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SIEMENS MAINTENANCE MANUAL
SIEMENS SINUMERIK 840D CONTROL
MAINTENANCE MANUAL
FADAL MACHINING CENTERS, LLC
Corporate Office.......................................phone (818) 407-1400............................. fax (818) 407-0020
Service / Parts..........................................phone (818) 727-2100............................. fax (818) 407-1004
Programming Support ..............................phone (818) 727-2100............................. fax (818) 407-0061
support@fadal.com
20701 Plummer Street, Chatsworth, California 91311 USA
OCTOBER 2005

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   Summary of Contents for Siemens SINUMERIK 840D

  • Page 1

    SIEMENS MAINTENANCE MANUAL SIEMENS SINUMERIK 840D CONTROL MAINTENANCE MANUAL FADAL MACHINING CENTERS, LLC Corporate Office........phone (818) 407-1400......fax (818) 407-0020 Service / Parts..........phone (818) 727-2100......fax (818) 407-1004 Programming Support ......phone (818) 727-2100......fax (818) 407-0061 support@fadal.com 20701 Plummer Street, Chatsworth, California 91311 USA...

  • Page 2

    FADAL MACHINING CENTERS MAN_0126_R1...

  • Page 3: Table Of Contents

    SIEMENS MAINTENANCE MANUAL TABLE OF CONTENTS 1.0 SPECIFICATIONS ............................. 1 1.1 ILLUSTRATIONS & DATA FOR ALL VMC MODELS ................2 ............................2 1.1.1 VMC 2216 1.1.2 VMC 3016 ..............................................................6 1.1.3 VMC 4020 ............................8 1.1.4 VMC 6030 ............................10 1.1.5 VMC 8030...

  • Page 4

    FADAL MACHINING CENTERS ..........................44 3.1.4 POWER CHECK 3.2 TRANSFORMER TAPPING ........................49 3.3 PHASE CONVERTER ROTARY ......................50 3.4 LEVELING ............................51 ........................51 3.4.1 FOR ALL BOX WAY VMCS 3.5 HOLD DOWN CLAMPS ........................54 3.6 OPTICAL FIBER CABLE HANDLING ....................55 3.7 COUPLER INSTALLATION ON AXIS MOTOR OR BALLSCREW .............56 3.8 PENDANT INSTALLATION .........................59 3.9 GENERAL ............................60 3.10 CHIP CONVEYOR ..........................61...

  • Page 5

    SIEMENS MAINTENANCE MANUAL ........................85 5.3.2 FIXTURES / SUB PLATES ........................85 5.3.3 MACHINE ASSEMBLIES 5.4 SOLVING THE THERMAL EXPANSION PROBLEM ................87 ......................87 5.4.1 GENERAL CONSIDERATIONS .......................... 87 5.4.2 AMBIENT SOURCES 5.5 READING STATUS GROUP ....................... 88 5.6 VMC MAINTENANCE ......................... 89 ..........................

  • Page 6

    FADAL MACHINING CENTERS TABLE OF CONTENTS MAN-0126_R1...

  • Page 7: Specifications

    SIEMENS MAINTENANCE MANUAL 1.0 SPECIFICATIONS This section provides dimensions/specifications of machines (VMCs 2216, 3016, 4020, 6030, 8030, 3020, 4525, and 6535). Dimensions represent in inches and millimeters. OCTOBER 2005 SPECIFICATIONS...

  • Page 8: Illustrations & Data For All Vmc Models

    FADAL MACHINING CENTERS 1.1 ILLUSTRATIONS & DATA FOR ALL VMC MODELS 1.1.1 VMC 2216 Figure 1-1: VMC 2216 NOTE Dimensions represented in inches and [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 9

    SIEMENS MAINTENANCE MANUAL Table 1-1: VMC 2216 Specifications 2216 SPECIFICATIONS 2216 STANDARD 2216 METRIC Table Size 39" x 16" 750 mm x 406 mm Floor to Table 31" 787 mm T-Slots (No. x Width x Span) 3 x .708" x 4.33"...

  • Page 10: Vmc 3016

    FADAL MACHINING CENTERS 1.1.2 VMC 3016 Figure 1-2: VMC 3016 NOTE Dimensions represented in inches and [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 11

    SIEMENS MAINTENANCE MANUAL Table 1-2: VMC 3016 Specifications 3016 SPECIFICATIONS 3016 STANDARD 3016 METRIC Table Size 39" x 16" 750 mm x 406 mm Floor to Table 31" 787 mm T-Slots (No. x Width x Span) 3 x .708" x 4.33"...

