Needed Parts
- festo reed contact for stud clamp open drill unit 1. From the current sensor is the plastic
housing badly damaged, due to this it is impossible to secure this sensor properly.
Replacement is needed, as the current sensor just hangs freely.
3x reed contact in total ? Possibly wise to take atleast 2 extra reedcontacts to the customer.
3x 000-1128 Proximity sensor SME-8M-DS-24V-K-5-OE
- Control board for driver. The Y3-control board is not functioning anymore. The sercos is not
being transmitted through this board anymore.
1x control board, Rexroth CSB01.1N-SE-ENS-NNN-L2-S-NN-FW
001-0950 CSB01.1N-SE-ENS-NNN-L2-S-NN-FW
- 1x EL5101. In group U57 terminal U57.06 we have an bad EL5101, the card gives problems
during startup. Replacement is recommended.
000-1186 Bus terminal EL5101 encoder interface
- 1x EL3152, this card gives allot of problems when enabled. Card is located in the saw. An
quote has already been send, has it also been ordered???
11-03-2020 RZ:
Offerte 20035659
- Problems with Z1- axis, the Z1 axis kept giving F3131 errors. I was unable to fully focus on this
issue as different errors kept happening. As for now I am completely unable to reset the
machine, cause of the problems with the Y3. I can’t exactly tell wat the problems are with the
Z1-axis.
It is recommended to send over an complete Z1-axis, so: servo motor, control board, power
section, motor feed cable and the encoder cable.
1x Servo motor, MSK070D-0450-NN-M1-UG1-NNNN ( Beware this is an motor with brake )
000-3857 Servo motor MSK070D-0450-NN-M1-UG1-NNNN
1x servo drive HCS02.1E-W0054-A-03-NNNN
000-1108 Servo drive HCS02.1E-W0054-A-03-NNNN
1x control board CSB01.1N-SE-ENS-NNN-L2-S-NN-FW
001-0950 CSB01.1N-SE-ENS-NNN-L2-S-NN-FW
1x motor feed cable ( Kan geen kabel nummers of iets vinden via het schema of op de kabel )
001-0959 Power supply cable RKL4309/022,0 (X,Y,Z)
1x Motor encoder cable =54-W4 MAT90419888
001-0957 Encoder cable RKG4200/023,5
- 30x M6x10 of 12 mm imbus or torx screws, these are needed for putting back the brackets
on the drivers.
000-3209 30 PC Hexagon socket screw M6x10 12.9
- 4x Cable bracket for bottom side of driver. ( If unclear and picture needed let me know! Have
them on my phone ) X1, Z1, Y2, Z2, Z3 and ZB are all missing there brackets. Found 2 back in
the cabinet. The remaining brackets are missing.
000-1513 6 PC Shield connection HAS02.1-002-NNN-NN
Info foto’s Christiaan:
- 1x cable clamp for EMC mount ? 8 or 10 mm wide
000-9089 1 PC EMC clamp SK 8
- 1x Exchange unit drill unit 2, Vacam model.
000-5429 Drilling unit (Exch.) VA Vacam version
- Ethercat cards for imprint:
o Ek1100 000-1174 Bus coupler EK1100 24Vdc
o EL1104 000-1177 Bus terminal EL1104 4x D.I. 24Vdc
o EL5101 000-1186 Bus terminal EL5101 encoder interface
o EL9110 000-1188 Bus terminal EL9110 24Vdc supply
o EL2024 000-1181 Bus terminal EL2024 4x D.O. 24V 2,0A
o EL9011 000-1187 Bus terminal EL9011 end cover
- Reed contact for tool changer out. Toolchanger 3.
1x reed contact for toolchanger, Beware this is reedcontact wit the M8 3P connector on the
other end. Not an open end!!!
000-1525 Proximity sensor T-slot N.O. 24V plug
- Repairing infeed dragdog
o 16 x bearing
o 8 axle
o 16x countersunk M6 screw L=12
o 16x countersunk washer ( geen idee hoe die verzonken ringetjes heten )
o 16x distance bushing
Basically 4 complete dragdogs except for the chain and drag dog itself.
002-0893 16 PC Bearing 6300-2RSR ø10
003-5751 8 PC Tempered pin 1¼" Triplex chain L=104
000-3321 16 PC Countersunk head screw M6x20 8.8 ZPL
002-4620 16 PC Round bar ø20 L=4,5
000-3408 16 PC Flat washer M16 ZPL
002-4621 16 PC Round bar ø15 L=26
- 1x detection strip for infeed crosstransport drag dog.
000-3775 1 PC Slide contact 12x1 Acc. Drwg
- Lubrication from the saw an new LUB300 is needed
1x LUB300
000-1132 1 PC Oil-mist lubricator LUB300 3/4 CD
- Track rollers saw worn
4x track roller
000-1011 4 PC Track roller LR5202-2Z ø15
- Broken HM block, the HM block resting on top of the blade is broken.
1x HM block
000-1437 1 PC Carbide Toolbit 8x8x50 h6
- 40x hexagon bolt for mounting covers. M6x10
000-3243 40 PC Flange bolt M6x10 10.9 ZPL
10-03-2020
CvdS
- Problems with ethercat, There is an issue in the U65 group. The EL3152 is causing the
machine too have lost frames, and RX/TX errors. Due to these failures the ethercat gives
communication errors.
For now, the EL3152 has been disabled in Twincat. The card has removed from the system,
the card is still connected to the wires but just not inserted into the rest of the PLC anymore.
This card has now temporarily replaced for an EL4031, just to prevent that we have to slide
everything back and forward. This newly added EL4031 has also been added to Twincat. An
new EL3152 needs to be ordered.
BEWARE that when the new card EL3152 is installed, first the twincat configuration needs to
be made original again!!!
