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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
Plinganserstraße 150
81369 München

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-Bit´s
PLC-Data (Tool changer positions etc.) .................................................................31
PLC-BIT´s (Service and commisioning bit´s) ................................................... 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 ½" 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 1,7 ms Position


(digitale Regelung) 0,8 ms RPM
0,4 ms Current

Acceleration 180 ms
0 to 30 m/min

DECKEL MAHO GmbH - Service Subject to change Dated:  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

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 7


Dialog 112

CPU QX141-1 I/O QX524


Flash-ROM
Module

/ 5 &(6
4; 4;
 
Kern-Software GBI-Software
Mitsubishi PLC-Software

&6+ to operating
panel

S-RAM
GBI-Macros
PLC-Deckel

&6$

&6$ 2x RS 232
EE-PROM

7DVWHU
Machine parameters

6FKDOWHU
&6+

/('*UQ

/('*UQ

Digital output drives


&6+ S-RAM
(Axes/Spindle)
236kB

NC-Programme
Deckel-Macros
&'3

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 8


Digital drives DC 50V Dialog 112 Dialog 112

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 9


Digital drive DC 50V with A Axis

Netzteil Spindel Z-Achse X/Y-Achse U-Achse A-Achse


MDS-A-CV-300 MDS-A-SP-185 MDS-A-V1-35 MDS-A-V2-3535 MDS-A-V1-10 MDS-A-V1-05

Abschluß-
stecker

DECKEL MAHO GmbH - Service


CN1A CN1B CN1A CN1B CN1A CN1B CN1A CN1B CN1A CN1B

Steuerung
CN4 CN9 CN4 CN9 CN4 CN9 CN4 CN9 CN4 CN9 CN4

Subject to change
CN9 CN5 CN6 CN2 CN3 CN2L CN3L CN2 CN3 CN2 CN3

Dated:
CN7 CN8 CN2M CN3M


Tacho A-Achse

W16 Tacho Spindel


W14 Tacho Z-Achse
Masstab
W13 Tacho Y-Achse

W12 Tacho X-Achse


Masstab
Masstab
W17 Tacho Wechsler
W

Page 10
Dialog 112
Dialog 112
Digital drive DC 70/100V Dialog 112

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 11


Digital drive DC70/100V with A Axis

Netzteil Spindel Z-Achse X/Y-Achse A-Achse


MDS-A-CV-300 MDS-A-SP-185 MDS-A-V1-35 MDS-A-V2-3535 MDS-A-V1-05

Abschluß-
stecker

DECKEL MAHO GmbH - Service


CN1A CN1B CN1A CN1B CN1A CN1B CN1A CN1B

Steuerung
CN4 CN9 CN4 CN9 CN4 CN9 CN4 CN9 CN4

Subject to change
CN9 CN5 CN6 CN2 CN3 CN2L CN3L CN2 CN3

Dated:
CN7 CN8 CN2M CN3M


Tacho A-Achse
W

W16 Tacho Spindel


W14 Tacho Z-Achse
Masstab
W13 Tacho Y-Achse

W12 Tacho X-Achse


Masstab
Masstab

Page 12
Dialog 112
Dialog 112

Interface wiring Dialog 112

CNC control Periphery equipment (Computer etc.)


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

25 pol. Plug 25 pol. Socket

CNC Control Periphery equipment (Computer etc.)


25 pol. Plug 9 pol. Socket
GND 1 ( 1 DCD
TXD 2 ( 2 RXD
RXD 3 ( 3 TXD
RTS 4 ( 7 RTS
CTS 5 ( 8 CTS
DSR 6 ( 6 DSR
DTR 20 ( 4 DTR
GND 7 ( 5 GND Signal ground

9 pol. Socket
25 pol. Plug

DECKEL MAHO GmbH - Service Subject to change Dated:  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 IN/OUT 6. 2/3

# <0> <1> <2> <3> <4> # <0> <1> <2> <3> <4>
1 DEVICE NAME PC 16 TITLE FEED OUT 0 0 0 0 0
2 BAUD RATE 1 0 0 0 0 17 FEED CHR. 0 0 0 0 0
3 STOP BIT 1 0 0 0 0 18 PARITY V 0 0 0 0 0
4 PARITY EFFECTIVE 0 0 0 0 0 19 TIME-OUT SET 0 0 0 0 0
5 EVEN PARITY 1 0 0 0 0 20 RST IGNORE 0 0 0 0 0

6 CHR. LENGTH 3 0 0 0 0 21 EIA CODE [ 00 00 00 00 00


7 TERMINATOR TYPE 0 0 0 0 0 22 ] 00 00 00 00 00
8 CODE 1 00 00 00 00 00 23 # 00 00 00 00 00
9 CODE 2 00 00 00 00 00 24 * 00 00 00 00 00
10 REWIND CODE 00 00 00 00 00 25 = 00 00 00 00 00

11 HAND SHAKE 1 0 0 0 0 26 : 00 00 00 00 00
12 DC CODE PARITY 0 0 0 0 0 27
13 DC2/DC4 OUTPUT 0 0 0 0 0 28
14 CR OUTPUT 1 0 0 0 0 29
15 EIA OUTPUT 0 0 0 0 0 30 PRINTER TYPE 0 0 0 0 0

Configuration on PC Programme header V24 Programme header


Floppy
9600 Baud % oder 1 Blank line % oder 1 Blank line
7 Data bit O200 (Remarks) O200 (Remarks)
1 Stop bit N1 X . . . N1 X . . .
EVEN Parity N2 G0 . . . N2 G0 . . .
RTS ON N100 M30 N100 M30
CTS ON % %

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 14


Dialog 112

Interface description

1 DEVICE Name of Interface. z.B. PC, PLT max. 3 Characters


NAME

2 BAUD Input of Baudrate 0 =19200 bps


RATE 1 = 9600 bps
2 = 4800 bps
3 = 2400 bps
4 = 1200 bps
5 = 600 bps
6 = 300 bps
7 = 110 bps

3 STOP Stop Bits 1 = 1 bit


BIT 2 = 1.5 bit
3 = 2 bit

4 PARITY Parity checking 0 = no parity bit


EFFEC- I = parity bit
TIVE

5 EVEN Parity checking 0 = odd


PARITY 1 = even

6 CHR. Length of a character 0 = 5 (Bit)


LENGTH 1 =6
2 =7
3 =8

7 TERMI- Last character for termination of


NATOR Data Read in 0 = no termination chatacter
TYPE 1 = EOB or EOR
2 = EOB
3 = EOR
4 = any character
5 = any 2 characters

8 Code 1 Setting the character 1 , if the character 0 to FF (hex)


4 or 5 is entered in # 7

9 Code 2 Setting the character 2 , if the character 0 to FF (hex)


5 is entered in # 7

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 15


Dialog 112

Interface description

10 REWIND Should be used compatible to the Tape 0 to FF (hex)


CODE reader .Will not be rewound with „0“
PARITY

11 HAND RS-232-C Communiations Interface is 1 = RTS/CTS System


SHAKE is being configuriert 2 = No Handshake
3 = DC Code System
(XON / XOFF Protokoll)

12 DC Valid only if 3 has been selected in #11 0 = No parity


CODE ist 1 = With even parity
PARITY

13 DC2 When the data is sent from the NC- 0 = without DC2 and DC4
DC4 System to the Output and the unit is 1 = with DC2, without DC4
OUTPUT started through DC Code 2 = without DC2, with DC4
3 = with DC2, with DC4

14 CR By selecting, a < CR > will be inserted 0 = no


OUTPUT before the < LF > 1 = insert

15 EIA Output in ISO or EIA Code. 0 = ISO Code Output


OUTPUT Code is automatically identified on 1 = EIA Code Output
input

16 TITLE Gives the titel (Programme number and 0 = no


FEED remarks) at the beginning. Specially for 1 = give title
OUT punched tape

17 FEED Forward character. 0 bis 999 characters


CHR. Amount of empty characters at the
beginning of the punched tape

18 PARITY Whether parity is evaluated within block 0 = no


V 1 = valid

19 TIME- Time-out for the verification of the 0 to 999 (0,1 sec)


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

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 16


Dialog 112

Schnittstellen-Beschreibung

20 Data Enter: whether data for computer link are 0 : ISO


ASCII ISO or ASCII 1 : ASCII

21 EIA The alternative codes for the 6 characters 0 to FFH


22 Code which exist in the ISO format but not in
23 [] # * = : the EIA format are mentioned here.
24 The code entered here should not exist in
25 the EIA format; and it should not equal
26 parity H

30 Printer Enter printer type 0 = No printer


Type 1 = Nada
2 = Epson

DECKEL MAHO GmbH - Service Subject to change Dated:  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

DECKEL MAHO GmbH - Service Subject to change Dated:  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 Example


Ba 1 (Manual) #1 .... 100 (Time deviation)
F3 (Customer service) #2 .... X, Y, Z , U or 1 für Spindle
FD <ENTER> (Password) #3 .... 1 (Current)
F2 (Configuration) #4 .... 200 (Amplitude)
F3 (Process) #5 .... 0 (Zero line shifting)
#44 Set F0 selection to 1
Shift Diagnosis

DECKEL MAHO GmbH - Service Subject to change Dated:  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

DECKEL MAHO GmbH - Service Subject to change Dated:  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

DECKEL MAHO GmbH - Service Subject to change Dated:  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 0

Spindle 3-6 (is always the last axis)

Unused F

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 22


Dialog 112

Entering tool changer position in machine parameters


PLC-Data

BA1 (Manual)
F9 (Continue)
F3 (Customer service)
FD <ENTER> (Password)
F2 (Configure)
F9 (Continue)
F9 (Continue)
F2 (PLC-Data)
(see page 31)

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

Control German English French Italian Spanish

Base page 4/7 #21 lang 2 ........ 2 ................ 1 ................. 1 ................. 1................... 1
PLC Data #8 ............................ 0 ................ 1 ................. 2 ................. 4................... 3
Register R2234 ........................ 0 ................ 1 ................. 1 ................. 1................... 1
Macro 9999 #33 ....................... 0 ................ 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 (Manual)
F9 (Continue)
F4 (Language)
There are always two languages existing in the control, for example German and English.

