OmniTurn - Trouble shooting guide

OmniTurn - Trouble shooting guide
OmniTurn - Trouble shooting guide
The Yellow power light won’t come on
The yellow power light indicates that the 12V power supply is working. The 12V should come on when the
system is turned on and the computer is working.
•
•
•
•
•
Be sure there is power to the machine
Check that disconnect on spindle cabinet is ON
Check that the CNC Control is plugged into socket on back of machine
Check the fuse on the back of the control box.
Check fuses on step-down transformer in spindle cabinet
The Blue servo light won’t come on
The Blue servo light indicates that the servos have been turned on. If this won’t illuminate that means there
is a problem with the drives or their control system.
• Check that the Emergency stop is released
• Check the relay on the connect card in the control, be sure it is plugged in
The Monitor won’t come on
• If the rest of the system works (the yellow light comes on and, after 1 minute, you
can turn on Caps Lock Light on keyboard) but you do not get an image on the screen
there is a problem with the monitor; check the cable on the back of the monitor. Make
sure 12V cable from CRT, is attached to J7 on connect card.
• If the Caps Lock Light won’t light, the computer is probably not booting up.
The Red Motion Stop light come on every time you try to move the slide
• Check that the Spindle Drive is not faulted; press the reset button on the the spindle drive
cabinet located at the left side of GT-75 and GT-Jr.
• Check the hatch on GT-Jr, or any interlocked doors on your system. To jog the machine
with door open during setup, get the interlock bypass key from your supervisor.
• If you have a barfeeder, check that the end of bar circuit is not activated
“Servo Axis Error” when you try to jog the slide:
Most common cause is from over-travelling the slide and hitting a “hard stop”.
• Press ”ESC”, this will reset the control. If the control shuts down again when you try to
jog the axis go to the next step.
• Check Emergency Stop button on CNC; be sure it’s reset
• Check the two thermal overloads inthe control. These are located on the rear panel of
the CNC. It can take a few minutes for the overload to cool enough to be reset. Press
“Esc” and try to jog again.
• Turn the control off, wait 15 seconds, turn the control on again. This will reset the Servo
driver card. If the control shuts down again when you try to jog, go to the next step.
• Check for loose motor cable; set power off, then disconnect and reconnect.
• If only one axis is giving you problems, do the following:
- Turn the control off and swap the cables to the motors, Z to X and X to Z. When you try
to jog in Z, the X motor should move; when you try to jog in X, the Z motor should move.
- Turn the control back on and try to jog in the good axis; if the “bad” motor moves, the
motor is probably ok and the motion control card is bad; if the motor doesn’t move, it’s
probably bad. Try the other axis and verify your conclusions.
- If you have questions about this procedure, call the factory (541-332-7004)
6.1
OmniTurn - Trouble shooting guide
Positioning Problems:
The slide has problems with repeating a size
Using Ctrl-C & Ctrl-H to diagnose repeatability problems
These two tests will determine if the problem is in the control or the axis motor without needing any additional tooling or indicators.
NOTE: before starting this check to see that all connections on the MC-2 and servo cables are clean and
have no obvious defects. Check to see all pins on the axis cables are level and not pushed back.
Ctrl-C and Ctrl-H are diagnostic tools to help determine the cause of repeatability problems.
If Ctrl-C does not indicate zero, the problem is internal to the MC2.
If Ctrl-H does not indicate zero, the problem could be the motor encoder or encoder circuitry on the MC2.
• Establish Home as normal (press 9, then Cycle Start), then move slightly away from
Home and establish Home again (press 9, then Cycle Start) to clear all registers.
• Load “smaltest”, which is a test program which makes a one inch circle inside a one
inch square centered one half inch from machine home. If “smaltest” is not available
just run the following program:
g90g94f300
x1
z-1
x0z0
m30
• Set Cycle Repeat and let it run twenty times. Go to Jog Mode when program is done.
• Press H key, then X, then Z. Now press and hold Ctrl Key, then press C Key. X and Z
readings should be zero. If the axis you’re having trouble with is not zero, the problem is
probably a bad motion control (MC2) card.
• Jog the slide a little ways from home, then Establish Home (press 9, then Cycle Start).
Press and hold Ctrl Key, then press H Key. X and Z readings should be zero. If the axis
you’re having trouble with is not zero, the problem could be a bad MC2 card or a bad
motor encoder.
• If the either Ctrl-C or Ctrl-H reports non-zero, press E-Stop to shut servos off, then swap
motor connections at back of CNC, and test again.
• If same axis reports non-zero, the problem is a bad MC2. If opposite axis reports nonzero, the problem is bad motor encoder.
A repeatability or size problem which persists despite good readings with Ctrl-C and Ctrl-H indicates a
mechanical problem: loose coupler, excess backlash, entire slide loose on ways, bad spindle, tooling, etc.
Review some of the suggestions on the next page for help in determining the mechanical cause of the
repeatablilty or size problem.
6.2
OmniTurn - Trouble shooting guide
Positioning Problems:
The slide has problems with repeating a size
•
•
•
•
•
•
•
The part is moving, check your work holding fixture
Be sure the tooling is held tightly
If you have an attachment, see if the slide is loose on the lathe
The ball screw nut has come loose in it’s housing
Loose encoder at the end of the axis motor
Loose coupling between the Servo motor and the ball screw for axis movement
Bad motor-tach-encoder; bad cable; bad motion control card
To see if it is a mechanical problem position the slide close to the spindle, mount an indicator on the slide
so it touches the headstock, zero out the indicator and then push and pull the slide with servos on. The
indicator should show some movement as you push and pull on the slide. However it should return to Zero
when you let go. If the slide does not come back to Zero then there is something loose, (Slide, Ballscrew nut,
Ballscrew taper roller bearing, etc).