For now we don’t have any ethercat errors anymore coming from this group, but as the
EL3152 is missing. We had to disable the entire saw. So currently the saw is unable to work.
- No enable at outfeed roller conveyor.
This problem was caused by an error at the EL2904 ( U34.07 ), according to the flash code
there was an error at output 1. I have restarted this ethercat terminal since then the problem
has happened a few times again.
I have then checked the 24V of this ethercat terminal, the I/O voltage was 22,3 V and the Bus
voltage was 22,2. These are really low values, it could be that the main reason for the card to
go into error is because the voltage drops below it’s lower threshold. For this reason I
increased the voltage of the system, so now we got +-24 V on this last ethercat terminal. As
wel on the I/O- and Bus connections.
Ever since I increased the voltage of the system I haven’t had any issues with the EL2904
giving issues.
Adviced is to keep an eye on it, and if the issue reoccurs it would most likely mean that the
relays are going bad. They will then draw too much current and causing the card to go in
error.
- No air pressure at booster input.
During the day I suddenly received an error from the machine that there was no pressure
anymore.
Customer had to do some stuff to the compressor and now the pressure is ok again.
11-03-2020
CvdS
- Problems with startup, when the main switch is turned on then the PC also starts up. But the
PC-ON button is not pressed. Once the PC is then turned on, it also directly switches back off
once it reaches the windows main screen.
Then when the PC is really requested to turn on then the PC-ON button needs to be pressed.
Reason for the PC to randomly turn on is unknown so far. Needs to be investigated.
- Problems with ethercat when starting up. All twinsafe cards give an error or undervoltage.
Today when I measured the voltage, is it again 24V throughout the entire system. But it
appears that the customer has installed an additional UPS in the 24V system. When the main
switch is turned off the 24V system stays active, until the entire UPS is drained.
Possibly there is an delay during power up between the I/O supply and bus supply, which
causes the undervoltage warning? Cause once it is turned on in the morning and we turn it
back off and then we turn it back on then there is no problem at all. Only now we didn’t wait
for the UPS to completely drain.
For both UPS it appears they have an an ON/OFF function, but currently there is just an
bridge in both UPS to keep them constant on. Normally I would expect that these need to be
switched to prevent the UPS to completely drain overnight?
As I kept having issues with the machine, and I wasn’t able normally power down the
machine, I did some research on the used UPS. There is an timer on the front of the UPS, this
timer was set to “unlimited” I have now decreased this timer to 0.5. Now when the main
switch is turned off, then all power from the machine drops after +- 1 min.
When the machine is now also turned back on the next morning I didn’t have any
undervoltage errors anymore.
- Sercos failure at Y3-drive. Suddenly during testing/working on the machine I had an “break”
in my sercor circuit. The break is caused by the Y3 control board, no communication is able to
pass through this board.
The sercos circuit has been altered, the Y3 and Z3 has been removed from the circuit.
Twincat has been altered as well and in Vacam the axis’s are disabled.
Later on I made the entire sercos circuit back original, this because the machine not going to
run anyways because of all the issues. All wiring has been made back original. But BEWARE I
have left the unit 3 and the Z1 all disabled in Vacam. This is done because the motor from
those axis’s have been of the machine, due to this the position is incorrect. The position
needs to be checked before they can be used again.
New sercos card is needed!
- Ethercat failure during startup, when the machine is started up for the first time in the
morning we get an ethercat failure. This failure is located in the U57 group and then terminal
U57.06 ( EL5101 ), this card doesn’t allow any communication to pass through to the other
terminals.
When you then wait for +- 10 mins, the problems clears itself and the machine works again.
It is highly recommended to replaced this ethercat terminal as it appears it isn’t 100%
anymore!
- It is adviced to check all earth connections from all wires, from basically all drivers if the
protective shielding from the cables is connected or not!!
Also see parts list for needed parts!!!
- It is highly recommended to check the settings from ALL reed contacts from the stud clamps
Multiple sensor are either not set right or not secured properly!!!
When left like this there is the risk of ripping of an tool changer from the machine.
- The stud clamp from drill unit 2 is very bad. The studclamp hardly closes once released.
It is highly recommended to replace this drill head for an exchange unit.
- Problems with Imprint. The imprint is currently disabled in Vacam.
It appears multiple blocks from this station are missing. Adviced is to take an complete new
station to the machine and install wat is needed. I can’t tell wat is still working and wat isn’t.
- Reed contact tool changer 3 can’t be secured anymore. The locking screw from this reed
contact is completely missing. Due to this the reed contact is not secured anymore. Due to
this the signal tool changer out will not always come on.
It is highly recommended to replace this reed contact for an new one.
- From the infeed cross transport basically all axles are bend or broken, most of the bearings
are gone/ broken. And most of the nesacarily hardware to mount everything is also gone.
- Detection strip infeed drag dog is missing. Because of the detection strip missing it will not be
posiilble to use automatic infeed.
It is recommended to order an new detection strip
- All infeed cross transport drag dogs are damaged. None of the dragdogs is still all complete.
It is adviced to repair all dragdogs from the infeed.
- Saw lubrication is not working anymore, the lubrication station has been set to its maximum
but hardly any oil comes out.
It is highly recommended to replace the lubrication unit.
- Track rollers from the saw are worn, the track rollers are over 0,6 mm worn measured from
top to bottom.
It is adviced to replace these bearings.
- The hardmetal guidance block that pushes on top of the blade is broken.
It is recommended to replace this hardmetal block for an new one.
- Problems with roller conveyor. According to the operator they have an issue with the roller
conveyors. Apparently when the roller conveyors are used not always the correct sections
are used, and even sometimes some rollers would run inverted.
As the machine has never ran during my visit I haven’t seen this myself, this would need to
be looked at when the machine is back running again.
