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DECKEL MAHO

Technical documentation

DC V-Machines with Dialog 112


Version 3.02
(from SW-Level 1.3xx)

Service Documentation
Release - December 1995
Informations from MS-KS
DECKEL MAHO GmbH
Plinganserstrae 150
81369 Mnchen

M. Menacher

Hinweis

Contents subject to change.


All rights on this Documentation,
especially the right of duplication and
circulation as well as those of translation
remain reserved.
No part of this documentation may, in any
form (by Photocopy, Mikrofilm or any other
method) be reproduced or by utilisation of
electronic systems be duplicated or
distributed without prior written permission
of DECKEL MAHO GmbH Abt. MS-KS

Copyright 1995 DECKEL MAHO GmbH Munich

Contents

Control and Drives


Technical data ......................................................................................................... 6
Power supply QX084 ............................................................................................... 7
CPU QX141-1 and I/O QX524 ................................................................................... 8
Digital drive DC50 V ........................................................................................... 9-10
Digital drive DC70/100 V .................................................................................. 11-12

Interface RS-232
Data transfer cable ................................................................................................13
Interface configuration ............................................................................................14
Interface description ........................................................................................ 15-17

Software levels
CNC-PLC ...............................................................................................................18
Parameters ............................................................................................................18
Axes ......................................................................................................................18
Spindle ...................................................................................................................18

List of adjustments
Software-limit switches X/Y/Z-Axis ........................................................................19
Reference points X/Y/Z-Axis ..................................................................................19
Magazine wheel U-Axis .........................................................................................19
Oscilloscope function ............................................................................................19

Loading of Grundig / Mitsubishi Macros


Loading Grundig Macros ........................................................................................20
Loading Mitsubishi Macros ....................................................................................20
Reading Deckel Macros out ..................................................................................21
Reading Deckel Macros in .....................................................................................21

Servo / Spindle Module


Exchanging of Servo / Spindle module ..................................................................22
Coding the modules ...............................................................................................22

Tool changer positions - Language changeover


Entering tool changer positions into the PLC ........................................................23
Language changeover ............................................................................................23

Contents

Adjustments
Power ON, Programme start .................................................................................24
PLC RUN/STOP .....................................................................................................25
Deckel Macros .......................................................................................................25

Spindle orientation
Spindle orientation .................................................................................................26
Adjustment of quadrant transtition .........................................................................26

Adjustment of spindle encoder


Adjustment of Spindle encoder (Symmetry und Phase length) .............................27

Diagnosis
Diagnosis screen ...................................................................................................28

Mitsubishi Options screen


Mitsubishi Options .................................................................................................29

Axes compensation
Axes compensation X, Y, Z ...................................................................................30

PLC-Data / PLC-Bits
PLC-Data (Tool changer positions etc.) .................................................................31
PLC-BITs (Service and commisioning bits) ................................................... 32-36

Service-Softkeys
Service-Softkeys for TC (Toolchanger and PC (Palletchanger) .............................37

In and Outputs
In and Output screen .............................................................................................38

Inhaltsverzeichnis

DECKEL-Macros
All Macros 90xx .....................................................................................................39
calibration of measuring tip ....................................................................................39

PLC-flow
Functional flow .......................................................................................................40

NC-Memory expansion, Formating, NC-Option setting


Replacing CPU und I/O cards (Formating memory) ........................................ 41-42
NC-Memory expansion and option setting ....................................................... 43-44

Options
Measuring systems DC50-V ..................................................................................45
Measuring systems DC70V/100V ..........................................................................46
Spindle 8000/15000 ...............................................................................................47
Magazine wheel with 30 tools ................................................................................47
Tool break detector ................................................................................................48
Tool length measurment ........................................................................................48
Touchprobe ............................................................................................................48
IKUEZ (Internal coolant) .........................................................................................49
Light barrier ............................................................................................................49
Pallet changer ........................................................................................................49
Roto-Clear... ...........................................................................................................49
End of work shut-off ...............................................................................................49
UVV-Tool room solution .........................................................................................49
Digitsing .................................................................................................................49
Feed stop all axes .................................................................................................49
A-Axis ....................................................................................................................50
External axis release X23 ......................................................................................50
Spindle turning without axis block .........................................................................50
Spindle turning output Y14 ....................................................................................50
Override 100% (M84-M87) .....................................................................................50
External Pallet acknowledgement .........................................................................50

Error list
SPS Error messages ....................................................................................... 51-68

In and Outputs
DC50V ............................................................................................................. 69-73
DC70V-DC100V ............................................................................................... 74-77
Enclosure: Machine Dats sheets (DEMO)
Programming list und Alarmmessages

Dialog 112

Technical Data

Processor type

68040/25 MHz (Motorola 32 Bit)

Operating voltage

110 V AC

Colour monitor

14"

Floppy disc drive

3 " MS-DOS compatible (Option)


18,4 KB Transfer rate
14 ms block working time

Programme memory

236 KByte
Option 472KB, 2 MB

Inputs

40 Inputs 0/24 V

Outputs

16 Outputs 0,5 A
24 Outputs 2 A

Interfaces

2x RS 232 bis 19.200 Baud

Block working time

8 ms
1,6 ms High Speed Mode

Oscilloscope Function

Drive signals

Digital drive

5 Axes and Spindle (30 KW)

Probing times
(digitale Regelung)

1,7 ms Position
0,8 ms RPM
0,4 ms Current

Acceleration
0 to 30 m/min

180 ms

DECKEL MAHO GmbH - Service

Subject to change

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Page 6

Dialog 112
Powersupply QX084

110 V Input

Special fuse
Mains 110 V

110 V Output
(Monitor unit)
Power supply ON
24 Volt Error
Battery Error
Cotrol ON/OFF
CNC-Reset
0V
0V
- 12 V
+ 12 V
+ 5V
+ 5V
Battery Test
+ Battery
- Battery
Battery plug
+ 5V
0V
GND
GND
+ 24 V
0V

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Page 7

Dialog 112
CPU QX141-1

I/O QX524

Flash-ROM
Module

Kern-Software
Mitsubishi

GBI-Software
PLC-Software

4;


&(6

4;


&6+

to operating
panel

&6$

2x RS 232

S-RAM

GBI-Macros
PLC-Deckel

7DVWHU

EE-PROM

&6$

Machine parameters

6FKDOWHU

&6+

/('*UQ
/('*UQ

&6+

Digital output drives


(Axes/Spindle)

S-RAM

236kB

NC-Programme
Deckel-Macros

&'3

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Page 8

Digital drives DC 50V Dialog 112

Dialog 112

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Page 9

Dated:



CN9

CN4

CN7

CN5

CN9

CN1A

CN8

CN6

CN4

CN1B

Abschlustecker

CN2

CN9

CN3

CN4

CN1B

MDS-A-V1-35

CN1A

W14 Tacho Z-Achse

W16 Tacho Spindel

MDS-A-SP-185

Masstab

MDS-A-CV-300

Z-Achse

CN2M

CN2L

CN9

CN1A

CN3M

CN3L

CN4

CN1B

MDS-A-V2-3535

X/Y-Achse

W13 Tacho Y-Achse

Spindel

Steuerung
W12 Tacho X-Achse

Netzteil

Masstab

Subject to change
CN2

CN9

CN3

CN4

CN1B

MDS-A-V1-10

U-Achse

CN1A

W17 Tacho Wechsler

DECKEL MAHO GmbH - Service


Tacho A-Achse
W

Masstab

Digital drive DC 50V with A Axis

CN2

CN9

CN1A

CN3

CN4

CN1B

MDS-A-V1-05

A-Achse

Dialog 112

Page 10

Digital drive DC 70/100V Dialog 112

Dialog 112

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Page 11

Dated:



CN9

CN4

CN7

CN5

CN9

CN1A

CN8

CN6

CN4

CN1B

Abschlustecker

CN2

CN9

CN3

CN4

CN1B

MDS-A-V1-35

CN1A

W14 Tacho Z-Achse

W16 Tacho Spindel

MDS-A-SP-185

Masstab

MDS-A-CV-300

Z-Achse

W12 Tacho X-Achse

Spindel

CN2M

CN2L

CN9

CN3M

CN3L

CN4

CN1B

CN2

CN9

CN1A

CN3

CN4

CN1B

MDS-A-V1-05

MDS-A-V2-3535

CN1A

A-Achse

Masstab

X/Y-Achse

W13 Tacho Y-Achse

Netzteil

Masstab

Subject to change

Tacho A-Achse

DECKEL MAHO GmbH - Service


W

Steuerung

Digital drive DC70/100V with A Axis

Dialog 112

Page 12

Dialog 112

Interface wiring Dialog 112


CNC control
25 pol. Plug
GND 1
TXD 2
RXD 3
RTS 4
CTS 5
DSR 6
DTR 20
GND 7

Periphery equipment (Computer etc.)


25 pol. Socket
( 1 GND screening
( 2 TXD
( 3 RXD
( 4 RTS
( 5 CTS
( 6 DSR
( 20 DTR
( 7 GND Signal ground

25 pol. Plug

25 pol. Socket

CNC Control
25 pol. Plug
GND 1
TXD 2
RXD 3
RTS 4
CTS 5
DSR 6
DTR 20
GND 7

Periphery equipment (Computer etc.)


9 pol. Socket
( 1 DCD
( 2 RXD
( 3 TXD
( 7 RTS
( 8 CTS
( 6 DSR
( 4 DTR
( 5 GND Signal ground

9 pol. Socket

25 pol. Plug

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Page 13

Dialog 112
Reading In and Out of NC-Programmes and Machine Parameters

!! Important !!
Set machine and channel (Interface) correct
For interface wiring see page 11
Channel 1 = X110 (left socket on control cabinet)
Channel 2 = X164 (right socket on control cabinet)
#1 and ALL
Reading out of all NC-Programmes
#1 and <ENTER> Reading In of all NC-Programmes
#2 Tool-Data
#3 Machinen parameters
#99 and ALL2
Reading Out of all tool data
#99 and <ENTER> Reading In all tool data
(Before Reading In or Out, switch PLC to "stop" see page 25)
I/O DEVICE PARAMETER 9600 Baud, 7 Bit, 1 Stop-Bit, Even Parity
#
1
2
3
4
5

<0>
PC
1
1
0
1

DEVICE NAME
BAUD RATE
STOP BIT
PARITY EFFECTIVE
EVEN PARITY

6 CHR. LENGTH
7 TERMINATOR TYPE
8
CODE 1
9
CODE 2
10 REWIND CODE
11
12
13
14
15

HAND SHAKE
DC CODE PARITY
DC2/DC4 OUTPUT
CR OUTPUT
EIA OUTPUT

<1> <2> <3> <4>


0
0
0
0

3
0
0
0
00 00
00 00
00 00
1
0
0
1
0

0
0
0
0
0

0
0
0
0
0

0
0
0
0

0
0
0
0

0
0
0
0

0
0
0
0
0
0
00 00 00
00 00 00
00 00 00
0
0
0
0
0

0
0
0
0
0

#
16 TITLE FEED OUT
17 FEED CHR.
18 PARITY V
19 TIME-OUT SET
20 RST IGNORE
21 EIA CODE [
22
]
23
#
24
*
25
=

26
:
27
28
29
30 PRINTER TYPE

Configuration on PC

Programme header V24

9600 Baud
7 Data bit
1 Stop bit
EVEN Parity
RTS ON
CTS ON

% oder 1 Blank line


O200 (Remarks)
N1 X . . .
N2 G0 . . .
N100 M30
%

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IN/OUT 6. 2/3

Subject to change

<0>
0
0
0
0
0

<1>
0
0
0
0
0

<2> <3> <4>


0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

00
00
00
00
00

00
00
00
00
00

00
00
00
00
00

00

00

00

00

00

00
00
00
00
00

00
00
00
00
00

Programme header
Floppy
% oder 1 Blank line
O200 (Remarks)
N1 X . . .
N2 G0 . . .
N100 M30
%

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Page 14

Dialog 112

Interface description

DEVICE
NAME

Name of Interface. z.B. PC, PLT

max. 3 Characters

BAUD
RATE

Input of Baudrate

0
1
2
3
4
5
6
7

STOP
BIT

Stop Bits

1 =
2 =
3 =

PARITY
EFFECTIVE

Parity checking

0 = no parity bit
I = parity
bit

EVEN
PARITY

Parity checking

0 = odd
1 = even

CHR.
LENGTH

Length of a character

0
1
2
3

= 5 (Bit)
=6
=7
=8

TERMINATOR
TYPE

Last character for termination of


Data Read in

0
1
2
3
4
5

= no termination chatacter
= EOB or EOR
= EOB
= EOR
= any character
= any 2 characters

Code 1

Setting the character 1 , if the character


4 or 5 is entered in # 7

0 to FF (hex)

Code 2

Setting the character 2 , if the character


5 is entered in # 7

0 to FF (hex)

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Subject to change

=19200
= 9600
= 4800
= 2400
= 1200
= 600
= 300
= 110

Dated:

bps
bps
bps
bps
bps
bps
bps
bps

1 bit
1.5 bit
2 bit



Page 15

Dialog 112

Interface description

10

REWIND
CODE
PARITY

Should be used compatible to the Tape


reader .Will not be rewound with 0

0 to FF (hex)

11

HAND
SHAKE

RS-232-C Communiations Interface is


is being configuriert

1 = RTS/CTS System
2 = No Handshake
3 = DC Code System
(XON / XOFF Protokoll)

12

DC
CODE
PARITY

Valid only if 3 has been selected in #11


ist

0 = No parity
1 = With even parity

13

DC2
DC4
OUTPUT

When the data is sent from the NCSystem to the Output and the unit is
started through DC Code

0
1
2
3

14

CR
OUTPUT

By selecting, a < CR > will be inserted


before the < LF >

0 = no
1 = insert

15

EIA
OUTPUT

Output in ISO or EIA Code.


Code is automatically identified on
input

0 = ISO Code Output


1 = EIA Code Output

16

TITLE
FEED
OUT

Gives the titel (Programme number and


remarks) at the beginning. Specially for
punched tape

0 = no
1 = give title

17

FEED
CHR.

Forward character.
Amount of empty characters at the
beginning of the punched tape

0 bis 999 characters

18

PARITY
V

Whether parity is evaluated within block

0 = no
1 = valid

19

TIMEOUT
SET

Time-out for the verification of the


transmission. Error message if the
transmission of a block or 250 characters
exceeds this time. Time may have to be
changed if the Baud rate is changed.