  • Page 12: Vmc 4020

    FADAL MACHINING CENTERS 1.1.3 VMC 4020 Figure 1-3: VMC 4020 NOTE Dimensions represented in inches and [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 13

    SIEMENS MAINTENANCE MANUAL Table 1-3: VMC 4020 Specifications 4020 SPECIFICATIONS 4020 STANDARD 4020 METRIC Table Size 48" x 20" 1,219mm x 508 mm Floor to Table 32" 813 mm T-Slots (No. x Width x Span) 5 x .708" x 3.74"...

  • Page 14: Vmc 6030

    FADAL MACHINING CENTERS 1.1.4 VMC 6030 Figure 1-4: VMC 6030 NOTE Dimensions represented in inches & [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 15

    SIEMENS MAINTENANCE MANUAL Table 1-4: VMC 6030 Specifications 6030 SPECIFICATIONS 6030 STANDARD 6030 METRIC Table Size 62.5 x 30" 1,588mm x 762 mm Floor to Table 36" 914 mm T-Slots (No. x Width x Span) 5 x .708" x 5.512"...

  • Page 16: Vmc 8030

    FADAL MACHINING CENTERS 1.1.5 VMC 8030 Figure 1-5: VMC 8030 NOTE Dimensions represented in inches & [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 17

    SIEMENS MAINTENANCE MANUAL Table 1-5: VMC 8030 Specifications 8030 SPECIFICATIONS 8030 STANDARD 8030 METRIC Table Size 82.5" x 30" 2,096 mm x 762 mm Floor to Table 36" 914 mm T-Slots (No. x Width x Span) 5 x .708" x 5.512"...

  • Page 18: Vmc 3020

    FADAL MACHINING CENTERS 1.1.6 VMC 3020 Figure 1-6: VMC 3020 NOTE Table and head shown at cold start position. Top of head cover at cold start position. Add 18” for max operating height. Subtract 2” for install height. Dimensions represented in inches & [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 19

    SIEMENS MAINTENANCE MANUAL Table 1-6: VMC 3020 Specifications 3020 SPECIFICATIONS 3020 STANDARD 3020 METRIC Table Size 40.5" x 20" 1,029 mm x 508 mm Floor to Table 31" 787 mm T-Slots (No. x Width x Span) 5 x .708" x 3.74"...

  • Page 20: Vmc 4525

    FADAL MACHINING CENTERS 1.1.7 VMC 4525 Figure 1-7: VMC 4525 NOTE Table and head shown at cold start position. Top of head cover at cold start position. Add 18” for max operating height. Subtract 2” for install height. Dimensions represented in inches & [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 21

    SIEMENS MAINTENANCE MANUAL Table 1-7: VMC 4525 Specifications 4525 SPECIFICATIONS 4525 STANDARD 4525 METRIC Table Size 53.5" x 25" 1,359mm x 635mm Floor to Table 31" 787mm T-Slots (No. x Width x Span) 5 x .708" x 4.92" 5 x 18mm x 125mm Cutting Feed Rate .01-400 ipm (600 ipm @ 150%)

  • Page 22: Vmc 6535

    FADAL MACHINING CENTERS 1.1.8 VMC 6535 SIDE VIEW FRONT VIEW TOP VIEW - BASE TOP VIEW Figure 1-8: VMC 6535 NOTE Dimensions represented in inches & [millimeters]. SPECIFICATIONS MAN-0126_R1...

  • Page 23

    SIEMENS MAINTENANCE MANUAL Table 1-8: VMC 6535 Specifications 6535 SPECIFICATIONS 6535 STANDARD 6535 METRIC Table Size 74.8" x 26.5" 1,899mm x 673.1mm Floor to Table 40.3" 1024mm T-Slots (No. x Width x Span) 5 x .708" x 4.92" 5 x 18mm x 125mm Cutting Feed Rate .01-400 ipm (600 ipm @ 150%)

  • Page 24: Fadal Bolt Torque Specifications

    FADAL MACHINING CENTERS 1.2 FADAL BOLT TORQUE SPECIFICATIONS Table 1-9: Fadal Bolt Torque Specifications COMPONENT MODEL LOCATION BOLT SIZE TORQUE UNIT COLUMN COLUMN TO BASE 5/8"-11 X X.50 HHB FT-LBS COLUMN COUPLER SET SCREW 1/4"-20 X 0.50 SHSS IN-LBS COLUMN Z B/S MOUNT IN BACK 3/8"-16 X X.XX HHB FT-LBS...

