OPERATION MANUAL. TYPE:C-Type Series CONTROLLER:FANUC 0iMD / 18iMB / 31iB VERSION NO.:AFEQFI03 DATE:2012/05/03 AWEA MECHANTROINC CO.

Transcription

1 OPERATION MANUAL TYPE:C-Type Series CONTROLLER:FANUC 0iMD / 18iMB / 31iB VERSION NO.:AFEQFI03 DATE:2012/05/03 AWEA MECHANTROINC CO., LTD NO.15,Keyuan 2nd Rd., Taichung City, Taiwan TEL: FAX: sales@awea.com.tw

2 CONTENTS CONTENTS 1 OPERATOR S CONTROL OPERATOR S CONTROL PANEL LCD/MDI Panel Machine Operator's Panel Magazine Operator's Panel POWER UP AND POWER DOWN INSPECTION BEFORE OPERATION Checking before Power Up Power Up Checking After Power Up Checking by Manual DOOR INTERLOCK SAFETY INSTRUCTION POWER DOWN Emergency Stop Other Stops Power Down POWER ON PROCEDURE LIST POWER OFF PROCEDURE LIST OPERATION INSTRUCTION MODE SELECTION MANUAL OPERATION Reference Point Return Jog Feedrate Operation Handle Wheel Operation Spindle Manual Operation Spindle Tool Unclamping Manual Operation Tool Magazine Manual Operation Chip Conveyor Manual Operation and Trouble Shooting Coolant Tank MDI OPERATION MDI Function AUTOMATIC OPERATION Executing Automatic Operation Block Skip Manual Absolute Program Restart PROGRAM CHECK AND TEST Machine Lock Z Axis Cancel Dry Run Feedrate Override Jog Override Rapid Override Spindle Speed Override TOOL SETTING Tool Number Setting Initialization TROUBLE SHOOTING TROUBLE SHOOTING GUIDE I

3 CONTENTS 4.2 ALARM MESSAGE WITH REMEDIAL MEASURES Arm Type Drum Type RESET OF OVER TRAVEL Soft Limit Over Travel Hard Limit Over Travel THE SOLUTION PROCEDURES OF TOOL CHANGE INTERRUPTION Arm Type Drum Type APPENDIX INTRODUCTION OF APC Operations APC Control Cautions OPERATION MANUAL OF APC CONTROL PANEL BOARD FUNCTIONS OF THE BUTTONS APC Manual Mode Button Unclamp APC Pallet APC JOG Model APC Pallet Lifts Up APC Pallet Goes Down APC Rotate APC Pallet C.W Rotate APC Pallet C.C.W APC Door Interlock Complete Preparation of APC ILLUSTRATION OF APC MANUAL OPERATION PANEL BOARD Use Occasion Cautions TROUBLES SHOOTING Instructions of Warning Message M CODE LIST II

4 III CONTENTS OF FIGURE CONTENTS OF FIGURE Figure 1-1 LCD/MDI panel(18i-mb 10.4" color) Figure 1-2 Software operator's panel (18i-MB 10.4" color) Figure 1-3 Software operator's panel (0i-MD 8.4" color) Figure 1-4 Software operator's panel (0i-MD 10.4" color) Figure 1-5 Software operator's panel (31i-B 10.4" color) Figure 1-6 Machine operator s panel Figure 1-7 Magazine operator s panel Figure 1-8 Magazine operator s panel Figure 3-1 Alarm message(18i-mb 10.4"LCD) Figure 3-2 Parameter setting screen(18i-mb 10.4"LCD) Figure 3-3 PMC Control system screen(18i-mb 10.4"LCD) Figure 3-4 PMCPRM screen(18i-mb 10.4"LCD) Figure 3-5 PMC DATA screen(18i-mb 10.4"LCD) Figure 3-6 PMC G. DATA screen 1(18i-MB 10.4"LCD) Figure 3-7 PMC G. DATA screen 2(18i-MB 10.4"LCD) Figure 3-8 PMC G. DATA screen 3(18i-MB 10.4"LCD) Figure 3-9 PMC G. DATA screen 4(18i-MB 10.4"LCD) Figure 3-10 COUNTR screen(18i-mb 10.4"LCD) Figure 3-11 Alarm message(0i-md 8.4"LCD) Figure 3-12 PMCMNT system screen(0i-md 8.4"LCD) Figure 3-13 PMCMNT DATA screen(0i-md 8.4"LCD) Figure 3-14 PMCMNT DATA screen 1(0i-MD 8.4"LCD) Figure 3-15 PMC DATA screen 2(0i-MD 8.4"LCD) Figure 3-16 PMCMNT DATA screen 3(0i-MD 8.4"LCD) Figure 3-17 PMC DATA screen 4(0i-MD 8.4"LCD) Figure 3-18 COUNTR screen(0i-md 8.4"LCD) Figure 3-19 Alarm message(0i-md 10.4"LCD) Figure 3-20 PMC MAINTE system screen(0i-md 10.4"LCD) Figure 3-21 PMC MAINTE DATA screen(0i-md 10.4"LCD) Figure 3-22 PMC MAINTE DATA screen 1(0i-MD 10.4"LCD) Figure 3-23 PMC MAINTE DATA screen 2(0i-MD 10.4"LCD) Figure 3-24 PMC MAINTE DATA screen 3(0i-MD 10.4"LCD) Figure 3-25 PMC MAINTE DATA screen 4(0i-MD 10.4"LCD) Figure 3-26 COUNTR screen(0i-md 10.4"LCD) Figure 3-27 Alarm message(31i-b 10.4"LCD) Figure 3-28 PMC MAINTE system screen(31i-b 10.4"LCD) Figure 3-29 PMC MAINTE DATA screen(31i-b 10.4"LCD) Figure 3-30 PMC MAINTE DATA screen 1(31i-B 10.4"LCD) Figure 3-31 PMC MAINTE DATA screen 2(31i-B 10.4"LCD) Figure 3-32 PMC MAINTE DATA screen 3(31i-B 10.4"LCD) Figure 3-33 PMC MAINTE DATA screen 4(31i-B 10.4"LCD) Figure 3-34 COUNTR screen(31i-b 10.4"LCD) Figure 3-35 Remove the fixed teeth Figure 3-36 Install gauge Figure 3-37 Tool magazine Figure 3-38 Operator panel screen(18i-mb 10.4"LCD) Figure 3-39 Operator panel screen(0i-md 8.4"LCD) Figure 3-40 Operator panel screen(0i-md 10.4"LCD)

5 CONTENTS OF FIGURE Figure 3-41 Operator panel screen(31i-md 10.4"LCD) Figure 3-42 Tool gauge Figure 3-43 Magazine mounting plate Figure 3-44 Tool is within spindle Figure 3-45 Rotate tool Figure 3-46 Parameter setting screen(18i-mb 10.4"LCD) Figure 3-47 Parameter setting screen(0i-md 8.4"LCD) Figure 3-48 Parameter setting screen(0i-md 10.4"LCD) Figure 3-49 Parameter setting screen(31i-b 10.4"LCD) Figure 3-50 Parameter setting screen(18i-mb 10.4"LCD) Figure 3-51 Parameter setting screen(0i-md 8.4"LCD) Figure 3-52 Parameter setting screen(0i-md 10.4"LCD) Figure 3-53 Parameter setting screen(31i-b 10.4"LCD) Figure 3-54 ATC JOG(18i-MB 10.4"LCD) Figure 3-55 ATC JOG & CCW(18i-MB 10.4"LCD) Figure 3-56 ATC JOG(0i-MB 8.4"LCD) Figure 3-57 ATC JOG & CCW(0i-MD 8.4"LCD) Figure 3-58 ATC JOG(0i-MD 10.4"LCD) Figure 3-59 ATC JOG & CCW(0i-MD 10.4"LCD) Figure 3-60 ATC JOG(31i-B 10.4"LCD) Figure 3-61 ATC JOG & CCW(31i-B 10.4"LCD) Figure 3-62 M6T1(18i-MB 10.4"LCD) Figure 3-63 M6T1(0i-MD 8.4"LCD) Figure 3-64 M6T1(0i-MD 10.4"LCD) Figure 3-64 M6T1(31i-B 10.4"LCD) Figure 5-1 APC Control Panel Board IV

6 1 OPERATOR S CONTROL 1 OPERATOR S CONTROL 1-1

7 1 OPERATOR S CONTROL 1.1 Operator s Control Panel LCD/MDI Panel LCD/MDI consisted of LCD (18i-MB 10.4" color) and keyboard, shown as Figure 1-1. Figure 1-1 LCD/MDI panel(18i-mb 10.4" color) A. Key function The position push-button indicates the current position of the slides. The information is spread over pages. In "EDIT" mode, the cursor can be moved any desired command by using the cursor Forward or Reverse. In "MDI" mode, the cursor can be input the data to the buffer memory. In "AUTO" mode the cursor can be displayed current commands. The OFFSET push-button displays either the offset chapter or work shift chapter. Repeatedly pressing "OFFSET" push-button will alternately display on chapter or the other. The button displays setting of the System Diagnostic data and System parameter data. Graphic display function. This button displays Alarm messages of interest to the operator in two chapters. 1-2

8 1 OPERATOR S CONTROL The software operator's panel is shown as following figure which can be determined by the following procedure: 1. Press the Offset & Setting button. OPR OPERAT PANEL 2. Select the manual by pressing this button which located under the LCD Select the OPR soft-key by pressing the button located under the LCD(For 18i-MB 10.4" color LCD, 0i-MD 8.4" color LCD) Select the OPERAT PANEL soft-key by pressing the button located under the LCD(For 0i-MD 10.4" color LCD). 4. Press the page button down, then the following picture will be displayed. 1-3

9 1 OPERATOR S CONTROL Figure 1-2 Software operator's panel (18i-MB 10.4" color) Figure 1-3 Software operator's panel (0i-MD 8.4" color) Figure 1-4 Software operator's panel (0i-MD 10.4" color) 1-4

10 1 OPERATOR S CONTROL Figure 1-5 Software operator's panel (31i-B 10.4" color) PRG REST: "ON" indicates program restart function is effective. ATC JOG: "ON" indicates ATC turn forward. ATC CCW: "ON" indicates ATC turn backward, ATC JOG need "ON". 4TH RUN: "ON" indicates the 4 th axis is effective. MAN ABS: "ON" indicates Manual increment add on the absolute coordinate. OVC.: "ON" indicates feedrate override is ineffective. AFL: "ON" means M, S, T code will be neglected. TEACH: "ON" means teach-in function turns ON. 1. This key is used to shift the cursor a short distance in the reverse direction. 2. This key is used to shift the cursor a short distance in the forward direction. Several pages are included in the chapter selected with each function button. The page is selected with PAGE button. NOTE: The data displayed on the screen disappears when one of the function buttons and the "CAN" key are pressed. Thereafter, when either function button is pressed, the corresponding screen is displayed again. When the unit is not used with the long-term power turned on; then turn off the screen. This is effective to prevent the image quality from deteriorating. 1-5

11 1 OPERATOR S CONTROL B. Keyboard functions Press this key to reset the CNC, to cancel an alarm, etc. Cursor shift keys: 1. This key is used to shift the cursor a short distance in the forward direction. 2. This key is used to shift the cursor a short distance in the reverse direction. 3. This key is used to shift the cursor a short distance in the left side direction. 4. This key is used to shift the cursor a short distance in the right side direction. Page change keys: 1. This key is used to change over the page on the LCD screen in the forward direction. 2. This key is used to change over the page on the LCD screen in the reverse direction. Program Editing Keys: This button is used in Edit mode to alter a data word in an enabled program stored in memory. INSERT The "INSERT" button is used in Edit mode to insert data words, an entire block or several blocks of data, into an enabled part program stored in memory. It is also used when entering a part program into memory from the MDI keyboard. 1-6