To check if the slide for repetition try running a simple program that will show the type of error that you are
getting clearly. Run the program in “cycle repeat”:
g90g94f300(TEST PROGRAM FOR Z AXIS)
t30(Move the slide so indicator is 1 inch away from headstock)
x0z1
z.1
f20z0 (Creep up on the indicator)
g04f1(Read the indicator during the dwell)
f300z1
m30
g90g94f300(TEST PROGRAM FOR X AXIS)
t31(Move the slide so indicator is 1 inch away from headstock)
xlz0
x.1
x0f20
g04f1(Read the indicator during the dwell)
f300x1
M30
After running the program and studying the way the indicater repeats, or doesn’t, you should have an idea
of what your mechanical problem could be. If not, call the factory and describe the type of error that you
are seeing, for example: constant creeping in one direction, random movement in both directions, jumping.
6.3
OmniTurn - Trouble shooting guide
Computer won’t complete start-up
• You get a message that the OmniTurn is ”Initializing” and on the next line there is a
number: ie. 255.
• This indicates that the OmniTum Motion card is not found. This card has either come
loose and needs to be resettled or replaced. See notes on replacing system cards.
The slide crashes whenever a program is run
Problem
•
•
•
•
The HOME position has been improperly set
Either the tool offsets have not been set or have been lost
Your program is incorrect
Check the XnZn statements after a tool change, be sure you have one for each and they
are correct.
Solutions
•
•
•
•
•
Reset HOME
Check your tool offset table
Check your program
Reset the tool
Reload the tool offset table, see F10 in the automatic mode
Spindle won’t come on
•
•
•
•
•
Check that both Emergency stops are reset, on control face and operator station
Turn the ”spindle override” pot on the control face full CW
Turn the spindle switch on the control face to ”AUTO”
Check that the pin on the head of the hardinge to lock the spindle is pulled out
Push the red button on the spindle drive box.
This is a reset for the inverter used to vary the spindle speed. This could be tripped for a
number of reasons:
• Low or high voltage
• The duty cycle is too much; cycle time is too short and too often.
• Noise from coolant pump or other contacts
• Acceleration and Deacceleration are to short. Parameters can be set to change these:
call the factory (541.332.7004)
• Spindle drive box must be turned on (attachments only)
• Cables to the spindle drive box must be plugged in
• Check that MISC cable from the OmniTum CNC to Spindle Cabinet is connected
• Check that Operator Station Cable is connected to Spindle Cabinet
6.4
OmniTurn - Trouble shooting guide
OMNITURN MOTOR REPLACEMENT INSTRUCTIONS
Removal:
1. You need to have the room to access the motor coupling on X or Z axis in order to change the
motor, so first move the slide away from the motor.
2. Remove the sheet metal covering the slide nearest the motor you wish to change. On X-Axis this
cover is held with acorn nuts on 1/4-20 all-thread; on Z-Axis the cover is held by the three
phillips head screws through the scale. Remove the motor cover, which is held with one screw.
3. Loosen the cap screw holding the clamp on the coupling on the motor side. Turn the coupling as
required to access the allen screw.
4. Remove two 3/8-18 cap screws that hold the motor mount and motor to the base. You may have
to lightly tap the motor mount to remove it from the machine, as it is pinned with dowel pins.
5. Remove four 10-32 cap screws that hold the motor to the motor mount.
Replacement:
1. Attach the replacement motor to the motor mount with four 10-32 cap screws.
7. Notice the mark on the end of the motor shaft and another on the face of the motor. These
marks are aligned when the motor is at “home”. Turn the motor shaft so that the marks are 1/2
turn apart; that is 1/2 turn, or 0.100” from “home”. If X-Axis, push the slide all the way down,
against the stop; if Z-Axis, push the slide all the way to the right, against the stop.
8. Attach the motor mount to the base, slipping the shaft into the coupler. Don’t let the shaft turn
much. Tighten the motor mount to the machine before tightening the clamp on the coupler.
9. Replace the sheet metal as required.
10. After re-assembly, jog the axis to both ends and verify that the pointer will go just slightly past
“12” and “0”, then establish Home as usual. If the pointer does not indicate ”0”, loosen it and
move it to zero.
CAUTION - YOUR TOOL OFFSETS HAVE CHANGED. The slide will not home exactly where
used to: If you are set up on a job you should re-set all offsets.
6.5
OmniTurn - Trouble shooting guide
To Disassemble the CNC Control
Un-plug power cord, then remove the blue cover.
Remove six screws holding front panel.
“Upper Half”
It is not necessary to disconnect cables to frontpanel. Stow panel in notches at rear of top chassis
To gain access to the computer, disconnect all
cables at rear of CNC, remove eight screws and
set chassis aside.
“Lower Half”
6.6
OmniTurn - Trouble shooting guide
OmniTurn CNC “Top Half”
To adjust the spindle speed with a tach:
1. Issue M03 S0 from MDI; adjust SP MIN for no rotation.
2. Issue M03 S4000 (S3000 on attachments); adjust SP MAX
for correct rpm.
3. Re-check M03 S0 and adjust as required.
6.7
OmniTurn - Trouble shooting guide
OmniTurn CNC “Connect Card”
SPINDLE
MISC
Z MOTOR
X MOTOR
PWR CORD
12
12
8
4
8
4
SPIN SW
1
CN4
SPIN POT
TS4
AC IN
P
COMP
P
N
1
TS2
12
F
R
CN3
8
4
1
12
F
R
8
4
1
CN2
CN1
J3
THIPR
N
R1
R2
1CR
G
J4
J1
D1
REF LS
X
Z
N
N
X DRIVE
J9
CONNECT2A
N/C ELECTRONICS
PORT ORFORD,OR
J6
J7
ARM. RELY
C2
C1
J2
JP1
IN 00
IN 01
IN 02
IN 03
IN 04
IN 05
IN 06
+12SW
OUT 03
OUT 02
GND
CRDY
+12SO
+12PS
AC HI
AC SW
ESTP
CRT GND
CRT+
+12 IN
GND
TS1
POTS
J1
6.8
J2
BUS + 5
BUS - 4
BUS - 3
MOTOR + 2
MOTOR - 1
NC 1
SIGNAL GND 2
NC 3
SIGNAL+ 4
SIGNAL - 5
TACH - 6
TACH + (GND) 7
MTR CURR 8
CURR LIMIT 9
LS/ECB 10
INHIBIT 11
+ LIMIT 12
- LIMIT 13
FAULT OUT 14
EXT RESET 15
NC 16
LOOP GAIN
CURR LIMIT
TACH GAIN
SIGNAL GAIN
OmniTurn CNC Servo Amplifier
BALANCE
DRV
Z DRIVE
P
COMP
FAN
G
P
J5
OmniTurn - Trouble shooting guide
FLOPPY DRIVE
OmniTurn CNC “Bottom Half”
POWER
SUPPLY
P8
DRIVE BAY
P9
TF-486F
KEYBOARD JACK
CN8 (BLK wires to CENTER)
SIM
SIM
2
1
HARD DRIVE
IDE1
IDE2
FDC
COM1
CPU
COM2
PCI1
cpu fan
COM CABLES ISA1 SLOT
ISA2 SLOT
VGA CARD ISA3 SLOT
SPK
ISA4 SLOT
ISA5 SLOT
ISA6 SLOT
MC2B CARD AT ISA7 SLOT
CLOCK IC
MC2 CARD AT ISA8 SLOT
6.9
OmniTurn - Trouble shooting guide
Replacing the MC2 (Motion Control or C-AXIS cards)
To access these cards the entire “top half” of the control must be removed:
•
•
•
•
Unplug the power cord.
