts
1 Snap fastener 100 950 302 2

2 Base 200 290 948 1
3 Filter and tube 1
4 Filter 200 290 963 1
5 Cover and couplings 200 290 947 1
6 Cover and base seal 200 290 946 2
Resins (Load of 25 L) 100 342 355

(1)
(7)
(1)
(2)
4752
2614
(5) Outlet (B) (A) Inlet
(6)
Inlet (4)
Outlet (3)
2615

Wire check, quality and storage
Frequency Whenever the wire is renewed.
Procedure/ The wire is the cutting tool. Therefore, it is very important to check its qualities.
Adjustment
Check the condition of the wound wire:
- The winding should be homogeneous, non-interrupted, without twisting, cross-overs or overlap of
turns.
- There should be no marks, folds, dents or traces of abnormal oxidation on the wire.
- The wire should be smooth to the touch.
- The wire colour shall be regular.
- Check the wire diameter, average tolerance: 1 - 2 µ
Consequences:
• Store the wires in a dry area.
• Quickly store half-used spools.
Comment: When replacing a wire spool, always lock the wire as shown in the drawing on the next
page to prevent the wire coils crossing.

1203

Checking and adjustment of top and bottom minimum injection
ROBOFIL 290P/310P/510P
Frequency Adjust the injection flow rates according to your applications.
Procedure/ In the EXE mode, select «MANUAL», then «SWITCH ON CONTACT», display the injections.
Adjustment • Set the top minimum injection rate using valve (1).
The water should flow from the top head in a regular column as shown in illustration (A).
• Adjust the bottom minimum injection rate using valve (2).
The water should flow from the bottom head as shown in illustration (B).
! With the «Very high finishing injection» option 250 < H < 390 mm, make sure that
there are no air bubbles liable to cause wire breakage.
List of wear parts
1 Tube HP dia. 10/8 100 444 906 8m ~ Angst &Pfister

(1)
(2)
5377
A B
2617 2616

Check and adjustment of flow and minimum injections
ROBOFIL 190
Frequency Adjust the injection flow rates according to your applications.
Procedure/ By means of the faucets (1) and (2) adjust the injection flows:
Adjustment • Set the top minimum injection rate using valve (1).
The water should flow from the top head in a regular column as shown in illustration (A).
• Adjust the bottom minimum injection rate using valve (2).
The water should flow from the bottom head as shown in illustration (B).

(1)
(2)
4657
Low pressure zone
4658
A 2617
B
2616

Top and bottom wetting contact presence check
Frequency Before each machining operation.
Procedure/ For the top wetting contact:

Adjustment • Select EXE mode «MANUAL» «SWITCH ON CONTACT».
• Visually check that the water fills the machining contact block (1) to 2/3 level.
For the bottom wetting contact:

• Remove the Plexiglas cover (2).
• Close the door.
• Select EXE «MANUAL» «SWITCH ON CONTACT».
• Visually check that the jet comes out between the wire evacuation rollers (3).

(1)
(2)
(3)
1530a
Water jet

Check for presence of upper and lower contact wetting
ROBOFIL 190
Frequency Before every machining job.
Procedure/ For upper contact wetting.

Adjustment • Type AUX,59.
• Check visually that the water fills the machining contact block (1) up to at least 2/3 full.
For lower contact wetting.

• Remove the Plexiglass cover (2).
• Close the door.
• Type AUX,59
• Check visually that a jet comes out between the two wire evacuation rollers (3).

(1)
4670
(2)
(3)
1530a
Water jet

Earthing braid and current feed cable tests
Frequency
Procedure/
Adjustment Earthing braid test:
• Check that the 6 braids (A)(A') / (G) are correctly attached.
• Check that the earthing braid is correctly attached to the cabin (F).
• Check braid quality: braid frayed, cut or loosened from the terminals.
• Check that the insulation sleeves are neither torn nor split.
• Check that there is no oxidation on the work-piece plate or on the terminals at the attachments (if
necessary clean with chlorothene).
• Disconnect the earthing braids and measure their resistance.
Checking of machining cables (B)(B'):

• Check that the cables are correctly attached to the terminal strips (C).
• Check that the current infeed cables are correctly attached to the Plexiglas cover of the bottom
head (D).
• Check that the cables are correctly positioned in the take-up pulleys (E).
• Check the quality of cables (B): no fraying, cuts, no loose connections.
List of wear parts
ROBOFIL 290P/310P
B Current infeed cable (L 1100) 100 432 528 4
G Braid 15 x 300 100 942 008 6
ROBOFIL 510P
A Braid 15 x 200 100 448 008 4
F+A' Braid 15 x 500 100 448 328 3
B Top current infeed cable
(L 2000) 200 433 309 2
B' Top current infeed cable
(L 1450) 200 433 310 4

ROBOFIL 290P/310P
(G)
ROBOFIL 510P
846 b
(B) (E) (B)
1483a
(A)
(B') (D)
(C)
(A')
(E)
1488a
(F)

Check of electrical leads
ROBOFIL 190
Frequency
Procedure/
Adjustment Check of machining cables (A):
• Check that the cables are properly fixed to the attachments (B).
• Check that the electrical leads are properly fixed onto the Plexiglass cover of the bottom head (C).
• Check the quality of the cables (A): sheaths not torn, not cut, not de-crimped.

A A
B
B
C
A
A 4660

Wire feed (unwinding) stability test
Frequency Before machining, check the wire feed rate and brake calibration.
Procedure/ In the EXE mode «GENERATOR PARAMETERS», check that the brake voltage corresponds to the type
Adjustment of wire used. In the same page, check the wire feed speed.
• Fit the tensionmeter.
• Activate the wire feed and operate the brake.
• Check that the tension indicated on the tensionmeter is stable (±25g).
The moving pulley should remain stable.
Example: Wire dia. 0.25 mm.

Setting 1 kg ±20g, variation ±25g.
Comment: Depending on the technology used, the value obtained should be equal to the
theoretical value ±20g; if not, refer to the brake adjustment procedure.

1848

Wire tension check
Frequency Weekly check of wire tension and brake calibration.
Procedure/ Tensionmeter calibration:

1021
Adjustment • Suspend the wire used for machining from a hook or ring.
• To this wire, couple a weight of 1 kg if SW25X 1.3 kg if LT or SW30X
• Calibrate the tensionmeter dial (1) by comparing the value read to the actual
value of the weight.
Brake check/calibration:
• Install tensionmeter (1) in the machining area.
• Depending on the technology used, check that the value measured equals the technology
theoretical value ± 20 g
- If yes end of check
- if not see below.
Brake calibration procedure:

The brake calibration procedure is used to precisely determine a correction curve and can be easily
adapted for the various types of brake. Moreover, it is possible to define the range over which the
brake is to be used, while retaining the same accuracy (small wires).
!
As long as the calibration has not been correctly performed, the machine will display
error «E680 Brake Calibration incorrect».
The following reference points are:

(key EXE, page «SERVICE» «WIRE PARAMETERS»).
– Ref. Point 1 : 220 Ref. Point 4 : 1000
These values define the brake characteristic slope change points; when correctly initialised, proceed
as follows:
• Set the 2 parameters Meas. val 0, Meas. val 1 to zero.
• Switch the machine on and off; error E680 should be displayed at this moment.
• In the MANUAL mode, select the «GENERATOR PARAMETERS» menu; program parameter WB=0
and WS=10.
• Actuate the wire feed and brake.
• Using the tensionmeter, measure the wire feed chain residual tension; note this value.
• Program parameter WB=0,22 and wait approximately 10 [s] for the brake to stabilise
(the LED's on the «Wire feed» and «Brake» keys should not flash).
• Using the tensionmeter, measure the tension of point 1 and note this value.
• Program parameter WB=0,5 and wait approximately 10 [s] for the brake to stabilise.
• Using the tensionmeter, measure point 2 and note this value.
• Using the tensionmeter, measure the tension at point 3 and note this value.

Procedure/ • Stop the wire feed and return to the EXE-SERVICE-WIRE PARAMETERS menu.
Adjustment • Store the measured values at the corresponding points.
• Switch the machine off, then switch on again.
With some types of wire, the highest tension values cannot be measured; therefore, by-
!
default values must be entered.
If the LED of the brake key flashes permanently, this means that the brake is not demagnetising. In this
case, successively press the «BRAKE START» and «FEED STOP» buttons on the front panel; the
automatic demagnetisation cycle begins.
By-default values:
FI 190/290P FI 310P/510P
(frein à poudre) (frein électromagnétique)
Val. Mes. 0 0 0
Val. Mes. 1 0 0
Val. Mes. 2 400 350
Val. Mes. 3 600 725
Val. Mes. 4 1000 1750
Val. Mes. 5 1200 2300
Val. Mes. 6 2500 2700

Top and bottom high pressure check
Frequency When there is an important difference between the pressure reading on the pressure gauges in the
INFO mode and that recommended for the technology.
Procedure/ • Clamp a flat ground steel part.

Adjustment • Check the top surface flatness (< 50 µm)
• In the EXE mode and «GENERATOR PARAMETERS» page, set parameter INJ to 4 and engage the
top and bottom injections.
• Using the remote control (low speed), lower the Z axis carefully until maximum pressure is
obtained.
• Check the following injection points:
Value status 0 = closed Pressure
Yv14 Yv15 Yv21 Yv20 Pump M15 50 Hz Pump M15 60 Hz
0 0 1 1 INJ P. (bar) P. (bar)
1 1 1 1 1 2.2+/-0.8 3+/-0.8
1 1 1 0 2 3.5+/-0.8 4.5+/-0.8
1 1 0 1 3 7.5+/-0.8 8.5+/-0.8
1 1 0 0 4 12+/-0.8 12+/-0.8
! If one of the blue 10/8 dia. tubes carrying high pressure is bent (folded) (white
breakage), replace the tube immediately.
List of wear parts
1 Tube HP dia 10/8 100 444 906 8m ~ Angst + Pfister

40 < H < 80
Min. 50 mm Min. 50 mm
1496
To clean tank
Top injection bottom pressure
Top injection top pressure
1464

Check of upper and lower high pressure
ROBOFIL 190
Frequency When pressure is inadequate.
Procedure/ • Clamp a ground plane workpiece in steel.

Adjustment • Check the flatness of the upper surface (<50 µm).
• Set the upper and lower injection faucets at 4.
• Using the remote control (slow speed) lower the Z axis very carefully until maximum pressure is
obtained.
• Check several levels of flows
! If one of the 10/12 dia. blue hoses supplying high pressure has become bent (white
crack) replace it immediately.
List of wear parts
No Designation Charmilles No Qty. per machine Supplier
Hp hoses Ø 10/12 130 000 194 2

40 < H < 80
Min. 50 mm Min. 50 mm
0-26.5 l/min A
0-24.8 l/min B
4657
High pressure zone
4658

Replacement of electrical equipment cabinet
air filters and wire conditioning
Frequency Filter (2): Every month, or more frequently if the premises are dusty.
Filter (1) and filter (1'): If too dirty or if there are electrical equipment cabinet temperature problems.
Procedure/ • Remove attaching grid (1) by removing the screws.

Adjustment • Remove the filter and fit a new filter.
• Open the electrical equipment cabinet door and replace filter (1').
• Open the door of the wire preparation cabinet.
• Unscrew the screw (3) and pull the bar (4) upwards.
• Unscrew (5), remove the filter (2) and clean it with water.
! The air flow indicator arrow should be directed towards the inside of the cabinet.
List of wear parts
No Description Charmilles No. Qty. per machine Supplier
1 Air filter 108 626 140 1

1' Air filter 108 732 900 1
2 Air filter 200 422 640 1

ROBOFIL 310P EMC/510P
3997
2648
(5) ROBOFIL 190/290P/310P/510P
(1)
(4)
2647
(2)
4059 (1')
(4)
(3)
2620
4753

Checking/replacement of annealing contacts
ROBOFIL 310P/510P
Frequency If annealing problems during threading or rethreading.
Procedure/ • Check the contact for quality and cleanliness.

Adjustment
CORRECT
Clean with solvent

mini 2 mm
INCORRECT
• Check whether sleeve (3) is dirty or blackened. Clean with solvent (e.g., chlorothene).
• Replace the contact brush if the contact is worn.
- unscrew caps (2),
- replace contact brush (1).
! Never handle the contact during machining or during a machining cycle.
List of wear parts

1 Annealed contact brush 100 343 525 2

2 Cap 100 342 185 2
3 Annealed contact sleeve 100 446 275 1

; ;;;
;;;
;
;;;;;
(2)
;
;;;
; ; ;
;;;
;; ; ; ;
;;
; ; ; ;
;;;
;
;
; ;;;
;;;
; ; (1)
;; ;; ;;;;
; ; ; ; ;
;; ;;;
;;;
;
;; ; ; ; ;
;;;;;;;;;;;;;;
(3)
;;
;;;
; ; ; (1)
;;;
;
;;;; ;
(2)
844
1544

Wire drive roller check and replacement
of bottom machining contacts
Frequency
Procedure/ Check the quality of wire drive rollers (2)(2'):

Adjustment • If rollers (2)(2') are worn: refer to troubleshooting chapter.
• If rollers (2)(2') are dirty or blackened, clean with solvent (P3, chlorothene).
Check contact (1) quality:

• If the contact does not bear correctly against the disk.
• If the contact is worn or dirty, clean it or, if necessary, replace it by unscrewing both screws (4).
! Never handle the contact during machining.