12 1 OPERATOR S CONTROL DELETE The "DELETE" button is used in edit mode to delete a data word, an entire block, or several blocks of data, from an enabled part program stored in memory. It is also used to delete a complete part program from the program Directory. The "CAN" button is used to erase incorrect data entered on the MDI keyboard before "Insert" button is pressed. Character are erased singularly each time the button is pressed starting with the last character entered. That means when the address key or the numerical key is pressed next, the position where the alphabet or the numeral is inserted next is indicated by "-". When the cancel key is pressed, the character immediately before the "-" is canceled. The INPUT button is used when entering information from the MDI keyboard. When an address or numerical key is pressed, the alphabet or the numeral is input once to the key input buffer, and it is displayed on the LCD screen. To set the data input to the key input buffer in the offset register, etc., press the Input key. Address and alphabet and other symbol. Softkeys: (special functions) Left direction softkey: This key is used for returning to the previous status. Right direction softkey: This key is used for returning to the next operation functions. 1-7

13 1 OPERATOR S CONTROL Machine Operator's Panel MAG SPD ALARM STATUS HOME G ST EMER ENCY O P NC X Y Z 4TH 5TH O A R R E S T E M E R G E N Z A AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN % mm/min F0 % % AXIS AUX FUNCTION MANUAL POWER Z Y V SBK BDT M01 CW AUTO MAN BLOW ON F2 X END X F1 DRN MLK Z ZLK STOP FORWD FORWD BACK SCTN OFF Y Z V AUTO H.INT DOOR CCW CW CCW LIGHT APO Figure 1-6 Machine operator s panel 1-8

14 1 OPERATOR S CONTROL The description of Machine control panel will be as below: A. Emergency stop: G ST EMER ENCY O P O A R R E S T E M E R G E N Z A If you press the Emergency Stop button on the machine operator's panel, the machine movement stops in a movement, mechanical reference point will disappear. Spindle stops rotating automatically. The button is locked when pressed. The button can be unlocked by twisting it. B. Rotary switches: 1. MODE selector: EDIT It is used when editing a part program stored in memory; to add data to memory; to delete data from memory and to modify data in memory. To use this mode, Program Protect switch must in "OFF" position. AUTO Press the cycle start button of the operating panel. The program in the AUTO operation memory will be executed. When pressed, automatically operation begin and cycle start lamp lights. MODE MDI HANDLE DNC Machine can be direct transfer the program while machine in auto operation. DNC JOG AUTO EDIT RAPID ZRN MDI The common of the multiple blocks can be input from the LCD/MDI panel to the MDI operation buffer memory. The program in the MDI operation buffer memory can be edited in the same method as that for the program registered in the memory. Press the START key of the operating panels the program in the MDI operation buffers memory will be executed. HANDLE can be used to move all axes manually. Select the axis to be moved by the axial selector, the selected axis can be moved by Manual Pulse Generator. Handle Multiplication can be set by actuating one of the three steps X1, X10, X

15 1 OPERATOR S CONTROL JOG operation can be moved selected axis and moves in its directions (X+, X-, Y+, Y-, Z+, Z-), Feed rate can be set by Jog feed rate override switch. Actuate and hold the corresponding axis key, the machine axis moves continuously at the set traversing rate. Release the axis key held so far, the traverse movement will stop. AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN RAPID operation can be moved selected axis and moves in its directions, Feed rate can be set by Rapid feed rate override switch. Actuate and hold the corresponding axis key, the machine axis moves continuously at the set traversing rate. Release the axis key held so far, the traverse movement will stop. ZRN set to the Home position, press the selected axis to be the reference point. The machine stops at the reference point return, lighting the Axes Home position LED. If 3 axes are selected simultaneously by three switches, three axes moves are allowed at the same time. % mm/min Cutting Feed rate Override: (1) With this dial, it is possible to override the feed rate designated by the program. An override of 0 to 200% divide to 16 step, this switch provides to the feed rate of G01, G02, G03 and other G code which may using this feed rate for cutting. (2) Jog Feed rate Override: With this dial, it is possible to override the feed rate designated by the program. An override of 0 to 3,700 mm/min. divide to 16 step, this switch provides to the JOG or Dry RUN feed rate switch. F % Rapid Feed rate Override: The Rapid Override switch of 100%, 50%, 25% and F0 is provided, when the rapid traverse rate is 20 m/min. and this dial is set to 50%, actual rate becomes 10 m/min. F0 is a constant value specified by the parameter. Rapid override is effective by the following functions: (1) by G00. (2) during canned cycle. (3) in G27 and G28. (4) Manual rapid traverse. 1-10

16 1 OPERATOR S CONTROL % Spindle Speed Override: The spindle speed override switch allows the operator to modify programmed spindle speeds in steps of 10% from 50% to 120%. The actual spindle speed what you commended can be seen on the LCD and displays current block "S". The switch is active in AUTO, MDI or Dry Run modes. C. Key switches: 1. Program Protect switch: The Program Protect key-switch should be turned to the ON or EDIT position (left turn) and key removed except when part program editing is required. Part program can be deleted from memory or modified in any way when switch is in the OFF position (right turn). With this control, it can be operated by following process: 1) The program registered in memory and modified. 2) Re-setting the coordinate system. 3) Keying machine parameter by manual. 4) Setting the PC parameter and timer parameter. 2. SET/AUTO KEY: 1) Auto mode A. The key is switched to the auto mode when the interlocked movable guard is closed. a. All functions of electrical system including motor and solenoid valve will be functional normally. b. The movements of spindle and servo axis will be executed normally. c. The powered movements of machine will be operated automatically. d. The movement of automatic tool change will be executed. e. In the handle mode, the operator can control the direction of axis directly by the use of handwheel. f. Machine maintenance will be not permitted under this situation. B. The key is switched to the auto mode when the interlocked movable guard is open. a. All functions of electrical system including motor and solenoid valve will be not performed. b. The movements of spindle and servo axis will be stopped. 1-11

17 1 OPERATOR S CONTROL c. The powered movements of machine will be stopped. d. The movement of automatic tool change will be stopped. e. The handwheel will be disabled. f. Machine maintenance will be not permitted under this situation. g. The power supply of servo system will be off after delayed 4 seconds. 2) Setting mode A. The key is switched to the setting mode, wherever the interlocked movable guard is closed or opened, the statements are the same as the following. a. All functions of electrical system including motor and solenoid valve will be not performed. b. Spindle rotation will only be initiated by pressing two buttons at the same time. One button is enabling device and the other is clockwise and counterclockwise of spindle. Spindle speed will not exceed 50 rpm. If the operator releases one of the two buttons, the spindle movement will be stopped immediately. c. The movements of servo axis will only be initiated by pressing two buttons at the same time. One button is enabling device and the other is the direction of axis. Axis speed will not exceed 2m/min. If the operator releases one of the two buttons, the servo axis movement will be stopped immediately. d. The powered movements of machine will be stopped. e. The movement of automatic tool change will be stopped. f. The operator can control the direction of axis by pressing the two enable buttons simultaneously on the handwheel. g. Machine maintenance is permitted under this situation 1-12

18 D. Push-buttons: CW 1 OPERATOR S CONTROL 1. Spindle CW push-button (included red lamp): The spindle CW push-button is an illuminating, momentary type, push-button. The light must be "OFF" for spindle CCW mode operation. Effective by mode selected in Handle position (push-button illuminated). Spindle rotates in clockwise direction. Note: After machine "ON", spindle speed must be keyed in the memory by MDI mode, then this button is effective for pressing. CCW 2. Spindle CCW push-button (included red lamp): The spindle CCW push-button is an illuminating, momentary type, push-button. The light must be "OFF" for spindle CW mode operation. Effective by mode selected in Handle position (push-button illuminated). Spindle rotates in counterclockwise direction. Note: After machine "ON", spindle speed must be keyin in the memory by MDI mode, then this button is effective for pressing. STOP 3. (1) Spindle Stop push-button (including green lamp): In the HANDLE mode, press the button will stop the spindle rotation. (2) Spindle Orientation push-button (including green lamp): In the ZRN mode, press the button for spindle orientation. 4. Cycle Start push-button: The Cycle Start push-button is used to initiate programs in AUTO, MDI, Dry Run, and Machine Lock modes. It is illuminated while a data block is being executed. When control is in an End of Block, Feedhold or MDI condition, the button will not be illuminated. If Feedhold push-button is pressed during execution of a part program, Cycle Start light will turn "OFF". 5. Cycle Stop push-button: The button allows the operator to stop all axial motion during execution of an enabled part program. It is active in memory AUTO, MDI (Block by Block), Dry Run and Machine Lock modes. It is illuminated when active. It has no effect on active spindle speed. At M.S.T. operation continues up to the end of the block. Cycle Start light and Spindle CW or CCW button light will turn "OFF" when feed hold is activated. Normal operation maybe resumed by pressing Cycle Start push-button. 1-13

19 1 OPERATOR S CONTROL X X Y Y Z Z 6. X + push-button: The X+ push-button is momentary type switch that allows the operator to jog the X axis in plus X direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position. 7. X - push-button: The X- push-button is momentary type switch that allows the operator to jog the X axis in minus X direction. It is enabled when mode is selected in JOG position. 8. Y + push-button: The Y+ push-button is momentary type switch that allows the operator to jog the Y axis in plus Y direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position. 9. Y - push-button: The Y- push-button is momentary type switch that allows the operator to jog the Y axis in minus Y direction. It is enabled when mode is selected in JOG position. 10.Z + push-button: The Z+ push-button is momentary type switch that allows the operator to jog the Z axis in plus Z direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position. 11.Z - push-button: The Z- push-button is momentary type switch that allows the operator to jog the Z axis in minus Z direction. It is enabled when mode is selected in JOG position th + push-button: The 4th + push-button is momentary type switch that allows the operator to jog the 4th axis in CW direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position th - push-button: The 4th - push-button is momentary type switch that allows the operator to jog the 4th axis in CCW direction. It is enabled when mode is selected in JOG position. 1-14

20 1 OPERATOR S CONTROL SBK V V th + push-button: The 5th + push-button is momentary type switch that allows the operator to jog the 5th axis in CW direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position th - push-button: The 5th - push-button is momentary type switch that allows the operator to jog the 5th axis in CCW direction. It is enabled when mode is selected in JOG position. 16.Single Block push-button: The Single Block push-button is an illuminating, latch type switch push-button used to initiate AUTO, MDI, Dry Run and Machine Lock modes. It is illuminated while the push-button is being pressed. One block of the program is executed, and then the execution is stopped. If the cycle start button is pressed, the next block is executed and then the execution is stopped again. The Single Block push-button must be pressed a second time to be de-activated. BDT DRN 17.Block Skip push-button: The Block-Skip push-button is an illuminating, latching type that causes the control to ignore any block containing a Slash code ( / ). The function is active when the push-button is illuminated. When the push-button is not illuminated, the data block is executed. If the slash code is the first character in the block, all data to the EOB character will be ignored when the push-button is active. If the slash code is placed in the middle of a block, only data from the slash code to the EOB character will be ignored; while data proceeding the slash code will be executed. To exit from Block Skip, press push-button a second time. The push-button is active in Dry Run and Machine Lock. 18.Dry Run push-button: The Dry Run push-button is an illuminated, latch type switch that causes the control to execute of a program and running with feedrate of JOG OVERRIDE. 1-15

