(1) model: low-speed wire cutting machine CUT 100D.
Fault symptom: unable to thread automatically.
Troubleshooting: During automatic threading, the upper head nozzle sprays water normally, but the lower head nozzle should absorb water, but spray water outwards. Check the water tank pipeline, and find that the valve below the throttle valve (pipe connection for water absorption) is closed, and the thread threading is normal after opening. However, it is found that as soon as the electrode on the punch touches the workpiece, the knife will be lifted immediately, and it is impossible to carry out electrical discharge machining. There are two possibilities: discharge board failure or wiring failure. Based on the principle of easy before difficult, check the connection first and find that a negative connection has been disconnected. After connecting, troubleshoot. The low-speed WEDM cutting 150HSS also had a similar fault, but the phenomenon was that it could not be discharged. According to experience, the connection should be given priority in this case. The failure of the discharge board has only been encountered once: the failure message 735 appears on the SPRINT20 of the low-speed wire cutting machine. It is found that there is too much dust on the No.7 discharging plate PMO2 1 1.
(2) Model: low-speed wire cutting machine CUT 100D.
Fault information: 104.
Fault phenomenon: when the machine tool moves to the limit of -30.50mm in the negative direction of the U axis when it returns to zero, the machine tool still keeps moving (when the manual travel switch moves to the positive direction of the U axis, the machine tool can only return to zero), and when it goes straight to -36.00mm, it crashes and has to be stopped artificially.
Troubleshooting: Remove the travel switch, and measure pins 2 1 and 22 of J5 socket of WID282 circuit board with multimeter. The input voltage is +20V. Turn off the machine, press the travel switch by hand, and measure pins 2 1 and 22 of J5 socket of WID282 circuit board with multimeter. The switch shows normal. It is preliminarily concluded that there is something wrong with the two control boards STB203 and IMC202. The circuit boards of STB20 1, STB202 and STB203 (the circuit board of STB202 has nothing to do with this fault, so they were all replaced for fear of screwing up at that time) are the same as those of SPRINT20 machine tool. The fault remains the same. In addition, the related circuit boards DBE20 1, IMC202, DMC20 1, DMC202 and SBC20 1 have been changed. At this time, it can move in the positive direction of the U-axis, but it cannot be flush (the indicator lights GL4 and GL6 on the circuit board of STB202 are not lit. SE5 intermediate relay coil has no +24V voltage, so the water pump cannot work). Considering that the flushing mode of SPRINT20 is different from that of CUT 100D, all the circuit boards are replaced, and a 450 message appears after startup, and the cooling system is out of order and there is no flushing. Press the manual button (whether the U, V, X and Y axes are positive or negative), the machine tool can only move once, the 450 message appears again, and then it crashes. This situation seems to be related to DWC205 board. So the DWC205 circuit board was replaced, which had no effect. Finally, replace the DMC202 board of the substation stationmaster (the low-speed WEDM has several single-board computer control boards, and the main single-board computer (stationmaster) controls all sub-boards (substation stationmaster) respectively, and each single-board computer summarizes the work of each function control board to the main single-board computer control board). After starting the machine, the screen displays garbled code, but the remote control box does not display. Plug in the circuit board again and turn it on, and the garbled code will be eliminated. Messages 123, 109, 42 1, 300, 30 1, 45 1, 486, 450, 108 appear, indicating that the power circuit board of the LPS220 has After careful inspection, I found that all the lights were on. Plug it tightly before starting, and troubleshoot. In fact, the message 104 appears, which may only be due to poor contact of STB0 1 or STB03.
(3) Model: low-speed WEDM SPRINT20.
Fault information: 42 1, 123.
Fault symptom: M2 wire feeding motor does not rotate.
Troubleshooting: Move the counterweight up and down, change the resistance of Rx2 magnetic potentiometer, and M2 motor will not stop. Measure pins 3 and 4 of J6 socket of DWC206 circuit board, and there is no voltage output. Unplug the DWC206 board and find that the V5 field effect transistor BDW84D is open. After replacement, the M2 motor rotates normally.