2 x 100 446 687 (1)
(4) 109 044 060
733
130 003 359 (2) (2') 130 003 360
2 x 130 003 362
2 x 130 003 263
2 x 109 044 114

6047

Brake belt wear and wire preparation platen
belt wear check
Frequency Change the belt when the depth of the groove marked by the wire is approximately 0.1 to 0.2 mm.
This results in irregular drive of the pulleys when the brake is operated for a tension of 1.8 kg.
Procedure/ Brake belt:

Adjustment • Push pulley (1) towards the top of the platen.
• Remove belt (2).
• Fit a new belt, with the rough side facing outwards and respecting the direction marked on the
label.
Wire preparation platen belt:

• Unscrew screw (3) using 5 mm Imbus wrench.
• Lower pulley (4), then remove belt (5).
• Fit a new belt and tension it by pushing part (4) towards the top of the platen.
List of wear parts

2 Brake belt 100 447 506 1

5 Wire preparation platen belt 100 446 880 1

(5) (2)
(4)
(1)
(5)
1487
ROBOFIL 51
0P CHARMILLES
TECHNOLOGI
ES
1418 b

X, Y, U, V and Z axis drive lubrication
Frequency As soon as the following two messages appear: «A050: Axis greasing demanded».
«F051: Axis greasing mandatory».
Procedure/ Filling of grease gun:

Adjustment • Unscrew cylinder (1) on the head of gun (2).
• Turn handle (3) one-quarter of a turn and pull chain (4) fully, then jam the chain in the slot.
• Fill the gun with grease, making sure to avoid formation of air pockets (allow the grease to push
the piston gently).
• Screw in cylinder (1).
• Release chain (4) and lock handle (3) by turning it one-quarter of a turn.
• Slightly unscrew bleed valve (5) to evacuate any air present. When the grease begins to come
out of the valve, tighten valve (5).
• Pump a few strokes until grease comes out of the end-fitting.
ROBOFIL 510P X, Y, U, V and Z axis greasing:
• Cut the wire.
• Close the door.
• On screen EXE, press «START CYCLE»; the greasing cycle will begin automatically.
• Using the gun, fill the 25 grease nipples (6), pumping 5 times into each nipple.
! Each pump stroke must last 5 seconds minimum, otherwise there is a risk of a pressure
surges and tube bursting. If this instruction is not respected, grave damage can be
caused to the machine.
Do not use other grease runs than those supplied with the machine. The maximum
pressure in the lines is 20 bars!
• When greasing is completed, press the «STOP CYCLE» key.
ROBOFIL 290P/310P greasing (X, Y, U and V axes):
• Cut the wire.
• Close the door.
• Using the gun, fill the grease nipples (7), pumping 5 times into each nipple.
• Remove old grease from points (8) and (9) and wipe these points. Grease (8) and (9) of all the
axes using a paintbrush.
• On screen EXE, «START CYCLE». The greasing cycle will begin automatically.
• After a few minutes, press «STOP CYCLE».
ROBOFIL 290P/310P Z axis greasing:
The Z axis is accessible from the rear of the machine and greasing is performed using a paintbrush.
• Apply BLASOLUBE 301 grease to the following points:
- To drive wheel (A).
- To rack (B).
! Do not use greases other than BLASOLUBE 301. Make sure that the grease is
absolutely clean.
Use caution around moving parts. Replace all guards.
List of wear parts
Grease gun 200 449 141 1

Blasolube 301 grease 100 447 470 Blaser

(5) (2) (1) (4) (3)
2874
ROBOFIL 510P
1529
4080
(6)
(9) (7) (9)
ROBOFIL 290P/310P
Z axis
Motor
;;;;;
;;;;;
B
A
(8)
2872

Lubrication of X, Y, U, V and Z axes drives
ROBOFIL 190
Frequency As soon as either of the following messages is displayed: "A050: Axis lubrication requested"
"F051: Axis lubrication mandatory"
Procedure/ Lubrication of X, Y, U, and V axes:

Adjustment • Cut the wire.
• Close the door.
• Using the pump (1) filled exclusively with BLASOLUBE 301, load the 18 lubricating nipples (3) of
the X, Y, U, and V axes, pumping twice on each nipple.
• In the EXE screen, press the “START CYCLE” key. The lubrication cycle will start automatically.
• After a few minutes, press the “STOP CYCLE” key.
Lubrication of the Z axis:

The Z axis is accessible from the wire feed equipment panel.
• Remove the plate (2).
• Move the Z axis until the grease nipple appears.
• Apply (2X) BLASOLUBE 301 grease to the greasing point by means of the pump.
! Do not use any other lubrication product except BLASOLUBE 301. Ensure that the
grease is absolutely clean.
List of wear parts
N° Designation Charmilles N° Qty. per machine Supplier
1 Grease pump 100 448 716 1

Blasoluble grease 100 447 470 Blaser

(1)
1781
(3)
(3)
4754
(3)
4756
(3)
4755
(2)
4664

Cleaning of the plate-type heat exchanger
Frequency • Every 6 months
Procedure/ • Close the cold water inlet tap.

Adjustment • Switch off the machine.
• Remove the rear panel of the machine
• Disconnect the 4 pipes (41, 42, 51 and 52) connected to the exchanger.
• Loosen the screws (1).
• Take out the heat exchanger.
• Fill the exchanger with anti-limescale product via the hole (51), and rinse.
• Remove electrovalves Y24 and clean by means of an anti-limescale product.
Comment The use of ice-cold deionized water enables this periodic maintenance operation to be
avoided.

ROBOFIL 290P/310P ROBOFIL 510P
(1)
4390 4389
(51) (52)
(41)
(42)
(41) (52)
(51) (42)
4392 4391
(1) (1)
51
41
(41) Dielectric output

(42) Dielectric input
52 (51) Cold water input
42
(52) Cold water output
1510
(Y24)
4393

Cleaning of the plate heat exchanger
ROBOFIL 190
Frequency Every 6 months
Procedure/ • Close the iced water inlet faucet.

Adjustment • Switch off the machine.
• Remove the rear panel of the machine.
• Disconnect the 4 hoses (41, 42, 51 and 52) connected to the exchanger.
• Unscrew the screws (1).
• Take out the heat exchanger.
• Fill the exchanger with an anti-limescale product through the hole (51) and rinse.
• Remove the electrovalves Y24 and clean by means of an anti-limescale product.
Note This periodic maintenance operation can be avoided by the use of deionized iced water.

(1)
52
42 51
41
4665
(1)
Y24
4666

Wire calibration
Frequency Every 250 machining hours.
Procedure/ The Offset Tachy (wire feed), Offset Command (wire feeder) and Ton/Toff (threading) are
Adjustment automatically adjusted by means of a self-calibration procedure.
The Offset Tachy and Ton/Toff parameters are related: these intervene simultaneously in operation of
the threading device; it is for this reason that these parameters must be validated together.
Comment This procedure is accessible only from the «Maintenance» (Adjuster) level.
• Place the machine UV axes so that the wire is straight.

• Remove the threading tube or raise it sufficiently so that the wire does not jam in the tube during
threading motor calibration.
• Fit the wire and check that it feeds correctly.
• Stop the wire feed and go to «WIRE SET-UP» of the EXE mode.
• Press the wire feed button to start the calibration cycle.
• After a few minutes, the cycle is completed and the recommended values are displayed. Press the
corresponding keys of the menu to validate the desired parameters.
Comment While running the cycle, the «wire feed» and «threading» LED's flash.
For part of the motor cycle, threading is activated and the wire unwinds into the tank.
This is normal.

Top head maintenance: sleeves, sapphires and guides
Approximately Distributor guide

every 6 months sleeve block
Approximately Sleeve, sapphire D.4

every 6 months blade block
Robofil 310P
510P
Approximately 2 x sleeve; sapphire D.4
every 6 months rethreading block
Wear = Top contact

100 h/surface contact block
Approximately Injection chamber block

every 6 months sapphire subassembly
;;
Approximately
every 1,000 hours
Top wire guide
;;
1548

Removal/installation of blocks top head
ROBOFIL 290P
Distributor block
4 x O-ring seals
Machining contact block
2 M6 screws
(1)
(2)
Injection chamber
(3)
(4)
1495
Comment: It is not necessary to remove the injection chamber when removing the blocks.
- Remove Plexiglas cover (4): 2 knurled screws.
- The distributor block is removed by unscrewing the two M6 screws (Imbus 5 mm
wrench).
- The contact block is removed by unscrewing the 2 screws (1) from the side plate; then
unscrew screw (2).
- The contact-holder is removed by unscrewing screw (3).
Installing the blocks:

• Reverse the procedure for the contact block, then fit the distribution block.
• When installing the block, check the condition of the O-ring seals.

Removal/installation of blocks top head
ROBOFIL 310P/510P
Distributor block
Four 6 mm O-ring seals
Blade block
Two M6 screws
Three 6 mm O-ring seals
Three 6 mm O-ring seals
(1)
(2)
Injection chamber
(3)
(4)
1497
Comment: It is not necessary to remove the injection chamber when removing the blocks.
- Remove Plexiglas cover (4): 2 knurled screws.
- The distributor block is removed by unscrewing the two M6 screws (Imbus 5 mm
wrench).
- The contact block is removed by unscrewing the 2 screws (1) from the side plate; then
unscrew screw (2).
- The contact-holder is removed by unscrewing screw (3).
Installing the blocks:

• Reverse the procedure for the contact block, then fit the 3 other blocks in sequence.
• When installing the block, check the condition of the O-ring seals.

Removal/refitting of blocks of the top head
Checking/replacement of distributor block
ROBOFIL 190
Frequency
Note: It is not necessary to remove the injection chamber to take out the blocks.
- Remove the Plexiglass (4), 2 knurled screws.
- The distributor block is removed by unscrewing the 2 M6 screws (5 mm hexagon key).
- The contact block is removed by unscrewing the 2 screws (1) of the side plate, then
unscrewing the screw (2) of the electrical lead braid.
- The contact support is removed by unscrewing the screw (3).
Refitting of the blocks:

• Proceed in the reverse order for the contact block, then reinstall the distribution block.
• When refitting the block, check the condition of the O-ring seals (5).
Distributor block
4667
4668 4669
List of wear parts

N° Designation Charmilles N° Qty per machine Supplier
A 130 000 234 1

Distributor block 130 000 035 1

Distributor block
2 X M6
(1)
(4)
Injection chambers
4670
(2)
4671
(5)
(3)
4672

Checking/replacement of distributor block
Frequency If problem occurs
Procedure/ • Remove distributor block (1).

Adjustment • Check the components for leakage.
• Clean with compressed air.
1497
Withdrawal of blade
Y6 + wire ejection
(rethreading) Withdrawal of contact Y4
Blade Y5 advance
Suction jet water Y27
(1)
946
List of wear parts
1 Distributor block assembly

ROBOFIL 310P/510P 104 325 170 1
ROBOFIL 290P 104 325 180 1

Checking/replacement of distributor block guide sleeve
Frequency Check straightness of guide sleeve every 6 months.
Procedure/ • Check and/or replacement components (1) + (2).

Adjustment • Check straightness of guide sleeve (2).
• Use a shadow projector.
• Unscrew using special CT tool No. 104 452 140
;;;
;;;
;;;
Ø0.8 ± 0.1 (1)
(2)
(3)
9 -0.2°
1.2±0.04
1200b
List of wear parts
1 Suction nozzle guide 100 445 138 1

2 Guide sleeve (Sapphire) 100 441 423 1
3 Suction nozzle 100 445 139 1

Cleaning/replacement of top - bottom injection chamber
Frequency Monthly
Procedure/ Removal:
Adjustment • Remove the three M5 screws (4 mm wrench).
• Pull the assembly downwards.
• Remove top nut (5) and nut (6).
• Using special CT tool No. 104 452 140, clean part (A).
!
- Pull clearly in the wire direction, if necessary rotating the chamber on itself.
- Check O-ring seals before fitting chamber (2).
- When fitting, it is recommended to lubricate seals (2).
- Pay attention to fitting direction of port (4).
- For wire guide cleaning, see p. 1.1.70.
;;;;;;
;;
947
(2)
(3)
(See next §)
(4)
; ;
;;;;
;;
;;;
; ;; ;;;;
;
;;;
;;
;; ; ;
;;;
;;
;;
;;
;;
;;
3 X M5
(1)
(5)
(6)
CT special tool (A)

No. 104 452 140
4231
1085
List of wear parts
1 Top injection chamber assembly

310P/510P 104 329 700 1
Bottom 310P/510P 104 329 690 1
Top/bottom 190/290P 104 329 690 1
2 O-ring seals 109 410 207 4 PRP 030 830 70 SH

Checking straightness of top - bottom guide sleeves
Frequency Monthly
Procedure/ • Unscrew (3), clean and test.

Adjustment • Check straightness of (3) using a profile projector.
947
;;;;;;
;;
(2)
(3)
(4)
; ;
;;;;
;;
;;;
; ;; ;;;;
;
;;;
;;
;; ; ;
;;;
;;
;;
;;
;;
;;
(1) 3 X M5
Ø0.8 ± 0.1 (3)

9 - 0.2
°
Ø0.8 ± 0.1
M8
1194
List of wear parts

3 Sapphire subassembly 104 447 350 2

Removal/exchange of blade block
ROBOFIL 310P/510P
Frequency Turn the blade if there is a wire-cutting problem.

Replace the backing blade after having turned the blade 4 times.
Check for leakage.
Every 6 months, check quality of sapphire sleeve D4.
Procedure/ Black/backing blade removal:

Adjustment • Remove the blade block (1).
• Push piston (2) into the cutting position (position A on drawing).
• Unscrew the M3x5 top screw (Imbus 1.5 mm wrench),(screw (3)) while holding the backing
blade-holder (12).
! Hold the backing blade (11) with the finger.
• Extract blade (10) and backing blade (11).