21 1 OPERATOR S CONTROL M01 19.Optional Stop push-button: The Optional Stop push-button is an illuminated, latch type switch that causes the control to stop execution of a part program after completing a block containing an M01 code. The function is active when the push-button is illuminated. An M01 code is ignored when the push-button is not illuminated. The push-button can be activated before or during a block containing an M01 code. When a block containing an activated M01 is completed, all slide motion and spindle rotation ceases, coolant pump turns OFF, Feed Hold push-button is illuminated and Optional Stop push-button flashes. The push-button is active in Dry Run and Machine Lock modes. MLK APO 20.Machine Lock push-button: The push-button is an illuminating, latching type push-button. The light must be OFF for normal machine operation. When Machine Lock mode is active (push-button illuminated), all axes motion is inhibited. To exit from Machine Lock mode, press the push-button again. 21.Auto power Off push button: The push-button is an illuminating, latching type push-button. M30 function will be active after this button has been depressed (push-button illuminated). CW 22.Tool magazine index forward push-button: Press the button, magazine will be forwarding. (button is illuminated) CCW 23.Tool magazine index reverse push-button: Press the button, magazine will be reversing. (button is illuminated) BLOW 24.Air blower push-button: The air blower function will be active (button is illuminated) when this button is depressed. 1-16

22 1 OPERATOR S CONTROL END 25.Overtravel Release push-button: When the axes overtravel, set the mode selector in Handle position, press Overtravel button, in the mean time, release the axes by Manual Handwheel. Caution: Machine may cause machine damage due to axis move to wrong direction while pressed the button and protection sensor bypass is active. MAN 26.Coolant Manual push-button: Press the button, the coolant will be distributed. Press the button again, the coolant will be stopped. AUTO 27.Coolant Auto push-button: The push-button is an illuminating push-button. Press the button, coolant will be distributed in accordance with M08, M13, M14, M28, M51 command in Automatic operation. When coolant is being distributed in Automatic operation, pressing this button again will stop coolant flow. FORWD BACK 28.Chip Conveyor forward push-button: The chip conveyor "ON" is active when the push-button is illuminated. When the push-button pressed a second time, the chip conveyor is always "OFF" regardless of operating mode. 29.Chip Conveyor Reverse push-button: The chip conveyor reverse "ON" is active when the push-button is illuminated. When the push-button pressed a second time, the chip conveyor is always "OFF" regardless of operating mode. DOOR 30.Door open push-button: The push-button is an illuminating momentary type push-button. Press this button while the machine is stationary, the door will be opened. H.INT 31.Handle Interruption push-button: Press the button, the axis can be moved by means of handwheel. 1-17

23 1 OPERATOR S CONTROL Z ZLK 32.Z axis lock button: Press the button, Z axis will be locked (light is illuminated). AUTO 33.Auto Home return button: Press the push-button (push-button light will come on), Z axis will move to its home position automatically. After Z axis is at its home position, Y axis will follow the Z axis procedure, and then the X axis. ON 34.Power ON button: Press this button to turn the control ON. OFF 35.Power OFF button: Press the button to turn the control OFF. FORWD 36. Chip Screw ON button: Press the button to active the chip screw, to stop it by press the button once again. LIGHT 37. Work light button: Press the button to turn the work lights ON, to press the button again, the lamp will be light out. SCTN 38.Smoke exhaust button: Press the button to turn the smoke exhaust ON, to press the button again, the lamp will be light out. 39. Floor clean water button: Press the button to turn the floor clean water ON, to press the button again, the lamp will be light out. 1-18

24 1 OPERATOR S CONTROL 40. Enabling device button: A.Press the button and spindle CW push-button or spindle CCW push-button at the same time to start the spindle rotation. Spindle speed will not exceed 50 rpm. If the operator releases one of the two buttons, the spindle movement will be stopped immediately. B.Press the button and manual feed axis direction selection button at the same time to initiate the axis movement. Axis speed will not exceed 2m/min. If the operator releases one of the two buttons, the axis movement will be stopped immediately. 1-19

25 1 OPERATOR S CONTROL E. LED Lamps: HOME X Y Z 4TH 5TH 1. X Axis Home position L.E.D. The X axis Home position light will be flashed whenever the X axis move to the reference points and will light up when the X axis returned to the HOME position. 2. Y Axis Home position L.E.D. The Y axis Home position light will be flashed whenever the Y axis move to the reference points and will light up when the Y axis returned to the HOME position. 3. Z Axis Home position L.E.D. The Z axis Home position light will be flashed whenever the Z axis move to the reference points and will light up when the Z axis returned to the HOME position th Axis Home position L.E.D. The 4th axis Home position light will be flashed whenever the 4th axis move to the reference points and will light up when the 4th axis returned to the HOME position th Axis Home position L.E.D. The 5th axis Home position light will be flashed whenever the 5th axis move to the reference points and will light up when the 4th axis returned to the HOME position. NC ALARM a. NC alarm light b. Way lubrication abnormal indicator. c. Low air indicator. STATUS a. ATC ready indicator. b. M02 / M30 indicator. c. Spindle high gear indicator. 1-20

26 1 OPERATOR S CONTROL F. LED Display: MAG SPD a. Tool number of spindle. Display current tool number of spindle. b. Tool number of magazine. Display current tool number of magazine. 1-21

27 1 OPERATOR S CONTROL G. Manual Pulse Generator 1. Axial position selector Selecting which axis you want to move. (X, Y, Z,4 th,5 th ) 2. Handle Multiplication Switch 3. Manual Pulse Generator 4. Enabling device button 5. Emergency stop X1: X10: When switch is placed at X1 position each graduation the M.P.G. represents mm. When switch is placed at X1 position each graduation the M.P.G. represents mm. When switch is placed at X1 position X100: each graduation the M.P.G. represents mm. The feedrate can be adjusted precisely by using the Manual Pulse Generator. The incremental Jog handwheel allows the operator to jog a slide in increments when Mode Select Switch is in Handle position. The value of each handwheel increment depends on the setting of Handle Multiplication switch and the axis to be jogged depends on the setting of Axial Position Selector. Press the button and spindle CW push-button or spindle CCW push-button at the same time to start the spindle rotation. Spindle speed will be limited under 50 rpm. If the operator releases one of the two buttons, the spindle movement will be stopped immediately. Press the button and manual feed axis direction selection button at the same time to initiate the axis movement. Axis speed will not exceed 2m/min. If the operator releases one of the two buttons, the axis movement will be stopped immediately. Press the button to immediately stop all actions machines. 1-22

28 1 OPERATOR S CONTROL H. Programming finish and alarm light: Red lamp (R): Yellow lamp (Y): Green lamp (G): It will be flashing every 0.5 second when machine alerts. It will be flashing every 0.5 second when program is finished. It will be shining when machine is in normal operation. I. Open operation door, front door, side door: 1. All axes and spindle stop. 2. Program is not running. 3. Select mode switch to setting (SET) mode. DOOR 4. Press DOOR to open operation door. 5. The door is automatically locked after being closed. 6. Press DOOR to open the operation door. If one wants to open the other doors, press DOOR again. 1-23

29 1 OPERATOR S CONTROL Magazine Operator's Panel EM ERG ENCY MAGAZINE POST NUMBER STOP TOOL SET NUMBER CALL TOOL NUMBER Figure 1-7 Magazine operator s panel 1-24

30 1 OPERATOR S CONTROL A. Open Magazine door: 1. Select Key switch to HANDLE mode. 2. Switch Mode selector to the symbol DOOR. 3. Press START button (ATC side) to open the ATC door. 4. When ATC door is closed, it locks automatically. 5. If ATC door is not closed, the alarm occurs when switching to other modes. 1-25

31 1 OPERATOR S CONTROL AUTO MANUAL Figure 1-8 Magazine operator s panel 1. MODE selector: AUTO: Can be auto tool change, and door of magazine lock. MANUAL: Not can auto tool change, and door of magazine unlock. CW 2. Magazine index forward: Select "MANUAL" mode, press "Magazine (CW)" button, then magazine will be indexing reverse. CCW 3. Magazine index reverse: Select "MANUAL" mode, press "Magazine (CCW)" button, then magazine will be indexing reverse. 1-26

32 2 POWER UP AND POWER DOWN 2 POWER UP AND POWER DOWN 2-1

33 2 POWER UP AND POWER DOWN 2.1 Inspection Before Operation Checking List to be followed before operation of the machine is as follows: Checking before Power Up DANGER The electric box, motor, transformer and relay boxes with a high-voltage mark have terminals of lethal voltage. Only electrical experts with official qualification are authorized to open their covers and doors. Cable and wire with damaged film can cause electric leakage or shock. Double-check that there is no damage on cable and wire. Failure to follow this warning will result in serious personal injury or death from electric shock. Check point Check item Method Remark Air filter unit 1. Drain the water in reservoir? Check visually 2. Any lub. oil in reservoir? Check visually 3. Air pressure 5-7 kg/cm 2? Check visually Spindle Oil 1. Temperature setting value? Check visually Cooler 2. Oil sufficient? Check visually 3. Any leakage? Check visually Chip conveyor 1. Chips removed? Check visually Coolant Tank 1. Chips removed? Check visually 2. Coolant sufficient? Check visually 3. Any leakage? Check visually Chip collectors 1. Chips removed? Check visually 2. Anything other than chips? Check visually Slide cover 1. Any chips accumulated? Check visually Magazine door 1. Any chips accumulated? Check visually Table 1. Any chips accumulated? Check visually Spindle 1. Spindle taper clean? Check visually 2-2

34 2 POWER UP AND POWER DOWN Electric cabinet 1. Door closed? Check visually 2. No damage or disconnection on external wiring or cables? Check visually 3. Earth grounded? Check visually General 1. Machine environment well sorted out? Check visually 2. No looseness of bolts on cover, etc.? Check visually 2-3

35 2 POWER UP AND POWER DOWN Power Up DANGER CAUTION DO NOT touch any switches or buttons when hands are wet. CHECK the machine environment is clean so that convenient for operation. CHECK cooler oil, coolant and pneumatic pressure are sufficient to work. WARM UP the machine for approx. 15 minutes after turning the power ON WHEN setting the spindle speed above 3,000 rpm, pay the closest attention. Power-up procedure is a systematic method of safely turning on the control and the prepared machine for operation. The following are comprehensive descriptions of the 3 axes procedure: 1. Turn MAIN SWITCH and AIR SWITCH "ON". 2. Press POWER ON push-button. When buzzer has beeped, that indicates that the control is in an EMERGENCY STOP condition. Press EMERGENCY STOP push-button in clockwise direction to make certain it is released; beep will be disappeared. Machine is ready for operation. 3. To Zero return axes: (a) Set Mode Selector at HOME position. (b) Set Rapid Override Switch at 50%. Press Home position return push-button (push-button light will come on). Z axis will move to the Home position (positive direction). After Z axis Home position L.E.D. lights up showing the Z axis is at the reference zero position, (c) then Y axis will follow up the Z axis procedure, and move to the Home position automatically until all axes Home position L.E.D. light up indicated that all axes are at their reference zero position. (d) Procedure (c) can be operated by the manual push-button of each axis. Press and release X+ push-button, X axis will move to the positive side of (e) Home position. After X+ push-button light is out and X Home position L.E.D. lights up indicating that the X axis is at its reference zero position, press the Y+ and Z+ (f) push-buttons. When the slides arrive at their reference zero position, Y+ and Z+ push-button lights will be out and Home position L.E.D. Y and Z will light up. Turn Rapid Override Switch to 100% and try procedure (e) again, to be sure (g) this function is O.K. 2-4

