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• Xavier Hernandez

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TROUBLESHOOTING

MTX / ZX / BX PUNCHING MACHINES

VERSION10 - 2013

E N G L I S H

Contents 1 2 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.6 2.7 2.8 2.9 2.10 ANNEX A 3 4 5

Installation ------------------------------------------------------------------------------------------------------------------------------------------ 3 Operation ------------------------------------------------------------------------------------------------------------------------------------------- 3 CNC status ------------------------------------------------------------------------------------------------------------------------------------ 3 Machine status-------------------------------------------------------------------------------------------------------------------------------- 4 Machine status - Page 1 ---------------------------------------------------------------------------------------------------------------- 4 Machine status - Page 2 ---------------------------------------------------------------------------------------------------------------- 5 Machine status - Page 3 ---------------------------------------------------------------------------------------------------------------- 7 Machine status - Page 4 ---------------------------------------------------------------------------------------------------------------- 8 Multitool status ------------------------------------------------------------------------------------------------------------------------------- 10 Multitool Status - Page 1 --------------------------------------------------------------------------------------------------------------- 10 Multitool Status - Page 2 ----------------------------------------------------------------------------------------------------------------11 LOADING-UNLOADING Status -------------------------------------------------------------------------------------------------------- 12 LOADING-UNLOADING Status - Page 1------------------------------------------------------------------------------------------ 12 LOADING-UNLOADING Status - Page 2------------------------------------------------------------------------------------------ 12 LOADING-UNLOADING Status - Page 3------------------------------------------------------------------------------------------ 13 LOADING-UNLOADING Status - Page 4------------------------------------------------------------------------------------------ 13 LOADING-UNLOADING Status --------------------------------------------------------------------------------------------------------- 14 Entering a password -------------------------------------------------------------------------------------------------------------------- 14 TROUBLESHOOTING - Flex Hydraulic Component Troubleshooting - Page 2 ----------------------------------------- 15 TROUBLESHOOTING - Standard Hydraulic Component Troubleshooting - Page 2 ---------------------------------- 16 TROUBLESHOOTING - Axis Sensor Tests - Page 3 --------------------------------------------------------------------------- 16 TROUBLESHOOTING - Index Troubleshooting - Page 4 --------------------------------------------------------------------- 17 TROUBLESHOOTING - Scrapdoor - Page 5 ------------------------------------------------------------------------------------ 20 TROUBLESHOOTING - Vacuum System Troubleshooting - Page 6------------------------------------------------------- 21 TROUBLESHOOTING - Hole Centring - Page 7 -------------------------------------------------------------------------------- 21 VARIABLES ---------------------------------------------------------------------------------------------------------------------------------- 23 POINTS---------------------------------------------------------------------------------------------------------------------------------------- 24 IMMEDIATE COMMANDS ---------------------------------------------------------------------------------------------------------------- 25 STARTING APPLICATIONS -------------------------------------------------------------------------------------------------------------- 26 CONFIGURATION -------------------------------------------------------------------------------------------------------------------------- 26 TROUBLESHOOTING - Ladder diagram - Page 5 ------------------------------------------------------------------------------------- 27 TROUBLESHOOTING - Ladder diagram - Page 6 ------------------------------------------------------------------------------------- 28 “ADVANCED” IMMEDIATE COMMANDS ------------------------------------------------------------------------------------------------- 29

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TROUBLESHOOTING 1

Installation

As far as Euromac “Troubleshooting” is concerned, if you are working with an Access data base (DAO) on a PC on which this was not installed, you must install the version with all DAO options.

2

Operation

After installation, Troubleshooting can be activated in either of the following manners: from the main menu of all 3 pages (Programming, Simulation and Work), press the MENU key and select "Troubleshooting"; press the CTRL (F21) key along with the MENU key. The following window appears:

2.1

CNC status

Select the "CNC status" option with the menu keys on the keyboard and press ENTER to display the following window: This page displays the current status and position of all machine axes. When the machine's main motor is off,

the "Executor status" and "EXECUTOR error" will be in the condition shown in the figure.