• Test the blade (visual). Replace if blunt or turn the blade over.
• Check the 4 seals (13).
• Fit the complete assembly in the reverse order. Do not omit to fit spring (4).
• Check for leakage.
Start a wire cut and, at the moment in which the piston cuts the wire, there should be a pressure
reading of 5 bars at least on the pressurised air unit pressure gauge, on the back of the machine.
• If a problem occurs, check the seals.
• Remove flange (5) and the M4x8 screw (6). (Imbus 3 mm wrench).
• Remove M3x5 bottom screw (7) (Imbus 1.5 mm wrench) holding flange (8).
• Remove (8) (bottom guide flange) and (9) (pressure flange).
• Push the piston; extract it via position A.
• Fit the piston, then the flanges and tighten the M3x5 screws.
!
Check the condition of the O-ring seals
Checking the sapphire sleeve D.4:

• Unscrew (7) (Imbus 1.5 mm wrench) and remove (8).
• Remove the M3x3 screw (6) (Imbus 1.5 mm wrench) and check sapphire (18).
Check flatness and

Ø
cleanliness
3.
5
Ø1
±
(11)
0.
5±
OK
2
0.1
Ø1.9 ± 0.1
4.5 + 0.1
(10)
OK
If the edge is round,

The edge is marked;
the cut will not be
turn the backing
clean; rotate the Ø0.8 ± 0.1
blade through 90°
blade by 90° or
or replace it
replace it ø 4h8
984 985 1194

1497 Check the 1197
condition of
the 4 O-ring
(1) seals (13)
position B
position A
(2)
(12) (5) (6) (11) (4) (10)

Front view (3) Top Side view
(18) (7) Bottom (9) (17) (9)

1198
3xM3 screw (8) (14) (15) (16) (2)
! Check the condition of the O-ring seals if the blade-holder (2) is removed.
List of wear parts

1 Wire-cutter subassembly 204 315 170 1

4 Spring 200 441 726 1
10 Blade 100 442 848 1
11 Ceramic backing blade 100 445 990 1
13 O-ring seal 109 410 003 4 PRP 006 830 70 SH
14 O-ring seal 109 410 202 1 PRP 015 830 70 SH
O-ring seal 109 410 027 1 PRP 013 830 70 SH
15 NTH seal 109 412 034 1 NTH K16013 NEOTE
16 O-ring seal 109 410 201 1 PRP 014 830 70 SH
O-ring seal 109 410 009 1 PRP 012 830 70 SH
17 NTH seal 109 412 037 1 NTH S08012 NEOTE
18 Sapphire sleeve D4 100 441 423 4

Checking/replacement of top machining contact
Frequency As soon as the tungsten contact wire is equal to the wire radius.
Procedure/ Changing the top contact:

Adjustment • In the EXE mode, type «MANUAL» «SWITCH OFF CONTACT».
• Remove the Plexiglas cover from the top head without removing the block (1).
• Remove contact-holder (3) (Imbus screw (2) using 5 mm Imbus wrench).
8 tracks are available per contact (2 per surface, by turnover).
• Turn contact (4) (Imbus screw (5)) through 90° to use the 4 surfaces and 4 tracks, then turn it over
(180°) to use the 2nd track of each surface.
• Clean and fit the contact-holder (3).
! When refitting the contact and after having turned it over or replaced it, there are no
adjustments required.
Criteria for deflection of wire by the contacts:

To ensure correct contact, the wire must bear over a sufficient length (3 mm minimum). However, to
prevent breakage due to excessive rubbing, the wire must not come into contact with the edges of the
contact.
Check:
• Coat the contacting surfaces of the contacts on
the wire with a waterproof ink; the surfaces
Wire contact
should be new.
• Unwind the wire at tension 1 kg (for 10
seconds).
• Check that the wire trace is within limits. If the
mark is out of tolerance, check the contact- 6mm maxi.
holder mechanism and replace is necessary 3mm mini.
(3).
• Clean the contact and fit the assembly.
1549
List of wear parts
1 Retractable contact subassembly 104 315 161 1

2 Top/bottom contact block special screw 100 446 493 1
3 Top contact-holder block 100 444 750 1
4 Top SINTERED contact 100 432 997 1

ROBOFIL 310P/510P
2 tracks per surface
1549
2619
Plexiglas cover
(1)
917
(4) (2) (3)

ROBOFIL 290P
Hex socket head screw M4 x 8 s/steel

ISO 4762
2618
Plexiglas cover

Checking/replacement of the top machining contact
ROBOFIL 190
Frequency As soon as the wear on the tungsten contact is equal to the wire radius.
Procedure/ Replacement of the top contact:

Adjustment • Remove the Plexiglass cover of the top head without removing the block (1).
• Remove the contact support (3) (hex. socket head screw (2) - (5 mm hexagon key).
8 tracks per contact are available (2 per face, by turning over).
• Rotate the contact (4) (hex. socket head screw (5)) by 90° to use 4 faces and 4 tracks, then rotate
it again (180°) to use the second track of each face.
• Clean and refit the contact support.
! When refitting the contact and after having turned it over or replaced it, there are no
adjustments required.
Criteria for deflection of wire by the contacts:

To ensure correct contact, the wire must bear over a sufficient length (3 mm minimum). However, to
prevent breakage due to excessive rubbing, the wire must not come into contact with the edges of the
contact.
Check:
• Coat the contacting surfaces of the contacts on
Wire contact
the wire with a waterproof ink; the surfaces
should be new.
• Unwind the wire at tension 1 kg (for 10
seconds).
• Check that the wire trace is within limits. If the
6mm maxi.
mark is out of tolerance, check the contact- 3mm mini.
holder mechanism and replace is necessary
(3).
• Clean the contact and fit the assembly.
1549
List of wear parts
N° Designation Charmilles N° Qty. per machine Supplier
1 Contact sub-assembly 104 315 160 1

4670
Plexiglass cover
(1)
(3)
4672
(2)
(4)
Hexagon socket head screw

M4 x 8 stainless steel

Top and bottom wire guide cleanliness check
Frequency Every 1,000 hours machining
Procedure/ • Using special tool, loosen nut (1) and (1').

Adjustment • Remove the nozzle assembly; then, using the special tool, unscrew nuts (6) and (6') containing the
wire guides.
• Check the wire guide straightness using a shape projector.
• Clean all the parts.
To clean the wire guides, use:
- Products such as alcohol or trichloroethylene. (Never leave the guides to soak in products for more
than 30 seconds).
- Ultrasonic lower power baths without leaving the guides in direct contact with the bath: maximum
time 10 seconds.
- In the event of difficulties, it is possible to polish the inside of the guide with slightly abrasive fabric.
! Never use solvents for glue.
• Reassemble the complete guide, paying attention to the top and bottom directions for (6) and (6'),
(7) and (7').
Ø6 - 0.015
Clean flat surfaces 4±0.1
ØD = Ød
+ 0.002
+ 0.004
4±0.1
OK
Ø6 - 0.015 1193 a
Note: - The threading nozzle is fragile and must never be forced.

For 310P/510P - After each disassembly, a wire alignment and nozzle adjustment cycle shall be
machines only performed.
! The top and bottom wire guides have different outside diameters. Make sure that the
guide is correctly positioned in the nut before tightening the nut slightly with a special
tool.
List of wear parts
1 Nut top 100 447 011 1

1' plastic bottom 100 443 733 1
3 Nozzle assembly 104 323 510 2
4 Special tool 104 472 700 1
5 Top/bottom spring 100 447 060 2
5'
top 290P 100 432 545 1
6 Nut top 310P/510P 100 444 744 1
6' bottom 100 444 760 1
7 Wire guide top dia. 0.25 100 432 511 1
7' (complete) bottom dia. 0.25 100 430 586 1
8 Threading nozzle D1.8 (310P/510P) 100 431 787 1
9 O-ring seal PRP013 830 70 54 109 410 027 2
10 Injection top 310P/510P 104 329 700 1
chamber bottom 310P/510P 104 329 690 1
top+ bottom 290P 104 329 690 1

(7)
(8)
(9)
(6)
(2)
; ; ;
;;; ;
;;;; ;
(3) Nozzle assembly
;
;
;;;
;
;;;
; ;
;;; ;
;;;;;;
; ;
;
;;; ;
;;;;;;
; ;
(1)
;;;;
; ; ; ;;;
; ;
(10)
(5)
;;; ;;;
(1')
1545
(6')
(9')
1091
(7')
(4)
1087
Special tool
CT N° 104 472 700

Injection nozzle check
When there is an important difference between the pressure reading in the INFO «SURVEY» mode
Frequency and that recommended by the technology.
Procedure/ • Using the special tool, loosen nut (1) and (1').
Adjustment • Remove the nozzle assembly.
• Clean the various parts and check the nozzles (scratches, dents, etc.).
• If necessary, replace and clean the injection chamber before fitting the assembly, then manually
check that the small nozzle (2) is not jammed (prescribed clearance 0.01/0.05).
After each removal, adjust the nozzle.
List of wear parts
1 Nut top 100 447 011 1

1' plastic bottom 100 443 733 1
3 Nozzle assembly 104 323 510 2
4 Special tool 104 472 700 1
5 Top/bottom spring 100 447 060 2
5'
top 290P 100 432 545 1
6 Nut top 310P/510P 100 444 744 1
6' bottom 100 444 760 1
7 Wire guide top dia. 0.25 100 432 511 1
7' (complete) bottom dia. 0.25 100 430 586 1
8 Threading nozzle D1.8 (310P/510P) 100 431 787 1
9 O-ring seal PRP013 830 70 54 109 410 027 2
10 Injection top 310P/510P 104 329 700 1
chamber bottom 310P/510P 104 329 690 1
top+ bottom 290P 104 329 690 1

(7)
(8)
(9)
(6)
(2)
; ; ;
;;; ;
;;;; ;
(3) Nozzle assembly
;
;
;;;
;
;;;
; ;
;;; ;
;;;;;;
; ;
;
;;; ;
;;;;;;
; ;
(1)
;;;;
; ; ; ;;;
; ;
(10)
(5)
;;; ;;;
(1')
1545
(6')
(9')
1091
(7')
(4)
1087
Special tool
CT N° 104 472 700

Rewiring drawer maintenance
ROBOFIL 310P/510P
Frequency If problems with contact braid or annealing during rethreading.
Procedure/ • Remove the top head rethreading drawer according to the drawer removal procedure.
Adjustment
Replace the contact braid (1):
• Place the rethreading drawer on a table. Turn it over so that the wire ejection sleeve is blocked by
the table.
!
Do not loosen Imbus screw (2) if the port is not blocked, since sleeve (3) is ejected with
a certain degree of force by the spring.
• Remove the contact braid (1).

• Compress sleeve (3) using a screwdriver while fitting a new contact braid (1) and tightening the
Imbus screw (2). Make sure to insert part (6) in the groove of piston (3).
Replacing contact D.3:

• Using the 1.5 mm Imbus wrench, unscrew screw (4).
• Fit a new contact.
• Fit and tighten the screw.
;;;;
;;;;
;;;;
;;;;
;;;;
;; ;;; ;;
;;
(4) + (5)
;;
;;;
;;
;;;
;;;
(6)
(7)
(3)
;;;
(2)
;;;;
;;
;
;;;;
(1)
;;
List of wear parts

1 Brake s/assy 204 476 280 1

2 Grubscrew 209 045 451 1
3 Sleeve 200 447 445 1
4 Modified M2x8 screw 200 447 643 1
5 Contact D.3 200 447 638 1

Date Description
Report No.:
Name :
Meter hours : Name :
Report No.:
Name :
Report No.:
Name :

Log book
This book is an indispensable part of your machine tool Report No.:
Name :

It is to be the link between the machine operators and the record of all maintenance,
incidents, failures and necessary repairs occuring on the equipement.
It is therfore important to be very precise in filling in the entries in this book in order
to make it a helpful data source for Charmilles Technologies representatives who
may need to check the machine.
Please refer to the attach model and duplicate the free pages to constituate your
log book. Report No.:
Before calling Charmilles Technologies Service in case of a failure, please be ready Name :
to answer all the questions on the attached chek list. Log book
Thank you very much for your co-operation.

Check list for emergency calls
Call your agent ......................................... Tel. ..............................
1. Customer's name :
Person to be contacted :
Telephone number :
Machine type :
Serial number :
Software version :
<Page INFO> <SERVICE>
2. Description of fault. If message on screen, note the error number, togeether

with the error number in the STATUS page.
3. Refering to the user's manuel, follow the maintenance and repair instructions
as a function of the fault.
4. Run the self-diagnosis and note the error number.

Note: Save yours programmes first.
5. Is it possible to reproduce the fault?

Yes : See question 6
No : See question 7
6. Detailed description of manner in which fault occured.

Description of programme technology and manipulation
7. How often does the problem occur? When?

During machining, centering, programming, movement etc.
8. Card (PCB) test. Switch off the cabinet, disconnect the cards and connect the
cards again with an antistatic protection bracelet. Switch on the cabinet, read
the software. Check whether the problem has disappeared.
Log book

Date Description
16/9/96 07.00 Machine switched on
16/9/96 09.30 Exchange of wire belts
Report No.:
Name :
Meter hours : 2137 Name : J. Smith
16/9/96 16.30 "E636" scale V" fault (during machining)
Performed check-list, no improvement
17.00 Called Charmilles service
E
Report No.:
Meter hours : 2145 Name :
P
J. Smith L Name :
M
17/9/96 07.45 Arrival of Charmilles service engineer. Exchange V scale
A
and preamplifier
Meter hours :
E X Name :
Report No.:
Name :
Conner
4281
17/9/96 10.45 Startup machining (Punch 6876)
Report No.:
Name :
17/1/91 18.00 Next shift
Please check wire tension
Report No.:
Name :
CHARMILLES TECHNOLOGIES 5 950 980/E/21.07.1997 P. 3

1.2.3
Date Description
Report No.:
Name :
Report No.:
Name :
Report No.:
Name :
Report No.:
Name :
Report No.:
Name :
CHARMILLES TECHNOLOGIES 5 950 980/E/21.07.1997 P. ...

1.2.5
Date Description
Report No.:
Name :
Report No.:
Name :
Report No.:
Name :
Report No.:
Name :
Report No.:
Name :
CHARMILLES TECHNOLOGIES 5 950 980/E/21.07.1997 P. ...

1.2.7
List of error messages
ROBOFIL
190/290P
310P/510P
List of error messages
Introduction 2.3
Error message numbering 2.3
Table
Errorof
Error message alphabetic identification 2.3
Comments 2.3 Messages
contents

Error
Messages

Introduction
Error message numbering
Error messages are classified under two distinct types:

- Error messages generated by the PC module; RUN TIME ERRORS.
- Error messages from the three processors: COM, EXE and PIL.
- COMMUNICATION processor error messages.
These messages are numbered 001 to 599.
These messages manage communication errors between the user an the
machine. Generally, these are syntax, programming and file management
errors.
- EXECUTION processor error messages.

These messages are numbered 600 to 799.
These messages manage displacement and movement (execution) machine
errors. Generally, these are axis errors, the various protective covers open
and measurement cycle errors.
- GENERATOR processor error messages.

