XYZ Machine Tools ProtoTRAK SLX CNC, Safety, Installation, Maintenance, Service & Parts List Manual

Page 1: ...anual Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 USA T 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales southwesternindustries com service...

Page 2: ...effort has been made to include all the information required for the purposes of this guide XYZ Machine Tools assumes no responsibility for inaccuracies or omission and accepts no liability for damag...

Page 3: ...3 3 5 Problems Reading the Floppy Disk 27 3 3 6 System Will Not Turn ON 28 3 3 7 System Will Not Boot Up 28 3 3 8 System Reboots by Itself 28 3 3 9 System Shuts Off 28 3 3 10 Will Not Hold Calibration...

Page 4: ...m the Lathe 88 6 2 3 Troubleshooting the Indexer 89 6 2 4 Troubleshooting the Cable Breakout Box 89 7 0 Drawings Parts Lists Fig 1 SLX 1630 Floor Plan Layout Space Specifications 5 Fig 2 Anchor Bolt S...

Page 5: ...se adequate point of operation safeguarding It is the responsibility of the employer to provide and ensure point of operation safeguarding STATEMENT OF INTENDED USE To be used for the turning of cold...

Page 6: ...ing parts Wear adequate safety headgear 7 Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes 8 Take off gloves before you start the machine Gloves are easily caught...

Page 7: ...o the workpiece or the cutting tool Never start the machine including the rotation of the spindle if the tool is in contact with the part 22 Don t use dull or damaged cutting tools They break easily a...

Page 8: ...on Service Parts List Manual 2 0 Installation Read and understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layout Space Requirements Figure 1 May not...

Page 9: ...the wood pallet ATTENTION Immediately report in writing any damages observed at this time that can be attributed to the transportation or improper handling moving of the machine 2 3 Shortages Invento...

Page 10: ...the way surfaces 13 Position the saddle and tailstock to the center of the bed for leveling 14 Check the level of the machine The machine should be level to within 0 02 mm longitudinally and 0 01 mm t...

Page 11: ...N position in DRO to test 27 Wipe down the machine prior to leaving CAUTION If the PRO TURN 1630 has a chuck mounted to the spindle make sure the cam locks are tight and the chuck jaws are engaged ont...

Page 12: ...Spindle Diameter Front Bearing 80 mm Number of Bearings 2 Bearing Class Radial Runout P5 Number of Spindle Speed Ranges 1 Spindle Speed Range RPM 150 2500 Tailstock Quill Travel 127 mm Quill Diameter...

Page 13: ...arbonate sealed membrane and gasket sealed control enclosure to lock out contamination 266 7 mm color LCD for clear presentation of prompts status information and part graphics Modular design simplifi...

Page 14: ...with a forklift having less than 2722 kg capacity for the 1630 The shipping weight of the machines including electronics is 1247 kg Place the machine in position on top of the 4 rest pads for the SLX...

Page 15: ...le move freely and smoothly over their entire length 2 9 Leveling The precision and durability of the lathe depends on it being leveled properly Final inspection can be done only when the machine has...

Page 16: ...icity A 110 volt power source is needed for the pendant and is provided by the transformer DANGER Be certain that 415 volt electricity is used only with a machine labeled 415 volts and at the electric...

Page 17: ...arying loads in the system The electrical load on the machine will vary based on the type of cut taken and the speed of the motor Static phase converters can only be used on machines with a non varyin...

Page 18: ...on the pendant to match up the connectors with the correct port The machine ID key and option keys should be plugged into the port labeled as such The test port and X and Y handwheel ports will be le...

Page 19: ...15 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 6 Cable Connections...

Page 20: ...16 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 7 Pendant Cable Connections Left Side...

Page 21: ...spindle check to make sure the headstock oil reservoir is full A site glass is located under the spindle cover If low fill the site level with Mobil DTE 24 or equivalent oil through the plug located...

Page 22: ...lly to control the Interval Time between pumping cycles and the Discharge Time of each pumping cycle The pump can also be run manually through a key found under service codes The following describes t...

Page 23: ...e pump at the beginning of each day or allowing the Auto Lube to run dry may cause severe damage to the 1630 lathe way surfaces and ballscrews The settings for the lube pump can be viewed by doing the...