DECKEL MAHO GmbH - Service Subject to change Dated:  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 (in Hours)


Parameter #501 -> Programme run (in Hours)

Hour counter
(variable)

Call
BA 1
F9 (Continue)
F2 (C-Modal)
> (Page 2/2)

#1 Date
#2 Time
#3 Power on (complete time of control switch on)
#4 Auto CNC (Programme running time from cycle start to M02, M30)
#5 AutoMach (Programme running time, substracting the stand still time due to internal
Feed Hold or override = 0, Cycle stop, ...)

DECKEL MAHO GmbH - Service Subject to change Dated:  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 (Manual)
F9 (Continue)
F3 (Customer service)
FD <ENTER> (Password)
F2 (Configure)
F9 (Continue)
F6 (Macros)

Macro screen
<CODE> <TYPE> <PROGRAMM>
1 G [01] 211 1 9211
2 G [02] 248 1 9248

11 M [01] 6 1 9006
12 M [02] 33 1 9033
...

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

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 25


Dialog 112

Spindle orientation

BA 1 (Manual)
F9 (Continue)
F3 (Customer service)
FD <ENTER> (Password)
F2 (Configuration)
F9 (Continue)
F9 (Continue)
F1 (Spindle)
> Turn to page 4/30
#15 (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: -40%
Z-Axis downwards: -20%
Difference = 20 #9 LMC1 = 20

DECKEL MAHO GmbH - Service 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 Amplitude adjustment of phase A


- VR4 Amplitude adjustment of phase B

- VR5 Referencepoint adjustment (zero point crossing of A-Phase)

VR2 VR4
GND

VR1 VR3

B
A
VR5 Z

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 27


Dialog 112

Diagnosis

[Servo Monitor] Diagn 3. 1/3

<X> <Y> <Z> <U>


KV (1/sec) 0 0 0 0
Droop (i) 0 0 0 0
Speed (rpm) 0 0 0 0
Current (%) 5 -4 -3 -2
MAX CUR1 (%) 161 143 182 35
MAX CUR2 (%) 6 5 32 3
Overload (%) 0 0 0 0
OverReg (%) 0 0 0 0
AMP DISP D1 D2 D3 D5
Alarm
Cyc Cnt (p) 80002 -80002 -20004 -55051
GRDSP 8.000 8.000 8.000 15.000
Mains 4.539 4.166 3.831 6.082
MAC POS 0.000 0.000 0.000 9.000
MOT POS 333.685 -146.900 -200.165 -359.990
SCA POS 333.685 -146.900 -200.165 -359.990
FB Error. (i) 0 0 0 0
DFB Comp (i) 0 0 0 0

Example:
DC50-V (Axes moving )

Trailing error (Droop) X Y Z


G0 ca: 15000 15000 10000
F1000 ca: 500 500 500

Current (%) X Y Z+ Z-
G0 ca: 20 15 4 60
F1000 ca: 10 5 40 15

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 28


Dialog 112

Mitsubishi Options

# # # # # Diag 6. 4/5
1 FF 14 67 27 00 40 100 53
2 E3 15 FF 28 00 41 600 54
3 FF 16 33 29 00 42 000 55 10
4 BF 17 00 30 00 43 0 56
5 FC 18 00 31 00 44 1 57
6 FB 19 00 32 00 45 58
7 BF 20 00 33 1 46 59
8 F7 21 00 34 4 47 60
9 FF 22 FF 35 10 48 61
10 9D 23 00 36 00 49 4 62
11 37 24 FE 37 D 50 63
12 BF 25 00 38 100 51 64
13 DE 26 00 39 60 52

# 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 (MC-ERR Seite 1/11)


#1 cmpax (Values as per data sheets)
#2 drcax (Values as per data sheets)
#3 rdvno (Values as per data sheets)
#4 mdvno (Values as per data sheets)
#5 pdvno (Values as per data sheets)
#6 sc (Values as per data sheets)
#7 spcdv (Values as per data sheets)

Page 2/11 X-Axis (Values as per data sheets)


Page 3/11 Y-Axis (Values as per data sheets)
Page 4/11 Z-Axis (Values as per data sheets)

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 30


Dialog 112

PLC-Data

MP Values Remarks

#1 90 Interval time for central lubrication in minutes


#2 60 Max. amount of lube impulses when below oil level
#3 7 Amount of Axes
#4 10000 Feed in manual mode
#5 10000 Feed in test mode
#6 60 Max. hydraulic running time in minutes
#7 10 End of work shut-off in minutes
#8 0 Display of second language
#9 0 Position for spindle orientation
#10 743969 X-Axis 1.position magazine position (DC50-V) pallet change pos. (DC70-V)
#11 507000 X-Axis 2.position (waiting position) DC50-V
#12 507000 X-Axis 3.position (centre of measuring tip) DC50-V
#13 616487 Y-Axis 1.position pallet change pos(DC50-V) tool change pos(DC70/100-V)
#14 422106 Y-Axis 2.position pallet change position DC50-V
#15 423500 Y-Axis 3.position (centre of measuring tip"minus 8 mm") DC70/100V
#16 -99200 Z-Axis 1.position (In position) down
#17 Z-Axis 2.position (Out position) up
#18 Z-Axis 3.position
#19 Palett_2 Coordinate shifting X-Axis
#20 Palett_2 Coordinate shifting Y-Axis
#21 Palett_2 Coordinate shifting Z-Axis
#22 20 (30) Amount of magazine pockets
#23 50 Window for "Magazine exactly in position"
#24 10 time for screen saver
#25 -445912 Position of tool length measuring tip (Z-coordinate)
#26 499500 (#26) OT+ <X> SW-limit switch machining area [Micrometer] DC50V
#27 744000 (#27) OT+ <X> SW-limit switch magazine area [Micrometer] DC50V
#28 617000 (#28) OT+ <Y> SW-limit switch machining area [Micrometer] DC70/100V
#29 618000 (#29) OT+ <Y> SW-limit switch magazine area [Micrometer] DC70/100V
#30
#31
#32 Temperature compensation
#33 Endposition X, Y, Z at the Ref.point mark [Micrometer]
#34 Endposition X opposite Ref.point mark [Micrometer]
#35 Endposition Y opposite Ref.point mark [Micrometer]
#36 Endposition Z opposite Ref.point mark [Micrometer]
#37 ACCESS
#38 BA 1 (Manual)
#39 F9 (Continue)
#40 F3 (Customer service)
#41 FD <ENTER> (Password)
#42 F2 (Configure)
#43 F9 (Continue)
#44 F9 (Continue)
F2 (PLC-Data)
#45
#46 5 Delay from "Tool clamper open" (DC50-V) [Unit approx. 50 ms]
#47 0 Delay from "Tool clamper close" [Unit approx. 50 ms]
#48 301 Version of machine parameters

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 31


Dialog 112

PLC-BIT’s (Software level 1.2xx)

MP Bit Marker Text

#1_Bit0 M400 Reference point search turning X-Axis


#1_Bit1 M401 Reference point search turning Y-Axis
#1_Bit2 M402 Reference point search turning Z-Axis
#1_Bit3 M403 Reference point search turning C-Axis
#1_Bit4 M404
#1_Bit5 M405
#1_Bit6 M406
#1_Bit7 M407

#2_Bit0 M408 Push button assignment turning X-Axis


#2_Bit1 M409 Push button assignment turning Y-Axis
#2_Bit2 M410 Push button assignment turning Z-Axis
#2_Bit3 M411 Push button assignment turning C-Axis
#2_Bit4 M412
#2_Bit5 M413
#2_Bit6 M414
#2_Bit7 M415

#3_Bit0 M416 CNC Software level >= 1.3


#3_Bit1 M417 SA: External Palett acknowledgement at loading area, X 4B
#3_Bit2 M418 SA: IBAG Spindle installed
#3_Bit3 M419 M53/M54 "Spindle turning" without feed hold during run up
#3_Bit4 M420 Signal "Spindle turning" on output Y14
#3_Bit5 M421 2. Language fixed
#3_Bit6 M422 M18 with standby in gripper
#3_Bit7 M423 Palett deviation compensation active

#4_Bit0 M424 4. Axis is 1.round axis


#4_Bit1 M425 5. Axis is 1.round axis
#4_Bit2 M426 Light barrrier "Magazine pocket free"
#4_Bit3 M427 External release of axes
#4_Bit4 M428 Option: Roto Clear
#4_Bit5 M429 Constant hydraulic
#4_Bit6 M430 4.Axis is magazine axis
#4_Bit7 M431 Hydraulic with level switch
Access
#5_Bit0 M432 IKUEZ (Internal coolant) BA 1 (Manual)
#5_Bit1 M433 Spindle Star / Delta - Switchover F9 (Continue)
#5_Bit2 M434 Chip flushing F3 (Customer service)
FD <ENTER> (Password)
#5_Bit3 M435 Override 100% fixed
F2 (Configure)
#5_Bit4 M436 Measuring tip F9 (Continue)
#5_Bit5 M437 Laser measuring unit F9 (Continue)
#5_Bit6 M438 Touch probe F2 (PLC-Data)
#5_Bit7 M439 UVV-Tool room solution F5 (Bit selection)

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 32


Dialog 112

PLC-BIT’s (Software level 1.2xx)

