Some problem I need to get fixed.

[Delw]

First off the machine works fine, just some minor issues that are driving me crazy.
the machine was supposibly rebuilt 3 years ago, its a 1996 40x20 fadal

I get motor overload #12 when ever do a circle and a z move at the same time, doing a X Y and Z move is no problem. this problem has been going on for 2.5 years since I bought it.

I replaced the x axis motor last year along with the y axis resolver.

still have the problem. so a few months ago I called fadal and figured we would try to get it resolved. we found out the following errors were way off so in checking that they had me tune the drives, they are suppose to run at 680 however mine were at like 200-300 so figured this could have been the problem. I adjusted the pots to 680 all three, shut machine down power back up tried it in helical and gave them same issue, however it wouldnt rapid at 100% anymore. but at least the drives are tuned properly so for the last month I been running at 50% rapids which is really no big deal figure I would fix this problem the next go round when I have time.



wednesday I came in turned the machine on the the y axis started shuttering really bad both directions. first thing I thought was crap the ways are messed up. nope it looks fine. pretty loud. so today I decided to start playing again.
today I tuned the drives with my digital volt meter to 1.660, took the resolver off and did a quick feel check, also check the comutator and brushes, they were all good, took the covers off again NO problems, Check backlash and tightness of the table all good.
in working with other old machines over the coarse of time, the shuttering is really acting like brushes being worn or the comutator(sp) being dirty).

the machine still cuts fine and I have NO problem with size, however on anything over 50IPM I can see cut marks in aluminum, its more of a visual cause I am still getting a 125 finish on the scale.

BTW I also have a 8meg ram card card and I get unrecoverable memory error from time to time as well.

so now I am at a lose, Any idea? Besides sell it and buy another haas LOL (just joking)
does anyone know of anyone that will load/rent boards to find problems with in the heical turning part?

Thanks
Delw

[denmar]

Yes, for METRIC BALLSCREWS AMPS SHOULD BE SET 1.66V
0-1 IS A FINE TUNNING FOR THE AMPS TOO.

[Delw]

Denmar
I have that program in from the factory it said 680 and 1.660 volts , Fadal in chatsworth had me do that a few months ago with the same numbers also. The feed rate in the factory program is at 100 ipm not 150 like you have( maybe thats why the following errors are a different number)? I always had 2 axis that blinked 1-0 it was the z and the y. fadal told me they should be 0 all the time when the machine was stopped and that the blinking was just motors/resolvers being old ie typical and it was not really a problem.
that moment I set the drives to 680 was the moment I had to jump down to 50% rapid. The guy I had on the phone with fadal( not neal) said then there is something else wrong and we need to work on that. being me, since it ran at 50% I let it go and didnt follow up..

now that you jogged my memory if I remember correctly the org following errors were somewhere around 550-600 when running that program, not 2-300 like I mentioned above( my wife also confirmed your 595 numbers were what it was as she was watching the numbers while I was in the back turning pots lol) . thats why Fadal had me change them to the the 680.

Today I came in to play with the machine, figured I would yank the motor and check everything better. fired the machine up and got a resolver error/motor over heat alarm, tapped on the y axis resolver and worked for a quick jog then alarmed out.
so I am betting the y resolver is bad and thats why the Y axis is shuttering?.
I will get a new one tomorrow, then work on the helical issue again. and the Jog at 100% issue.

also the program like you types out is imbedded in the memory of the fadal, The tech I had on the phone had me pull it up as it got wiped out when I had the memory alarm.

Thanks for your help. if there is anything more that you can think of let me know. I really should get this machine running in tip top shape electronic wise and get all these little NON Issue things put to bed, I am just the type of guy if it works DONT f with it LOL

Delw

[Neal]

Delw--
The 680 following error is for a rotary motor and not the linear X,Y, or Z. If you have DC motors then tune them to 595 following error. If you have AC servo motors then tune them to either 302 or 600 depending on the axis eprom versions on the 1010 cards. AC0015 or earlier would be 302 and AC0017 or later would be 600.

