1. Startup procedure

Transcription

1 Training Syllabus Training Overview: This class will teach you basic operation of your NEW CNC Router. It is a hands -on class for operators as well as programmers. SAFTEY FIRST!!! WEAR SAFTEY GLASSES WHEN CLEANING OR RUNNING THE MACHINE. MAKE SURE THE POWER IS OFF WHEN CLEANING THE MACHINE. 1. Startup procedure 1.1. Check the utilities Compressed air. The main air inlet to the machine is in the back. The pressure must register at least 90 psi. There is a low pressure monitor alarm should the air pressure drop below the necessary level Electrical. Make sure the main power to the machine is on, the green power on button will be lit Controller Turn on the monitor by pressing the GREEN button in the upper left corner above the monitor One of the first screens you will encounter is the boot mode directive. It is not necessary to take any action on this page, however if you click the green gear (boot in normal mode) the boot process will be sped up dramatically.

2 1.2.3.Note that the control will be in Emergency Stop when first powered on and alarm message will be displayed Power Up the machine Release the RED E-stop button on the control panel (above and to the right of the monitor) by rotating it clockwise ¼ turn, it will pop out Locate the E-STOP RESET on the screen, and use the mouse to click it. Note all clicks use the LEFT mouse button. Wait about 5 seconds to allow the system to energize.

3 1.3.3.Note that there will be an alarm message telling you that the Axes Not Referenced Home the machine Locate the Find Zero button on the main screen, and using the mouse, click it The home position is UP, FORWARD, LEFT. The Z (up /down) axis will always move first, traveling up to the home (or zero) position. Next the X,Y and A (if equipped) will all seek their home or zero locations Locate and click the AXES + SPINDLE button.

4 1.4.4.Locate and click the Jog Button if it is not already highlighted Make sure the jog keys are blackened (below RIGHT) Next note the direction decals on the machine. X moves the spindle left and right. Y moves the entire bridge forward and backward. Z moves the spindle up and down. CAUTION: THE MACHINE, AND ESPECIALLY THE Y AXIS WILL COAST EVEN AFTER THE BUTTON IS RELEASED.

5 1.4.7.The speed of the movement is determined by the FEED RATE OVER RIDE PERCENT Adjust the feed rate with the Feedrate + and Feedrate buttons. One click = 5% 2. Mounting the tools Cleanliness is next to good-ly-ness 2.1. CLEAN EVERYTHING EVERYTIME! 2.2. Match the collet size with the tool shank. Collets only go smaller from nominal size, never larger Mount the collet into the collet nut (without tool) using a rocking motion Thread the collet nut on the tool holder 2.5. Set the tool so that the top of the flute is just above the face of the collet face 2.6. Tighten securely 2.7. Load the tools in the tool rack in the appropriate location NOTE the location must match with the part program. BE CAREFUL to load into the proper place. 2.8 Before any other programs are run, first you must run the spindle warm up program. This program is designed to get the spindle to a safe operating condition through the process of continuously ramping up the spindle speed to warm up the ceramic bearings in the spindle. 2.9 NOTE: when running this program you should have an empty tool holder in the spindle with NO COLLET, NO COLLET NUT, and NO TOOL. 3.0 NOTE: at the beginning of this program you will not hear the spindle turning due to a lower speed of rotation, however the spindle WILL BE TURNING. At no point during the warm up should you place your hands anywhere near the spindle.

6 3.1 Refer to figure 7. If you are not familiar with loading a program. 3. Learn how to change tools. T# M Start from the MAIN screen If you are on the Axes + Spindle screen, locate and click the MAIN button AUTO TOOL CHANGE 3 POINT CHECK Verify that the tool in the spindle and the Tool number in the control and empty place in the tool carousel all agree. (If not see section 4 subsection.8 for M106 command) 3.3. Locate and click the MDI Button In the MDI field type T1 M6 (where T1 = tool 1, T2 = tool2, T3 = tool 3 etc.) and press ENTER on the keyboard. ALL LETTERS MUST UPPER CASE, SET THE KEYBORD TO CAP LOCKS.

7 3.5. Press the cycle Start Button 4. Manual tool change Raise the dust hood by pressing the dust hood button Locate the manual tool change button on the left side of the spindle.

8 4.3. VERIFY WITH YOUR EYES THAT THE SPINDLE IS STOPPED. NEVER EVER PUT YOUR HAND UNDER THE DUST HOOD WITHOUT LOOKING FIRST Hold the tool firmly with one hand and press the tool release button with the other. The tool will release with a firm knock out Next hold the new tool in one hand and put it near the empty spindle nose Press the tool change button and load the tool.

