VERTICAL MACHINING CENTER OPERATION MANUAL I-SERIES-CAM

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1 VERTICAL MACHINING CENTER OPERATION MANUAL I-SERIES-CAM

2 07.10,2010 FANUC 18M,0I,18I,21I 1. PREFACE INSTALLATION AND POWER ON INPUT POWER ON SPECIFICATIONS OF ELECTRICAL UNITS STEPS FOR MAIN POWER ON OPERATOR PANEL MDI PANEL DESCRIPTION SOFTWARE PANEL DESCRIPTION MACHINE OPERATOR PANEL MANUAL OPERATION MANUAL HOME POSITION RETURN MANUAL MOVEMENT OF 3-AXES OPERATION OF SPINDLE CLAMP / UNCLAMP MANUAL MAGAZINE OPERATION SPINDLE OPERATION EXPLANATION OF ATC HYDRAULIC TYPE ATC CAM TYPE ATC EXPLANATION OF OTHER INSTALLATIONS AUTO LUBRICATOR OPERATION AND RELATED SETTINGS COOLER UNIT HYDRAULIC UNIT (HYD.) CHIP CONVEYOR (CHIP) WORK LIGHT / ALARM LIGHT AUXILIARY FUNCTIONS M CODE EXPLANATION PLC SETTING TIMER SETTINGS KEEP RELAY SETTING SETTING MODIFICATION TROUBLESHOOTING AUTO RE-REGISTERING TOOL NUMBER (M23) LARGER TOOL MANAGEMENT SPECIAL CUSTOMIZED FUNCTION

3 1. PREFACE This manual describes the operation, basic machining procedures and troubleshooting of SHARP vertical machining center. It also includes details for the CNC control, like auxiliary function for M code, sequence for operation and PLC settings like timer and keep relay. The programming of the CNC control can be found in a separate manual, along with the service manual. The function of vertical machining center is not solely decided by machine tool company, because the CNC control and servo system also have serious influence. In this manual we have described as much as possible all the various functions. Therefore, functions which are not provided in your machine may be optional functions. Do not modify the machine designing or add any electric device without our permission, otherwise it may cause serious problem. Notes: 1. The programming and maintenance of CNC: please refer to the programming and maintenance manual of FANUC. 2. The installation and points for attention of machine: please refer to installation manual of SHARP. 1-1

4 2. INSTALLATION AND POWER ON When connecting the electric power to the cabinet, the user must use a transformer to switch the voltage because the interior operation of the cabinet is AC220V. In accordance with the local voltage specification Please refer to the diagram Fig.2-1 for connection instruction. Please connect the power to the Input terminal of transformer where the opposite voltage is and then connect the Output terminal (AC220V) to the NFB of the electrical cabinet. Fig

5 2.1 INPUT POWER ON Connect the power-on cables as show in Fig.2-2 SHARP MACHINERY CO.,LTD Note: Please make sure to power-off when connecting the power cables, and to cover lid when connection is completed. Be sure to have ground connection to prevent the noise on the NC unit. Fig

6 2.2 SPECIFICATIONS OF ELECTRICAL UNITS VMC - 650~1200 AC220V 60HZ 10% 3PHASE supply wire 8m 2 VMC ~21100 AC220V 60HZ 10% 3PHASE supply wire 14m 2 VMC - 650~1200 distribution of consumption: AC220v MAIN POWER SWITCH 75A 75(A) AC220v 9.7(A) 34(A) 0.1(A) 6.5(A) 0.28(A) 4.2(A) 0.1(A) TRANSFORMER SPINDLE MOTOR OIL LUBRICATOR HYDRAULIC UNIT HEAT EXCHANGE ON CABINET SPINDLE COOLER SYSTEM MOTOR FAN AC110V AC110V 16.2(A) 1.4(A) 8.2(A) (1.5A) CONTROL POWER SEVO MOTORS FOR 3-AXES COOLANT PUMP POWER OUTPUT Control power 4 SOL + 15 relay + 1 work light + 1 revolving lamp Non-fuse breaker Transformer: a N1/n2 V1/V2 220/ a = I2/I1 9.7/I1 I1 4.85(A) 4.85(A) 220(V) 1067(VA) P.S.: If input voltage is 380V, please use 23KVA transformer. 2-3

7 VMC ~21100 distribution of consumption: AC220V MAIN POWER SWITCH 75A 96.18(A) AC220V 9.7(A) 53(A) 0.1(A) 6.5(A) 0.28(A) 4.2(A) 0.1(A) TRANSFORMER SPINDLE MOTOR OIL LUBRICATOR HYDRAULIC UNIT HEAT EXCHANGE ON CABINT SPINDLE COOLER SYSTEM COOL SYSTEM FAN AC110V AC24V 22.2(A) 1.4(A) 8.2(A) (1.5A) CONTROL POWER SERVO MOTORS FOR 3-AXES COOLANT PUMP POWER OUTPUT Control power 4 SOL + 15 relay + 1 work light + 1 revolving lamp Non-fuse breaker Transformer: a N1/N2 V1/V2 220/ a I2/I1 9.7/I1 I1 4.85(A) 4.85(A) 220(V) 1067(VA) P.S.: If input voltage is 380V, please use 30KVA transformer. 2-4

8 2.3 STEPS FOR MAIN POWER ON 2-5 SHARP MACHINERY CO.,LTD Please use multi-meter to check if R.S.T. phases are shorted to ground connection; if the machine oil tube is correct; and if the emergency stop button is pressed down, (located on operator panel). Be sure all those items that we mentioned are done, and then turn main power ON. In this time the transformer, the fan and the servo amp. must be in stand-by state. You will see the power light ON which is displayed on the operator s panel. After that please follow the step to turn main power ON: (1) Press power ON push button that is located on the operator panel. (2) NC power ON. (3) NC starts and screen on (that indicates an alarm message of EMG Stop). If there is other alarm signal displayed in screen at this time. Please refer to alarm list of electric circuit. If NC alarm, then refer to operator s manual of NC. When releasing emergency stop button, there should be no alarm message on screen. And you could hear the noise of hydraulic unit pump working. If the hydraulic pressure does not increase, it means that phase of the input power is wrong (please see Fig.2-1). Please turn power OFF and exchange R and S phase then it will be restored. Before dispatch all the axes, especially Z-axis, are secured to avoid displacement during delivery. After finishing power connection, be careful to remove all fixtures and move all axes back to home position (reference). No matter starting or stopping the machine, the NC has to be on EMG status. It means that when you turn Power ON, start NC first, then release EMG; and press EMG first, then stop NC before you turn power OFF. After you success to power ON at the first time, you have to remove all firmer, level the machine and test each-function one by one during this time to avoid some unknown damage from delivery. If there are any question for main power ON please contact with us or our agent. After power ON, please check the following items: (1) If each-axis has a normal electrical current consumption? (2) If oil lubricator is consuming oil and working normally? (3) If spindle orientation is correct? (4) If Z-axis tool change position is correct? (5) If ATC and magazine are working correctly? (6) If low / high gear changes smoothly. (7) Check other function like chip conveyor, coolant, work light, status light, electrical solenoids