Page 24: ...sure all the Way surfaces are getting proper lubrication If not check to make sure that the lube pump is functioning properly Also check for any pinched or blocked oil lines X Z axis Drive Trains are...

Page 25: ...ing Work piece not properly supported Use steady rest or follow rest reduce overhang from chuck headstock or tailstock Looseness in the gib or misalignment of ball screw Gib adjustment See Gib Adjustm...

Page 26: ...ostics See Mechanical Drive Train X Z Section 4 2 Calibration See Section 5 2 2 Calibration Failure of the spindle encoder Run service code 133 to check if the encoder counts Replace spindle encoder S...

Page 27: ...Gibs using the X axis Gib adjustment procedures See section 5 2 1 Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of t...

Page 28: ...nstant Code 127 Measure s the backlash in the system Code 128 Enter backlash compensation Possible Cause Check This Too much backlash entered in Code 128 Recheck the machines backlash See Section 5 2...

Page 29: ...check the connection from the computer module to the LCD see Section 5 1 3 Fuse blown in pendant Remove fuse and check continuity Computer Pendant failed See Computer Pendant Section 4 3 3 3 2 Bad Pic...

Page 30: ...iagnostics Section 4 4 Computer Pendant failure See Computer Pendant diagnostics Section 4 3 3 3 5 Problems Reading the Floppy Disk Programs Not Saved Properly The floppy drive will not read or write...

Page 31: ...uter Pendant failed See Computer Pendant diagnostics Section 4 3 Transformer output Check 110 V Transformer output 3 3 9 System Shuts Off During operation the system shuts off and will not turn back o...

Page 32: ...h the cable breakout box then none of these functions will work If the E Stop button is depressed and no message is displayed on the screen then either the E Stop button pendant spindle control module...

Page 33: ...repeat but with a dial indicator mounted to the spindle traversing the length of a gage block or some other measurement standard the measurement is not accurate Note If your part has incorrect dimensi...

Page 34: ...r Service Code 313 Check the line that specifies the product If the product does not match the machine then the machine ID key will need to be replaced 3 4 5 X and Z Axis Electric Handwheels Turn in W...

Page 35: ...dle Motor U V and W Caution Be sure to shut off all power to the machine before attempting to switch any wires 3 5 4 Excess Gearbox Noise Gearbox noise is louder than normal Run the lathe at the gear...

Page 36: ...t and reassemble 3 5 6 Tailstock Barrel is Stiff The tailstock barrel is stiff or not smooth moving through its travel The tailstock barrel subassembly jams inside the tailstock Possible Cause Check T...

Page 37: ...yield acceptable results It is good machining practice to avoid the use of shop air to clean the chips off a machine This risks blowing chips into the sliding way surfaces and compromising the perform...

Page 38: ...ase spindle speed Use a higher rake angle tool Make sure tool is not dull or chipped Use proper grade of cutting tool Use coolant Check to see if tools are on the centerline Long workpieces out of rou...

Page 39: ...travel Values that differ from that of above may correspond to misaligned ball screws The following steps take you in a logical sequence through the assemblies If the step doesn t isolate or resolve t...

Page 40: ...insufficient indication that it is bad this will just be a costly delay to resolving the real problem See Z Ball Screw Removal Section 5 1 13 X Ball Screw Removal Section 5 1 11 Aligning Z Ball Screw...

Page 41: ...disk drive is working If format does not work reboot control and see if it now works If it does not work replace the computer module 7 Press ALT ESC to get back to PT4 software 4 4 Motor Diagnostics...

Page 42: ...power cable or computer module In some cases it is not always obvious which component is causing the problem This example will help us pinpoint the problem through a trial and error process Let s assu...

Page 43: ...m is shipped out assuming the customers shop has 415 V power If the transformer secondary tap is set on 115 volts Measure the voltage coming out of the transformer by placing the voltmeter across the...

Page 44: ...control module has 1 5 amp fuse 1 3 amp fuse and 1 12 amp fuse The spindle control module also has 6 110 V outlets that supply power to the pendant spindle lube pump indexer lamp and the door fan 4 C...

