SMARTSHOP III FANUC SERIES Oi-MF CNC MANUAL

Transcription

1 SMARTSHOP III FANUC SERIES Oi-MF CNC MANUAL LAGUNA TOOLS 2072 Alton Parkway Irvine, California Ph: , Laguna Tools, Inc. LAGUNA and the LAGUNA Logo are the registered trademarks of Laguna Tools, Inc. All rights reserved.

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3 1. Table of Contents GENERAL INFORMATION... 8 SAFETY RULES... 8 LIMITED WARRANTY... 9 NOISE EMISSION SPECIFICATION SHEET RECEIVING YOUR MACHINE MAINTENANCE Lubrication Daily checks Weekly checks INTRODUCTION TO CNC MACHINES MACHINE PARTS (LAGUNA SMART SHOP III) BASIC COMPONENTS AUTOMATIC TOOL CHANGER (ATC) MANUAL TOOL RELEASE BUTTON AUTOMATIC TOOL TOUCH-OFF SWITCH MACHINE INSTALLATION MACHINE LOCATION UNPACKING THE MACHINE ASSEMBLY & SETUP CLEANING THE MACHINE FITTING THE DUST HOSE ELECTRICAL CONNECTIONS COMPRESSED AIR CONNECTION CONNECTING THE VACUUM PUMP ASSEMBLING ISO-30 CONES WITH ROUTER BITS SELECTING THE CORRECT ROUTER BIT WORKING WITH VACUUM TABLES AND SPOIL BOARDS LAGUNA SMARTSHOP III CONTROL CABINET PARTS CNC CONTROLLER MODULE LAYOUT Display Screen USB Memory Slot Compact Flash (CF) Memory Slot Keypad [Hard Keys] Keypad (Soft Keys) OPERATOR KEYBOARD MODULE LAYOUT Emergency Stop Button Spindle Speed Override Knob Function Keys Page. 3

4 LIGHT TOWER Red Light Yellow Light Green Light COMMON CNC OPERATOR SCREENS BOOT SCREEN POSITION SCREEN PROGRAM EDIT SCREEN OPERATION BASICS TURNING ON THE MACHINE TURNING OFF THE MACHINE MACHINE MOVEMENT OPERATIONS Jog Axes Homing Jog Axes using the Manual Pulse Generator (MPG) Manual Tool Release SETTING WORK COORDINATES AND TOOL OFFSETS AUTOMATIC TOOL TOUCH-OFF Z-OFFSETS FOR TOOLS SETTING SPOILER BOARD THICKNESS SETTING WORK COORDINATES SETTING DRILL BLOCK OFFSETS FOR X AND Y AXES SETTING DRILL BLOCK Z-AXIS OFFSET PROGRAM OPERATIONS VIEWING AND NAVIGATING DIRECTORIES View CNC Controller Program Directory View Directory Of Memory Devices (USB Memory OR CF Memory Card) LOADING PROGRAMS Load Program From CNC Controller Memory COPYING PROGRAMS Copy Program from USB or CF Memory Card to CNC Controller Memory Copy Program From CNC Memory to USB or CF Memory Card DELETING PROGRAMS Delete Program From CNC Controller Memory Delete Program from USB Memory or CF Memory Card EDITING PROGRAMS Edit Program on CNC Controller RENAMING PROGRAMS Rename a Program on CNC Controller CREATING NEW PROGRAMS Create a Program on CNC Controller LOADING AND RUNNING PROGRAMS ON CNC CONTROLLER Page. 4

5 Loading a Program Starting a Program in AUTO Mode (after program is loaded into CNC memory) Running a Program In Single-Block Mode STOPPING PROGRAMS Stopping a Running Program Resume a Stopped Program MDI MODE Entering Commands in MDI Mode ALARMS OT0500 (X,Y,Z,B,C) + OVERTRAVEL (SOFT) OT0501 (X,Y,Z,B,C) - OVERTRAVEL (SOFT) Clearing Soft Over-Travel Alarms Clearing Soft Over-Travel Alarms During Homing OT0506 (X,Y,Z,B,C) + OVERTRAVEL (HARD) OT0507 (X,Y,Z,B,C) - OVERTRAVEL (HARD) Clearing Hard Over-Travel Alarms (Hard Over-Travel Switch Override) SW0100 PARAMETER ENABLE SWITCH ON Clearing Parameter Enable Switch Alarm DS0001 SYNC EXCESS ERROR (POS DEV) Clearing Sync Excess Errors: Refer to Parameter DS0300 (X,Y,Z,B,C) APC ALARM: NEED REF RETURN Clearing Ref Return Alarms DS0306 (X,Y,Z) APC ALARM: BATTERY VOLTAGE DS0307 (X,Y,Z) APC ALARM: BATTERY LOW DS0308 (X,Y,Z) APC ALARM: BATTERY LOW Clearing Low Battery Voltage Alarms PS0090 REFERENCE RETURN INCOMPLETE Clearing Reference Return Incomplete Alarms PS0224 ZERO RETURN NOT FINISHED Clearing Zero Return Not Finished Alarms EX1006 SPINDLE OVER TEMP Clearing Spindle Over-Temperature Alarms (DI X0025.0) SV0001 SYNC ALIGN ERROR Clearing Sync Excess Errors: Refer to Parameter SV0005 SYNC EXCESS ERROR (MCN) Clearing Sync Excess Errors: Refer to Parameter MEMORY CARD PROGRAM PC TOOL OPERATION CREATING AND MODIFYING FANUCPRG.BIN MOUNTING THE CF MEMORY CARD UNMOUNTING THE CF MEMORY CARD ADVANCED CONFIGURATION INFORMATION INFORMATION FOR SYSTEM ADMINISTRATORS Setting System Time and Date Page. 5

