Operating Manual. Heidenhain TNC 640 XT 630 5AX XT 630 5F XT 760 XT 1000

Transcription

1 Operating Manual Heidenhain TNC 640 XT 630 5AX XT 630 5F XT 760 XT 1000 Original instructions (CE) Document Number Issue B July 2016 XT series Heidenhain TNC640 Operating_ B (CE) Page 1/56

2 CONTENTS Page 1.1 INTENDED USE IMPORTANT SAFETY NOTICE WARNING! SAFETY LISTS ALL COUNTRIES GUARD WINDOW SAFETY BEFORE SWITCHING ON WARRANTY INFORMATION ROUTINE INSPECTION MAINTENANCE PROCEDURE MACHINE WARM UP AUTOMATED SPINDLE WARM UP SPINDLE OPERATING CONDITIONS SPINDLE MAINTENANCE SPINDLE TOOLING INTERRUPTING MACHINING COMPLETING A JOB SAFETY DEVICES TNC 640 VISUAL DISPLAY UNIT KEYBOARD AND CONTROL PANEL CONTROLS ON THE TNC MODE SELECT SWITCH MACHINE POWER ON AND REFERENCE MACHINE POWER OFF EMERGENCY STOP SOFT KEY LAYOUT MANUAL AXIS JOG ELECTRONIC HANDWHEEL 34 XT series Heidenhain TNC640 Operating_ B (CE) Page 2/56

3 2.11 MANUAL TOOL LOAD/UNLOAD LOADING TOOL MAGAZINE VIA FRONT GUARD DOOR TOOL TABLE POCKET TABLE ATC OPERATION IN MDI MODE M-FUNCTION CODES DATUM SETTING PROGRAM RUN MANUAL OPERATION OF SPINDLE WASH DOWN GUN USER PARAMETERS SERVICE FUNCTION ATC ARM RECOVERY POCKET TABLE REFORMING STACK LIGHTS 54 APPENDIX ONE: SPINDLE OUTPUT DIAGRAM 55 XT series Heidenhain TNC640 Operating_ B (CE) Page 3/56

4 1.1 INTENDED USE This 5 Axes Milling machining centre is a numerically controlled machine tool designed to shape cold metal by the application of rotating cutting tools capable of performing two or more machining processes (e.g. boring, drilling, milling, thread tapping) at one set-up of a workpiece and incorporating automatic facilities to: Select and change tools from a magazine Change the position of the workpiece relative to the spindle mounted cutter Select and apply spindle speeds and axis feeds Control ancillary services (e.g. coolant flow) XT series Heidenhain TNC640 Operating_ B (CE) Page 4/56

5 1.2 IMPORTANT SAFETY NOTICE WARNING! It is the user s responsibility to be acquainted with the legal obligations and requirements in the use and application of the machine, particularly under the Health and Safety at Work Act 1974 and in the British Standard document PD 5304:2005 Guidance on the Safe Use of Machinery and other standards and safety codes applicable in the country of use. SAFE INSTALLATION It is the customer s responsibility to ensure the machine is installed in a safe operating position, with all service pipes and cables clear of the operation area so as not to cause a hazard. Access must be allowed for safe maintenance, swarf and oil disposal including safe stacking of machined and un-machined components. MACHINE GUARDING The Hardinge Machining Center is fitted with completely enclosed guards as standard. In certain cases and tooling applications additional guarding may have to be provided by the user. The standard machine guarding has special safety interlocks on the guard doors that comply with the Machinery Directive. Guards and interlocks must be kept fully maintained and tested by the customer and shall not be removed. The guards are made with clear observation windows having high impact resistance to provide operator safety and a clear unobstructed view of the operations in process. The opening of any guard door provides access to potential hazard areas. Opening of the front working area guard doors is not allowed whilst the spindle is rotating but it is still possible to manually initiate axis movements whilst these doors are open albeit at a reduced traverse rate. Extreme care must therefore be used at all times. SOFTWARE Unauthorised changing of machines software or control parameters is hazardous and is not permitted. Hardinge will not accept any liability whatsoever for unauthorized changes in this area. AUTHORISED PERSONNEL AND TRAINING Operating, service and maintenance engineers shall be authorised by the User Company and properly trained in the use of the machine. SAFE WORKING PRACTICE Workholding devices, lifting equipment, tooling and their use shall be the responsibility of the user. It is the user s responsibility to protect against the hazards caused by swarf, leaking oil or coolant and their use. Use of proprietary oil or coolant is the responsibility of the user. Special instructions from the suppliers concerning their use should be carefully read and understood before use. To prevent bodily injury, safe working practices should be employed when operating or servicing the machine. CONNECTING/DISCONNECTING ELECTRICAL CABLES FOR MACHINE ACCESSARIES AND OPTIONAL EQUIPMENT Machine power must be OFF before connecting/disconnecting terminals, adapters, receptacles and cable connectors for any equipment, accessory or optional equipment to/from the machine. This action will allow personnel to avoid accident electrical shock, otherwise which could cause serious personal injury and machine damage. XT series Heidenhain TNC640 Operating_ B (CE) Page 5/56