Neal

[Delw]

so I am guessing the guy who refurbished this machine is a hack(. and put the wrong software in?, all the programs in the fadal calling them(o5812 5813etc) up x y and z have the same msg in them. tune drives to 1.660 or 680 ( the forgein guy at fadal told me to tune them to 680 he said it should be on the program as well)

the motors I have are the long ones mtr 0010
the eproms on the 1010 cards are y axis 2 eproms same numbers ( I will check x and Z and if different will post)
10-4020
v90.7z
xyz-axis
u10-1994

thanks Neal

[Delw]

Just out of curiosity should I check the software version on every board? maybe thats why it wont do the helical moves?

[Neal]

Delw--
The program for XY and Z is O5811 and for the rotary it is O5815. Check the eproms on slots 9, 10, & 11 (x,y,&z in order). For a 1010-4 card check eproms at U7 and U10 and for 1010-5 &6 card check the eproms at U15 and U18.

As far as the helical motion, the minimum input to the control is .0001". If the control is asked to split a mov ement of less than .0001" it can not do it and will alarm with either helical motion is too large or too short. This is a relationship between the rise or fall of the Z axis and the length of the arc. You can effect this situation by changing the arc length, the Z stroke and possible slow down the feed rate.


Neal

[Delw]

Neal,
I dont have program o5811, I have
o5812(x balance 680) for the x
o5813 (y balance 680), for the y
o5814 (z balance 680), for the Z

the software version on all the axis's are the same( as listed above)
I have a 1010-5d card my rigid tap card it reads
ele-0001
rt0006
rigid tap
u15-4206 and u18-4206

on the helical motion you and I tried the speeds and also changing the rads and z moves
heres the thread when you and I last worked on it
http://www.cnczone.com/forums/showthread.php?t=59126

I never followed up on that one MY bad.

[Neal]

At ENTER NEXT COMMAND type TA,7 and a few selections of the service programs will load into the control. You can delete them when you are done because they are hard coded in the 1610 module and won't be erased from there and only deleted from program storage memory.
The eproms for for the 1010-5d cards should be V95.1Z (the latest version) would be my recommendation. With these eproms the following error should be 595 and not 680.
These are DC servo motors. The 680 is only for the rotary axis.

Neal

[Delw]

Neal
Ta,7 gave me the program back. THANK YOU
The program does say use the COM and Sig lugs for ajustment at the 595 or 1.440dcv

I was told to use the "BAL" and "SIG" lugs

there is no COM pot but there is a COMP pot, I never touched that one

on my boards I have 2 long ones with screws "SIG" and "BAL" and the Z board has a "TACH"

then below those there are C.L then L.S. then COMP on a more squarish and thin lug.
below is a pic of the drives

Delw

[Neal]

Only use the BAL and SIG pots to make the adjustments. If the motor hums then touch up the COMP pot.

Neal

[Delw]

I balanced them to the proper spec. 595
still can't run at 100% only 50% other wise it just kicks the servos off.
it doesnt make any difference if I jog the x y or z at 100% either one will kick the servos off at 100%
because I still have that rubbing noise in the y I took the Y motor off and ran it with out being hooked up to the machine to eliminate the mechanical part(table of the machine) its pretty rough feeling, however when I spin it with power off it feels nice and smooth.
so i am replacing the tach with a motor that I have laying around with a magnet that came off a while ago and try that.

The tach did look good and the brushes were fine with plenty of pressure.


One other thing when I have the following error at 595 the digital meter reads 1.45 not 1.44, when I Adjust via digital to 1.440 the following error reads 560-570

the x and Z following errors flukuate about 4 points, the Y flucuates about 28 points cant get it to settle down( hence why i am going to try a different tach.)

if the tach doesnt change anything I am going to swap the x and Y drive cards and see if it follows.

Delw


Delw