0 to 999 (0,1 sec)

DECKEL MAHO GmbH - Service

Subject to change

= without DC2 and DC4


= with DC2, without DC4
= without DC2, with DC4
= with DC2,
with DC4

Dated:



Page 16

Dialog 112

Schnittstellen-Beschreibung

20

Data
ASCII

Enter: whether data for computer link are


ISO or ASCII

0 : ISO
1 : ASCII

21
22
23
24
25
26

EIA
Code
[] # * = :

The alternative codes for the 6 characters


which exist in the ISO format but not in
the EIA format are mentioned here.
The code entered here should not exist in
the EIA format; and it should not equal
parity H

0 to FFH

30

Printer
Type

Enter printer type

0 = No printer
1 = Nada
2 = Epson

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Page 17

Dialog 112

Software levels

CNC / PLC
Diagnosis
Softkey F6 (Config)
MAIN
BOAD
FONT
LANG1
LANG2
PLCu = Software level PLC

Machinen parameters
BA Manual
Softkey F9 (Continue)
Softkey F3 (Customer service)
Password FD <ENTER>
Softkey F2 (Configure)
Softkey F9 (Continue)
Softkey F9 (Continue)
Softkey F2 (PLC-Data)
#48 = Software level machine parameters

Axis module X/Y/Z/U


Button Diagnosis
Softkey F3 (Servo)
Turn to page 3 with ">"
SW/VER = Software level axis module

Milling spindle
Button Diagnosis
Softkey F4 (Spindle)
Turn to page 1 with ">"
SW/VER = Software level spindle

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Page 18

Dialog 112

Adjustment procedure
Software limitswitch X/Y/Z Axes
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F9
(Continue)
F2
(Axis)
#13 OT (- Limitswitch)
#14 OT (+ Limitswitch)
Distance to next grid point X/Y/Z (Reference point)
Button Diagnosis
F3
(Servo)
Net (is distance "Reference point - cam switching point" to next grid point)
Should be between 2 - 6
Reference point shifting Magazine wheel (U-Axis)
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F9
(Continue)
F2
(Axis)
F3
(Ref.Pt.)
#13 U-Axis
Adjusting magazine wheel:
Open magazine loading door (Switch off regulator release)
Release magazine wheel brake (Bit selection #8 Bit 5) page 32/33
! Important ! The calculated value in the display "U-Axis" (Diagnosis)
- write 9.000 in #13 (20 Magazine)
- write 6.000 in #13 (30 Magazine)

Oscilloscope function
Ba 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configuration)
F3
(Process)
#44 Set F0 selection to 1
Shift Diagnosis

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Example
#1 .... 100
(Time deviation)
#2 .... X, Y, Z , U or 1 fr Spindle
#3 .... 1
(Current)
#4 .... 200
(Amplitude)
#5 .... 0
(Zero line shifting)

Subject to change

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Page 19

Dialog 112

Grundig-/Mitsubishi-Macros
Grundig-Macros are Boring and Cycles.
Grundig macros
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F4
(Load cycles)
<ENTER>

Mitsubishi macros laden


BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F9
(Continue)
F1
(Base)
>
(page 4/7
#38 set fix_p to 1
BA 3 (Programming)
F8
(Data transfer)
F1
(Reading in)
#4
<ENTER>
#38

set fix_p to 0

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Page 20

Dialog 112

Reading In and Out of DECKEL macros


These are (9001-9xxx) stored in a protected portion of the memory
Reading out of macros
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
#40 Unlock edit lock B (Display should be blue)
F9
(Continue)
F1
(Base)
>
(Page 4)
#39 Type edlk_c "0"
BA 3 (Programming)
F8
(Data transfer)
F2
(Reading out)
#1
(.....) (.....) Macro numbers (9001-9xxx )
or all Deckel Macros und NC-Programmes will be read out with "ALL"

Reading in macros
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
#40 Unlock edit lock B (Display should be blue)
F9
(Continue)
F1
(Base)
>
(Page 4)
#39 Type edlk_c "0"
BA 3 (Programming)
F8
(Data transfer)
F1
(Reading in)
#1
(.....) and Macro number (9001-90xx )
or all Deckel Macros und NC-Programmes will be read in with "ENTER"
!!! DO NOT FORGET !!!
Set #39 to "1"

#40 (EdlinB) NC-Prg. 8000 - 9999 protected


#39 (EdlinC) NC-Prg. 9000 - 9999 protected

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Page 21

Dialog 112

Exchanging of Servo / Spindel module


Copying of Software to the Module
Should an axis or spindle module need to be exchanged, care must be taken to load the valid
software into the module.

Procedure
- Mainswitch off
- Remove defective module
- Install new module
- Turn coding switches on new Servo or Spindle module by 180
- Pull out left and right Flashrom
- Plug Master Flashrom in left position
- Control on
- A menu is displayed on the monitor
- Adjust servo or spindle module as per instructions
- Control off
- Plug both System Flashroms in again
- Turn coding switches on new Servo or Spindle module by 180 back to normal position
- Control on
Coding of indvidual modules
X-Axis
0
Y-Axis
1
Z-Axis
2
U-Axis
3
A-Axis
4
B-Axis
5
Power supply

Spindle

3-6 (is always the last axis)

Unused

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Page 22

Dialog 112

Entering tool changer position in machine parameters


PLC-Data
BA1
F9
F3
FD
F2
F9
F9
F2

(Manual)
(Continue)
(Customer service)
<ENTER> (Password)
(Configure)
(Continue)
(Continue)
(PLC-Data)
(see page 31)

Language change (Software level: CNC 1.-24 / PLC 05VWC43-00)


Control

German

English

Base page 4/7 #21 lang 2 ........ 2 ................


PLC Data #8 ............................ 0 ................
Register R2234 ........................ 0 ................
Macro 9999 #33 ....................... 0 ................

French

Italian

Spanish

1 ................. 1 ................. 1................... 1


1 ................. 2 ................. 4................... 3
1 ................. 1 ................. 1................... 1
1 ................. 2 ................. 4................... 3

Example for Register setting, setting back:


DEVICE
DATA
MODE
( R2234 )
(
1)
( 1 ) = (setting)
(
0 ) ( 1 ) = (setting back)

Software level: CNC 1.-35/ PLC 05VWC55-00 or 07VWC55-00:


BA1
F9
F4
There

(Manual)
(Continue)
(Language)
are always two languages existing in the control, for example German and English.

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Page 23

Dialog 112

Hour counter
(non variable)

Power on
NC-Programme processing time
This Function enables
- the display of the complete time of control switch on
(exact: the drive amplifier with switch control on)
- the display of the complete NC-Programme processing time (from cycle start
to end of Programme respectively break with [SHlFT + BREAK), substracting the
stand still time due to internal Feed Hold).
The times are displayed in hours in the globalen variables #500 und #501
Call
BA 2
Select programme 9030
Start programme (Cycle start)
BA 3
F6
(parameter)
Parameter #500 -> Mainswitch on
Parameter #501 -> Programme run

(in Hours)
(in Hours)

Hour counter
(variable)
Call
BA 1
F9
(Continue)
F2
(C-Modal)
>
(Page 2/2)
#1
#2
#3
#4
#5

Date
Time
Power on
Auto CNC
AutoMach

(complete time of control switch on)


(Programme running time from cycle start to M02, M30)
(Programme running time, substracting the stand still time due to internal
Feed Hold or override = 0, Cycle stop, ...)

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Page 24

Dialog 112

PLC RUN/STOP
BA 1 (Manual)
Press SHIFT BREAK
F9
(Continue)
F3
(Customer service)
FD
(Password)
F3
(Contactplan)
Display: MELDAS 500 SERIES PLC PROGRAMMING TOOLS
with MESSG. LADDER IO ST FILE
F7
(FILE)
Display: 2WRITE 4RUN/SR
F4
(RUN/SP)
Display: 0:RUN 1:STOP ( )
1
(Press <ENTER> , to stop PLC)
Press shift und button "5" (Dialog Mode)

Setting Deckel Macros


BA1
F9
F3
FD
F2
F9
F6

(Manual)
(Continue)
(Customer service)
<ENTER> (Password)
(Configure)
(Continue)
(Macros)

Macro screen
<CODE>
1 G [01]
211
2 G [02]
248
11 M [01]
12 M [02]
...

6
33

<TYPE>
1
1

<PROGRAMM>
9211
9248

1
1

9006
9033

Input line
e.g.. : tool length measuring macro
# ( 16 ) ( 91 ) ( 1 ) ( 9091 )

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Subject to change

Dated:



Page 25

Dialog 112

Spindle orientation
BA 1
F9
F3
FD
F2
F9
F9
F1
>
#15

(Manual)
(Continue)
(Customer service)
<ENTER> (Password)
(Configuration)
(Continue)
(Continue)
(Spindle)
Turn to page 4/30
(OPST) Type "0" (Reference point shifting)

BA 1 (Manual)
F4
(Customer service)
FD <ENTER> (Passwort)
F1
(Service)
Switch 1
(WW-SERVICE) <ENTER>
Switch 2
(Spindle orientation) <ENTER>
activate spindle orientation with cycle start
Estimate position of spindle dog to desired tool changing position (in degrees)
Multiply estimated value by 11,3777
Enter this value into #15 (OPST) and orient the spindle again.
Correct with 1 or more if necessary.
(1=11,3777 Units)

(1 Unit = 0,0878 degrees)

Spindle dog position for "Spindle orientation" (M19)


DC50-V is on the opposite side of the magazine
DC70-V, DC100-V is on the side of the Magazine

Compensating quadrant crossings


- Move Axis with F1000 in plus / minus direction
- Note current values from diagnosis screen
- Evaluate difference between plus and minus movements
- Enter values of the respective axis in machine parameter #9 LMC1 (Servo 2/2)
Example:
Z-Axis upwards:
Z-Axis downwards:
Difference = 20

DECKEL MAHO GmbH - Service

-40%
-20%
#9 LMC1 = 20

Subject to change

Dated:



Page 26

Dialog 112

Adjusting spindle encoder


Symetry und Phase position

Adjustment of the coder in the motor


1. Connect oscilloscope (2 channel) to measuring point A and B against GND
2.

Speed S1800, Override 100%

3.

While spindle is turning


- VR1 Adjustment of 0 point of phase A
- VR3 Adjustment of 0 point of phase B
- VR2
- VR4

Amplitude adjustment of phase A


Amplitude adjustment of phase B

- VR5

Referencepoint adjustment (zero point crossing of A-Phase)

VR2

VR4

VR1

VR3

VR5

DECKEL MAHO GmbH - Service

GND

B
A
Z

Subject to change

Dated:



Page 27

Dialog 112

Diagnosis
[Servo Monitor]
KV
(1/sec)
Droop
(i)
Speed
(rpm)
Current
(%)
MAX CUR1 (%)
MAX CUR2 (%)
Overload (%)
OverReg
(%)
AMP DISP
Alarm
Cyc Cnt
(p)
GRDSP
Mains
MAC POS
MOT POS
SCA POS
FB Error. (i)
DFB Comp (i)

Diagn 3. 1/3
<X>
0
0
0
5
161
6
0
0
D1
80002
8.000
4.539
0.000
333.685
333.685
0
0

<Y>
0
0
0
-4
143
5
0
0
D2

<Z>
0
0
0
-3
182
32
0
0
D3

-80002
8.000
4.166
0.000
-146.900
-146.900
0
0

-20004
8.000
3.831
0.000
-200.165
-200.165
0
0

15000
500

15000
500

10000
500

<U>
0
0
0
-2
35
3
0
0
D5
-55051
15.000
6.082
9.000
-359.990
-359.990
0
0

Example:
DC50-V (Axes moving )
Trailing error (Droop)
G0
F1000

ca:
ca:

Current (%)
G0
F1000

ca:
ca:

DECKEL MAHO GmbH - Service

20
10

15
5

Subject to change

Z+
4
40

Z60
15

Dated:



Page 28

Dialog 112

Mitsubishi Options
#
1
2
3
4
5
6
7
8
9
10
11
12
13

FF
E3
FF
BF
FC
FB
BF
F7
FF
9D
37
BF
DE

#
14
15
16
17
18
19
20
21
22
23
24
25
26

67
FF
33
00
00
00
00
00
FF
00
FE
00
00

#
27 00
28 00
29 00
30 00
31 00
32 00
33
1
34
4
35 10
36 00
37 D
38 100
39 60

#
40 100
41 600
42 000
43
0
44
1
45
46
47
48
49
4
50
51
52

#
53
54
55 10
56
57
58
59
60
61
62
63
64

Diag 6. 4/5

# 41 Working memory in meters


600 = 236kB RAM
1200 = 472kB RAM
2500 = 1MB RAM
5000 = 2MB RAM
# 34 Number of Axes (DC50V with A-Axis = 5)
# 49 Number of Axes (DC50V with A-Axis = 5)
# 16 = B3 Zero point G54.1
# 25 = 10

Ethernet

Access
Diagnosis
F6
(Config)
>
(Turn to page 4)

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 29

Dialog 112

Axis compensation
If after a software upgrade new parameter files are being read in, it is important that the tool
changer and compensation values are entered into the new files
(see data sheets in ciruit diagram file)
(see DEMO data sheets in the enclosure)
Axis compensation
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F9
(Continue)
F2
(Axes)
#11 G0 back
(Values as per data sheets)
#12 G1 back
(Values as per data sheets)
F5
#1
#2
#3
#4
#5
#6
#7

(MC-ERR Seite 1/11)


cmpax
(Values as per data sheets)
drcax
(Values as per data sheets)
rdvno
(Values as per data sheets)
mdvno
(Values as per data sheets)
pdvno
(Values as per data sheets)
sc
(Values as per data sheets)
spcdv
(Values as per data sheets)

Page 2/11
Page 3/11
Page 4/11

X-Axis
Y-Axis
Z-Axis

(Values as per data sheets)


(Values as per data sheets)
(Values as per data sheets)

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 30

Dialog 112
PLC-Data
MP
#1
#2
#3
#4
#5
#6
#7
#8
#9
#10
#11
#12
#13
#14
#15
#16
#17
#18
#19
#20
#21
#22
#23
#24
#25
#26
#27
#28
#29
#30
#31
#32
#33
#34
#35
#36
#37
#38
#39
#40
#41
#42
#43
#44
#45
#46
#47
#48