MP Bit Marker Text

#6_Bit0 M440 Option: Display with correction calculation


#6_Bit1 M441 Option: Function 9
#6_Bit2 M442 Option: Switch off (End of work shut-off)
#6_Bit3 M443 Option: Clamp / Unclamp
#6_Bit4 M444 Option: Digitise
#6_Bit5 M445 Option: Screen saver
#6_Bit6 M446 Option: Function 11
#6_Bit7 M447 Option: Function 12

#7_Bit0 M448 Activate service functions


#7_Bit1 M449 Unselect palett changer
#7_Bit2 M450 Unselect automatic tool changer
#7_Bit3 M451 No MAH: Tool not in tool table
#7_Bit4 M452 Unselect X-Axis
#7_Bit5 M453 Unselect Y-Axis
#7_Bit6 M454 Unselect Z-Axis
#7_Bit7 M455 Unselect spindle

#8_Bit0 M456 Ignore feed lock


#8_Bit1 M457 Ignore spindle lock
#8_Bit2 M458 Ignore read in lock
#8_Bit3 M459 Ignore machine halt
#8_Bit4 M460 Simulate Palett acknowledgement
#8_Bit5 M461 Open magazine brake
#8_Bit6 M462 VPC-Error simulation with button "Tool clamper open"
#8_Bit7 M463

#9_Bit0 M464 Switch off hydraulic function


#9_Bit1 M465 Switch off central lubrication function
#9_Bit2 M466 Switch off spindle lubrication function
#9_Bit3 M467 Switch off standard coolant function
#9_Bit4 M468 Ignore Error message hydraulic
#9_Bit5 M469 Ignore Error message central lubrication
#9_Bit6 M470 Ignore Error message spindle lubrication
#9_Bit7 M471 Ignore Error message standard coolant

#10_Bit0 M472 Switch off spindle motor coolant function


#10_Bit1 M473
#10_Bit2 M474
#10_Bit3 M475
#10_Bit4 M476 Ignore Error message spindle motor coolant
#10_Bit5 M477
#10_Bit6 M478
#10_Bit7 M479

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 33


Dialog 112

PLC-BIT’s (Software-level 1.2xx)

MP Bit Marker Text

#11_Bit0 M480
#11_Bit1 M481
#11_Bit2 M482 Temperature compensation
#11_Bit3 M483
#11_Bit4 M484
#11_Bit5 M485
#11_Bit6 M486
#11_Bit7 M487

#12_Bit0 M488
#12_Bit1 M489
#12_Bit2 M490
#12_Bit3 M491
#12_Bit4 M492
#12_Bit5 M493
#12_Bit6 M494
#12_Bit7 M495

#13_Bit0 M496 Machinen type


#13_Bit1 M497 Machinen type
#13_Bit2 M498 Machinen type
#13_Bit3 M499 empty
#13_Bit4 M500 empty (Spindle)
#13_Bit5 M501 empty (Spindle)
#13_Bit6 M502 empty
#13_Bit7 M503 empty

#14_Bit0 M504 Measuring position in G1 (M91)


#14_Bit1 M505 Positioning logic for tool change and tool length measurement
#14_Bit2 M506 empty
#14_Bit3 M507 empty
#14_Bit4 M508 empty
#14_Bit5 M509 empty
#14_Bit6 M510 empty
#14_Bit7 M511 empty

#15_Bit0 M512 empty


#15_Bit1 M513 empty
#15_Bit2 M514 empty
#15_Bit3 M515 empty
#15_Bit4 M516 empty
#15_Bit5 M517 empty
#15_Bit6 M518 empty
#15_Bit7 M519 empty

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 34


Dialog 112

PLC-BIT’s (Software level 1.2xx)


Additional BIT´s 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 1 Alarm messages on


#50_Bit1 1 Alarm messages‘over R’ Register mode
#50_Bit2 1 Guide messages on
#50_Bit3 0
#50_Bit4 1 Messages on all screens ON
#50_Bit5 0 Alarmmessages on all screens 1 Guide messages
#50_Bit6 0
#50_Bit7 0

#51_Bit0 1 Onboard on
#51_Bit1 0
#51_Bit2 0
#51_Bit3 0
#51_Bit4 0
#51_Bit5 0
#51_Bit6 0
#51_Bit7 0

#53_Bit0 0
#53_Bit1 0
#53_Bit2 0
#53_Bit3 0
#53_Bit4 0
#53_Bit5 0
#53_Bit6 0
#53_Bit7 0

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 35


Dialog 112

PLC-BIT’s (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 0
#61_Bit1 1 Highspeed Outputs Y10 - Y1F
#61_Bit2 0
#61_Bit3 0
#61_Bit4 0
#61_Bit5 0
#61_Bit6 0
#61_Bit7 0

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


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

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


Switch 18: ........... Open door
Switch 19: ........... Close door
Switch 20: ........... Unclamp pallet
Switch 21: ........... Clamp pallet
Switch 22: ........... Pallet clamped
Switch 23: ........... Y-Axis pallet 1
Switch 24: ........... Y-Axis pallet 2
Switch 25: ........... Deposit pallet 1
Switch 26: ........... Bring pallet 1
Switch 27: ........... Deposit pallet 2
Switch 28: ........... Bring pallet 2
Switch 29: ........... Position X-Axis
Switch 30: ...........
Switch 31: ...........
Switch 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 HEX 7 6 5 4 3 2 1 0 HEX
X 0000 oooooooo 00 X 0000 7 6 5 4 3 2 1 0
X 0008 oooooooo 00 X 0008 F E D C B A 9 8

X 0010 oooooooo 00 X 0010 17 16 15 14 13 12 11 10


X 0018 oooooooo 00 X 0018 1F 1E 1D 1C 1B 1A 19 18

X 0020 oooooooo 00 X 0020 27 26 25 24 23 22 21 20


X 0028 oooooooo 00 X 0028 2F 2E 2D 2C 2B 2A 29 28

X 0030 oooooooo 00 X 0030 37 36 35 34 33 32 31 30


X 0038 oooooooo 00 X 0038 3F 3E 3D 3C 3B 3A 39 38

X 0040 oooooooo 00 X 0040 47 46 45 44 43 42 41 40


X 0048 oooooooo 00 X 0048 4F 4E 4D 4C 4B 4A 49 48

X 0050 oooooooo 00 X 0050 57 56 55 54 53 52 51 50


X 0058 oooooooo 00 X 0058 5F 5E 5D 5C 5B 5A 59 58

X 0060 oooooooo 00 X 0060 67 66 65 64 63 62 61 60


X 0068 oooooooo 00 X 0068 6F 6E 6D 6C 6B 6A 69 68

X 0070 oooooooo 00 X 0070 77 76 75 74 73 72 71 70


X 0078 oooooooo 00 X 0078 7F 7E 7D 7C 7B 7A 79 78

X 0080 oooooooo 00 X 0080 87 86 85 84 83 82 81 80


X 0088 oooooooo 00 X 0088 8F 8E 8D 8C 8B 8A 89 88

X 0090 oooooooo 00 X 0090 97 96 95 94 93 92 91 90


X 0098 oooooooo 00 X 0098 9F 9E 9D 9C 9B 9A 99 98

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

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 38


Dialog 112

Deckel macros

MP Macro Call Description Machine


# 1 9211 G211 Calculation macro DC50V DC70V DC100V
# 2 9248 G248 Overmeasurement DC50V DC70V DC100V
programming
#11 9006 M06 TC automatic DC50V DC70V DC100V
#12 9033 M33 TC manual DC50V DC70V DC100V

#13 9219 M219 Spindle orientation DC50V DC70V DC100V


#14 9090 M90 Tool breakage DC50V DC70V DC100V

#15 9092 M92 Calibration DC50V DC70V DC100V

#16 9091 M91 Tool length measurement DC50V DC70V DC100V


(Option)
9030 power on, automatic running DC50V DC70V DC100V
9999 Text-Macro (Languages) 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 3INSERT 4DELETE 5CONVT 6MONIT MENU

DECKEL MAHO GmbH - Service Subject to change Dated:  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 LED´s 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 cell data type


( xxx ) ( ) (x)

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

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 LED´s 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 M_Param 4. 1/6 1 Y SPEC 0000


Servo M_Param 4. 1/6 2 Y MTYP 0082
Servo M_Param 4. 1/6 9 Y RNG1 100

Servo M_Param 4. 1/6 1 Z SPEC 0000


Servo M_Param 4. 1/6 2 Z MTYP 0082
Servo M_Param 4. 1/6 9 Z RNG1 100

Servo M_Param 4. 1/6 1 A SPEC 0000


Servo M_Param 4. 1/6 2 A MTYP 0080
Servo M_Param 4. 1/6 9 A RNG1 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 M_Param 4. 1/6 1 Y SPEC 0000


Servo M_Param 4. 1/6 2 Y MTYP 8082
Servo M_Param 4. 1/6 9 Y RNG1 20

Servo M_Param 4. 1/6 1 Z SPEC 0000


Servo M_Param 4. 1/6 2 Z MTYP 8082
Servo M_Param 4. 1/6 9 Z RNG1 10

Servo M_Param 4. 1/6 1 A SPEC 0010


Servo M_Param 4. 1/6 2 A MTYP 8080
Servo M_Param 4. 1/6 9 A RNG1 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 M_Param 4. 1/6 1 Y SPEC 0000


Servo M_Param 4. 1/6 2 Y MTYP 0082
Servo M_Param 4. 1/6 9 Y RNG1 100

Servo M_Param 4. 1/6 1 Z SPEC 0000


Servo M_Param 4. 1/6 2 Z MTYP 0082
Servo M_Param 4. 1/6 9 Z RNG1 100

Servo M_Param 4. 1/6 1 A SPEC 0000


Servo M_Param 4. 1/6 2 A MTYP 0080
Servo M_Param 4. 1/6 9 A RNG1 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 1 Y SPEC 0000