36 2 POWER UP AND POWER DOWN Checking After Power Up Check Point Check item Method Remark Motor 1. No abnormal sound or heat? Check visually Air unit 1. Air pressure (5-7kg/cm 2 )? Check visually 2. Hose leakage? Check visually Coolant unit 1. Pump running perfect? Check visually Hydraulic unit 1. System pressure (40 kg/cm 2 )? Check visually LCD screen 1. No alarm displayed? Check visually Operation panel 1. Warning lamp lights? Check visually Checking by Manual No Check item Check result 1. Each axis + direction? - direction? Normal Fault 2. Each axis over travel, + direction? - direction? Normal Fault 3. Each axis Home return? Normal Fault 4. Spindle rotation direction? Orient? Stop? Unclamp? Normal Fault 5. Tool magazine index direction in CW? CCW? Normal Fault 2-5

37 2 POWER UP AND POWER DOWN 2.2 Door Interlock Safety Instruction 1. The following activities are not allowed when the door is opened. It could cause alarm. (1) Press the CYCLE START button to execute the program. (2) Moving X, Y, Z axis (JOG, RAPID or ZRN). (3) Manual coolant ON (Except wash gun). (4) Execute the manual tool magazine while magazine door opened. 2. The following activity will be ineffective when press the Door open button. (1) program is executing (2) spindle is rotating (CW, CCW, locating, or shift) or stalling (3) X, Y or Z axis is moving (Feedate, JOG, RAPID, ZRN) (4) chip conveyor is ON (clockwise, counterclockwise) (5) cooler is spraying 3. To force the door open without pressing the door open button will be cause the machine in E-stop status. 4. Spindle speed will be limited in 50 rpm, and Feedrate will not be higher than 2,000 mm/min. 2-6

38 2 POWER UP AND POWER DOWN 2.3 Power Down CAUTION All personnel must know the location of Emergency Stop buttons and how to use them in case of Emergency. CAUTION ALWAYS lock the Main Switch by locker to protect unauthorized personnel. DO NOT leave keys on the switches or lockers after machine is turned off. To prevent damage the controller, machine tool or drives during shutdown, follow the Power-Down procedure listed below: 1. Establish a condition which ensures that the machine tool will not be damaged when control is shutdown. Ideally, establish an end-of-program condition with all axes at Home position. If this can not be accomplished, a cycle stop is adequate, but try to position the axes clear of the workpieces. 2. Press Emergency Stop push-button. If rotating, spindle will dynamically brake to a stop. Any axis motion will also cease. Power is removed from axes drive motors and spindle drive motor, thus disabling axes and spindle. 3. Press Power OFF push-button. 4. Turn disconnect switch OFF and turn Air switch OFF. Note: The machine is placed in E-Stop before the control is turned OFF is to remove power in two distinct steps; first from the drive motor, then from the drives. Removing all power at once can damage the machine. 2-7

39 2 POWER UP AND POWER DOWN Emergency Stop In case of any emergency cases: 1. Press the emergency button which is nearest button as soon as possible. 2. Machine will be stopped immediately. 3. Screen will display the alarm message "Not ready". 4. After the emergency situation has solved, turn the switch clockwise to release the emergency button. 5. Then the NC control is ready automatically. 2-8

40 2 POWER UP AND POWER DOWN Other Stops There are several methods to stop machine during machine in AUTO or MDI operation. The descriptions are as below: A. Program Stop (M00) Stops program, stops spindle, turns coolant OFF, "Tool release" push-button is activated. "Feedhold" light flashes intermittently. Cycle operation is stopped after a block containing M00 is executed. When the program is stopped, all existing modal information remains unchanged as in single block operation. The cycle operation can be restarted by specifying a CNC start. It is the programmer's responsibility to program an M03, M04, M13, or M14 to restart spindle and turn coolant on when restarting the program after an M00 program stop. B. Optional Stop (M01) Performs the same function as M00 but will not stop the cycle unless "Optional Stop" push-button is activated (illuminated) before the block containing the M01 is read by the control. If "Optional Stop" is not activated, the cycle will continue without stopping. When active, the "Cycle Start" light goes out, "Optional Stop" lights up and "Feed Hold" light is illuminated. This function is useful when it is necessary to gauge the workpiece during setup. Pushing "Cycle Start" push-button allows program to continue. It is the programmer's responsibility to program an M03, M04, M08, M13 or M14 to restart spindle and turn coolant on when restarting program after an M01 Optional Stop. M01 ON: Press the button, button lamp will light up. Machine will be stopped after the block containing the M01 is read by the control. Machine will be restarted after release the Optional Stop push-button. OFF: Release the button, button lamp will go out. Machine will continue without stopping after the block containing the M01 is read by the control. C. End Of Program (M02, M30) The M02 or M30 is used at the end of the program. It is usually the last block programmed. It stop the spindle, and turns coolant off. "Cycle Start" light goes out and Feedhold light flashes intermittently. When entering a program in memory from MDI keyboard, placing M30 at end of Program will cause program to automatically return to stop when M30 is encountered in the enabled program. 2-9

41 D. Single Block 2 POWER UP AND POWER DOWN It is illuminated while the push-button is being pressed. One block of the program is executed, then machine will be hold on, the execution is stopped. SBK ON: It will be illuminated while the push-button is being pressed. One block of the program is executed, and then the execution is stopped. If the Cycle Start button is pressed, the next block is executed and then the execution is stopped again. At the end of each program block, the machine is placed in a Feed Hold condition. Rapid Traverse Feedrate Traverse OFF: It will be de-activated while the bush-button is being released. Note 1: When G28 & G30 are in the same block, the execution will stop in G28 or G30 whatever which G code is executed. Note 2: In Canned cycle, machine will stop at the end of point 1, 2 and 6 during Single Block is activated. Note 3: When Single Block is activated, machine will not be executed during a block containing an M98P ; M99; and G65. But machine will be executed during a block containing an address other than O, N or P, and M98, or M99. Note 4: NC will be shifted into Single block status automatically when the mode selector change to EDIT or MDI mode while program is in executing. 2-10

42 2 POWER UP AND POWER DOWN E. Feedhold button Note 1: Note 2: The axial movement will be feedhold temporary when this push button has been depressed while machine in operation at the mode of AUTO or MDI selection, but spindle and coolant will be active continuously. The light will light up when Feedhold button has been depressed. The feed will be decelerated when machine axis is moving. Dwell will be cancelled when program is in G04 status. M.S.T or B action will be executed till end of single block. If mode selector turn to Handle mode while program is executing, the NC will be shift to machine block status. NC will be alert while program is executing, then NC will be shift to machine lock status. If machine to be operated continuously, then push the Cycle start button once again. F. Spindle Reset The spindle can be stopped during machine in AUTO operation. Press Feed Hold button, machine will stopped, then push Spindle Stop button, the push-button will be illuminated. The spindle will be restarted after pressing Cycle Start button, all axes movement will be executed 1.5 sec. later on. STOP The Spindle stop push-button can also be used to manually release the tool holder from the spindle, once pressed the button, the button light will be flashed then push the footswitch for tool unclamping which is located in front of the operator s door. The drawbar will stay in the open position as long as the button is held depressed. The button light will be flashed in 30 seconds valid for tool unclamping from Spindle. The spindle unclamping function will be invalid once light flashing stopped. This push-button is available only when spindle rotation is stopped and machine is out of cycle. 2-11

43 2 POWER UP AND POWER DOWN G. Reset The Reset push-button is active anytime control is ON. It cancels active spindle speeds and slides motions, resets G and M codes to start-up conditions and cancels active offsets. If Tool Change is progressing when "Reset" is pressed, ATC will progress continuously until "Reset" is held depressed. "Reset" is also used to clear an alarm State after fault has been corrected. To return a program in memory to the beginning, press "Program" push-button. 2-12

44 2 POWER UP AND POWER DOWN Power Down When the control loses power, either because of a power fail or because the Power Off push-button has been pressed, the control system disables all outputs, including the machine power permission control relay. If the control power is lost during any data entry operation, the correctness of the data being entered cannot be guaranteed and should be verified. All information previously entered into the system is retained; active information such as an operator entered MDI block is lost. There are some mechanical safety devices on the machine that can protect the operator or third party. A list is as below: Safety Items Power ON Power Lost Spindle Tool Power Drawbar Clamp Clamp Spindle Tool Power Drawbar Unclamp Clamp Spindle Motor Rotating Stop All Axes Movement Moving Stop Z Axial Brake Unclamp Clamp Tool index for searching tool Indexing Stop Power Switch On Off Controller Power Unit On Off Reset procedure after power lost: 1. Turn the main power OFF. 2. Depressed the E-Stop on the operator's panel. 3. Replace the workpiece or tools if necessary due to bad quality caused by the power lost. After power returning back, power up by the procedure mentioned above. Returning all cutting conditions before power lost, then cycle start continuously. 2-13

45 2 POWER UP AND POWER DOWN 2.4 Power on Procedure List DANGER CAUTION DO NOT touch any switches or buttons when hands are wet. CHECK the machine environment is clean so that convenient for operation. CHECK cooler oil, coolant and pneumatic pressure are sufficient to work. WARM UP the machine for approx. 15 minutes after turning the power ON. WHEN setting the spindle speed over 3,000 rpm, pay the closest attention. 1. Turn ON Air Switch. 2. Turn ON the Main Power Switch of electrical cabinet at the back of the machine. ON 3. Press the Power On button on the machine operator s panel to switch the numerical control on. G ST EMER ENCY O P O A R R E S T E M E R G E N Z A 4. Release the Emergency Stop button. 5. Set the Mode Selector in Handle position. Move all axes away 200mm from Home position by Manual Pulse Generator. 2-14

46 2 POWER UP AND POWER DOWN 6. To Zero return axes: (a) Set the Mode Selector in ZRN position. (b) Set Rapid Feedrate Override Switch at 50%. X Y AXIS Z END Z Y X V F1 V (c.1) Manual: The Zero return procedure can be operated by the manual push-button of each axis. Press and release -X push-button, X axis will move to the Home position. Press the +Y and +Z push-buttons, Y axis and Z axis will move to the Home position. AUTO (c.2) Auto: Press the Auto Home return button, Z axis will move to its Home position automatically. After Z axis is at its Home position, X axis will follow the Z axis procedure and then the Y axis. HOME X Y Z 4TH 5TH 7. All axes Home position LED lamps will light up when all axes returned to the Home position. 2-15

47 2 POWER UP AND POWER DOWN 2.5 Power Off Procedure List CAUTION ALWAYS lock the Main Switch by locker to protect unauthorized personnel. DO NOT leave keys on the switches or lockers after machine is turn off. SBK 1. If the program is executing, the operator need to press the Single Block push-button. One block of the program is executed, and then the execution is stopped. 2. Press the RESET push-button to stop all machine movements. G ST EMER ENCY O P O A R R E S T E M E R G E N Z A 3. Press the Emergency Stop button. OFF 4. Press the Power Off button on the machine operator s panel to switch the numerical control off. 5. Turn OFF the Main Power Switch. 2-16

48 3 OPERATION INSTRUCTION 3 OPERATION INSTRUCTION 3-1

49 3 OPERATION INSTRUCTION 3.1 Mode Selection According to the safety regulation whenever mode selection, all movement must be stopped. If mode exchange between AUTO / MDI and HANDLE / JOG / HOME, spindle, all axial movements will be stopped. Returning to the mode of AUTO, press the CYCLE Start button, machine will be start. Returning to the HANDLE mode, it must be started from the beginning. 1. Returning to Auto mode for executing the program, and then spindle rotating will be remain the same as previous RPM & direction. CAUTION 2. Turn the mode selection from AUTO to HANDLE mode during program in executing, if each of axis displacement has been determined. It will affect the machine dimension when the program is executing continuously. Whenever cancel or stop temporary to execute the program in AUTO mode, please follow the regular procedure to avoid any mode exchange. 1. Cancel programming execution (1) Push the E-stop button. (2) Press the Reset button. 2. Stop programming execution temporary 2-1 Feedhold: (1) Push FEED HOLD button. (2) To Returning back - Push CYCLE START button. 2-2 Feedhold; spindle stop: (1) Push FEED HOLD button, Axis movement will be stopped. Then push the Spindle stop button, the spindle will be stopped. If the spindle stop is not depress after the axis movement has been completely stopped, then spindle will not be stopped. (2) Push the CYCLE STOP button, the axial movement will be stopped, then the spindle will be stopped automatically. (3) Returning back to the previous status - by pushing the CYCLE START button,then spindle will be returning to rotate, axial movement will be remain the same as before. 3-2