Values
90
60
7
10000
10000
60
10
0
0
743969
507000
507000
616487
422106
423500
-99200

20 (30)
50
10
-445912
499500
744000
617000
618000

Remarks
Interval time for central lubrication in minutes
Max. amount of lube impulses when below oil level
Amount of Axes
Feed in manual mode
Feed in test mode
Max. hydraulic running time in minutes
End of work shut-off in minutes
Display of second language
Position for spindle orientation
X-Axis 1.position magazine position (DC50-V) pallet change pos. (DC70-V)
X-Axis 2.position (waiting position) DC50-V
X-Axis 3.position (centre of measuring tip) DC50-V
Y-Axis 1.position pallet change pos(DC50-V) tool change pos(DC70/100-V)
Y-Axis 2.position pallet change position DC50-V
Y-Axis 3.position (centre of measuring tip"minus 8 mm") DC70/100V
Z-Axis 1.position (In position) down
Z-Axis 2.position (Out position) up
Z-Axis 3.position
Palett_2 Coordinate shifting X-Axis
Palett_2 Coordinate shifting Y-Axis
Palett_2 Coordinate shifting Z-Axis
Amount of magazine pockets
Window for "Magazine exactly in position"
time for screen saver
Position of tool length measuring tip (Z-coordinate)
(#26) OT+ <X> SW-limit switch machining area [Micrometer] DC50V
(#27) OT+ <X> SW-limit switch magazine area
[Micrometer] DC50V
(#28) OT+ <Y> SW-limit switch machining area [Micrometer] DC70/100V
(#29) OT+ <Y> SW-limit switch magazine area
[Micrometer] DC70/100V
Temperature compensation
Endposition X, Y, Z at the Ref.point mark
Endposition X opposite Ref.point mark
Endposition Y opposite Ref.point mark
Endposition Z opposite Ref.point mark

[Micrometer]
[Micrometer]
[Micrometer]
[Micrometer]
ACCESS
BA 1 (Manual)
F9
(Continue)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F9
(Continue)
F9
(Continue)
F2
(PLC-Data)

5
0
301

Delay from "Tool clamper open" (DC50-V)


Delay from "Tool clamper close"
Version of machine parameters

DECKEL MAHO GmbH - Service

Subject to change

[Unit approx. 50 ms]


[Unit approx. 50 ms]

Dated:



Page 31

Dialog 112

PLC-BITs (Software level 1.2xx)


MP Bit

Marker

Text

#1_Bit0
#1_Bit1
#1_Bit2
#1_Bit3
#1_Bit4
#1_Bit5
#1_Bit6
#1_Bit7

M400
M401
M402
M403
M404
M405
M406
M407

Reference point search turning X-Axis


Reference point search turning Y-Axis
Reference point search turning Z-Axis
Reference point search turning C-Axis

#2_Bit0
#2_Bit1
#2_Bit2
#2_Bit3
#2_Bit4
#2_Bit5
#2_Bit6
#2_Bit7

M408
M409
M410
M411
M412
M413
M414
M415

Push button assignment turning X-Axis


Push button assignment turning Y-Axis
Push button assignment turning Z-Axis
Push button assignment turning C-Axis

#3_Bit0
#3_Bit1
#3_Bit2
#3_Bit3
#3_Bit4
#3_Bit5
#3_Bit6
#3_Bit7

M416
M417
M418
M419
M420
M421
M422
M423

#4_Bit0
#4_Bit1
#4_Bit2
#4_Bit3
#4_Bit4
#4_Bit5
#4_Bit6
#4_Bit7

M424
M425
M426
M427
M428
M429
M430
M431

#5_Bit0
#5_Bit1
#5_Bit2
#5_Bit3
#5_Bit4
#5_Bit5
#5_Bit6
#5_Bit7

M432
M433
M434
M435
M436
M437
M438
M439

DECKEL MAHO GmbH - Service

CNC Software level >= 1.3


SA: External Palett acknowledgement at loading area, X 4B
SA: IBAG Spindle installed
M53/M54 "Spindle turning" without feed hold during run up
Signal "Spindle turning" on output Y14
2. Language fixed
M18 with standby in gripper
Palett deviation compensation active
4. Axis is 1.round axis
5. Axis is 1.round axis
Light barrrier "Magazine pocket free"
External release of axes
Option: Roto Clear
Constant hydraulic
4.Axis is magazine axis
Hydraulic with level switch
IKUEZ (Internal coolant)
Spindle Star / Delta - Switchover
Chip flushing
Override 100% fixed
Measuring tip
Laser measuring unit
Touch probe
UVV-Tool room solution

Subject to change

Access
BA 1 (Manual)
F9
(Continue)
F3
(Customer service)
FD
<ENTER> (Password)
F2
(Configure)
F9
(Continue)
F9
(Continue)
F2
(PLC-Data)
F5
(Bit selection)

Dated:



Page 32

Dialog 112

PLC-BITs (Software level 1.2xx)


MP Bit

Marker

#6_Bit0
#6_Bit1
#6_Bit2
#6_Bit3
#6_Bit4
#6_Bit5
#6_Bit6
#6_Bit7

M440
M441
M442
M443
M444
M445
M446
M447

#7_Bit0
#7_Bit1
#7_Bit2
#7_Bit3
#7_Bit4
#7_Bit5
#7_Bit6
#7_Bit7

M448
M449
M450
M451
M452
M453
M454
M455

#8_Bit0
#8_Bit1
#8_Bit2
#8_Bit3
#8_Bit4
#8_Bit5
#8_Bit6
#8_Bit7

M456
M457
M458
M459
M460
M461
M462
M463

#9_Bit0
#9_Bit1
#9_Bit2
#9_Bit3
#9_Bit4
#9_Bit5
#9_Bit6
#9_Bit7

M464
M465
M466
M467
M468
M469
M470
M471

Switch off hydraulic function


Switch off central lubrication function
Switch off spindle lubrication function
Switch off standard coolant function
Ignore Error message hydraulic
Ignore Error message central lubrication
Ignore Error message spindle lubrication
Ignore Error message standard coolant

#10_Bit0
#10_Bit1
#10_Bit2
#10_Bit3
#10_Bit4
#10_Bit5
#10_Bit6
#10_Bit7

M472
M473
M474
M475
M476
M477
M478
M479

Switch off spindle motor coolant function

DECKEL MAHO GmbH - Service

Text
Option: Display with correction calculation
Option: Function 9
Option: Switch off (End of work shut-off)
Option: Clamp / Unclamp
Option: Digitise
Option: Screen saver
Option: Function 11
Option: Function 12
Activate service functions
Unselect palett changer
Unselect automatic tool changer
No MAH: Tool not in tool table
Unselect X-Axis
Unselect Y-Axis
Unselect Z-Axis
Unselect spindle
Ignore feed lock
Ignore spindle lock
Ignore read in lock
Ignore machine halt
Simulate Palett acknowledgement
Open magazine brake
VPC-Error simulation with button "Tool clamper open"

Ignore Error message spindle motor coolant

Subject to change

Dated:



Page 33

Dialog 112

PLC-BITs (Software-level 1.2xx)


MP Bit

Marker

#11_Bit0
#11_Bit1
#11_Bit2
#11_Bit3
#11_Bit4
#11_Bit5
#11_Bit6
#11_Bit7

M480
M481
M482
M483
M484
M485
M486
M487

#12_Bit0
#12_Bit1
#12_Bit2
#12_Bit3
#12_Bit4
#12_Bit5
#12_Bit6
#12_Bit7

M488
M489
M490
M491
M492
M493
M494
M495

#13_Bit0
#13_Bit1
#13_Bit2
#13_Bit3
#13_Bit4
#13_Bit5
#13_Bit6
#13_Bit7

M496
M497
M498
M499
M500
M501
M502
M503

Machinen type
Machinen type
Machinen type
empty
empty (Spindle)
empty (Spindle)
empty
empty

#14_Bit0
#14_Bit1
#14_Bit2
#14_Bit3
#14_Bit4
#14_Bit5
#14_Bit6
#14_Bit7

M504
M505
M506
M507
M508
M509
M510
M511

Measuring position in G1 (M91)


Positioning logic for tool change and tool length measurement
empty
empty
empty
empty
empty
empty

#15_Bit0
#15_Bit1
#15_Bit2
#15_Bit3
#15_Bit4
#15_Bit5
#15_Bit6
#15_Bit7

M512
M513
M514
M515
M516
M517
M518
M519

empty
empty
empty
empty
empty
empty
empty
empty

DECKEL MAHO GmbH - Service

Text

Temperature compensation

Subject to change

Dated:



Page 34

Dialog 112

PLC-BITs (Software level 1.2xx)


Additional BITs have to be set
MP Bit
S
Text

#49_Bit0
1
Timer values from programme - 0 Timer values from table
#49_Bit1
1
Counter values from programme - 0 Counter values from table
#49_Bit2
1
Activate integrating timers (T96-T103)
#49_Bit3
1
Keep counter (C0 - C23)
#49_Bit4
0
#49_Bit5
1
Switch off screen on DIO error
#49_Bit6
1
Overtemprature shutoff for screen
#49_Bit7
1
Overtemprature shutoff for controller on
#50_Bit0
#50_Bit1
#50_Bit2
#50_Bit3
#50_Bit4
#50_Bit5
#50_Bit6
#50_Bit7

1
1
1
0
1
0
0
0

Alarm messages on
Alarm messagesover R Register mode
Guide messages on

#51_Bit0
#51_Bit1
#51_Bit2
#51_Bit3
#51_Bit4
#51_Bit5
#51_Bit6
#51_Bit7

1
0
0
0
0
0
0
0

Onboard on

#53_Bit0
#53_Bit1
#53_Bit2
#53_Bit3
#53_Bit4
#53_Bit5
#53_Bit6
#53_Bit7

0
0
0
0
0
0
0
0

DECKEL MAHO GmbH - Service

Messages on all screens ON


Alarmmessages on all screens 1 Guide messages

Subject to change

Dated:



Page 35

Dialog 112

PLC-BITs (Software level 1.2xx)


MP Bit
S
Text

#57_Bit0
1
Highspeed Inputs X0 - X0F
#57_Bit1
0
#57_Bit2
0
#57_Bit3
0
#57_Bit4
0
#57_Bit5
0
#57_Bit6
0
#57_Bit7
0
#61_Bit0
#61_Bit1
#61_Bit2
#61_Bit3
#61_Bit4
#61_Bit5
#61_Bit6
#61_Bit7

0
1
0
0
0
0
0
0

Highspeed Outputs Y10 - Y1F

Macro parameter
see page 38

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 36

Dialog 112

Service switch for setup of tool changer


Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch

01: ........... Tool changer service


02: ........... Spindle orientation
03: ........... X+ SW-limit switch to magazine area
04: ........... X+ SW-limit switch to machining area
05: ........... X-Axis magazine position
06: ........... X-Axis waiting position
07: ........... Y-Axis tool change position
08: ........... Z-Axis In position (down)
09: ........... Z-Axis Out position (up)
10: ........... Gripper turning 180 degrees
11: ........... Gripper turning 0 degrees
(Basic position DC 70/100V)
12: ........... Arm standby position -> Magazine
13: ........... Arm magazine position -> Standby position (Basic position DC 70/100V)
14: ........... Arm standby position -> Spindle position
15: ........... Arm Spindle position -> Magazine position
16: ........... Release Magazine / Axes

Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch
Switch

17: ........... Pallet changer service


18: ........... Open door
19: ........... Close door
20: ........... Unclamp pallet
21: ........... Clamp pallet
22: ........... Pallet clamped
23: ........... Y-Axis pallet 1
24: ........... Y-Axis pallet 2
25: ........... Deposit pallet 1
26: ........... Bring pallet 1
27: ........... Deposit pallet 2
28: ........... Bring pallet 2
29: ........... Position X-Axis
30: ...........
31: ...........
32: ...........

Select one maingroup and one function,


and start with cycle start.
e.g.: moving forward and backward to the TC position in the Magazine area (DC50-V)
#1
(TC-Service)
#9
(Z-Axis out position up)
#6
(X-Axis waiting position)
#3
(X+ SW-limitswitch to magazine area) # 4
(X+ SW-limit switch to work area)
#5
(X-Axis Magazine position)
#1
(is automatically erased)
Access
BA 1 (Manual)
F3
(Customer service)
FD
<ENTER> (Password)
F1
(Service)

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 37

Dialog 112
In- Outputs, Markers
76543210
X 0000 oooooooo
X 0008 oooooooo

HEX
00
00

7
X 0000 7
X 0008 F

6 5 4 3 2 1
6 5 4 3 2 1
E D C B A 9

0
0
8

X 0010 oooooooo
X 0018 oooooooo

00
00

X 0010 17 16 15 14 13 12 11 10
X 0018 1F 1E 1D 1C 1B 1A 19 18

X 0020 oooooooo
X 0028 oooooooo

00
00

X 0020 27 26 25 24 23 22 21 20
X 0028 2F 2E 2D 2C 2B 2A 29 28

X 0030 oooooooo
X 0038 oooooooo

00
00

X 0030 37 36 35 34 33 32 31 30
X 0038 3F 3E 3D 3C 3B 3A 39 38

X 0040 oooooooo
X 0048 oooooooo

00
00

X 0040 47 46 45 44 43 42 41 40
X 0048 4F 4E 4D 4C 4B 4A 49 48

X 0050 oooooooo
X 0058 oooooooo

00
00

X 0050 57 56 55 54 53 52 51 50
X 0058 5F 5E 5D 5C 5B 5A 59 58

X 0060 oooooooo
X 0068 oooooooo

00
00

X 0060 67 66 65 64 63 62 61 60
X 0068 6F 6E 6D 6C 6B 6A 69 68

X 0070 oooooooo
X 0078 oooooooo

00
00

X 0070 77 76 75 74 73 72 71 70
X 0078 7F 7E 7D 7C 7B 7A 79 78

X 0080 oooooooo
X 0088 oooooooo

00
00

X 0080 87 86 85 84 83 82 81 80
X 0088 8F 8E 8D 8C 8B 8A 89 88

X 0090 oooooooo
X 0098 oooooooo

00
00

X 0090 97 96 95 94 93 92 91 90
X 0098 9F 9E 9D 9C 9B 9A 99 98

HEX

Access
Diagnosis button
F5 ......................... (PLC)

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 38

Dialog 112

Deckel macros
MP
# 1
# 2

Macro
9211
9248

Call
G211
G248

Machine
DC50V DC70V DC100V
DC50V DC70V DC100V

M06
M33

Description
Calculation macro
Overmeasurement
programming
TC automatic
TC manual

#11
#12

9006
9033

#13
#14

9219
9090

M219
M90

Spindle orientation
Tool breakage

DC50V DC70V DC100V


DC50V DC70V DC100V

#15

9092

M92

Calibration

DC50V DC70V DC100V

#16

9091

M91

Tool length measurement


DC50V DC70V DC100V
(Option)
power on, automatic running DC50V DC70V DC100V
Text-Macro (Languages)
DC50V DC70V DC100V

9030
9999

DC50V DC70V DC100V


DC50V DC70V DC100V

Reading in and out of macros see page 21


Setting macros see page 25

Measuring tip "moving in and out"


- Move Y axis in plus direction to end position (only DC50V)
- Erase error message with Reset switch (only DC50V)
- Block movement mode
- N1 M150
[Measuring tip comes out]
- N2 G04 X20
[Measuring tip stays out for 20 seconds]
- N3 M30
[Measuring tip goes in]
"Calibrating" measuring tip
- Change spindle tool with M6 T0
- Change calibrating tool with known length manually
- G54 set zero (in zero point shifting table )
- M92 H ... ... (length of the calibrating tool) R ... ... (radius of the calibrating tool)
- Cycle start
This function is active in block and automatic mode.