6 Screen Capture of the CNC Controller CONNECTING THE CNC CONTROLLER TO THE NETWORK Setting Up the Ethernet Port Setting Up FTP Transport (for connection to PC) Testing the Network Connection (PING) Connecting to the PC Copying Files Using FTP Protocol (via ethernet) SYSTEM BACKUP AND RESTORE Full System Backup and Restore Using USB Memory Device Restoring Parameters from Backup Files SRAM Backup (CF Memory Card Only) SRAM Restore (CF Memory Card Only) SETTING AND UNDERSTANDING SYSTEM PARAMETERS AND VARIABLES Macro Variable List Access and Modify Macro Variables AUTOMATIC TOOL CHANGER MEMORY AND COUNTER LOCATIONS Instructions to Initialize/Verify Program State and Tool Changer Position TOOL TOUCH-OFF SETTING COORDINATES AND DETERMINING Z-OFFSET ALL ABOUT MACROS CONTENTS OF O8012 SET VARIABLE NAMES MACRO CONTENTS OF O8113 PROBE LENGTH OFFSET MACRO CONTENTS OF O9001 TOOL CHANGE MACRO CONTENTS OF O9002 TOOL TOUCH-OFF MACRO CONTENTS OF O9003 ATTACH 4 TH AXIS HARDWARE CONTENTS OF O9004 DETACH 4 TH AXIS HARDWARE CONTENTS OF O9020 AIAPC PARAMETER SETTING MACRO About 9020 Macro Variable Values DIGITAL INPUTS AND OUTPUTS VIEW THE STATE OF A DIGITAL INPUT VIEW THE STATE OF A DIGITAL OUTPUT CHANGE THE STATE OF A DIGITAL OUTPUT THE LADDER LADDER BACKUP FROM CNC CONTROLLER LADDER III SOFTWARE COMPILE AND EXPORT FOR LOADING INTO CNC CONTROLLER LADDER LOAD NEW LADDER INTO CNC CONTROLLER SYSTEM CONFIGURATION PARAMETERS RATE AND LIMIT PARAMETERS SERVO TUNING PARAMETERS APPENDIX M-CODE LIST SAMPLE G-CODE Page. 6

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8 General Information Safety Rules As with all machinery, there are certain hazards involved with the operation and use of your machine. Using it with caution will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result. If you have any questions relating to the installation and operation, do not use the equipment until you have contacted your supplying distributor. Read the following carefully and fully before operating the machine. 1. Keep the working area clean and ensure adequate lighting is available. 2. Do not wear loose clothing, gloves, bracelets, necklaces or ornaments. 3. Do wear face, eye, respiratory and body protection devices as indicated for the operation or environment. 4. Ensure that the power is disconnected from the machine before tools are serviced or any attachment is to be fitted or removed. 5. Never leave the machine with the power on. 6. Do not use dull, gummy or cracked cutting tools. 7. Ensure that the keys and adjusting wrenches have been removed and all the nuts and bolts are secured. Page. 8

9 Limited Warranty New machines and accessories sold by Laguna Tools carry a one-year warranty effective from the date of shipping. Machines sold through dealers must be registered with Laguna Tools within 30 days of purchase to be covered by this warranty. Laguna Tools guarantees all new machines and accessories sold to be free of manufacturers defective workmanship, parts and materials. We will repair or replace, without charge, any parts determined by Laguna Tools, Inc. to be a manufacturer s defect. We require that the defective item/part be returned to Laguna Tools with the complaint. Any machines returned to Laguna Tools must be returned with packaging in the same manner in which it was received. If a part or blade is being returned it must have adequate packaging to ensure no damage is received during shipping. In the event the item/part is determined to be damaged due to lack of maintenance, cleaning or misuse/abuse, the customer will be responsible for the cost to replace the item/part, plus all related shipping charges. This limited warranty does not apply to natural disasters, acts of terrorism, normal wear and tear, product failure due to lack of maintenance or cleaning, damage caused by accident, neglect, lack of or inadequate dust collection, misuse/abuse or damage caused where repair or alterations have been made or attempted by others. Laguna Tools, Inc. is not responsible for additional tools or modifications sold or performed (other than from/by Laguna Tools, Inc.) on any Laguna Tools, Inc. machine. Warranty maybe voided upon the addition of such described tools and/or modifications, determined on a case-by-case basis. Software purchased through Laguna Tools Inc. is not covered under this warranty and all technical support must be managed through the software provider. Software is non-refundable. Normal user alignment, adjustment, tuning and machine settings are not covered by this warranty. It is the responsibility of the user to understand basic machinery operation, settings and procedures and to properly maintain the equipment in accordance with the standards provided by the manufacturer. Parts, under warranty, are shipped at Laguna Tools, Inc. s cost either by common carrier, FEDEX ground service or a similar method. Technical support to install replacement parts is primarily provided by phone, fax, or Laguna Tools Customer Support Website. The labor required to install replacement parts is the responsibility of the user. Laguna Tools is not responsible for damage or loss caused by a freight company or other circumstances not in our control. All claims for loss or damaged goods must be notified to Laguna Tools within twenty-four hours of delivery. Please contact our Customer Service Department for more information. Only new machines sold to the original owner are covered by this warranty. For warranty repair information, call

10 Noise emission Given there exists a relationship between noise level and exposure times, it is not precise enough to determine the need for supplementary precautions. The factors affecting the true level of exposure to operators are clearly the amount of time exposed; the characteristics of working environment; other sources of dust and noise, etc. For example, adjacent machines may impact the level of ambient noise. It is also possible that exposure level limits will vary from country to country. Specification sheet Note: The specification will depend on the machine that is ordered. Most machines are made to order, and therefore the specification will vary depending on the machine you require. Receiving your machine Note: It is probable that your machine will be delivered by a third party. Before you unpack your machine, you will first need to inspect the packing, invoice and shipping documents supplied by the driver. Ensure that there is no visible damage to the packing or the machine. You must do this prior to the driver leaving. All damage must be noted on the delivery documents and signed by you and the delivery driver. You must then contact the seller, Laguna Tools, within 24 hours. It is advisable to photograph any shipping damage to support an insurance claim. Note: Laguna Tools, Inc. endeavors to test each machine prior to shipping, and you may find sawdust in or on your machine. Page. 10