Page 45: ...41 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 10 Electrical Box Parts...

Page 46: ...LABEL REVISION LEVEL 1 24 22779 21 LABEL 1 25 21786 4 ADAPTER ASSY SLX E STOP JUMPER 1 30 24360 SLX 1630 AC DRIVE PROGRAMMED SLX 1630 1 31 24144 SHEETMETAL SLX POWER MODULE 1 32 21891 FILTER HIGH POWE...

Page 47: ...pendant is pressed 3 LED labeled TAP MODE light should be on whenever you are not tapping Light will be off when in the tap event 4 LED labeled TAP REVERSE this light will be on when the spindle chan...

Page 48: ...uld be on whenever the REV key on the pendant is being pressed 4 LED labeled LI SEL 4 is not used and should never be on 5 LED labeled LI SEL 3 this LED should be on whenever a tool position on the Do...

Page 49: ...45 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 11 Spindle Control Module LED s...

Page 50: ...s engaged for a threading routine Logic to Servo PWM This port is used to keep continuous feedback between the servos and the cable breakout box 110 VAC Outlet The outlet is for powering up the coolan...

Page 51: ...ode 33 or Code 313 These values will be valuable for troubleshooting 4 8 1 1 CODE 33 Software ID Code 33 is the software identification procedure The two types of software in the control include Softw...

Page 52: ...pgrade disk in floppy drive and press this service code New software will automatically download and control will reboot Please perform alignment routine afterwards 4 8 1 8 CODE 318 Activate Converter...

Page 53: ...ssing the Reset button The manual feature should only be used in extreme cases where the AUTO routine did not solve the problem Manual adjusts above 12 may lead to servo related problems 4 8 2 2 CODE...

Page 54: ...encoder is not reading then it will need to be replaced The feedrate should be a minimum of 180 ipm for X and 120 ipm for Z Shops with higher voltages will see higher values If the feedrate is less th...

Page 55: ...ore the calibration and backlash factors have been factors into the counts 4 8 3 4 Code 132 Electronic Hand Wheel Test Turn the X or Z axis electronic hand wheel The display should show movement as th...

Page 56: ...9 Code 326 Error Message Display Error Message Display is used to describes error messages 4 8 4 Operator Defaults Options Codes The following codes allow the user to set programming defaults or turn...

Page 57: ...e Emergency Stop 2 Remove the servo driver from the panel inside the electric cabinet 3 Remove the 4 cap screws that hold the servo driver and its heat sink plate to the panel 4 Disconnect the cable c...

Page 58: ...sure 11 Replace computer module or LCD enclosure 12 Follow the instructions in reverse order when reinstalling the new computer module or LCD enclosure 13 Make sure that all connectors are properly se...

Page 59: ...55 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 12 Figure shown with inner sheet metal removed Computer Module LCD Enclosure Replacement...

Page 60: ...ystem Flash Disk located on the back side of the mother board by pushing the eject button on the flash drive 9 Firmly insert the replacement System Flash Disk into the drive making sure that the label...

Page 61: ...57 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 13 Figure shown with inner sheet metal removed Flash Disk Replacement...

Page 62: ...s very important to keep the power cables and logic cables separated from each other The power cables consist of the 2 110 volt servo motor cables and 4 110 volt power cables for the pendant spindle m...

Page 63: ...a flange plate 5 1 10 Spindle Encoder Replacement 1 Unplug or remove all power from the lathe 2 Open the rear spindle cover to gain access to the encoder 3 Loosen setscrews on flexible coupling and t...

Page 64: ...60 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 15 SLX 1630 X Axis Drive Train...

Page 65: ...all 7204BECBP 2 20 15885 Spacer S45C 1 21 SLX 16300 Bearing Housing S45C 1 22 16314 Nut Clamp S45C j19x16UNF 1 23 24A 0216 Cone Clamping Element Brass 1 24 98481A090 Woodruff Key 3 1 8 x1 2 1 25 16983...

Page 66: ...1 72 Socket Head Cap Screw M12x65L 4 73 23337 81 Wiper Bedway Left Front Rubber 25 0334 1 74 24704 Ballscrew Z Axis SCM415 25 0310 1 75 Cover Bearing AVH7205 1 76 23940 Bearing Set Angular Contact Bal...