9 3. OPERATOR PANEL The operator panel is divided into two areas; the upper area is controller operator panel for display and MDI, and bottom area is the machine operator panel. 3.1 DISPLAY AND MDI PANEL Below is the description of the controller operator panel: 8.4 Color LCD/MDI (Standard type, sheet key) FANUC 18MC 8.4 COLOR LCD/MDI 3-1

10 10.4 Color LCD/MDI (Standard type, sheet key) SHARP MACHINERY CO.,LTD FANUC 18IB, 21IB 10.4 LCD/MDI 3-2

11 FANUC 0I-C (Standard type, sheet key) SHARP MACHINERY CO.,LTD FANUC 0I-C 8.4 LCD/MDI 7.2 LCD/MDI 3-3

12 FANUC 0i-D 10.4 LCD/MDI 3-4

13 3.1.1 MDI PANEL DESCRIPTION Item Description Function 1 Power ON/OFF key Press this buttons to turn CNC ON and OFF ON OFF 2 Reset key Press this key to reset the CNC, to cancel an alarm, etc. RESET 3 Help key Press this key to use the help function when uncertain HELP about the operation of an MDI key. (help function) 4 Soft key The soft key has various functions, according to the Applications. The soft key functions are displayed at the bottom of the CRT screen. 5 Address and numeric keys Press these keys to input alphabetic, numeric, and other characters. 6 7 Shift key SHIFT Input key INPUT Some key have two characters printed on their key top. Pressing the (SHIFT) key switches between them. Then the function indicated at the bottom right corner and the key can be entered. When an alphanumerical key is pressed, the data is input to the buffer, and it is displayed on the CRT screen. To copy the data register input tool offset memory by pressing INPUT key. This key is same as INPUT key of the soft keys, and either one can be pressed to produce the same result. 8 Cancel key Press this key to delete the last character or symbol. CAN 3-5

14 SHARP MACHINERY CO.,LTD 9 Program edit keys Press these keys when editing the program ALTER INSRT DELET ALTER INSRT DELET : Alteration : Insertion : Deletion 10 Function keys Press theses keys to switch display screens for each function. POS PROG : Press this key to display the position screen. : Press this key to display the program screen OFFSET SETTING SYSTEM : Press this key to display the offset/setting screen : Press this key to display the system screen MESSAGE GRAPH CUSTOM :Press this key to display the message screen : Press this key to display the graphics screen : Press this key to display the custom screen (conversational macro screen) 11 Cursor move keys There are four different cursor move keys: :This key is used to move the cursor to the right direction in a character distance :This key is used to move the cursor to the left direction in a character distance :This key is used to move the cursor to the upward direction in a character distance :This key is used to move the cursor to the downward direction in a character distance 12 Page change keys : This key is used to changeover the page on PAGE the CRT screen in the forward direction. PAGE : This key is used to changeover the page on the CRT screen in the backward direction. 3-6

15 3.2 SOFTWARE PANEL DESCRIPTION Push MDI board. To OFFSETS SETTING function button displayed OFFSET SETTING WORK OPR OPR to get into the screen of software operator panel. PAGE OPERATOR PANEL M/C LOCK : OFF ON DNC MODE : OFF ON MEMO KEY : OFF ON AUX LOCK : OFF ON PRO RESET : OFF ON MAN ABS : OFF ON HD.INT : OFF ON 4TH PASS : OFF ON ACTUAL POSITION (ABSOLUTE) X Y Z SO TO HAN MACRO SETTING OPR The functions of the software operator panel are as shown below: Operated mode ON OFF by cursor move key to select (1) M/C LOCK When the switch is set to ON position, the coordinate value will vary in machine screen, but the 3 axes will not move. (NOTE: X, Y, Z axes must take reference position after OFF). (2) DNC MODE During the DNC operation mode (REMOTE), it is possible to perform machining (DNC operation) while a program is being read in via reader/puncher interface, or remote buffer. The program won t save in the control s memory. (3) MEMO KEY Please set memory protect key to ON when you add, input, modify or delete program at EDIT mode, even input or modify parameter at MDI mode. (4) AUX LOCK When the switch is set to ON position the M.S.T.A.B code will be directly by-passed and skip to next block. (5) PRO RESET Program restart (Option, please see FANUC S SERIES 0-MC OPERATOR MANUAL). 3-7

16 +4 -Y +Z -4 +Y -Z OPT2 OPT3 OPT4 OPT5 SHARP MACHINERY CO.,LTD (6) MAN ABS This switch decides whether the amount of manual movement is to be added to the absolute value. (Suggestion: Keep the switch ON, otherwise the workpiece reference position may be wrong.) (7) HANDLE INSERTS (HD.INT): In any mode, the MPG can control any of the 3-axes movement by turnig the handwheel. (8) 4, 5 AXIS BYPASSING(4NG):OFF indicates use of the 4/5 axis. ON indicate neglect of the function for 4/5axis. 3.3 MACHINE OPERATOR PANEL This section is to explain the function of every button and switch of machine operator panel. +X -X 3-8

17 (1) POWER ON: This button turns the NC power ON. (2) POWER OFF: This button turns the NC power OFF. (3) EMERGENCY STOP: This button stops all machine motion in emergency. To release it, turn it clockwise. (4) EMG RELEASE: This button prevents the over travel from wrong setting of software limits or over travel situation of machine from wrong operation. When it works, the indicate light will on and all motion are the same as E-STOP condition. The step of release: A: Check which axis (X, Y, Z) was over traveled. B: Select HANDLE mode. C: Turn the axis switch to the over-traveled axis from hand wheel box, and press this button in the meanwhile. D: Press reset key to eliminate ALARM message, then re-execute 3-axes home position (reference). (5) MODE SELECT: This switch is used to specify an operation mode. Below is the explanation of each mode: AUTO: AUTO MDI EDIT EDIT: This mode is used to register, modify, add or delete of program and link personal computer to transfer parameter or program. M.D.I.: This mode can execute the command in register. This mode is used to execute a program stored in memory. 3-9