11 Maintenance Lubrication You must regularly (minimum 30wt oil lubricant. Spray daily every 12 hours) lubricate the rails. Use a thin layer of and wipe off the excess. Daily checks 1. Clean the machine and lubricate unpainted surfaces with a 30wt oil lubricant. Wipe off any excess and buff with a dry polishing cloth. This will reduce the likelihood of rust forming. 2. Check cutter teeth for chips and dullness. 3. Generally inspect the machine for damage and loose or worn parts. 4. Collets and spindle collet holes must be cleaned regularly. Ensure that the slots in the collets are free of sawdust, as sawdust builds up and will stop the collet compressing. If the collet or spindle holes are not clean, the router bit may not run true and this will affect the performance of your machine. Collet fitted to spindle nut Weekly checks 1. Clean the cutters. 2. Check cutter teeth for chips and dullness. 3. Generally inspect the machine for damage and loose or worn parts. 4. Check the dust extraction for blockages, as any large bits could cause blockages. 5. Check that all the electricall connectors are fitted correctly and are not loose. Page. 11

12 Introduction to CNC Machines The CNC is designed to give you years of safe service. Read this owner s manual in its entirety before assembly or use. The advantage of the CNC machine is that it can, in most cases, fully machine the complete job without it being removed from the table so you have finished parts of high accuracy that are totally repeatable. It can also produce intricate carvings with the purchase of the relevant software. Nesting is also a valuable feature of CNC machining that saves on waste and costs. It is possible to reduce the amount of different machines in the shop as the CNC will perform multiple functions and is a must for cabinetmakers and seriouss woodworkers. Machine Parts (Laguna Smart Shop III) Spindle and Drill Block with Safety Housing 4 Dust Collection Port Caterpillar Track Gantry 8-Station Rotary Automatic Tool Changer (ATC) Vacuum Table Vacuum Zone Control Valves Caterpillar Track Page. 12

13 Basic Components Vacuum Table The bed of the machine consists of a heavy steel all-welded frame with a composite work table that is machined for use with a vacuum pump. The table includes T-slots (and clamps) for special fixturing. The T-slots are used to clamp the job or fixtures to the bed. Gantry The gantry straddles the bed and carries the Spindle, Drill Block, and X and Z axes motion components. It is moved along the length of the bed by precision Helical Rack-and-Pinions with drive motors on each end of the gantry. Spindle and Drill Block Assembly The spindle and drill block is moved along the gantry by a precision Helical Rack-and-Pinion ball screw system. The assembly is positioned in the vertical axis by a high precision ball-screw mechanism. The spindle and drill block assembly are shielded in a safety housing. All motion is controlled by the machine s CNC controller. Frame The frame is a heavy steel all-welded construction that provides a rigid platform for the other components and ensures accuracy as well as edge finish. Electrical Control Cabinet A standalone electrical control panel houses all of the major electrical components and control systems. Caterpillar Tracks There are two major caterpillar tracks that run along the side of the machine and behind the gantry. This special trough carries all the electrical and control cables and air lines. Vacuum Control Valves The machine has six (6) vacuum control valves that can be used to direct the vacuum to specific vacuum table zones. Automatic Tool Changer (ATC) The rotary tool changer included eight (8) tool stations to accommodate a large range of tools. Each of the stations includes an ISO-30 gripper assembly. Station positions are controlled by the CNC controller. A safety shroud (not pictured) encloses the rotary mechanism. Dust Collection Port (4 diameter) A 4 diameter dust collection port is provided to interface into a standalone dust collection system. This port, when used properly, reduces airborne particles, dust and chips during fabrication. Page. 13

14 Automatic Tool Changer (ATC) The Automatic Tool Changer consists of a rotary-motion platform and eight (8) tool holders or grippers mounted to the platform. The machine control knows the current position of the platform and will rotate it accordingly to load and unload tools automatically as required by the program. Manual Tool Release Button The tool holder can be released from the spindle manually by pressing the manual release button. The machine must be put into JOG state by pressing the [JOG] button on the Operator Keyboard. The manual tool release button is located on the back of rotary 8- position tool changer. Jog the spindle near the rotary tool changer so it is within easy reach. Note. When the manual release button is pressed the clamping method is released and the tool will fall out. Place your hand so that the tool holder [not the cutter] is supported. Manual Tool Release Button To manually insert a tool holder, hold the tool holder is the spindle hole while pressing the manual release button. Once the button is released, the tool holder will be pulled up into the spindle hole and clamped in position. Note. You will notice that there is air escaping from the spindle hole. This is to blow any dust out of the spindle hole and keep it clean. Note. Keep the tool holders clean, lubricated with Teflon. Note. The spindle hole is susceptible to rust and must be kept clean and lubricated with a Teflon lubricant. Page. 14

15 Automatic Tool Touch-Off Switch The automatic tool touch-off system is used to measure the tool lengths automatically. This system s operation is described later in this manual. Touch-Off Switch Page. 15

16 Machine Installation Machine Location Before unpacking the machine, select the area where the machine will be installed. There are no hard-and-fast-rules for its location, but below are a few guidelines: 1. There should be an area around the machine suitable for the length of material that will be machined as well as any loading and unloading requirements. 2. There should be adequate lighting in the work area. The better the lighting, the better the productivity and safety. 3. The floor area under the machine should be flat and solid so that the machine frame does not shift as the gantry and tool plate traverse. Concrete is preferable. 4. Consider the electrical and air supplies, vacuum pump location and dust collection when identifying an area to place the machine. Unpacking the Machine Unpacking the machine will require tin snips (to cut through banding), a knife and an adjustable wrench. Follow the steps below: 1. Using the tin snips, cut the banding that is securing the machine to the Pallet (if fitted). 2. WARNING: EXTREME CAUTION MUST BE USED BECAUSE THE BANDING CAN SPRING AND CAUSE INJURY. 3. Remove the box from the CNC machine (if fitted) and any other packaging material. The parts ordered with the machine will be packed on or inside the machine.(please note, The machine is heavy, and it is recommended that professional assistance [rigging] be used for unloading and placing the machine). 4. Use a fork lift with sufficient lifting capacity and forks that are long enough to reach the complete width of the machine before attempting to lift the machine. 5. Remove the securing bolts that attach the machine to the pallet (if fitted). 6. Approaching the machine from the side, lift the machine on the frame taking care that there are no cables or pipes in the area of the forks. 7. Move the machine to the required position and install the Supporting foot leveling feet. 8. Then lower the machine gently to the floor. 9. Level the machine so that all the supporting feet are taking the weight of the machine and no rocking is taking place. Page. 16