These messages are numbered from 800 to 999.
These messages manage generator adjustment errors. Generally, these errors
concern mode parameters and power cabinet temperature.
Error message alphabetic identification
These messages are divided into three categories:

- Messages prefixed by A.
These messages are a simple warning in the event of a fault; program execution is
not interrupted.
- Messages prefixed by E.
Depending on the value of parameter COE (see Command Programming» chapter
5.1), execution of the program is suspended (COE = 0). Or program execution is
not interrupted in the event of a fault (COE = 1), but the message is simply
displayed.
- Messages prefixed by F.
Program execution is interrupted in the event of a fault and cannot be continued,
whatever the value of parameter COE.
Comments
- Error messages are sometimes followed by the 8 first characters of the ISO block
containing the error.
- For action to be taken following EXECUTION error messages occur, refer to the
«Corrective maintenance - Troubleshooting» chapter of the maintenance manual.
- If an error persists after having performed the operations demanded, or if an error Error
appears regularly, contact a CHARMILLES TECHNOLOGIES agent. Messages

Run Time Errors
The messages are displayed on the screen and on the 7 segment display (see
location of components of the electrical cabinet).
If a problem arises proceed as follows:

•Note the error numbers
•Run the On-board Diagnostic
•Consult the list below.
To reload the software, refer to the software loading procedure
A– Operation OK: the 7 segment display is blank but the two

decimal points flash.
B– Run Time errors
- 8000 – 9FFF Contact CT

- 8.8.8.8. Check the default configuration of the jumpers (see location of
components of the electrical cabinet).
notation: x=0 to 9 or A to F
- CFxx: Fault on console: run the utilities of the service diskette
- Cdxx + CCxx Check the default configuration of the jumpers (see location of
components of the electrical cabinet)
- Cb00 to Cb03 Change the console assembly, contact CT
- Cb04 to Cb05 Reload the software and run the On-board Diagnostic
- Cb06 to Cb08 Reload the software and run the On-board Diagnostic
- C367 to C372 Reload the software and run the On-board Diagnostic
- C57F Problem of power supply to numerical control, contact CT
- CA82 Run the On-board Diagnostic
- CA00 General failure of numerical control, contact CT
- b1xx Reload the software and run the On-board Diagnostic
- Dxxx Reload the software and run the On-board Diagnostic
- bbxx Reload the software and run the On-board Diagnostic
- bExx Reload the software and run the On-board Diagnostic
- bFxx: Reload the software and run the On-board Diagnostic
- bOxx Reload the software and run the On-board Diagnostic
Error
Messages

E001: Invalid command
The NC does not recognize this command.
Amend the syntax or consult the list of commands.
E002: Comma expected
In commands, the symbol «,» separates the parameter indicator (e.g. X,Y,L etc.) from
the parameter and separates parameters from each other.
Amend the syntax of the command.
E003: Illegal character
The NC does not recognize this character.
Amend the character.
E004: Illegal integer
The NC expects a value of a letter group.
Amend the value.
E005: Illegal number
The number concerning a parameter must be included within a certain range of use.
Amend the value.
E006: Parameter non editable
Attempt to change (RLD) an uneditable parameter in the TEC file installed
Correct the request.

Use another TEC file or directly modify the setting.
E007: Syntax error
The syntax of the language used defines the whole of the rules to be followed to
carry out a command program.
Amend the syntax
E008: Number too big
The number concerning a parameter must be included within a certain range of use.
Amend the value.

Error
Messages

E009: Illegal command
This command cannot be executed
E010: Illegal number
A number given in the command is illegal (the number of the setting, the point... does
not exist in the table.
Amend the number.
E011: Internal error
Communication module error
Re-initialize the machine or reload the software if necessary.
E012: Missing parameter
A parameter or a name is mandatory in this command.
Specify the command.
E013: Too many LOOP commands
Too many loops are used in the same file (max. 5 levels).
E014: Nested subprograms not allowed
A part program can only call up 1 level of sub-program

(CCF command illegal in a sub-program).
Modify the command file
E018: Access only with key
Operator key active. Access for adjustment of the generator is only possible with the
key.
E030: HPA too small, H used =>
In a REX command, the workpiece height requested is lower than the limit accepted
by the technology selected.
Choose a value within the legal limits
E031: HPA too large, H used =>
In a REX command, the workpiece height requested is lower than the limit accepted
by the technology selected.
Error
Messages Choose a value within the legal limits.

A050: Lubrication of axes requested
Carry out lubrication of axes according to the periodic maintenance procedure,

chapter 1.
F051: Lubrication of axes mandatory
Carry out lubrication of axes according to the periodic maintenance procedure,

chapter 1.
E070: Execution inactive
Error between the COMMUNICATION and EXECUTION modules.

Re-initialize the machine and restart the operation.
E071: Generator inactive
Error between the COMMUNICATION and PILOT modules.

Re-initialize the machine and restart the operation.
E072: Internal error ring buffer
Problem of dialogue between EXE and COM.

The «Programs under way» et «Monitor» pages are no longer updated.
Continue execution of the part-program. If this is not possible, reload the
COMMUNICATION software.
E073: Measurement out of tolerance
The difference between one of the touch sensing operations and the mean value of
these touches is more than MTOL.
Clean the electrode or modify MTOL.
A075: Power restored
The numerical control detects restoration of power; this indication is used for the auto-
restart sequence.
A076: Attention automatic re-start
After a restoration of power, la NC starts up the operation again in accordance with

the parameter ART (automatic restarting) after 30s.
Problem of writing in EEPROM. (The EEPROM contains the configuration parameters)

Reload the software and check the configuration parameters.
Error
Messages

A078: Temporary option
A temporary option has ended.
A079: Error with 8087
Coprocessor missing or defective.
E080: Rethread active
E081: No automatic restart
The machine is in a state that does not allow automatic restart.

After power is restored the NC must be started up again by the operator.
E082: Software and machine incompatible
Incompatibility between the loaded software and the configuration detected (e.g.:
Die sinking software on wire machine).
E083: Clock error
A085: Texts do not match
The LNG file which has just been inserted does not have the same number of texts as
the previous one. Texts may be missing or erroneous texts may appear.
A100: Zero segment
The distance between the start and finish is lower than the tolerance.
Check that the presence of this segment is of no consequence.
E101: Incoherent radius
Starting radius - final radius > TOL

Correct the part-program.
E102: Illegal G39 or G38
G39 is not preceded by a segment G01, G02 or G03.

Amend and start again.
E103: Reversed line
A segment of the programmed path is reversed after offsetting.

E104: Arc suppressed

Error
Messages The programmed radius is smaller than the value of the path offset.

E105: Segments do not intersect
The offset path is no longer continuous.
E106: Illegal taper change
The change of taper angle is incorrect or impossible
Amend the value of the angle
E107: G38 without geom. segment
G38 is not followed by G00, G01, G02.
Abandon the program under way.

Check the last errors announced, amend and start again.
If the problem persists, reload the program.
E160: Incorrect value
Change the value.
E161: Not enough memory
The succession of settings is too great for the memory capacity
Simplify the program or create two programs.
E162: Setting does not exist
The setting chosen does not exist in the selected table of settings.
Check the setting or the choice of table.
E163: Missing file EXPERT.CTX
The EXPERT.CTX file was not loaded or has not been read
Reload the diskette.
E164: Missing technology
The desired technology file is not available.
Activate the stored technology (mode EXE, <Activate tables> or check the choice of
Error
table. Messages

E165: Missing text file
The XXXXXX.TXT text file was not loaded or has not been read
Load the text file.
E166: Old version of techno.
The desired technology file is not available
Load the corresponding technologies into the machine software.
E167: No sequence in memory
No sequence has been created. Re-reading of a sequence is not possible.
Abandon the request.
E168: No standard technology
Manual construction is impossible.
Load the new technologies.
E169: No user technology
The user technologies (U...TEC) are not stored in memory.
Load the user technologies.
E171: CT standard sequence cannot be erased
The standard sequences supplied by CT can be recognized by the CT logo.

These files are protected and cannot be deleted.
A200: Incomp. numeric format
Correct the syntax
A201: Unrecognized function
Non-existent G or M code.
Correct the syntax.
E202: G30.without tangency
After taper in G30 mode, the straight line is not at a tangent to the circle.
Error
Messages Correct the path.

E203: Repeated function
The same code appears in the line twice.
Correct the line.
A204: Incompatible functions
Correct the ISO syntax and start again.
E205: Invalid word E or D
The number allocated to the setting or the offset is not listed.
Amend the offset number or setting number and start again.
E206: incomp. word, modal funct.
Dimension without associated modal function.
Correct the ISO syntax.
E207: Illegal character
Non-accepted character in the ISO program-part.
Modify the character.
E208: % missing
An ISO program must begin with %.
E209: End of file without M02
An ISO program must end with M02
F210: Negative Z not allowed
Z must always be strictly positive
Correct the value.
E211: Z nul
Z must always be strictly positive

Error
Correct the value Messages

E212: Value overflow
The dimensions must be less than 10 m
Correct and amend.
E213: Z, W or R with tilted wire
A change in these values is only allowed if the wire is straight.
Correct the path
E214: Illegal Aux func.
The option «user» M functions is not implanted or the key diskette has not been read
E215: File TEC without strategy
E216: Strat., data incompatible
F301: Internal memory full
Simplify the part-program.
F302: Internal error
Load the communication software and restart the operation.
F303: Execution inactive
EXE processor not synchronized.
Switch off and switch on the machine.
F305: Internal error
E306: impossible rethreading
The program does not contain G92, M6 or M16
Rethread manually and continue the program.
Error
Messages

F306: Impossible rethreading
The program does not contain G92, M6 or M16

Restart the program.
E307: Position outside path.
The present position is not on the path

Restore manually and continue the program.
A401: CRTC Internal error
Problem of communication between the CRTC board and the COM processor
(CCU).
Continue the operation and if necessary re-initialize the machine. After the error
message, the CRTC board is automatically and completely re-initialized.
A402: CRTC: Internal transfer error
(CCU).
A403: CRTC: mathematical error
(CCU). Could possibly be due to incorrect initialization of the references.
If necessary re-initialize the references.
A404: CRTC Internal error
Hardware problem on the CRTC board.
A405: CRTC: Invalid interrupt
Hardware problem on the CRTC board or problem at the bottom of the bin.
A410: Auto-Scale: Memory full
During drawing of a part-programme or a command in AUTO mode, the number of

segments is too high to be memorized.
Continue the operation. Error

To obtain a complete drawing, choose the PARAM mode and redraw the program. Messages

A411: CRTC: Incompatible version
CRTC wire version on die sinking machine or vice versa.
A412: Printer fault
Printer not connected or switched off.
Check the printer.
A413: Printer error
A414: Printer: paperm out
E501: No channel available
The number of files allocated to the internal work of the numerical control exceeds
the machine’s capacity.
Restart the operation.

Re-initialize the machine.
E502: Illegal device
The requested unit is unknown to the NC.
Start again by giving an existing unit name (MEM:, A:, B:, and DNC: depending on
the case).
E503: Illegal filename
A file name can contain a maximum of 6 alphanumerical characters and 3

characters for the extension (ISO, etc).
The file name must be of the type «MEM:XXXXXX.XXX»
E504: Invalid file
The specific file (...TEC,...OFS, etc.) is not suitable in this case.
Try with a different file.
E505: Non-existent file
The file does not exist in the directory requested.
Start again by giving a file name.
E506: File not open
Error The requested file is not open.

Messages

E507: Directory not initialised
The new diskettes must be initialised in the MS-DOS format in order to be used on the
machines.
Initialise the diskette (mode PREP <File>, <Initialise>).
E508: File protected
The file concerned can be neither deleted nor modified.
E509: File already exists
A file under the same name already exists
Restart giving a different file name.
E511: Not enough room
The volume used does not have enough room to accept an additional file.
Use another volume or delete one or more files.
E512: Directory full
The volume is limited in number of programs and capacity

(MEM= 114 files, A or B = 112 files).
Use another volume or delete one or more files from the directory.
Problems in the file management software.
Try to continue, otherwise, reload the COM software.
E514: Serial device error
The requested peripheral indicates an error.

Check the peripheral (DNC option).
E515: Invalid channel number
The «channel» parameter represents the communication channel used.
Check the value (mode EXE, <Service>, <Communic.>).

Error
Messages

E516: Invalid protocol code
The protocol number specifies the mode of communication selected.
Check the value (mode EXE, <Service>, <Communic.>).
A517: Operation aborted
End of file transfer by MENU command.

(interruption of transfer by the MENU).
E519: Invalid operation
The instruction given is not valid for the peripheral concerned (use of DNC).
E520: Parity error
Unsatisfactory reading by the reader or DNC peripherals.
Restart and check the protocol (mode EXE, <Service>, <Communic.>)
E521: Time-out
The NC and the peripheral are communicating; The reply time from one machine to
another has elapsed before the transfer of information starts or restarts.
Check the link between the NC and the peripheral.
E522: Buffer overflow
The NC and the peripheral are communicating; the numerical control processes the
characters coming from the central computer in blocks of 512.
It may be necessary to ask the latter to suspend transmission until the numerical control
is once again ready.
Repeat the operation.
E523: Floppy disk switched
The diskette must not be taken out during a transfer.
E524: Illegal block number
The diskette must not be taken out during a transfer.

Error
Messages

E525: Incompatible format
The table file is unsuitable for this version of the software.
Check compatibilities (XXX.TEC, etc..).
E560: Protocol error
During a transfer between the NC and a diskette, the transmission is not possible
according to the protocol.
Check the state of the diskette.

Restart the operation. If the defect persists, change the diskette.
E561: End of tape
Problem with the diskette used.
Check the state of the diskette.

Restart the operation. If the defect persists, change the diskette.
E562: No floppy disk
No diskette or problem with the diskette used.
Check the state of the diskette and restart the operation.

If the defect continues, change the diskette.
E563: Write protected
Remove write protection on the diskette.
E564: Data error
Check the state of the diskette and restart the operation. If the defect continues,
change the diskette.
E565: Motor stopped
Problem with the disk drive.
Check diskette drive operation.

