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    32 views91 pages

    Service Manual

    Uploaded by

    Juan De la cruz

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 91
    DM3000H SERVICE MANUAL DM3000H_ POWER INSTALLATION WARNING I. THEINPUTPOWER VOLTAGE MUST BE WITHIN THE RANGE OF 210VAC “~~ 240. VAC. IF THE MACHINE IS OPERATED BEYOND THE VOLTAGE RANGE, THE USER IS SOLELY RESPONSIBLE FOR ALL DAMAGES INCURRED TO THE MACHINE. I. THE PRIMARY SIDE OF THE TRANSFORMER IS NOT CONNECTED. DO NOT'TURN ON ‘THE MAIN POWER SWITCH BEFORE CARRYING ON THE FOLLOWING PROCEDURE. POWER INSTALLATION L USE VOLTMETER TO MEASURE THE VOLTAGE ON THE POWER LINE DEDICATED TO ‘THE DM3000H. RECORD THE VOLTAGE READING. WARNING: a) TAKE ACTUAL MEASUREMENT. DO NOT ASSUME NORMAL VOLTAGE. ») IP THE POWER LINE VOLTAGE IS: CONSTANTLY BELOW 205 VAG OR, CONSTANTLY ABOVE 245 VAC. DONOT CONNECT POWER TO THE MACHINE. Il REMOVE THE COVER ON THE TRANSFORMER HOUSING. CONNECT THE POWER LINE ‘TO PROPER TERMINAL ACCORDING TO THE INPUT POWER VOLTAGE AS SHOWN ON PAGE3. WARNING: THE TERMINAL SHOULD BE SELECTED SO THAT THE INPUT POWER ‘VOLTAGE CAN BE EQUAL TO OR LESS THAN THE TAP VOLTAGE, INDICATED ON THE PRIMARY SIDE. II. CALIBRATE THE SPINDLE AMPLIFIER (REFER TO CALIBRATION PROCEDURE). t Main power NN teh ‘Transformer | BACK VIEW OF THE MACHINE an ies oa Vv son] rsd a ona} “az ‘AndNl YaAOd HOOGEKE see pu ves} ONT SOINOMLHOSW VNAG | ava | sinners aos SISS¥HO_aNY cNngys SMICTInE OL ui NOWWOO “ENNOSD Hava 3 eel j on 3NVLTOA ee inet HL OL a¥vOE NOLNEIeLSIC YaMOd eaanes SWNIRESL : xad0d OL 440 ad NIN YAN 10 NO 38 CTNOHS WAd INOS «sion aw QvA Ore ‘ QWA Obe <--> Sea x Fane IWA 0&2 Hat QVA 02 <--> S22 * at OWA 082 «LITTES «BWA O82 <-> Oe # 30S AGWWTSa_WOST SNIGTINg WOSS SHVIWA avL aS (COVA 0¥2 ~ OVA oT2)_3NIT aaMOd Tri mod av SHL NO ZOVLT0A SHI 3enSvan L mL. Mm. DM3000H SPINDLE CALIBRATION PROCEDURE INITIALIZE THE MACHINE, SELECT MANUAL MODE, ADJUST #/- 10% SPINDLE OVERRIDE KNOB TO THE CENTER, ‘TEST / OFFSET ADJUSTMENT. CONTROLLER DISPLAY PRESS KEY INCH? YES FR X/M=nn NEXT FR Z/M=nn NEXT TOOL CALIB? NO. MANUAL MOVE? No WORKING LIMIT? NO PROBE SET? NO. DIAGNOSTIC? YES CHECKSUM OF ROM? NO. RAM TEST? NO. SPINDLE CALIB? YES 1000 410 228 NEXT RPM ALL RANGE ‘THE SPINDLE SHOULD STOP AT THIS TIME. IF THE SPINDLE STILL ROTATES, ADJUST POT. #4 (TEST / OFFSET PORT) ON THE SPINDLE AMPLIFIER UNTIL THE SPINDLE IS FULLY STOPPED. THEN PRESS "NEXT" KEY, AND PRESS "NO" KEY TO ALL PROMPTS UNTIL THE CONTROLLER BACKS TO "MODE", IV. REF. IN GAIN ADJUSTMENT. REPEAT THE STEPS IN Ill, UNTIL YOU GET TO: ‘SPINDLE CALIB? PRESS "YES" ooo 410 228 NOW, COMPARE THE SPINDLE SPEED DISPLAYED ON THE SPINDLE RPM SCREEN WITH ‘THE ABOVE NUMBERS. IF THE RPM DISPLAY DOES NOT MATCH ONE OF THE NUMBERS CONTROLLER DISPLAYS, ADJUST POT. #3 (REF. IN GAIN PORT) ON THE SPINDLE AMPLIFIER UNTIL THE NUMBERS MATCH. THEN PRESS 'NEXT", "NEXT", "NO"...."NO” TO BRING THE CONTROL BACK TO "MODE". PROGRAMMED SPINDLE SPEED ADJUSTMENT SELECT PROGRAM ENTER MODE, KEY IN THE FOLLOWING PROGRAM: STARTINS 00 ‘SPINDLE ON (SPINDLE SPEED) SP = 1000 HALT END SELECT PROGRAM RUN MODE, RUN THE ABOVE PROGRAM. OBSERVE THE SPINDLE SPEED DISPLAYED ON THE SPINDLE RPM SCREEN. THE SPINDLE SPEED SHOULD BE 1000 RPM +/- 10%, IFNOT, ADJUST THE +/- 10% SPINDLE OVERRIDE KNOB TO BRING ‘THE SPEED INTO THE RANGE. PRESS "NEXT KEY TO END THE PROGRAM. DRIVER RESISTOR POWER PACKAGE LZ Af, Boars POWER DISTRIBUTION BOARD MAIN POWER Y SWITCH | 5 Z caP Bi] Hoe] r_\ SPINDLE CIRCUIT HEATSINK [NTERF# BRAKER SPINDLE an VI. SPINDLE SPEED FINE ADJUSTMENT. ‘SELECT MANUAL MODE. CONTROLLER DISPLAY PRESS KEY INCH? YES FR X/M=nn NEXT FR Z/M=nn NEXT TOOL 1 Xx X=n. nnn SHIFT, SPINDLE ON/OFF SPINDLE ON? Yes X=n.nnnn SPINDLE SPEED CONTROLLER DISPLAY PRESS KEY SPD SP=26 (WAIT 10 SECONDS) CLEAR (2~3 TIMES) SPD SP=? 