17 Assembly & Setup Cleaning the machine The machine is shipped with the non-painted surfaces protected from rust by a film of grease. The grease must be removed with WD40 or similar solvent, as it attracts saw dust and dirt. The surfaces should then be coated with a Teflon lubricant or similar. Teflon tends to dry and will not attract sawdust and dirt. Fitting the dust hose 1. Fit a 4-inch dust hose (not supplied) to the dust collection port located at the top of the machine and secure with the clamp. Ensure that the clamp is tight. 2. The head of the machine will move across the complete table, and the dust hose will follow the head. If there is insufficient slack, the hose may break or be damaged. It is suggested that the hose be suspended from the ceiling of the shop with sufficient slack so it will not restrict movement. This will also keep the hose from becoming a tripping hazard. Electrical Connections There is one electrical connection required. The main power cable is connected to the main power switch on the side of the machine control cabinet. The machine requires 3-phase 220V. Consult the machine specifications to determine the amperage requirements for your specific machine. When wiring the machine to the electrical system, keep the power cable as short as possible and oriented so that it does not create a trip hazard. Note: A qualified electrician must carry out the electrical installation. Compressed Air Connection The machine is supplied with an air regulator. The input air regulator regulates the air pressure that is supplied to the machine. The machine will require an air supply that can deliver a constant minimum pressure of 6 bar (85 psi). The input air regulator will need to be adjusted to 6 bar (85 psi) once the machine has been connected to the air supply. No air pipe is supplied, as the length will depend on your installation. To adjust the air pressure, pull the cap out [up] and rotate until the gauge reads the correct pressure. Once the pressure is adjusted, push the cap in. It is strongly recommended that 6.5 bar (95 psi) be supplied Air regulator Page. 17

18 to the machine and that the regulator then be set to 6 bar (85 psi). This will ensure that the machine always has the minimum required air pressure. The input regulator has a moisture trap that must be emptied each day. It is important that the air supplied to the machine is clean and dry. The machine will not perform consistently if the air is wet or dirty, as any dirt and moisture will block the valves. Wet, damp or dirty air will damage your machine and cause inconsistent performance. The pneumatic system does not need any type of lubricant. Some types of lubricant can damage the machine and compromise the machine s functions. Caution: During maintenance, always disconnect the air supply. Connecting the Vacuum Pump The machine is provided with a 2 inch pipe for the hose connection to your vacuum pump. The pipe is connected to the manifold located under the table. Connect the other end to your vacuum pump. Ensure that it is clamped securely. Vacuum pipe. Assembling ISO-30 Cones with Router Bits 1. Select a router bit and correctly sized collet. The parts necessary are shown in the picture at the right. 2. Fit the collet into the spindle nut. Press the collet into the spindle nut until it snaps into place. Note. The router bit must not be fitted into the collet until the collet has been fitted into the spindle nut. With the router bit fitted into the collet, the collet cannot compress and snap into the spindle nut. The face of the collet and the face of the spindle nut will be close to flush. Note. To remove the collet hold the spindle nut and press the collet on the side. The collet will compress and pop out. Do not Page. 18

19 try and remove the collet while a cutter is fitted, as the collet will not compress and pop out. 3. Fit the spindle nut and collet assembly onto the spindle cone and thread by hand. Press the bit into the collet but note, the flute of the router bit must not be inside the collet and should be a minimum of 1/16 outside the collet. Place the cone assembly into the supplied tool holder. Tighten the cone assembly with the supplied wrench as shown in the picture. Do not over tighten. Final assembly Note: Use this process to install each of the router bits into tool holders, being careful to use the correct collet size for each router bit. Note. Keep your collets clean and blow all dust out of the slots. Fine dust accumulates and will affect the clamping action. Page. 19

20 Selecting the Correct Router Bit There are five basic types of router bits: straight, up shear, down shear, combination (also called compression), and form tools (round over, ogee, etc.). Each type of bit has a specific application for use. Straight Router Bits These are the standard router bits that are commonly used with handheld routers and are readily available at home centers. They will work but will generally not produce the edge finishes that are available with the spiral designed router bits. Up Shear Router Bits These bits have flutes that are spiraled upward (a standard twist drill is an example of this type of bit). This bit design removes the chips from the kerf but has a tendency to chip the top surface, especially veneers or melamine surfaces. Ball nose Router Bits are a variation of the up shear bit design but have a radiuses end. These bits are typically used for 3D surfacing applications. Down Shear Router Bits These bits are similar to the up shear but with an opposite spiral that actually tends to pack the chips into the kerf. These bits prevent chipping the material surface, especially with veneers or melamine surfaces, and are an excellent choice for machining dadoes and other joinery that do not extend completely through the material. Combination (Compression) Router Bits These bits combine the advantages of both up shear and down shear designs. The top section of the tool is down shear to prevent chipping the top surface of the material and the lower part of the bit is up shear to prevent chipping the bottom surface of the material. Combination Router Bits are the preferred configuration for machining veneered plywood as well as melamine surfaced product. A variation of the bit is called the Mortising Compression router bit. With this bit, the up shear portion of the bit is less than ¼ in length so that the bit can be used on ¼ veneered plywood and for dados. Form Router Bits Form Router Bits typically are available in standard profiles such as round-over, ogee, cove, etc. Router bits that have a shape associated with them would be classified with this group. Page. 20