Servo M_Param 4. 1/6 2 Y MTYP 8082
Servo M_Param 4. 1/6 9 Y RNG1 20

Servo M_Param 4. 1/6 1 Z SPEC 0000


Servo M_Param 4. 1/6 2 Z MTYP 8082
Servo M_Param 4. 1/6 9 Z RNG1 10

Servo M_Param 4. 1/6 1 A SPEC 0010


Servo M_Param 4. 1/6 2 A MTYP 8080
Servo M_Param 4. 1/6 9 A RNG1 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 # Description Value

Spindle 1/30 1 slimt 1 8000


Spindle 1/30 2 slimt 2 0
Spindle 1/30 5 smax 1 8000
Spindle 1/30 6 smax 2 0
Spindle 1/30 7 smax 3 0
Spindle 1/30 8 smax 4 0
Spindle 1/30 13 stap 1 4000
Spindle 1/30 14 stap 2 0
Spindle 2/30 10 TSP 8000
Spindle 5/30 25 CINP 03E8
Spindle 12/30 87 SP87 50
Bit selection 1/1 5 Bit 1 0

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

Parameter group Page # Description Value

Spindle 1/30 1 slimt 1 15000


Spindle 1/30 2 slimt 2 15000
Spindle 1/30 5 smax 1 2199
Spindle 1/30 6 smax 2 15000
Spindle 1/30 7 smax 3 15000
Spindle 1/30 8 smax 4 15000
Spindle 1/30 13 stap 1 2199
Spindle 1/30 14 stap 2 4000
Spindle 2/30 10 TSP 15000
Spindle 5/30 25 CINP 03E8
Spindle 12/30 87 SP87 100
Bit selection 1/1 5 Bit 1 1

Magazin wheel DC50-V


30 tools (Option)

Parameter group Page # Axis Description Value

Axis M_Param 2. 1/2 1 U rapid 7200


Axis M_Param 2. 1/2 2 U clamp 7200
Servo M_Param 4. 1/6 7 U PC2 30
Servo M_Param 4. 4/6 23 U SV023 4
PLC Data M_Param 10 1/1 22 U 30

DECKEL MAHO GmbH - Service 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

1 mot used

Rec.:
Eff.:
Sol.:
WTB: A001 PLC: M 208 Modul:

3 Star Delta switchover

Rec.: Change of spindle speed which requires star delta switchover


Eff.: Feed halt all axes
Sol.: automatically
WTB: A003 PLC: M 210 Modul: spigetr

4 PC not in base position

Rec.: Automatic pallet changer not in base positon


Eff.: Feed halt all axes
Sol.: Move pallet changer back to base position with appropriate
softkey
WTB: A004 PLC: M 211 Modul: pw

5 Safety function

Rec.: 1. Galvanic seperation of drives or


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

6 IKUEZ Internal coolant Flow control

Rec.: IKUEZ-Pump for internal coolant supply is switched on but


flow control switch is not active
Eff.: Feed block all axes
Sol.: Automatic
WTB: A006 PLC: M 213 Modul: ikuez

7 Synch. Handcontrol unit

Rec.: transmission of a selection switch change to the hand control


unit is not complete
Eff.: Feed block
Sol.: Automatic
WTB: A007 PLC: Modul: handstl

8 Touch probe

Rec.: The command „Touch probe ON“ is present and standby signal of
touchprobe is missing
Eff.: Feed block all axes
Sol.: CNC-Reset
WTB: A008 PLC: M 215 Modul: messtast

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 51


Dialog 112

9 Spindle speed not reached

Rec.: The actual spindle speed does not correspond to the desired
speed
Eff.: Feed halt of main axes
(but no feed block in G0 blocks)
Sol.: Automatic
WTB: A009 PLC: M 216 Modul: sammel

10 No base position TC

Rec.: Automatic tool changer (ATC) is not in base position


Eff.: Feed block all axes
Sol.: Move tool changer back to base position with appropriate
softkey
WTB: A010 PLC: M 217 Modul: wzw

17 X-Axis: Releasing ATC

Rec.: While releasing ATC, feed for X axis is blocked


Eff.: Feed block for X axis
Sol.: Automatic, continue releasing
WTB: A017 PLC: M 224 Modul: wzw

25 Y-Axis: Releasing ATC

Rec.: While releasing ATC, feed for Y axis is blocked


Eff.: Feed block for Y axis
Sol.: Automatic, continue releasing
WTB: A025 PLC: M 232 Modul: wzw

26 Y-Axis: Measuring tip not back

Rec.: When measuring tip is fully extended, feed of Y axis is


blocked till measuring tip has returned
Eff.: Feed block for Y axis
Sol.: Automatisch
WTB: A026 PLC: M 233 Modul:messd_v3

33 Z-Axis: Measuring tip not in Position

Rec.: Feed block for Z axis is active till measuring tip is out
Eff.: Feed block for Z axis
Sol.: Automatic
WTB: A033 PLC: M 240 Modul:messd_v4

34 Z-Axis: Releasing ATC

Rec.: While releasing ATC, feed for Z axis is blocked


Eff.: Feed block for Z axis
Sol.: Automatic, continue releasing
WTB: A034 PLC: M 241 Modul: wzw

41 A-Axis: Releasing ATC

Rec.: While releasing ATC, feed for A axis is blocked


Eff.: Feed block for A axis
Sol.: Automatic, continue releasing
WTB: A041 PLC: M 248 Modul: wzw

49 TC-Mag: Releasing ATC

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 52


Dialog 112

Rec.: While releasing ATC. feed for tool magazine is blocked


Eff.: Feed block for tool magazine
Sol.: Automatic, continue releasing
WTB: A049 PLC: 256 Modul: wzw

82 TC not in base position

Rec.: ATC is not in base position


Eff.: Spindle block
Sol.: Move ATC back to base position with appropriate softkey
WTB: A082 PLC: M 289 Modul: wzw

83 Star Delta switchover

Rec.: Change of spindle speed which requires star delta switchover


Eff.: Feed halt all axes
Sol.: automatically
WTB: A083 PLC: M 290 Modul: spigetr

84 PC not in base position

Rec.: Automatic pallet changer not in base positon


Eff.: Feed halt all axes
Sol.: Move pallet changer back to base position with appropriate
softkey
WTB: A084 PLC: M 291 Modul: pw

85 Safety function

Rec.: 1. Galvanic seperation of drives or


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

86 Manual toolchange call

Rec.: M33 was programmed or the switch „Tool change“ was pressed
Eff.: Spindle block
Sol.: End manual tool change;Cycle Start
WTB: A086 PLC: M 293 Modul: handwzw

87 Spindle block by touch probe

Rec.: Touch probe was changed into spindle


Eff.: Spindle block
Sol.: Change touch probe back into magazine
WTB: A087 PLC: M 294 Modul: messtast

88 Workpiece loose !!

Rec.: Input workpiece clamped is not active or Function workpiece


clamped / Unclamped not avaiable
Eff.: Spindelblock Cycle stop
Sol.: Input workpiece clamped
WTB: A088 PLC: M 295 Modul: wstspan

97 Axis lubrication defect

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 53


Dialog 112

Rec.: axisThelubrication cycle was not activated two times in


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 Axis lubrication

Rec.: Oil below lower level


Eff.: Read in block in the mode „Automatic“
Sol.: Top up central lube unit for Guide ways
WTB: A098 PLC: 305

99 Coolant low

Rec.: Coolant low in water tank in the mode "Automatic"


Eff.: Read in block in automatic procedure
Sol.: Top up coolant
WTB: A099 PLC: M 306

100 Spindle orientation

Rec.: Spindle is oriented by M 19


Eff.: Read in block till spindle is oriented
Sol.: Automatic
WTB: A100 PLC: M 307

101 Manual toolchange call

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

102 WZW 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 which requires star delta switchover


Eff.: Read in block in automatic procedure
Sol.: Automatic
WTB: A103 PLC: M 310

104 PC 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 tip not in Position

Rec.: Read in block as long as measuring tip is out


Eff.: Read in block in automatic procedure
Sol.: Automatic
WTB: A106 PLC: M 313 Modul:messd_v3

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 54


Dialog 112

129 Programmed stop M0/M1

Rec.: M 0 was programmed or M 1 was programmed while


„Selective stop“ was active
Eff.: Machine Stop (Cycle stop)
Sol.: Cycle Start
WTB: A129 PLC: M 336 Modul: bedienta

130 Axis lubrication faulty

Rec.: The axis lubrication cycle was not activated two times in
series. i.e. the lube pressure was not reached
Eff.: Maschine stop (Cycle stop)
Sol.: Check pressure switches; bleed lines
WTB: A130 PLC: M 337 Modul: schmiz

131 Axis lubrication level low

Rec.: Lube level low


Eff.: Machine stop (Cycle stop)
Sol.: Top up central lube unit for Guide ways
WTB: A131 PLC: M 338 Modul: schmiz

132 Coolant low

Rec.: Coolant low in water tank in the mode "Automatic"


All axes stop or G0 block
Eff.: Machine stop (Cycle stop)
Sol.: Top up coolant
WTB: A132 PLC: M 339 Modul: ikuez

133 Manual toolchange call

Rec.: M33 was programmed or the switch „Tool change“ was pressed
Eff.: Machine stop ( Cycle stop)
Sol.: Acknowledge manual tool change and cycle start
WTB: A133 PLC: M 340 Modul: handwzw

134 Motor spindle coolant defect

Rec.: Confirmation message of spindle cooling missing


Eff.: Machine stop (Cycle stop)
Sol.: Check transmitter
WTB: A134 PLC: M 341 Modul: spimoku

135 Fault from ATC

Rec.: Fault from automatic tool change


Eff.: Machine stop (Cycle stop)
Sol.: see exact messages
WTB: A135 PLC: M 342 Modul: wzw ???