18 HANDLE: This mode can control 3-axes movement by turning hand wheel. The movement can be adjusted by incremental selector. JOG: In this mode, program of axis is controlled by FEEDRATE OVERRIDE and JOG FEEDRATE and the feed rate is displayed on operator panel. RPD: This mode is used to move axis in rapid traverse and the speed is adjusted by RAPID OVERRIDE %. ZER: This mode is used to return 3-axes to machine zero (home position) and the speed is adjusted by RAPID OVERRIDE %. (6) CYCLE START: Press this button, to start a program in auto mode and the lamp lights during the programmed operation. The function of CYCLE START for the following mode: AUTO MODE: To continue executing program. MDI MODE: To executed the input program of MDI. ZER MODE: To return 3-axes zero simultaneously. SINGLE BLOCK MODE: To execute one block only. (7) FEED HOLD: When this button is pressed, the program will pause automatically. Please notice the following situation: Rigid tapping: FEED HOLD is not performed until tapping cycle is finished. FEED HOLD : Could only stop the feed of 3-axes. (8) SPINDLE CLOCKWISE (M03): In handle mode, it will start spindle clockwise by pressing this button and the speed will be decided by the S command in the register (NC power ON must execute S command to use on MDI mode) (9) SPINDLE COUNTER CLOCKWISE (M04): In handle mode, it will start spindle counter clockwise direction by pressing this button, and the speed will be decided by the S command in the register. (NC power ON must execute S command to use on MDI mode) (10) SPINDLE STOP (M05): To stop spindle by pressing the switch, if not in HANDLE mode, press RESET key to stop spindle. 3-10

19 (11) ORIENTATION: This switch will move the spindle to the orient position and then lock the spindle. To cancel the orientation, press M05. (12) COOLANT: To switch ON/OFF coolant pump. If safe door was opened or under maintenance mode, this button will be no functional. (13) WORK LIGHT: To switch ON/OFF work light. (14) Z-AXIS LOCK: This function will lock Z-axis, the coordinate value of Z-axis still varies on screen. After release, Z-axis has to return zero. This button should be pressed at least 3 seconds for function activation or release. (15) DRY RUN: When this button is ON, the feed and rapid traverse do not work, all movement is controlled by FEEDRATE OVERRIDE & JOG FEEDRATE. (16) SINGLE BLOCK: When the button is ON, the controller will execute one block only and stop AUTO and MDI mode. (17) BLOCK SKIP: When this button is ON, all block with slash / are ignored. (18) OPTION STOP: When this button is ON, the M01 code will work, the optional-stop will not be performed with only M01 code or with only this button on. 3-11

20 (19) CHIP CVYR: To switch ON/OFF chip conveyor. If safe door was opened or under maintenance mode, this button will be + press switch to function. (20) AUTO POWER OFF: When this button is ON, the main power of the machine will be switched OFF after executing M30 or M02 command. (21) AXIS FEED DIRECTION: There are X, Y, Z, 4-4 sets axis feed direction +4 -Y +Z +X -X that can be chosen. (To perform rapid traverse push AXIS FEED DIRECTION and RAPID button simultaneously). -4 +Y -Z OPT2 (22) INDEX: Push this button once for magazine rotating one step, hold this button for continuous rotation. ( INDEX can only make a clockwise turn. If safe door was opened or under maintenance mode, this button will be + press switch to function. (23) 1.SP TOOL / 0.STAND-BY TOOL: When this button is OFF, tool number of the stand-by tool will be displayed at the tool number indicator. Otherwise the tool number of spindle tool will be shown. (24) RAPID OVERRIDE %: To adjust the rapid travel speed, it is available in the following modes: % a. Rapid travels of G00/G08/G30/G60 and canned cycle. b. The movement of RAPID & ZER mode. (25) JOG FEEDRATE & FEEDRATE OVERRIDE % % x mm/min In manual mode movement: (a) Available in JOG & RUN mode (b) Range: mm/min In RAPID and ZER modes movement: (a) Available to F command that exists in program (b) Available range: 0-200% (c) Unavailable in tapping cycle. 3-12

21 (26) SPINDLE OVERRIDE %: It can be adjusted in any mode. x % min The range is: 50%-120% (27) SPINDLE LOAD %: To display the actual load of spindle motor. Please pay attention when LOAD METER is over 120% (28) TOOL NO.: This indicator displays the number of SP TOOL or STAND-BY TOOL. (29) MAIN POWER LIGHT (L1): To indicate the main power is ON (The main power switch is located on the right side of machine). 4 (30) ATC STAND-BY: The ATC does not work when the lamp does not light. When ATC works, the lamp won t light. The lamp lights when all the status of ATC are OK. 4 (31) 4-AXIS UNCLAMP: To indicate the 4th-axis is unclamped and can be operated. (The lamp does not light when there is no 4th-axis)

22 (32) LUB ALARM: It lights ON when Lubrication tank is empty or pump malfunction. L H 4 (33) GEAR H/L: To show the spindle gear position H. lamp light when spindle gear is on high speed position. L. lamp light when spindle gear is on low speed position. X Y L H (Belt type spindle has no GEAR H/L lamp). 4 (34) MIRROR X/Y: X lamp will light when executing M71 command. Y lamp will light when executing M72 command. X Y L H 4 (35) HOME POSITION X/Y/Z/4: In manual or program sequence, lamp will light after performing home position (reference position return). (36) AXIS FEED DIRECTION RAPID BUTTON: To quickly move every axis by combining with AXIS FEED DIRECTION. When in ZER mode, the light will indicate whether the home position is performed. (37) OP1: For additional option. In additional 5 th axis: +5PB function. (When use CE operator panel) (38) OP2: When using axis feed direction button, must enable OP2 button then can move the axis. In additional 5 th axis: +5PB function. (39) OP3: For customer add option. Or alarm horn activation. (40) OP4: Manual activation of coolant tank motor. 3-14

23 (41) OP5: Oil mist separator activation. SHARP MACHINERY CO.,LTD (42) ENABLE: Both hand operation. (43) HANDLE / AUTO: Select manual or automatic selection button. In HANDLE, the ZER, HANDLE, JOG/RPD, MDI and EDIT modes can be used. In AUTO, only the AUTO mode can be used. 3-15

24 4. MANUAL OPERATION 4.1 MANUAL HOME POSITION RETURN There are two ways to return to home position as below: (1) In ZERO mode, press HANDLE button, press the OP2 button, press the ENABLE button, then press the button for each axis to return to ZERO. It works even if pushing more than one button simultaneously. The axes home position direction has been marked ( ). When the selected axis starts, the speed is controlled by RAPID OVERRIDE switch and the default direction are -X, +Y, +Z. When the limit switch of an axis contacts its dog, the axis will decelerate to a default low speed until limit switch leaves dog and starts to finds ZERO signal of motor s encoder. After that the axis will stop and the indication lamp of that axis will light on. When 3 axes have returned to reference position, the RAPID lamp will light too. Thereafter at any position of the 3 axes, just select ZERO mode and all RAPID lamp will light to remind customer that has performed reference positioning. (2) In ZERO mode, press HANDLE button, press the OP2 button, press the ENABLE button, then push CYCLE START button, Z-axis will move to reference position first. When Z-axis decelerates, the X and Y axes will move to reference position at the same time. The detail action and time for lamps light-on are the same as above mentioned. Please note: (I) Set KEEP RELAY K4.7 = 1 (Please refer to chapter 9) 4.2 MANUAL MOVEMENT OF 3-AXES (1) MANUAL HANDLE OPERATION: In HANDLE mode, select AXIS DIRECTION SWITCH and control the movement of 3-axes by HAND WHEEL. The movement can be controlled by INCREMENTAL FEED SWITCH. (2) JOG OPERATION (slow feed): In JOG/RPD mode, press HANDLE button, press OP2 button, press ENABLE button then press AXIS DIRECTION BUTTON + or - to move 3-axes, and to adjust the movement by FEEDRATE OVERRIDE & JOG FEEDRATE that is on operator panel. (3) RPD OPERATION (rapid traverse): IN JOG/RPD mode, press HANDLE button, press OP2 button, press ENABLE button then simultaneously press RAPID and AXIS DIRECTION SWITCH +, - to move 3-axes, the movement is adjusted by RAPID OVERRIDE % 4-1