(See the procedure)
E601: Limit X
End of positive mechanical X travel has been reached
Move the table in the - X direction. Error

Messages

E602: Limit X
End of negative mechanical X travel has been reached
Move the table in the + X direction.
E603: Overflow X-counter
A violent impact has occurred along the axis.

The loss of references is fatal to the program.
Look for the mechanical causes of the impact and re-take the references. If the
message persists, re-initialize the machine.
E604: Motor X
Problem with the X axis motor
Check that nothing is hindering X axis movement

Check the fuse on the X APM board.
Check whether the red LED of the X APM board is lit up.
E605: Overflow X-deviation
An impact on the axis, moving or stationary, has occurred.

This message is typically due to a collision on the axis in question.
Check that no condition external to the machine is restraining or blocking the axis.
Re-take the references if they are lost.
Check the fuse on the X APM board.
E606: Scale X
The signal of the X scale is too weak
Re-initialize and then contact CT.
E607: Limit Y
End of positive mechanical Y travel has been reached
Move the table in the - Y direction.
E608: Limit Y
End of negative mechanical Y travel has been reached
Move the table in the + Y direction.

Error
Messages

E609: Overflow Y-counter

E610: Motor Y
Problem with the Y axis motor
Check that nothing is hindering Y axis movement

Check the fuse on the Y APM board.
Check whether the red LED of the Y APM board is lit up.
E611: Overflow Y-deviation

Check the fuse on the Y APM board.
E612: Scale Y
The signal of the Y scale is too weak
E613: Limit Z
End of positive mechanical Z travel has been reached
Move the table in the - Z direction.
E614: Limit Z
End of negative mechanical Z travel has been reached
Move the table in the + Z direction.
E615: Overflow Z-counter
A violent impact has occurred along the axis. The loss of references is fatal to the
program.
Look for the mechanical causes of the impact and re-take the references. Error
If the message persists, re-initialize the machine. Messages

E616: Motor Z
Problem with the Z axis motor
Check that nothing is hindering Z axis movement

Check the fuse on the Z APM board.
Check whether the red LED of the Z APM board is lit up.
E617: Overflow Z-deviation

Check the fuse on the Z APM board.
E618: Scale Z
The signal of the Z scale is too weak
E625: Limit U
End of positive mechanical U travel has been reached
Move the table in the - U direction.
E626: Limit U
End of negative mechanical U travel has been reached
Move the table in the + U direction.
E627: Overflow U-counter

E628: Motor U
Problem with the U axis motor
Check that nothing is hindering U axis movement

Check the fuse on the U APM board.
Check whether the red LED of the U APM board is lit up.
Error
Messages

E629: Overflow U-deviation

Check the fuse on the U APM board.
E630: Scale U
The signal of the U scale is too weak
E631: Limit V
End of positive mechanical V travel has been reached
Move the table in the - V direction.
E632: Limit V
End of negative mechanical V travel has been reached
Move the table in the + V direction.
E633: Overflow V-counter

Look for the mechanical causes of the impact and re-take the references.
If the message persists, re-initialize the machine.
E634: Motor V
Problem with the V axis motor
Check that nothing is hindering V axis movement

Check the fuse on the V APM board.
Check whether the red LED of the V APM board is lit up.
E635: Overflow V-deviation

Check that no condition external to the machine is restraining or ocking the axis. Error
Re-take the references if they are lost. Messages
Check the fuse on the V APM board.

E636: Scale V
The signal of the V scale is too weak
E637: Dielec. level 1
(ROBOFIL 1020) The dielectric level in the work tank is insufficient at the start of
machining.
Top up the level and then check the float S1 according to the procedure
(maintenance manual 1)
E639: Tank temperature fault
Temperature in the work tank exceeds the programmed limits.
Correct the limits or check the cooling circuit for the water of the reservoir.
E640: Diel. temp. 2
Check operation of the cooling circuit. If necessary, restart the pumps with the
command AUX,51.
E641: Low dielectric level
Restart the pumps with the command AUX,51.
E642: Supply pressure
Main compressed air supply below 5 bars
Set at 6 bars the valve located on the filter/regulator of the pneumatic deck
If the problem persists, see maintenance manual 1.
E644: Internal error number
(ROBOFIL 1020) Robot option: access to micro sequencer impossible.
Initialize the machine and if problem persists, contact CT.
E645: Lubric. tank level
(ROBOFIL 1020) Check the oil level in the tank of the lubrication unit.
Error
Messages

E646: Lubric. pressure
(Robofil 1020) Insufficient pressure for lubrication.
Check that no hose of the circuit is disconnected, see maintenance manual 1

.
E648: Wire broken
The wire presence coder is not turning or is no longer turning at the correct speed.
The software considers the wire is broken.
Put the wire back in position. If the fault persists, check the wire advance circuit.
(maintenance manual 1)
E649: Rethreading failure
The number of rethreadings allowed in this part-program has been exceeded.

If ATH=2, the machine automatically goes on to the next part-program; otherwise the
machine stops.
Recommence a new threading cycle.

If the fault is repeated, refer to the maintenance manual 1.
Software problem

If the problem persists, re-load the «communication» software and then contact CT.
Software problem

Software problem

Error
Messages

Software problem

Interruptions on the CCU EXE board
Re-initialize the machine. If the problem persists, run the autodiagnostic.
Defective memory.
Re-initialize the machine. If the problem persists, use the autodiagnostic.
Defective memory.
The software detects a fault.
E658: Machine error
The CCU PIL board fails to answer.
Check that the CCU PIL and the buses are properly plugged in.
If the problem persists, run the autodiagnostic.
The machine attempts to execute two operations at the same time too quickly.
Try to start the operation again, otherwise re-initialize the machine.
Error
Messages

E660: Wire brake fault
Defective functioning of brake
Check the APM F fuse and then the stability of wire advance
See the maintenance manual 1.
E661: Collision
The wire is in short circuit

Separate the wire from the workpiece.
Detection is done by active electrical touch.


If the problem persists, contact CT
E664: Machine error
Problem of wire slackness concerning an axis (not determined by the software)

Check that nothing is blocking the moving axes.
Re-initialize the machine and resume the operation.
If the problem persists in simulation, lower the simulation speed.

If the problem persists, contact CT
E666: Electrical sensor error
The machine attempts to withdraw after making an electrical touch but the contact
continues.
Recommence the touch.

If the problem persists, check that the wire is not in short circuit.
Check workpiece cleanliness, wire quality, deionization, then see maintenance
manual 1.
Error
Messages

The software detects a fault on the board CCU EXE
Abort the operation and start again.

E669: Short-circuit on wire
Short circuit detected during machining

Separate the wire from the workpiece
Check that the generator setting parameters are in accordance with the technology
tables.
E672: No axis references
When a cycle is started, a reference on at least one axis is lacking.
Take the missing reference (EXE mode, <reference>)
(ROBOFIL 1020) Robot option: Problem with the micro sequencer board.
Start the operation again. If the problem persists, re-initialize the machine.
E680: Brake set up illegal
The brake has not been calibrated.
Measure the brake calibration values and memorize them according to the
procedure (maintenance manual 1).
If the fault persists, contact CT.
E681: Position outside path
The return to the starting point in suspension mode is incorrect.

Press <return contour>
Start the operation again. Re-initialize the machine.

E683: Wire evacuation fault
Wire slipping on the brake belt.

•Check or replace the brake belt.
Error •Check the annealing pulley.
Messages •Check the condition of the evacuation belts.

E684: Impossible operation
Fatal error
Abort execution of program and re-take references.
If the problem persists, re-initialize the machine.
E687: EXE coprocessor fault
The CCU-EXE card is faulty.

Contact CT.
E689: Machine error
The machine tries to change the mode of the pilot too quickly
Start the operation again. Re-initialize the machine.
A690: Internal error number
(ROBOFIL 1020) Concerns «Eject 1000».

The end of travel of the evacuation shield is activated.
Check that nothing is hindering the movement of the X, Y axes.

Withdraw in manual mode.
E692: Incompatible version
In the INFO mode <service>, note the software versions, run the autodiagnostic and
contact CT.
E693: Front cover open
(ROBOFIL (1020) Close the front cowling containing the wire spool or release switch
S18.
If the 16/25 kg reel option is installed, check the switch S25 for closing the door.
E694: Rear cover open
Close the cowling or replace the drum cover or release the switch of the drum cover.
E695: HF supply fault
Check the installation of the Micro-Cut - SUFI option.
Re-initialize the machine. If the problem continues, contact CT.

Error
Messages

E697: E2 power source defect
Check circuit breaker Q9.
E699: Internal transfer error
Problem of dialogue between the CCUs.
Re-read the «Communication» software.

If the problem persists, run the autodiagnostic and check the peripheral board.
E700: Remote control error
A key of the remote control is continuously pressed.

Go back into «Manual» without touching the remote control.
If the problem persists, check the fuse of the IFMAC board then see maintenance
manual 1.
E701: Position lost
Several successive automatic restarts have caused an exceeding of the value of

parameter 6 (power fail number) in EXE mode, <service> <execution parameters>
Re-initialize the machine and re-take the references.
E702: Scales correction not valid
Incoherence in the scales corrections
Re-initialize the machine and contact CT.
E703: Wire cutting failure
The wire presence sensor detects that the wire is still present after the action of the
cutter.
Start up a threading cycle.

If the problem persists, check the condition of the counter-cutter and the pneumatic
control. See maintenance manual 1.
E704: External equipment failure
(ROBOFIL 1020) «Advanced M functions» option

The machine is awaiting acknowledgement from an external device.
Check the connections of the machine equipment.

Check the configuration of the equipment.
Error
Messages

E705: Water too conductive
Bad deionization of water in work tank.
Adjust the deionization potentiometer. Check the condition of the deionization resins.
A706: Filters delivery too low
(ROBOFIL 1020) The filters are saturated.
The two filtration circuit manometers should indicate < 3.5 bars; if not, change the
filters. If the problem persists, see maintenance manual 1.
E707: Door open: safety key
For safety reasons, this command is not allowed with the door open.
To allow this command with the door open, start execution again while keeping one
of the safety keys pressed down (speed variation keys of the remote control) .
E708: Tank emptying time-out
(ROBOFIL 1020) Robot option: the software does not detect «empty tank»
acknowledgement.
Check that the tank has emptied correctly, then check the condition of the «empty
tank» detection float (declare the «empty tank detection» option).
E709: Tank cabine/door open
This command is not allowed with the cabine/door open.
Close the door.
E710: Piston not stay down
(ROBOFIL 1020) «Eject 1000» option: the machine has not detected the return of
the piston to the upper position.
Start the operation again. If the problem persists, check that the piston has gone up;
if not, check the compressed air supply and the switch S51.
E711: Slug not evacuated
(ROBOFIL 1020) «Eject 1000» option:

The machine has not detected the low position of the piston.
Check that the slug has in fact been evacuated.

Check the part-program, the compressed air supply and the switch S52. Error
Messages

A712: Cancel changer cycle
(ROBOFIL 1020) The machine indicates that the robot will be initialized to interrupt
the operation under way.
This message is displayed after a robot function is aborted.
E713: Simulation, forbiden measure
Measure in another mode
E714: Checksum EXE error
Problem of checksum on the CCU-EXE software

If the problem persists, reload the machine software then contact CT.
E715: Clean water level too low
The filters are saturated.
The two filtration circuit manometers should indicate < 3.5 bars; if not, change the
filters.
If the problem persists, seemaintenance manual 1.
A716: Insufficient dielectric quantity
Add dielectric.
A717: Wire reel fault
When switched on, the machine checks the presence of wire.
If the wire is not in position, the message is normal.

If the wire is in position, readjust the setting of the spool movement coder.
Check the fuse on the ALF APM board.
E718: Movement outside limits
The movement requested is outside the programmed software limits (EXE mode
<manual> <travel limits>
Change the limits, change the order of movements or remove the travel limit
(command word ALE, 0).
Error
Messages

E719: Rethreading non in position
The gripper for automatic rethreading is not correctly indexed.
Carry out an initialization cycle with the AUX, 79 command.

If the problem persists, refer to the maintenance manual 1.
E720: Rethread failure
The wire has not been taken up in the gripping pin of the rethreading device.
Pass the wire through the guide manually.

Start the operation again.
If the problem persists, see the maintenance manual 1.
A733: reference taking advised
This message is a warning.
It is advisable to re-take all references again as soon as possible, even if the asterisk
does not appear (EXE mode, <reference>) since otherwise the next restart may not
take place correctly.
E734: Spraying mode
The modal command for requesting aspersion AUX, 23 is activated.
This command can be cancelled with AUX, 22.
E735: Threading motor fault
The wire presence sensor indicates failure of the threading motor to turn during a
threading sequence.
Check that the wire is not jammed and then resume the operation.
If the problem persists, check the wire circuit.
Check the fuse on the IF wire panel.
E742: Unknown strategy
The dialogue between the CCU COM and CCU EXE boards is not correct
Stop machining. Re-read the technologies.

Re-read the Charmilles software.
Error
Messages

E746: Threading motor fault
The «wire presence» sensor or the switch-index of the threading motor indicate failure
of the latter to turn during a rethreading sequence.
Check that the wire is not jammed and then resume the operation.
If the problem persists, check the wire circuit maintenance manual 1.
E747: Wire broken during wire cut
The «wire presence» sensor does not see the wire advancing before cutting it: the
wire is broken during preparation.
Switch on the wire advance and check whether the wire is in fact broken.
If so, there is a wire preparation problem.
Check the wire table, otherwise re-initialize the machine.
Check the coder and the threading motor and if the problem persists, see
maintenance manual 1.
E748: Wire evacuation default
The wire is in short circuit at the rear of the machine (between the lower wire guide
and the drum).
Replace the wire in the evacuation belts, press the RESET S35 button before
continuing the operation.
E749: Wire table not initialized
Bad reading of the wire table.
Reload a new table.