21 Working With Vacuum Tables and Spoil Boards The more effective the vacuum table setup, the more secure the parts will be held in place. Follow the instructions below to obtain optimum results. The vacuum table has six (6) zones that can be used to configure the vacuum supply depending on the type of application. The table has vacuum ports for each zone that extract the air and generate the vacuum. The table also has grooves to ensure that the air is extracted evenly across the zones. Each zone is controlled by a valve lever located at the front of the machine. Vacuum Table Vacuum Zone On/Off Levers Spoil Board Material and Precautions For machining parts from panel materials (cabinets, fixtures, casegoods, etc.) a technology referred to as Flow-Through fixturing is employed. A sheet of porous material (usually MDF [medium-density-fiberboard]) is placed on top of the vacuum table. The panel material that is to be machined is actually placed on top of the MDF, and the vacuum passes through the MDF and holds the panel material down as it is machined. Great care should be taken when machining parts free to limit the extension of the tool into the spoil board materials. The purpose is to limit vacuum infiltration through grooves in the spoil board. This also allows the processing of various nests without any setup time on the machine. This technology is the basis for nestedbased manufacturing (NBM). Functions of the Spoil Board 1. To protect the vacuum table from damage. The cuter extends only a few thousandths of an inch past the material thickness. Without the spoil board, the cutters could damage the surface of the vacuum table. 2. To transfer the vacuum from the table to the job. This means that the spoil board has to be porous to allow air flow to the panel material. Low cost MDF has proven to be a very good material for this purpose. 3. To provide a zero setup environment for processing panel products. Page. 21

22 Spoil Board Preparation When MDF is sourced for the spoil board, it should be no thinner than 3/4 inch. Contrary to what might seem logical, the thicker the MDF the Spoil board edge better the suction that is created. Flow-Through fixturing maintains a careful balance between air flow through the MDF and the infiltration that occurs as the kerfs are machined. It is not recommended that the spoil board material be thicker than 1 inch. The MDF manufacturing process causes the top and bottom surfaces of the material to be compressed. It is necessary, therefore, to remove the compacted top and bottom surfaces. This process is termed fly-cutting and requires the removal Edge sealing wax of approximately from each surface. This process also ensures that the machining plane and spoil board surface are parallel. The spoil board edges are very porous, and sealing them can improve the part holding ability. Hard candle wax is an excellent product for sealing the spoil board edges because it contains no water and is very easy to apply. Never use a water-based product to seal the edges of the board as this will make the board expand and become unsuitable for use as a spoil board. Even some glue products contain water and can affect the edges of the spoil board. Note. Do not confuse flatness with bow. If the board is bowed, the vacuum may not pull the board flat on the table. Never try to use a bowed MDF panel as a spoil board. Use the following procedure for preparing the spoil board: 1. Cut the spoil board to the size of the table of the machine if necessary. 2. Apply gasketing to the outermost vacuum grooves on the table surface. 3. Place the spoil board on the vacuum table, being careful not to displace the vacuum gasketing. 4. Prior to placing the spoil board onto the vacuum table, ensure that the table is clean and free from sawdust and dirt. 5. Turn on the vacuum pump and check for leaks. 6. Fly cut the surface of the spoil board, removing approximately to insure that the compressed surface of the material is removed. 7. Once the material surface is machined, turn off the vacuum pump, turn the spoil board over and repeat the process for the other side. (Remember to ensure that the table and spoil board are clean.) Spoil board use. Each time a new job is machined, there may be shallow cuts into the spoil board in areas where the cutter passes through the material. Prior to placing a sheet of material on the spoil board, clean with a hand-held blower or vacuum cleaner. Dirt under the material will reduce the vacuum, and in extreme cases, parts may move Page. 22

23 during the machining process. In general, keeping everything clean is the key to achieving good, repeatable results. Precautions regarding spoil boards. The spoil board is porous and will absorb moisture. As moisture is absorbed the dimensions of the board will change. In general this will not be a problem as the changes from day to day are not that excessive and will typically be over the complete board. There are, however, exceptions. It is a good practice to keep material on the top surface of the spoil board overnight to prevent warping due to uneven moisture absorption by the material. Also, once a spoil board has been used and has kerf cuts that resulted from machining parts, it is a good idea to fly cut the surface again. This time it should only be necessary to remove of material since the only purpose is to produce a smooth, flat surface, and that amount should remove the machining marks. The spoil board must cover the complete table and sit on the flats around the table. If the spoil board does not cover all the vacuum slots, the vacuum may be lost and the panel material will not be pulled down onto the spoil board effectively. Page. 23

24 Laguna SmartShop III Control Cabinet Parts CNC Controller Emergency Stop Button Manual Pulse Generator (MPG) Operator Keyboard Vacuum Pump Controls Main Power Disconnect (located (loca on side of cabinet.) Page. 24

25 CNC Controller Module Layout Compact Flash (CF) Memory Card Slot Display Screen USB Memory Slot Soft Keys Keypad [Hard Keys] Display Screen Main screen for viewing machine operation and status. USB Memory Slot USB interface for transferring programs and system backup. Compact Flash (CF) Memory Slot Memory interface for system backup and memory expansion. Keypad [Hard Keys] CNC Controller functions keys with printed labels. Keypad (Soft Keys) CNC Controller function keys without printed labels. Note: Soft Keys are keys whose functions change depending on the operation being performed. They do not have a printed label however the text shown directly above the key is the key s currently assigned function. Throughout this manual, a soft key will be indicated using round parenthesis () around the text display above the corresponding key; For example, as displayed above (ABS)(REL)(ALL) A Hard Key has a printed label and its function does not change. A hard key will be indicated using square brackets [ ] around the key s printed label; For example, as displayed above [POS][PROG] Page. 25

26 Operator Keyboard Module Layout Emergency Stop Button Spindle Speed Override Function Keys Motion Speed Override Emergency Stop Button Pressing the Emergency Stop Button stops all machine motion. Spindle Speed Override Knob Turning the spindle speed override knob will change the spindle rotation 0% to 120% of programmed rotation rate. Motion Speed Override Knob Turning the motion speed override knob will change each axes travel 0% to 120% of programmed travel speed. Function Keys Operator Keyboard Function Keys. Light Tower A light tower is located at the top of the control cabinet. Its purpose is to provide color-coded machine status. More than one light may be lit at one time. Red Light When lit an alarm condition exists. View alarm information on the CNC Controller screen Yellow Light When lit the CNC Controller is executing program code. Green Light When lit the CNC Controller is powered and functional. Page. 26