6 1.3 SAFETY LISTS ALL COUNTRIES It is the user s responsibility to ensure all local regulations and safety instructions are followed. Users should consult with their own safety representative to ensure that all such regulations are known and acted upon. Additional safety notices may exist for certain specific countries for which Hardinge may be able to advise. Please ask. DON T run the machine until you have made clear to your supervisor that you understand the potential hazard of spindle rotation, the throwing of coolant and the removal of swarf from the cutting process. DON T run the machine until you have read and understood all manuals provided with the machine. DON T run the machine until you have read and understood all the machine and control keys. DON T run the machine for the first time without a qualified instructor. Ask your supervisor for help when you need it. PROTECT your eyes. Wear safety glasses with side shields at all times. DON T get caught in moving parts. Remove watches, rings, jewellery, neckties and loose fitting clothes. PROTECT your head. Wear a safety helmet when working near overhead hazards. KEEP your hair away from moving parts. PROTECT your feet. Always wear safety shoes with steel toecaps and oil resistant soles. Gloves are easily caught in moving parts. TAKE THEM OFF before you turn on the machine. Loose objects can become flying projectiles. REMOVE all loose items (wrenches, chuck keys, rags etc.) from the machine before starting. NEVER operate a machine tool after taking strong medication, using non-prescription drugs, prescription drugs or consume alcohol which may impair concentration. ALWAYS make sure the working and cutting zone is safeguarded. PROTECT your hands. Make sure the spindle is stopped before manually changing a tool or a workpiece. PROTECT your hands. Make sure the spindle is stopped before manually clearing away swarf or oil. Use a brush or chip scraper. NEVER use your hands. PROTECT your hands. Make sure the spindle is stopped before manually adjusting the work piece or fixture or coolant nozzle. PROTECT your hands. Make sure the spindle is stopped before you take measurements. PROTECT your hands. Make sure the spindle is stopped before you move a safeguard. Never reach round a safeguard. PROTECT your hands. Make sure the machine is switched off and electrically isolated before making any mechanical adjustment. PROTECT your hands. Beware sharp edges of cutting tools when changing and handling tools. PROTECT your hands. Beware of sharp edges on newly machined components wear gloves when unloading. PROTECT your eyes and the machine. Never use a compressed air hose to remove swarf or to clean out air vents. KEEP the work area well lighted. Ask for additional lighting if needed. DON T slip. Keep your work area clean and dry. Remove swarf, oil and obstacles. NEVER lean on the machine. Stand away when machine is running. DON T get trapped. Avoid pinch points caused between other machines and the machine you are working. PREVENT objects from flying loose. Securely clamp and locate the workpiece. XT series Heidenhain TNC640 Operating_ B (CE) Page 6/56