25 4.3 OPERATION OF SPINDLE CLAMP / UNCLAMP VMC-137~above: There are two CLAMP and UNCLAMP push button at the metal of magazine, please select HANDLE mode, press HANDLE button, then position the Z-axis and press UNCLAMP to take off spindle tool. Load the new tool and press CLAMP button for the spindle to hold the tool to complete operation. VMC-116~below: 1. There are only one CLAMP / UNCLAMP button on the front of magazine, when pressing down this button is UNCLAMP function and releasing it is CLAMP function. 2. Another method, in MDI mode, run program M84 to unclamp, and M88 to clamp. 4.4 MANUAL MAGAZINE OPERATION (1) MAGAZINE HOME POSITION RETURN OPERATION: Select ZER mode, press HANDLE button, press INDEX button that show on the panel. Then the magazine starts rotation until stopped at the position of no.1 stand-by tool position. This function only available for VMC-137 ~above. (2) MAGAZINE ROTATION OPERATION: Select HANDLE mode, press HANDLE button, press ENABLE button then press INDEX button that show on the panel. Then moved one pot in clockwise (CW) direction. Keep pressed this button to let magazine rotating. For VMC-137 and 30T ATC ~ above: The control box at the lower of magazine has two buttons MG. and MG. for magazine forward CW and for magazine FOR REV reverse. Push button once for moving one pot. Keep button pressed to let magazine rotate. 4.5 SPINDLE OPERATION (1) In MDI mode, press HANDLE button, input M03 or M04 and speed S CYCLE START After started the speed can be adjusted by SPINDLE OVERRIDE 50%~120%. (2) In HANDLE mode, press Handle button, it will start when executed M3 (M4) S indication. Press ENABLE button, then M3 and M4 then the spindle will rotate according to S value that you have input before. 4-2

26 5. EXPLANATION OF ATC Please make sure that Z-axis reference position and spindle reference position are at the right point before executing M6 command. Especially, after you reinstalled Z-axis motor or orientation sensor. The compensation parameter for Z-axis tool change position is No.1241 The compensation parameter for spindle orientation position is No.4031 There are HYDRAULIC type ATC and CAM type ATC for FANUC system. The following are explanations for OPERATION and TOOL-REGISTRATION. 5.1 HYDRAULIC TYPE ATC OPERATION I. ATC STAND-BY: The ATC will be in STAND-BY state, except executing M06. If ATC is not in stand-by, then M06 command won t be executed and Z-axis will not move. When the STAND-BY LED indication of ATC lights on, it means ATC is in STAND-BY. When executing M06 the light will be OFF. II. TOOL CHANGE CYCLE (1) TOOL CHANGE OF MDI MODE M06 or T code execution are available in MDI mode. In MDI mode, first press PROGRAM CYCLE, then key in M06 and press to execute M06. M19 START (spindle orientation) will start automatically when execute M06. So it s not necessary to execute M19 spindle orientation. When tool change is done, the ATC STAND-BY will light on. In MDI mode, when Z-axis back to reference position using single movement to execute tool change is OK. But MDI single movement is only provide for ATC troubleshooting. During this time spindle tool and stand-by Tool doesn t change in the tool table. So to reset tool table is necessary when finishing this command. Make sure all tool are correct. 5-1

27 M codes for HYDRAULIC TYPE ATC: SHARP MACHINERY CO.,LTD M19 : SPINDLE ORIENTATION M82: POT. DOWN M83 : ARM 60 M84 : SPINDLE TOOL UNCLAMP M85 : ARM DOWN M86 : ARM CW180 M87 : ARM UP M88 : SPINDLE TOOL CLAMP M89 : ARM 0 M90 : POT. UP M91 : ARM180, ORIGINAL POSITION 180 (ARM DOES NOT MOVE) In MDI mode, Z-axis must return home position (reference) first when use M CODE for TOOL CHANGE, and sequentially input M codes until ATC-STAND-BY lights on. M codes for TOOL CHANGE is used on ATC troubleshooting. Please use M06 for tool change to prevent mistake in normal operation. The detail of ATC manual troubleshooting will explained later on. (2) AUTO TOOL CHANGE MODE: To execute M06 tool change in AUTO MODE (MACRO), it means when executing M06 in program it will call the sub-program automatically. And after executed, it will return back to main-program. Do not modify or delete the program of NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM AFTER OF FANUC 0M-C SYSTEM. THE MOTION OF SUBPROGRAM: Simultaneously executing Z-axis returning to home position, POT DOWN, SPINDLE ORIENTATION (M19). The customer doesn t have to write G91 G30 Z0 and M19 commands before M06. But if tool have interference, please check whether manual tool withdraw or spindle orientation are necessary. Start tool change mechanism, and to execute the cycle of tool change: POT.DOWN, ARM 60, SPINDLE UNCLAMP, AIR BLOW, ARM DOWN, ARM 180, ARM UP, SPINDLE CLAMP, ARM 0, POT UP, CHECK ATC stand-by, 5-2

28 END M06. (ARM = Change tool holder, POT = tool cup). SHARP MACHINERY CO.,LTD If M07 or M08 or M12 is applied, the code of M09 is not necessary to be written down. M07 M08 M12 will pause during executing M06 tool change, and start automatically when M06 finished. If using MACRO for tool change in AUTO mode, M06 and T code are allowed to write down at the same block. Suggestion: Try not to write them together in one block to save time for tool change. (MODE 1) : M06 T07; : TOOL NO.7 MACHINING PROCESS M06 T08; : TOOL NO.8 MACHINING PROCESS : (MODE 2) : M06; T07; : TOOL NO.7 MACHINING PROCESS M06 T08; ; TOOL NO.8 MACHINING PROCESS : is one block during executing M06. At this time press FEED HOLD key the program will stop after finishing the ATC tool changing. CAUTION: Do not stop the process of tool change abnormally (like EMG STOP AIR-PRESSURE DROP and UNUSUAL POWER OFF, etc.). If do, please RESET, in manual mode clear the last step, go to ATC STAND-BY, then re-execute tool change. 5-3