27 Common CNC Operator Screens Boot Screen The window below is displayed after CNC Controller boots. Position Screen. This window is used to display the current position of each axis, feedrate, and cycle time. It is displayed by pressing the [POS] key on the CNC Controller. Pressing the [POS] key multiple times will toggle through Absolute position, Relative position, and ALL positions screen. Pressing (ABS), (REL), or (ALL) soft keys will display, Absolute position, Relative position, or ALL position screens, respectively. Page. 27

28 Program Edit Screen The window shown below displays the contents of the currently loaded program. This window can be used to display and edit programs as well as display program lines as they are being run. Page. 28

29 Operation Basics Turning On the Machine 1. Make sure there are no objects or people near the machine that can be damaged or injured by machine movement. 2. Make sure the Emergency Stop button is released by rotating it clockwise. ON POSITION 3. Rotate the main contact switch clockwise until it clicks in place at the ON position. 4. As CNC Controller powers up, the screen will display a series of status messages. When the system has completed the startup process the screen below will be displayed. The light tower will have the green light illuminated. SYSTEM RUNNING Page. 29

30 Turning Off the Machine Turn off the main power by rotating the main contact switch counter-clockwise to the OFF position. Rotate knob to OFF position. Page. 30

31 Machine Movement Operations HANDLE REF JOG Jog Axes Press [JOG] to enter jog mode. Press [-X], [+X], [-Y],[+Y],[-Z] or [+Z] to jog axis in desired direction. Press and hold [RAPID] to jog axis at higher rate. If an axis over-travel message is displayed, jog the machine away from its positive or negative limit, then press RESET to clear the message. X-Y-Z Direction RAPID Homing Position each axis about 12 inches from its respective home position. For X and Y that is in the negative direction, Z is in the positive direction. Press [REF], then press [-X]. When the X-switch is tripped, the X-motion stops. Press [REF], then press [-Y]. When the Y- switch is tripped, the Y-motion stops. Press [REF], then press [+Z]. When the Z- switch is tripped, the Z-motion stops. If equipped; Press [REF], then press [B+]. When the B-switch is tripped, the B-motion stops. Press [REF], then press [C-]. When the C-switch is tripped, the C-motion stops. Note: In [REF] mode, axes will only travel toward their home position. Jog Axes using the Manual Pulse Generator (MPG) Press [HANDLE] button to enter MPG Mode. Select axis (X Y Z) to be moved using the Axis Selector Knob If equipped, additional axis selections are available. Select motion multiplier, X1 for slow (precision) movement speed X10 for faster movement speed X100 for fastest movement speed Rotate knob clockwise to move axis in positive direction Rotate knob counter-clockwise to move axis in negative direction. If an axis over-travel message is displayed, jog the machine away from its positive or negative limit, then press [RESET] to clear the message. Page. 31

32 Jogging the Tool Changer Magazine The tool changer magazine can be jogged manually by pressing the [unlabeled] key to the right of [+Y] and above [-X]. Spindle must be in the down position. Manual Tool Release The tool holder can be released from the spindle manually by pressing the manual release button. The machine must be put into JOG state by pressing the [JOG] button on the Operator Keyboard as shown previously. The manual tool release button is located on the back of rotary 8-position tool changer. Jog the spindle near the rotary tool changer so it is within easy reach. Note. When the manual release button is pressed the clamping method is released and the tool will fall out. Place your hand so that the tool holder [not the cutter] is supported. Setting Work Coordinates and Tool Offsets Automatic Tool Touch-Off Z-Offsets for Tools 1 8 Z-offsets for Tools 1 8 are determined automatically by the tool touch-off procedure, M-Code M401. Press [PROG][MDI] TxM401 [EOB][INSERT][CYCLE START], where x is tool number 1 8. Note: This will create machine motion. The CNC Controller will perform the touch-off procedure and automatically update the tool offset table for the corresponding tool. To view the offset table for Tools 1 8, press [SET/OFF](OFFSET). Z-Offsets for Tools 1-8 Page. 32

33 Setting Spoiler Board Thickness Measure the thickness of the spoiler board. Enter the thickness in the [SET/OFF](WORK) screen at NO. 00 EXT block Z-Coordinate (example ). Setting Work Coordinates JOG the spindle to the desired X Y location (front left corner of work surface). Note the Machine coordinates from the Position Screen [POS] (example X=2.8700; Y=3.9000). Enter the X and Y values in the [SET/OFF](WORK) screen G54 No. 01 set of coordinates. Spoiler Board Thickness X and Y Work Coordinates Page. 33

34 Setting Drill Block Offsets for X and Y Axes 1. Extend front most drill (T11;) 2. Jog machine so the drill is located at the front-left most corner of the work surface. 3. Lower Z until the drill just makes contact with the work surface. 4. Note machine values for X, Y, and Z axes. This is the drill block work space origin. 5. Enter X and Y coordinate values for T11 into G54.1 P01 area. To access the Offset Value screen enter: [SET/OFS](WORK)[PG DN] [PG DN] to G54.1 P01 section for the first drill. 6. Enter the X and Y values for the drill. 7. REPEAT for each drill in the drill block. Hint: Drills are positioned 32mm (1.26 ) apart. Add or subtract (1.26 ) to previous drill s values to set the work space offsets for each drill. T11 G54.1 PO1 Coordinates T13 G54.1 PO3 Coordinates T12 G54.1 PO2 Coordinates T14 G54.1 PO4 Coordinates Press [PG DN] to access additional G54.1 Px coordinate groups. Page. 34

35 Sample work coordinate values for a 5 x 5 drill block with the following orientation: T19 T18 T17 T16 T15 T14 T13 T12 T11 Drill Group X Y Z T11 G54.1 P T12 G54.1 P T13 G54.1 P T14 G54.1 P T15 G54.1 P T16 G54.1 P T17 G54.1 P T18 G54.1 P T19 G54.1 P Setting Drill Block Z-Axis Offset 1. To enter drill Z axis offset, press [SET/OFS](OFFSET)[PG DN]..[PG DN] until 011 row is displayed. 2. Enter the offset value (example, ) for Tool 11 in the GEOM (H) field, then press [INPUT]. 3. Repeat for remaining drills present in the drill block. Note: Z value will not change unless a drill has a different bit length. Drill (T11) Z-Offset Value.... Drill (T16) Z-Offset Value Page. 35