1000 COMPARE THE CONTROLLER DISPLAY WITH THE SPINDLE RPM SCREEN DISPLAY. IF ‘THE NUMBERS DO NOT MATCH, ADJUST POT, #3 UNTIL THE NUMBERS MATCH. VII. REPEAT STEPS IN TIE, MAKE SURE, AT: @ RPM ALL RANGE. ‘THE SPINDLE IS FULLY STOP. SYSTEM OVERVIEW * CONTROLLER * POWER CONTROL DISTRIBUTION * AXES SUB-SYSTEM * SPINDLE SUB-SYSTEM + CONTROLLER. ‘The controller is the "brain" of the system. It provides program control, machine status display and performs all math calculations. It instructs the axes, spindle, and ATC through the power control distribution to perform many operations of the machine, The controller can be removed from the machine to provide offline programming at a Desk~ Top Interface Unit. * POWER CONTROL DISTRIBUTION. The power distribution is an interface between the controller and axes, spindle, atc, I\O and encoder. It also has its own mi¢ro-processor to control power up/down the machine through the front panel key board and monitor the emergency door switch . * AXES SUBSYSTEM. The axes subsystem provides the actual T,X,Z axes table movement under command from the controller.The following components make up the axes subsystem. For X,2 axis For T axis Stepper driver board Step driver board Stepper motor Stepper motor Limit switch Opto board Limit switch Air solenoid * SPINDLE SUBSYSTEM. ‘The spindle subsystem controls the operation of the DC spindle motor under command from the controller in program mode, and from local speed knob in local mode.The following components make up the spindle subsystem. Spindle control board AMC amplifier De motor Encoder , Optocouple(index) vBUS regulator SYSTEMS DESCRIPTION ELECTRICAL INPUT POWER REQUIREMENTS ‘The DM3000H requires 220 VAC, single phase input, the ground wire is connected to earth ground. The systems nominal power consumption is less than 2.5 KVA however the servo amplifier may experience transient peaks of 20 amps, thus boosting the output power to 4.5 KVA for very brief periods. Input transformer T1, provides multiple primary voltage taps. For proper input power connection the customer must chose the tap that most closely matches the voltage measured on his input line at the time of installation. ‘AC_AND DC POWER. 9 VAC = Source voltage for initial turn on. 9 VAC is a secondary tap voltage on the input transformer, Tl and is connected to Pin 1 of J13 on the power distribution board. It is rectified and regulated to 5 volts De and called +5V1. +5V1 powers the primary logic control circuits that scan the switches and controls the interlocks for all other power-on switching functions. 18_VAC _- Source voltage for solenoid actual 18VAC is measured with respect to the secondary 0 volt 1BVAC_(Cont..) center tap on Tl, It connects to pin 3 of J13 on the power distribution board. When rectified and regulated, it provides 12vpc at 1 amp and is used for solenoid power. Earlier DM3000H's developed 24VDC for this purpose so the customer may find either voltage available for solenoid control. 110 VAC ~ Utility source for AC_ device: The 110 VAC, measured with respect to the end-0-volt tap on the secondary of Tl, is used to supply power to the, coolant pump, lube pump and fan motors. It also powers the Lambda 48vDc and S5VDC power supplies and the spindle motor brake. It connects to pin 5 of J11 on the power distribution board where it is controlled by the on/off. interlocks of the system. 120 VAC Power to the spindle amplifier 120 VAC is measured with respect to the end-0-volt tap of the secondary of Tl. It is primarily used to power the spindle amplifier and is the source voltage for the 160 volt bus that powers the spindle motor. In addition to spindle power, 120VAC is rectified, filtered and regulated’to supply the following control voltages; 1. +5V3 - Used in the RS232 communication driver circuits. uu 120_vac_(Cont.) 2. #12, #15 and ~15 ~ Used on analog devices on the spindle interface board, 4#5V2_- Main VCC source. +5v2 at 3 amps, is the main VCC for the distribution board, the controller and all other peripheral circuits that require a VCC supply. This voltage is supplied by the externally mounted, 5 volt, Lambda power supply. +48VDC - Pulse motor power. +48vpc at 7 amps, powers the pulse motors that drive x, % and the tool turret. The +48V supply is a Lambda power supply+ ELECTRICAL CONTROL OF THE SPINDLE. The spindle of the DM3000H is powered by a permanent magnet 4 HP motor. It in turn, is powered by a pulse wave modulated, servo amplifier by AMC. When the machine is turned on, 120 VAC is applied to the amplifier at the AMC's terminals 1 and 2 of TB 201. an internal electronic switch holds off the turn on of the amplifier until the spindle-on switch is selected on the operators panel. 