9 4.7. Next select the MDI button 4.8. In the MDI field type M106 T# where # = the tool number (i.e. 1 for tool 1, 2 for tool 2, etc) (e.g. M106 T1), then ENTER. As with all MDI commands press Cycle Start to run the code Once again, it is always a good idea to make sure that the tool in your spindle matches the tool in your program and also the number on the carousel associated with that tool. 5. Qualify (Measure) the tool length. M401 T# 5.1. Place the TTO at the designated spot 5.2. Always make sure that the bottom of your TTO as well as its respective place on the machine are clean and free of dust, metal, etc. this ensures an accurate measurement.

10 5.3. go to your main screen and look above the dust hood operation button for the button labeled Tool Offsets 5.4. This Button will bring you to the Qualified Tool Measure screen where you are given the option to measure a single tool. Or you can choose to measure multiple tools with the ALL button.

11 As seen in the picture above, the user has chosen to measure all tools 1-3 and you will notice that once the measure button in the center of the screen has been clicked it will become green during the operation. NOTE: As always make sure that the TTO is on the machine before you begin your measure. 6. Set the UAO (work piece zero) User Absolute Origin. (UAO,#) Note: In order to successfully set the UAO, you must FIRST measure all the tools you wish to use starting with tool #1. SECOND you MUST set your UAO with tool #1, even if you do not intend to use tool # Go to the Axes + Spindle screen Move the machine, using the Jog keys, so that the CENTERLINE of the tool is within 12 inches of the Zero point In order to move in a more controlled manner, activate the MPG by pressing the button and note the message Make sure the VACUUM IS ON, as it will affect the Z position.

12 Turn on the power to the pump(s) Turn on the vacuum flow valve Now hold the MPG and set the axis and increment to move the machine to the exact location of the ZERO Now exit MPG mode by pressing any other mode button (jog pictured below) Select the Origin/Tool at the top of the screen and click on Origin preset

13 6.3. Type the Origin number (1~100) and the origin values (zero) in X,Y,Z and A fields and click OK when finished. NOTE you may want to only set the Z axis to zero, in this case leave the other fields empty Return to the Main screen 6.5. Press the MDI button

14 6.6. Type (UAO,α) where α = the number of the UAO that you want enable (1~100). (eg (UAO,1) will enable UAO #1). The origin will be displayed as below Test the Work Coordinates- Make sure there is an active UAO (see 5.2) Make sure that the tool offset is active. The number in the Tool and Offs MUST MATCH Bring up the MDI box and type G1 X0 Y0 Z0 F100 and PRESS ENTER Prior to selecting cycle start, it is a good idea to turn your feed rate down to a low number, for example 10% to give you adequate time to hit the emergency stop if the machine does not move where you intend it to Press the cycle start button to move the machine to the set zero point You may tool change to a different tool and test the length setting. 7. Load a program into the CNC Plug your USB memory stick into the cable

15 7.2. Click the Part Program, then Part Program Management 7.3. Next click your USB stick from the list on the LEFT 7.4. Click the program you wish to run from the list on the RIGHT. For example Perimeter cut is the program pictured below Highlight the program you wish to run and using the right click button on your mouse. When the drop down menu appears click copy to copy the program Next click the program menu which is located directly above your USB menu. Right click it and when prompted by the drop down menu click paste. This will move your program from the USB stick to the computer in the CNC machine In order to be able to view the program you just loaded into the computer you must click away from the program screen and then click back to it. The program will now be visible in the drop down menu Next highlight the program you have just uploaded to the computer.

16 7.9. Now click the Activate Part icon at the top of the window. 8. Test your programs with an MPG Prove Out 8.1. The MPG prove out function allows you to run your program at varying speeds determined by how quickly you turn the dial on the handwheel, if you stop turning the handwheel your program will immediately stop. This tool becomes very useful when you want to check things like the depth of your cut, start points, length, height, width of your program, etc In order to complete an MPG Prove Out, first load the program you would like to run and make sure your machine is homed and your UAO and TTO heights have been set. Once completed go to your main screen and locate the auto button Next locate the mpg prove out button and activate it (To the left of the find zero button).