136 Speed not reached

Rec.: Spindle speed is not reached


Eff.: Maschine Halt (Zyklus Stop)
Sol.: Reset
WTB: A136 PLC: M 343 Modul: sammel ???

137 PC not in base position

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 55


Dialog 112

Rec.: Automatic pallet changer not in base position


Eff.: Machine stop (Cycle stop)
Sol.: Release via softkey
WTB: A137 PLC: M 344 Modul: pw

138 Fault from PC

Rec.: Fault in automatic pallet changer procedure


Eff.: Machine stop (Cycle stop)
Sol.: see exact messages
WTB: A138 PLC: M 345 Modul: pw

139 Safety function

Rec.: 1. Galvanic seperation of drives or


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

140 TC not in base position

Rec.: ATC not in base position


Eff.: Machine stop (Cycle stop)
Sol.: Release via softkey
WTB: A140 PLC: M 347 Modul: wzw

141 Hydraulic level low

Rec.: Oil level in hydraulic level low


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

142 Magazine door open

Rec.: An automatic tool change is called and magazine door is open


Eff.: Machine stop (Cycle stop)
Sol.: Close magazine door and press cycle start
WTB: A142 PLC: M 349 Modul: wzw

143 Reference point of magazine unknown

Rec.: An automatic tool change is called and the ref point of the
magazine is unknown is open (only with DC 50V)
Eff.: Machine stop (Cycle stop)
Sol.: Release ATC in reverse
Approach ref point of magazine
WTB: A143 PLC: M 350 Modul:

144 Spindle - tool no. not O.K.

Rec.: An automatic tool change is called and the present T word is


not the is not the last automatically changed T word
Eff.: Machine stop (Cycle stop)
Sol.: 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 Subject to change Dated:  Page 56


Dialog 112

WTB: A144 PLC: M 351 Modul: vsm

145 A-Stop-Ta at Incr/Refpkt

Rec.: Increment movementsar reference point approaching has been


interrupted by pressing „Constant feed stop“
Eff.: Machine stop (Cycle stop)
Sol.: Cycle start
WTB: A145 PLC: M 352 Modul:

146 M6-Macro

Rec.: Cycle stop from the TC macro. The M6 call was interrupted as
it cannot be carried out
Eff.: Machine stop (Cycle stop)
Sol.: Correct programme and or data
WTB: A146 PLC: M 353 Modul:

147 Fault during PLC-Axis positioning

Rec.: A contradiction occured during positioning of the axes by the


PLC (during tool or pallet change)
Eff.: Machine stop (Cycle stop)
Sol.: Call service dept
WTB: A147 PLC: M 354 Modul: aposbef

148 T-No.-Error; Check VPC

Rec.: During opening and closing of the grippers during an


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

149 Tool clamp not OK

Rec.: Tool clamp should be closed and the confirmation


„Tool clamp is closed“/“Tool clamp is open“ is not OK
Eff.: Machine stop Cycle stop)
Sol.: Check switch for position sensing
WTB: A149 PLC: M 356 Modul: handwzw

150 Hydraulic running time is not OK

Rec.: 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.
Eff.: Machine stop (Cycle stop)
Sol.: Remove fault (e.g. Override = 0, etc.) and continue with
cycle start. Release stuck function wit softkeys
WTB: 150 PLC: M 357 Modul: hyd

151 Too many moving axes


Rec.: This message is generated if in an embargo version e3 more
than three axes are moved
Eff.: Machine stop (Cycle stop)
Sol.: Change NC programme so that not more than three axes are
moved in a NC block
WTB: A151 PLC: M 358 Modul:emb_e3

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 57


Dialog 112

152 Entering S word newly

Rec.: 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
Eff.: Machine stop (Cycle stop)
Sol.: Enter the S word required in the manual mode newly
WTB: A152 PLC: M 359 Modul: handwzw

153 Workpiece loose !!

Rec.: Input workpiece clamped is not active or Function workpiece


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

154 Magazine not in position

Rec.: Input magazine in Position is not received within one second


Eff.: Cycle stop
Sol.: Correct magazine position
WTB: A154 PLC: M 361 Modul:v4_mag

155 Digitising is active

Rec.: 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)
Eff.: Cycle stop
Sol.: Press softkey digitising
WTB: A155 PLC: M 362 Modul:digi

156 Subprogramme jump

Rec.: The CNC control transmits the M Function M98 or M99 to the
PLC
Eff.: Cycle stop
Sol.: Switch shift reset
WTB: A156 PLC: M 363 Modul:digi

161 T word missing by standby

Rec.: M18 has been programmed without T word


Eff.: Machine stop: Fault from Tool changer
Sol.: Correct NC programme
WTB: A161 PLC: Modul: vsm

162 Spindle / Standby position are empty

Rec.: M6 T0 programmed, but spindle and standby position are already


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

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 58


Dialog 112

163 Tool is in the spindle

Rec.: M6 Tx programmed and Tx is already in the spindle


Eff.: None
Sol.: Automatically at next tool change or reset
WTB: A163 PLC: Modul: vsm

164 WZ ist in der 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 positioned in standby

Rec.: M18 Tx programmed but standby position is already ocupied with


Ty. Tool Tx cannot be positioned in standby.
Eff.: None
Sol.: Automatically at next tool change or reset
WTB: A165 PLC: Modul: vsm

166 Tool not found in standby position.

Rec.: M18 Tx programmed and tool is not in magazine table


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

167 T word not programmed

Rec.: No T word programmed for M18


Eff.: No standby of tool
Sol.: Programme correctly
WTB: A167 PLC: Modul: wzw

169 Pallet release missing

Rec.: Call pallet change but pallet release is missing


Eff.: Machine stop: Fault from pallet changer
Sol.: Switch „Pallet release“ and cycle start
WTB: A169 PLC: Modul: pw

170 Magazine door open

Rec.: The magazine door is open


Eff.: None
Sol.: Close magazine door
WTB: A170 PLC: Modul: mag

171 Pallet is in machining area


Rec.: Pallet change call and pallet to be changed is already in
machining area (M61 oder M62)
Eff.: None
Sol.: At next pallet change or at reset
WTB: A171 PLC: Modul: pw

172 Palette ist im Beladungsraum

Rec.: M63 programmed and machining area is empty


Eff.: None
Sol.: At next pallet change or at reset

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 59


Dialog 112

WTB: A172 PLC: Modul: pw

173 Pallet change not possible

Rec.: M60 and machining area is empty


Eff.: Machine stop (Cycle stop)
Sol.: Change NC programme
WTB: A173 PLC: Modul: pw

174 T word missing at serial tool change

Rec.: M6
programmed without T word
Eff.: Machine stop: Fault from tool changer
Sol.: Change NC programme
WTB: A174 PLC: Modul: vsm

175 Transfer change with T word

Rec.: Empty spindle in exchange fot T word


Eff.: MAH: Fault from tool change
Sol.: Change NC programme
WTB: A175 PLC: Modul: vsm

177 Tool magazine is fully occupied

Rec.:
Eff.:
Sol.:
WTB: A177 PLC: Modul: vsm not used

178 Tool not found

Rec.: The selected change tool is not found


Eff.: Machine stop: Fault from tool changer
Sol.: Change NC programme or enter tool number into magazine table
WTB: A178 PLC: Modul: vsm

179 TC not in base position

Rec.: Break off of tool change with TC not in base position


Eff.: Machine stop (Cycle stop)
Sol.: Release with softkey
WTB: A179 PLC: Modul: wzw

180 Tool life exceeded

Rec.: Life of selected change tool is exceeded; Sister tool


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

181 Referencing the X axis

Rec.: The 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.
Eff.: The releasing cannot be contnued directly
Sol.: Change to the mode 1.6 „Reference point“ and approach
Reference point of X axis
Then continue releasing via softkey

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 60


Dialog 112

WTB: A181 PLC: G 996 Modul: wzw

182 Referencing the Y axis

Rec.: The
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 Referencing the Z axis

Rec.: The
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 axis selected

Rec.: While releasing the TC after reference point loss, it is


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

186 Hydraulic oil level low

Rec.: Level in hydraulic unit under minimum; Hydraulic not running


Eff.: Already running hydraulic functions will not be interrupted
the next function will not be carried out and Machine stop
occurs
Sol.: Top up oil in hydraulic unit
WTB: A186 PLC: G 290 Modul: hyd

187 Coolant low

Rec.: Coolant low but pump does not run


Eff.: None
Sol.: Refill coolant in tank
WTB: A187 PLC: Modul: ikuez

188 M-Function invalid

Rec.: A M-function was programmed which is not analysed by the PLC


Eff.: None
Sol.: Reset
WTB: 188 PLC: Modul: mdec

189 Drives failure

Rec.: Fault from drive amplifier while control on


Sol.: Main switch Off / On

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 61


Dialog 112

WTB: 189 PLC: Modul: maein

190 IKUEZ: 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 pressure pump defective

Rec.: Fault in the high pressure pump of the IKUEZ Internal coolant
unit
Eff.: Machine stop (Cycle stop: Fault in the IKUEZ Internal coolant
unit
Sol.: Remove fault
WTB: 191 PLC: Modul: ikuez

192 IKUEZ: Rotary filter defective

Rec.: Fault in the rotary filter / skimmer of the IKUEZ Internal


coolant unit
Eff.: Machine stop (Cycle stop: Fault in the IKUEZ Internal coolant
unit
Sol.: Remove fault
WTB: 192 PLC: Modul: ikuez