50 3 OPERATION INSTRUCTION CAUTION 1. Normal programming edit at the end of the program will be M02 or M30 which means program to be ended and delete all information in the temporary storage. 2. If programming edit of M02 or M30 at the end of program was missing, then it is necessary to push the RESET button after program execution ending. Or press the RESET button before doing any operation on the machine. 3. If machine did not follow mentioned above regulation, then following condition will be happened: O0000; M03 S300; % At MDI mode: <1> Key-in the sample program as mentioned left: a. Push the CYCLE START button, then spindle will be rotating in 300 rpm in CW, then program M03 S300 will be disappeared. b. Change the mode to HANDLE, spindle will be stopped. c. Mode selector turning back to MDI, then push the CYCLE START button, spindle rotation will be ineffective. d. Press the RESET button to end all procedure. O0000; M03 S500 X500.; Z-300.; X-500.; Z300.; % <2> Key-in the sample program as mentioned left: a. Push the CYCLE START button, then spindle will be rotating in 300 rpm in CW, all axes will be moving normally. b. Change the mode to HANDLE, the axis movement will be stopped first, spindle will be stopped few second later, the LCD will keep the same. c. Mode selector turning back to MDI, then push the CYCLE START button, spindle rotation will be kept remain the same in 500 rpm, then axis movement will be remain the same as before. The program execution will be disappeared, but spindle will be rotating in 500 rpm because of there is neither M05 nor M02, M30 in the program. d. Press the RESET button to ending all action. 3-3

51 3 OPERATION INSTRUCTION 3.2 Manual Operation Reference Point Return CAUTION It is necessary to move each axis 200mm away from Home position by manual Handle mode before reference point return. AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN (1) Set the mode selector in HOME ZRN position. Home mode is selected, if X, Y, Z, or 4th are selected simultaneously by three or four push-buttons (X+, Y+, Z+, or 4th +), three or four axes moves are followed at the same time. Note: Before Home return positioning, moves away min. 200 mm from Home position by using M.P.G. handwheel. HOME X Y Z 4TH 5TH AXIS Z Y V (2) If press X- button, Z axis will move to its home position. After Z axis is at its home position, Z axis position will be reset in "0". There are three possibilities to interrupt the home return function: Press the Reset push-button on LCD/MDI panel. Turn the mode selector away from HOME position. Press the Emergency Stop button. X Y END Z X F1 V (3) After Z axis is at its home position, Y axis will follow the Z axis procedure, and then the X axis 4th axis. F % 100 (4) Each selected axis will be moving to its HOME position with Rapid feedrate to the designed deceleration position, then move to the HOME position with 200 mm/min feedrate. The feedrate override switch can be adjusted while the axis is moving. 3-4

52 3 OPERATION INSTRUCTION Jog Feedrate Operation A. Jog Mode AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN (1) Set the mode selector in position. JOG mode is selected, X axis can be moved by pressing X+ momentary push-button (button is illuminated) that allows the operator to jog the X axis in the plus X direction with its Jog Override Feedrate. Axial movement will stopped by released the push-button. Depress X- push-button (button is illuminated) that allows the operator to jog the X axis in the minus X direction with its Jog Override Feedrate. Y, Z, 4th axes are the same as X axis procedure X Y % mm/min 200 AXIS END Z Z Y X V F1 V (2) Select JOG feedrate override switch With this dial, it is possible to override the feedrate designated by the program. An override of 0 to 3,600 mm/min. divide to 16 step, this switch provides to the JOG feedrate switch. Tolerance will be ±3% (3) Select the axis what you want to move. JOG or RAPID mode is selected, all axis can be moved by pressing X+,X- or Y+, Y-, etc. momentary push-button (button is illuminated) that allows the operator to jog the X axis in the plus or minus X direction with its Jog Override Feedrate. Axial movement will stopped by released the push-button. 3-5

53 3 OPERATION INSTRUCTION B. RAPID override mode AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN (1) Set the mode selector in position. RAPID mode is selected, X axis can be moved by pressing X+ momentary push-button (button is illuminated) and that allows the operator to move the X axis in the plus X direction with its Rapid Override Feedrate. Axial movement will stopped by released the push-button. Depress X- push-button (button is illuminated) and that allows the operator to move the X axis in the minus X direction with its Rapid Override Feedrate. Y, Z, 4th axes are the same as X axis's procedure. F % 100 (2) Select the RAPID override switch The Rapid Override switch of 100%, 50%, 25%, and F0 is provided, when the Rapid traverse rate is 20 m/min. and this dial is set to 50%, actual rate becomes 10 m/min., F0 is a constant value specified by the parameter. X Y AXIS Z END Z Y X V F1 V (3) Select the axis what you want to move. JOG or RAPID mode is selected, all axis can be moved by pressing X+, X- or Y+, Y-, etc. momentary push-button (button is illuminated) and that allows the operator to move the X axis in the plus or minus X direction with its Rapid Override Feedrate. Axial movement will stopped by released the push-buttons. 3-6

54 3 OPERATION INSTRUCTION Handle Wheel Operation AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN (1) Set the mode selector in HANDLE position. Select the axis to be moved by the axes selector, the selected axis can be moved by Manual Pulse Generator (M.P.G.). Handle Multiplication can be set by actuating one of the three steps X1, X10, X100. (2) Set the Axis select mode The axis to be moved is selected by setting of Axis select mode. The Handle wheel allows the operator to move a slide in increments when Mode Select Switch is in X, Y, Z or 4th position. (3) Set the Handle Multiplication Switch The value of each hand wheel increment depends on the setting of Handle multiplication switch and the axis to be jogged depends on the setting of Axis select Mode. A list of movement amount per degree is as below: Input system X 1 X 10 X 100 Metric input (mm) Inch input (inch) (4) Handle wheel To rotate the wheel in one turn (360 ), it will create 100 pulse. Turn in CW direction, the axis will be moving in "+" direction, Turn in CCW direction, the axis will be moving in " -" direction. Note 1: Note 2: If the Handle is rotated in excess of 5 turns /sec, there is a difference between the Handle rotation amount and the machine movement distance. Rotating the Handle too fast when X100 is selected, moves the tool or table at a rate as fast as the rapid traverse rate. A sudden stop gives the machine tool a shock. 3-7

55 3 OPERATION INSTRUCTION Spindle Manual Operation CAUTION Do not approach the spindle while it s running. Stop the spindle before maintain the spindle. Be sure the tool clamping is secured before spindle running. The spindle can be rotated by 4 push buttons when the mode at Manual mode selection (including Handle, Rapid, Jog). When the spindle is running, mode shift to Auto mode position, then the spindle will be stopped. CW Spindle CW push button: The spindle CW push-button is an illuminating, momentary type push-button. The light must be OFF for spindle CCW mode operation. Effective by mode selected in Handle position, press the CW push-button. Spindle rotates in clockwise direction. Spindle Stop push-button: Spindle can be stopped by the following methods: STOP (1)Press the Reset button in Handle mode, spindle will be stopped immediately. The push-button will be illuminated whenever spindle is not in running. (2)Commanded M05 when mode selector is in AUTO position. (3)Press the push-button on the programmer's panel or Emergency stop button. The CW & CCW push-buttons will light out when spindle is stopped. CCW Spindle Counter Clockwise (CCW) push-button: The spindle CCW push-button is an illuminating, momentary type push-button. The light must be OFF for spindle CW mode operation. Effective by mode selected in Handle position, press the CCW push-button. Spindle rotates in counter clockwise direction. 3-8

56 3 OPERATION INSTRUCTION Spindle Tool Unclamping Manual Operation CAUTION DO NOT approach the spindle while it s running. BE SURE that the power been turned off before servicing the spindle unit. CHECK AND MAKE SURE that the spindle is stopped while cleaning the spindle taper. MUST STOP the axial movement while in spindle tool loading and unloading. WARNING MAKE SURE that there is no tool in the tool pockets of the magazine of whatever number is occupied on the spindle. IF the spindle has been occupied by a tool, DO NOT modify the spindle tool number at the value of "0". The tool must be performed by dimension check, clean and tightened pull stud before spindle loading. The tool to be mounted must meet the specified specifications as below: Max. tool dia./adjacent (mm) BM-850 BM-1020 BM-1200 BM /150 90/150 90/150 90/150 Max. tool length (mm) Max. tool weight (kg)

57 3 OPERATION INSTRUCTION Max. tool dia./adjacent (mm) BM-1400 BM-1600 BM-1800 BM / / / /250 Max. tool length (mm) Max. tool weight (kg) BM-2500 Max. tool dia./adjacent (mm) 130/250 Max. tool length (mm) 300 Max. tool weight (kg) 15 AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN Set the mode selector at the Handle or Jog or Rapid position. Press Tool Unclamp push-button on the spindle head to let spindle unclamp. Press Tool Unclamp push-button on the spindle head to let spindle clamp. 3-10

58 3 OPERATION INSTRUCTION Tool Magazine Manual Operation WARNING MAKE SURE all items as mentioned below before tool loading at magazine. (1) Before your requested tools are put into the magazine, pre-check tool tips are in good condition and tighten and clean the tool holder. (2) The tool to be mounted should meet the specified specifications as the list shown below. (3) During mounting of your requested tools in the magazine, Make sure that your expected tool pocket numbers are assigned by the controller. A. Magazine index forward CW Select "HANDLE" mode, press "Magazine (CW)" button, then magazine will be indexing forward. B. Magazine index reverse CCW Select "HANDLE" mode, press "Magazine (CCW)" button, then magazine will be indexing reverse. C. Loading & Unloading from the Magazine Be caution when loading the tool at the magazine: 1. Before your requested tools are put into the magazine, pre-check tool tips are in good condition and tighten and clean the tool holder. 2. The specification of the tool must be as below: BT40 BT50 Max. tool diameter Max. tool length Max. tool weight Tool magazine door must be closed at all time. 4. During mounting of your requested tools in the magazine, make sure your expected tool pocket numbers are assigned by the controller. 3-11

59 3 OPERATION INSTRUCTION Chip Conveyor Manual Operation and Trouble Shooting A. Operation FORWD Press this button on the operator panel, and then the chips shall be coming out from the conveyor. Users could stop the conveyor by pressing this button again. FORWD Press the button to active the chip screw, to stop it by press the button once again. CAUTION DO NOT remove the chips by hands in order to avoid any injury. B. How to remove the chip from the table? 1. Use brush or water gun to clean the chip to screw conveyor. 2. Turn the chip conveyor ON to remove the chip from screw conveyor. C. Trouble shooting 1. Use hook to remove the chip from the conveyor. 2. Check the conveyor condition. FORWD Press this button once for forwarding BACK Press this button for reversing. 3. If it still does not move, it means the motor might be broken. Please contact with your agency. 3-12

60 3 OPERATION INSTRUCTION Coolant Tank 1. Manual operation MAN The cock must be turned on first. Press this button; the indicator will light up and the coolant will come out from spindle side. Press this button again; the indicator will black out and the coolant will stop. 2. Command M08: Coolant ON M09: Coolant OFF 3. Water gun MAN The cock must be turned OFF. Press this button. The water gun will be enabled when the light illuminates. Press this button again, and the water gun will be stopped. 3-13