Page 67: ...ning the clamp nut first engage a few threads Then lightly tighten the locking screw slowly so that when you slowly thread the lock nut inwards you can feel some contact between the two threads 3 Once...

Page 68: ...loosen tailstock bearing housing 4 Snug but do not tighten the yoke mounting bolts 5 Move the ball screw manually and move the carriage to the tail stock end 6 Tighten the yoke this will align it vert...

Page 69: ...65 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 17 SLX 1630 Z Axis Drive Train...

Page 70: ...Ball 7204BECBP 2 20 15885 Spacer S45C 1 21 SLX 16300 Bearing Housing S45C 1 22 16314 Nut Clamp S45C 19x16UNF 1 23 24A 0216 Cone Clamping Element Brass 1 24 98481A090 Woodruff Key 3 1 8 x1 2 1 25 1698...

Page 71: ...7205 BECBP 2 77 SLX 16302 Spacer S45C 1 78 24A 0308 Seat Bearing S45C 1 79 Socket Head Cap Screw M8x25L 4 80 16452 Nut Clamp S45C 19x16UNF 1 81 24A 0216 Cone Clamping Element Brass 1 82 16983 1 Pulley...

Page 72: ...7 N m Note that the torque required to start breaking away torque the spindles rotation will be higher 3 Loosen the three setscrews on the spindle adjusting nut The spindle adjusting nut on the SLX 16...

Page 73: ...ailstock Alignment 5 1 18 Spindle Motor Wiring The SLX 1630 spindle motor is wired for 415 volts in the configuration The wiring consists of 3 phase power for the motor and 110 V power for the spindle...

Page 74: ...to move the cross slide back and forth to measure the amount of play The dial indicator should only move between a 0 005 mm and a 0 01 mm If it moves more than this then tighten the gibs 3 Turn the X...

Page 75: ...and set up of your system They should be re set when indicated in the Troubleshooting section or after the replacement of the computer module or any parts of the drive train Calibration is used teach...

Page 76: ...metric standard in a chuck in the spindle 13 Set up the magnetic base and 002 mm indicator on the cross slide 14 When the indicator is zeroed at the beginning of the standard press the INC SET key 15...

Page 77: ...ose bolts brackets bearings etc The backlash can also be found manually with a 0 002 mm indicator with the following method Load the indicator to zero from one direction and zero out the DRO Move the...

Page 78: ...dstock gearbox oil must be drained and flushed after the first 150 hours of operation A small percentage of kerosene may be added to the gearbox to flush out dirt and sediment Operate the machine for...

Page 79: ...should be cleaned and oiled frequently Figure 24 Tailstock Oil 5 2 3 3 Miscellaneous Information For all oilers on the machine use medium S A E NO 30 machine oil Before filling reservoirs or oil cups...

Page 80: ...ach tool station If there is a problem refer to the troubleshooting section 6 1 2 Removing the Indexer from the Lathe 1 Turn the main power off to the machine 2 Unhook the air line from the air regula...

Page 81: ...rk correctly Do not exceed 1034 kPa 150 PSI This will void the warranty on the indexer Check to make sure the air regulator is set to at least 552 kPa 80psi Fault 88 Indexer Not Initialized This messa...

Page 82: ...piece of square stock to rotate the turret manually to a true position Make sure to reverse the air lines back when complete It will be obvious when the indexer is back to a true position The indexer...

Page 83: ...79 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 25 Indexer Mounting...

Page 84: ...80 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 26 Indexer Cable Routing...

Page 85: ...problem refer to the troubleshooting section 6 2 2 Removing the Indexer from the Lathe 1 Turn the main power off to the machine 2 Disconnect 2 cables from the black box mounted on top of the lathe See...

Page 86: ...from the PLC used to run the 4 tool indexer 6 2 4 1 PLC Inputs There are 8 inputs to the PLC 7 of which are used for the 4 tool indexer For inputs 1 through 4 the corresponding LED light will be on de...