36 PROGRAM OPERATIONS For Program Operations the [HARD KEYS] shown below will be used. [EDIT] [MDI] (SOFT KEYS) [PROG] [SYSTEM] [PAGE UP] [PAGE DN] Viewing and Navigating Directories View CNC Controller Program Directory [PROG][EDIT](FOLDER) (Press [Up Arrow] or [Down Arrow] buttons to scroll through list of programs) View Directory Of Memory Devices (USB Memory OR CF Memory Card) [PROG][EDIT](FOLDER) (Press [Up Arrow] or [Down Arrow] buttons to scroll through list of programs) To view the directory of a different device press [PROG][EDIT](OPRT)(DEVICE CHANGE). Select the device. Directory Structure The CNC has a directory structure as described below. To navigate to other directories, highlight the directory name then press [INPUT]. The directory name and path will be displayed at the top of the display. The contents of the selected directory will be displayed in the main window. Select RETURN TO UPPER FOLDER [INPUT] to return to previous folder. //CNCMEM/MTB1 //CNCMEM/MTB2 //CNCMEM/SYSTEM //CNCMEM/USER/LC1 Location for CNC Macros Empty Empty Empty Page. 36

37 //CNCMEM/USER/LC2 //CNCMEM/USER/LIBRARY //CNCMEM/USER/PATH1 //CNCMEM/USER/PATH2 Empty Empty Program File Storage Empty Loading Programs Load Program From CNC Controller Memory [PROG][EDIT](highlight the program number)(oprt)(main ). The selected program number will be preceded with symbol. For The program number will also be displayed at the top of the CNC display. Copying Programs Copy Program from USB or CF Memory Card to CNC Controller Memory (SET I/O CHANNEL = 17 for USB; I/O CHANNEL = 4 for MEMORY CARD) [PROG][EDIT](OPRT)(DEVICE CHANGE)(USBMEM) or (MEMORY CARD). (Press [Arrow Up] or [Arrow Down] buttons to scroll through list of programs) Highlight the program name then press (COPY). Note: Press the (Up Arrow) or (Down Arrow) to see the selected program name is highlighted. Press (DEVICE CHANGE)(CNC MEM)(PASTE). The program file will be copied to the CNC Memory. Copy Program From CNC Memory to USB or CF Memory Card (SET I/O CHANNEL = 17 for USB; I/O CHANNEL = 4 for MEMORY CARD) [PROG][EDIT](OPRT)(DEVICE CHANGE)(CNC-MEM). (Press [Arrow Up] or [Arrow Down] buttons to scroll through list of programs) Highlight the program name then press (COPY). Note: Press the (Up Arrow) or (Down Arrow) to see the selected program name is highlighted. Press (DEVICE CHANGE)(USB MEM) or (MEMORY CARD), then (PASTE). The program file will be copied to the selected device. Deleting Programs Delete Program From CNC Controller Memory [PROG][EDIT](OPRT)(DEVICE CHANGE)(CNCMEM). Press [Arrow Up] or [Arrow Down] buttons to scroll through list of programs) Highlight the program name then press (DELETE). Press (EXEC) to delete or (CAN) to cancel operation. Page. 37

38 Delete Program from USB Memory or CF Memory Card [PROG][EDIT](OPRT)(DEVICE CHANGE)(USBMEM) or (MEMORY CARD) Press [Arrow Up] or [Arrow Down] buttons to scroll through list of programs. Highlight the program name then press (DELETE). Press (EXEC) to delete or (CAN) to cancel operation. Editing Programs Edit Program on CNC Controller [PROG][EDIT](FOLDER) Press [Arrow Up] or [Arrow Down] buttons to scroll through list of programs. Highlight the program name then press (MAIN PROGRAM). Press (PROG). The program is displayed. MODIFY existing field: Highlight field to be edited. Enter new field data, then press [ALTER] to replace field data. DELETE existing field: Renaming Programs Highlight field to be deleted, then press [Delete] to delete field. INSERT new program line: Highlight field ahead of the new field/line to insert Enter new field [INSERT] or Enter new program line [EOB][INSERT] Note: Every command line must end with an end of block [EOB] which is displayed as a semi-colon (;). CHANGES ARE INSTANTLY SAVED. Rename a Program on CNC Controller [PROG][EDIT](FOLDER) Press [Arrow Up] or [Arrow Down] buttons to scroll through list of programs. Highlight the program name then press (MAIN PROGRAM). Press (PROG). The program is displayed. Highlight first line of program that displays program name. Page. 38

39 Enter new program name (e.g. O1098),then press [ALTER] to replace field data Program O1099 has now been renamed to O1098. Program O1099 no longer exists. Creating New Programs Create a Program on CNC Controller [PROG][EDIT] Enter Filename (e.g. O1099), then press (NEWPRO). Program O1099 now exists. Insert program lines as desired. Loading and Running Programs on CNC Controller Loading a Program [PROG][EDIT](FOLDER)(OPRT) Highlight the program name then press (MAIN PROGRAM). The program name is now preceded by and its name is displayed at the top of the CNC display. Press (PROG). The program s contents are now displayed. Starting a Program in AUTO Mode (after program is loaded into CNC memory) [PROG][AUTO][CYCLE START] Running a Program In Single-Block Mode [PROG][AUTO][SINGLE BLOCK] [CYCLE START] to advance program to next line. Program will run one line at a time. Press [CYCLE START] to progress through program manually line-by-line. Stopping Programs Stopping a Running Program [CYCLE STOP] to halt all motion except rotation of spindle or drill block. Press [RESET] to stop spindle or drill block rotation and to move to beginning of program. Resume a Stopped Program To restart a stopped program press [CYCLE START]. The program will continue. Note: If [RESET] has been pressed then the program will restart from the beginning. Page. 39

40 MDI Mode MDI Mode allows the operator to control the machine by entering specific M-Codes and G-Codes. Entering Commands in MDI Mode For a single line [PROG][MDI] enter command. Example, T8M06[EOB] [INSERT] [CYCLE START] to execute command. For multiple command lines separate commands with [EOB] key. Example, T8M06[EOB]M03S12000[EOB][INSERT] [CYCLE START] to execute command. Page. 40