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TROUBLESHOOTING 2.2

Machine status

The second option of the main menu is "Machine status". This is composed of 4 pages. The first page is:

2.2.1

Machine status - Page 1

Press the ENTER key on this option and the following page appears:

Press the "down arrow" key to move from one field to another. As you do this, the relative icon will appear on the right hand side of the machine, along with a description of the position of the parameter, as shown in the figure. The most important fields in this page are: • MINIMUM X LIMIT SWITCH (SQ4 - ON), which displays the status of the input (IF.37 for the UR100 CNC or IF.76 for the M68) of the X axis sensor on the right hand side. • MAXIMUM X LIMIT SWITCH (ZERO) (SQ5 - ON), which displays the status of the input (IF.38 for the UR100 CNC or IF.77 for the M68) of the X axis sensor on the left hand side. This is also used during axis homing. • MINIMUM Y LIMIT SWITCH (SQ6 - ON), which displays the status of the input (IF.39 for the UR100 CNC or IF.78 for the M68) of the Y axis sensor on the front side of the machine. • MAXIMUM Y LIMIT SWITCH (ZERO) (SQ7 - ON), which displays the status of the input (IF.40 for the UR100 CNC or IF.79 for the M68) of the Y axis sensor on the rear side of the machine. This is also used during axis homing. IMPORTANT: when these axes are half way along their stroke, the "STATUS" indication must be 'ON', as shown. • POWER ON KM1 (KMG - ON), which is the input (IF.41 for the UR100 CNC or IF.86 for the M68) that signals whether the machine motor is on (in this case, it will be ON).

!

If faults occur, the symbol “ “ will appear next to the status. Check accordingly. To go to the next page, press the "Down" arrow until the red square in on key

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>>>

.

TROUBLESHOOTING 2.2.2

Machine status - Page 2

Page 2 of the "Machine Status" option is illustrated below:

Where: • SENSOR 1-2-3 UNDER PUNCH. (SQ9 - SQ10 - SQ11 - OFF) are the clamp's safety sensors. In normal working condition, which means that the sensors are disengaged, status must be 'OFF'. On the contrary, check because you may have to replace them. Sensors are arranged as follows:

SQ30*

SQ10

SQ11

SQ9

SQ31* * Only for 12-station machines

Main cylinder and the relative IF are:SQ9 - IF.23 SQ10 - IF.24 SQ11 - IF.253 SQ30 - IF.29 SQ30 - IF.30 •

for the UR100 CNC / IF.81 for the M68 for the UR100 CNC / IF.82 for the M68 for the UR100 CNC / IF.83 for the M68 only for 12-station MTX only for 12-station MTX

PED. FOR OPEN. CLAMPS/PUNCH. MAN. (SB9) this is the input (IF.36 for the UR100 CNC or IF.76 for the M68) of the pedal that opens the clamps.

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TROUBLESHOOTING •

MANUAL JOG INC. AXIS X (SA3/1) is the input (IF.4) of the selector that moves the X axis leftwards in manual mode.

•

MANUAL JOG DEC. AXIS X (SA3/2) is the input (IF.5) of the selector that moves the X axis rightwards in manual mode.

•

MANUAL JOG INC. AXIS Y (SA4/1) is the input (IF.6) of the selector that moves the Y axis towards the rear side of the machine in manual mode.

•

MANUAL JOG DEC. AXIS Y (SA4/2) is the input (IF.7) of the selector that moves the Y axis towards the front side of the machine in manual mode.

•

MANUAL / AUTOMATIC SELECT. (SA5) is the input (IF.8) of the operating mode selector: Automatic or Manual mode; when the input is OFF, the machine is in MANUAL mode; when the input is ON, the machine is in AUTOMATIC mode.

•

AXIS HOMING BUTTON (SB4) is the input (IF.10) of the yellow button for axis homing or for resetting errors; it is ON when the button is pressed and OFF if it is not.

•

•

CYCLE START BUTTON (SB5) is the input (IF.11) of the black "Cycle Start" button; it is ON when the button is pressed and OFF if it is not.

•

CYCLE STOP BUTTON (SB6-ON) is the input (IF.12) of the red "Cycle Stop" button; it is ON when the button is not pressed and OFF when it is.

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TROUBLESHOOTING

2.2.3

•

PUNCH. SEMIAUTO MODE SELECTOR (SA2.1-ON) is the input (IF.2) of the black 3-position selector in its left position (Semiautomatic mode).