29 5.1.2 TROUBLESHOOTING BRIEF INTRODUCTION FOR EVERY CONFIGURATION HYDRAULIC TYPE ATC (FIGURE A, B, C, D) L1: LOCK PIN IN - POSITION DETECT L2: POT IN - POSITION DETECT L3: POT OUT - POSITION DETECT L4: MAG. HOME - POSITION DETECT L5: COUNT - SENSOR A L6: COUNT - SENSOR B L7: ARM 60 L8: ARM DOWN L9: ARM UP L10: SPINDLE CLAMP - POSITION DETECT L11: SPINDLE UNCLAMP - POSITION DETECT L12: SPINDLE HIGH GEAR - POSITION DETECT L13: SPINDLE LOW GEAR - POSITION DETECT L14: SPINDLE ORIENTATION - SENSOR L17: ARM 180 L18: ARM M1: MAG MOTOR P1: MG FORWARD - PUSH BUTTON P2: MG REVERSE - PUSH BUTTON P3: SPINDLE CLAMP - PUSH BUTTON P4: SPINDLE UNCLAMP - PUSH BUTTON 5-4

30 SHARP MACHINERY CO.,LTD CONDITIONS FOR STAND-BY: To execute M06, the ATC must be in 18M STAND-BY situation, and has to satisfy the following conditions: AIR PRESS. X FOR VMC-15800~above LOOK PIN IN L1 ON X POT IN L2 ON X POT OUT L3 OFF X TOOL CLAMP L10 ON X TOOL UNCLAMP L11 OFF X ARM 0 L4 ON X ARM 60 L5 OFF X ARM UP L6 ON X ARM DOWN L7 OFF X ARM CW 180 L8 OFF X ARM CCW 180 L9 ON X I and 18I and 21I AIR PRESS. X6.0 FOR VMC-15800~above LOOK PIN IN L1 ON X5.4 POT IN L2 ON X5.5 POT OUT L3 OFF X5.6 TOOL CLAMP L10 ON X5.0 TOOL UNCLAMP L11 OFF X5.1 ARM 0 L4 ON X7.1 ARM 60 L5 OFF X7.2 ARM UP L6 ON X7.3 ARM DOWN L7 OFF X7.4 ARM CW 180 L8 OFF X7.5 ARM CCW 180 L9 ON X7.6 18M & 0I & 18I & 21I I/O signal diagnose location SYSTEM PMC PMCDGN STATUS X0 SEARCH 0ID I/O signal diagnose location SYSTEM *3 PMCMNT STATUS X0 SEARCH 5-5

31 When the ATC STAND-BY lamp doesn t light during maintenance, please use DGNOS to examine above items and make sure all limit switch are correct.(please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction). 5-6

32 FIG (A) 5-7

33 FIG (B) FIG (C) 5-8

34 FIG (D) FIG (D) TOOL JAM M06 can t be done. There are two situations as below: Stop after POT DOWN: (1) Z-axis has not returned home position (2) Spindle orientation has not finished (3) POT OUT LIMIT has not ON (4) Tool search error (Tool registration has some mistake) (5) Air pressure is not enough Try to find the reason as mentioned items. Then use MDI to execute M90 (POT IN), and back to ATC STAND-BY. After it, re-execute M Stop during ATC ARM motion: (1) Reset NC (2) Remove the ATC sequence protection (SET K1.4=1). Also you could set K0.1=0 and K1.3=1 when it is necessary. (3) In MDI mode, to perform reverse operation of M codes for tool change (please refer to section 2.1.2) until arm returns

35 SHARP MACHINERY CO.,LTD (4) If ARM has already reached 180, please do M91 (ARM180 ) (5) Recover the protection of manual ATC operation (Set K1.4=0) (6) ATC STAND-BY light ON (7) POWER OFF/ON SETTING TOOL REGISTRATION Setting tool registration must be in MDI mode, and set write-down protection (PWE)= 1, then set tool registration in DATA page. Please refer to ELECTIC CIRCUIT page N2, the addresses of tool registration. Here are descriptions for setting tool registration as below: C00: To set the amount of tool. If magazine are 30 tools, set 30. If 24 tools just set 24 (Be sure to set the right numbers, otherwise it will cause the machine to select the wrong tools) 0IC/18/21I setting SYSTEM PMC PMCPRM COUNTER 0ID setting SYSTEM *3 PMCMNT COUNTER D10: Setting spindle tool number. D11~D40: To set the tool number for POT No. 1~30, D11 is corresponding to Pot No. 1, etc. Be sure the tool number should not be bigger than 99 (for 24-tool magazine, D35~D40 should be kept empty). 0IC/18/21I setting SYSTEM PMC PMCPRM DATA G.DATA 0ID setting SYSTEM *3 PMCMNT DATA ZOOM If ATC has tool-selection mistake, please re-check the tool registration and correct the mistake. Otherwise there will be some alarm when executing T code USING & NEGLECTING MACRO FOR TOOL CHANGING MACRO is for M06 tool change, the benefit for using MACRO is as follows: 1. In AUTO mode, it will be able to execute M06 and T CODE in one block. 2. Before M06, it is not necessary to write Z-axis home position return at tool change. 3. To reduce the time for tool change. Simultaneously executing POT-OUT & SPINDLE ORIENTATION and Z-AXIS returning to the point of tool change. For special reasons, if you don t want using MACRO to execute tool changing. There is explanation of neglecting MACRO in the next section (1). 5-10

36 Subprogram of tool change % O9001 (M06 SUB. LIFE BIG TOOL) PROGRAM NUMBER AND EXPLANATION G40 G80; #148=#4114; #3003=1; SINGLE BLOCK IS DISABLED #3004=1; FEED HOLDING IS DISABLED #1113=0; POT DOWN SIGNAL OFF #1115=0; ATC ROTATION OFF #103=#4003; #149=#4120; M05; (T#149); G04X0.2; IF[#1015EQ1]GOTO50; TO DECIDE IF T IS SPINDLE TOOL #1100=1; G91G30Z0M19; Z AXIS RETURN TO SECOND REFERENCE POSITION, SPINDLE POSITION IF[#1014EQ0]GOTO40; TO DECIDE IF SPINDLE TOOL IS BIG TOOL G4X0.3; N20; IF[#1013EQ1]GOTO30; SAVE THE CURRENT G-CODE OF THIRD GROUP #1115=1; ATC ROTATION ON GOTO20; N30; #1115=0; ATC ROTATION OFF M05; #1113=1; POT DOWN SIGNAL ON G4X0.2; M19; #1113=0; POT DOWNSIGNAL OFF M06; T#149; EXECUTING TOOL CHANGING N40; (T#149); IF[#1015EQ1]GOTO50; TO DECIDE IF T IS SPINDLE TOOL G4X0.2; #1100=0; M06; EXECUTING TOOL CHANGING N50; #1100=0; G#103; #3003=0; SINGLE BLOCK IS AVAILABLE #3004=0; FEED HOLD ENABLE N#148; M99; RETURN TO MAIN PROGRAM % 5-11