Edit the wire table (EXE mode <edit tables>, change nothing and exit the editor.
Recommence the operation. If the problem persists, reload the software and contact
CT.
E750: X movement fault
Movement fault The machine detects excessive wire slackness and blocks the axis.
In dry run mode,
decrease the value Check that no obstacle is hindering the X axis movement, move the axis in «manual»
of VSIM (see "User mode, carry out a return contour and resume the operation.
parameters). If the fault persists, re-initialize the machine and start the operation again.
Error
Messages

E751: Y movement fault
The machine detects excessive wire slackness and blocks the axis.
Check that no obstacle is hindering the Y axis movement, move the axis in «manual»
mode, carry out a «return contour» and resume the operation.
If the fault persists, re-initialize the machine and start the operation again.
E752: Z movement fault
Check that no obstacle is hindering the Z axis movement, move the axis in «manual»
E754: U movement fault
Check that no obstacle is hindering the U axis movement, move the axis in «manual»
E755: V movement fault
Check that no obstacle is hindering the V axis movement, move the axis in «manual»
A762: Manual palette change
(ROBOFIL 1020) «Robot» option: A pallet changing cycle is in progress
Remove the current pallet, replace it with the new one and resume the operation by
means of the command PCH,Px,M
E767: Changer: palette number
(ROBOFIL 1020) «Robot» option: The pallet number does not exist
Check the number of the first pallet memorized in EEPROM or correct the command.
Error
Messages

E770: Lock tank door : time out
(ROBOFIL 1020) «Robot» option: The time taken to lock the side door of the tank is
too long.
Check that nothing is hindering the operation of the locking system, that the
pneumatic circuit is correct and that the detection switch is functioning properly.
E771: Unlock tank door : time out
(ROBOFIL 1020) «Robot» option: The time taken to unlock the side door of the tank
is too long.
Check that nothing is hindering the operation of the unlocking system, that the
pneumatic circuit is correct and that the detection switch is functioning properly.
E772: Closing tank door : time out
(ROBOFIL 1020) «Robot» option: The time taken to close the side door of the tank is
too long.
Check that nothing is hindering the operation of the door, and that the pneumatic
circuit and the detection switch are functioning.
E773: Opening tank door : time-out
(ROBOFIL 1020) «Robot» option: The time taken to open the side door of the tank is
too long.
Check that nothing is hindering the operation of the door, and that the pneumatic
circuit and the detection switch are functioning.
E774: Filling without pallet
(ROBOFIL 1020) «Robot» option: It is not possible to fill the tank if no pallet is
installed.
Put a pallet in position and carry out the command PCH,Px,M
Fault on the axis board.

If the problem persists, run the autodiagnostic and contact CT.
Error
Messages






A801: Undefined action
If the problem persists, re-initialize the machine. Search the Pilote software for
threading machine in 186.
A803: Abnormal state
Timing problem.
Operate the auto-diagnostic and check the PA-SA board.
Error
Messages

A804: Machining impossible
Restart the operation. If the problem persists, reload the softwares and contact CT.
A805: Machining impossible
Restart the operation. If the problem persists, reload the softwares and contact CT.
A806: M illegal
The mode requested is not listed
Use a permitted machining mode.
A813: V too small
V no-load voltage 80, 100, 120, 140, 160 and 200 Volts
Amend the value 80 < V < 200.
A814: V too big
V no-load voltage 80, 100, 120, 140, 160, 200 Volts
Amend the value 80 < V < 200.
A815: Internal error
Problem of dialogue between processors.
Restart the operation. Re-initialize the machine.

If the problem persists, reload the softwares and contact CT.
A825: TMM too big
Technology paramater not accessible.
Re-read the technology, and if the problem continues reload the software.
A834: Aj too small
AJ mean reference voltage for servo-control in 1/2 volt.
Amend the value: 0 <Aj <2000 or re-read the technology.
Error
Messages

A835: Aj too big
AJ mean reference voltage for servo-control in 1/2 volt.
Amend the value: 0 <Aj <2000 or re-read the technology.
A837: GUM too big
Technology paramater non-accessible.
Re-read the technology, and if the problem continues reload the software.
A838: Power unit temp. fault
(ROBOFIL 1020) Temperature too high ( > 51.5 degrees) at power boards:
Warning.
Check:
- the temperature of the premises < 30 degrees
- the cleanliness of the air filter of the cabinet
A839: Motor ampli temp. fault
(ROBOFIL 1020) Temperature too high ( > 42.3 degrees) at the motor amplifiers:
Warning.
Check:
A843: Illegal polarity
Illegal inversion of polarity.
Amend the sign of the voltage.
A846: Incorrect techno. parameter

A849: Protection too large
Re-read the technology.

Error
Messages

A851: Annealing incorrect
Annealing problem during preparation of wire for threading.
Check:
- the wire table used
- the threading parameters
- the wire circuit, contacts, and speed
See maintenance manual 1.
A852: Unknown wire
EL: nature of the wire.
Re-read the technology. Amend the EL setting parameter

A854: F Limit
During a machining job, there is too high a frequency in strategy in the angles.
(security).
Amend the value of B.
Abandon the operation. Re-initialize the machine and start again.

If the problem persists, operate the autodiagnostic.
A859: Incorrect elec. touch parameter
Electrical touch = 1 or 2
Correct the «electrical touch» parameter (EXE mode <service>, <execution

parameters>.

Error
Messages

E862: TAC illegal
Short pulse time adjustable in steps of 0.1 micro-seconds.
Reload the setting or amend the value 2 (.2 µs) < TAC < 9 (.9 µs) in accordance
with M, VP, A. (Tac < A).
A865: DND incorrect
Technology parameter not accessible
Re-read the technology and resume the operation
A866: TL illegal
Technology parameter not accessible.
A869: TOD illegal
A870: RTE illegal
A871: DEC illegal
A872: A modified
A Pulse duration from 0.2 to 3 micro-second in steps of 0.1.

The value entered is incorrect, either too big, or too small.
The value taken into account is the minimum or maximum admissible value.
Check that the value taken into account is in fact the desired value.
Error
Messages

A873: TAC modified
TAC: Short pulse time adjustable from 0.2 to 0.9 micro seconds in steps of 0.1.
The value entered is incorrect, either too big or too small.
A874: B modified
B: Duration of pause between 2 pulses of 1.6 to 25 micro seconds.

B is a function of the maximum frequency of the setting and of A.
A875: IAL modified
IAL: current for starting the process, 1 to 16.5 Amperes.

A903: UPA regulator defect
Problem of regulation on UPA
Check that the UPRA board is properly inserted.

A904: UPR3 commutator defect
Problem of commutation on UPR3
Check that the board is properly inserted.

A905: Regulator error UPR3
Problem of regulation on UPR3
Check that the board is properly plugged in.

Error Re-initialize the machine. If the problem persists, run the autodiagnostic.
Messages

A906: Comm error UPR4
Problem of commutation on UPR4.

E907: Regulator error UPR4

E908: Mains voltage too high
Peak of +10% on the three-phase network

Check the mains voltage.
To resume operation, switch on the circuit breakers of the electrical cabinet.
E909: Mains voltage too low
Drop of -15% on the three-phase network.

Check the mains voltage.
Reset Q2 and Q4 again
E910: Comm. error UPA
Problem of commutation on UPA.

E911: Limit error UPA
Problem of limitation on UPA

E912: Comm error UPR1

Error
Messages


E914: Comm. error UPR2


E916: Power unit temp. fault
Temperature too high ( > 55 degrees) at power boards:

(level 13): fatal defect.
Check:
E917: Motor ampli temp. fault
Temperature too high ( > 45 degrees) at the motor amplifiers: fatal defect.
Check:
E918: EPROM error
Re-initialize the machine and then, in INFO mode, <service>, note the software
number and contact CT.
E919: Generator re-initialized
Problem of memorization of settings.
Carry out a REX or re-initialize the machine.

Error
Messages

to
Re-initialize the machine. Contact CT.
E927: PA/SA card fault
Check that the card is properly slotted in. If the problem co tinues, run the auto-
diagnostic.

to
E998: Check
Reload the «communication» software

Note the letter displayed after «Check» and also the operation in progress, and
contact CT.
Error
Messages

Error
Messages

3.1 Location of machine units
Location of units
3.2 Location of units of

ROBOFIL electrical cabinet
190/290P
310P/510P
See
Location of machine units
Introduction 3.1.3
ROBOFIL 290P/310P/510P :
ROBOFIL 190 :
Overall view of machine (rear view) 3.1.19 Table of

contents

See

See
Introduction
The purpose of this document is to make it easy to locate a unit of the machine. This
will be helpful when carrying out a troubleshooting procedure or when making
telephone contact with the after-sales service of Charmilles.
The column entitled "See" enables you to discover more about certain units by
referring you to a relevant note, page, chapter, etc.

Overall view of the machine (front view)
See
ROBOFIL 51
0P CHARMILLES
TECHNOLOG
IES
Wire feed equipment panel p 3.1.6
Top and bottom heads p 3.1.10
Electrical cabinet Ch. 3.2
1418b

Overall view of the machine (rear view)
See
p 3.1.12 Dielectric
equipment panel
1464a
p 3.1.11 Pumps
p 3.1.15 Mechanical
equipment area
p 3.1.8/9 Wire preparation

cabinet

Wire feed equipment panel
ROBOFIL 500
CHARMILLES
TECHNOLOGIES
See
ROBOFIL 310P with lateral wire cabinet

ROBOFIL 510P
Brake belt
Pulley connected to threading

motor (M10) and to brake
3883
Annealing pulley
ROBOFIL 290P
ROBOFIL 310P without lateral wire cabinet
Brake belt
Belt of wire
preparation panel
ROBOFIL 290P: Pulley
Pulley connected to the
connected to wire presence
reel drive motor (M12)
encoder (C9) and to brake.
ROBOFIL 310P:
Pulley connected to wire
Return pulley for rear presence encoder (C9), brake
16 kg reel cabinet (only and threading motor (M10)
on ROBOFIL 310P) Annealing pulley
ALF encoder adjustment screw Rocker pulley servo-

controlling the reel drive
motor (M12)
3543

Threading motor (M10) - Brake -
Clutch - Wire encoder (C9)
See
p. 3.1.6 Pulley of wire feed

equipment panel
3888
3685
Threading motor (M10)

No. CT 100 542 465
Clutch No. CT 100 434 139
Electromagnetic brake
No. CT 100 422 449
Wire presence encoder

(C9) No. CT 100 434 370

Wire preparation cabinet (lateral)
See
8 ROBOFIL 310P
Belt of wire prepartion

panel 7
5
4023
Rocker pulley
4 Cover and screw of ALF
3 encoder
Reel drive pulley
2
ROBOFIL 510P
1 Double groove pulley
4024
Cover and screw of ALF

1487 encoder
Rear view:
Reel drive motor (M12)
Notched belt of reel drive

motor (M12)
4025
ALF encoder

Wire preparation cabinet (rear)
See
2148
Torque limiter
Adjustin ring
3811

Top and bottom heads
ROBOFIL 500
CHARMILLES
TECHNOLOGIES
See
Air inlet:
contact retraction; Y4,
cutter advance; Y5*,
cutter retraction; Y6*
Water inlet: Suction jet water

high pressure injections, YV27*
minimum injections,
contact wetting, Distributer block
threading jet*
Cutter block*
Rethreading block*
Top injection chamber

3798
* Only on ROBOFIL 310P/510P and 290P machines

if automatic threading-rethreding option is fitted
Lower injection
chamber
Wire drive rollers
Contact bushing
Grooved roller for wire drive
Brush contact
Crimping pinion
1530

Pumps
See
ROBOFIL 510P
M12
Plate-type heat exchanger

M11
M13
S5
S28
S4
4027
ROBOFIL 290P/310P
4026
M11
M12
S28
M13
S4
S5
Pumps:
M11: Auxiliary pump
M12: High pressure injection pump
M13: Filtration pump
Probe:
S28: Deionization probe
Floats:
S4: Check of clean reservoir
S5: Check of polluted reservoir

Dielectric equipment panel
See
ROBOFIL 310P
ROBOFIL 290P
A
S 34
Yv18
Yv27
Yv13 Yv14
Yv16 Yv15
Yv20 Yv21
Yv21 Yv16 Yv20
Yv18 Yv15
Yv14
2145a
2114a
BP14 BP15
BP14 BP15
ROBOFIL 510P
Yv16 Yv21
Yv13 Yv20
Yv27 Yv15
Yv18 Yv14
S34
Y24
1496d
BP14 BP15

Dielectric equipment panel - Automatic filling unit
See
Miscellaneous:
A: Pneumatic equipment panel; see p 3.1.14
B: Plate-type heat exchanger
S34: cooling by heat exchanger; thermostat for adjusting the dielectric temperature, and dielectric
temperature defect switch.
cooling by refrigerator unit; dielectric temperature defect switch.
Valves:
Yv13: Opens the threading injection circuit (threading jet) (ROBOFIL 310P/510P)
Yv14: Opens the lower high pressure injection circuit
Yv15: Opens the upper high pressure injection circuit
Yv16: Opens the "lubrication" circuits; upper and lower contact wetting
and upper and lower minimum injections
Yv18: Opens the internal deionization circuit
Yv20: By-pass 1, high pressure injection
Yv21: By-pass 2, high pressure injection
Y24 : If heat exchanger; opens the cooling circuit
Yv27: Opens the wire suction circuit in threading (ROBOFIL 310P/510P)
Pressure probe:
p. 3.2.8 BP14: Pressure of the lower high pressure injection; to analog interface, connector +E10 -X393
p. 3.2.8 BP15: Pressure of the upper high pressure injection; to analog interface, connector +E10 -X395
;;;
;;;
;;;
;;;
;;;
;;;
4052
5376
Mains water opening/closing

(automatic filling)

Pneumatic equipment panel
See
Y14
Y20
Y21
Y16
Y27
Y15
Y13
Y18
Network pressure
adjusting button
Filter
4028
S23
Y4
Y5
Y6
S23: Probe of compressed air to IF MAC, connector X6

Y4: Contact retraction
Y5: Cutter advance*
Y6: Cutter retraction*
Y13: Command of valve YV13*
Y14: Command of valve YV14
Y27: Command of valve YV27*
* Only on ROBOFIL 310P/510P or 290P with threading/rethreading option

Motors and scales
See
ROBOFIL 290P/310P
Z motor
V motor
V scale
U scale U motor
X motor
X scale
Y scale
Wire drive Y motor

motor(M11)
4029
ROBOFIL 510P
Z motor
V motor
V scale
U scale U motor
X scale X motor
Y scale
Wire drive motor Y motor
(M11) 4030