•

PUNCH. AUTO MODE SELECTOR (SA2.2-ON) is the input (IF.3) of the black 3-position selector in its right position (Automatic mode).

•

LOCKING SELECT. (SA1) is the input (IF.1) of the green 2-position selector for releasing turrets (MTX or MBX) or for safety during opening of basket (ZX or BX).

•

PUNCH. UP / RELEASE BUTTON (SB3 - OFF) is the input (IF.9) of the button for raising the main cylinder and/or releasing the basket (BX or ZX machines).

Machine status - Page 3

Page 3 of the "Machine Status" option is illustrated below:

Where: • PICKUP CYLINDER 1 SENSOR (SQ12A - ON) is the input (IF.26) of the sensor detecting the top left hand position of the pick-up cylinder. 7

TROUBLESHOOTING •

PICKUP CYLINDER 2 SENSOR (SQ12B - ON) is the input (IF.27) of the sensor detecting the top right hand position of the pick-up cylinder.

•

ENABLE POWER FROM CNC (K12-ON) is the output (OF.20 on the A10 card) that activates the CNC when the main motor can be turned on.

2.2.4

Machine status - Page 4

Page 4 of the "Machine Status" option is illustrated below:

Where: • UPPER TURRET LOCK. CYLINDER RAISED (SQ21) is the input (IF.17 for the UR100 CNC or IF.25 for the M68) of the sensor detecting the raised position of the upper turret locking cylinder (i.e. turret released). 8

TROUBLESHOOTING • • • • • • • • •

•

• • • • •

When the LED on the sensor is on, this input must be ON. UPPER TURRET LOCK. CYLINDER LOWERED (SQ22) is the input (IF.18 for the UR100 CNC or IF.26 for the M68) of the sensor detecting the lowered position of the upper turret locking cylinder (i.e. turret locked). When the LED on the sensor is on, this input must be ON. UPPER TURRET RESET (SQ17) is the input (IF.19 for the UR100 CNC or IF.29 for the M68) of the sensor detecting zero position of the upper turret. When the LED on the sensor is on, this input must be ON. LOWER TURRET LOCK. CYLINDER RAISED (SQ23) is the input (IF.49 for the UR100 CNC or IF.27 for the M68) of the sensor detecting the raised position of the lower turret locking cylinder (i.e. turret locked). When the LED on the sensor is on, this input must be ON. LOWER TURRET LOCK. CYLINDER LOWERED (SQ24) is the input (IF.50 for the UR100 CNC or IF.28 for the M68) of the sensor detecting the lowered position of the lower turret locking cylinder (i.e. turret released). When the LED on the sensor is on, this input must be ON. LOWER TURRET RESET (SQ18) is the input (IF.51 for the UR100 CNC or IF.30 for the M68) of the sensor detecting zero position of the lower turret. When the LED on the sensor is on, this input must be ON. UPPER TURRET CASING MICRO (SQ3) is the input (IF.22 for the UR100 CNC or IF.75 for the M68) of the upper turret casing open safety switch. When the casing is raised, this input is ON. CENTRE TABLE IN POSITION MICRO (SQ25) is the input (IF.52 for the UR100 CNC or IF.35 for the M68) of the tipping table open safety switch. When the table is lowered, this input is ON. TWO-HANDED CONTROL 1 (SB10) is the input (IF.13 for the UR100 CNC or IF.33 for the M68) of button SB10 for manual turret rotation (to be pressed with SB11). TWO-HANDED CONTROL 2 (SB11) is the input (IF.14 for the UR100 CNC or IF.34 for the M68) of button SB10; this key has 3 functions: 1. It is used for manual turret rotation (to be pressed with button SB10). 2. It raises the main cylinder to its top-most position. 3. On ZX or BX machines, it raises the punch holder basket after turning the green selector.