37 2) Neglect of MACRO tool change: SHARP MACHINERY CO.,LTD 1. Select MDI mode OFFSET 2. Press SETTING key parameter key set PWE=1 3. Change the setting of parameter 6071 (No.6071=0 to neglect this MACRO, No.6071=6(M6) uses MACRO) 4. Set PWE=0 5.2 CAM TYPE ATC OPERATION (1). ATC STAND-BY: The ATC will be in STAND-BY state, except executing tool change. If ATC is not stand-by, then M06 won t be executed and Z-axis will not move. When the LED (on operator panel) of ATC STAND-BY lights on, it means ATC is STAND-BY. When executing M06 the light is OFF. (2). TOOL CHANGE CYCLE I. TOOL CHANGE OF MDI MODE To execute M06 or T code are available in MDI mode. In MDI mode, first press PROGRAM, then key in M06 and press INPUT to execute M06. M19 (spindle orientation) will start automatically when execute M06. So it s not necessary to execute M19 spindle orientation. When tool change is done, the ATC STAND-BY will light on. II. MDI SINGLE BLOCK In MDI mode, when Z-axis back to reference position using single block to execute tool change is OK. But notice that CAM single block method is only provide for ATC calibration. During this time spindle tool and standby Tool doesn t change in the tool table. Before you use single block, first, set K5.3=1 (please notice that setting K5.3=1 will have danger of operating). We suggest you take down of tools and turn POWER OFF then restart again when it finishes.( K5.3 will change to 0 automatically after POWER OFF and ATC STAND-BY lights ON.). We will explain how to set K5.3=1 at chapter 8.3. When it is finished on the OFFSET SETTING screen PWE have to be set to 0. Otherwise, 100 P/S AL and MDI can t work. There are steps 5-12

38 for MDI single block as follows: SHARP MACHINERY CO.,LTD M19 : SPINDLE ORIENTATION M82: POT. DOWN M83 : ARM CW, M89: ARM CCW (COUNTER CLOCKWISE) M84 : SPINDLE TOOL UNCLAMP M83 : ARM CW, M89: ARM CCW M88 : SPINDLE TOOL CLAMP M90 : POT UP Please turn POWER OFF and ON when finished otherwise STAND-BY light won t lights ON. Please execute M83 ARM CW if there are tools on spindle or POT. When execute M89 ARM CCW have to consider with if SPINDLE CLAMP/UNCLAMP finished. Suggestion: don t use tools during this time. M03 and M89 could use alternately, Example: M83 ARM 60 M89 ARM 0 M83 ARM 60 M83 ARM 180 UP M89 ARM DOWN 180 M89 ARM 0 stop position (step 1.) (step 2.) (step 3.) The above actions can operator by M83 or M89 in sequence. Please be careful to operate it, because this part is very different from HYDRAULIC TYPE ATC. (3) TOOL CHANGE OF AUTO MODE To execute M06 tool change in AUTO MODE (MACRO), it means when executing M06 in program it will call the sub-program automatically. And after executed, it will back to main-program. Do not modify or delete the program of NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM F FANUC 0M-C SYSTEM. 5-13

39 THE MOTION OF SUBPROGRAM SHARP MACHINERY CO.,LTD Simultaneously executing Z-axis returning to reference position, POT DOWN, SPINDLE ORIENTATION (M19). The customer doesn t have to write G91 G30 Z0 and M19 commands before M06. But if tool have interference, please check that if tool withdraw and spindle orientation are necessary. Start tool change mechanism, and to execute the cycle of tool change: POT.DOWN => ARM 60 => SPINDLE UNCLAMP, AIR BLOW => ARM DOWN => ARM 180 => ARM UP => SPINDLE CLAMP => ARM 0 => POT UP => CHECK ATC in stand-by => END M06 (ARM = change tool holder, POT = tool cup) If use MACRO for tool change in AUTO mode, it is allowable M06 and T code in the same block. Suggestion: Do not write them together in one block to save time for tool change. (MODE 1) : M06 T07; : TOOL NO.7 MACHINING PROCESS M06 T08; : TOOL NO.8 MACHINING PROCESS : (MODE 2) : M06; T08; : TOOL NO.8 MACHINING PROCESS M06; T09; ; 5-14

40 TOOL NO.9 MACHINING PROCESS : is one block during executes M06 call sub-program in programming, At this time press FEED HOLD key the program will stop until ATC tool changing finished. NOTE: Do not stop the process of tool change abnormally (like EMG STOP, AIR- PRESSURE DROP and unusual power off, etc.). Please RESET, in manual mode finish the last operation, then go to ATC STAND-BY, then re-execute tool change. 5-15

41 3) TOOL SEARCH The way for tool management (MAG) is random. The tool doesn t correspond to any POT. When executing T code, first the controller decides the corresponding POT of tool, then starts magazine, uses the shortest path to decide MAG.CW or MAG.CCW, then puts tool on STAND-BY position. Do not stop ATC unusually during magazine rotation (Like EMG STOP, AIR-PRESSURE-DROP or UNUSUAL POWER-OFF). Otherwise tool counter will mistake. The tool registration have to be reset. (We will describe the way to reset registration at next chapter.) To search a tool is available for MDI or AUTO mode. In HANDLE mode, please refer to MANUAL MAGAZINE OPERATION to see how to perform the movement of magazine TROUBLESHOOTING CONFIGURATION CAM ATC (FIGURE E, F, G, H) L1 :LOCK PIN IN - POSITION DETECT L2 :POT IN - POSITION DETECT L3 :POT OUT POSITION DETECT L4 :MAG. HOME - POSITION DETECT L5 :COUNT - SENSOR A L6 :COUNT - SENSOR B L7 :CAM STOP - POSITION DETECT L8 :CAM CHECK - POSITION DETECT L9 :CAM HOME - POSITION DETECT L10:SPINDLE CLAMP - POSITION DETECT L11:SPINDLE UNCLAMP - POSITION DETECT L12:SPINDLE HIGH GEAR - POSITION DETECT L13:SPINDLE LOW GEAR - POSITION DETECT L14:SPINDLE ORIENTATION - SENSOR M1:MAG. MOTOR P1:MG FORWARD - PUSH BUTTON P2:MG REVERSE - PUSH BUTTON P3:SPINDLE CLAMP - PUSH BUTTON P4:SPINDLE UNCLAMP - PUSH BUTTON 5-16