See
Alphabetical index of units
ALF encoder 3.1.6/8

Automatic filling unit 3.1.13
Brake belt 3.1.6
Brake, magnetic 3.1.7
Clutch 3.1.7
Deionization probe (S28) 3.1.11
Electrovalve YV.. 3.1.12
Electrovalve Y... 3.1.14
Head, lower 3.1.10
Head, upper 3.1.10
Level float (S4, S5) 3.1.11
Motor, X, Y, U, V and Z axes 3.1.15
Pneumatic equipment panel 3.1.14
Pumps 3.1.11
Reel drive belt 3.1.6/8
Reel drive motor (M12) 3.1.6/8
Rocker arm 3.1.6/8
Scales 3.1.15
Threading motor (M10) 3.1.7
Traffag regulator (S34) 3.1.12
Wire drive motor (M11) 3.1.15
Alphabetical Wire feed panel 3.1.6
index Wire presence encoder (C9) 3.1.7

See

ROBOFIL 190
Overall view of machine (front view)
See
Wire feed equipment panel p. 3.1.20
Top head p. 3.1.22
Electrical cabinet Ch. 3.2
4683

ROBOFIL 190
Overall view of machine (rear view)
See
p. 3.1.24 Dielectric equipment

panel
S34 dielectric
temperature adjustment
thermostat
p. 3.1.23 Pumps
4684
p. 3.1.25 Mechanical
equipment area

ROBOFIL 190
Wire feed equipment panel
See
Swinging arm
Brake pulley
Acces to Z axis lubrification Ch. 1.1

4664
Unspooling panel
Wire reel axis
4688
Reducer
M40 motor
4689

Brake - Wire presence encoder (S41)
See
Wire presence encoder (S41)
Wire brake
4690

ROBOFIL 190
Top head
See
Top machining cable
Machining contact blok
Top injection chamber
Bottom machining cable

4670
High pressure and

minimum injections
Contact wetting
4671

ROBOFIL 190
Pumps - Float switch - Deionization probe
See
4684
Filtration pump M13
Injection pump M12
Deionization probe (S28)
S4 clean water tank float switch
Valve for the 8 filter option
S5 dirty water tank float
4693

ROBOFIL 190
Dielectric equipment panel
See
4684
Plate-type heat exchanger

(option)
Y18 deionization
Y16 contact wetting
4694
If heat exchanger:
Y24 opens the cooling circuit
4666
4684
Mains water opening/closing

(automatic filling)
4696

ROBOFIL 190
Motors
See
4684
Motor U
Motor X
4661
Motor Z
Motor V
Motor Y
Wire drive motor

4662

See
Automatic filling unit 3.1.24

Brake 3.1.21
Deionization probe (S28) 3.1.23
Dielectric equipment panel 3.1.24
Electrovalve Y... 3.1.24
Head, lower 3.1.10
Head, upper 3.1.22
Level float (S4, S5) 3.1.23
Motor, X, Y, U, V and Z axes 3.1.25
M40 motor 3.1.20
Pumps 3.1.23
Rocker arm 3.1.20
Traffag regulator (S34) 3.1.19
Wire drive motor 3.1.25
Alphabetical Wire feed panel 3.1.20
index Wire presence encoder (S41) 3.1.21

See
4001
Location of units of electrical cabinet
Overall view 3.2.3

Identification of components 3.2.3 Table of
Location
Alphabetical index 3.2.32 contents
of units

See
4001
Location
of units

Overall view
Identification of components
See
There are 4 blocks each preceded by a prefix
Block 1 Essential reference Prefix =

4001
Block 2 Position Prefix +
Block 3 Identification of equipment Prefix -
Block 4 Identification of terminals Prefix :
In the electrical cabinet, only block 2 and 3 are used.
Examples:
+ G19
Block 2
Position G, Level 19
- K1
Block 3
Identification of equipment K= relay
E F L
A
20
19
18
Sector 17
G
16
p. 3.2.24 A 15
14
p. 3.2.31 B 13
12
p. 3.2.17 C 11 C
10 C
p. 3.2.4 D
9 B
8
p. 3.2.5 E
7
6
p. 3.2.18 F
5
p. 3.2.22 G 4
3
2d
m
p. 3.2.23 H
J
p. 3.2.23 J 0
H
Level
D 4000
Location
of units

Sector D
Configuration jumpers (default configuration)
D
See
2889
4001
Lab SW2 Version SW1

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
O
5D
5D
I
GDH 08 ALCO UN GDH 08 ALCO UN
4002
2890
4230
HL1, S1, HL2, S2
+D17 -HL1
+D17 -S1
+D17 -HL2
+D16 -S2
+D16 -S6
2899
Location 3974
of units

Sector E
E
See
p. 3.2.13/16 40 V supply
4001
p. 3.2.16 5±12/+24 V supply
p. 3.2.15 APMT motor ampli. boards
2138c
PC Module
2161b
p. 3.2.9 Numerical control
5V ± 12V supply
2137b
p. 3.2.8 Accumulators
p. 3.2.8 IF analog
p. 3.2.8 DEIO
3200 5559
p. 3.2.7 Power units
2136a
4379b
Location
of units

Sector E
Safety equipment panel + circuit breakers panel
See
+E5 -F3
+E5 -K4
4001 +E5 -K5
+E5 -K6
+E5 -K7
+E5 -K3 +E5 -T6
4001
+E5 -T1
C1
V1
+E5 -X19
+E3 -F15
+E3 -F5 +E3-K10

+E3 -Q10
4379b
+E3 -Q2 +E3 -Q8

+E3 -Q3
+E3 -Q4
+E3 -Q5
+E3 -Q7
Relays: +E5 -K3 Time-lag relay, mains network return

+E5 -K4 Manual switching off
+E5 -K5 Power off
+E5 -K6 CAP (high power supply control)
+E5 -K7 CAX (110V auxiliary supply control)
+E3 -K10 Stopping of machining
Circuit breakers:+E3 -Q3 20A, general protection of 110V after -T3
+E3 -Q4 6A, protection of power boards aux. 110V
+E3 -Q5 4A, protection of fans
+E3 -Q7 4A, protection of NC 5/±12V and -A10 (-24V)
+E3 -Q8 Protection of transformer -T2
+E3 -Q10 10A, protection of PC module, screen, optical transmission, APMT,
analog IF
+E3 -Q2 Protection of transformer -T3 input
Fuses: +E5 -F3 1AT, protection of secondary transformer T1
+E3 -F5 2AT, protection of machine lighting -HL1
+E3 -F15 2AT, protection of security 24V (-T6)
Transformers: +E5 -T1 16VA, 24VAC mains network return (RESTART)
Location +E5 -T6 30VA, security 24DC after C1 and V1
of units

Sector E
Power unit, UPR, UPA 16, RUPA boards
See
Notes:
DSR, DRR = regulation on UPR
DCC, DSC, DTC = commutation on UPR
DCL, DTL, DAL = limiter on UPA 16
DTC, DAC, DCC = commutation UPA 16
4001
UPR 2192
DSR = voltage defect (aux. supply)

DRR = Regulation defect
DCC = Current defect (commutation)
DSC = voltage defect (aux. supply)
DTC = Temperature defect
Fuse, 0.5A/250V
UPA 16 2193
DCL = Commutation defect

DTL = Temperature defect
DAL = voltage defect (aux. supply)
DTC = Temperature defect
DAC = voltage defect (aux. supply)
DCC = Current defect (commutation)
Fuse, 0.5A/250V
RUPA 2194
LD1 = Commutation defect

LD2 = voltage defect (aux. supply)
Fuse, 0.315A/250V
Location
of units

Sector E
Deionization and IF analog boards
See
+E10 -X1 24V supply input from CN mother board +F13 -X372 p. 3.2.20
+E10 -X2 Deionization probe connection (S28)
+E10 -X393 Connection of probe BP14 (used for reading the value of p. 3.1.12
4001
the lower injection pressure).
+E10 -X395 Connection of probe BP15 (used for reading the value of p. 3.1.12
the upper injection pressure).
+E10 -X396 Connection of flat cable (10 poles) to PA/SA board, connector p. 3.2.9
+E12 -X371
+E10 -X397 110V supply input.
Fuse, 250 mAT Accumulators
+E10 -X1 +E10 -X397
DEIO IF ANALOG
3200
+E10
-X3 IF/DEIO connection
+E10 -X396
+E10 +E10
-X2 Dielectric measurement cables -X395
+E10
-X393
Location
of units

Sector E
Numerical control
See
p. 3.2.26 +E11 -X103

Connection on I/O Execution board to IF MAC connector +A13-X105
p. 3.2.17 +E12 -X83Connection on peripheral board to PC module +C14 -X71
p. 3.2.8 +E12 -X371
Connection on PA/SA to IF analog board +E10 -X396
p. 3.2.19 +E12 -X383
Connection on I/O Pilot board to mother board of power units
4001
connector +F9-X325
+E12 -X379 Connection on UA+SAL+Restart board
+E11-X2 Connection of accumulators
UA+SAL+Restart
I/O Pilot
PA/SA
CCU Pilot
CCU Communication
Peripheral
CCU Execution
Axe TV4 X,Y, Z
Axe TV4 U,V
Axe TV4 EF-ALF
I/O Execution
+E12 -X83 +E12 -X379

+E12 -X383
+E12 -X371
+E11 -X103 +E11-X2
3825
Location
of units

Sector E
DNC3 board and its configuration
4 3 2 1 4 3 2 1
See
O
SJ2
I
O
4001 SJ1
I
SJ3
O = Off
3980a
I = On
8 7 6 5 4 3 2 1
Carte DNC3
Configuration
RS 232
2137b
SJ1 = OFF
SJ2 = OFF
SJ3
1 OFF
2 OFF
3 OFF
4 OFF
5 OFF
6 OFF
7 OFF
3980
8 ON
3979
Peripheral board
Location
of units

Sector E
Other configurations
See
OFF SJ1 ON
Rx = Rx 1-6 Rx = Tx
Tx = Tx Tx = FIx
4001
OFF SJ2 ON
RS 232 1-6 RS 422

RS 423
WAVESHAPE CONTROL
SJ3 SWITCH ON
8 RS 232
6 RS 423 19.2 KBd
5 RS 423 9.6 KBd
4 RS 423 4.3 KBd
3 RS 423 2.4 KBd
2 RS 423 1.2 KBd
1 RS 423 50 to 600 Bd
Set the correct switch to ON.
Example for R S423 at 9600 bauds
SJ1 = SJ2 = OFF
SJ3 1 OFF
2 OFF
3 OFF
4 OFF
5 ON
6 OFF
7 OFF
8 OFF
Location
of units

Sector E
UA+SAL+Restart board
See
4001
2137b
J19
(2)
SW1
J20 +80V not used

J21 ø (80) not used
J22 +40V
J23 ø (40V)
J25 +24V Measurement
J26 ø(24V) points
J27 +12V
J28 -12V
J29 J30 +5V
X2
X2
LD1
LD2
J34
LD3
LD4
LD5
LD6
(1)
LD7
LD8
745c
Location
of units

Sector E
UA+SAL+Restart board
See
(1) LEDS power supplies monitoring

RES EXT Initialization of microprocessors on CCU boards at power-on
NMI Order of saving of essential data in the event of power supply
defect
DALC +5V defect 4001
DRES 110V defect
DALS 24V defect
SDD sum of defects
DALM 4 APM rack 40V power supply defect
! It is forbidden to take out the UA+SAL+REST from the NC rack, as it leads to loss of the COM
software:
NMI Reset DALC DRES DALS SDD DALM4 1=Led ON

0=Led OFF
0 0 1 1 1 1 1 Normal operation
1 0 0 1 1 0 1 5V defect
1 0 1 0 1 0 1 110V defect
1 0 1 1 0 0 1 24V defect
1 0 1 1 1 0 0 40V defect
(2) The battery switch must be set at ON.

When the switch is at ON and a power failure occurs, the accumulator block (connected on –X2)
maintains supply to the memories, and their contents are saved during the power cut (3 days).
The accumulator block is charged permanently once power is switched on.
Jumper at J19, J29, J34
The presence of the jumper J19 forbids restart after three minutes according to the standards.
Location
of units

Sector E
Configuration of AXE TV4 boards

+ 5V
+ 12V
See
4 A 8 - 12V
+ 24V
40V/80V DC
2161 Error
4001
Correct display for configuration of

2137b
AXE boards: AXE E-F-ALF 4
AXE U-V A
AXE X-Y-Z 8
PAL
X3 X4 X5
978808
X1
PAL
978807
S1
AXE board: configuration

E - F - ALF Z - Y - X U - V - (A) PAL
978809
X14 X15 X16
X12
SH= H1= 4 8 A
X3
X2 X19
X44 X37 X38 X45 X39 X40 X46 X42 X43
X4
X5 X34
X9 - X10 - X11
4232
X13
X17
X18
X20
X21
X22
X23 In the event of replacement, position the jumpers of the new
X25 board as for those of the board to be replaced.
X26
= ON
X27
X28
X29
X30
X31
X32
X33
X35 ROBOFIL 190/290/3X0
X36 Z - Y - X U - V - (A)
X14 - X15 - X16
4233a
Location
of units

Sector E
APMT boards
See APMT E-F-ALF - Triple motor amplifier board.