Disconnect the cables at the back (two axis motors, MISC, Encoder, PLC (optional)
Remove the blue cover
Remove front panel. (Two screws on the face and two on each side). Lift and set on top
of control. Disconnect the keyboard cable from lower half of control.
• Unplug all cables going to control “lower half”, being careful not to damage cables on
removal (12VDC power, Power Cord, RS232 Cable, Monitor Cable, C-Axis Encoder
Cable (opt), MC2B I/O Cable (opt), Spindle Encoder Cable, MC2 I/O Cable)
• To remove upper half of control, unscrew (8 screws).
• Carefully lift controls upper half of control and set aside.
MONITOR CABLE
12VDC POWER
RS232 CABLE
C-AXIS ENCODER CABLE (opt)
GREEN
C-Axis STICKER
COM 1 PORT
SPINDLE
ENCODER
CABLE
COM 2 PORT
115
KEYBOARD
CABLE
I/O CONNECTOR
POWER CORD
VIDEO CARD
MC2 I/O CABLE
MC2B I/O CABLE (opt)
With computer facing as shown, you will see one or two motion control cards (depending on model),
mounted on the right side. Remove top brace.
FOR MC2 CARD:
Remove 5” ribbon cable that is attached to this motion card and pull cable out of slot away from card.
Pull card straight up out of motherboard.
Place new card in same space, pushing straight down gently into motherboard.
Carefully work 5” cable back through slot and attach to MC2 card.
FOR MC2B (C AXIS) CARD:
Remove 5” ribbon cable that’s attached to this motion card.
Pull card straight up out of motherboard.
Place new card in same space, pushing straight down gently into motherboard.
Attach the MC2B’s 5” cable to card.
Replace top brace. Screw down tightly.
6.10
OmniTurn - Trouble shooting guide
Setting OMNITURN Servo Amps
This needs to be done if you ever have to replace a servo AMP
Tools required: A digital voltmeter (DMM or DVM)
Fine tipped probes, or paper clips
Jewlers common screwdriver or “tweaker”
1. With the OmniTurn control completely powered down, depress ”CONTROL ON” and allow the
control to boot up to the point where the message ”PLEASE TURN ON SERVOS” is displayed.
DO NOT TURN SERVOS ON AT THIS TIME
2. With the computer turned on, but the servos still turned off set the balance pot on the MC2 card
• To do this set your meter to measure DC voltage on lowest range, or Auto Range.
• Put your meter on pins 4 and 5 of the Signal plug. This is a brown connector on the top of the
card. Verify that your meter is making contact. If your meter tips are too large to make contact
with the wires in the plug gently insert a small wire (a paper clip will work) into the top of the
plug and test off of it.
• With meter on Brown and Black wires for X axis, adjust “Zero X” pot through hole in monitor
chassis for 0.000 ±.005V on your meter. Refer to monitor drawing on page 6-12 to locate acces
hole in monitor chassis.
• Put the meter on Green and Blue wires for Z axis, and adjust “Zero Z” pot through hole in
monitor chassis for 0.000 ± .005V on your meter.
The Adjustment Pots for balancing X
and Z axis with servos off are accessable
through hole in chassis:
TEST POINTS FOR STEP #2
Brn/Blk (X-Axis) and Blu/Grn (Z-Axis) wires
6.11
SP MAX
SIGNAL CONNECTOR
SP MIN
Servo amp “Signal Connector”
ZERO Z
MC2 ADJUSTING POTS
ZERO X
MONITOR
This completes setting the balance pots on the MC2 card. Proceed to next page.
OmniTurn - Trouble shooting guide
Setting OMNITURN Servo Amps, con’t
3. On both servo amps
adjust CURRENT LIMIT full CW (10 turns)
adjust COMP full CCW (10 turns)
adjust LOOP GAIN full CW (1 turn)
TURN SERVOS ON NOW
4. Turn the servos on now. Go to the Jog mode. The MC2 card has some built in diagnostics that
help balance the card. To set the offset for the drive press and hold the Ctr and then E. This will
pop up a window on the screen:
Set Test/Offset for Ø when slide is stopped
Set Ref In Gain for 100 in Med. Jog
Following Error
X:
Ø
Z:
Ø
5. Use a small screw driver to adjust the ”BALANCE” pot on the OMNITURN AMP. Turn the pot
until the value on the screen is 0. Do this procedure with the slide at rest, no motion. Do this for
both the X and Z axes.
6. Now use the screw driver to adjust the ”SIGNAL GAIN”. To do this move the slide at medium
jog speed (2 on Jog Menu). Adjust for 150 while jogging. Do this for both Axes. Re-adjust the
BALANCE for zero at rest (not jogging).
6. Next, adjust the TACH pot for 100 while jogging at medium speed (2 on Jog Menu). Do this for
both Axes. Re-adjust the BALANCE for zero at rest (not jogging).