  • Page 25: 2216 & 3016 Table

    SIEMENS MAINTENANCE MANUAL 1.2.1 2216 & 3016 TABLE Figure 1-9: 2216 & 3016 Table Table 1-10: 2216 & 3016 Table Dimensions VMCS 2216 & 3016 16.00" (406.4 mm) 40.50" (1028.7 mm) 36.00" (914.4 mm) 3.67" (93.22 mm) 4.33" (109.98 mm)

  • Page 26: 3020 & 4525 Table

    FADAL MACHINING CENTERS 1.2.2 3020 & 4525 TABLE Figure 1-10: 3020 & 4525 Table Table 1-11: 3020 & 4525 Table Dimensions VMC 3020 VMC 4525 20.00” (508 mm) 25.00” (635 mm) 41.75” (1060.45 mm) 54.76” (1390.90 mm) 36.00” (914.40 mm) 49.00”...

  • Page 27: 4020 Table

    SIEMENS MAINTENANCE MANUAL 1.2.3 4020 TABLE Figure 1-11: 4020 Table Table 1-12: 4020 Table Dimensions VMC 4020 20.00” (508 mm) 49.00” (1244.66 mm) 43.50” (1104.9 mm) 2.52” (64 mm) 3.740” (95 mm) OCTOBER 2005 SPECIFICATIONS...

  • Page 28: 6030 Table

    FADAL MACHINING CENTERS 1.2.4 6030 TABLE Figure 1-12: 6030 TABLE Table 1-13: 6030 Table Dimensions VMC 6030 30.00” (762 mm) 63.50” (1612.9 mm) 58.00” (1473.2 mm) 3.976” (101 mm) 5.512” (140 mm) SPECIFICATIONS MAN-0126_R1...

  • Page 29: 8030 Table

    SIEMENS MAINTENANCE MANUAL 1.2.5 8030 TABLE Figure 1-13: 8030 Table Table 1-14: 8030 Table Dimensions VMC 8030 30.00” (762 mm) 83.50” (1612.9 mm) 78.00” (1473.2 mm) 3.976” (101 mm) 5.512” (140 mm) OCTOBER 2005 SPECIFICATIONS...

  • Page 30: 6535 Table

    FADAL MACHINING CENTERS 1.2.6 6535 TABLE Figure 1-14: 6535 Table Table 1-15: 6535 Table Dimensions VMC 6535 35.00” (889 mm) 74.76” (1899 mm) 69.50” (1765 mm) 2.74” (70 mm) 4.92” (125 mm) SPECIFICATIONS MAN-0126_R1...

  • Page 31: T-slots For All Tables

    SIEMENS MAINTENANCE MANUAL 1.2.7 T-SLOTS FOR ALL TABLES METRIC Figure 1-15: T-Slots for All Tables Table 1-16: Metric T-Slot Dimensions for All Tables T-SLOT DIMENSIONS 0.7086” - 0.7093 ” (17.998 mm - 18.016 mm) 1.190” - 1.250” (30.22 mm - 31.75 mm) 0.482”...

  • Page 32: Recommended Mainline Fuses / Circuit Breakers

    FADAL MACHINING CENTERS 1.3 RECOMMENDED MAINLINE FUSES / Table 1-17: Circuit Breakers for the New Sheet Metal CIRCUIT BREAKERS SPINDLE 380-415 V 480 V TYPE 3 PHASE 3 PHASE 5 HP 10 HP 50 Taper 70 A SPECIFICATIONS MAN-0126_R1...

  • Page 33: Pre-installation Procedures

    SIEMENS MAINTENANCE MANUAL 2.0 PRE-INSTALLATION PROCEDURES OCTOBER 2005 PRE-INSTALLATION PROCEDURES...

  • Page 34: Foundation

    FADAL MACHINING CENTERS 2.1 FOUNDATION WARNING! The VMC MUST be placed on a surface that will support the combined weight of the VMC, options, fixtures, and tooling, etc. (refer to the VMC Specifications section at the beginning of this manual for VMC weights). 1.

  • Page 35

    SIEMENS MAINTENANCE MANUAL Installation). For high performance machines, the machine must be bolted to achieve maximum performance. Figure 2-2: Anchor Stud Installation Table 2-1: Isolation Pad Dimensions MACHINE A (DEPTH) B (WIDTH) 2216/ 3016 7ft 9in 9ft 6in 4020 8ft 7in...

  • Page 36

    FADAL MACHINING CENTERS 4. Use proper eye and hearing protection while performing this step. Remove dust and rubble from the hole with compressed air and brush. 5. Insert capsule in the hole, either end first. 6. Select proper 1/2” SQ. drive socket and attach to sup-r-setter. 7.

  • Page 37

    SIEMENS MAINTENANCE MANUAL thicker with # 4 rebar 18” on center three inches off the ground. For stress lines in the concrete make sure they are such that they do not go under any of the machines. (If they do, this will eventually defeat the purpose of the pad.) The top of the felt, if used, should be sealed with a caulking compound to prevent oils and coolants from penetrating the ground.