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 39

Dialog 112

PLC
Functional procedure
BA 1 (Manual)
Shift Diagnosis
F4
(LADDER)
F2
(CIRCUT)
F6
(MONIT)
Y1
(Example for Input Y1)

PLC

LADR

) Input line
1READ

2WRITE

DECKEL MAHO GmbH - Service

3INSERT

4DELETE

5CONVT

Subject to change

6MONIT

Dated:

MENU



Page 40

Dialog 112

Procedure for changing the CPU QX141-1 und I/O QX 524


newly formating the memory
Note: All machine parameters,NC programmes and Deckel macros will be lost while
exchanging the CPU.
1.

Store machinen parameters of the old CPU via the serial I/0.
!! (Note the interface configuration as these will be lost after formating the memory).
Store all NC programmes and Deckel macros (Prg.9001 ...) via the serial I/0.

2.

Mainswitch off

3.

Change CPU

4.

Flip DIP switches 1 and 3 on the CPU to the right

5.

Unplug bus cable from the amplifier (CSH 21 on the CPU)

6.

Mainswitch on
The two LEDs on the front of the CPU light up shortly and go off again
After they light up again, the whole RAM section of the CPU including
the Custom RAM and the NC Programme memory on the QX524 is erased
Selected options remain.

7.

Main switch off


Flip both the DIP switches back to the left

8.

Main switch on

9.

Configure Interface (Baudrate etc...)

10.

Read in machine parameters.

11.

Main switch OFF- ON (Very important !!)

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 41

Dialog 112

Procedure for changing the CPU QX141-1 und I/O QX 524


newly formating the memory
12.

Formating the memory


call control parameter
#40 Edit lock B must be blue
Call BASE Parameter picture 4/7
#38 fix_p ........................ "1"
#39 edlk_c ...................... "0"
BA3
Data tranfer
Activate F4 Delete
Type "Format" in the second bracket, press Enter
Answer the confirmation call after deletion with "Y"
<ENTER>
The Memory will be formated

13.

Copy the Mitsubishi Cycles from ROM into RAM.


Activate Softkey Read in
Type "4" into first bracket, Press Enter
The cycles will be read in

14.

Mainswitch Off - On
BA 3
F8 Data transfer
400 programme inputs and 236 K Bytes must be free

15.

Load Grundig Macros (see page 20)


Important !!
set # 38 after reading in back to 0

16.

Read customer programmes and FD macros back in again

17.

Set parameter # 39 to 1

18.

Mainswitch Off
Reconnect bus cable to CPU

19.

Control is now ready

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 42

Dialog 112

NC Memory expansion and setting Mitsubishi options


Note: By expanding the memory all NC programmes macros and machine
parameters are lost.
1.

Save all NC programmes and tool data via the serial I/O

2.

Set PLC to Stop (see page 25)

3.

Press Shift + 6
F5
(PLC/IF)

4.

Enter password

5.

Press Shift + 8
F9
(continue)
F1
(addition)
Set options (see page 29)

6.

Main switch Off - On

7.

Save machine parameters

8.

Main switch "Off"

9.

Only for memory expansion > 472KB

cell

data

( xxx ) (

type

) (x)

Remove I/0 CPU from the control unit.


Remove the present memory card after removing the 4 holding screws and replace
with new one.
Push the I/0 CPU back into the control unit.
10.

Flip DIP switches 1 and 3 on the CPU to the right

11.

Unplug bus cable from the amplifier (CSH 21 on the CPU)

12.

Mainswitch on
The two LEDs on the front of the CPU light up shortly and go off again
After they light up again, the whole RAM section of the CPU including
the Custom RAM and the NC Programme memory on the QX524 is erased
Selected options remain.

13.

Main switch off


Flip both the DIP switches back to the left

14.

Main switch on

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 43

Dialog 112

NC Memory expansion and setting Mitsubishi options


15.

Configure Interface (Baudrate etc...)

16.

Read in machinenparameters.

17.

Main switch OFF- ON (Very important !!)

18.

Formating the memory


call control parameter
#40 Edit lock B must be blue
Call BASE Parameter picture 4/7
#38 fix_p ......................... "1"
#39 edlk_c ...................... "0"
BA3
Data tranfer
Activate F4 Delete
Type "Format" in the second bracket, press Enter
Answer the confirmation call after deletion with "Y"
<ENTER>
The Memory will be formated

19.

Copy the Mitsubishi Cycles from ROM into RAM.


Activate Softkey Read in
Type "4" into first bracket, Press Enter
The cycles will be read in

20.

Mainswitch Off - On
BA 3
F8 Data transfer
400 programme inputs and 236 K Bytes must be free

21.

Load Grundig Macros (see page 20)


Important !!
set # 38 after reading in back to 0

22.

Read customer programmes and FD macros back in again

23.

Set parameter # 39 to 1

24.

Mainswitch Off
Reconnect bus cable to CPU

25.

Control is now ready

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 44

Dialog 112

Options
Measuring system
Measuring system DC50-V
Indirect measuring system without scale (Standard)
Parameter group
Page # Axis Description Value

Servo M_Param 4. 1/6 1 X


SPEC
0000
Servo M_Param 4. 1/6 2 X
MTYP
0082
Servo M_Param 4. 1/6 9 X
RNG1
100
Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

Y
Y
Y

SPEC
MTYP
RNG1

0000
0082
100

Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

Z
Z
Z

SPEC
MTYP
RNG1

0000
0082
100

Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

A
A
A

SPEC
MTYP
RNG1

0000
0080
100

Measuring system DC50-V


Direct measuring system with scale (Option)
Parameter group
Page # Axis Description Value

Servo M_Param 4. 1/6 1


X
SPEC
0010
Servo M_Param 4. 1/6 2
X
MTYP
8082
Servo M_Param 4. 1/6 9
X
RNG1
20
Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

Y
Y
Y

SPEC
MTYP
RNG1

0000
8082
20

Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

Z
Z
Z

SPEC
MTYP
RNG1

0000
8082
10

Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

A
A
A

SPEC
MTYP
RNG1

0010
8080
4

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 45

Dialog 112

Options
Measuring system
Measuring system DC70/100-V
Indirect measuring system without scale (Standard)
Parameter group
Page # Axis Description Value

Servo M_Param 4. 1/6


1 X
SPEC
0000
Servo M_Param 4. 1/6
2 X
MTYP
0082
Servo M_Param 4. 1/6
9 X
RNG1
100
Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

Y
Y
Y

SPEC
MTYP
RNG1

0000
0082
100

Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

Z
Z
Z

SPEC
MTYP
RNG1

0000
0082
100

Servo
Servo
Servo

M_Param 4. 1/6
M_Param 4. 1/6
M_Param 4. 1/6

1
2
9

A
A
A

SPEC
MTYP
RNG1

0000
0080
100

Measuring system DC70/100-V


Indirect measuring system with scale (Option)
Parameter group
Page # Axis Description Value

Servo M_Param 4. 1/6 1 X


SPEC
0000
Servo M_Param 4. 1/6 2 X
MTYP
8082
Servo M_Param 4. 1/6 9 X
RNG1
20
Servo M_Param 4. 1/6
Servo M_Param 4. 1/6
Servo M_Param 4. 1/6

1
2
9

Y
Y
Y

SPEC
MTYP
RNG1

0000
8082
20

Servo M_Param 4. 1/6


Servo M_Param 4. 1/6
Servo M_Param 4. 1/6

1
2
9

Z
Z
Z

SPEC
MTYP
RNG1

0000
8082
10

Servo M_Param 4. 1/6


Servo M_Param 4. 1/6
Servo M_Param 4. 1/6

1
2
9

A
A
A

SPEC
MTYP
RNG1

0010
8080
4

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 46

Dialog 112

Options
Spindle DC50/70/100 V
Spindle 8000 RPM (Standard)
Parameter group

Page

Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Bit selection

1/30
1/30
1/30
1/30
1/30
1/30
1/30
1/30
2/30
5/30
12/30
1/1

1
2
5
6
7
8
13
14
10
25
87
5

Description
slimt 1
slimt 2
smax 1
smax 2
smax 3
smax 4
stap 1
stap 2
TSP
CINP
SP87
Bit 1

Value
8000
0
8000
0
0
0
4000
0
8000
03E8
50
0

Spindle DC50/70/100 V
Spindle 15000 RPM (Option)
Parameter group

Page

Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Spindle
Bit selection

1/30
1/30
1/30
1/30
1/30
1/30
1/30
1/30
2/30
5/30
12/30
1/1

1
2
5
6
7
8
13
14
10
25
87
5

Description
slimt 1
slimt 2
smax 1
smax 2
smax 3
smax 4
stap 1
stap 2
TSP
CINP
SP87
Bit 1

Value
15000
15000
2199
15000
15000
15000
2199
4000
15000
03E8
100
1

Magazin wheel DC50-V


30 tools (Option)
Parameter group
Axis
M_Param 2.
Axis
M_Param 2.
Servo M_Param 4.
Servo M_Param 4.
PLC Data M_Param 10
DECKEL MAHO GmbH - Service

Page

1/2
1/2
1/6
4/6
1/1

1
2
7
23
22

Axis
U
U
U
U
U

Description

Value

rapid
clamp
PC2
SV023

7200
7200
30
4
30

Subject to change

Dated:



Page 47

Dialog 112

Options
Tool break detector
Parameter group
Page # Bit Value T brk. Value w/o Tbrk.

Bit selection M_Param 13


1/1 5 4
1
0
Parameter group
#
Call
Programme No.

Macro
14
M90
9090
Macro
15
M92
9092

Tool length measurement

Parameter group
#
Call
Programme No.

Macro
16
M91
9091

Touch probe DC50/70/100-V


Parameter group
Page # Bit Value with Tp. Value w/o Tp

Bit selection
1/1 5 6
1
0

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 48

Dialog 112

Options
IKUEZ Internal coolant DC50/70/100-V
Parameter group
Page # Bit Value with IKUEZ Value w/o IKUEZ

Bit selection
1/1 5 0
1
0

Light barrrier "Magazine pocket free" DC50-V


Parameter group
Page # Bit Value with light b. w/o light b.

Bit selection
1/1 4 2
1
0
Pallet Changer
Parameter group
Page # Bit Value with PC Value w/o PC

Bit selection
1/1 7 1
0
1
Roto-Clear
Parameter grouo
Page # Bit Value with RC Value w/o RC

Bit selection
1/1 4 4
1
0
End of work shut-off (FS)
Parameter group
Page # Bit Value with FS Value w/o FS

Bit selection
1/1 6 2
1
0
UVV-Tool room solution (WL)
Parameter group
Page # Bit Value with WL Value w/o WL

Bit selection
1/1 5 7
1
0
Digitising
Parameter group
Page # Bit Value with Digi Value w/o Digi

Bit selection
1/1 6 4
1
0
Feed stop all axes (VH)
Parameter group
Page # Bit Value with VH Value w/o VH

Bit selection
1/1 4 3
1
0
DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 49

Dialog 112

Options
A-Axis DC 50V
Parameter group
Page # Bit Value with A Value w/o A

Bit selection
1/1 4 1
1
0
PLC-Data
3
31
15
(with clamping) Bit selection
1/1 6 3
1
0
A-Achse DC 70/100V
Parameter group
Page # Bit Value with A Value w/o A

Bit selection
1/1 4 0
1
0
PLC-Data
3
15
7
(with clamping) Bit selection
1/1 6 3
1
0
External axis release X23
Parameter group
Page # Bit Value with A Value w/o A

Bit selection
1/1 4 3
1
0
Spindle turning without axis block (M53 M54)
Parameter group
Page # Bit Value with V Value w/o V

Bit selection
1/1 3 3
1
0
Spindle turning output Y14
Parameter group
Page # Bit Value with S Value w/o S

Bit selection
1/1 3 4
1
0
Override 100% (M84 M85 M86 M87)
Parameter group
Page # Bit Value with O Value w/o O

Bit selection
1/1 5 3
1
0
External Pallet acknowledgement
Parameter group
Page # Bit Value with P Value w/o P

Bit selection
1/1 3 1
1
0

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 50

Dialog 112
SPS error messages Dialog 112
Stand: 23.08.1994

mot

used

Rec.:
Eff.:
Sol.:
WTB:
3

A001

Star

PLC:

Delta

M 208

Modul:

switchover

Rec.:
Change
of
spindle
speed
which
requires
Eff.:
Feed halt all axes
Sol.:
automatically
WTB:
A003
PLC:
M 210
Modul:
spigetr
4

PC

not

Rec.:
Eff.:
Sol.:
WTB:
5

Safety
Rec.:
Eff.:
Sol.:
WTB:

Eff.:
Sol.:
WTB:
Synch.
Rec.:
Eff.:
Sol.:
WTB:
8

Touch

delta

switchover

position

with

appropriate

function
1. Galvanic seperation of drives or
2. Selection of key mode not correct or
3. Fault in key switch
Feed stop, spindle block and Cycle stop
1. Close door or press acknowledge
2. Select proper key mode
3. Replace key switch
A005
PLC:
M 212
Modul:
uvv
Internal

coolant

Flow

control

IKUEZ-Pump for internal coolant supply


flow control switch is not active
Feed block all axes
Automatic
A006
PLC:
M 213
Modul:
ikuez
Handcontrol

is

switched

on

but

to

hand

unit

transmission of a selection switch


unit is not complete
Feed block
Automatic
A007
PLC:
Modul:
handstl

change

the

control

probe

Rec.:
Eff.:
Sol.:
WTB:

base

Automatic pallet changer not in base positon


Feed halt all axes
Move
pallet
changer
back
to
base
position
softkey
A004
PLC:
M 211
Modul:
pw

IKUEZ
Rec.:

in

star

The command Touch probe ON


touchprobe is missing
Feed block all axes
CNC-Reset
A008
PLC:
M 215
Modul:

DECKEL MAHO GmbH - Service

Subject to change

is

present

and

standby

signal

messtast

Dated:



Page 51

of

Dialog 112

Spindle
Rec.:
Eff.:
Sol.:
WTB:

10

No

base

Rec.:
Eff.:
Sol.:
WTB:
17

X-Axis:

speed

not

reached

The actual spindle speed does not correspond


speed
Feed halt of main axes
(but no feed block in G0 blocks)
Automatic
A009
PLC:
M 216
Modul:
sammel
position

Y-Axis:

Automatic tool changer (ATC)


Feed block all axes
Move tool changer back to
softkey
A010
PLC:
M 217
Modul:
Releasing

Y-Axis:
Rec.:
Eff.:
Sol.:
WTB:

33

Z-Axis:
Rec.:
Eff.:
Sol.:
WTB:

34

Z-Axis:

Releasing

Measuring

Measuring

tip

not

A-Axis:

tip

Feed block
Feed block for
Automatic
A033
PLC:

Releasing

TC-Mag:

Releasing

DECKEL MAHO GmbH - Service

base

in

base

position

position

with

appropriate

wzw

axis

is

blocked

is

blocked

wzw

axis

wzw

not

in

for Z
Z axis

fully extended, feed


tip has returned

of

axis

is

Modul:messd_v3

Position
axis

M 240

is

active

till

measuring

tip

is

out

Modul:messd_v4

ATC
Z

axis

is

blocked

is

blocked

wzw

ATC

Rec.:
While releasing ATC, feed for
Eff.:
Feed block for A axis
Sol.:
Automatic, continue releasing
WTB:
A041
PLC:
M 248
Modul:
49

not

back

Rec.:
While releasing ATC, feed for
Eff.:
Feed block for Z axis
Sol.:
Automatic, continue releasing
WTB:
A034
PLC:
M 241
Modul:
41

is

ATC

When measuring tip is


blocked till measuring
Feed block for Y axis
Automatisch
A026
PLC:
M 233

Releasing

desired

ATC

Rec.:
While releasing ATC, feed for
Eff.:
Feed block for Y axis
Sol.:
Automatic, continue releasing
WTB:
A025
PLC:
M 232
Modul:
26

the

TC

Rec.:
While releasing ATC, feed for
Eff.:
Feed block for X axis
Sol.:
Automatic, continue releasing
WTB:
A017
PLC:
M 224
Modul:
25

to

axis

wzw

ATC

Subject to change

Dated:



Page 52

Dialog 112

Rec.:
While releasing ATC. feed for
Eff.:
Feed block for tool magazine
Sol.:
Automatic, continue releasing
WTB:
A049
PLC:
256 Modul:
wzw
82

TC

not

in

base

tool

magazine

Star

Delta

appropriate

PC

not

Rec.:
Eff.:
Sol.:
WTB:
85

Safety
Rec.:
Eff.:
Sol.:
WTB:

86

97

Axis

position

toolchange

with

appropriate

call

M33 was programmed or the switch Tool


Spindle block
End manual tool change;Cycle Start
A086
PLC:
M 293
Modul:
handwzw
block

by

touch

change

was

pressed

probe

Touch probe was changed into spindle


Spindle block
Change touch probe back into magazine
A087
PLC:
M 294
Modul:
messtast

Workpiece

Eff.:
Sol.:
WTB:

switchover

1. Galvanic seperation of drives or


2. Selection of key mode not correct or
3. Fault in key switch
Feed stop, spindle block and Cycle stop
1. Close door or press acknowledge
2. Select proper key mode
3. Replace key switch
A085
PLC:
M 292
Modul:
uvv

Spindle

Rec.:

delta

function

Rec.:
Eff.:
Sol.:
WTB:
88

base

star

Automatic pallet changer not in base positon


Feed halt all axes
Move
pallet
changer
back
to
base
position
softkey
A084
PLC:
M 291
Modul:
pw

Manual
Rec.:
Eff.:
Sol.:
WTB:

87

in

softkey

switchover

Rec.:
Change
of
spindle
speed
which
requires
Eff.:
Feed halt all axes
Sol.:
automatically
WTB:
A083
PLC:
M 290
Modul:
spigetr
84

blocked

position

Rec.:
ATC is not in base position
Eff.:
Spindle block
Sol.:
Move ATC back to base position with
WTB:
A082
PLC:
M 289
Modul:
wzw
83

is

loose

!!

Input workpiece clamped is not active


clamped / Unclamped not avaiable
Spindelblock Cycle stop
Input workpiece clamped
A088
PLC:
M 295
Modul:
wstspan
lubrication

DECKEL MAHO GmbH - Service

or

Function

workpiece

defect

Subject to change

Dated:



Page 53

Dialog 112

Rec.:

axis
lubrication
cycle
was
not
activated
two
series. i.e. the lube pressure was not reached
Eff.:
Read in block in the mode Automatic
Sol.:
Check pressure switch; Bleed lines
WTB:
A097
PLC:
M 305
98

Level
Rec.:
Eff.:
Sol.:
WTB:

99

The

Coolant

Axis

Oil below lower level


Read in block in the mode Automatic
Top up central lube unit for Guide ways
A098
PLC:
305
low

Spindle

in the mode
procedure

"Automatic"

orientation

Rec.:
Spindle is oriented by
Eff.:
Read in block till
Sol.:
Automatic
WTB:
A100
PLC:
M 307
101

Manual

toolchange

M 19
spindle

is

oriented

call

Rec.:
M33 was programmed or the switch Tool
Eff.:
Read in block in automatic procedure
Sol.:
End manual tool change;Cycle Start
WTB:
A101
PLC:
M 308
102

WZW

in

lubrication

Rec.:
Coolant low in water tank
Eff.:
Read in block in automatic
Sol.:
Top up coolant
WTB:
A099
PLC:
M 306
100

times

change

was

pressed

aktiv

Rec.:
Automatischer WReczeugwechsel ist aktiv
Eff.:
Read in block in automatic procedure
Sol.:
Beendigung des automatischen WZW
WTB:
A102
PLC:
M 309
103

Star

Delta

switchover

Rec.:
Change
of
spindle
speed
Eff.:
Read in block in automatic
Sol.:
Automatic
WTB:
A103
PLC:
M 310
104

PC

which
requires
procedure

star

delta

switchover

active

Rec.:
Automatic Pallet changer is active
Eff.:
Read in block in automatic procedure
Sol.:
End of pallet change
WTB:
A104
PLC:
M 311
106

Measuring
Rec.:
Eff.:
Sol.:
WTB:

tip

not

in

Position

Read in block as long as measuring tip


Read in block in automatic procedure
Automatic
A106
PLC:
M 313
Modul:messd_v3

DECKEL MAHO GmbH - Service

Subject to change

is

out

Dated:



Page 54

Dialog 112

129

Programmed
Rec.:

Axis

Axis

lubrication

Rec.:
Eff.:
Sol.:
WTB:

Coolant low
All axes stop
Machine stop
Top up coolant
A132
PLC:

Eff.:
Sol.:
WTB:
Manual

toolchange

Rec.:
Eff.:
Sol.:
WTB:
134

level

for Guide ways


Modul:
schmiz

in water tank
or G0 block
(Cycle stop)
M 339

in

the

Modul:

mode

spindle

from

Rec.:
Eff.:
Sol.:
WTB:
136

Speed

ikuez

call

coolant

PC

pressed

missing

ATC

not

not

was

defect

Fault from automatic tool


Machine stop (Cycle stop)
see exact messages
A135
PLC:
M 342

Rec.:
Eff.:
Sol.:
WTB:
137

"Automatic"

M33 was programmed or the switch Tool change


Machine stop ( Cycle stop)
Acknowledge manual tool change and cycle start
A133
PLC:
M 340
Modul:
handwzw

Motor

Fault

in

low

Rec.:
Confirmation message of spindle cooling
Eff.:
Machine stop (Cycle stop)
Sol.:
Check transmitter
WTB:
A134
PLC:
M 341
Modul:
spimoku
135

times

low

Rec.:

133

faulty

Lube level low


Machine stop (Cycle stop)
Top up central lube unit
A131
PLC:
M 338

Coolant

while

The axis lubrication cycle was not activated two


series. i.e. the lube pressure was not reached
Maschine stop (Cycle stop)
Check pressure switches; bleed lines
A130
PLC:
M 337
Modul:
schmiz

Eff.:
Sol.:
WTB:

132

lubrication

Rec.:

131

M0/M1

was programmed or M 1 was programmed


Selective stop was active
Machine Stop (Cycle stop)
Cycle Start
A129
PLC:
M 336
Modul:
bedienta

Eff.:
Sol.:
WTB:
130

stop

change
Modul:

wzw ???

Modul:

sammel

reached

Spindle speed is not reached


Maschine Halt (Zyklus Stop)
Reset
A136
PLC:
M 343
in

base

DECKEL MAHO GmbH - Service

???

position

Subject to change

Dated:



Page 55

Dialog 112

Rec.:
Automatic pallet changer not
Eff.:
Machine stop (Cycle stop)
Sol.:
Release via softkey
WTB:
A137
PLC:
M 344
Modul:
138

Fault

from

in

base

pw

PC

Rec.:
Fault in automatic pallet changer
Eff.:
Machine stop (Cycle stop)
Sol.:
see exact messages
WTB:
A138
PLC:
M 345
Modul:
pw
139

Safety

1. Galvanic seperation of drives or


2. Selection of key mode not correct or
3. Fault in key switch
Feed stop, spindle block and Cycle stop
1. Close door or press acknowledge
2. Select proper key mode
3. Replace key switch
A139
PLC:
M 346
Modul:
uvv

Eff.:
Sol.:
WTB:
TC

not

in

Rec.:
Eff.:
Sol.:
WTB:
141

142

base

position

ATC not in base position


Machine stop (Cycle stop)
Release via softkey
A140
PLC:
M 347
Modul:

Hydraulic
Rec.:
Eff.:
Sol.:
WTB:

procedure

function

Rec.:

140

position

level

wzw

low

Oil level in hydraulic level low


Machine stop (Cycle stop)
Check oil return; top up oil
A141
PLC:
M 348
Modul:
hyd

Magazine

door

open

Rec.:
An automatic tool change is called and magazine
Eff.:
Machine stop (Cycle stop)
Sol.:
Close magazine door and press cycle start
WTB:
A142
PLC:
M 349
Modul:
wzw
143

Reference
Rec.:
Eff.:
Sol.:
WTB:

144

Spindle
Rec.:
Eff.:
Sol.:

point

of

magazine

tool

no.

not

is

open

point

of

the

unknown

An automatic tool change is called and the ref


magazine is unknown is open (only with DC 50V)
Machine stop (Cycle stop)
Release ATC in reverse
Approach ref point of magazine
A143
PLC:
M 350
Modul:
-

door

O.K.

automatic tool change is called and the present T word is


not the is not the last automatically changed T word
Machine stop (Cycle stop)
Correct the T word:
1. with manual tool change
2. By deleting the second corretive value and bringing the
original T-number back into the spindle

DECKEL MAHO GmbH - Service

An

Subject to change

Dated:



Page 56

Dialog 112

WTB:
145

A144

A-Stop-Ta
Rec.:
Eff.:
Sol.:
WTB:

146

Eff.:
Sol.:
WTB:
147

Fault

during

T-No.-Error;

has

been

WTB:
clamp
Rec.:
Eff.:
Sol.:
WTB:
Hydraulic
Rec.:
Eff.:
Sol.:
WTB:
Too

many
Rec.:

Eff.:
Sol.:
WTB:

M6

call

Check

was

interrupted

as

positioning
of

the

axes

by

the

VPC

During opening and closing of the grippers during an


automatic tool change, the entries between the spindle and
tool pocket are exchanged
Machine
stop
(Cycle
stop)
after
completion
of
tool
change
Check
magazine
table
and
actual
status
of
tool
positioning
In case of contradiction please correct reality or table
(Please inform service)
A148
PLC:
M 355
Modul:
wzwctrl

Eff.:
Sol.:

Tool

PLC-Axis

The

A
contradiction
occured
during
positioning
PLC (during tool or pallet change)
Machine stop (Cycle stop)
Call service dept
A147
PLC:
M 354
Modul:
aposbef

Rec.:

151

vsm

Incr/Refpkt

Cycle stop from the TC macro.


it cannot be carried out
Machine stop (Cycle stop)
Correct programme and or data
A146
PLC:
M 353
Modul:

Eff.:
Sol.:
WTB:

150

Modul:

Increment
movementsar
reference
point
approaching
interrupted by pressing Constant feed stop
Machine stop (Cycle stop)
Cycle start
A145
PLC:
M 352
Modul:

Rec.:

149

at

M 351

M6-Macro
Rec.:

148

PLC:

not

OK

Tool clamp should be closed and the confirmation


Tool clamp is closed/Tool clamp is open is not
Machine stop Cycle stop)
Check switch for position sensing
A149
PLC:
M 356
Modul:
handwzw
running

time

is

not

OK

OK

The hydraulic ran longer than the PLC parameter permitted


(e.g. 1 hour). This happens when a function with hydraulic
gets stuck and machining is interrupted.
Machine stop (Cycle stop)
Remove fault (e.g. Override = 0, etc.) and continue with
cycle start. Release stuck function wit softkeys
150 PLC:
M 357
Modul:
hyd
moving axes
This message is generated if in an embargo version e3 more
than three axes are moved
Machine stop (Cycle stop)
Change NC programme so that not more than three axes are
moved in a NC block
A151
PLC:
M 358
Modul:emb_e3

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 57

Dialog 112

152

Entering

Rec.:

Workpiece
Rec.:

154

newly

The S word displayed in the manual mode shows the last


spindle speed programmed in this mode.
In the mean time another S word has been processed in the
automatic mode; this S word is active in the CNC. There is
therefore a discrepancy in the displayed S word and the
effective S word
Machine stop (Cycle stop)
Enter the S word required in the manual mode newly
A152
PLC:
M 359
Modul:
handwzw

Eff.:
Sol.:
WTB:
153

word

loose

!!