7. Adjust the COMP pot CW ‘til some noise is heard in the servo motor, then turn CCW one turn. If
no noise is heard at rest, run the slide in Jog 3 and see if smoothness and response is improved
by adjustment. Best results are obtained by repeating a simple program which runs the slides
back and forth at 300 ipm and adjusting for best performance.
SIGNAL GAIN: Jog; set for 150±5;
TACH: Jog: set for 100±5
adjust Tach next .
after Signal Gain . Re-adjust Balance
COMP: Set CW 'til noisy, then CCW one turn
BALANCE: Set for 0 counts at rest
CURRENT LIMIT: Set Full CW
LOOP GAIN: Set Full CW (1 turn)
6.12
E
L
R
N
otbd5.dcd 10/06
D
M
DISC-1
[OPTIONAL]
PLC
I
F
P
E L DN I P S
230VAC IN
S
D
PALM BOX
S
DOWN
X
ENCLOSURE
6.13
WORK LAMP
COOLANT PUMP
R
SPIN
O
CONNECT
CARD
MISC
X
1
X-AXIS
LINE IN
I
PLC
COM2
RSR22
CONV
PLC (OPT)
T
0
Standard 5hp Inverter Drive
OmniTurn BLOCK DIAGRAM
(MC2)
MOTION
CONTROL
CARD
MC2 I/O
SPINDLE
Z-AXIS
Z AXIS MTR
SPINDLE
ENCODER
P
CNC CONTROL
Z AXIS AMP
X AXIS AMP
SPINDLE
MOTOR
E
MISCELLANEOUS CABLE (TB1)
M
T
1
AUXILLIARY (PLC) CABLE [OPTIONAL]
V
OmniTurn - Trouble shooting guide
OmniTurn - Trouble shooting guide
NOTE: This drawing includes optional components
and references not on all panels.
PLC X0 (rst)
(Option)
"NOT" FAULT
REVERSE
SPINDLE
SPINDLE
COOLANT
8
6
5
8
6
5
8
6
5
8
6
5
8
6
5
4
2
1
4
2
1
4
2
1
4
2
1
4
2
1
FLT
M03
M04
LINE
IN
PART CATCHER
OR AUX
M08
DISC1
1L1
3L2
5L3
Bussmann I
ON
CDNF32
M25
9
12
10
10
13
14
9
12
10
13
14
9
12
25
A
12
14
25
A
9
13
25
A
10
14
2
A
12
13
2
A
14
2
A
0
OFF
F6
F5
F4
F3
F2
F1
13
10
2T1
9
4T2
6T3
PLC 0V
(Option)
LIGHT IS ON WITH
NO FAULT
LIGHT IS ON
WHEN ACTIVE
PLC PWR
PLC PWR
(Option)
TB1
SP.ANALOG COM
1
SP.ANALOG
SP.ON/OFF 12VDC
3
PB E-STOP 12VDC
4
M03
5
M04
6
PLC 12V COM
+
7
PLC 12VDC
8
CTRL RDY 12VDC
9
M08
10
M25
11
M13
12
+
+
14
6
Slide Brake
3
Parts Catcher
+
13
M12
SP Air
4
+
15
2
Collet Unclamp
1
Collet Clamp
16
17
18
12V COM
19
20
TO PROVIDE CONSTANT LUBE TO COL CLSR
MOVE CC Lube COM FROM TB1-21 TO TB1-22
WHEN CYCLE TIME IS 40 SEC OR LESS.
USE SP OFF/AUTO SW TO STOP AIR FLOW.
+
21
12V COM
P.B. E-STOP
INHIBIT
CC Lube
22
23
24
CYCLE START
5
25
Alternate Conn
for Short Cycle
DOOR INTERLOCK
26
27
28
6.14-1.vsd
(ac_pnl5.dcd)
30
PARAMETERS w/5hp WEG
ACCEL=019: Set to 2.0 for Attachments
with Vari-Speed pulleys
DECEL=020: Set to 3.0 for Attachments
with Vari-Speed pulleys
-----------------------------------------------------------TO RE-INITIALIZE: SET NO 1 TO 8.
AFTER INITIALIZATION SET AS FOLLOWS:
001=3
011=135
058=3
002=1
012=230
106=1.7
003=1
019=1.0
109=250
004=2
020=1.0
110=23
007=1
036=12.9
001=1 (LOCK)
NOTE: If you are NOT using WEG 5hp motor,
036,106 & 110 must be set: refer to GPD315
manual,
page 2.3 thru 2.5
M
AC SPINDLE DRIVE PANEL JUN2007
29
FEEDHOLD
F1,F2,F3 = INVERTER
F4,F5,F6 = COOLANT PUMP
KEY SWITCH BYPASS
(SPINDLE DRV DOOR)
6.14
Omni Turn
0V
GND
J6
+12V IN
E-STOP
+
1
2
P
S
12V
RED
2
REF DES:
MC2 (2ACM)
+12SW GRN
B
1CR
T
RED
1
BLK
2
WHT
3
RED
YEL
8
YEL
BLK
2
WHT
3
2
9
+12V CTRL RDY
9
12
+12V SP.OFF/AUTO
12
1
10
SPINDLE ANALOG
10
11
SP.ANALOG COMMON
11
6.15
10
Dual
Palm
Buttons
4
33
4
4
3
11
ORG
BRN
4
GRN
25
24
30
Clamp
3
5
VIO
7
BRN
GRN
6
BLU
4
U
4
BLU
10
VIO
B
I
P
22
J8
SERR
U19
TS2
SPINDLE
OVERRIDE
6
M03
6
32
32 U17 (U12)
4
M04
4
15
15
U17 (U6)
5
M08
5
14
14
U17 (U7)
1
M25
1
16
16
U17 (U13)
8
INHIBIT
8
30
30 U16
CYCLE START
14
8
13
MOTION STOP
13
27
27 U16 (U8)
7
31
31
3
34
l
34 U17 (U13)
12
18
7
M12
3
M13
c
MISC CABLE
T
OPERATORS
12V
14
15
n
3
37 COMMON
THIPR-5
7
4
37
21
5
3
12
23
2
ORG
12
SP.OFF/AUTO
4
4
3
12V COMMON
9
E-STOP
1
2
19
STATION
C
S
N
PART OF
CONNECT
CARD
8
U15 (U8)
U17 (U12)
a
PART OF
37 PIN RIBBON
2
C
PART OF
M
C
ENCLOSURE
A
L
misc_cb1.dcd 3/08
L
OmniTurn - Trouble shooting guide
22
1
INVERTER DRIVE
E
C
n r uT i nm
O
S
I
M
AND OPERATORS STATION
OmniTurn - Trouble shooting guide
NOTE: This drawing includes optional components
and references not on all panels.