61 3 OPERATION INSTRUCTION 3.3 MDI Operation MDI Function The MDI mode provides the operator with the means to manually enter and execute program information one block of information at a time. MDI blocks are executed independent of the Active NC program. Each MDI block is completely executed before the next MDI block can be entered. The MDI mode is terminated by depressing one of the other mode keys. If an MDI block is displayed in the MDI Block entry area when the MDI mode is terminated, the block is erased. The control state which was active when the MDI mode was entered is retained when the MDI mode is terminated, unless the state is changed from end of block to end of program while in the MDI mode, in which case the end of program state is retained. Note: The MDI mode can not be terminated if the cycle of an MDI block has been started and has not been completed (in cycle or suspended in the middle of the block). 3-14

62 3 OPERATION INSTRUCTION A. Programming MODE MDI HANDLE AUTO EDIT DNC JOG RAPID ZRN Set the mode selector in MDI position. Press the PRGRM push-button, the LCD screen will displayed as below: The program No. O0000 will be inserted automatically. To program in MDI mode is the same as program editing. The length of a program which can be prepared is limited to one page of a LCD screen. In the above case, the longest program is 6 lines with specification of the parameter, if the mode is switched to that of no modal information display, up to 10 lines of program can be prepared. If the number of lines of program exceeds the limit, % will disappear and insertion and modification operation will become impossible. To delete a program by press the RESET push-button (when parameter no. 057 is set as MBCLR=1) or O DELETE. About program editing, please refer to FANUC operation manual. 3-15

63 3 OPERATION INSTRUCTION B. Program Execution Set the cursor on the head of the program. (Start from an intermediate point is possible) Press the START push-button on the FANUC Panel or Cycle Start push-button on the Control Panel. Machine will start to run. When the program end (M02, M30) or % is executed, the program will be erased automatically and the operation is end. By command of M99, return to the head of the program is performed. 3-16

64 3 OPERATION INSTRUCTION C. Cautions and others: Programs registered in the program memory can be called as subprogram. In this case, the nest of subprogram is up to 2-loops combined with automatic operation (AUTO) program. (If a caution macro option is provided, up to 4-loops combined is possible.) If the custom macro option is provided, even in the MDI mode, custom macro program preparation and execution is possible. However, when a macro program which call another macro program, macro call is not possible. 3. A program to be prepared in the MDI mode uses program memory vacant area. If there is no vacancy in the program memory, program preparation in the MDI mode is not possible. 4. Program prepared in the MDI mode will be erased in the following cases: a. In MDI operation, if M02, M30 or % is executed. b. In AUTO mode, if memory operation is performed. c. In EDIT mode, if any editing is performed. 5. d. Background editing is performed. The editing operation during the stop of MDI operation will start from the cursor position which makes start, but not from the current cursor position. 3-17

65 3 OPERATION INSTRUCTION 3.4 Automatic Operation Executing Automatic Operation The program which stored in memory can be executed in AUTO mode, only one program can be performed at the same time. To search the program number and enable it as follows: AUTO EDIT DNC MODE MDI HANDLE JOG RAPID ZRN (1) Set the mode selector in EDIT position. When once an expected program is selected, load the program by pressing the RESET push-button on the FANUC operator's panel. (2) Set the mode selector in AUTO position. (3) Press the soft-key under the mode selection of MONITOR, the programming O number will be showing up. (1) Call the required program. (2) Press the CYCLE START push-button, the button light will come on. After automatic operation is started, the following are executed: (1) A one-block command is read from the specified program. (2) The block command is decoded. (3) The command execution is started. (4) The command in the next block is read. (5) Buffering is executed. That is, the command is decoded to allow immediate execution. (6) Immediately after the proceeding block is executed, the execution of the next block can be started because buffering has been executed. (7) Hereafter, automatic operation can be executed by repeating the steps (4) to (6). 3-18

66 3 OPERATION INSTRUCTION Block Skip BDT (1) ON: Depressed the push-button, button light will come ON. The function is active when the push-button is illuminated. The control will ignore any block containing a Slash code ( / ) when mode selector is in AUTO or MDI position. (2) OFF: Released the push-button, button light will turn OFF. When the push-button is not illuminated, the data block is executed, even any block containing a Slash code ( / ). For example: N1 G54; N2 G90 G81 X50.Z-20. R3.F100; / N3 X30.; ( Slash code is in front of the block ) N4 X10.; N5 G80; M30; Please refer to the FANUC Programming Manual for detail. 3-19

67 3 OPERATION INSTRUCTION Manual Absolute This ON/OFF soft-key selects whether the amount of manual movement is to be added to the absolute value. For example: : N001 G01 G90 X100.0 Y100.0 F1000 ; N002 X200.0 Y150.0; N003 X300.0 Y200.0; When block N002 has been executed after manual operation (X axis , Y axis ) at the end of movement of block N001. ( 220, 250 ) (1) ( 120, 200 ) Manual Absolute is OFF Manual Operation ( 200, 150 ) ( 100, 100 ) Manual Absolue is ON 3-20

68 3 OPERATION INSTRUCTION When the Feed Hold button is pressed while block N002 is being executed, manual operation (Y axis +75.0) is performed, and the cycle start button is pressed and released. Y (300, 275) Manual Absolute is OFF (200, 225) Manual Absolute is ON (2) Manual Operation (150, 200 ) (200, 150) (300, 200) (100, 100) (150, 125) When the Feed Hold button is pressed while block N002 is being executed, manual operation (X axis +75.0) is performed, the control unit is reset with RESET button, and block N002 is read again. ( 300, 275 ) Manual Absolute is OFF (3) Manual Operation ( 150, 200 ) ( 200, 225 ) Manual Absolute is ON ( 300, 200 ) ( 200, 150 ) ( 100, 100 ) 3-21

69 3 OPERATION INSTRUCTION (4) When there is only one axis in the following command, only the commanded axis returns. N1 G01 G90 X100.0 F500 ; N2 X200.0 ; N3 Y150.0; Manual absolute is ON Manual Operation Manual Absolute is OFF When the following commands are incremental commands, operation is the same as when the MANUAL ABSOLUTE push-button is OFF. NOTE: The following conditions will be happened when manual operation is performed during cutter radius compensation. (5) A.The MANUAL ABSOLUTE push-button is OFF and cutter compensation is being performed. After manual operation is performed with the Manual Absolute push-button in OFF position during cutter compensation, automatic operation is restarted then the tool moves parallel to the movement that would have been performed. If manual movement had not been performed, the amount of separation equals to the amount that was performed manually. Manual Absolute is OFF - Tool Path Tool Path Program Path Manual Operation 3-22

70 3 OPERATION INSTRUCTION B.The MANUAL ABSOLUTE push-button is ON and cutter radius compensation is being performed. Machine operation upon return to automatic operation after manual intervention with the manual absolute push-button in ON position during execution with an absolute command program in the cutter radius mode will be described. The vector, the remaining part of the current block and the beginning of the next block is shifted in parallel the amount of manual movement performed is included in the calculations of the vectors of the two blocks subsequent to the current block. This also applies when manual operation is performed during cornering. a. During block execution Program path (Absolute command) Example 1: Tool Path (before manual operation) Manual Operation Assume that the Feed Hold was applied at point PH while moving from PA to PB of programmed path PA, PB, and PC and that the tool was manually moved to PH'. The block end point PB moves to the point PB' by the amount of manual movement, and vectors VB1 and VB2 at PB also move to VB1' and VB2'. Vectors VC1 and VC2 between the next two blocks PB - PC and PC - PD are discarded and new vectors VC1' and VC2' (VC2' = VC2 in the example above) are produced from the relation between PB' - PC and PC - PD. However, since VB2' is not a newly calculated vector, correct offset is not performed at block PB' - PC. Offset is correctly performed after PC. 3-23

71 3 OPERATION INSTRUCTION Program Path (Absolute Command) Manual Operation Tool Path VA1' Example 2: This is an example when manual operation is performed during cutter radius cornering. VA2', VB1', and VB2' are vectors moved in parallel with VA2, VB1 and VB2 by the amount of manual movement. The new vectors are calculated from VC1 and VC2. Then correct cutter radius is performed for the blocks following PC. b. Manual operation was performed when execution of a block was terminated by single block stop. Manual Operation Tool Path Program Path (Absolute Command) Vectors VB1 and VB2 are shifted by the amount of manual operation. Sub-sequence processing is the same as case (a) described above. An MDI operation can also be intervened as well as manual operation. The movement is the same as that by manual operation. 3-24

72 3 OPERATION INSTRUCTION Program Restart This function specifies Sequence No. of a block to be restarted when a tool is broken down or when it is desired to restart machining operation after a day off, and restart the machining operation from that block. It can also be used as a high speed tape check function. A. When a tool is damaged (P type): a. Press Feed Hold to escape the tool, and replace it with a new one. Modify the offset amount if it varies. b. Press PRGRM to display the present program. c. Turn the Mode selector in Handle or Rapid position in order to move Z, Y, or X axis to change the tool. d. Depressed the Program Restart push-button on the machine control panel. The button light will come on. e. Find the program head, press RESET push-button during memory operation. Selected AUTO mode position and press O and. f. Press P Sequence No., and search the block with Sequence No. to be restarted. When the same sequence No. appears many times, for example, when the subprogram is accessed several times in searching Sequence No. in the subprogram, specify the frequency of a block with its sequence No. in upper 4 digits, and specify Sequence No. in lower 4 digits as illuminated below. P Frequency Sequence No. When the block is the first time, the upper 4 digits can be omitted. Further, the leading zero can be omitted expect Sequence No. when the frequency is specified. 3-25

73 3 OPERATION INSTRUCTION g. After completion of block search, the LCD screen is changed to the program restart screen. Please refer to the screen as below. (DESTINATION) shows the position where the machining operation is restarted. (DISTANCE TO GO) shows the distance between the current tool position and the machining restart position. The figure at the left side of the axis name shows the order (parameter setting) described later when the tool moves to the restart position. M...Shows M code commanded recently 35 times in the past. T...Shows T code commanded recently 2 times in the past. S...Shows S code command in the last. B...Shows B code command in the last. Display the most previously commanded code in the head. Each code is cleared with the program restart command and the cycle start command in reset conditions. h. Released Program Restart push-button, button light will turn off. At this time, the figure at the left side of axis name (DISTANCE TO GO) flickers as well as Restart message at the right side. i. Check the screen, and if M, S, T or B code should be output, select the MDI mode and output M, S, T or B code from MDI. Each code in this case is not displayed on the program restart screen. Selected Handle mode, push Spindle CW button to rotate which speed will be following the spindle speed executed by last block. j. During memory operation, select AUTO mode and check that the distance of DISTANCE TO GO is correct, and the tool does not hit the workpiece or others. If it is about to collide with an obstacle, move the tool manually to the location where it does not collide, then press CYCLE START button. At this time, the tool moves to the machining restart position in the Dry Run mode by one axis in the order set to the parameters No to 0127, thus restarting machining operation in succession. Manual Absolute button must be depressed all the time. 3-26

74 3 OPERATION INSTRUCTION PRPGRAM RESTART O0500 N0010 (DESTINATION) M X Y Z A *** *** *** *** *** *** (DISTANCE TO GO) *** *** *** *** *** 2 X Y T Z S A B ****** 14:32:15 AUTO RSTR PRGRM CURRNT NEXT CHECK RSTR B. When restarting machining operation after the following cases (Q type): 1. When power is turned OFF once. 2. When the emergency stop button is depressed once. When the coordinate system is changed after automatic operation is previously 3. stopped. For example: (a) When G92 was set from MDI. (b) When the coordinate system was shifted. (c) When the automatic coordinate system was set by the reference point return. (d) When the coordinate system was modified by "RESET". 3-27