7 SAFETY LISTS ALL COUNTRIES (Cont.) PREVENT cutter breakage. Use correct cutter speed and axis feed rate for the job. Make manual over ride adjustments of axis feed rate or spindle speed if you notice unusual noise or vibration. Ask your supervisor for help if you need it. PREVENT cutter breakage. Rotate the spindle in a clockwise direction for right handed tools, counter clockwise for left handed tools. Use the correct tool for the job. PREVENT work piece and cutter damage. Never start the machine when the cutter is in contact with the work piece. Dull and damaged tools break easily. Inspect tools and tool holders. Keep tools sharp. Keep overhang short. KEEP all lubrication reservoirs maintained at the correct level. Always keep to the maintenance schedule. Certain materials such as magnesium are highly flammable in dust and chip form. See your supervisor before working these materials. PREVENT fire. Keep flammable liquids and materials away from the work area and from hot swarf. PREVENT the machine from moving unexpectedly. When leaving the machine unattended, not producing, leave switched in the MANUAL mode, with the EMERGENCY STOP button depressed. DON T use the machine in a volatile atmosphere. Electrical devices fitted to the machine are for normal factory use and are not explosion proof. ALWAYS keep the machine clean and do not let swarf collect. ALWAYS keep the area around the machine clean and tidy. Opening the guards creates the potential for residual coolant and swarf to fall to the swarf tray and possibly to the floor. Good housekeeping minimizes the potential for trips, slip or fall of all personnel. DON T reach into any control or power case, unless electrical power is OFF. DON T touch electrical equipment when hands are wet or when standing on a wet surface. ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before restarting the machine. This machine tool is a machining center, and is intended for the use in machining materials with the work piece fixed to the table, and the cutting tool rotating in the spindle. The machine should not be used for any other purpose. INFORM all other personnel who approach the machine about the hazards described in this safety list. When making adjustments with spanners, always ensure that the required leverage is safely applied. Always avoid slippage. Always apply the leverage by pulling, never by pushing. Always use the correct size spanner. Ensure the spanner is not damaged. Do not use organic chemical solvents to clean the machine guards or compressed air services equipment. This machine is intended for use in an industrial environment and must not be used in the residential, commercial and light industrial environment. The windows fitted to Hardinge Machining Centers are manufactured from bulletproof polycarbonate sheet. This material does deteriorate with age, and should be exchanged within the time period described later in this manual. Any workholding device used in conjunction with this machining center must fit within the working envelope available. Under no circumstances must any such workholding device be used when it would require the need to override/defeat the safety interlocks fitted as standard to this machine. XT series Heidenhain TNC640 Operating_ B (CE) Page 7/56

8 1.4 GUARD WINDOW SAFETY This Bridgeport Machining Centre is fitted with laminated vision panels to both provide protection from ejected tool tips (or similar parts of the tool) and to prevent the harmful effects of metalworking fluids reducing the effectiveness of the window. Guidance on the replacement of windows is given in the Operators Safety Manual, section 1.7. XT series Heidenhain TNC640 Operating_ B (CE) Page 8/56

9 1.5 BEFORE SWITCHING ON Training on all aspects of this machine tool is available from Hardinge. Please contact your Hardinge representative for further details. Cables, cords or electric wires of which insulation is damaged can produce current leaks and electric shocks. Check their condition before connecting. A qualified electrician should only carry out connection of the power cable to the machine. Ensure the power cable to the machine main isolator has sufficient current carrying capacity to handle the electric power used. Cables which must be laid on the floor must be protected against chips, oil and coolants penetration, which might cause damage. In the event of power failure, turn off the main circuit breaker immediately. Fuses and circuit breakers should be replaced only with suitably rated alternatives. Safety devices should be replaced only with the machine manufacturers recommended parts. Protect the CNC unit, operating panel, and electric cabinet etc from shocks which could cause a failure of malfunction. Check the condition of the warning labels. If they are missing or become illegible, order replacements from Hardinge according to the part number on the label plate. Do not remove warning labels. After unpacking the machine clean all rust preventatives from the machine with a non-volatile cleaning fluid. Lightly lubricate each sliding part before trying to operate the machine. Use recommended oil brands and appropriate levels for all lubricating systems. See the instruction plate at the rear of the machine. The coolant system comprises of a tank at the front of the machine and a set of coolant pumps located towards the rear of the machine depending upon exact specification. Whilst it is possible for a workpiece to be machined without the use of any the coolant/lubricant on the short term application occasionally, it is strongly recommended that the operator follow the steps outlined below: 1. Clean dirt and chips from the waycovers prior to commencing machining each day. 2. Lubricate with oil the front edge area of the wiper's on the waycovers so that the rubbing surface does not become dry from reduced service life. If the workpiece always to be machined without the coolant/lubricant on the application, it is strongly recommended that please select the special design waycover assembly of Hardinge for this application whilst you put an order for a Hardinge machine. XT series Heidenhain TNC640 Operating_ B (CE) Page 9/56