NOTE: All relay coils have diodes:
13
RLY
Op Plug
14
11
Spindle
OFF/AUTO
12VDC
Palm Box
E-Stop
TB1
Misc Plug
10
12
BLK
1
RED
BRN
RED
3
3
YEL
8
Spindle Analog to Inverter
2
Switched 12VDC
Spindle ON/OFF on Control
4
12V COM
Sp.Pres
4
CC Lube
8
M03
6
M04
6
5
BLU
13
13
7
GRN
14
M03
14
M04
20
5
D5
21
MOVE CC Lube COM FROM TB1-21 TO TB1-22
TO PROVIDE CONSTANT LUBE TO COL CLSR
WHEN CYCLE TIME IS TEN SEC OR LESS.
USE SP OFF/AUTO SW ON CNC TO STOP AIR FLOW.
6
22
10
19
8
6
NSK Air
7
Slide Brake
Ctrl Rdy (+12V)
9
9
YEL
PLC 12VDC
Part Catch
14
13
FLT
TB1
TB1
26
27
DOOR INTERLOCK
(GTJr ONLY)
BLU
2
Clamp
1
INV.FLT
9
3
Unclamp
M04
6
M03 10
M25
1
M08
5
M13
3
BLK
ORN
RED
13
11
10
13
M25
14
14
M08
12
D1
13
X2 (BLK)
14
Clamp
SP.FLT
(Drv Cab)
D2
M12
7
Unclamp
6
10
7
GRY
BRN
15
X1 (RED OR WHT)
16
D6 (PLC ISOLATION)
BLU
17
VIO
18
M03
M04
9
9
1
1
WHT
Palm Box
E-Stop
2
23
D3
29
Dual
Palm
Buttons
FEEDHOLD
5
4
13
PNK
ORG
GRN
INHIBIT
CYCLE START
8
BRN
D4
30
25
24
14
VIO
BLK
FLT
PLC X0 (RST)
6
BLK
10
PLC 0V
1
BLK
12V COM
ac_sch1b.dc2 NOV 2005
ADDED D6 PLC ISOLATION DIODE
19
9
1
12V COM
OmniTurn
2
WHT
AC SPINDLE CONTROL LOGIC
6.16
OmniTurn - Trouble shooting guide
NOTE: This drawing includes optional components
and references not on all panels.
12
8
10
6
9
5
F6
M
F5
F4
2A
COOLANT
PUMP
M08
10A
FT1
FT3
220VAC
110VAC
FT2
5A
(MOUNTED
ON XFMR)
STEP DOWN
XFMR
OUTLETS FOR
WORKLAMP AND CONTROL
FOR SINGLE PHASE
CONNECT LINE TO
L1 AND L2.
220VAC
LINE
SW1
L1
2
L2
4
L3
6
RED
F3
L1
T1
L2
T2
L3
T3
RED
F2
SPINDLE
MOTOR
M
BLK
F1
25A
Misc
Plug
Sp.Sig
0-10V
10
COM
11
TB1
RED
BLK
2
FR
1
FC
YASKAWA GPD315
(5HP)
S1
9
YEL
14
9
FLT
2
WHT
1
Closes
on
Fault
19
8
ORG
12
ORG
VIO 23
24
BLU
Spindle Reset
Opens
on
Fault
23
9
12V COM
S4
D6 (PLC isolation)
FLT
YEL
12
MB
DOOR
INTERLOCK
SP.FLT
(Drv Cab)
PalmBox
Connector
PalmBox
2
E-Stop
BLK
13
8
M04
S2
Ctrl Rdy
(+12V)
M03
RED
BLU
SC
BRN
ORG
MC
Parameters w/5hp WEG GT75 & GTJr
Attachment params in [brackets]
B1
Accel: No 19 = 1.0 [2.0]
Decel: No 20 = 1.0 [3.0]
To re-initialize: set No 1 to 8
DBR
B2
=1
019 = 1.0 [2.0]
=1
020 = 1.0 [3.0]
=2
036 = 12.9
=0
058 = 3
= 135 [120] 106 = 1.8
= 230
109 = 250
110 = 23
NOTE: If you are NOT using WEG 5hp
motor, 036, 106 & 110 must be set: refer
to GPD315 manual, page 2-3 thru 2-5.