Control of fwire drive E, reel drive ALF, and brake F motors
LD1 - Motor E current defect led
LD3 - Motor ALF current defect led
APMT U-V - Amplifier board, U-V axes motor
LD1 - U axis motor current defect led
4001
LD2 - V axis motor current defect led
APMT X-Y-Z - Amplifier board, X-Y-Z axes motor
2138c
LD1 - Z axis motor current defect led
LD2 - Y axis motor current defect led
LD3 - X axis motor current defect led
APMT E-F-ALF 2182

LD3
Fuse ALF: 5 AT/250 V
Fuse F: 1 AT/250 V
LD1 Fuse E: 5 AT/250 V
APMT U-V 2183
LD2
Fuse V: 8 AT/250 V
LD1 Fuse U: 8 AT/250 V
APMT X-Y-Z 2184

LD3
Fuse X: 8 AT/250 V
LD2
Fuse Y: 8 AT/250 V
LD1
Fuse Z: 8 AT/250 V
Location
of units

Sector E
40V DC, +5V, ±12V and +24V supply
See
4001
F1 (6.3 AT)
2138c
F4 (2 AT)
5V, ±12/24V supply

F2 (6.3 AT)
40V supply
Location
of units

Sector C
Connection of PC module C
C
See
4001
2890
+C14 -X78
+C14 -X72
+C14 -X71
2897
+C14 -X78 to keyboard interface board +D11 -X84

p. 3.2.9 +C14 -X71 to peripheral board +E12 -X83
+C14 -X72 to screen
Location
of units

Sector F
Electrical cabinet
F
See
APMT motherboard p. 3.2.21

4001
3830a
4227
Fuse +C17- X76

+C17 -F1 (input110V)
(2A)
PC module
Fuse 2.5A
CNC motherboard p. 3.2.19

chassis (rear)
3832
UPR power p. 3.2.19

chassis (rear)
3533
Self
Location
3532
of units

Sector F
Motherboard of power unit
See
CN motherboard
4001
3832
X167 X171
X353 X317
X367 X359 X343 X337 X325 X312 X308
Motherboard of power units

3972
+F9 -X367 CAP (controls power supply, contorls relay K6)

CAX (controls auxiliary supply (110V), controls relay K7)
+F9 -X343 from temperature probe +F20-ST2
+F9 -X337 from temperature probe +F10-ST1
+F9 -X308 input -24V of regulated A10 supply
p 3.2.21 input +40V from +F18-X19 of APMT motherboard to +F9 -X312 (supply monitoring)
input +110V from T3
+F9 -X312 to NC motherboard on +F11-X171 (monitoring of 24/40/110V supply)
+F9 -X359 to NC motherboard on +F11-X167 (link between I/O pilot and power motherboard)
+F9 -X353 to power output board X253
p 3.2.9 +F9 -X325 to I/O Pilot connector +E12-X383
+F9 -X317 -24V input from -A10 supply Location
of units

Sector F
NC motherboard
+F13 -X372 3832 See

To deionization
board
+E10 -X1
4001
+F11 -X103 to IF MAC p. 3.2.26

+A13 -X103
from X scale
from Z scale
from U scale
from ALF encoder

+F11-X112ALF
+F11-X117 U
+F11-X125 Z
+F11-X128 X
Grounding bar
+F11-X171
+F11-X167
+F11-X118 V
+F11-X126 Y
+F11-X110 F
from FIL encoder

+F10-X129
+F10-X121
+F10-X113
3836 3835
to +F17-X1 APMT motherboard p. 3.2.21

(axes E, F, ALF)
from V scale
to +F17-X5 APMT motherboard (axes U, V) p. 3.2.21
from Y scale
to +F17-X9 APMT motherboard (axes X, Y, Z) p. 3.2.21
to +F9 -X359 link between power motherboard and I/O pilot p. 3.2.19
to power motherboard +F9 -X312 power supply monitoring p. 3.2.19
Location
of units

Sector F
APMT motherboard
See
+F18 -X2: to ALF motor and tacho (reel drive M12)

+F19 -X3: to brake M9
+F19 -X4: to E motor and tacho (wire drive M11)
4001
+F19 -X7: to V tacho motor
+F19 -X8: to U tacho motor
+F18 -X10: to X tacho motor
+F19 -X11: to Y tacho motor
+F19 -X12: to Z tacho motor
+F19 -X4
+F19 -X3
+F19 -X7
+F19 -X8
+F19 -X12
+F19 -X11
+F18 -X2
+F18 -X10
3830a
p. 3.2.20 +F17 -X9 to +F10 -X129

" +F17 -X5 to +F10 -X121
" +F17 -X1 to +F10 -X113
p. 3.2.19 +F18 -X19 monitoring of 40V supply to

UPR +F9 -X308 motherboard
Location
of units

Sector G
Mains network input panel
See
N L3 L2 L1
4001
4763
+G19 -F1
+G19 -F2
+G19 -F11
+G19 -F12
+G19 -Z1
+G19 -K2
4380b
+G19 -QS1
+G19 -Z1 400V input filter

+G19 -QS1 400V main switch
+G19 -K2 Machine power-on control relay
+G19 -F1 0.25AT fuse, protection of transformer -T1 input
+G19 -F2 0.25AT fuse, protection of transformer -T1 input
+G19 -F11 0.5AT fuse, protection of transformer –T6 input
+G19 -F12 0.5AT fuse, protection of transformer –T6 input
Location
of units

Sector H and J
See
H
400V
380V
0V
4001
4381
4382
Transformer +H -T3 of 110V and 24V

machine lighting supply
+J -Q9: 20A circuit breaker,

protection of secondary 4.7V
of transformer +H -T2
+J -Z2: Filter of transformer +H -T2
4383 4384
L2 380V
L1 380V
L3 380V
Transformer +H -T2 of 3.95 kVA

Location
L2 400V
L1 400V
L3 400V
machining power
of units

Sector A
J
See
4001
IF wire panel V3 p 3.2.25
Annealing transformer p 3.2.25
4223
Terminal block +A17 -X61 p 3.2.25
4224
IF MAC p 3.2.26
4225
Power supply +A9 -A10

(regulated 24V)
Cable head p 3.2.28
RDRC circuit p 3.2.30
Pump relays and circuit breakers p 3.2.29
4229
Location
of units

Sector A
A
IF wire panel V3 and annealing transformer
See
+A18 -X12 +A18 -X13 +A18 -X8 +A18 -X9

+A18 -K1 +A18 -K2 4001
IF board
wire panel V3
Fuse, 1.6 A
Annealing
transformer
4223
+A18 -T5 +A18 -F8 +A18 -F9
Terminal block
+A17 -X61
4224
+A17 -F10 +A17 -K18
+A18 -K1 Clutch control

+A18 -K2 Threading motor control (M10)
+A18 -X8 To IF MAC X4.24(16) and X8.29(20)
+A18 -X9 From threading motor M20 and travel limit S40 via 41X16
+A18 -X12 To IF MAC X8.31(22) and X8.32(23)
+A18 -X13 From threading motor M10 via 41X13
+A18 -T5 Manual annealing transformer 110 V/7.5V
+A18 -F8 Fuse 7.5 V 8 AT
+A18 -F9 Fuse
+A17 -F10 Supply fuse -A10 (-24 V) 6.3 A
+A17 -K18 Machine lighting control relay

Sector A
A
IF MAC
See
4001
X13
X6
+A13 -X103
X12
X4
X11
X3
X10
X2
X9
+A13 -X105
X1
F1
4225
X8 X7

Sector A
A
IF MAC
See
4001
F1 Fuse (-24 V) 6.3 AT
p 3.2.9 +A13 -X105 To I/O execution board, connector +E11 -X103
p 3.2.20 +A13 -X103 To NC motherboard, connector +F11 -X103
X1 24 V input
X2 Injection 2 Y21
Injection 1 Y20
Contact wetting Y16
Threading jet Y13
Upper high pressure injection Y15
Lower pressure injection Y14
Remote control
X3 (option)
X4 Rethreading gripper travel limit S40
X6 Float S5
Float S4
Air pressure defect S23
X7 Pumps M11, M12, M13

Machine lighting control
X8 Contact retraction Y4
Cutter advance Y5
Cutter retraction Y6
Threading motor (direction) M10
Threading motor (speed) M10
Rethreading motor M20
X9 Machining contactor K5/K6

Annealing contactor K2/K3
Autodiag. contactor K8
Autodiag. contactor K9
Acquisition on annealing K10
RDRC circuit X3
Brass wire maching K1
Ballast contactor K7
X10 Suction nozzle Y27

Deionization Y18
Clutch
Slug recovery piston Y30 (option)
X12 Remote control

Sector A
A
Cable head
See
+A10 -K6 +A10 -K1
4001
+A10 -X6
+A10 -X4
+A10 -X1
+A10 -K10
+A10 -X8
+A10 -K2
+A10 -K3
+A10 -K9
+A9 -X16
+A9 -K5
+A8 -K8
+A8 -K7
UPA cable
to machining
area
3473
+A8 -X26 +A8 -X17
+A10 -X1 UUS coaxial cable for voltage measuring to PA/SA

+A10 -X4 Input of UPA cable from power motherboard
+A10 -X6 Voltage measuring cable; from machining area mountings
+A10 -X8 To pulley
+A9 -X16 Control of relays of cable head from IF MAC X9
+A8 -X17 To RDRC circuit, connector +A7-X2
+A8 -X26 To RDRC circuit, connector +A7-X2
+A10 -K10 ACRC: Acquisition on annealing
+A10 -K9 CSS: Diagnostic contactor
+A8 -K8 CSUPA: Diagnostic contactor
+A8 -K7 CC1: Ballast contactor, 50
+A10 -K6 CUSM: Machining contactor
+A9 -K5 CUSM: Machining contactor
+A10 -K3 CRC: Annealing contactor
+A10 -K2 CRC: Annealing contactor
+A10 -K1 FLT: Brass wire machining

Sector A
A
Relays and circuit brakers of pumps
See
4001
Q11 Q12 Q13
4226
K11 K12 K13
Circuit breakers:
Q11 Auxiliary pump M11
Q12 Injection pump M12
Q13 Filtration pump M13
Relays:
K11 Auxiliary pump M11, controlled by I/O execution via IF MAC X7.29(20)
K12 Injection pump M12, controlled by I/O execution via IF MAC X7.33(24)
K13 Filtration pump M13, controlled by I/O execution via IF MAC X7.31(22)

Sector A
A
RDRC circuit
See
4001
+A7-X3
+A7-X2
+A7-X1
+A6-X4
Resistor
3754
+A6-X4 Input of RDRC circuit, 80 V

+A7-X1 To resistors
+A7-X2 From cable head, connectors +A8-X17, +A8-X26
+A7-X3 From IF MAC, connector X9.18(10)

Sector B
A B
Relay K40
See
4001
4001
K40
4762
K40 Control relay of "reverse motor" M40.

A
See
4001
APM 5/±12/24V supply 3.2.5

APM 40V supply 3.2.16
APMT board 3.2.15
APMT motherboard 3.2.21
Axis board 3.2.9/14
Cable head 3.2.28
CCU communication board 3.2.9
CCU exe board 3.2.9
CCU pilot board 3.2.9
Circuit breaker panel 3.2.6
Configuration jumper 3.2.4
DNC3 board 3.2.10
Electrical cabinet, front 3.2.5
Electrical cabinet, rear 3.2.18
Fuse, wire heater 3.2.25
I/O execution board 3.2.9
I/O pilot board 3.2.9
IF analog board 3.2.8
IF MAC board 3.2.26
IF wire panel V3 board 3.2.25
Mains network input panel 3.2.22
NC motherboard 3.2.20
NC 5/±12 V supply 3.2.5
PA/SA board 3.2.9
PC module 3.2.17
Peripheral board 3.2.9
PI deio 3.2.8
Power supply, 24V 3.2.24
Power units 3.2.5
Power units motherboard 3.2.19
RDRC circuit 3.2.30
Safety equipment panel 3.2.6
Alphabetical Transformer 3.2.6/23
index UA+SAL+Restart board 3.2.9/12

Contact
Charmilles Technologies SA
rue du Pré-de-la-Fontaine 8-10
1217 Meyrin 1, Geneva/Switzerland
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Charmilles Robofil 190 290P 310P 510P 1-2 Maintenance Manual

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Charmilles Robofil 190 290P 310P 510P 1-2 Maintenance Manual

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ROBOFIL 190 • 290P • 310P • 510P

205 964 540/E/08.2000 ver. B

205 946 940/E/09.08.2000

Les illustrations contenues dans ce manuel se rapportent aux machines ROBOFIL de

Le illustrazioni contenute in questo manuale si riferiscono alle macchine ROBOFIL

CHARMILLES TECHNOLOGIES 205 915 200/FEDIEs/08.10.1999 1

2. List of error messages

Document designed and written by N. Fujisé and F. Zaslawski, CTSA-Geneva.

The technical data is from our R&D department, CTSA-Geneva.

CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000 0.1

0.2 CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000

Period maintenance procedures 1.1.1

List of periodic maintenance operations 1.1.3

Log book 1.2.1

List of error messages 2.1

Location of machine units 3.1

Overall view of machine (front view) 3.1.4

Overall view of machine (rear view) 3.1.5

Alphabetical index of units 3.1.16

Overall view of machine (front view) 3.1.18

Overall view of machine (rear view) 3.1.19

CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000 0.3

Overall view 3.2.3

Alphabetical index of units 3.2.32

Troubleshooting procedures 4.1

0.4 CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000

Checks and adjustments

Replacement, removal and installation

On-board diagnostic 5.1

STARTUP DIAGNOSTIC 5.8

CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000 0.5

Transport and handling 6.4

Choice of working premises 6.7

Equipping the premises (Outside connections) 6.12

0.6 CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000

Data sheet ROBOFIL 190 6.15

Data sheet ROBOFIL 290P 6.17

Data sheet ROBOFIL 310P 6.19

Data sheet ROBOFIL 510P 6.21

Set of diagrams 7.1

CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000 0.7

0.8 CHARMILLES TECHNOLOGIES 205 947 000/E/10.08.2000

CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000 1.1.1

Monthly servicing or number of machine hours servicing

Six-monthly or more servicing

CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000 1.1.3

Procedure/ Check the condition of the wires and replace if necessary.

List of wear parts

No. Description Charmilles No. Qty. per machine Supplier

3 Circlips 209 227 224 4

1.1.4 CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000

CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000 1.1.5

! It is preferable to replace the filters of both batteries simultaneously. When disposing of

List of wear parts

N° Description N° Charmilles Qty. per machine Supplier

3 Circlips 209 227 224 8/10

1.1.6 CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000

1st circuit 2nd circuit

Dirty water tank Clean water tank

CHARMILLES TECHNOLOGIES 205 947 030/E/27.06.2000 1.1.7

! It is preferable to replace the filters of the two batteries simultaneously.

List of wear parts