17 8.4. Once active, you will be prompted with the message 016 Caution! MPG Proveout Active 8.5. Make sure that your tool is not touching the table and click the green cycle start button. This will begin your program (caution, once you click start it will go to and run the first line of your program, usually a spindle power on code) 8.6. From this point on your program will run only when the handwheel is being turned, if you wish to run the program normally after you are satisfied with your prove out, simply click the proveout button again and it will put the machine back into normal operating mode NOTE: if you un-click the proveout function during a program the feed rate will remain at 0% until you manually turn it up with your feed rate override buttons. 9. Machine Shut Down 9.1. Execute an ATC command (e.g. M6 T1) to place a tool in the spindle if there is already not one loaded. It is important to leave a tool in your spindle when the machine is not being operated to prevent dust intrusion Next you will depress the Emergency Stop Button on your control cabinet Once you have completed these steps you are safe to click the Off button on your control cabinet above the screen. Congratulations! You have successfully run your New CNC Router. 10. Maintenance & Lubrication schedule LOCK OUT THE POWER SO THAT IT CAN NOT BE TURNED ON DURING CLEANING. PROTECT YOURSELF FROM THE LUBRICANTS DURNIG APPLICATION BY WEARING RUBBER GLOVES Daily with power off and air disconnected Bleed and check compressed air separator Inspect & Clean wire ways for debris Clean and inspect keyboard and mouse using light compressed air Clean dust away from the rails, gear rack, Spindle, tool holders and ATC mechanism with compressed air. Keep a tool holder in the spindle during cleaning. NEVER blow compressed inside the spindle!

18 10.3. Daily with power on Run the spindle warm up program each morning before starting production Weekly with power off Clean and inspect spindle nose with clean soft rag. NEVER use compressed air! Clean cabinet cooler inlet by directing compressed air alternately into the inlet and exhaust side of the cooler Lubricate the three rack and pinions, one on top of the bridge and one on either side of the base. Start by using a clean rag and compressed air hose to clean any debris from the rack, then reapply a thin film of new lube. Wipe away excess immediately Gear lube Part # 1254K Lubricate the ATC cam using the gear lube spray Clean the Z axis drip tray of excess oil using a cloth Every two weeks with the power off and air disconnected Clean the Vacuum inlet filters. Make sure to not allow dust to enter the pump during cleaning. Use compressed air to clean Every two weeks with the power on Clean and inspect tool holders and spray with dry film lubricant. If you see nicks or dents on the mounting surfaces, do NOT use the holders. They must be replaced Tool holder release spray. Item # 4JB m_mmc=ppc:googlepla-_-lubrication-_-lubricants-_- 4JB33&ci_src= &ci_sku=4JB33&ef_id=UxNYEgAAAMZqHUqy: :s Monthly with the power on Lubricate dust hood slide with dry gear spray Inspect and adjust movement of dust hood Clean spindle nose and lube spindle drawbar. (You MUST use the recommended grease to keep your warranty in effect.) Remove tool holder and clean the spindle nose with a clean, soft rag and acetone. Then disconnect the air line on the TOP RIGHT of the spindle. Then Insert the pipe of the spray can into each the slots between the segments of the collet and, spray a small amount of grease. Do not over grease. Replace hose to top right air inlet on the spindle. Replace empty tool holder to nose of spindle. Run the spindle for 1 minute at 12,000 rpm. Then clean any excess grease from tool holder and spindle nose Video Link Special drawbar grease.

19 Quarterly Vacuum inside of control cabinet Annual Replace worn or broken ATC fingers Replace dust brushes Inspect dust hose for wear, replace as needed Lube vacuum pump with the grease gun provided. 7.5-horse power vacuum pumps require 15 grams of grease/60 pumps of the grease gun for EACH of the 2 ports every 2000 hours. 10-horse power vacuum pumps require 45 grams of grease/180 pumps of the grease gun for EACH of the 2 ports every 2000 hours. Grease can be found at the following site: ?gclid=CjwKEAiA9JW2BRDxtaq2ruDg22oSJACgtTxcr-_E1iZ50_EiAt-Elm- M4pTDCT7NzDztc3vXp_-vSxoCPiXw_wcB For directions on filling your grease gun please visit the link to youtube below: Every 2 Years Replace the X and Y axis drive belt Bearing lubrication schedule: When pumping bearings, EACH PUMP of the grease gun should take 20 seconds from start to finish. If you try to do this quicker you will break your grease lines or the grease line fittings. 4 pumps weekly to: (4) Y-axis lubrication points 2 pumps weekly to: (4) X-axis lubrication points Ball Screw lubrication point 1 pump weekly to: (4) Z-axis lubrication points 1 pump monthly to: ATC lubrication point 1 pump every 3 months (4) drill bank rail bearings Talking Points/ Becoming a better operator: -gasketing your table -plane your table -making gasketed fixtures

20 -return to profile during program -resume program in mpg proveout -cutting different materials -setting up your shop correctly -know your tooling -setting origins at the top vs bottom of material -utilizing your software