002
003
004
007
011
012
DBR = 30 OHMS 500W
[DBR = 30 OHMS 250W]
OmniTurn
OCT 2006
AC SPINDLE DRIVE (GPD 315 5HP)
gpd5_sc.dc2
6.17
TS4
TS4
N
AC
SW
P
TS4
P
LINE
N FILTER
G
4
0V
CONTROL
ON
E-STOP
GRN
WHT
AC BLK
HI
13
P
COMP
1
1
12
12V
A
TS1
TS4
ESTP
P
SERVO POWER SUPPLY
TO SERVO AMPS
1
N
N
+12V IN
J6
GND
CRT+
H
12
12
MONITOR
J7
CRT
GND
DRV
G
RED
110VAC
RED +12PS
GRN
LINE
2
22
1
24
23
GRN
BLU
BLU
+12SW
8
12SO
12V
12
J9
X2
HR
MTR
X2
CONTROL
ON
SERVOS
ON
X1
X1
X2
CYCLE
START
1CR
SP.OFF/AUTO
X2
MOTION
STOP
21
22
J8
Armature
Relay
1CR
REF DES:
MC2 (2ACM)
13
X1
ORG
X1
6.18
SERVOS
ON
RED/BLK OUT03
13
13
WHT/BLK OUT02
33
33 U17 (U7)
9
9
U15 (U9)
19
19
U41 (U11)
37
37 COMMON
WHT IN02
1
14
3
U17 (U6)
1CR
10
BLK CRDY
:
E
T
O
N
TS1 AND TS4 ARE PART OF CONNECT CARD
THIS DWG APPLICABLE TO CNC CTRL S/N WITH "AM" SUFFIX
2CR
14
6
ORG GND
JOG STICK
3
Z- 23
2 4 NO
GRN/WHT IN06
11
11
Z+ 21
2 2 NC
RED/WHT IN05
29
29 U16 (U14)
X- 14
1
BLK/WHT
IN04
10
10
X+ 12
11 NC
BLU/BLK
IN03
28
28 U16 (U8)
8
8
27
27 U16 (U8)
NO
CYCLE
START
24
GRN/BLK IN00
13
SPINDLE
OVERRIDE
U15 (U14)
U15 (U8)
23
MOTION
STOP
3
U15 (U15)
ORG/BLK IN01
1
BLU/RED TOP
ORG/RED TS2
WHT/RED
PART OF
CONNECT
CARD
PART OF
37 PIN RIBBON
PART OF
MC2 CARD
BOT
FRONT PANEL INTERFACE
fp_sch4.dc2 jun 2002
OmniTurn - Trouble shooting guide
F1
TS1
COMPUTER &
POWER SUPPLY
P
N
A
F
10A
N
TS1
FAN
OmniTurn - Trouble shooting guide
10A
F1
110VAC
LINE
LINE
FILTER
CONTROL
ON
E-STOP
TS4 TS1
P
P
N
AC
HI
14
13
12
TS4
P
SERVO POWER SUPPLY
TO SERVO AMPS
ESTP
N
G
TS1
11
72VDC
G
N
0V
DRV
NOTE:
TS1 AND TS4 ARE PART OF CONNECT CARD
THIS DWG APPLICABLE TO CNC CTRL S/N WITH "A" SUFFIX
PART OF
MC2 CARD
GND
J6
+12PS
12
+12SW GRN
12V IN
12V 12
24
ARMATURE
RELAY
23
21
22
1CR
12SO
1CR
2CR
U15 9
RED
9
IN02
BLU
WHT
13
1CR
U41 19
19
37
37
COM
CRDY
BLK
GND
ORG
CONTROL
ON
SERVOS
ON
14
0V=ENABLE; GRN LIGHT ON AMP
12V=INHIBIT
0V
72VDC
U19 17
18
17
18
X AXIS SIG
COMMON
P2
(DB9)
7
1
2
3
4
ARMATURE
RELAY
YEL
BLK
BRN
RED
ORG
CNC
REAR
PANEL
SERVOS
ON
2CR
11
4
5
2
4
SERVO
5 AMPLIFIER
7 (X AXIS)
6
1
5
WHT
X AXIS
OVERLOAD
X AXIS
CONN
WHT
9
Plus on Pin 9 = CW
rotation viewing face.
SNUBBER
BLK
2
3
4
2
3
4
A
B
Z
1
5
1
5
+5V
COM
9
U19 35
37
35
37
Z AXIS SIGNAL
COMMON
P3
(DB9)
7
1
2
3
4
ARMATURE
RELAY
WHT
GRN
BLU
VIO
GRY
11
4
5
2
4
SERVO
5 AMPLIFIER
7 (Z AXIS)
6
1
2CR
8
WHT
21
22
23
20
24
12
8
BLK
A
B
Z
+5V
COM
9
3
4
1
2
5
14
GRN
(DASHED LINES ARE PASS-THRU TRACES ON CONNECT CARD)
U5
U7
U7
L1
8
7
6
10
9
8
7
6
10
9
A
B
Z
+5V
COM
SERVO
MOTOR
ENCODER
Z MTE
BLK
M
WHT
+
WHT
T
+
BLK
A
B
Z
+5V
COM
GND
SPINDLE
CONN
3
4
1
2
5
PART OF
10 PIN RIBBON
GRN
WHT
YEL
RED
BLK
SHIELD
Plus on Pin 9 = CW
rotation viewing face.
SNUBBER
6
PART OF
37 PIN RIBBON
B
Z
+5V
COM
GND
Z AXIS
CONN
WHT
7
21
22
23
20
24
A
X AXIS
OVERLOAD
TACH
U6
U6
U3
L1
+
T
BLK
3
4
1
2
5
14
GRN
+
WHT
6
0V=ENABLE; GRN LIGHT ON AMP
12V=INHIBIT
0V
72VDC
M
WHT
7
TACH
U5
U4
U3
L1
X MTE
BLK
8
GRN
WHT
YEL
RED
BLK
SHIELD
SERVO
MOTOR
ENCODER
ENCODER
CONNECTOR
A BRN
B BLU
Z ORG
+5V RED
COM BLK
GND SHLD
A
B
C
D
F
F
SPINDLE
ENCODER
SPINDLE ENCODER CABLE
PART OF
MC2 CARD
PART OF
CONNECT CARD
OmniTurn
srvo_sch.dcd 1/2007
(changed AB overloads for panel mount)
(corrected Connect Card circuitry)
(corrected tach & motor colors)
SERVO DRIVE INTERFACE
6.19
OmniTurn - Trouble shooting guide
Four Way
Dual Solenoid
Ex
To Collet Clamp
R
In
IN
Regulator
(Adj)
FR
To Collet UnClamp
Four Way
Single Solenoid
Filter/Regulator
To Parts Catcher
Ex
To Parts Catcher
In
Three Way
Ex
In
R
To Spindle Bearings
Regulator
(6psi)
Ex
To Collet Closer Lube
In
R
Regulator
(15psi)
Ex
To Slide Brake
In
GT75 AIR
3/08 gt_air3.cdd
6.20
I
R
R
otbdcxy.dcd 10/06
M
230VAC IN
F
S
[OPTIONAL]
PLC
DISC-1
PALM BOX
SPINDLE
D
S
DOWN
X
ENCLOSURE
1
6.21
T
WORK LAMP
P
E
O
COOLANT PUMP
E
D
C
N
Z AXIS AMP
X AXIS AMP
P
1
O
SPIN
C
CONNECT
CARD
MISC
C
X
E
X-AXIS
(COM1)
RS232
A
PLC (OPT)
MOTION
CONTROL
CARD "B"
(MC2B)
(MC2)
MC2B
I/O
COM2
RSR22
CONV
PLC (OPT)
SPINDLE ANALOG
SPEC
MOTION
CONTROL
CARD
I
T
0
L
C-Axis Yaskawa (AC Servo)
OmniTurn BLOCK DIAGRAM
MC2 I/O
SPINDLE ENCODER
Z-AXIS
A
Z AXIS MTR
SPINDLE
ENCODER
C-AXIS ENCODER
C-AXIS
MOTOR
MISCELLANEOUS CABLE (TB1)
M
T
S
M
AUXILLIARY (PLC) CABLE [OPTIONAL]
C
OmniTurn - Trouble shooting guide
OmniTurn - Trouble shooting guide
NOTE: This drawing includes optional components
and references not on all panels.