41 Alarms Alarm conditions are displayed on the CNC Controller. When an alarm occurs, the red light on the light tower will be lit. Below is a list of some common alarms and instructions to clear them. Alarm Display on CNC Controller Alarm Present When Lit OT0500 (X,Y,Z,B,C) + OVERTRAVEL (SOFT) OT0501 (X,Y,Z,B,C) - OVERTRAVEL (SOFT) Clearing Soft Over-Travel Alarms A soft over-travel alarm occurs when an axis has traveled beyond a coordinate limit preset in the CNC Controller. This will occur if the axis has traveled too far in the (+) positive or (-) negative direction. To clear the alarm, jog the axis using [JOG] mode or [HANDLE] mode and the MPG unit. Once the axis has been jogged within the soft limit coordinates, press the [RESET] button to clear the alarm. Clearing Soft Over-Travel Alarms During Homing If a soft over-travel alarm occurs during homing, follow the procedure below. Set Parameter 1815 to (APC, APZ = 0) for all axis. Cycle power Home all Axes Set Parameter (APC) = 1 Home all Axes, then cycle power. OT0506 (X,Y,Z,B,C) + OVERTRAVEL (HARD) OT0507 (X,Y,Z,B,C) - OVERTRAVEL (HARD) Note: Any axis that creates a hard over-travel alarm will cause hard over-travel alarms for all axes. Page. 41

42 Clearing Hard Over-Travel Alarms (Hard Over-Travel Switch Override) If an axis trips an over-travel switch a HARD OVER-TRAVEL alarm occurs and the axis movement will be disabled. The axis must be moved off of the switch before the alarm can be cleared. To override the switch, press and hold the [unlabeled] button under the [+X] button and to the left of the [-Y] button. While pressing this button also press the [RESET] button to clear the alarm. While continuing to press the [unlabeled] button, jog the over-traveled axis off of the limit switch. Jogging the axis can be done using [JOG] mode button or [HANDLE] mode using the handheld manual pulse generator. Page. 42

43 SW0100 Parameter Enable Switch On Clearing Parameter Enable Switch Alarm A Parameter Enable Switch Alarm occurs at boot time if the ability to write/modify parameters on the CNC Controller is enabled. This alarm is cleared by pressing [RESET]. To prevent the alarm from occurring, Parameter Write ability can be disabled by accessing the SETTINGS screen by pressing the [SET/OFF] key, then (SETTING) soft key. Highlight the Parameter Write field and Enter 0, then [INSERT]. The Parameter Write ability is now disabled. DS0001 SYNC EXCESS ERROR (POS DEV) Clearing Sync Excess Errors: Refer to Parameter DS0300 (X,Y,Z,B,C) APC ALARM: NEED REF RETURN Clearing Ref Return Alarms A Reference Return Alarm indicates an axis or axes need to be homed. To home the specific axis, press [REF] key then X, -Y, or +Z depending on which axis or axes have alarmed. Once the axis has reached the home switch the alarm can be cleared by pressing [RESET]. DS0306 (X,Y,Z) APC ALARM: BATTERY VOLTAGE 0 DS0307 (X,Y,Z) APC ALARM: BATTERY LOW 1 DS0308 (X,Y,Z) APC ALARM: BATTERY LOW 2 Clearing Low Battery Voltage Alarms A four D-cell battery pack provides backup supply voltage to the servo motors. This supply voltage allows each servo motor to retain its absolute position coordinates while the system is not powered. If the CNC Controller detects low battery, a Battery Voltage Alarm will occur. To clear the alarm, change-out the batteries. Replace the batteries while the machine is powered. After the batteries have been changed, cycle the CNC Controller power to clear the alarm(s). Page. 43

44 PS0090 REFERENCE RETURN INCOMPLETE Clearing Reference Return Incomplete Alarms A Return Incomplete Alarm occurs if the axis has traveled too far (or not far enough) before reaching its home switch. To clear the alarm press [RESET]. Repeat the Reference Return process for the axis. Ideally, the axis should travel about 8 towards the home switch. PS0224 ZERO RETURN NOT FINISHED Clearing Zero Return Not Finished Alarms An axis whose absolute encoder position is not saved while the system is not powered requires a Reference Return before commands can be issued. Reference the axis then press RESET. EX1006 SPINDLE OVER TEMP Clearing Spindle Over-Temperature Alarms (DI X0025.0) The spindle over temperature switch has been activated. Inspect the spindle cooling equipment. After spindle cools sufficiently the switch will deactivate. Note: Not all systems or spindles support this alarm. SV0001 SYNC ALIGN ERROR Clearing Sync Excess Errors: Refer to Parameter SV0005 SYNC EXCESS ERROR (MCN) Clearing Sync Excess Errors: Refer to Parameter Page. 44

45 Memory Card Program PC Tool Operation Creating and Modifying FANUCPRG.BIN By using the Memory Card Program (FANUCPRG.EXE), you can create and modify (FANUCPRG.BIN), a memory card program file which functions from the CF Memory card of the CNC Controller and provides extended memory function. The maximum size of the memory card program file is 2048 Mbytes (2 Gbytes). Instructions for the Memory Card Program are provided in a separate FANUC document, named 05_J_pc_tool_for_memory_card.pdf. After FANUCPRG.BIN has been created it is transferred to the CNC Controller s CF memory card. Once the CF memory card is inserted into the CNC Controller it can be accessed using the following procedures. Mounting the CF Memory Card Press [PROG](DIR)(OPRT)(DEVICE)(MEMCARD)(MAIN P) The CF Memory Card will now be the source and destination of program functions. You will notice the directory of the programs in FANUCPRG.BIN, those selected using FANUCPRG.EXE. Memory Usage Memory Device Program Directory Unmounting the CF Memory Card To use the CNC Controller built-in memory the CF Memory Card must be unmounted. Press [PROG](DIR)(OPRT)(DEVICE)(UNMOUNT) The CNC Controller s built-in memory will now be the source and destination of program functions. Press (UNMOUNT) Soft Key Page. 45