  • Page 38: Shipping Dimensions

    FADAL MACHINING CENTERS 2.2 SHIPPING DIMENSIONS Table 2-2: VMC Shipping Dimensions LENGTH WIDTH HEIGHT WEIGHT Z MTR DWN 8030 17ft 8in 8ft 8in 10ft 2in 19,000lbs 8ft 8in 6535 14ft 9in 8ft 10in 11ft 3in 30,000lbs 11ft 3in 6030 13ft 2in 8ft 8in 10ft 2in 17,000lbs...

  • Page 39: Positioning

    SIEMENS MAINTENANCE MANUAL 2.3 POSITIONING 1. Place the VMC so that skylights or air vents are NOT directly overhead. Do not expose the machine to direct sunlight, or any other heat source. Do not place the machine in an area that will expose the machine to moisture, standing water, liquid or rain.

  • Page 40: Air Supply

    FADAL MACHINING CENTERS 2.4 AIR SUPPLY WARNING! Air pressure required: 120 psi before regulator, 80 psi after regulator, 15 scfm (stan- dard cubic feet per minute) momentary. 1. From the main air supply line attach a 3/8” air supply line for the VMC. The distance from the air compressor and number of machines attached should be taken into consideration when determining the size of piping for the main air supply line.

  • Page 41: Electrical Grounding

    SIEMENS MAINTENANCE MANUAL 2.5 ELECTRICAL WARNING! GROUNDING The importance of proper grounding CANNOT be over-emphasized! Improper grounding will result in a wide range of hard-to-diagnose problems in communica- tions, positioning, spindle motion, etc. 1. The grounding conductor shall be of copper. The material selected shall be 2.5.1 PRIMARY...

  • Page 42

    FADAL MACHINING CENTERS • intermediate metal conduit • electrical metallic tubing or cable armor 4. One end of the supplemental grounding conductor shall be attached to the VMC’s ground bus. The other end shall be effectively bonded to a copper cold water pipe that is in direct contact with the earth for 10 feet or more (See Figure 2-5: Bond Grounding Conductor to Copper Cold Water Pipe).

  • Page 43: Checking Grounding Integrity Of Fadal Vmcs

    SIEMENS MAINTENANCE MANUAL 2.6 CHECKING GROUNDING INTEGRITY OF FADAL VMCS 1. MUST conferm to NEC code as stated in the Maintenance Manual. 2.6.1 SPECIFICATION - GROUNDING FOR THE FADAL MACHINE 2. MUST be a continuous wire 8 AWG or larger between the VMC's ground bus and the building power distribution panel serving the VMC.

  • Page 44: Electrical Service

    FADAL MACHINING CENTERS 4. Turn off the VMC and measure the ground voltages (AC and DC) again. Record these readings. Voltages should be OV to .005V. 5. Voltages (AC or DC) across the ground wire will cause false resistance readings. If the ground voltages with VMC off are 0 (.005VAC max.), set meter to ohms and measure resistance between VMC ground bus and power distribution enclosure.

  • Page 45: Wiring

    SIEMENS MAINTENANCE MANUAL 2.6.7 WIRING Table 2-5: Wiring Requirements 40 Taper 480 VAC 3 Ø 10 AWG (6 mm ) stranded 8 AWG (10 mm ) stranded THHN THHN copper within 100 ft. copper 100 ft. or more from panel.

  • Page 46: Conduit

    FADAL MACHINING CENTERS 1. The number and size of conductors in any raceway shall not be more than will 2.6.8 CONDUIT permit dissipation of the heat. 2. The conduit must allow ready installation or withdrawal of the conductors without damage to the conductors or to their insulation. Table 2-6: Conduit Selection # OF CONDUCTOR SIZE...

  • Page 47: Installation Procedure

    SIEMENS MAINTENANCE MANUAL 3.0 INSTALLATION PROCEDURE WARNING! Before beginning the Machine Installation & Hook-Up it is important to review the entire Installation Procedure section. OCTOBER 2005 INSTALLATION PROCEDURE...

  • Page 48: Machine Installation & Hook-up

    FADAL MACHINING CENTERS 3.1 MACHINE INSTALLATION & HOOK-UP Tools Required 3.1.1 UNPACKING Hammer, 15/16” socket or wrench and knife 1. Remove the crate and/or protective material from around the VMC. 2. Remove the strapping material from the front doors. 3. Unload the boxes from the inside and/or around the VMC. 4.

  • Page 49: Air Supply

    SIEMENS MAINTENANCE MANUAL 3. At this point the VMC is ready for power and air connections. Hole provided for 1-1/4” bar minimum bar length 36” 1-8”eye bolt 2 places 1.5” eye bolt 2 places for 6535 Maximum fork width is 6.00”...