10 1.6 WARRANTY INFORMATION Hardinge warrants to the original purchaser only that all products manufactured by it will be free from defects in materials or workmanship, such warranty to remain in effect if and only if such products are used in accordance with all instructions as to maintenance and operations set forth in manuals and instruction sheets furnished by Hardinge. The machine manufacturer is not responsible for any danger or damage arising from improper operation of the machine. Some examples of improper use are listed below. 1. Adding to or modifying the machine without consulting Hardinge. 2. Operating the machine outside the machining range. 3. Improper use of a workpiece holding or peripheral device. 4. Using the machine with interlocks or protection covers removed. 5. Carrying out machine operation, programming or maintenance and inspection work without thoroughly understanding the caution information, i.e. without having read the instruction manuals carefully. 1.7 ROUTINE INSPECTION The schedules below are based on single shift operations using coolant at all times. Daily 1. Check pressure gauge reading. Air pressure 5.5bar (80psi) 2. Check that there is sufficient oil in the air lubricator. 3. Check motors and other parts for abnormal noises. 4. Check the lubrication of sliding parts for evidence of proper lubrication. 5. Check safety covers and safety devices for proper operation. 6. Check coolant level and fill as necessary. 7. Clean dirt and chips from the axes and empty the swarf trays. Weekly (In addition to daily routine) 1. Clean chips and dirt from the entire machine and wipe down. 2. Check the air filter at the rear of the electrical cabinet. Replace the filter element if it is contaminated. 3. Check all polycarbonate vision panels for signs of damage crazing, cracking etc. or reduced visibility and replace if necessary. Contact your Hardinge representative for details. Yearly (In addition to weekly routine) 1. Remove the filter from the air filter bottle and clean/replace. 2. Check spindle drive belt condition and tension. 3. Check lost motion. 4. Check the condition of the linear rail wipers. 5. Check the integrity of the electrical connections and inspect the condition of the insulation. 6. Check condition of coolant filters and replace as necessary. XT series Heidenhain TNC640 Operating_ B (CE) Page 10/56

11 1.8 MAINTENANCE PROCEDURE DANGER! Before carrying out any maintenance work, ensure that the machinery is switched off and disconnected from the main power supply. Also ensure that the necessary warning signs and /or locks are appointed to stop any unauthorized persons from switching the power on to the machine until the work is complete and the machinery is safe to operate. The above warning signs or indications should be secured by a semi-permanent means with the printing clearly visible. Only qualified and competent maintenance engineers should carry out machinery maintenance work. Working on live electrical equipment must be carried out by only suitably qualified electricians. WARNING! Over travel limit switches, proximity switches and interlock mechanisms including all functional parts should not be removed or modified. When working in high places, use steps or a ladder which are maintained daily for safety. Use only fuses, cable's etc. from reputable recognized manufacturers. CAUTION! The maintenance person should check that the machine operates safety after the work is completed. Maintenance and inspection data should be recorded and kept for reference. XT series Heidenhain TNC640 Operating_ B (CE) Page 11/56

12 1.9 MACHINE WARM UP If the machine is used to produce components immediately after being started, following a long idle period, sliding parts may be worn due to lack of oil and thermal expansion of the machine can jeopardize machining accuracy. To prevent this condition, always warm the machine up. Never start the spindle without a tool holder in place and tooling with a balance level of G2.5 or better should always be used. We recommend that the machine is Warmed up prior to first operation by running all axes for 10 to 20 minutes at about half or one third the maximum speed in the automatic operation mode before actual cutting. This automatic operation program should cause each machine component to operate. During this cycle check the correct function of these operations. Be particularly careful to warm up the spindle. SPINDLE WARM UP It is essential that the spindle in the machine is correctly warmed up before use. 15,000rpm DDS Spindle Short Term Spindle Warm up If the machine has been idle for over 24 hours, run the spindle at 25%, 50%, 75% & 100% of the maximum spindle speed individually for 5 minutes. Once this has been completed, the machine is ready for operation. If the machine has been idle for within one week, run the spindle at 25%, 50%, 75% & 90% of the maximum spindle speed individually for 10 minutes and 100% of the maximum spindle speed for 30 minutes. Once this has been completed, the machine is ready for operation. Long Term Spindle Warm up If the machine has been idle for over one week, run the spindle at 25%, 50%, 75% & 90% of the maximum spindle speed individually for 30 minutes and 100% of the maximum spindle speed for 120 minutes. Once this has been completed, the machine is ready for operation. 18,000rpm Built-in Spindle Daily Spindle Warm up The spindle should execute a daily pre-lubrication procedure before start the warm up procedure, i.e. turn ON the air/oil lubrication system and the air purge system simultaneously at least 20 minutes. If the machine has been idle for over eight hours and/or warm up the machine for start operating every day, the control will proceed a warm up cycle automatically before normal machine operation can be run. The CNC will display the message "160 Warm up is required!". Then the spindle warm up procedure will be executed after the pre-lubrication procedure has finished, which consist with 4 steps running (i.e. 25%, 50%, 75% and full speed of the maximum spindle speed, each step running for 5 minutes). Once this has been completed, the machine is ready for operation. XT series Heidenhain TNC640 Operating_ B (CE) Page 12/56