Eff.:
Sol.:
WTB:

Input workpiece clamped is not active


clamped / Unclamped not avaiable
Cycle stop
Input tool clamped
A153
PLC:
M 360
Modul: wstspan

Magazine

not

in

Digitising
Rec.:

Subprogramme
Rec.:
Eff.:
Sol.:
WTB:

161

word

Rec.:
Eff.:
Sol.:
WTB:
162

Spindle

workpiece

received

within

one

second

active

Digitising is active via softkey and a NC programme not


transmitted by the digitising computer, is started or the
programme transmitted by the digitising computer contains
subprogramme calls (M98/M99)
Cycle stop
Press softkey digitising
A155
PLC:
M 362
Modul:digi

Eff.:
Sol.:
WTB:
156

is

Function

position

Rec.:
Input magazine in Position is not
Eff.:
Cycle stop
Sol.:
Correct magazine position
WTB:
A154
PLC:
M 361
Modul:v4_mag
155

or

jump

The CNC control transmits


PLC
Cycle stop
Switch shift reset
A156
PLC:
M 363
missing

by

the

Function

M98

or

M99

to

the

Modul:digi

standby

M18 has been programmed without T word


Machine stop: Fault from Tool changer
Correct NC programme
A161
PLC:
Modul:
vsm
/

Standby

position

are

empty

Rec.:

M6 T0 programmed, but spindle and


without tools
Eff.:
None
Sol.:
Automatically at next tool change or
WTB:
A162
PLC:
Modul:
vsm

DECKEL MAHO GmbH - Service

Subject to change

standby

position

are

already

reset

Dated:



Page 58

Dialog 112

163

Tool

is

in

the

spindle

Rec.:
M6 Tx programmed and Tx
Eff.:
None
Sol.:
Automatically at next tool
WTB:
A163
PLC:
Modul:
164

WZ

ist

in

der

is

already

change
vsm

in

or

the

spindle

reset

Bereitstellung

Rec.:
M18 Tx programmed and Tx isalready in standby
Eff.:
None
Sol.:
Automatically at next tool change or reset
WTB:
A164
PLC:
Modul:
vsm
165

Tool

is

not

Rec.:
Eff.:
WTB:
166

167

Sol.:

Tool

standby

change
vsm

or

reset

magazine

table

missing

Call
pallet
change
but
pallet
release
is
Machine stop: Fault from pallet changer
Switch
Pallet
release
and
cycle
start
A169
PLC:
Modul:
pw
door

mag

in

machining
area
Pallet change call and pallet
machining area (M61 oder M62)

None
At
A171
ist

missing

open

The magazine door is open


None
Close magazine door
A170
PLC:
Modul:

Pallet
is
Rec.:

Rec.:
Eff.:
Sol.:

with

programmed

release

Magazine

Palette

ocupied

No T word programmed for M18


No standby of tool
Programme correctly
A167
PLC:
Modul:
wzw

Pallet
Rec.:
Eff.:
Sol.:

already

position.

not

word

Eff.:
Sol.:
WTB:
172

in

next tool
Modul:

Rec.:
Eff.:
Sol.:
WTB:
171

found

at

but standby position is


be positioned in standby.

M18 Tx programmed and tool is not in


Machine stop: Fault from tool changer
Enter desired tool into magazine table
A166
PLC:
Modul:
vsm

WTB:
170

standby

Tx programmed
Tool Tx cannot

Automatically
PLC:

A165

in

Rec.:
Eff.:
Sol.:
WTB:

Rec.:
Eff.:
Sol.:
WTB:
169

M18
Ty.

None

not

positioned

next pallet
PLC:
im

to

changed

is

already

in

change or at reset
Modul:
pw

Beladungsraum

M63 programmed and machining area


None
At next pallet change or at reset

DECKEL MAHO GmbH - Service

be

Subject to change

is

empty

Dated:



Page 59

Dialog 112

WTB:
173

A172

Pallet

change

Rec.:
Eff.:
Sol.:
WTB:
174

word

change

at

Tool

with

magazine

is

A177
not

TC

serial

tool

change

word

Empty spindle in exchange fot T


MAH: Fault from tool change
Change NC programme
A175
PLC:
Modul:
vsm

Rec.:
Eff.:
Sol.:
WTB:
179

missing

Transfer

Tool

possible

programmed without T word


Machine stop: Fault from tool changer
Change NC programme
A174
PLC:
Modul:
vsm

Rec.:
Eff.:
Sol.:
WTB:
178

fully

PLC:

Modul:

vsm

not used

found
The selected change tool is not found
Machine stop: Fault from tool changer
Change NC programme or enter tool number
A178
PLC:
Modul:
vsm

not

Tool

word

occupied

in

base

life

into

magazine

with

TC

not

in

base

position

wzw

exceeded

Rec.:

Life of selected change tool is exceeded; Sister


nonexistant
Eff.:
Machine stop (Cycle stop)
Sol.:
Change NC programme or alter tool life table or
WTB:
A180
PLC:
Modul:
vsm
181

Referencing
Rec.:

Eff.:
Sol.:

table

position

Rec.:
Break off of tool change
Eff.:
Machine stop (Cycle stop)
Sol.:
Release with softkey
WTB:
A179
PLC:
Modul:
180

pw

M6

Rec.:
Eff.:
Sol.:
WTB:
177

not

Modul:

M60 and machining area is empty


Machine stop (Cycle stop)
Change NC programme
A173
PLC:
Modul:
pw

Rec.:
Eff.:
Sol.:
WTB:
175

PLC:

the

tool
cycle

start

axis

tool change cycle was interrupted.


Reference points of axes were lost due to power failure.
The X axis has to be moved for the following release of the
tool changer.
The releasing cannot be contnued directly
Change to the mode 1.6 Reference point and approach
Reference point of X axis
Then continue releasing via softkey

DECKEL MAHO GmbH - Service

The

Subject to change

Dated:



Page 60

Dialog 112

WTB:
182

A181

Referencing

PLC:

the

Rec.:

G 996

Modul:

wzw

axis

tool change cycle was interrupted.


Reference points of axes were lost due to power failure.
The Y axis has to be moved for the following release of the
tool changer.
Eff.:
The releasing cannot be contnued directly
Sol.:
Change to the mode 1.6 Reference point and approach
Reference point of Y axis
Then continue releasing via softkey
WTB:
A182
PLC:
G 997
Modul:
wzw
183

The

Referencing

the

Rec.:

axis

tool change cycle was interrupted.


Reference points of axes were lost due to power failure.
The Z axis has to be moved for the following release of the
tool changer.
Eff.:
The releasing cannot be contnued directly
Sol.:
Change to the mode 1.6 Reference point and approach
Reference point of Z axis
Then continue releasing via softkey
WTB:
A183
PLC:
G 998
Modul:
wzw
184

Wrong

The

axis

Rec.:
Eff.:
Sol.:
WTB:
186

selected

While releasing the TC after reference point loss, it is


necessary to clock the individual axis. A wrong axis was
selected for referencing
Machine stop (Cycle stop)
Unselect wrong axis softkey
A184
PLC:
G 949
Modul:
wzw

Hydraulic

oil

level

Rec.:
Eff.:
Sol.:
WTB:
187

Coolant

occurs
Top
A186

Level
in
hydraulic
unit
under
minimum;
Hydraulic
not
running
Already
running
hydraulic
functions
will
not
be
interrupted
the next function will not be carried out and Machine stop
up oil
PLC:

in

M-Function

low

but

coolant
PLC:

Drives
Rec.:
Sol.:

unit
Modul:

hyd

pump
in

does

tank

not

Modul:

run
ikuez

invalid

Rec.:
A M-function
Eff.:
None
Sol.:
Reset
WTB:
188 PLC:
189

hydraulic
G 290

low

Rec.:
Coolant
Eff.:
None
Sol.:
Refill
WTB:
A187
188

low

was

programmed

Modul:

which

is

not

analysed

by

the

PLC

mdec

failure
Main

DECKEL MAHO GmbH - Service

Fault from
switch Off

drive
On

amplifier

while

Subject to change

control

on

Dated:



Page 61

Dialog 112

WTB:
190

189 PLC:
IKUEZ:

Modul:

maein

Motorschutzschalter

Rec.:

The
Motor
circuit
breaker
in
the
IKUEZ
Internal
coolant
unit
has tripped
Eff.:
Machine
stop
(Cycle
stop:
Fault
in
the
IKUEZ
Internal
coolant
unit
Sol.:
Reset motor circuit breaker
WTB:
190 PLC:
Modul:
ikuez
191

IKUEZ:

High

Rec.:

Fault

unit

Eff.:

IKUEZ:

Rotary

pump

in

the

Machine
unit
Remove fault
191 PLC:

Sol.:
WTB:
192

pressure

high

stop

filter

194

Max
Rec.:
Eff.:
Sol.:
WTB:

195

196

Min

level

Rec.:
Eff.:
Sol.:
WTB:
197

Chip

the

IKUEZ

Internal

coolant

ikuez

rotary

filter

(Cycle

stop:

skimmer

the

IKUEZ

Internal

tank below minimum


(Cycle
stop:
Fault
in

the

IKUEZ

Internal

coolant

Both level switches signal at the same time


Machine
stop
(Cycle
stop:
Fault
in
the
IKUEZ

Internal

coolant

clean

in

Modul:

clean
stop

tank
Modul:

Modul:
tank

level

machine

Rec.:

DECKEL MAHO GmbH - Service

Coolant

ikuez

not used

defect

switch
Modul:

ikuez

tank

The level in
Lifting pump
Automatically
196 PLC:
not

ikuez

tank

machine

flushing

ikuez

tank

machine

in

Fault

of

coolant

unit
Replace
195 PLC:

Sol.:
WTB:

coolant

Internal

switch

Rec.:
Eff.:

Internal

IKUEZ

194 PLC:

Level

IKUEZ

defective

unit
Top up coolant
193 PLC:

level

in

the

the

Coolant in
Machine

Sol.:
WTB:

Fault

of

in

low

Rec.:
Eff.:

pump

stop:

Modul:

Fault in the
coolant unit
Eff.:
Machine
stop
unit
Sol.:
Remove fault
WTB:
192 PLC:
Coolant

pressure

(Cycle

Rec.:

193

defective

machine tank is
is switched off
Modul:

lower than minimum


after 5 seconds

ikuez

possible
in

tank

for

dirty

coolant

Subject to change

Dated:



Page 62

Dialog 112

Eff.:
Sol.:
WTB:
198

Suppression of
Top up coolant
197 PLC:

IKUEZ:

Flow

Rec.:
Eff.:
Sol.:
WTB:
199

IKUEZ:

control

chip

flushing

Modul:

ikuez

defective

Pump for IKUEZ Internal coolant unit is


control is active for more than 5 seconds
Machine
stop
(Cycle
stop:
Fault
in
the

unit
Remove fault
198 PLC:

Flow

Rec.:

amount

Modul:

too

circuit

breaker

Mode

change

Rec.:

202

Switch

Star

204

Orienting

Key

low

IKUEZ

Internal

coolant

flow

even
coolant

has

and

mode

tripped

active

change

is

missing
area

door

was

not

opened

switchover

203 PLC:

Rec.:
Eff.:
Sol.:
WTB:
205

condition

delta

Rec.:
Eff.:
Sol.:
WTB:

shows

cabinet

The control is off and the machining


and closed
Drives cannot be coupled
Open and close machining area door
202 PLC:
Modul:
uvv

Eff.:
Sol.:
WTB:

Internal

blocked

on

Rec.:

203

control

The ATC or Pallet changer is


called
Mode change is suppressed
Cycle stop ,then change mode
201 PLC:
Modul:

Eff.:
Sol.:
WTB:

IKUEZ

flow

tripped

Rec.:
Motor
circuit
breaker
in
Eff.:
Emergency off
Sol.:
Reset motor circuit breaker
WTB:
200 PLC:
Modul:
201

and

low

The

Motor

off

ikuez

pump for the IKUEZ Internal coolant


unit is swiched off and the flow control
after two seconds
Eff.:
Machine
stop
(Cycle
stop:
Fault
in
the
unit
Sol.:
Remove fault
WTB:
199 PLC:
Modul:
ikuez
200

swiched

position

Modul:

spimoku

not used

missing

M19 and orienting position missing


Machine stop (Cycle stop)
Check machine parameters
204 PLC:
Modul:
spiricht

switch

DECKEL MAHO GmbH - Service

position

not

correct

Subject to change

Dated:



Page 63

Dialog 112

Rec.:

The position of the key switch between normal and setup


changed even though the axes and or spindle are moving
The new key position is not accepted
Cycle stop and correct key position
205 PLC:
Modul:
uvv

Eff.:
Sol.:
WTB:
206

Key

switch

defective

Rec.:

The key switch for changing the position between


setup is defective
Eff.:
Machine
stop
(Cycle
stop):
Safety
function
Sol.:
Remove fault
WTB:
206 PLC:
Modul:
uvv
207

Machining

area

door

is

Magazine

pocket

Rec.:

not

normal

and

unlocked

Rec.:
The machining area door is
Eff.:
None
Sol.:
Close or open door
WTB:
207 PLC:
Modul:
uvv
208

was

unlocked

but

not

opened

free

magazine pocket is gaurded by a light barrier


The tool change procedure orients itself by the Magazine and
tool table. A contradiction between the magazine table and
physical occupation of the magazine could lead to a collision
Eff.:
Machine stop (Cycle stop)
Sol.:
Release tool changer in reverse and correct magazine
occupation and or tool table
WTB:
A208
PLC:
G 928
Modul:
wzw
209

M-Function
Rec.:
Eff.:
Sol.:
WTB:

210

Loading
Rec.:
Eff.:
Sol.:
WTB:

211

Eff.:
Sol.:
WTB:
End

of

Rec.:
Eff.:

running

The CNC has called a M function in the PLC;


acknowledgement is blocked
The M function is being processed. The NC
further processed after acknowedgement of
Automatic
209 PLC:
Modul:
sammel
enclosure

is

selection

The

programme will
the M function

not

ok
was
processing

or

shutoff

The machine
Machine off

DECKEL MAHO GmbH - Service

be

changer unit is open


is stopped or not

It was tried to start a programme although none


selected in mode 2.1
Cycle start without function
Select programme in BA 2.1 and then start the
the test
A211
PLC:
Modul:
sammel
work

open

The loading enclosure of the Pallet


The processing of the pallet changer
permitted
close enclosure
210 PLC:
Modul:
pw

Programme
Rec.:

212

The

was

switched

off

Subject to change

by

the

end

of

Dated:

wotk

shutoff



Page 64

Dialog 112

Sol.:
WTB:
213

Switch
A212

Function

not

Rec.:
Eff.:
Sol.:
WTB:
214

216

maein

available
available

in

the

machine

configuration,

softkey
PLC:

Axis

lubrication

failed

Rec.:
Eff.:

Lubrication pressure not achieved


Cycle stop when a G0 block is called or all axes
Read-in lock after second fault in lube impulse
Check pressure switch
A214
PLC:
Modul:
schmiz

Modul:

Alarm

Spindle

Touch

Touch

standing

are

standing

Battery

spiallg

empty

Barrety for touch probe MP10 empty


Feed stop all axes
Replace battery or reset (Deletion of
A217
PLC:
Modul:
messtast

probe

are

amplifier

Fehler aus SpindelverstaRecer


Emergency off
Main switch Off/On
A216
PLC:
Modul:
probe:

was

aggallg

Axis
lubrication
level
not
OK
Rec.:
Lube level low
Eff.:
Cycle stop when a G0 block is called or all axes
Read-in lock after second fault in lube impulse
Sol.:
Top up central lube unit for guide way
WTB:
A215
PLC:
Modul:
schmiz

Rec.:
Eff.:
Sol.:
WTB:
218

again
G 8 Modul:

A
function
not
selected via softkey

Rec.:
Eff.:
Sol.:
WTB:
217

on

None
Release
A213

Sol.:
WTB:
215

machine
PLC:

not

feed

stop)

ready

Rec.:

Signal path touchprobe - OMM interrupted or cannot be


activated
Eff.:
Feed stop all axes
Sol.:
Clean
OMM.
remove
obstacle
interrupting
optical
signal
Observe 5 second rest time for touchprobe
WTB:
A218
PLC:
Modul:
messtast
219

Magazine

pocket

Rec.:

is

locked

tool is automatically removed from the magazine and


marking is 9 (automatic oder manual)
Eff.:
Cycle stop
Sol.:
Rewrite
marking
with
0-2
and
check
tool
(tool
break
WTB:
A219
PLC:
Modul:
vsm
220

Max.time:
Rec.:
Eff.:
Sol.:

Unclamp

path.

the
detector)

workpiece

Reserved

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 65

Dialog 112

WTB:
221

Max.

A220
time:

Rec.:
Eff.:
Sol.:
WTB:
222

A221

Input

gripper

Eff.:
Sol.:
WTB:
Input

Eff.:
Sol.:
WTB:
Input
Rec.:
Eff.:
Sol.:
WTB:
225

Input
Rec.:
Eff.:
Sol.:
WTB:

226

Input
Rec.:
Eff.:
Sol.:
WTB:

227

Input
Rec.:
Eff.:
Sol.:
WTB:

228

Input
Rec.:
Eff.:
Sol.:
WTB:

229

Input

wstspan

Modul:

wstspan

Workpiece

PLC:
0

degrees

missing

Input X4 (x70:b30) gripper has turned


missing
Process stopped
Please contact service department
A222
PLC:
Modul:
wzw_v4
gripper

Rec.:

224

Clamp

Modul:

Reserved

Rec.:

223

PLC:

180

degrees

position

position

position

locked

locked

DECKEL MAHO GmbH - Service

door

S_207

position

S_204

missing

position

S_218

missing

position

S_205

missing

locked

S_219

missing

locked

S_219

is

faulty

Input XB (x70:z26) TC gripper claw


Process stopped
Please contact service department
A228
PLC:
Modul:
wzw_v4
pallet

degrees

missing

Input XB (x70:z26) TC gripper claw


Process stopped
Please contact service department
A227
PLC:
Modul:
wzw_v4
tool

180

is

missing

Input X6 (x70:d28) TC in spindle


Process stopped
Please contact service department
A226
PLC:
Modul:
wzw_v4
tool

to

S_206

missing

Inputg X3 (x70:d30) TC in standby


Process stopped
Please contact service department
A225
PLC:
Modul:
wzw_v4
spindle

degrees

missing

Input X7 (x70:b28) TC in magazine


Process stopped
Please contact service department
A224
PLC:
Modul:
wzw_4v
standby

missing

Input X5 (x70:z30) gripper has turned


missing
Process stopped
Please contact service department
A223
PLC:
Modul:
wzw_v4
magazine

to

not

Zero

missing

Subject to change

Dated:



Page 66

is

Dialog 112

Rec.:
Eff.:
Sol.:
WTB:
230

Input

Input X41 (x71:b16) raising door to PC


Process stopped
Please contact service department
A229
PLC:
Modul:
pw_v4 pw_v3
pallet

Rec.:
Eff.:
Sol.:
WTB:
231

door

closed

double

carriage

position-1

Rec.:

232

Input
X47
position missing
Process stopped
Please contact
A231
PLC:

Input

double

carriage

233

Input
Rec.:
Eff.:
Sol.:
WTB:

234

Input
Rec.:
Eff.:
Sol.:
WTB:

235

Input
Rec.:
Eff.:
Sol.:
WTB:

236

Input
Rec.:

Eff.:
Sol.:
WTB:
237

Input

raised

missing

double

carriage

position-1

in

alternating

carriage

position-2

in

alternating

service department
Modul:
pw_v4
position-2

Input
X48
position missing
Ablauf steht
Please contact
A232
PLC:

pallet

closed

missing

(x71:b12)

Rec.:
Eff.:
Sol.:
WTB:

missing

missing

Input X42 (x71:z16) raising door to PC


Process stopped
Please contact service department
A230
PLC:
Modul:
pw_v3 pw_v4

Input

Eff.:
Sol.:
WTB:

open

missing

(x71:b12)

double

service department
Modul:
pw_v4

missing

Input
X4E
(x71:z08)
pallet
raised
missing
Process stopped
Please contact service department
A233
PLC:
Modul:
pw_v3 pw_v4
pallet

lowered

missing

Input X4D (x71:b08) pallet lowered missing


Process stopped
Please contact service department
A234
PLC:
Modul:
pw_v3 pw_v4
pallet

clamped

missing

Input X4C (x71:d08) pallet clamped missing


Process stopped
Please contact service department
A235
PLC:
Modul:
pw_v3 pw_v3
pallet

deposited

missing

DC 70/100 V Input X46 (x71:d12) pallet is changed


DC 50 V
Input X01 (x70:b32)
PC position-1 pallet in depositing pos. or Input
PC position-2 pallet in depositing pos. missing
Process stopped
Please contact service department
A236
PLC:
Modul:
pw_v3 pw_v4
pallet

Rec.:

DECKEL MAHO GmbH - Service

brought
DC

70/100

missing
X03

(x70:d30)

missing
V

Input

X45

(x71:z14)

Subject to change

pallet

changed

Dated:

missing



Page 67

Dialog 112

DC 50 V
Input X00 (x70:d32)
PC pos. 1 transfer position to machine or Input
PC pos. 2 transfer position to machine missing
Eff.:
Sol.:
WTB:
238

Input

Process stopped
Please contact
A237
PLC:
pallet

Rec.:
Eff.:
Sol.:
WTB:
239

Input

Eff.:
Sol.:
WTB:

pos

occupied

missing

occupied

missing

(Double

missing

(Double

missing

Input X44 (x71:d14) PC pallet pos 1 occupied


carriage occupied missing)
Process stopped
Please contact service department
A239
PLC:
Modul:
pw_v3 pw_v4

DECKEL MAHO GmbH - Service

(x70:z32)

service department
Modul:
pw_v3 pw_v4

Input X43 (x71:d14) PC pallet pos 1 occupied


carriage occupied missing)
Process stopped
Please contact service department
A238
PLC:
Modul:
pw_v3 pw_v4

pallet

Rec.:

pos

X02

Subject to change

Dated:



Page 68

Dialog 112

Inputs DC50 V - 2880


X
X00
X01
X02
X03
X04
X05
X06
X07
X08
X09
X0A
X0B
X0C
X0D
X0E
X0F
X10
X11
X12
X13
X14
X15
X16
X17
X18
X19
X1A
X1B
X1C
X1D
X1E
X1F
X20
X21
X22
X23
X24
X25
X26
X27
X28
X29
X2A
X2B

Plug
(x70:d32)
(x70:b32)
(x70:z32)
(x70:d30)
(x70:b30)
(x70:z30)
(x70:d28)
(x70:b28)
(x70:z28)
(x70:d26)
(x70:b26)
(x70:z26)
(x70:d24)
(x70:b24)
(x70:z24)
(x70:d22)
(x70:b22)
(x70:z22)
(x70:d20)
(x70:b20)
(x70:z20)
(x70:d18)
(x70:b18)
(x70:z18)
(x70:d16)
(x70:b16)
(x70:z16)
(x70:d14)
(x70:b14)
(x70:z14)
(x70:d12)
(x70:b12)
(x70:z12)
(x70:d10)
(x70:b10)
(x70:z10)
(x70:d08)
(x70:b08)
(x70:z08)
(x70:d06)
(x71:d32)
(x71:b32)
(x71:z32)
(x71:d30)

Remarks
PC position 1 transfer position to machine
PC position 1 pallet in depositing position
PC position 2 transfer position to machine
PC position 2 pallet in depositing position
Magazine position free

Return message (Star) Motor spindle


Return message (Delta) Motor spindle
Drives uncoupled
Reference point 4. axis (Magazine)
Tool in spindle clamped
Tool in spindle unclamped

Central lube pressure reached


Central lube oil level OK
Measuring tip resting position
Measuring tip measuring position
Motor circuit breaker OK
Machine OK
Cooling motor spindle OK
Switch: Normal position
Reference point cam X
Reference point cam Y
Reference point cam Z
Reference point cam TC magazine
Magazine: Call
Magazine door closed
Coolant: Low (IKUEZ)
Switch: Setup
1.Rotary axis clamped
1.Rorary axis unclamped
Hydraulic oil level OK
External release of axes and spindle
Machining area doors closed and locked
Machining area doors open and unlocked
Acknowledgement switch hand control unit
* Emergency Off

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 69

Dialog 112

Inputs DC50 V - 2880


X
X2C
X2D
X2E
X2F
X30
X31
X32
X33
X34
X35
X36
X37
X38
X39
X3A
X3B
X3C
X3D
X3E
X3F
X40
X41
X42
X43
X44
X45
X46
X47
X48
X49
X4A
X4B
X4C
X4D
X4E
X4F
X50
X51
X52
X53
X54

Plug

Remarks

(x71:b30) Reference cam 1.Rotary axis


(x71:z30) (Reference cam 6.axis)
(x71:d28) (Reference cam 7.axis)
(x71:b28) (Reference cam 8.axis)
(x71:z28)
(x71:d26) Renishaw probe ready
(x71:b26) Renishaw probe battery low
(x71:z26) Level under below minimum (IKUEZ)
(x71:d24) Motor circuit breaker IKUEZ OK
(x71:b24) * Coolant Max level
(x71:z24) Flow control Q>2 l/min (IKUEZ)
(x71:d22) Coolant: Lifting pump on
(x71:b22) Interferance rotary filter skimmer (IKUEZ)
(x71:z22) Interferance high pressure pump (IKUEZ)
(x71:d20) Reserved for special option
(x71:b20) Reserved for special option
(x71:z20) Acknowledgement M 106
(x71:d18) Acknowledgement M 108
(x71:b18) 1.Rotary axis clamped
(x71:z18) 1.Rotary axis unclamped
(x71:d16) Pallet safety housing closed
(x71:b16) Raising door to PC open
(x71:z16) Raising door to PC closed
(x71:d14) PC position 1 occupied
(x71:b14) PC position 2 occupied
(x71:z14)
(x71:d12)
(x71:b12)
(x71:z12)
(x71:d10)
(x71:b10)
(x71:z10)
(x71:d08) Pallet clamped
(x71:b08) Pallet lowered
(x71:z08) Pallet raised
(x71:d06) Pallet unclamped
(CDP21L1-B22) Touch probe inserted from Digi-PC
(CDP21L1-A22) Automatic active from Digi-PC
(CDP21L1-B21) Axes stop Digi-PC
(CDP21L1-A21) Regulator release from Digi-PC
(CDP21L1-B20) BTB (Ready) from Digi-PC

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 70

Dialog 112

Outputs DC50 V - 2880


X

Y00
Y01
Y02
Y03
Y04
Y05
Y06
Y07
Y08
Y09
Y0A
Y0B
Y0C
Y0D
Y0E
Y0F
Y10
Y11
Y12
Y13
Y14
Y15
Y16
Y17
Y18
Y19
Y1A
Y1B
Y1C
Y1D
Y1E
Y1F
Y20
Y21

Plug
(x50:d32)
(x50:b32)
(x50:z32)
(x50:d30)
(x50:b30)
(x50:z30)
(x50:d28)
(x50:b28)
(x50:z28)
(x50:d26)
(x50:b26)
(x50:z26)
(x50:d24)
(x50:b24)
(x50:z24)
(x50:d22)
(x50:b22)
(x50:z22)
(x50:d20)
(x50:b20)
(x50:z20)
(x50:d18)
(x50:b18)
(x50:z18)
(x50:d16)
(x50:b16)
(x50:z16)
(x50:d14)
(x50:b14)
(x50:z14)
(x50:d12)
(x50:b12)
(x50:z12)
(x50:d10)
(x50:b10)
(x50:z10)
(x50:d08)
(x50:b08)
(x50:z08)
(x50:d06)
(x50:b06)
(x50:z06)

Remarks
+ UB 1 (2 Ampere)
+ UB 1 (2 Ampere)
Open raising door to PC
Close raising door to PC
Clamp pallet
Unclamp pallet