1 | Spindle Control (Cont.) The speed control input for the spindle is a + 0 - 10 V analog input signal to the AMC amplifier. Refer to the AMC maintenance manual for a complete description. Dynamic Braking Contro: fhe dynamic braking board regulates the 160 volt bus and protects against amplifier shutdowns. The spindle motor xequires voltage from the bus to accelerate and maintain a continuous speed. When the motor decelerates, it acts like a generator and pumps energy back into the bus causing the voltage to rise. To prevent damage, the amplifier will shut off when the bus voltage rises to 180 volts. To avoid annoying shutdowns, the dynamic braking board intercepts the voltage rise at 175 volts and shunts the excess regenerative energy to ground through a 5 ohm 500 watt resistor, Spindle Modes, Automatic and Manual Control Depressing the local/program switch on the operators panel will alternately select automatic or manual control of the spindle. Upon turn on, the spindle defaults to automatic mode. In automatic, spindle speeds and direction are controlled by Spindle Modes (Cont.) the resident programmed instructions in the controller. fo change the spindle mode to manual, push the Local/Program switch once, the green LED will illuminate indicating the spindle is in manual (local) mode. In manual, the programmed spindle commands are ignored and the spindle direction is fixed to CCW. RPM is selected by the pot setting on the operators panel marked, “Local-Speed-Control. Depressing the Local/Program switch for the second time will cancel manual mode. The LED will extinguish and the spindle control is back in auto and will once again recognize the programmed spindle codes. Belt settings, Low, Medium and High there are 3 belt settings which help to maximize the torque over the full range of spindle speeds. They are; Low = 0 to 1000 RPM Medium - 0 to 1800 RPM High - 0 to 4500 RPM Spindle Transducers Phreadi coder A 1000 line incremental encoder is mounted on a 3 to 1 belt drive to the spindle. This encoder provides synchronization pulses between the spindle and the 2 axis for threading. Spindle Transducers (Cont.) RPM and Marker Switches Two LED driven, photo-sensitive switches straddle a disc which is mounted on the spindle. One switch lines up to a pattern of three holes spaced 120 degrees apart and generates pulses as the spindle rotates. These pulses are directed to the digital RPM display on the operators panel. The second switch is aligned to detect a single slot on the same disc. The LED light passing through the slot generates a signal that is used as the insertion marker pulse for multiple pass threading. The Power Distribution Board The power distribution board is the hub’ of the system. All power and control signals are applied to and interlocked by, this board. There are two fuses mounted on the Power Distribution board, a 10 amp and 3amp. The 10 amp protects the externally mounted Lambda power supplies and the 3 amp protects all other 110 volt devices. 30 LED's and. 6 neon indicators provide a system status display. Refer to pg. 3 of the electrical diagrams for a complete description of these indicators. Axis Drives and Motors The axis driver boards receive incremental step and direction commands from the power distribution board. In turn, the drivers deliver +48 volt pulses in the proper sequence to control direction and speed of the stepping motors. With each pulse, The axes and turret motor shafts index 1.8 degrees. This translates into .0001" of slide motion for X and Z axis. This is the minimum increment of motion or better known as, the pulse resolution of the system. The maximum programmable feedrate is 50 IPM and the maximum rapid traverse rate is 100IPM Boo: rat Posit: me Turret positioning is not pulse weight or feedrate sensitive. Although the turret is driven by a pulse motor, similar and slightly smaller than the xX and 2 axis, the indexing to tool positions is controlled by three optical switches. These switches are mounted