193 Coolant low clean tank

Rec.: Coolant in clean tank below minimum


Eff.: Machine stop (Cycle stop: Fault in the IKUEZ Internal coolant
unit
Sol.: Top up coolant tank
WTB: 193 PLC: Modul: ikuez

194 Max level in machine tank

Rec.:
Eff.:
Sol.:
WTB: 194 PLC: Modul: ikuez not used

195 Level switch machine tank defect

Rec.: Both level switches signal at the same time


Eff.: Machine stop (Cycle stop: Fault in the IKUEZ Internal coolant
unit
Sol.: Replace level switch
WTB: 195 PLC: Modul: ikuez

196 Min level in machine tank

Rec.: The level in machine tank is lower than minimum


Eff.: Lifting pump is switched off after 5 seconds
Sol.: Automatically
WTB: 196 PLC: Modul: ikuez

197 Chip flushing not possible

Rec.: Coolant in tank for dirty coolant

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 62


Dialog 112

Eff.: Suppression of chip flushing


Sol.: Top up coolant
WTB: 197 PLC: Modul: ikuez

198 IKUEZ: Flow control defective

Rec.: Pump for IKUEZ Internal coolant unit is swiched off and flow
control is active for more than 5 seconds
Eff.: Machine stop (Cycle stop: Fault in the IKUEZ Internal coolant
unit
Sol.: Remove fault
WTB: 198 PLC: Modul: ikuez

199 IKUEZ: Flow amount too low

Rec.: The
pump for the IKUEZ Internal coolant
unit is swiched off and the flow control shows low flow even
after two seconds
Eff.: Machine stop (Cycle stop: Fault in the IKUEZ Internal coolant
unit
Sol.: Remove fault
WTB: 199 PLC: Modul: ikuez

200 Motor circuit breaker tripped

Rec.: Motor circuit breaker in control cabinet has tripped


Eff.: Emergency off
Sol.: Reset motor circuit breaker
WTB: 200 PLC: Modul:

201 Mode change blocked

Rec.: The ATC or Pallet changer is active and a mode change is


called
Eff.: Mode change is suppressed
Sol.: Cycle stop ,then change mode
WTB: 201 PLC: Modul:

202 Switch on condition missing

Rec.: The control is off and the machining area door was not opened
and closed
Eff.: Drives cannot be coupled
Sol.: Open and close machining area door
WTB: 202 PLC: Modul: uvv

203 Star delta switchover

Rec.:
Eff.:
Sol.:
WTB: 203 PLC: Modul: spimoku not used

204 Orienting position missing

Rec.: M19 and orienting position missing


Eff.: Machine stop (Cycle stop)
Sol.: Check machine parameters
WTB: 204 PLC: Modul: spiricht

205 Key switch position not correct

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 63


Dialog 112

Rec.: The position of the key switch between normal and setup was
changed even though the axes and or spindle are moving
Eff.: The new key position is not accepted
Sol.: Cycle stop and correct key position
WTB: 205 PLC: Modul: uvv

206 Key switch defective

Rec.: The key switch for changing the position between normal and
setup is defective
Eff.: Machine stop (Cycle stop): Safety function
Sol.: Remove fault
WTB: 206 PLC: Modul: uvv

207 Machining area door is unlocked

Rec.: The machining area door is unlocked but not opened


Eff.: None
Sol.: Close or open door
WTB: 207 PLC: Modul: uvv

208 Magazine pocket not free

Rec.: The
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 running

Rec.: The CNC has called a M function in the PLC; The M


acknowledgement is blocked
Eff.: The M function is being processed. The NC programme will be
further processed after acknowedgement of the M function
Sol.: Automatic
WTB: 209 PLC: Modul: sammel

210 Loading enclosure is open

Rec.: The loading enclosure of the Pallet changer unit is open


Eff.: The processing of the pallet changer is stopped or not
permitted
Sol.: close enclosure
WTB: 210 PLC: Modul: pw

211 Programme selection not ok

Rec.: It was tried to start a programme although none was


selected in mode 2.1
Eff.: Cycle start without function
Sol.: Select programme in BA 2.1 and then start the processing or
the test
WTB: A211 PLC: — Modul: sammel

212 End of work shutoff

Rec.: The machine was switched off by the end of wotk shutoff
Eff.: Machine off

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 64


Dialog 112

Sol.: Switch machine on again


WTB: A212 PLC: G 8 Modul: maein

213 Function not available

Rec.: A function not available in the machine configuration, was


selected via softkey
Eff.: None
Sol.: Release softkey
WTB: A213 PLC: Modul: aggallg

214 Axis lubrication failed

Rec.: Lubrication pressure not achieved


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

215 Axis lubrication level not OK


Rec.: Lube level low
Eff.: Cycle stop when a G0 block is called or all axes are standing
Read-in lock after second fault in lube impulse
Sol.: Top up central lube unit for guide way
WTB: A215 PLC: Modul: schmiz

216 Alarm Spindle amplifier

Rec.: Fehler aus SpindelverstaRecer


Eff.: Emergency off
Sol.: Main switch Off/On
WTB: A216 PLC: Modul: spiallg

217 Touch probe: Battery empty

Rec.: Barrety for touch probe MP10 empty


Eff.: Feed stop all axes
Sol.: Replace battery or reset (Deletion of feed stop)
WTB: A217 PLC: Modul: messtast

218 Touch probe not ready

Rec.: Signal path touchprobe - OMM interrupted or cannot be


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

219 Magazine pocket is locked

Rec.: A
tool is automatically removed from the magazine and the
marking is „9“ (automatic oder manual)
Eff.: Cycle stop
Sol.: Rewrite marking with 0-2 and check tool (tool break detector)
WTB: A219 PLC: Modul: vsm

220 Max.time: Unclamp workpiece

Rec.: Reserved
Eff.:
Sol.:

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 65


Dialog 112

WTB: A220 PLC: Modul: wstspan

221 Max. time: Clamp Workpiece

Rec.: Reserved
Eff.:
Sol.:
WTB: A221 PLC: Modul: wstspan

222 Input gripper 0 degrees missing

Rec.: Input X4 (x70:b30) gripper has turned to 0 degrees S_206 is


missing
Eff.: Process stopped
Sol.: Please contact service department
WTB: A222 PLC: Modul: wzw_v4

223 Input gripper 180 degrees missing

Rec.: Input X5 (x70:z30) gripper has turned to 180 degrees S_207 is


missing
Eff.: Process stopped
Sol.: Please contact service department
WTB: A223 PLC: Modul: wzw_v4

224 Input magazine position missing

Rec.: Input X7 (x70:b28) TC in magazine position S_204 missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A224 PLC: Modul: wzw_4v

225 Input standby position missing

Rec.: Inputg X3 (x70:d30) TC in standby position S_218 missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A225 PLC: Modul: wzw_v4

226 Input spindle position missing

Rec.: Input X6 (x70:d28) TC in spindle position S_205 missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A226 PLC: Modul: wzw_v4

227 Input tool locked missing

Rec.: Input XB (x70:z26) TC gripper claw locked S_219 missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A227 PLC: Modul: wzw_v4

228 Input tool locked faulty

Rec.: Input XB (x70:z26) TC gripper claw locked S_219 is not „Zero“


Eff.: Process stopped
Sol.: Please contact service department
WTB: A228 PLC: Modul: wzw_v4

229 Input pallet door missing

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Dialog 112

Rec.: Input X41 (x71:b16) raising door to PC open missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A229 PLC: Modul: pw_v4 pw_v3

230 Input pallet door closed missing

Rec.: Input X42 (x71:z16) raising door to PC closed missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A230 PLC: Modul: pw_v3 pw_v4

231 Input double carriage position-1 missing

Rec.: Input X47 (x71:b12) double carriage position-1 in alternating


position missing
Eff.: Process stopped
Sol.: Please contact service department
WTB: A231 PLC: Modul: pw_v4

232 Input double carriage position-2 missing

Rec.: Input X48 (x71:b12) double carriage position-2 in alternating


position missing
Eff.: Ablauf steht
Sol.: Please contact service department
WTB: A232 PLC: Modul: pw_v4

233 Input pallet raised missing

Rec.: Input X4E (x71:z08) pallet raised missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A233 PLC: Modul: pw_v3 pw_v4

234 Input pallet lowered missing

Rec.: Input X4D (x71:b08) pallet lowered missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A234 PLC: Modul: pw_v3 pw_v4

235 Input pallet clamped missing

Rec.: Input X4C (x71:d08) pallet clamped missing


Eff.: Process stopped
Sol.: Please contact service department
WTB: A235 PLC: Modul: pw_v3 pw_v3

236 Input pallet deposited missing

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


DC 50 V Input X01 (x70:b32)
PC position-1 pallet in depositing pos. or Input X03 (x70:d30)
PC position-2 pallet in depositing pos. missing
Eff.: Process stopped
Sol.: Please contact service department
WTB: A236 PLC: Modul: pw_v3 pw_v4

237 Input pallet brought missing

Rec.: DC 70/100 V Input X45 (x71:z14) pallet changed missing

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Dialog 112

DC 50 V Input X00 (x70:d32)


PC pos. 1 transfer position to machine or Input X02 (x70:z32)
PC pos. 2 transfer position to machine missing