42 CONDITIONS FOR STAND-BY: To execute M06, the ATC must be in STAND-BY situation, and has to satisfy the following items: 18MC AIR PRESS. X FOR VMC-15800~ABOVE LOCK PIN IN L1 ON X POT IN L2 ON X POT OUT L3 OFF X TOOL CLAMP L10 ON X TOOL UNCLAMP L11 OFF X CAM STOP L7 OFF X CAM CHECK L8 ON X CAM HOME L9 ON X COUNTER A SENSOR L5 ON X FOR VMC-137~ABOVE COUNTER B SENSOR L6 ON X FOR VMC-137~ABOVE 0IC & 18I & 21I AIR PRESS. X6.0 FOR VMC-15800~ABOVE LOCK PIN IN L1 ON X5.4 POT IN L2 ON X5.5 POT OUT L3 OFF X5.6 TOOL CLAMP L10 ON X5.0 TOOL UNCLAMP L11 OFF X5.1 CAM STOP L7 OFF X4.3 CAM CHECK L8 ON X4.4 CAM HOME L9 ON X4.5 COUNTER A SENSOR L5 ON X6.1 FOR VMC-137~ABOVE COUNTER B SENSOR L6 ON X6.2 FOR VMC-137~ABOVE 5-17

43 SHARP MACHINERY CO.,LTD 0IMATE AIR PRESS. X26.0 LOCK PIN IN L1 ON POT IN L2 ON X25.5 POT OUT L3 OFF X25.6 TOOL CLAMP L10 ON X25.0 TOOL UNCLAMP L11 OFF X25.1 CAM STOP L7 OFF X24.3 CAM CHECK L8 ON X24.4 CAM HOME L9 OFF X24.5 SENSOR L5 ON X26.1 SENSOR L6 ON X M & 0I & 18I & 21I I/O signal diagnose location SYSTEM PMC PMCDGN STATUS X0 SEARCH 0ID I/O signal diagnose location SYSTEM *3 PMCMNT STATUS X0 SEARCH When the ATC STAND-BY lamp doesn t light during maintenance, please use DGNOS to examine above items, make sure that every limit switch is correct. (Please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction). 5-18

44 FIG (E) 5-19

45 FIG (F) 5-20

46 FIG (G) 5-21

47 FIG (H) K-TYPE ATC L9 CAM HOME SENSOR L7 CAMP UNCLAMP SENSOR L5 COUNTER SENSOR L8 CAM CLAMP SENSOR 5-22

48 L2 POT IN SENSOR L3 POT OUT SENSOR MODEL CV6 AIR PRESS. X6.0 POT IN L2 ON X5.5 POT OUT L3 OFF X5.6 TOOL CLAMP L10 ON X5.0 TOOL UNCLAMP L11 OFF X5.1 CAM STOP L6 ON X4.5 CAM UNCLAMP L7 OFF X4.3 CAM CLAMP L8 OFF X4.4 CAM HOME L9 ON X4.2 COUNTER SENSOR L5 ON X6.1 When the ATC STAND-BY lamp doesn t light during maintenance, please use DGNOS to examine above items, make sure that every limit switch is correct. (Please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction). 5-23

49 L6 CAM STOP SENSOR L7 CAM UNCLAMP SENSOR L8 CAM CLAMP SENSOR L9 CAM HOME SENSOR L5 COUNTER SENSOR L2 POT IN L3 POT OUT 5-24

50 5.2.3 TOOL JAM M06 can t be done, there are two situations as below: Stop after POT OUT (1) Z-axis has not returned HOME (2) Spindle orientation has not finished (3) POT OUT LIMIT has not ON (4) Tool search error (Tool registration has some mistake) (5) Air pressure is not enough Try to find the reason as mentioned items. Then use MDI to execute M90 (POT IN), and back to ATC STAND-BY. After it, re-execute M Stop during ATC ARM motion (1) POWER OFF during M06 tool change (2) EMG emergency stop happened during M06 tool change (3) ARM not stop at right position (4) ARM sensor L7, L8, L9 have malfunction (5) TOOL CLAMP/UNCLAMP ( L10, L11) not finished (6) The signal for finished spindle orientation is missing. (7) CAM motor overload (8) The breaker for CAM motor didn t work There are a few ways to solve those problems but in any case have to observe the following principles: i. POWER OFF during M06 stopped. ii. Take off tools for safety reason iii. Be sure follow the below steps: (1) Troubleshooting by MANUAL Please use this reliable and safe way to solve the problem If the engineer is not familiar with logic of tool change. The steps are as below: i) POWER OFF (It only execute in POWER OFF situation) ii) Take out the cover of CAM motor. Please refer to sketch (E), (H) M2 cam motor position. iii) Release the device of motor breaker. Please refer to sketch (H1). (Breaker model might differ). iv) In motor breaker released situation, use spanner to wrench CW or CCW until ARM back to 0 position. Be sure there is no tool on the ARM. Because of it will be very danger when spindle is on CLAMP while POWER OFF. 5-25

51 v) After ARM back to 0 position, wrench motor breaker to original place, then turn POWER ON again. vi) To execute M90 POT UP In MDI mode. When ATC STAND-BY lights on. then it s done. (2) Troubleshooting by manual ARM JOG Operation: Please turn POWER OFF POWER ON EMG. Select HANDLE mode, press HANDLE button, simultaneously press +X and -X for three seconds. CYCLE START FEED HOLD lights ON means SPINDLE CLAMP lights ON means SPINDLE UNCLAMP Press CYCLE START, ARM JOG ( ) movement Press FEED HOLD, ARM JOG ( ) movement In JOG procedure, If there are tool on ARM or POT please notice that spindle CLAMP/UNCLAM position and release all tools. You also would use MDI mode to execute M84 (tool UNCLAMP) M88 (tool CLAMP) M82 (POT DOWN), M90 (POT UP). Use JOG moves ARM to 0 In MDI mode, to execute M90 POT UP then ATC will back to original position. POWER OFF after ATC back to original position, then ATC STAND-BY will light ON, otherwise M06 can t be executed. (3) Troubleshooting by automatic Operation: Please turn POWER OFF POWER ON EMG. Select HANDLE mode, press HANDLE button, simultaneously press +X and -X for three seconds. POWER OFF after ATC back to original position, then ATC STAND-BY will light ON, otherwise M06 can t be executed. 5-26