COOLING UNIT OVERLOAD CUTOUT TRIPPED (QM1 OR QM5) is the status of the input (IF.46 for the UR100 CNC or IF.92 for the M68) of overload cut-out QM1 (main pump motor) and/or QM5 (motor for the oil cooling system radiator). In normal working conditions, this input is OFF. If it is ON, check the two switches. AUTOMATIC LUBRICATION OIL LEVEL (SL4) is the status of the input (IF.45 for the UR100 CNC or IF.91 for the M68) that signals when oil in the rear lubrication tank drops below the minimum threshold. This input is OFF when the amount of oil is sufficient. UPPER INDEX SENSOR (SQ26) is the status of the input (IF.20 for the UR100 CNC or IF.38 for the M68) of the 0° reference sensor of the upper index or of axis C. LOWER INDEX SENSOR (SQ27) is the status of the input (IF.53 for the UR100 CNC or IF.39 for the M68) of the 0° reference sensor of the lower index or of axis E. DIE LIFTING CYLINDER OPEN (SQ29) is the status of the input (IF.48) of the "forward position" sensor of the die lifting cylinder in 12-station MTX machines. When the sensor is not engaged, the input is ON. DIE LIFTING CYLINDER CLOSED (SQ28) is the status of the input (IF.42) of the "back position" (idle position) sensor of the die lifting cylinder in 12-station MTX machines. When the sensor is not engaged, the input is ON.

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TROUBLESHOOTING 2.3

Multitool Status

The third option of the main menu is "Multitool Status". This consists of 2 pages. The first is:

2.3.1

Multitool Status - Page 1

Page 1 of "Multitool Status" is illustrated below:

Where: • MAX. CYLINDER UPSTROKE (SQ1) is the input (IF.28 for the UR100 CNC or IF.88 for the M68) of the sensor detecting raised position of the main cylinder. When the LED on the sensor is on, this input must be ON. • TOOL INSERTED (SQ2-ON) is the input (IF.22 for the UR100 CNC or IF.75 for the M68) of the micro switch detecting closed condition of the upper casing of MTX machines or basket closed condition of BX or ZX machines. When the casing or the basket are closed, this input is ON, as shown in the main description. • MULTITOOL ZERO SENSOR (SQ13) is the input (IF.87 for the UR100 CNC or IF.80 for the M68) of the Multitool motor resetting sensor. When the LED on the sensor is on, this input must be ON.

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TROUBLESHOOTING 2.3.2

Multitool Status - Page 2

Page 2 of "Multitool Status" is illustrated below:

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TROUBLESHOOTING 2.4

LOADING-UNLOADING Status

The 4th option of the main menu is the "LOADING-UNLOADING Status". It can only be selected if the option is available. This section is composed of 4 pages. The first is illustrated below:

2.4.1

LOADING-UNLOADING Status - Page 1

2.4.2

LOADING-UNLOADING Status - Page 2

Page 1 of LOADING-UNLOADING Status:

Page 2 of LOADING-UNLOADING Status:

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TROUBLESHOOTING 2.4.3

LOADING-UNLOADING Status - Page 3

2.4.4

LOADING-UNLOADING Status - Page 4

Page 3 of LOADING-UNLOADING Status:

Page 4 of LOADING-UNLOADING Status:

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TROUBLESHOOTING 2.5

LOADING-UNLOADING Status

The fifth option of the main menu is "TROUBLESHOOTING". This consists of 6 pages.

2.5.1

Entering a password

Select this item and confirm with the ENTER key. The password prompting window will appear:

If you do not enter a password, you may open the section but you cannot modify/activate parameters and/or functions.

Enter password 2 4 6 8 and a page with asterisks, as shown below, will appear:

The first page that appears is: TROUBLESHOOTING - Sensor Troubleshooting - Page 1:

This page displays the status of all sensors. If you have a FLEX machine, the following page appears:

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TROUBLESHOOTING :

2.5.2

TROUBLESHOOTING - Flex Hydraulic Component Troubleshooting - Page 2

Where •

Copy (F1) By pressing you activate the control for performing the "Copying" function, during which the Top Dead Centre position of the main cylinder is found.

•

Autocalibration (F2) you activate the control for autocalibration of the hydraulic circuit after By pressing maintenance has been performed.

•

•

By pressing position.

Head upstroke (F3)

you activate the control for raising the main cylinder to its top-most

Special for Flex (F4) you activate the control for refilling all hydraulic components with oil By pressing after replacement of valves and/or of the Flex system motor. After turning on the main motor, press F4 2-3 times at the most (make sure there are no punches and/or Multitools under the main cylinder), followed by F3 to raise the main cylinder to its top-most position. Perform air purging 3 or 4 times, as described in the Manual. Now press F2 to perform autocalibration.