Eff.: Process stopped


Sol.: Please contact service department
WTB: A237 PLC: Modul: pw_v3 pw_v4

238 Input pallet pos 1 occupied missing

Rec.: Input X43 (x71:d14) PC pallet pos 1 occupied missing (Double


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

239 Input pallet pos 2 occupied missing

Rec.: Input X44 (x71:d14) PC pallet pos 1 occupied missing (Double


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

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 68


Dialog 112

Inputs DC50 V - 2880

X Plug Remarks

X00 (x70:d32) PC position 1 transfer position to machine


X01 (x70:b32) PC position 1 pallet in depositing position
X02 (x70:z32) PC position 2 transfer position to machine
X03 (x70:d30) PC position 2 pallet in depositing position
X04 (x70:b30) Magazine position free
X05 (x70:z30) —
X06 (x70:d28) —
X07 (x70:b28) —
X08 (x70:z28) Return message (Star) Motor spindle
X09 (x70:d26) Return message (Delta) Motor spindle
X0A (x70:b26) Drives uncoupled
X0B (x70:z26) Reference point 4. axis (Magazine)
X0C (x70:d24) Tool in spindle clamped
X0D (x70:b24) Tool in spindle unclamped
X0E (x70:z24) —
X0F (x70:d22) —
X10 (x70:b22) Central lube pressure reached
X11 (x70:z22) Central lube oil level OK
X12 (x70:d20) Measuring tip resting position
X13 (x70:b20) Measuring tip measuring position
X14 (x70:z20) Motor circuit breaker OK
X15 (x70:d18) Machine OK
X16 (x70:b18) Cooling motor spindle OK
X17 (x70:z18) Switch: Normal position
X18 (x70:d16) Reference point cam X
X19 (x70:b16) Reference point cam Y
X1A (x70:z16) Reference point cam Z
X1B (x70:d14) Reference point cam TC magazine
X1C (x70:b14) Magazine: Call
X1D (x70:z14) Magazine door closed
X1E (x70:d12) Coolant: Low (IKUEZ)
X1F (x70:b12) Switch: Setup
X20 (x70:z12) 1.Rotary axis clamped
X21 (x70:d10) 1.Rorary axis unclamped
X22 (x70:b10) Hydraulic oil level OK
X23 (x70:z10) External release of axes and spindle
X24 (x70:d08) Machining area doors closed and locked
X25 (x70:b08) Machining area doors open and unlocked
X26 (x70:z08) Acknowledgement switch hand control unit
X27 (x70:d06) * Emergency Off
X28 (x71:d32) —
X29 (x71:b32) —
X2A (x71:z32) —
X2B (x71:d30) —

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 69


Dialog 112

Inputs DC50 V - 2880

X Plug Remarks

X2C (x71:b30) Reference cam 1.Rotary axis


X2D (x71:z30) (Reference cam 6.axis)
X2E (x71:d28) (Reference cam 7.axis)
X2F (x71:b28) (Reference cam 8.axis)
X30 (x71:z28) —
X31 (x71:d26) Renishaw probe ready
X32 (x71:b26) Renishaw probe battery low
X33 (x71:z26) Level under below minimum (IKUEZ)
X34 (x71:d24) Motor circuit breaker IKUEZ OK
X35 (x71:b24) * Coolant Max level
X36 (x71:z24) Flow control Q>2 l/min (IKUEZ)
X37 (x71:d22) Coolant: Lifting pump on
X38 (x71:b22) Interferance rotary filter skimmer (IKUEZ)
X39 (x71:z22) Interferance high pressure pump (IKUEZ)
X3A (x71:d20) Reserved for special option
X3B (x71:b20) Reserved for special option
X3C (x71:z20) Acknowledgement M 106
X3D (x71:d18) Acknowledgement M 108
X3E (x71:b18) 1.Rotary axis clamped
X3F (x71:z18) 1.Rotary axis unclamped
X40 (x71:d16) Pallet safety housing closed
X41 (x71:b16) Raising door to PC open
X42 (x71:z16) Raising door to PC closed
X43 (x71:d14) PC position 1 occupied
X44 (x71:b14) PC position 2 occupied
X45 (x71:z14) —
X46 (x71:d12) —
X47 (x71:b12) —
X48 (x71:z12) —
X49 (x71:d10) —
X4A (x71:b10) —
X4B (x71:z10) —
X4C (x71:d08) Pallet clamped
X4D (x71:b08) Pallet lowered
X4E (x71:z08) Pallet raised
X4F (x71:d06) Pallet unclamped
X50 (CDP21L1-B22) Touch probe inserted from Digi-PC
X51 (CDP21L1-A22) Automatic active from Digi-PC
X52 (CDP21L1-B21) Axes stop Digi-PC
X53 (CDP21L1-A21) Regulator release from Digi-PC
X54 (CDP21L1-B20) BTB (Ready) from Digi-PC

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 70


Dialog 112

Outputs DC50 V - 2880

X Plug Remarks

(x50:d32) + UB 1 (2 Ampere)
(x50:b32) + UB 1 (2 Ampere)
Y00 (x50:z32) Open raising door to PC
Y01 (x50:d30) Close raising door to PC
Y02 (x50:b30) Clamp pallet
Y03 (x50:z30) Unclamp pallet
Y04 (x50:d28) —
Y05 (x50:b28) —
Y06 (x50:z28) —
Y07 (x50:d26) —
Y08 (x50:b26) Measuring signal M 49 (200ms)
Y09 (x50:z26) Unclamp tool
(x50:d24) + UB 2 (2 Ampere)
(x50:b24) + UB 2 (2 Ampere)
Y0A (x50:z24) Blow out tool clamp
Y0B (x50:d22) Magazine: Loosen brake
Y0C (x50:b22) Z axis loosen motor brake
Y0D (x50:z22) Activate measuring tip
Y0E (x50:d20) Blow out measuring tip
Y0F (x50:b20) Rotoclear On
Y10 (x50:z20) PC drive position 1 right
Y11 (x50:d18) PC drive position 1 left
Y12 (x50:b18) PC drive position 2 right
Y13 (x50:z18) PC drive position 2 left
(x50:d16) + UB 3 (2 Ampere)
(x50:b16) + UB 3 (2 Ampere)
Y14 (x50:z16) Signal Spindle turning
Y15 (x50:d14) —
Y16 (x50:b14) —
Y17 (x50:z14) —
Y18 (x50:d12) Star (1)/Delta (0) - Switchover
Y19 (x50:b12) NC-Ready
Y1A (x50:z12) Magazine: Call
Y1B (x50:d10) Motor spindle cooling On
Y1C (x50:b10) Acknowledgement switch hand control unit
Y1D (x50:z10) Lock safety doors
(x50:d08) + UB 4 (0,5 Ampere)
Y1E (x50:b08) Drives On
Y1F (x50:z08) —
(x50:d06) + UB 5 (0,5 Ampere)
Y20 (x50:b06) Collective interferance message (H1)
Y21 (x50:z06) Hydraulic on

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 71


Dialog 112

Outputs DC50 V - 2880

X Plug Remarks

Y22 (x50:d04) Central lube On


Y23 (x50:b04) Coolant On
Y24 (x50:z04) Internal coolant (HD) On
Y25 (x50:d02) Coolant lifting pump On
Y26 (x50:b02) Coolant chip flushing On
Y27 (x50:z02) ???
(x51:d32) + UB 1 (2 Ampere)
(x51:b32) + UB 1 (2 Ampere)
Y28 (x51:z32) —
Y29 (x51:d30) —
Y2A (x51:b30) —
Y2B (x51:z30) —
Y2C (x51:d28) —
Y2D (x51:b28) —
Y2E (x51:z28) —
Y2F (x51:d26) —
Y30 (x51:b26) Reserved for special option
Y31 (x51:z26) Reserved for special option
(x51:d24) + UB 2 (2 Ampere)
(x51:b24) + UB 2 (2 Ampere)
Y32 (x51:z24) Clamping On 1. Rotary axis
Y33 (x51:d22) Clamping Off 1. Rotary axis
Y34 (x51:b22) nclamp workpiece
Y35 (x51:z22) —
Y36 (x51:d20) —
Y37 (x51:b20) —
Y38 (x51:z20) —
Y39 (x51:d18) —
Y3A (x51:b18) —
Y3B (x51:z18) —
(x51:d16) + UB 3 (2 Ampere)
(x51:b16) + UB 3 (2 Ampere)
Y3C (x51:z16) —
Y3D (x51:d14) —
Y3E (x51:b14) —
Y3F (x51:z14) —
Y40 (x51:d12) Reserved for special option
Y41 (x51:b12) Reserved for special option

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 72


Dialog 112

Inputs DC50 V - 2880

X Plug Remarks

Y42 (x51:z12) —
Y43 (x51:d10) —
Y44 (x51:b10) —
Y45 (x51:z10) —
(x51:d08) + UB 4 (0,5 Ampere)
Y46 (x51:b08) —
Y47 (x51:z08) —
(x51:d06) + UB 5 (0,5 Ampere)
Y48 (x51:b06) —
Y49 (x51:z06) Programme completed (H1)
Y4A (x51:d04) Programme running (H1)
Y4B (x51:b04) Switching function 1 (M 100 / M 101)
Y4C (x51:z04) Switching function 2 (M 102 / M 103)
Y4D (x51:d02) Switching function 3 (M 104 / M 105)
Y4E (x51:b02) Switching function 4 (M 106 / M 107)
Y4F (x51:z02) Switching function 5 (M 108 / M 109)
Y50 (CDJ21L1-B22) Cycle start to Digi-PC
Y51 (CDJ21L1-A22) Cycle stop to Digi-PC
Y52 (CDJ21L1-B21) Drive command X+ to Digi-PC
Y53 (CDJ21L1-A21) Drive command X- to Digi-PC
Y54 (CDJ21L1-B20) Drive command Y+ to Digi-PC
Y55 (CDJ21L1-A20) Drive command Y- to Digi-PC
Y56 (CDJ21L1-B19) Drive command Z+ to Digi-PC
Y57 (CDJ21L1-A19) Drive command Z- to Digi-PC
Y58 (CDJ21L1-B18) D112-BTB (ready) to Digi-PC
Y59 (CDJ21L1-A18) Spindle turning to Digi-PC
Y5A (CDJ21L1-B17) Automatik allows to Digi-PC