at the rear of the turret. They read the binary coded hole patterns on three corresponding disc's that are attached to, and rotate with the turret. There are two additional limit switches associated with the turret. One signals the system that the turret is out and ready to index. The other indicates when the turret is seated and locked in place. We 1/0 Interface Board RS232 Provisions for up-loading and down-loading programs between a remote computer and the DM3000H, exists through the DB25 connector, J3, on the I/O connector board. Communications is supported by the DYNACOM utility program which provide specific information regarding interface wiring and complete operational instructions for this feature. Syne 1/0 The Sync I/O ‘port provides communications to an -external device, eg. automatic part transfer system. Sync communications are initiated by the control key on the controller. when a CONTROL #2 command is read in the program, an output will switch low between pins 1 and 2 of 32, for 100 ms. After 100 ms, the program will continue. When a CONTROL #3 is read, (usually immediately following a control #2), advance of the program will stop and remain stopped until an active low is applied across pins 3 and 4 of J2 for at least 30 ms. Upon recognition of this signal the program will continue. eed I/0 The Barfeeder interface provides a hardware connection to two independent output strobes and one input enable line. Tt is not at present software supported. Probe Probe, J4. Currently not software supported. Initialization Switches Sometimes referred to as limit switches or Pogo switches the initialization switches perform a very important function. Designed and constructed with less than .0003" hysteresis, these switches accurately measure the lost motion of each axis and establish the reference from which all positions are measured, CAUTION: The initialization switches are not customary limit switches that protect the slides from over travel, and should not be used for, or depended on as such. Initialization Cych he purpose for initialization is to establish a physical xeference location for x and % axis and to measure and compensate for the reversal errors of each axis. When the system is turned on, the control display prompts the operator with, “READY ?". Answering "YES" to this will start the initialization cycle. The initialization sequence is as follows; 1. Because X and % may be on the switches when initialization Initialization (Cont. starts, the sequence begins with a short move of both axis, away from their respective switches. NOTE: Be certain the tool is not against the part before initialization. 2. After the clearance move, both axis reverse dixection and xapidly move toward their respective switches. 3, When individual contact is made with the switches, the slides will stop, reverse and move off the switch slowly until contact is broken, then they reverse and feed back until contact.is sensed for the second time. At this point, the control continues to move into the switch, against the plunger, for 100 counts. After 100 counts, the control reverses direction and counts back until the slides break contact. The difference between the 100 counts that was moved on the switch vs, the number of counts it took to get off the switch is determined and represents the lost motion of the slide, more commonly referred to as backlash. Tho CNC Controller The controller is interfaced to the power distribution board at J19. It is powered by +5V2 and its memory is protected by a 3.9 volt lithium battery when the power is turned off. Refer to the 3000H users manual for a complete description and programming instructions. ELECTRICAL DIAGRAMS DM3000H ELECTRICAL DIAGRAM INDEX POWER INPUT POWER DISTRIBUTION BOARD AND INTERCONNECTION POWER DISTRIBUTION BOARD STATUS AND DISPLAY SPINDLE CONTROL D.C. POWER SUPPLIES CONTROL OPERATOR SWITCH PANEL % AXIS DRIVER AND STEPPING MOTOR X AXIS DRIVER AND STEPPING MOTOR TURRET DRIVER AND STEPPING MOTOR ENCODER INDEX AND RPM DETECTOR I/O INTERFACE CONTROLLER INPUT = oe Sg, [esoae] loos] =: 1.2 % “ ae aa $ ned Te 3 “ft fe 3] ep 3 ava: gi. 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