52 SHARP MACHINERY CO.,LTD SETTING TOOL REGISTRATION Setting tool registration must be in MDI mode, and set write-down protection (PWE)= 1, then set tool registration in DATA page. Please refer to ELECTIC CIRCUIT page N2 the addresses of tool registration. Here are descriptions for setting tool registration as bellows: C00: To set the amount of tool. If magazine are 30 tools, set 30. If 24 tools just set 24 (Be sure to set the right numbers, otherwise it will cause the machine to select the wrong tools). The pot number in STAND-BY position: 0IC & 18I & 21I setting SYSTEM PMC PMCPRM COUNTER 0ID setting SYSTEM *3 PMCMNT COUNTER D10: Setting spindle tool number. D11~D40: To set the tool number for POT No. 1~30, D11 is corresponding to Pot No. 1, etc. Be sure the tool number should not be bigger than 99 (for 24-tool magazine, D35~D40 should be kept empty). 0IC & 18I & 21I setting SYSTEM PMC PMCPRM DATA G.DATA 0ID setting SYSTEM *3 PMCMNT DATA ZOOM If ATC has tool-selection mistake, please re-check the tool registration and correct the mistake. Otherwise there will be some alarm when executing T code USING & NEGLECTING MACRO FOR TOOL CHANGING MACRO is for M06 tool change, the benefit for using MACRO is as follows: 1. In AUTO mode, it will be able to execute M06 and T CODE in one block. 2. Before M06 is not necessary to write Z-axis return home. 3. To reduce the time for tool change. Simultaneously executing POT-OUT & SPINDLE ORIENTATION and Z-AXIS returning to the point of tool change. For special reasons, if you don t want using MACRO to execute tool changing. There is explanation of neglecting MACRO in next section

53 SUBPROGRAM OF TOOL CHANGE SHARP MACHINERY CO.,LTD % O9001 (M06 SUB. LIFE BIG TOOL) PROGRAM NUMBER AND EXPLANATION G40 G80; #148=#4114; #3003=1; SINGLE BLOCK IS DISABLED #3004=1; FEED HOLDING IS DISABLED #1113=0; POT DOWN SIGNAL OFF #1115=0; ATC ROTATION OFF #103=#4003; #149=#4120; M05; (T#149); G04X0.2; IF[#1015EQ1]GOTO50; TO DECIDE IF T IS SPINDLE TOOL #1100=1; G91G30Z0M19; Z AXIS RETURN TO SECOND REFERENCE POSITION, SPINDLE POSITION IF[#1014EQ0]GOTO40; TO DECIDE IF SPINDLE TOOL IS BIG TOOL G4X0.3; N20; IF[#1013EQ1]GOTO30; SAVE THE CURRENT G-CODE OF THIRD GROUP #1115=1; ATC ROTATION ON GOTO20; N30; #1115=0; ATC ROTATION OFF M05; #1113=1; POT DOWN SIGNAL ON G4X0.2; M19; #1113=0; POT DOWNSIGNAL OFF M06; T#149; EXECUTING TOOL CHANGING N40; (T#149); IF[#1015EQ1]GOTO50; TO DECIDE IF T IS SPINDLE TOOL G4X0.2; #1100=0; M06; EXECUTING TOOL CHANGING N50; #1100=0; G#103; #3003=0; SINGLE BLOCK IS AVAILABLE #3004=0; FEED HOLD ENABLE N#148; M99; RETURN TO MAIN PROGRAM % 5-28

54 NEGLECT MACRO TOOL CHANGE 1. Select MDI mode OFFSET SETTING 2. Press key parameter key set PWE=1 3. Change the setting of parameter 6071(No.6071=0 to neglect this MACRO, No.6071=6(M6) uses MACRO) 4. Set PWE=0 5-29

55 6. EXPLANATION OF OTHER INSTALLATIONS This chapter is to describe operation and explanation of other functions. Because the new software is updated too fast and there are many different requests from customers. Therefore, we only describe the standard function. About the optional functions, please refer to the attached information. 6.1 AUTO LUBRICATOR OPERATION AND RELATED SETTINGS The oil lubrication system is very important for machine tools. And the OILER is like the heart for oil lubrication system. If lubrication is not good it will cause servo motor a heavy load and abnormal current. If the oil supply of slide ways is short for a long time, it will cause bad accuracy and servo motor vibration, noise, heat etc. If serious, it will injure the slide ways. When power ON, after releasing EMG the LUB will retain the pressure immediately at the first time. Retain pressure time is set by PLC TIMER 2. The standard value is 15 sec. After the pressure detecting time (TMR 12,10 sec), if the pressure is still not enough, the 2010 LUB PRESSURE MISS alarm will be displayed. If the pressure is normal, the oil will start filling and the time intermittent counter will start to count. Same as the above condition, the pressure has to release within 10sec from filling oil, otherwise alarm 2010 will be displayed. When retain pressure and fill oil are all right, the time intermittent counter TMR 1 and TMR 3 will decide the time for next retain pressure. In auto mode, the intermittent time TMR 1 is 10 minutes. In handle mode, the intermittent time TMR 3 is 20 minutes. As above description, the cycle for oil lubricator is as follows: ON RETAINS PRESSURE PRESSURE DETECTS FILLS OIL PRESSURE DETECTS INTERMITTENT RETAINS PRESSURE (For the detail of setting PLC TIMER, please refer to page 8.1) TROUBLESHOOTING If the machine does not power ON for a long time, the slide ways will be dry. Please use MANUAL PUSH BUTTON to start oil lubricator a few times after machine ON. About the question of OILER we will explain as following: 1. ALARM 2010 ALARM 2010 is oil not enough. When ALARM happens, please fill oil within 6-1

56 30 minutes. If not, it will change CYCLE START to FEED HOLD. In auto mode, Single block is automatically engaged and the indicate lamp E4 will light. At this time, to fill oil and reset is the only way to solve this problem. If it still not works, maybe there are some other parts malfunctioned. Please ask the engineer of agent to help. 2. ALARM 2011 ALARM 2011 is pressure detection error. It happens mostly with the problems of oil tube. If happens during retain pressure, it means the pressure can not retained in time. Try to increase TMR 12 and TMR 2 (the maximum is 40 minutes). Please notice that value of TMR 12 should be larger than TMR 2. If the problem still exists, it means that there is problem in oil tube or pressure switch or the pump. 6.2 COOLER UNIT COOLER UNIT is to provide cooling and lubrication to spindle head during high speed rotation. We have gear and belt type spindles which use different type cooler units. But the principle and motion are almost the same as below: A pump withdraws warm oil from spindle head, and sends it back to cooler. The detector will check whether the oil temperature is higher than the setting value. If yes, the compressor will start automatically to cool down the oil until the temperature is lower than the setting, after that the compressor will stop. Because the cooling oil is a close-loop circulation system, the pump is non-stop, but the compressor works intermittently. The cooler unit starts work when power is ON and EMG is released. If alarm 1004 SPINDLE GEAR OIL AL is displayed at the first POWER ON, but cooler s panel displays nothing. It means that the phase of the input power is wrong. For the rest of problems, the 1004 ALARM will be displayed when cooler doesn t work. If the problem is not same as the above, please check the panel s display, and refer to the operation and troubleshooting manual of the oil cooler unit. Besides, the operation temperature range is also written in the manual of cooler unit. Usually, the temperature setting is room temperature adds the value that we set. For example, now the room temperature is 25, and the value is +5, so the temperature is not over 30. If over 30, the compressor will start. 6-2

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