75 3 OPERATION INSTRUCTION a. When power is turned ON or emergency stop is released, perform all necessary operations at that time, including the reference point return. b. Move the tool manually to the program starting point (machining start point), and keep the modal data and coordinate system in the same conditions as at the machining start. c. If necessary, set and modify the offset amount. d. Pressed the Program Restart push-button on the machine operator's panel. Button light will come ON. e. Press PRGRM to display the program. When it is not the specified one, search the specified program. f. g. Find the program head block. Press RESET During memory operation, select AUTO mode, and press O. Press Q "sequence NO." and search a block with Sequence No. to be re-started. When the same sequence No. appears many times, specify the frequency of a block with its sequence No. in upper 4 digits, and specify Sequence No. in lower 4 digits. h. i. j. Upon complete of block searching, the display on the LCD screen is changed to the Program Restart screen. Release the Program Restart push-button, this function will be ineffective. At this time, the figure at the left side of axis name (DISTANCE TO GO) blinks. Check the screen, and select the MDI mode if there are M, S, T or B codes to be specified, and output M, S, T or B codes from MDI, In this case, each code is not displayed on the program restart screen. k. During memory operation, return the operation mode to "AUTO" mode, check that the distance (DISTANCE TO GO) is corrected, and that the tool does nor hit against a work and others when moving to the machining restart position. If it is likely to hit against an obstacle, move the tool manually to the position where it does not collide, then press the CYCLE START button, At this time, the tool moves to the machining re-start position in the DRY RUN mode by one axis in the order preset to the parameters (No.0124 to 0127). For further details, please refer to the Section 4.5 PROGRAM RESTART of Chapter 4.AUTOMATIC OPERATION of FANUC OPERATOR S MANUAL Volume

76 3 OPERATION INSTRUCTION 3.5 Program Check and Test Machine Lock MLK This function is used to check a program. When Machine Lock mode is active (push-button is illuminated), move command pulses are inhibited. Consequently the position display is updated as specified by the program, but the tool does not move. The M, S, and T are executed. Note: When a G27, G28 or G30 command is specified, the tool does not go to the reference point and the reference point return completion led does not go on Z Axis Cancel Z ZLK When the PLC switch # 11 setting up at ON position, the Z axis will not be moved while machine at Manual/Auto operation. When the Z axis Cancel push-button is pressed, button is illuminated, an Z axis command can be ignored during Manual or AUTO operation. Position display up dates as if the axis were moving. To exit Z axis cancel, press push-button a second time, button lamp will lights out Dry Run DRN When the Dry Run push-button is pressed (button is illuminated) during in MDI or AUTO position, the Feed-rate specified by the program is ignored. G00 will kept the same as Rapid Feedrate, G01 will becomes as Max. Jog Feedrate by JOG Feedrate override switch control (P1410). To exit this function, press the push-button a second time, button lamp will lights out. 3-29

77 3 OPERATION INSTRUCTION Feedrate Override % mm/min 200 With this dial, it is possible to override the Feedrate designated by the program in MDI or AUTO mode. An override of 0 to 200 % can be applied to override all axes in G01 command. M48, M49 or Rigid Tapping function are always override 100%, this dial is not available Jog Override % mm/min 200 JOG mode is selected, X axis can be moved by pressing X+ momentary push-button (button is illuminated) that allows the operator to jog the X axis in the plus X direction with its Jog Override Feedrate. Axial movement will stopped by released the push-button. Depress X- push-button (button is illuminated) that allows the operator to jog the X axis in the minus X direction with its Jog Override Feedrate. Y, Z, 4th axes are the same as X axis procedure Rapid Override F % 100 The Rapid Override switch of 100%, 50%, 25% and F 0 is provided, when the rapid traverse rate is 18 m/min. and a G 00 is commanded in MDI or AUTO mode, this dial is set to 50%, actual rate becomes 9 m/min. F 0 is a constant value specified by the parameter. Rapid override is effective by the following functions: (1) by G00. (2) during canned cycle. (3) in G27 and G28. (4) Manual rapid traverse. (5) Rapid traverse in manual reference point return. 3-30

78 3 OPERATION INSTRUCTION Spindle Speed Override % The Spindle Speed Override switch allows the operator to modify programmed spindle speeds in steps of 10% from 50% to 120% during machine in MDI, AUTO or Dry Run mode. The actual spindle speed what you commanded can be seen on the LCD screen and displays current spindle speed at Spindle Speed meter. If commanded spindle speed is 2,000 RPM, set the Spindle Speed Override at 50%, the actual Spindle speed will be 1,000 RPM. 3-31

79 3 OPERATION INSTRUCTION 3.6 Tool Setting Tool Number Setting Initialization Tool Loading/Unloading & Tool Change Testing: WARNING MAKE SURE all items as mentioned below before tool loading at magazine. (1) Before your requested tools are put into the magazine, pre-check tool tips are in good condition and tighten and clean the tool holder. (2) The tool to be mounted should meet the specified specifications. (3) Tool magazine door must be closed all the time. Max. tool dia./adjacent (mm) BM-850 BM-1020 BM-1200 BM /150 90/150 90/150 90/150 Max. tool length (mm) Max. tool weight (kg) Max. tool dia./adjacent (mm) BM-1400 BM-1600 BM-1800 BM / / / /250 Max. tool length (mm) Max. tool weight (kg) Max. tool dia./adjacent (mm) Max. tool length (mm) 300 Max. tool weight (kg) 15 BM /

80 3 OPERATION INSTRUCTION WARNING MAKE SURE ALL FOLLOWING ITEMS MUST BE CORRECT BEFORE TOOL CHANGE. BE SURE that the tool number in the spindle and magazine are relative to each other. MAKE SURE that there is no tool in the tool pocket of the magazine when the tool is in the spindle. IF the spindle has been occupied by a tool, DO NOT modify the spindle tool number at the value of "0". The tool must be performed by dimension check, clean and tightened pull stud before spindle loading. WARNING Tool loading number must meet the required T# executed while tool table initialization. Following procedure is prohibited while tool initialization: Tool number initialization is no bigger than the maximum tool number of the machine. After tool initialization/modified, all process must be reconfirmed. The spindle tool number must be at the pocket where is empty in order to be sure that the tool returning back will not damage the tool magazine. 3-33

81 3 OPERATION INSTRUCTION A. Arm Type a. ATC Arm Type Tool Installation & Data Setting(18i-MB 10.4"LCD) 1. Push down the emergency stop button (Figure 3-1); Figure 3-1 Alarm message(18i-mb 10.4"LCD) 2. Press SYSTEM key; then push the soft key "PMC" to enter next screen (Figure 3-2); Figure 3-2 Parameter setting screen(18i-mb 10.4"LCD) 3-34

82 3. Press the soft key "PMCPRM" (Figure 3-3); 3 OPERATION INSTRUCTION Figure 3-3 PMC Control system screen(18i-mb 10.4"LCD) 4. Press the soft key "DATA" (Figure 3-4); Figure 3-4 PMCPRM screen(18i-mb 10.4"LCD) 3-35

83 5. Press down the soft key "G. DATA" (Figure 3-5); 3 OPERATION INSTRUCTION Figure 3-5 PMC DATA screen(18i-mb 10.4"LCD) (1) If the parameter K900#7 = 1, the figure 3-5, PMC DATA screen, is not displayed. (2) If the parameter K900#7 = 0, the figure 3-5, PMC DATA screen, is displayed. 6. When tools are dislocated or in the initial setup, it will need to reset the data values from address D0001~D0099 (Figure 3-6); Figure 3-6 PMC G. DATA screen 1(18i-MB 10.4"LCD) 3-36

84 3 OPERATION INSTRUCTION 7. During the initial installation, please make sure the initial values of the address D00101 to D00199 are tool state code. (Figure 3-7); Figure 3-7 PMC G. DATA screen 2(18i-MB 10.4"LCD) 8. If there are not the large diameter tools, set the initial values of D0201~D0216 are 0 (Figure 3-8); Figure 3-8 PMC G. DATA screen 3(18i-MB 10.4"LCD) 3-37

85 3 OPERATION INSTRUCTION 9. Setting the total pockets number of tool magazine in D0300 (Figure 3-9); Figure 3-9 PMC G. DATA screen 4(18i-MB 10.4"LCD) NOTE:Please turn the "ATC JOG" function on and turn it off while changing D Change to the COUNTR screen and rotate the tool magazine pocket to No.1 position. Setting C028[CURRENT]=0 (Figure 3-10); Figure 3-10 COUNTR screen(18i-mb 10.4"LCD) 3-38

86 3 OPERATION INSTRUCTION b. ATC Arm Type Tool Installation & Data Setting(0i-MD 8.4"LCD) 11. Push down the emergency stop button (Figure 3-11); Figure 3-11 Alarm message(0i-md 8.4"LCD) 12. Press SYSTEM key; then push the soft key "PMCMNT" to enter next screen (Figure 3-12); Figure 3-12 PMCMNT system screen(0i-md 8.4"LCD) 3-39

87 3 OPERATION INSTRUCTION 13. Press the soft key "DATA" (Figure 3-13); Figure 3-13 PMCMNT DATA screen(0i-md 8.4"LCD) 14. When tools are dislocated or in the initial setup, it will need to reset the data values from address D0001~D0099 (Figure 3-14); Figure 3-14 PMCMNT DATA screen 1(0i-MD 8.4"LCD) 3-40

88 3 OPERATION INSTRUCTION 15. During the initial installation, please make sure the initial values of the address D00101 to D00199 are tool state code. (Figure 3-15); Figure 3-15 PMC DATA screen 2(0i-MD 8.4"LCD) 16. If there are not the large diameter tools, set the initial values of D0201~D0216 are 0 (Figure 3-16); Figure 3-16 PMCMNT DATA screen 3(0i-MD 8.4"LCD) 3-41

89 3 OPERATION INSTRUCTION 17. Setting the total pockets number of tool magazine in D0300 (Figure 3-17); Figure 3-17 PMC DATA screen 4(0i-MD 8.4"LCD) NOTE:Please turn the "ATC JOG" function on and turn it off while changing D Change to the COUNTR screen and rotate the tool magazine pocket to No.1 position. Setting C028[CURRENT]=0 (Figure 3-18); Figure 3-18 COUNTR screen(0i-md 8.4"LCD) 3-42

90 3 OPERATION INSTRUCTION c. ATC Arm Type Tool Installation & Data Setting(0i-MD 10.4"LCD) 19. Push down the emergency stop button (Figure 3-19); Figure 3-19 Alarm message(0i-md 10.4"LCD) 20. Press SYSTEM key; then push the soft key "PMC MAINTE" to enter next screen (Figure 3-20); Figure 3-20 PMC MAINTE system screen(0i-md 10.4"LCD) 3-43

91 3 OPERATION INSTRUCTION 21. Press the soft key "DATA" (Figure 3-21); Figure 3-21 PMC MAINTE DATA screen(0i-md 10.4"LCD) 22. When tools are dislocated or in the initial setup, it will need to reset the data values from address D0001~D0099 (Figure 3-22); Figure 3-22 PMC MAINTE DATA screen 1(0i-MD 10.4"LCD) 3-44

92 3 OPERATION INSTRUCTION 23. During the initial installation, please make sure the initial values of the address D00101 to D00199 are tool state code. (Figure 3-23); Figure 3-23 PMC MAINTE DATA screen 2(0i-MD 10.4"LCD) 24. If there are not the large diameter tools, set the initial values of D0201~D0216 are 0 (Figure 3-24); Figure 3-24 PMC MAINTE DATA screen 3(0i-MD 10.4"LCD) 3-45