Page 87: ...tool indexer reports back up to 4 absolute positions to the PLC and the PLC will output up to 8 absolute positions back to the control ITEM TOOL 1 TOOL 2 TOOL 3 TOOL 4 TOOL 5 TOOL 6 TOOL 7 TOOL 8 BIT...

Page 88: ...84 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 27 Motor Driver Adjustments PLC Inputs and Outputs...

Page 89: ...85 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 28 Indexer Cable Breakout Box Mounting 1630...

Page 90: ...86 XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Service Parts List Manual Figure 29 4 Tool Indexer Cable Routing...

Page 91: ...arts List Manual 4 Tool Indexer Spare Parts List Item P N Title 1 23720 CABINET ASSY 4 TOOL INDEXER 2 23719 MOTOR ASSY 4 TOOL INDEXER 3 23718 3 4 INDEXER ASSY MODIFICATION 4 TOOL INDEXER 20 mm 4 23771...

Page 92: ...s Parts Lists Figure 30 Lathe Apron Assembly Item P N Title UseAs Qty 1 20082 2 ELECTRONIC HANDWHEEL X AXIS TRL EA 1 2 20082 3 ELECTRONIC HANDWHEEL Z AXIS TRL EA 1 3 20295 JOGSTICK ASSY EA 1 4 21046 H...

Page 93: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 89 Figure 31 1630 Machine Assembly...

Page 94: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 90 Figure 32 1630 Machine Assembly...

Page 95: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 91 Figure 33 1630 Machine Assembly...

Page 96: ...r FC25 1 15 Screw Adjusting S45C M20x2 5x220L 1 16 Hexagon Nut M20x2 5 3 17 50 0681 Spherical Washer Concave SS41 2 18 50 0682 Spherical Washer Convex SS41 2 19 25 0733 Stand End Cover SS41 1 20 24695...

Page 97: ...20C 4 46 77 0628 Spacer S20C 2 47 77 0626 Roller S45C 2 48 Socket Head Cap Screw M6x12L 5 49 25 0725 Guide Way Lower S45C 1 50 Domed Cap Screw M10 2 51 77 0629 Shaft S45C 2 52 22714 58 Bearing Deep Gr...

Page 98: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 94 Figure 34 1630 Headstock Assembly...

Page 99: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 95 Figure 35 1630 Headstock Assembly...

Page 100: ...CM440 25 0102 1 16 24717 Snap Ring S 78 2 17 24706 Gear Main Spindle S45C 77USA 0146 1 18 24732 Key 6x6x20L 1 19 24733 Snap Ring S 17 1 20 24707 Gear Spindle Encoder S45C 77USA 0145 1 21 6003 2RS Deep...

Page 101: ...MC1 25 0111 1 42 Socket Head Cap Screw M6x20L 2 43 Washer Flat M6 2 44 Washer Spring M6 2 45 24731 Gasket 25 0104 1 46 25 0103 Cover Headstock FC20 1 47 Socket Head Cap Screw M8x25L 6 48 Plug Oil PT 3...

Page 102: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 98 Figure 36 1630 Tailstock Assembly...

Page 103: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 99 Figure 37 1630 Tailstock Assembly...

Page 104: ...XYZ Machine Tools ProTURN SLX 1630 ProtoTRAK SLX CNC Safety Installation Maintenance Service Parts List Manual 100 Figure 38 1630 Tailstock Assembly...

Page 105: ...X30 25B SCREW SHCS STL BO EA 21 22712 21 51104 THRUST BEARING EA 22 22712 22 50 0510 00 DIAL IMPERIAL EA 23 22712 23 50 0511 00 HANDWHEEL EA 24 22712 24 50 03111 00 LOCKSCREW EA 25 22712 25 50 0513 00...

Page 106: ...02 49 22712 49 50 0534 00 SET SCREW EA 51 22712 51 50 0536 00 INDICATOR EA 52 22712 52 2X5LG RIVET 2x5LG EA 53 22712 53 50 0537 00 INDICATOR EA 56 22712 56 17 0504 0 2 SCREW EA 57 22712 57 14 0129 CEN...

Page 107: ...ies This warranty is expressly in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose and of any other obligations or...