LINE IN
"NOT" FAULT
SPINDLE
ENABLE
COOLANT
PART CATCHER
OR AUX
8
6
5
8
6
5
8
6
5
8
6
5
4
2
1
4
2
1
4
2
1
4
2
1
DISC1
1L1
3L2
5L3
Bussmann I ON
FLT
SPEN
M08
M25
CDNF32
0
OFF
TB1
14
12
10
13
14
9
12
10
13
14
9
12
13
14
9
12
10
13
10
2T1
9
4T2
6T3
1
SP.ON/OFF 12VDC
3
PB E-STOP 12VDC
4
+
7
12
14
17
18
12V COM
+
15
16
Collet Unclamp
1
Collet Clamp
F6
F5
F4
F3
F2
F1
MOVE CC Lube COM FROM TB1-21 TO
TB1-22 TO PROVIDE CONSTANT LUBE TO
COL CLSR, WHEN CYCLE TIME IS 10 SEC
OR LESS. USE SP OFF/AUTO SW ON
CNC TO STOP AIR FLOW.
+
21
P.B. E-STOP
2
F1,F2,F3 = INVERTER
F4,F5,F6 = COOLANT PUMP
19
20
12V COM
Parts Catcher
+
13
M12
3
25A
M13
+
25A
11
Slide Brake
25A
10
6
2A
9
M25
SP Air
+
8
M08
4
2A
PLC 12VDC
CTRL RDY 12VDC
PLC PWR
PLC PWR
5
6
PLC 12V COM
LIGHT IS ON
WHEN ACTIVE
2A
SPEN
LIGHT IS ON WITH
NO FAULT
22
23
5
CC Lube
Alternate Conn
for SHORT CYCLE
M17
(SOCKET)
25
INHIBIT
26
M23
M27
8
6
5
8
6
5
8
6
5
8
6
5
4
2
1
4
2
1
4
2
1
4
2
1
13
14
13
14
13
14
9
12
9
12
9
12
24
CYCLE START
M21
(SOCKET)
DOOR INTERLOCK
27
28
M
29
FEEDHOLD
30
KEY SWITCH BYPASS
(SPINDLE DRV DOOR)
14
12
10
1
2
3
4
10
5
6
7
8
10
13
10
9 10 11 12 13 14 15 16
TB2
M17
M21
M23
M27
BRN
RED
GRN
WHT
BLU
ORG
YEL
BLK
GRY
SERVO SPINDLE DRIVE PANEL 10/2004
OmniTurn
acs_lb21.dcd jul 2004
6.22
+12V
IN07
IN06
COM
IN05
9
4
3
6.23
BLU
GRN
VIO
BRN
ORG
BLK
YEL
WHT
MISCELLANEOUS CABLE
AND OPERATORS STATION
C-AXIS YASKAWA
OmniTurn
OPERATORS
STATION
(PALM BOX)
Unclamp
3
4
3
4
Clamp
3
4
4
4
33
4
3
Dual
Palm
Buttons
2
1
E-STOP
RED
7
6
10
5
4
3
8
2
1
AMP
CPC
(OPSTA)
OPENS
on FLT
COM
(0VDC)
SPINDLE DRIVE
YASKAWA
SGDH-50
CLOSED
w/M05
SPEN
TB1
1
5
7
10
11
25
24
30
15
12
18
8
19
22
2
3
4
23
9
M23
M17
TB2
10
9
8
7
6
5
4
3
2
1
PWM / SP.FLT
INTERFACE CCA
SP.FLT
CN5-1
CN3-2
CN3-1
SPINDLE DRIVE ENCLOSURE
M27
M21
CN2-1
1CN-6
+12V
TB1-9
CN2-2
1CN-5
CN4-1
CN5-2
FLT RELAY
CN4-3
SPEED & POSITION
+12V
(FLT-14)
1CN-31
1CN-32
13
19
TB1
SPEC CABLE
IN07
+12V
IN06
ORG
RED
12V COM
BLK
WHT
M27
IN05
M23
BLU
GRY
M21
YEL
M17
GRN
SERVO PWM
MISC CABLE
M13
M12
MOTION STOP
CYCLE START
INHIBIT
BRN
BLK
M08
5
1
8
14
13
7
3
M25
SPEN
6
12
+12V CTRL RDY
9
+12V SP.OFF/AUTO
12V COMMON
2
WHT
AMP
CPC
(MISC)
14
10
15
11
12
13
16
8
9
7
6
AMP
CPC
(SPEC)
5
1
8
14
13
7
3
6
12
9
2
AMP
CPC
(MISC)
CNC CONTROL
22
21
E-STOP
12 12V
37 COMMON
34
31
27
8
30
16
14
32
21
CN1-3
PART OF
CAX CARD
CN1-2
PWM DRIVER
BOARD
acs_misc.dcd 10/2004
12
30
11
5
29
15
14
13
33
CN1-1
CN2-2
CN2-1
PART OF
MC2 CARD
34 U17
31 U17
27 U16
8 U15
30 U16
16 U17
14 U17
32 U17
PART OF
37 PIN RIBBON
22
SP.OFF/AUTO
37
12
GRN
RED
PART OF
37 PIN CABLE
J8
+12SW
PART OF
CONNECT
CARD
1CR
+12PS
0V 12V
J6 +12V IN
GND
OmniTurn - Trouble shooting guide
OmniTurn - Trouble shooting guide
NOTE: This drawing includes optional components
and references not on all panels.