(4) Model: low-speed WEDM SPRINT20.
Fault symptom: M4 belt drive motor of machine tool does not rotate. Troubleshooting: M4 belt drive motor is controlled by three circuit boards DWC205, DMD2 12 and DMD2 15 respectively, and there is a single board computer on DWC205 circuit board for controlling and outputting electrical signals. DMD2 12 circuit board is a preamplifier board. DMD2 15 circuit board is a power-driven amplifier board. COMS triode on DMD2 15 circuit board directly drives M4 belt motor to rotate. According to the situation that the indicator light GL 1 of the DMD2 15 circuit board is not on, it is necessary to check the DMD2 15 circuit board to find that there is no voltage signal at the front pole. Check the previous circuit board DWC2 12, and no voltage signal is found. Finally, it is found that UA9638 output amplifier of DWC205 circuit board is broken down. After replacing it with a new one, troubleshoot it. On another occasion, the M4 belt drive motor started, and it could not be stopped by pressing the stop button. Measure J2 plug 1 1 and 12 of DMD2 12 circuit board at startup, and the voltage is+2.79V. After the self-inspection of the machine tool is completed, it will oscillate to 20.2V (J2 plug1and 60 when the manual threading button is pressed). Continue to check the four pins of SN75 182 double differential line receiver on DMD2 15 circuit board from front to back. The high level is +20V, the optocoupler transistor C is 2.3V, the R3 1 potentiometer 0.5V V3IRF750COMS transistor B is 0.75V, and the C is 40V (when the manual threading button is pressed, the C is extremely It is not difficult to judge that there is something wrong with the power-driven V3COMS transistor. After the measurement, the V3COMS transistor has been broken down. After replacing it with a new one, troubleshoot it.
7) Model: EDM machine tool 2U
Fault information: 4247, 349, 4302, 4493, 4442.
Fault phenomenon: After the oil of the machine tool is changed, during the machining process, after the above information appears, the circulating oil pump automatically turns off and the machine tool stops machining. It is suspected that air enters the pipeline during oil change. It is not possible to open the valve of the oil pump to deflate (afterwards, I learned that the 2U machine tool does not need to deflate after oil change because of its low oil level). In order to judge whether it is a control cabinet fault or an oil circuit fault, the S 10 oil relay is short-circuited (pins 7 and 8 of the PM 1 on-board AP 1 terminal board are connected by wires). At this time, the detection signal of the circuit is in an open state, and the microcomputer turns off the automatic protection of the oil pump. The machine tool can be processed completely. It means that it is an oil circuit fault. And the fault lies in the motor of the circulating oil pump. After the oil in the oil tank was drained, the oil pump was removed and it was found that the centrifugal rotor was covered with rags. After cleaning, I noticed that the oil cover sealing ring also has a small oil port, aiming at the two oil ports, and the machine tool is normal after starting.
(8) model: EDM machine tool1u.
Failure phenomenon: When the spindle electrode clamping button SE2 is pressed, the L2 solenoid valve sometimes does not exist. Therefore, the electrode clamping device is out of order and cannot be clamped.
Troubleshooting: The following four parts should be checked when this fault occurs: ① Whether the button is in good contact. ② Whether the solenoid valve is dirty or stuck. ③ ③ Whether ③③wid 230 and PEC202 circuit boards are faulty. (4) Whether there is poor contact with related wires. Press the SE2 button by hand, and the brightness of the GL2 and GL9 indicator lights on the PEC202 circuit board changes, indicating that the signal is sent out, and there is no problem in pressing the button. When testing the solenoid valve core with a screwdriver, sometimes it is magnetic, sometimes it is not magnetic, but it is not energized. The fault belongs to part 3 and part 4. Unplug PEC202 circuit board, connect +5V power supply to both ends of K 14 relay coil, and measure its normally open contacts with multimeter.
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