In the right hand section, you will find the parameters and inputs relating to operation of the FLEX system.

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TROUBLESHOOTING If you do not have a FLEX machine, the following page appears:

2.5.3

TROUBLESHOOTING - Standard Hydraulic Component Troubleshooting - Page 2

2.5.4

TROUBLESHOOTING - Axis Sensor Tests - Page 3

Where •

Sensor reading (F1) By pressing you activate the control for checking whether sensors are in good working order. The machine axes will move to the position corresponding to each sensor. Before performing 16

TROUBLESHOOTING this test, make sure that the work table is clear. If the test has been successfully completed, the message SENSOR TEST OK will appear in the white box at the centre of the screen. •

:

Pos. reading (F2) By pressing (only if the password has been correctly entered) you activate the control for recording machine stroke positions. In other words, the axes will move until the relative sensors have been engaged. This operation is recommended: when hole resetting positions are changed; after replacing an X or Y axis transmission component; if the previous function has not been successfully completed. After this function has been performed, to save the new positions in TopPunch software, go to the Machining Screen with the machine in manual mode, select F4 - User Configuration from the Main menu. When the settings appear, quit without making any modification.

2.5.5

TROUBLESHOOTING - Index Troubleshooting - Page 4

Where: • C axis: this is the current position of the upper index. • E axis: this is the current position of the lower index. • •

ZX/MTX C1 (VT.133): this is the Zero position of the upper index. ZX/MTX E1 (VT.134): this is the Zero position of the lower index. These refer to: BX and ZX machines MBX 6 and MTX machines with 6 or 12, in station N° 1

• •

MTX 5STZ-C4/6 STZ-C3 (VT137): this is the Zero position of the upper index. MTX 5STZ-E4/6 STZ-E3 (VT138): this is the Zero position of the lower index. These refer to: MTX 5-station machine, station N° 3 MBX or MTX 6-station machine, station N° 3 MTX 12-station, station N° 5

• •

MTX 6STZ-C5(VT170): this is the Zero position of the upper index. MTX 6STZ-E5(VT171): this is the Zero position of the lower index. These refer to: MBX or MTX 6-station machine, station N° 5 MTX 12-station, station N° 9 17

TROUBLESHOOTING TO MODIFY ONE OR MORE SETTINGS, GO TO THE RELATIVE FIELD USING THE UP OR DOWN ARROW KEYS AND PRESS “F24 -”. ENTER YOU SETTING AND PRESS ENTER. IF THE MACHINE IS NOT IN MANUAL MODE, SETTINGS CANNOT BE MODIFIED. ATTENTION! MODIFYING ONE OF THESE SETTINGS WITHOUT AN AUTHORISATION AND/OR WITHOUT SUITABLE EQUIPMENT MAY CAUSE SERIOUS DAMAGE TO TOOLS.

•

Machine status (F1) and the CNC status described in paragraph 2.1 "CNC Status", on page 3, will Press appear above the previous page. The following page appears:

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TROUBLESHOOTING

• :

• :

Im. commands (F2) Press and the immediate command window described in paragraph 2.1 "CNC Status", on page 3, will appear. The following page appears

Marposs 270 (F3) Press and the list of controls for operation of the mechanical centring device of Index stations appears above the previous page. The sensor of the centring instrument will be at 270°

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TROUBLESHOOTING

• :

Change station (F4) Press and the station changing function window will appear above the previous page. Enter the number of the station to move to the centre position towards the operator, press the ENTER key and hold down the 2 manual turret rotation keys until the turrets stop.

2.5.6

TROUBLESHOOTING - Scrapdoor - Page 5

These pages display all inputs and outputs relating to the scrap ejection function (350x350mm).

•

Press

Open workchute (F1)

to open the scrapdoor (optional, 350 x 350 mm version). To close, press the 20

TROUBLESHOOTING yellow error RESET key on the control console.

2.5.7

TROUBLESHOOTING - Vacuum System Troubleshooting - Page 6

This page displays all inputs and outputs relating to the scrap ejection function :

•

Press again.