  • Page 50: Power Check

    (ST-26), 5/16” hex bit socket and 3/4” open or box wrench. Verify the Main Power Fuses Siemens requires 3 phase power. Voltage must be 400 or 480 Volts (depending on Module). The voltage differences between each lug and ground (measured at incoming terminal) must be less than 5%.

  • Page 51

    SIEMENS MAINTENANCE MANUAL Verify the MOV Surge Suppressor Board 1. Locate the MOV Surge Suppressor Board (see Figure 3-2: MOV Surge Suppressor Board). Figure 3-2: MOV Surge Suppressor Board 2. Find the part number on the board. a. If your incoming voltage is over 380 VAC, then PCB-0146 should be installed.

  • Page 52

    FADAL MACHINING CENTERS Figure 3-3: Figure 3-4: INSTALLATION PROCEDURE MAN-0126_R1...

  • Page 53

    SIEMENS MAINTENANCE MANUAL Figure 3-5: Figure 3-6: OCTOBER 2005 INSTALLATION PROCEDURE...

  • Page 54

    FADAL MACHINING CENTERS Figure 3-7: INSTALLATION PROCEDURE MAN-0126_R1...

  • Page 55: Transformer Tapping

    SIEMENS MAINTENANCE MANUAL 3.2 TRANSFORMER 1. With the machine main power switch turned OFF, verify that the chart on the door of TAPPING the cabinet is the one for the transformer in the machine. 2. Measure the input voltage to the machine on the chart (Measure leg to leg the input power lines to the machine.).

  • Page 56: Phase Converter Rotary

    FADAL MACHINING CENTERS 3.3 PHASE The normal Fadal VMC requires three phase-input power. Some customers prefer to CONVERTER ROTARY use rotary phase converters. However, Fadal does not recommend the use of rotary phase converters. Rotary phase converters input single-phase 208 to 230 VAC and output three phase 230 VAC.

  • Page 57: Leveling

    SIEMENS MAINTENANCE MANUAL 3.4 LEVELING Leveling is an important first step in setting up the VMC. All calibration and squareness performed on the assembly line is done with the machine leveled. It is important to follow the sequence below precisely to ensure proper results.

  • Page 58

    FADAL MACHINING CENTERS 8. Place the level on the right hand way (the outer right hand way on the 6535) of the base with the small bubble towards the column. Take an accurate reading. (See Figure 3-8: Leveling Box Way.) Figure 3-8: Leveling Box Way.

  • Page 59

    SIEMENS MAINTENANCE MANUAL 13. Verify the spindle tram and, if necessary, adjust by slightly changing only the two front leveling screws. OCTOBER 2005 INSTALLATION PROCEDURE...

  • Page 60: Hold Down Clamps

    FADAL MACHINING CENTERS 3.5 HOLD DOWN Larger machines may vibrate, bump on reversals, and degrade floor finish. CLAMPS This may indicate that the base casting needs to be clamped to floor. Larger machines need to be clamped to the floor to prevent movement between the machine and the floor, and clamping holes are provided on all base castings for this purpose.

  • Page 61: Optical Fiber Cable Handling

    SIEMENS MAINTENANCE MANUAL 3.6 OPTICAL FIBER Careful handling of Optical Fiber Cable: CABLE HANDLING 1. Even though reinforcing cover used on the optical fiber code has enough mechani- cal strength, be sure not to be damaged by heavy materials drop.

  • Page 62: Coupler Installation On Axis Motor Or Ballscrew

    FADAL MACHINING CENTERS 3.7 COUPLER NOTE Motor and Ball Screw shaft must be clean and oil free. INSTALLATION ON AXIS MOTOR OR Follow the next procedure: BALLSCREW 1. Loosen both coupler HUB screws. 2. Mark coupler HUBs and SPIDER before disassembling to insure coupler is assem- bled back together the same way.

  • Page 63

    SIEMENS MAINTENANCE MANUAL 6. Install the SPIDER and set the tolerance on all 4 RAISED BOSSes to 0.015”-0.030” from the HUB using 2 (two) 0.015”(0.381mm) and 0.030” (0.762mm) feeler gages. Figure 3-10: Gages 7. Install Ball Screw coupler HUB on the SPIDER and set the tolerance on all 4 RAISED BOSSes to 0.015 “...

  • Page 64

    FADAL MACHINING CENTERS Table 3-1: Couplers MACHINE X AXIS Y AXIS Z AXIS 2216 KTR ROTEX GS24 KTR ROTEX GS24 KTR ROTEX AI GS24 .625x24mm .625x24mm .625x19mm 3016 3020 4020 4525 6030 8030 Z-AXIS 19ft X-AXIS 8ft Y-AXIS 8ft Figure 3-12: Motors Table 3-2: Couplers MACHINE X AXIS...