NOTE: All relay coils have diodes:
13
RLY
TB1
Op Plug
14
Spindle
OFF/AUTO
12VDC
Palm Box
E-Stop
3
YEL
8
Switched 12VDC
Spindle ON/OFF on Control
4
4
12V COM
8
SPEN
CC Lube
BRN
RED
3
Sp.Pres
12
6
5
BLU
13
SPEN
14
20
5
D5
SPEN
6
21
10
22
MOVE CC Lube COM FROM TB1-21 TO TB1-22
TO PROVIDE CONSTANT LUBE TO COL CLSR
WHEN CYCLE TIME IS TEN SEC OR LESS.
USE SP OFF/AUTO SW ON CNC TO STOP AIR FLOW.
8
6
NSK Air
7
DOOR INTERLOCK
(GTJr ONLY)
Slide Brake
Ctrl Rdy (+12V)
9
9
YEL
14
FLT
13
26
27
PLC 12VDC
BLU
Part Catch
9
3
M25
M08
1
5
BLK
ORN
13
11
10
13
M08
M25
14
CN4-1
14
FLT
9
M13
Unclamp
Clamp
CN5-1
1CN-31
12
D1
SRVO.FLT
13
OPENS ON FLT
1CN-32
14
1
SP.
FLT
CN4-3
2
D2
M12
Clamp
3
RED
CN5-2
7
Unclamp
6
7
GRY
BRN
15
SP.FLT
(Drv Cab)
16
BLU
17
SPEN
10
Palm Box
E-Stop
VIO
18
9
1
WHT
2
23
D3
29
Dual
Palm
Buttons
FEEDHOLD 13
5
4
ORG
GRN
INHIBIT
8
CYCLE START 14
1
PNK
BRN
30
25
FLT
24
1
9
VIO
BLK
12V COM
D4
19
12V COM
2
WHT
OmniTurn
acs_sch1.dcd oct 2004
YASKAWA SERVO SPINDLE CONTROL LOGIC
6.24
OmniTurn - Trouble shooting guide
12
8
10
6
9
5
F6
M
F5
F4
COOLANT
PUMP
M08
10A
FT1
FT3
220VAC
110VAC
FT2
5A
STEP DOWN
XFMR
(MOUNTED
ON XFMR)
OUTLETS FOR
WORKLAMP AND CONTROL
SW1
L1C
SP.CAB
25A
L1
2
L2
4
L3
6
RED
F3
L1
WHT
F2
L2C
L2
BLK
F1
YASKAWA
SGDH-50
L3
220VAC
LINE
B1
EXTERNAL REGEN
8.5 OHMS
250W
E
B2
SRVO.FLT
DC COM
1CN-32
(TB1-22)
CN4-2
12VDC
1CN-31
(FLT-14)
Spec
Plug
Pos.Sig
PWM
COM
6
7
CN4-3
CN4-1
BLK
SFLT
CN3-2
WHT
CN2-2
TB1
MOTOR/TACH
E
U
RED
V
WHT
W
BLK
M
1CN-5
CSPWM2 CCA
CN3-1
SP.FLT
DC COM
Opens
on
Fault
CN5-1
CN2-1
1CN-6
CN5-2
2CN
22
SPEN
Misc
Plug
Ctrl Rdy
(+12V)
9
YEL
2
BRN
23
WHT
Misc
Plug
1
8
26
27
1CN-40
Closes
on
Fault
1CN-42
TB1
1
2
FLT
2
13
TB1
MAGNETIC DOOR INTERLOCK
ON HATCH OF GT-Jr
(GT-75 HAS JUMPER HERE)
9
DC COM
FLT
SP.FLT
(Drv Cab)
Palm
Box
PB E-STOP
14
9
TB1
7
DC COM
1CN-33
B
1CN-19
Z
1CN-1
(SPEN-1)
AC SERVO SPINDLE DRIVE
acs_sch2.dcd oct2004
YASKAWA
6.25
8
12
ORG
Spindle Reset
A
1CN-35
GRN
POSITIONING
ENCODER
OUT
1CN-44
1CN-32
VIO
23
24
(TB1-28)
BLU DC COM
(FLT-1)
OmniTurn
5HP SPINDLE DRIVE
YASKAWA GPD315
8 8 8 8
DSPL
RUN
MIN
DATA
ENTER
MAX
STOP
RESET
<
BLK FAULT to FLT-13
BRN FAULT TO FLT-1
RED TO MO3-8
YEL TO MO4-8
VIO TO RESET PB-23
BLU TO RESET PB-24
ORG TO MO3-12, MO4-12
CLR ANALOG SIGNAL
BLK ANALOG COMMON
<
MB:
MC:
S1:
S2:
S4:
SC:
SC:
FR:
FC:
5.5
mm
MAMBMC CONTACT OUTPUT
1
2
SW1
ON
S5 S6 S7 P1 P2 R+ R- FS FR FC
S1 S2 S3 S4 SC PC S+ S- AM AC RP
SW1
SW2
OFF 1
ON
PNP
I
V 2
NPN
S5 S6 S7 P1 P2 R+ R- FS FR FC
LINE IN
DBR
RED
WHT
S1 S2 S3 S4 SC PC S+ S- AM AC RP
BLK
MA MB MC
MOTOR OUT
PARAMETERS w/5hp WEG
ACCEL=019
DECEL=020
-----------------------------------TO RE-INITIALIZE: SET NO 1 TO 8.
AFTER INITIALIZATION SET AS FOLLOWS:
001=3
011=120
036=12.9
002=1
012=230
106=1.8
003=1
019=1.0
109=250
004=2
020=1.0
110=23
007=0
NOTE: If you are NOT using WEG 5hp motor,
036,106 & 110 must be set: refer to GPD315 manual,
page 2.3 thru 2.5
6.26
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