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 73


Dialog 112

Inputs DC70/100 V - 2880, 2881

X Plug Remarks

X0 (x70:d32) Magazine is in position S_202


X1 (x70:b32) Magazine braking cam S_201
X2 (x70:z32) Magazine Reference point S_200
X3 (x70:d30) TC in standby position S_218
X4 (x70:b30) Gripper is turned to 0 degree S_206
X5 (x70:z30) Gripper is turned to 180 degree S_207
X6 (x70:d28) TC in spindle position S_205
X7 (x70:b28) TC in magazine position S_204
X8 (x70:z28) Return message (Star) Motor spindle
X9 (x70:d26) Return message (Delta) Motor spindle
XA (x70:b26) Drives uncoupled
XB (x70:z26) TC gripper claw locked S_219
XC (x70:d24) Input tool clamp closed S_272
XD (x70:b24) Input tool clamp open S_274
XE (x70:z24) Magazine button forward S_215
XF (x70:d22) Magazine button reverse S_216
X10 (x70:b22) Central lube pressure reached
X11 (x70:z22) Central lube oil level OK
X12 (x70:d20) Measuring tip resting position
X13 (x70:b20) Measuring tip measuring position
X14 (x70:z20) Motor circuit breaker OK
X15 (x70:d18) Machine OK
X16 (x70:b18) Cooling motor spindle OK
X17 (x70:z18) UVV Switch: Normal position
X18 (x70:d16) Reference point cam X
X19 (x70:b16) Reference point cam Y
X1A (x70:z16) Reference point cam Z
X1B (x70:d14) Reference point cam TC magazine
X1C (x70:b14) Magazine: Call
X1D (x70:z14) Magazine door closed
X1E (x70:d12) Coolant: Low (IKUEZ)
X1F (x70:b12) UVV Switch: Setup
X20 (x70:z12) (-OT1)
X21 (x70:d10) (-OT2)
X22 (x70:b10) Hydraulic oil level OK
X23 (x70:z10) External release of axes and spindle
X24 (x70:d08) Machining area doors closed and locked
X25 (x70:b08) Machining area doors open and unlocked
X26 (x70:z08) Acknowledgement switch hand control unit
X27 (x70:d06) * Emergency Off
X28 (x71:d32) (+OT1)
X29 (x71:b32) (+OT2)
X2A (x71:z32) (+OT3)
X2B (x71:d30) (+OT4)
X2C (x71:b30) Reference point cam 5. axis

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 74


Dialog 112

Inputs DC70/100 V - 2880, 2881

)X Plug Remarks

X2D (x71:z30) (Reference point cam 6.axis)


X2E (x71:d28) (Reference point cam 7.axis)
X2F (x71:b28) (Reference point cam 8.axis
X30 (x71:z28) —
X31 (x71:d26) Renishaw probe ready
X32 (x71:b26) Renishaw probe battery low
X33 (x71:z26) Level under below minimum (IKUEZ)
X34 (x71:d24) Motor circuit breaker IKUEZ OK
X35 (x71:b24) * Coolant Max level
X36 (x71:z24) Flow control Q>2 l/min (IKUEZ)
X37 (x71:d22) Coolant: Lifting pump on
X38 (x71:b22) Interferance rotary filter skimmer (IKUEZ)
X39 (x71:z22) Interferance high pressure pump (IKUEZ)
X3A (x71:d20) Reserved for special option
X3B (x71:b20) Reserved for special option
X3C (x71:z20) Acknowledgement M 106
X3D (x71:d18) Acknowledgement M 108
X3E (x71:b18) 1.Rotary axis clamped
X3F (x71:z18) 1.Rotary axis unclamped
X40 (x71:d16) Pallet safety housing closed
X41 (x71:b16) Raising door to PC open
X42 (x71:z16) Raising door to PC closed
X43 (x71:d14) PC pos. 1 occupied (Double carriage occupied)
X44 (x71:b14) PC pos. 2 occupied (Double carriage occupied)
X45 (x71:z14) Pallet has been brought in
X46 (x71:d12) Pallet has been brought out
X47 (x71:b12) Double carriage pos.-1 in alternating pos.
X48 (x71:z12) Double carriage pos.-2 in alternating pos.
X49 (x71:d10) —
X4A (x71:b10) —
X4B (x71:z10) —
X4C (x71:d08) Pallet clamped
X4D (x71:b08) Pallet lowered
X4E (x71:z08) Pallet raised
X4F (x71:d06) Pallet unclamped
X50 (CDP21L1-B22) Touch probe inserted from Digi-PC
X51 (CDP21L1-A22) Automatic active from Digi-PC
X52 (CDP21L1-B21) Axes stop Digi-PC
X53 (CDP21L1-A21) Regulator release from Digi-PC
X54 (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 Plug Remarks

Y0 (x50:z32) TC Intermediate pos. release Y_228


Y1 (x50:d30) Move TC to intermediate position Y_227
Y2 (x50:b30) Move TC to magazine Y_202
Y3 (x50:z30) Move TC to spindle Y_203
Y4 (x50:d28) Turn TC changer to 0 degrees Y_206
Y5 (x50:b28) Turn TC changer to 180 degrees Y_207
(x50:z28) —
Y7 (x50:d26) —
Y08 (x50:b26) Measuring signal M 49 (200ms)
Y09 (x50:z26) Unclamp tool
YA (x50:z24) Blow out tool clamp
YB (x50:d22) TC changer 2. change speed
Y0C (x50:b22) Z axis loosen motor brake
Y0D (x50:z22) Activate measuring tip
Y0E (x50:d20) Blow out measuring tip
Y0F (x50:b20) Rotoclear On
Y10 (x50:z20) Turn magazine forwards
Y11 (x50:d18) Turn magazine backwards
Y12 (x50:b18) —
Y13 (x50:z18) —
Y14 (x50:z16) Signal Spindle turning
Y15 (x50:d14) —
Y16 (x50:b14) PC-Transport Right
Y17 (x50:z14) PC-Transport Left
Y18 (x50:d12) Star (1)/Delta (0) - Switchover
Y19 (x50:b12) NC-Ready
Y1A (x50:z12) Magazine: Call
Y1B (x50:d10) Motor spindle cooling On
Y1C (x50:b10) Acknowledgement switch hand control unit
Y1D (x50:z10) Lock safety doors
(x50:d08) + UB 4 (0,5 Ampere)
Y1E (x50:b08) Drives On
Y1F (x50:z08) Magazine release
Y20 (x50:b06) Stoerung Sammelmeldung (rote Lampe)
Y21 (x50:z06) Hydraulic On
Y22 (x50:d04) Central lube On
Y23 (x50:b04) Coolant On
Y24 (x50:z04) Internal coolant (HD) On
Y25 (x50:d02) Coolant lifting pump On
Y26 (x50:b02) Coolant chip flushing On
Y27 (x50:z02) ???
Y28 (x51:z32) Open raising door to PC
Y29 (x51:d30) Close raising door to PC
Y2A (x51:b30) PC: Clamp pallet
Y2B (x51:z30) PC: Unclamp pallet

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 76


Dialog 112

Outputs DC70/100 V - 2880, 2881

X Plug Remarks
Y2C (x51:d28) Blow out air for PC On
Y2D (x51:b28) —
Y2E (x51:z28) Double carriage pos.-1 in alternating pos.
Y2F (x51:d26) Double carriage pos.-2 in alternating pos.
Y30 (x51:b26) Reserved for special option
Y31 (x51:z26) Reserved for special option
Y32 (x51:z24) Clamping On 1. Rotary axis
Y33 (x51:d22) Clamping Off 1. Rotary axis
Y34 (x51:b22) Unclamp workpiece
Y35 (x51:z22) —
Y36 (x51:d20) —
Y37 (x51:b20) —
Y38 (x51:z20) —
Y39 (x51:d18) —
Y3A (x51:b18) —
Y3B (x51:z18) —
Y3C (x51:z16) —
Y3D (x51:d14) —
Y3E (x51:b14) —
Y3F (x51:z14) —
Y40 (x51:d12) Reserved for special option
Y41 (x51:b12) Reserved for special option
Y42 (x51:z12) —
Y43 (x51:d10) —
Y44 (x51:b10) —
Y45 (x51:z10) —
Y46 (x51:b08) —
Y47 (x51:z08) —
Y48 (x51:b06) —
Y49 (x51:z06) Programme completed (Yellow lamp)
Y4A (x51:d04) Programme running (Green lamp)
Y4B (x51:b04) Switching function 1 (M 100 / M 101)
Y4C (x51:z04) Switching function 2 (M 102 / M 103)
Y4D (x51:d02) Switching function 3 (M 104 / M 105)
Y4E (x51:b02) Switching function 4 (M 106 / M 107)
Y4F (x51:z02) Switching function 5 (M 108 / M 109)
Y50 (CDJ21L1-B22) Cycle start to Digi-PC
Y51 (CDJ21L1-A22) Cycle stop to Digi-PC
Y52 (CDJ21L1-B21) Drive command X+ to Digi-PC
Y53 (CDJ21L1-A21) Drive command X- to Digi-PC
Y54 (CDJ21L1-B20) Drive command Y+ to Digi-PC
Y55 (CDJ21L1-A20) Drive command Y- to Digi-PC
Y56 (CDJ21L1-B19) Drive command Z+ to Digi-PC
Y57 (CDJ21L1-A19) Drive command Z- to Digi-PC
Y58 (CDJ21L1-B18) D112-BTB (ready) to Digi-PC
Y59 (CDJ21L1-A18) Spindle turning to Digi-PC
Y5A (CDJ21L1-B17) Automatik allows to Digi-PC

DECKEL MAHO GmbH - Service Subject to change Dated:  Page 77