FADAL SERVICE BULLETIN

Bulletin 9409 October 27, 1994

SERVO-TURRET PROBLEMS
More and more machines are being outfitted with 21 or on the same terminal. Second, the relay at K12 needs
30 tool Servo-Turret Tool Changers. These can be to be the part #1525 GREEN relay, and not the #1402
identified by noting that when a tool change is made, the black relay. If a black one is installed inadvertently, the
pause between tool selections from geneva operated turret may not stop at the requested tool. Third, the
changers is absent in Servo-Turret ATC's. Also, a Fuse F4 must have an AGC2 installed, and circuit
circuit board and amplifier are mounted to the right of breaker CB7 must be jumpered.
the inverter in the rear cabinet. A few problems When the machine is powered on, or when E-
occurred with the first few versions. Stop switch is released, then the Servo-Turret will find
Some changes have been made to the 204465 its own zero position. So that if the turret wheel is to be
worm gearbox as it appears on the next page. Later adjusted, the VMC must be powered ON, and one or
versions have reduced the amount of backlash by more turret moves made to ensure that the zero posi-
added spacers between the 7920-14N Nylock nut tion has been found.
and the pulley, and also between the two 4602-102
bearings. Some of the gearboxes were sent out with
the 4306 snap-ring not fully installed into its pocket. SOFTWARE DISCREPANCIES
This is visually identified by the distance between the It has been discovered that software programs have
two ears of the snap-ring. It should be almost 1/2 been corrupted when transferred between the main
inch and not 1/8" to 1/4" as it could be if installed computer on which software is composed and the
incorrectly. EPROM machine which burns in the modules. This has
Please note that the TURRET FACTOR been corrected, but software version 94.1M-3 was
should always be 1 and not any other number for partially issued when this was discovered. As a result,
Servo-Turret ATC's. Mis-positioning may occur with there are a few copies of 94.1M-3 that were issued
a larger number. Be careful to ask a customer or with a WHITE sticker (and a green dot). To identify
serviceman if he is working with a Servo-Turret when valid copies of 94.1M-3 from corrupted ones and any
coaching someone with SETP parameters over-the- earlier software versions, the sticker has been changed
phone when dealing with TURRET FACTOR. to GREEN (and a green dot). We will be using green
When diagnosing the Servo-Turret, mark the stickers until we run out of them. The current version
motor pulley with a felt pen, and observe if the motor that we are now shipping is 94.1P-3, and is with a green
always returns to the same mark while changing turret sticker.
positions. This will verify encoder integrity. The
encoder can also be tested with the ST40 Encoder SOFTWARE - BALDOR INVERTERS
Tester. Next verify that the motor pulley and motor
Software EPROMs, part number 0404-INV, have
shaft are always together by marking them. There is a
been changed for the Baldor inverters. Version 206F
second spacer shaft between the pulley and the motor
represents a change to the fault frequency where older
shaft, and although there is a hole in this spacer for the
versions were set at 5 fault recoveries per hour, and the
setscrew to go through, it may be tightening against the
new version is at an infinite number of fault recoveries.
spacer and not the shaft. Check belt tension, and then
This is most apparent on machines that have been set
check gear wear. There should not be much play in the
up on single-phase power, and the spindle motor
turret wheel at its edge.
accelerates too slow, then the inverter faults and recov-
Other items to check for: On the 1100-2
ers a couple of times. When the program asks for a
board, note that it is set up differently for the Servo-
third tool and accelerates again, it exceeds the 5 fault
Turret than it is for the standard tool-changer. First, the
recoveries in an hour and shuts down. This correction
Capacitor C2 is bypassed by putting both leads
(continued next column) can fit any of the "-175" series inverters. Order 0404-
INV.
 MAGIC 302 AIR VALVES, REGULATORS
If a customer reports error #13, MOTOR OVER- New air regulators have already begun appearing on new
LOAD, and he has a metric-screw machine, then machines. These are Watts regulators and are different
determine whether it occurs at idle, in a feed-rate cut, in from earlier versions. The plastic bowl that sometimes
a jog move, or in a rapid move. Error #13 occurs when cracked has been replaced with a metal bowl. The air
the following error becomes too large, and the control pressure range has been reduced to avoid the diaphragm
figures that the motor is stalling. cavitation that was seen on some 4246-1 VMC15
If the problem occurs at idle for a long period of regulators. The oiler has been eliminated to avoid some
time, then test further by clamping a ST39 clamp on of the MAC valve problems that we have experienced
ammeter around the brown output wire on the offending through the years.