Measuring signal M 49 (200ms)


Unclamp tool
+ UB 2 (2 Ampere)
+ UB 2 (2 Ampere)
Blow out tool clamp
Magazine: Loosen brake
Z axis loosen motor brake
Activate measuring tip
Blow out measuring tip
Rotoclear On
PC drive position 1 right
PC drive position 1 left
PC drive position 2 right
PC drive position 2 left
+ UB 3 (2 Ampere)
+ UB 3 (2 Ampere)
Signal Spindle turning

Star (1)/Delta (0) - Switchover


NC-Ready
Magazine: Call
Motor spindle cooling On
Acknowledgement switch hand control unit
Lock safety doors
+ UB 4 (0,5 Ampere)
Drives On

+ UB 5 (0,5 Ampere)
Collective interferance message (H1)
Hydraulic on

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 71

Dialog 112

Outputs DC50 V - 2880


X
Y22
Y23
Y24
Y25
Y26
Y27
Y28
Y29
Y2A
Y2B
Y2C
Y2D
Y2E
Y2F
Y30
Y31
Y32
Y33
Y34
Y35
Y36
Y37
Y38
Y39
Y3A
Y3B
Y3C
Y3D
Y3E
Y3F
Y40
Y41

Plug
(x50:d04)
(x50:b04)
(x50:z04)
(x50:d02)
(x50:b02)
(x50:z02)
(x51:d32)
(x51:b32)
(x51:z32)
(x51:d30)
(x51:b30)
(x51:z30)
(x51:d28)
(x51:b28)
(x51:z28)
(x51:d26)
(x51:b26)
(x51:z26)
(x51:d24)
(x51:b24)
(x51:z24)
(x51:d22)
(x51:b22)
(x51:z22)
(x51:d20)
(x51:b20)
(x51:z20)
(x51:d18)
(x51:b18)
(x51:z18)
(x51:d16)
(x51:b16)
(x51:z16)
(x51:d14)
(x51:b14)
(x51:z14)
(x51:d12)
(x51:b12)

Remarks
Central lube On
Coolant On
Internal coolant (HD) On
Coolant lifting pump On
Coolant chip flushing On
???
+ UB 1 (2 Ampere)
+ UB 1 (2 Ampere)

Reserved for special option


Reserved for special option
+ UB 2 (2 Ampere)
+ UB 2 (2 Ampere)
Clamping On 1. Rotary axis
Clamping Off 1. Rotary axis
nclamp workpiece

+ UB 3 (2 Ampere)
+ UB 3 (2 Ampere)

Reserved for special option


Reserved for special option

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 72

Dialog 112

Inputs DC50 V - 2880


X
Y42
Y43
Y44
Y45
Y46
Y47
Y48
Y49
Y4A
Y4B
Y4C
Y4D
Y4E
Y4F
Y50
Y51
Y52
Y53
Y54
Y55
Y56
Y57
Y58
Y59
Y5A

Plug

Remarks

(x51:z12)
(x51:d10)
(x51:b10)
(x51:z10)
(x51:d08) + UB 4 (0,5 Ampere)
(x51:b08)
(x51:z08)
(x51:d06) + UB 5 (0,5 Ampere)
(x51:b06)
(x51:z06) Programme completed (H1)
(x51:d04) Programme running (H1)
(x51:b04) Switching function 1 (M 100 / M
(x51:z04) Switching function 2 (M 102 / M
(x51:d02) Switching function 3 (M 104 / M
(x51:b02) Switching function 4 (M 106 / M
(x51:z02) Switching function 5 (M 108 / M
(CDJ21L1-B22) Cycle start to Digi-PC
(CDJ21L1-A22) Cycle stop to Digi-PC
(CDJ21L1-B21) Drive command X+ to Digi-PC
(CDJ21L1-A21) Drive command X- to Digi-PC
(CDJ21L1-B20) Drive command Y+ to Digi-PC
(CDJ21L1-A20) Drive command Y- to Digi-PC
(CDJ21L1-B19) Drive command Z+ to Digi-PC
(CDJ21L1-A19) Drive command Z- to Digi-PC
(CDJ21L1-B18) D112-BTB (ready) to Digi-PC
(CDJ21L1-A18) Spindle turning to Digi-PC
(CDJ21L1-B17) Automatik allows to Digi-PC

DECKEL MAHO GmbH - Service

Subject to change

101)
103)
105)
107)
109)

Dated:



Page 73

Dialog 112

Inputs DC70/100 V - 2880, 2881


X
X0
X1
X2
X3
X4
X5
X6
X7
X8
X9
XA
XB
XC
XD
XE
XF
X10
X11
X12
X13
X14
X15
X16
X17
X18
X19
X1A
X1B
X1C
X1D
X1E
X1F
X20
X21
X22
X23
X24
X25
X26
X27
X28
X29
X2A
X2B
X2C

Plug
(x70:d32)
(x70:b32)
(x70:z32)
(x70:d30)
(x70:b30)
(x70:z30)
(x70:d28)
(x70:b28)
(x70:z28)
(x70:d26)
(x70:b26)
(x70:z26)
(x70:d24)
(x70:b24)
(x70:z24)
(x70:d22)
(x70:b22)
(x70:z22)
(x70:d20)
(x70:b20)
(x70:z20)
(x70:d18)
(x70:b18)
(x70:z18)
(x70:d16)
(x70:b16)
(x70:z16)
(x70:d14)
(x70:b14)
(x70:z14)
(x70:d12)
(x70:b12)
(x70:z12)
(x70:d10)
(x70:b10)
(x70:z10)
(x70:d08)
(x70:b08)
(x70:z08)
(x70:d06)
(x71:d32)
(x71:b32)
(x71:z32)
(x71:d30)
(x71:b30)

Remarks
Magazine is in position S_202
Magazine braking cam S_201
Magazine Reference point S_200
TC in standby position S_218
Gripper is turned to 0 degree S_206
Gripper is turned to 180 degree S_207
TC in spindle position S_205
TC in magazine position S_204
Return message (Star) Motor spindle
Return message (Delta) Motor spindle
Drives uncoupled
TC gripper claw locked S_219
Input tool clamp closed S_272
Input tool clamp open S_274
Magazine button forward S_215
Magazine button reverse S_216
Central lube pressure reached
Central lube oil level OK
Measuring tip resting position
Measuring tip measuring position
Motor circuit breaker OK
Machine OK
Cooling motor spindle OK
UVV Switch: Normal position
Reference point cam X
Reference point cam Y
Reference point cam Z
Reference point cam TC magazine
Magazine: Call
Magazine door closed
Coolant: Low (IKUEZ)
UVV Switch: Setup
(-OT1)
(-OT2)
Hydraulic oil level OK
External release of axes and spindle
Machining area doors closed and locked
Machining area doors open and unlocked
Acknowledgement switch hand control unit
* Emergency Off
(+OT1)
(+OT2)
(+OT3)
(+OT4)
Reference point cam 5. axis

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 74

Dialog 112

Inputs DC70/100 V - 2880, 2881


)X
X2D
X2E
X2F
X30
X31
X32
X33
X34
X35
X36
X37
X38
X39
X3A
X3B
X3C
X3D
X3E
X3F
X40
X41
X42
X43
X44
X45
X46
X47
X48
X49
X4A
X4B
X4C
X4D
X4E
X4F
X50
X51
X52
X53
X54

Plug

Remarks

(x71:z30) (Reference point cam 6.axis)


(x71:d28) (Reference point cam 7.axis)
(x71:b28) (Reference point cam 8.axis
(x71:z28)
(x71:d26) Renishaw probe ready
(x71:b26) Renishaw probe battery low
(x71:z26) Level under below minimum (IKUEZ)
(x71:d24) Motor circuit breaker IKUEZ OK
(x71:b24) * Coolant Max level
(x71:z24) Flow control Q>2 l/min (IKUEZ)
(x71:d22) Coolant: Lifting pump on
(x71:b22) Interferance rotary filter skimmer (IKUEZ)
(x71:z22) Interferance high pressure pump (IKUEZ)
(x71:d20) Reserved for special option
(x71:b20) Reserved for special option
(x71:z20) Acknowledgement M 106
(x71:d18) Acknowledgement M 108
(x71:b18) 1.Rotary axis clamped
(x71:z18) 1.Rotary axis unclamped
(x71:d16) Pallet safety housing closed
(x71:b16) Raising door to PC open
(x71:z16) Raising door to PC closed
(x71:d14) PC pos. 1 occupied (Double carriage occupied)
(x71:b14) PC pos. 2 occupied (Double carriage occupied)
(x71:z14) Pallet has been brought in
(x71:d12) Pallet has been brought out
(x71:b12) Double carriage pos.-1 in alternating pos.
(x71:z12) Double carriage pos.-2 in alternating pos.
(x71:d10)
(x71:b10)
(x71:z10)
(x71:d08) Pallet clamped
(x71:b08) Pallet lowered
(x71:z08) Pallet raised
(x71:d06) Pallet unclamped
(CDP21L1-B22) Touch probe inserted from Digi-PC
(CDP21L1-A22) Automatic active from Digi-PC
(CDP21L1-B21) Axes stop Digi-PC
(CDP21L1-A21) Regulator release from Digi-PC
(CDP21L1-B20) BTB (Ready) from Digi-PC

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 75

Dialog 112

Outputs DC70/100 V - 2880, 2881


X
Y0
Y1
Y2
Y3
Y4
Y5
Y7
Y08
Y09
YA
YB
Y0C
Y0D
Y0E
Y0F
Y10
Y11
Y12
Y13
Y14
Y15
Y16
Y17
Y18
Y19
Y1A
Y1B
Y1C
Y1D
Y1E
Y1F
Y20
Y21
Y22
Y23
Y24
Y25
Y26
Y27
Y28
Y29
Y2A
Y2B

Plug
(x50:z32)
(x50:d30)
(x50:b30)
(x50:z30)
(x50:d28)
(x50:b28)
(x50:z28)
(x50:d26)
(x50:b26)
(x50:z26)
(x50:z24)
(x50:d22)
(x50:b22)
(x50:z22)
(x50:d20)
(x50:b20)
(x50:z20)
(x50:d18)
(x50:b18)
(x50:z18)
(x50:z16)
(x50:d14)
(x50:b14)
(x50:z14)
(x50:d12)
(x50:b12)
(x50:z12)
(x50:d10)
(x50:b10)
(x50:z10)
(x50:d08)
(x50:b08)
(x50:z08)
(x50:b06)
(x50:z06)
(x50:d04)
(x50:b04)
(x50:z04)
(x50:d02)
(x50:b02)
(x50:z02)
(x51:z32)
(x51:d30)
(x51:b30)
(x51:z30)

Remarks
TC Intermediate pos. release Y_228
Move TC to intermediate position Y_227
Move TC to magazine Y_202
Move TC to spindle Y_203
Turn TC changer to 0 degrees Y_206
Turn TC changer to 180 degrees Y_207

Measuring signal M 49 (200ms)


Unclamp tool
Blow out tool clamp
TC changer 2. change speed
Z axis loosen motor brake
Activate measuring tip
Blow out measuring tip
Rotoclear On
Turn magazine forwards
Turn magazine backwards

Signal Spindle turning

PC-Transport Right
PC-Transport Left
Star (1)/Delta (0) - Switchover
NC-Ready
Magazine: Call
Motor spindle cooling On
Acknowledgement switch hand control unit
Lock safety doors
+ UB 4 (0,5 Ampere)
Drives On
Magazine release
Stoerung Sammelmeldung (rote Lampe)
Hydraulic On
Central lube On
Coolant On
Internal coolant (HD) On
Coolant lifting pump On
Coolant chip flushing On
???
Open raising door to PC
Close raising door to PC
PC: Clamp pallet
PC: Unclamp pallet

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 76

Dialog 112

Outputs DC70/100 V - 2880, 2881


X
Y2C
Y2D
Y2E
Y2F
Y30
Y31
Y32
Y33
Y34
Y35
Y36
Y37
Y38
Y39
Y3A
Y3B
Y3C
Y3D
Y3E
Y3F
Y40
Y41
Y42
Y43
Y44
Y45
Y46
Y47
Y48
Y49
Y4A
Y4B
Y4C
Y4D
Y4E
Y4F
Y50
Y51
Y52
Y53
Y54
Y55
Y56
Y57
Y58
Y59
Y5A

Plug

Remarks

(x51:d28) Blow out air for PC On


(x51:b28)
(x51:z28) Double carriage pos.-1 in alternating pos.
(x51:d26) Double carriage pos.-2 in alternating pos.
(x51:b26) Reserved for special option
(x51:z26) Reserved for special option
(x51:z24) Clamping On 1. Rotary axis
(x51:d22) Clamping Off 1. Rotary axis
(x51:b22) Unclamp workpiece
(x51:z22)
(x51:d20)
(x51:b20)
(x51:z20)
(x51:d18)
(x51:b18)
(x51:z18)
(x51:z16)
(x51:d14)
(x51:b14)
(x51:z14)
(x51:d12) Reserved for special option
(x51:b12) Reserved for special option
(x51:z12)
(x51:d10)
(x51:b10)
(x51:z10)
(x51:b08)
(x51:z08)
(x51:b06)
(x51:z06) Programme completed (Yellow lamp)
(x51:d04) Programme running (Green lamp)
(x51:b04) Switching function 1 (M 100 / M 101)
(x51:z04) Switching function 2 (M 102 / M 103)
(x51:d02) Switching function 3 (M 104 / M 105)
(x51:b02) Switching function 4 (M 106 / M 107)
(x51:z02) Switching function 5 (M 108 / M 109)
(CDJ21L1-B22) Cycle start to Digi-PC
(CDJ21L1-A22) Cycle stop to Digi-PC
(CDJ21L1-B21) Drive command X+ to Digi-PC
(CDJ21L1-A21) Drive command X- to Digi-PC
(CDJ21L1-B20) Drive command Y+ to Digi-PC
(CDJ21L1-A20) Drive command Y- to Digi-PC
(CDJ21L1-B19) Drive command Z+ to Digi-PC
(CDJ21L1-A19) Drive command Z- to Digi-PC
(CDJ21L1-B18) D112-BTB (ready) to Digi-PC
(CDJ21L1-A18) Spindle turning to Digi-PC
(CDJ21L1-B17) Automatik allows to Digi-PC

DECKEL MAHO GmbH - Service

Subject to change

Dated:



Page 77