2.5.8

Open/Close Scrapdoor(F1)

to open the gate for ejection of punch cut-outs (optional). To close, press F1

TROUBLESHOOTING - Hole Centring - Page 7

This page is used to correct errors relating to hole positioning. 21

TROUBLESHOOTING To use this function, proceed as follows: • Begin a new program with sheet dimensions of over 1250 mm and insert a hole at a known position - e.g. 50 along the X axis and 50 along the Y axis. It is recommended to use a square punch so that it is easier to measure the distance from the edge. • Run the program and, as Y sheet loading position, enter the same position as the hole. Using a gage, measure the distance of the hole punched from the left and from the top edges. • If the hole is not smaller than the requested tolerance (usually ≤ 0.1 mm), fill in the fields by entering:

The hole positions programmed here

The positions measured with the gage here

These settings will be thus calculated

It is also important to select which locating pin has been used for sheet loading, namely the inner pin (press F1) or the outer pin (press F2).

APPLY (F3) NOW PRESS AND THE SETTINGS WILL BE SAVED IN THE CNC. TURN OFF THE MACHINE AND TURN IT ON AGAIN TO REPEAT THE AXIS HOMING PROCEDURE. MAKE SURE THAT THE POSITION OF THE HOLE IS CORRECT. REPEAT THE PROCEDURE WITH A SHEET HAVING AN X DIMENSION THAT IS LOWER THAN 1250 MM TO CHECK POSITIONS WITH REFERENCE TO THE INNER PIN.

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TROUBLESHOOTING 2.6

VARIABLES

This section can only be consulted/used after receiving an authorisation or assistance from Euromac personnel. When this option is selected, you will be prompted to enter a password, as described in chapter “2.5.1 Entering a password” on page 14. The following window appears:

This is a table containing all variables of the type selected. Variables can be VT (Buffered Variables, press F1), VP (Parameter Variables, press F2) and VV (Volatile Variables, press F3). Using the 4 arrow keys on the keyboard, select a variable. If the variable is outside the range of view, you can use the 'search' option by pressing SEARCH (F6) ,

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TROUBLESHOOTING The variable search window is shown below:

Enter the number of the variable and press ENTER. To modify a variable, press ENTER and the setting window will appear:

Enter the new settings and press ENTER again to confirm. As a general rule, variables can be modified when the machine is in MANUAL mode.

2.7

POINTS

This section displays all possible conditions of the machine's CNC:

Before opening this page, you will be prompted to enter a password, as described in chapter “2.5.1 Entering a password” on page 14.

24

TROUBLESHOOTING When F1, F2 and F3 are pressed, the points shown in columns 1, 2 and 3 will change respectively. You can select the following options:

Select with the up and down arrow keys and press ENTER to confirm. Since information is displayed in table format, you can select a point by using the 4 arrow keys on the keyboard. To move from one column to another, use

2.8

.

IMMEDIATE COMMANDS

This section is used to send commands to the CNC. The list is provided below:

Before opening this page, you will be prompted to enter a password, as described in chapter “2.5.1 Entering a password” on page 14. If you do not enter the correct password, you cannot open the page shown above. This page can only be used after receiving authorisation or assistance from Euromac.

25

TROUBLESHOOTING 2.9

STARTING APPLICATIONS

This section is used to send commands to the CNC. The list is provided below:

Where: • Copy directory c:\toppunch to: this copies the entire TopPunch directly into a specific position. It can be used for creating a backup copy of software. • Copy directory c:\serial to: this copies the entire SERIAL directory, which contains all parameters, CNC variables and configuration of TopPunch software into a specific position. • Copy Euromac.mch to (Only TopPunch) : this copies the TopPunch software configuration file into a specific position. • Copy SBL files to: this copies files generated by TopPunch to run the last program compiled from the VAR directory of TopPunch into a specific position.

2.10 CONFIGURATION

This section is used for configuration of troubleshooting software:

You can select a language - ENGLISH or ITALIAN - and the communication protocol; COMSERVER is selected when communication takes place by means of the RJ45 network cable (i.e. TCP-IP communication); COMDRV is selected when communication takes place by means of the serial cable connected to the COM1 port.

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