  • Page 65: Pendant Installation

    SIEMENS MAINTENANCE MANUAL 3.8 PENDANT In order to install pendant, follow the next procedure: INSTALLATION VMC 6535 1. Carefully remove shipping crate, with pendant inside, from machine and place it close to the right side of the machine. 2. Remove second (smaller) box from the machine.

  • Page 66: General

    FADAL MACHINING CENTERS 3.9 GENERAL Detach column breaks from spindle head and tool changer arm. side view Column breaks front view Figure 3-13: Column breaks Place the cable carrier (black flexible arc on top of the machine) onto appropriate screws and tight them with nuts. Figure 3-14: Cable carrier INSTALLATION PROCEDURE MAN-0126_R1...

  • Page 67: Chip Conveyor

    SIEMENS MAINTENANCE MANUAL 3.10 CHIP CONVEYOR 1. Place the chip conveyor in the coolant tank. 3.10.1 INSTALLATION PROCEDURE 2. Measure the height to the top of the conveyor sheet metal (should be approximately the height of the coolant tank). 3. Set the machine height (the machine should be on the small leveling pads) to slightly above the height established in step 2 above.

  • Page 68: Chip Conveyor Power And Controls

    FADAL MACHINING CENTERS 7. Adjust the machine height (during leveling and installation) to minimize the gap (or overlap) between the coolant tank face and the machine sheet metal, (Figure 3-17: Minimize Gap of Overlap). Figure 3-17: Minimize Gap or Overlap 8.

  • Page 69

    SIEMENS MAINTENANCE MANUAL 2. The control also has a variable speed control for the belt speed. The belt speed can be controlled from 2.60 ft./min. to 10.80ft/min. Figure 3-18: Control Operating Positions Figure 3-19: Emergency Stop (CE machines only) OCTOBER 2005...

  • Page 70

    FADAL MACHINING CENTERS INSTALLATION PROCEDURE MAN-0126_R1...

  • Page 71: Machine Maintenance

    SIEMENS MAINTENANCE MANUAL 4.0 MACHINE MAINTENANCE OCTOBER 2005 MACHINE MAINTENANCE...

  • Page 72: Scheduled Maintenance

    FADAL MACHINING CENTERS 4.1 SCHEDULED MAINTENANCE Daily 4.1.1 MAINTENANCE & LUBRICATION SCHEDULE 1. Check air pressure: Right regulator 120 psi. max. (Tool Out Only). Left Regulator 80-90 psi. 2. Check way lube level. Use Castrol Magna BD68, Shell Tonna 68V or Mobil Vactra #2 ONLY.

  • Page 73: Lubrication Of The Ways

    SIEMENS MAINTENANCE MANUAL 10. Grease Geneva wheel and gear using Kopr-Kote. 11. For high torque machines, check fluid level in the hydraulic actuator reservoir. Refill, if needed, with Mobil DTE Heavy Medium. 12. Inspect all cooling fans, clean screens if necessary.

  • Page 74: Cooling Fans

    FADAL MACHINING CENTERS 3. Remove the oil line that is between the way lube pump and the three port junction T that is located near the pump mount. 4. Verify that the flush pump air regulator is fully counterclockwise. 5. Attach an air line to the flush pump. WARNING! Verify that the air regulator is closed.

  • Page 75: Spindle & Ballscrew Cooling System

    SIEMENS MAINTENANCE MANUAL WARNING! Wear safety glasses! If the fan is turning slowly or not at all, it may require cleaning or replacement. The fan on the bottom of the junction box has a screen that requires periodic inspection and removal for cleaning.

  • Page 76: Tank Reservoir

    FADAL MACHINING CENTERS The tank reservoir is located next to the motor pump assembly in the chiller cabinet. 4.1.6 TANK RESERVOIR The tank has a 2 1/2 gallon capacity. Visually check the fluid level with the machine powered on. If the fluid level is less than 1/2 of the tank, mix the DOWFROST™ to a 50:50 solution, with deionized water, or sodium free distilled water and fill to no more than 3/4 full.

  • Page 77: Fluids

    SIEMENS MAINTENANCE MANUAL 4.1.7 FLUIDS Table 4-1: Fluids RESERVOIR FILL WITH Waylube CASTROL MAGNA BD68 SHELL TONNA 68V or MOBIL VACTRA #2 Spindle Cooling System DOWFROST™ CLEAR (Mixed 50/50 with de-ionized water or sodium free distilled water) Rotary Tables MOBIL GEAR 626...