93 3 OPERATION INSTRUCTION 25. Setting the total pockets number of tool magazine in D0300 (Figure 3-25); Figure 3-25 PMC MAINTE DATA screen 4(0i-MD 10.4"LCD) NOTE:Please turn the "ATC JOG" function on and turn it off while changing D Change to the COUNTR screen and rotate the tool magazine pocket to No.1 position. Setting C028[CURRENT]=0 (Figure 3-26); Figure 3-26 COUNTR screen(0i-md 10.4"LCD) 3-46

94 3 OPERATION INSTRUCTION d. ATC Arm Type Tool Installation & Data Setting(31i-B 10.4"LCD) 27. Push down the emergency stop button (Figure 3-27); Figure 3-27 Alarm message(31i-b 10.4"LCD) 28. Press SYSTEM key; then push the soft key "PMC MAINTE" to enter next screen (Figure 3-28); Figure 3-28 PMC MAINTE system screen(31i-b 10.4"LCD) 3-47

95 3 OPERATION INSTRUCTION 29. Press the soft key "DATA" (Figure 3-29); Figure 3-29 PMC MAINTE DATA screen(31i-b 10.4"LCD) 30. When tools are dislocated or in the initial setup, it will need to reset the data values from address D0001~D0099 (Figure 3-30); Figure 3-30 PMC MAINTE DATA screen 1(31i-B 10.4"LCD) 3-48

96 3 OPERATION INSTRUCTION 31. During the initial installation, please make sure the initial values of the address D00101 to D00199 are tool state code. (Figure 3-31); Figure 3-31 PMC MAINTE DATA screen 2(31i-B 10.4"LCD) 32. If there are not the large diameter tools, set the initial values of D0201~D0216 are 0 (Figure 3-32); Figure 3-32 PMC MAINTE DATA screen 3(31i-B 10.4"LCD) 3-49

97 3 OPERATION INSTRUCTION 33. Setting the total pockets number of tool magazine in D0300 (Figure 3-33); Figure 3-33 PMC MAINTE DATA screen 4(31i-B 10.4"LCD) NOTE:Please turn the "ATC JOG" function on and turn it off while changing D Change to the COUNTR screen and rotate the tool magazine pocket to No.1 position. Setting C028[CURRENT]=0 (Figure 3-34); Figure 3-34 COUNTR screen(31i-b 10.4"LCD) 3-50

98 3 OPERATION INSTRUCTION Executing M6 T_ to install tools into magazine. NOTE: G.. DATA (NO) 0001~ (NO) 0099 = tool pocket number (DATA) 0001~ (DATA) 0099 = actual tool number (random) (DATA) 0101~ (DATA) 0199 = tool state code 33: standard tool (diameter: Φ79 mm) 66: large diameter tool (diameter: Ф80~ Ф100 mm) 99: forbid using this pocket 00 or 0:tool pocket is empty; it is preparative to install new tool (DATA) 0300 = the total of tool magazine pockets a. When (DATA) 0300 = 24; (DATA) 0201~ (DATA)0212 = the range of inputting large diameter tool numbers b. When (DATA) 0300 = 30; (DATA) 0201~ (DATA)0215 = the range of inputting large diameter tool numbers ADDRESS PRESET CURRENT C000 tool magazine pocket number present pocket number C028 tool magazine pocket number present spindle tool number Table 1. "COUNTR" 3-51

99 3 OPERATION INSTRUCTION Address Data D D D : : D : : D D D : : D : : D D : : D Table 2. "DATA" 1 Example1: The totality of tool magazine pockets: 24 All tools are in different normal size diameters. (Table 2 & Table 3) Address Preset Current C C Table 3. "COUNTR"

100 3 OPERATION INSTRUCTION Example2: The totality of tool magazine pockets: 24 No. 23 Pocket is a large diameter tool set. No. 22 & No. 24 must set the value in "0" state, because the No.23 pocket is set in a large diameter tool. (Table 4 & Table 5) Address Value D D D : : D D D : : D D : : D D D D : : D D : : D Table 4 "G. DATA" 2 No. 23 Pocket is a large diameter tool set. Address Preset Current C C Table 5 "COUNTR"

101 Address Value D D D : : D D D D D D D D : : D D D D D D D D D : : D Table 6 "G. DATA" 3 3 OPERATION INSTRUCTION Example3: The totality of tool magazine pockets: 24 There are two large diameter tools separately within 2 pockets: No.21 & No.23. No. 20, No.22 and No. 24 must set in "0" state, because each of No.21 and No.23 is set in a large diameter tool (Table 6 & Table 7). Address Preset Current C C Table 7 "COUNTR"

102 3 OPERATION INSTRUCTION CAUTION It can not be assigned the tool pockets in continuous numbers, if there are two large diameter tools or more in the magazine. The following table presents 5 conditions with the result: Large diameter tool pocket No. No.23, No.22, No.21 No.23, No.22, No.20 No.23, No.21, No.20 No.23, No.21, No.19 No.23, No.21, No.15 Result Wrong Wrong Wrong OK OK If there is one large diameter tool pocket defined; then we must set in "no using" pockets state for the both-side, last and next, pockets of the defined large diameter tool pocket. 3-55

103 e. ATC Arm Type Tool Magazine Adjustment 1. Magazine position adjustment: 3 OPERATION INSTRUCTION Remove the fixed teeth of spindle (Figure 3-35), and mark them to make for restoring to original position after completing the installation. Figure 3-35 Remove the fixed teeth 2. Install the gauge to spindle and arm separately (Figure 3-36). Figure 3-36 Install gauge 3-56

104 3 OPERATION INSTRUCTION 3. Use the tool wrench to manually change the arm (Figure 3-37) or turn on the ATC JOG function (18i-MB 10.4"LCD Figure 3-38, 0i-MD 8.4"LCD Figure 3-39, 0i-MD 10.4"LCD Figure 3-40, 31i-B 10.4"LCD Figure 3-41); then press the CYCLE STRAT button. Figure 3-37 Tool magazine Figure 3-38 Operator panel screen(18i-mb 10.4"LCD) 3-57

105 3 OPERATION INSTRUCTION Figure 3-39 Operator panel screen(0i-md 8.4"LCD) Figure 3-40 Operator panel screen(0i-md 10.4"LCD) 3-58

106 3 OPERATION INSTRUCTION Figure 3-41 Operator panel screen(31i-md 10.4"LCD) 3-59

107 3 OPERATION INSTRUCTION 4. Until the arm rotates to the side of spindle, use the tool to correct the center points are all in same position (Figure 3-42). Figure 3-42 Tool gauge 5. Make sure the magazine position and angle are correct, screw the nut, and then set 2 pins in each location (Figure 3-43). Figure 3-43 Magazine mounting plate 3-60

108 3 OPERATION INSTRUCTION 6. Clamp a tool in spindle (Figure 3-44). Figure 3-44 Tool is within spindle 7. Rotate the arm to catch the tool which is in spindle. Then, adjust spindle Z position to rotate the tool smoothly (Figure 3-45). Figure 3-45 Rotate tool 3-61

109 3 OPERATION INSTRUCTION 8. Switch to machine coordinate screen, at the Step 7 we need to lift Z axis up 0.5mm. Then, input this machine coordinate value to PARAMETER Figure 3-46 Parameter setting screen(18i-mb 10.4"LCD) Figure 3-47 Parameter setting screen(0i-md 8.4"LCD) 3-62

110 3 OPERATION INSTRUCTION Figure 3-48 Parameter setting screen(0i-md 10.4"LCD) Figure 3-49 Parameter setting screen(31i-b 10.4"LCD) 3-63

111 3 OPERATION INSTRUCTION 9. Set the spindle orientation angle: to 4095 in PARAMETER Figure 3-50 Parameter setting screen(18i-mb 10.4"LCD) Figure 3-51 Parameter setting screen(0i-md 8.4"LCD) 3-64

112 3 OPERATION INSTRUCTION Figure 3-52 Parameter setting screen(0i-md 10.4"LCD) Figure 3-53 Parameter setting screen(31i-b 10.4"LCD) 3-65

113 3 OPERATION INSTRUCTION f. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(18i-MB 10.4"LCD) 1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPR OPERATION S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON Figure 3-54 ATC JOG(18i-MB 10.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND POCKET TOOL) 3-66

114 3 OPERATION INSTRUCTION 2. MANUAL ARM CCW FOR OPERATION SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPR OPERATION S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS Figure 3-55 ATC JOG & CCW(18i-MB 10.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND PACKET TOOL) 3-67

115 3 OPERATION INSTRUCTION g. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(0i-MD 8.4"LCD) 1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPR OPERATION S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON Figure 3-56 ATC JOG(0i-MB 8.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND POCKET TOOL) 3-68

116 3 OPERATION INSTRUCTION 2. MANUAL ARM CCW FOR OPERATION SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPR OPERATION S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS Figure 3-57 ATC JOG & CCW(0i-MD 8.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND PACKET TOOL) 3-69

117 3 OPERATION INSTRUCTION h. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(0i-MD 10.4"LCD) 1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPERAT PANEL OPERATION S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON Figure 3-58 ATC JOG(0i-MD 10.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND POCKET TOOL) 3-70

118 3 OPERATION INSTRUCTION 2. MANUAL ARM CCW FOR OPERATION SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPERAT PANEL OPERATION S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS Figure 3-59 ATC JOG & CCW(0i-MD 10.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND PACKET TOOL) 3-71

119 3 OPERATION INSTRUCTION i. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(31i-B 10.4"LCD) 1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPERAT PANEL OPERATION S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON Figure 3-60 ATC JOG(31i-B 10.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND POCKET TOOL) 3-72

120 3 OPERATION INSTRUCTION 2. MANUAL ARM CCW FOR OPERATION SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPERAT PANEL OPERATION S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS Figure 3-61 ATC JOG & CCW(31i-B 10.4"LCD) (1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND PACKET TOOL) 3-73

121 3 OPERATION INSTRUCTION B. Drum Type 1. COUNTER SET: (1) PRESS [SYSTEM] (2) [PMC] (3) [PMCPRM] (4) [COUNTR] NO. ADDRESS PRESET CURRENT 1 C000 # * 2 C C C C C C C C C #AMOUNT OF TOOL *CURRENT TOOL POT NO. 2. G-DATA SET: (1) PRESS [SYSTEM] (2) [PMC] (3) [PMCPRM] (4) [COUNTR] (5) [DATA] (6) [G-DATA] NO. ADDRESS DATA 0 D D D D D D D D0017 =SPINDLE TOOL NUMBER 3-74

122 3 OPERATION INSTRUCTION 1. It is necessary to make sure all tool pockets are empty. 2. Set spindle tool number in DATA of address D0010. The spindle tool number can not be 0. NO. ADDRESS DATA 0 D D D D D D D D0017 =SPINDLE TOOL NUMBER 3. If tool pocket number 1 is at the ready position, press the tool magazine index forward push-button, tool pocket number 1 will move forward and tool pocket number 2 will at the ready position. Pressing the tool magazine index reverse push-button, tool pocket number 2 will move backward and tool pocket number 1 will at the ready position. 4. Set 20 in # if there are 20 tools. Set 1 in *if the tool pocket number 1 is at the ready position. NO. ADDRESS PRESET CURRENT 1 C000 # * 2 C C C C C C C C C #AMOUNT OF TOOL *CURRENT TOOL POT NO. 3-75

123 3 OPERATION INSTRUCTION 5. Key in M06T1 then make sure HD.T=1 and NX.T=1 displayed as the following screen. Figure 3-62 M6T1(18i-MB 10.4"LCD) Figure 3-63 M6T1(0i-MD 8.4"LCD) 3-76