amplifier when it occurs. You may observe that the Soon new valve assemblies will be appearing
current increases at the limit stop when the limit stop where there are four valves on a single manifold under the
springs are mis-adjusted. Or, you may observe that the inverter cabinet, and there will NOT be an air box on the
machine is loaded with a heavy fixture, and the current side of the inverter cabinet to allow better access to the
increases when pushed to a certain position. Error #13 waylube pump unit. These will be unique in that three of
can occur during rapid moves, and the problem can be them, Hi/Low, and orientation, are operated with 80-
reduced by switching to 50% rapid. 90# regulated pressure; and the fourth, drawbar cylin-
If either of these scenarios is present, or a case der, will operate with maximum 120# regulated pressure.
of motor burnup is discovered, then the following Here are the part numbers:
modifications (MAGIC 302) must be performed.
4246-3 Regulator, Dual / filter assy
1. Replace any burn smell motors, and CAREFULLY 204246-1 Regulator, filter assy (VMC15)
inspect the resolver connector for broken pins. Also 204246-2 Regulator, filter assy w/ bulkhead
check the spider in the coupler for heat damage. 4248-700 Regulator, filter assy - Norgren
2. Change ALL software. Version 94.1M-3 or newer for 4246-101 Bowl, metal - (repl's plastic bowl)
the 201610-1 module and 90.8C or newer for the axis
software will help solve this problem.
3. SETP parameters are a little different. XYZ RAMP
is set to 160 for metric-screw machines instead of 100.
MOTOR OVERLOAD FACTOR is set to 2 instead of ST39 DIGITAL CLAMP-ON AMMETER
1. On Rigid Tapping machines that are metric-screw,
then set the Z TAP GAIN to NORMAL. Use the following chart as a guide when testing amperage
4. Set clock card from 12.25 to 12.5 seconds. Adjust loop used by axis motors at various conditions to help dis-
gain settings (SIG2) on amplifiers so that following error cover the source of a problem. Clamp on the brown
displayed on the screen reads 302, and adjust BAL to output wire of the axis amplifier and set the selector to
read 302 in both directions. This will work out to be about 200A and Peak Hold.
.735 volts DC from SIG to COM.
5. Don't forget to recalibrate Rigid Tapping GAIN setting
using our ST30 test tool. MEASURING AMP DRAW (PEAK HOLD)
Using tool ST-39 X-Axis Y-Axis Z-Axis
OTHER ERROR #13 CONDITIONS Idle at Center _____ _____ _____
If the customer reports the fault in a feed-rate cut, then Idle at Negative _____ _____ _____
determine whether or not he may be overworking the Idle at Positive _____ _____ _____
machine, has dull tools, inadequate coolant, etc. Also,
consider adding G9 to the problem area in the program, 25 IPM Feed _____ _____ _____
or M92 at the beginning of the program where it faults 150 IPM Feed _____ _____ _____
during contouring.
Errors during JOG can result when the Rapid - 100% _____ _____ _____
handwheel (MPG) is turned too fast or there is a
keyboard/MPG problem. Customer's Program _____ _____ _____
 GOLD CONNECTORS, AXIS CARDS BACKLASH
We have used for years the little gold connectors that are Backlash is generally represented as the amount of "slop"
bullet shaped to carry resolver signals to the axis in a powered driveline when changing rotational direc-
controller cards. We have discovered that many of tion. In the FADAL, backlash on NON-SCALE ma-
these connectors are making poor connections at the chines is a value applied to an axis when direction is
card sockets. We have sent out a bundle of tool number changed to take up this "slop" and position correctly in the
ST44's to each distributor, and now here are the new direction. When checking backlash, we originally
instructions to use them. This tiny little tool has a .040" were using the MPG handwheel and jogging back and
pin on one side to insert into the part number 1411 forth in .010" increments and measuring the differential
connector to measure the connector's "grip" on the pin. with an indicator from the spindle to a fixed item on the
Hold the connector vertically with the tool inserted and table.
see if gravity will not pull out the tool. If it does, then One of the things measured with this procedure
CAREFULLY insert the tubular end of the tool into the is friction, relative to stiction in the driveline. On metric-
connector to tighten up the gold contacts to grip the pin screw machines (those 40, 3016, 4020 machines built
side of the tool better. since October, 1993), we have increased friction and
Further, twist LIGHTLY the connector on the tightened up the driveline with the new ballscrews. The
wire to test the integrity of the crimped ferrule on the seals on the cooled-screws grip the shaft with friction, the
shield. If it spins on the wire, a new connector is needed. ballnut has a built-in preload that is tighter and has more
Obviously, if a great deal of force is used, then any friction, and in general all of these things have led to an
connector will break under this test.. inaccurate backlash value.