  • Page 78: Dual Arm Tool Changer

    FADAL MACHINING CENTERS The causes of abnormal wear and fractures will be apparent when the tool changer is 4.1.8 DUAL ARM TOOL CHANGER used without lubricant. It is very important to grease all moving parts of the tool changer at least once a week. Lubricant The lubricant should be changed annually, or when it has become visibly deteriorated.

  • Page 79

    SIEMENS MAINTENANCE MANUAL 2. Inspection: a. Check the parts of the tool falling mechanism for damage and wear. Add grease to the sliding base of the tool falling mechanism and the pull rod. b. Check the parts of the tool pots, tool discs, and snap rings for damage and tightness.

  • Page 80: Tests For Ce Safeguards On Fadal Machines

    FADAL MACHINING CENTERS 4.2 TESTS FOR CE These tests should be done when machine is first installed and after servicing when SAFEGUARDS ON any components are replaced. FADAL MACHINES 1. Power on machine but do reference. Start spindle. (Press Shift-Spindle on) •...

  • Page 81

    SIEMENS MAINTENANCE MANUAL Daily & Weekly Safety Tests for CE Safety Circuits To ensure proper functioning of safety circuits, the following tests should be performed on a regular basis. Daily Front Door Lock Daily Test for 2030-OA 1. Close all doors. Make sure machine is not in emergency stop.

  • Page 82: Chip Conveyor

    FADAL MACHINING CENTERS 4.3 CHIP CONVEYOR Please carry out daily, monthly, and yearly inspection according to the following 4.3.1 MAINTENANCE SCHEDULE CHIP directions. CONVEYOR Daily Inspection 1. Always keep oil in the speed reducer at the specified oil level. 2. Check motor for abnormal operation, i.e. noise, heat excessive current, etc. 3.

  • Page 83: Stopping The Chip Conveyor On Us And Ce Machines

    SIEMENS MAINTENANCE MANUAL 1. At the initial running, confirm the following before turning power on. a. Inspect for and remove any article other than material (chip, etc.) to be trans- ported on conveyor link belt portion. WARNING! Make sure hands, feet and clothing are clear of all moving parts.

  • Page 84

    FADAL MACHINING CENTERS Figure 4-3: Adjust Take-Up Bearing 3. Check roller chain between motor and conveyor for proper alignment and correct tension. Figure 4-4: Check Roller Chain 4. The greatest care should be exercised to keep friction surface of torque limiter free from oil when lubricating roller chain.

  • Page 85: General Information

    SIEMENS MAINTENANCE MANUAL 5.0 GENERAL INFORMATION OCTOBER 2005 GENERAL INFORMATION...

  • Page 86: Helpful Formulas

    FADAL MACHINING CENTERS 5.1 HELPFUL FORMULAS Degrees Fahrenheit (F) = (9/5 x degrees C) + 32 5.1.1 TEMPERATURE Degrees Celsius (C) = 5/9 x (degrees F-32) Inch (in) = millimeter x 0.03937 5.1.2 CONVERSION FACTORS Inch (in) = centimeter x 0.3937 Millimeter (mm) = inch x 25.4 Centimeter (cm) = inch x 2.54 Liter = gallon (U.S.) x 3.7854...

  • Page 87: Expansion Coefficients

    SIEMENS MAINTENANCE MANUAL Three-Phase Kilovolt-Amperes (KVA) = (Volts x Amperes x 1.73) / 1000 Formula 5.1.4 EXPANSION COEFFICIENTS Expansion amount = Coefficient x distance x degree of temperature change (Fahrenheit) Coefficients Steel .00000633 Cast Iron .00000655 Aluminum .00001244 pathname C:\CNCDATA\ filename PN1234.NC...

  • Page 88: Thermal Expansion

    FADAL MACHINING CENTERS 5.2 THERMAL EXPANSION Thermal expansion is a natural occurrence in materials subject to heat, and there are 5.2.1 OVERVIEW several sources of heat in any machining operation. In addition, different materials react to heat at different rates, and different subsystems of the VMC react to specific machining operations to different degrees, further complicating matters.

  • Page 89: Heat Sources

    SIEMENS MAINTENANCE MANUAL It comes as no surprise that the primary source of heat in machining is friction; however, 5.2.5 HEAT SOURCES some of the sources of friction, and all of the areas affected by a given friction source, may not be readily apparent. Additionally, the effects on the ambient temperature from various heat sources in the machine shop are often overlooked.

  • Page 90

    FADAL MACHINING CENTERS of carrying away the heat of the cut and minimizing the effects of thermal expansion resulting from that heat. Yet another practice that deserves mentioning is machining parts at temperatures significantly different from those at which the parts are inspected. If the inherent expansion of the part material from the heat of the machining process is outside tolerance once the part has cooled to inspection temperatures, the problem can only be resolved by correcting for the heat generated during machining so as to keep the part...