Now, check the socket on the card before We want to use the following procedure when
reinstalling the connector. The split in the "can" of the correcting backlash values with the BL command. This
socket may need to be bent back into a full circle. Then, example modifies the X-axis backlash.
the latch may need to be bent over SLIGHTLY to hold 1. Use an indicator mounted in the spindle, and touch off
the connector. a fixed block on the table on the top-right edge of the block
and with the indicator facing toward the right.
2. Jog away Z-.1 and X.1 and SETH. Tip will be below and
away from this edge.
3. Run the following program with the Feedrate in line N1
too far open good socket ST44 set to match the customer's most-used feedrate when
making parts where high accuracy is desired.
In sample tests on older or even newer machines, we N1 L100
N2 G91 G1 X-.1 F30. *move back to block
have found at least one weak connection on each
N3 G4 P66000 *wait for START, set zero
machine. To order replacement parts, order as follows: N4 Z.25 G5 * move up in Z above block
N5 X-.1 *move over top-of-block X-
1411 Connector, AMP Co-ax RG316U N6 X.1 *return
1411-1 Ferrule, AMP (fits 1411) N7 Z-.25 *move down to block
ST21 Crimper, AMP 45638-2 N8 G4 P66000 *wait for START,
ST44 Connector test tool N9 X.1 G5 *move away X+ get backlash
N10 M17
N11 M30
N12 L101.1
4. When paused at line N2, adjust the indicator for zero.
Press START to continue.
VMC15 X-BALLSCREW GREASE PORTS
5. When paused at line N7, read the indicator to see how
Still, a number of customers have been missing the X- many tenths the indicator is away from zero.
ballscrew grease ports under the table. Most have been Correct the backlash table and repeat several
greasing the Z-Ballscrew and guides, and also the Y- times. Adjust program and run for Y and Z axes. You
ballscrew and guides. Please remind them to look under will note that the backlash value will be different than with
the table for the third grease port. Use Mobil SHC-32 the original procedure, but will more closely approximate
which is available from us, or your local Mobil dealer. that needed for the customer's program.
Grease every 1-2 weeks.
 2-LOBE COUPLERS NEW INSTALLATION SHEET

Recently we have changed the couplers between the axis A new installation sheet is now mounted on each new
motors and the related ballscrews from 3-lobe couplers machine (sample enclosed). These first appeared on
(4284, 4284-1, and 4285) to a new 2-lobe design. machines in California for awhile. The idea is that
These couplers will not intermix with any of the 3-lobe instructions for installing power and ground wires and
couplers unless all 3 pieces are replaced together. You installing air lines are available for the customer to instruct
the installers before machine is setup. Further, a mini-
will notice that the design allows the two shaft axis to exist
off-center up to .050". In conjunction we will be addinginstallation report is on the back for the FADAL service-
a locating ring to ride between axis motors and their man to complete and mail or FAX back.
ballscrews, and then eventually change the ballscrew This will enable us to track how machines arrive
mount. at a facility relative to voltages and amplifier adjustments.
We have tweaked the machine for optimum performance
The part numbers are: at the factory, and found that due to rigid setup proce-
904550-1 Coupler, 2-lobe 5/8 inch bore dures, the adjustments we made are changed at setup.
904550-2 Coupler, 2-lobe 7/8 inch bore Please leave alone any clock card or amplifier adjust-
904549 Coupler disk insert, 2-lobe ments, and merely record what values are observed.
If the values are far off, we will reFAX a note
back for further correction, if needed. We will be
We will no longer ship out couplers along with replace-
carefully reviewing your results to find out if any adjust-
ment motors or ballscrews. Please remove the old
ments are changing between FADAL and the eventual
coupler and mount it on the new motor or ballscrew. You
site. Obviously for this program to work well, we will
will not need to return any old couplers on previously
need the form returned as soon as possible.
replaced motors that are waiting to be returned to
In California we found that many customers
FADAL.
were ripping off all the vinyl wrapping and this form off
the door to get at the footpads in the packing box. So
we now have a second copy taped by the disconnect
box.