  • Page 91: Non-uniform Expansion

    SIEMENS MAINTENANCE MANUAL 5.3 NON-UNIFORM EXPANSION The differing rates of expansion by unlike materials further complicate the problems 5.3.1 MATERIAL DIF- FERENCES created by the heat generated in the machining process. This applies both to parts stock, like aluminum, and to fixtures and sub plates, often also made of a material like aluminum.

  • Page 92

    FADAL MACHINING CENTERS on the table. Because of its large size, the table seems less affected by the heat of machining. It will expand, but it takes longer to heat or cool the entire table. In addition, the use of coolant tends to stabilize the temperature of the table at or close to coolant temperature.

  • Page 93: Solving The Thermal Expansion Problem

    SIEMENS MAINTENANCE MANUAL 5.4 SOLVING THE THERMAL EXPANSION PROBLEM A simplified description of the thermal environment in machining would state that heat 5.4.1 GENERAL CON- SIDERATIONS is generated through friction, and also input through ambient factors. That heat is transferred among the system components, and is either removed from the system through radiation, convection and evaporation, or absorbed by the components of the system (part, fixture, VMC).

  • Page 94: Reading Status Group

    FADAL MACHINING CENTERS 5.5 READING STATUS Reading a status in a computer can be very helpful for troubleshooting. Status is GROUP usually a byte or a word. The status is normally represented in hexadecimal. To demonstrate how a status byte is decoded, the command 1 byte in the diagnostics – display switches will be used.

  • Page 95: Vmc Maintenance

    SIEMENS MAINTENANCE MANUAL 5.6 VMC MAINTENANCE The fans in the cabinets must be functioning properly. The purpose of the fans in the 5.6.1 CABINET FANS cabinets is to cool the electronics and to move the heat out the vents. An excessive amount of heat in the cabinets, from clogged holes or nonfunctional fans, will transfer to the column and cause it to expand, as well as damaging the electronics.

  • Page 96

    FADAL MACHINING CENTERS This process is also effective for inspecting parts. By cooling the part prior to the finish cuts, the temperatures at final cut and at inspection can be brought closer. In this situation, the target temperature should also be close to the temperature at which the gauge is calibrated.

  • Page 97: Vmc Options

    SIEMENS MAINTENANCE MANUAL There are options that can be added to a standard VMC to help manage the thermal 5.6.4 VMC OPTIONS expansion problems. Probe A probe in the spindle can be used as a part of the program to discover what adjustments are required to compensate for thermal expansion.

  • Page 98: Conclusion

    FADAL MACHINING CENTERS Thermal expansion is a natural occurrence in any machining operation, and, when 5.6.5 CONCLUSION ignored, can significantly impact positioning repeatability. By identifying and eliminating unwanted heat sources, by calculating or measuring expansion effects and altering positioning accordingly, by performing regular maintenance on the VMC, and by adopting the machining practices outlined above, the effects of thermal expansion can be reduced.

  • Page 99: Index

    SIEMENS MAINTENANCE MANUAL INDEX 2216 & 3016 TABLE 19 3020 & 4525 TABLE 20 4020 TABLE 21 6030 TABLE 22 6535 TABLE 24 8030 TABLE 23 ACCURACY AND REPEATABILITY 82 AIR SUPPLY 34 AIR SUPPLY 43 ALTERNATE SERVICE 38 AMBIENT SOURCES 87...

  • Page 100

    FADAL MACHINING CENTERS GENERAL 60 GENERAL CONSIDERATIONS 87 GENERAL INFORMATION 79 HEAT SOURCES 83 HELPFUL FORMULAS 80 HOLD DOWN CLAMPS 54 ILLUSTRATIONS & DATA FOR ALL VMC MODELS 2 INSPECTION - CHECK GROUND WIRE COMING INTO VMC 37 INSTALLATION PROCEDURE 41 INSTALLATION PROCEDURE 61 LEVELING 51 LUBRICATION 89...

  • Page 101

    SIEMENS MAINTENANCE MANUAL RESTARTING THE CHIP CONVEYOR 77 SCHEDULED MAINTENANCE 66 SCHEDULED MAINTENANCE FOR DUAL ARM TOOL CHANGER 72 SHIPPING DIMENSIONS 32 SOLVING THE THERMAL EXPANSION PROBLEM 87 SPECIFICATION -GROUNDING FOR THE FADAL MACHINE 37 SPECIFICATIONS 1 SPINDLE & BALLSCREW COOLING SYSTEM 69...

  • Page 102

    FADAL MACHINING CENTERS INDEX MAN-0126_ R1...

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