13 Short Term Spindle Warm up If the machine has been idle for over one weeks, automated run the spindle for 60 minutes after the CNC displayed the message "160 Warm up is required!". Long Term Spindle Warm up If the machine has been idle for two weeks or more, automated run the spindle at the run-in procedure for 500 minutes after the CNC displayed the message "160 Warm up is required!". Once this has been completed, the machine is ready for operation. Caution: The balanced tool needs to be used on the spindle in the above operating procedure. Note: There is a risk of grease deterioration and standstill corrosion in spindles that have been idle for long periods which can reduce the life of the spindle. To prevent this, the spindle should be rotated manually, 5 to 10 times by hand every 2 months. This action should be performed with the power removed from the machine at the main isolator. XT series Heidenhain TNC640 Operating_ B (CE) Page 13/56

14 1.10 AUTOMATED SPINDLE WARM UP In order to prolong the life of the spindle it is essential to follow a warm up procedure after the machine has been idle for an extended period of time. When the spindle has not been used for more than 8 hours, the control will require a warm up cycle to be run before normal machine operation can continue. The NC will display the following message at the top of the screen display: When this message is displayed, the only automatic function permitted is a TOOL CALL in MDI mode, allowing a balanced tool to be loaded if necessary. Activating Spindle Warm-up 1. Select Manual or Hand wheel mode: or 2. Close guard doors. Press and hold the Spindle Start key for approximately 5 seconds, the NC will prompt to confirm if a suitable balanced tool assembly is in the spindle: 3. If a balanced tool is already in the spindle, press NC Start to continue. If the tool assembly is not balanced, or there is no tool present, cancel warm-up with NC Stop, load a suitable tool in the spindle, and return to step When NC start is pressed, the machine will begin spindle warm-up, and the following information will be displayed: 5. When the warm up is completed, the message Warm Up Successful will be displayed. XT series Heidenhain TNC640 Operating_ B (CE) Page 14/56

15 1.11 SPINDLE OPERATING CONDITIONS It is recommended that the spindle is not run continuously at high speed (above 10,000 rpm) for more than 12 hours. Instead reduce the speed to 500 rpm for 5 minutes before resuming high speed operation. Use coolant appropriate to the cutting process. Do not aim coolant directly at the spindle nose or submerge the spindle nose in coolant. The spindle is provided with an air purge system. Continue to run the air purge for 15 to 30 minutes after the spindle has stopped. Only then should the emergency stop button be pressed. Oil Chiller Unit OPTION Certain alarms within the oil chiller will protect the machine from further damage. Refer to the original manual supplied by the manufacturer SPINDLE MAINTENANCE Daily Maintenance. Clean the front nose of the spindle with dummy toolholder and a lint-free cloth but do not use compressed air. Check the taper for dirt. If necessary - use a cleaning arbor. Check coolant level in spindle chiller and top up if necessary. Check air supply. Check if spindle rotates easily and smoothly when turned by hand. Check if abnormal sound is generated. Check if excess heat is generated. Check if excess vibration is generated. Monthly Maintenance. Test tool change function. Check the spindle knock out distance. Activate the tool un-clamp pushbutton to check that the knock out distance is as specified in the maintenance manual. Note: prior to inserting a toolholder: ensure that the spindle taper is clean. XT series Heidenhain TNC640 Operating_ B (CE) Page 15/56

16 1.13 SPINDLE TOOLING Tooling with a balance level of G2.5 or better should always be used. Failure to do so will reduce spindle life and surface finish and may void the machine warranty. Do not use broken or worn tools. Avoid chatter and excessive vibration (do not exceed 4 mm/s). If using a tool with a length to diameter ratio of more than 5:1, limit the speed so that the vibration level does not exceed 1 mm/s. For safe operation, refer to the informative tag and make sure the tool holder and pull stud combination meet the standard as specified in the relevant Pre Delivery & Installation Guide. XT series Heidenhain TNC640 Operating_ B (CE) Page 16/56

17 1.14 INTERRUPTING MACHINING WARNING! When leaving the machine temporarily after completing a job, turn off the power on the operator panel with the Emergency Stop button and turn off the main isolator. Never turn off power during automatic operation or with the spindle or axes running unless an emergency occurs. It is better to interrupt the program by pressing the "Cycle Stop" push button COMPLETING A JOB Always clean the machine and supporting equipment down after use. Remove and dispose of chips and clean the covers and windows etc. Return each machine component to its initial condition. Check the wipers of axes waycovers for damage and replace if necessary. Check coolants, hydraulic oils and lubricants for level & contamination. Change them if you suspect they are contaminated. Clean the filter on the top of the coolant tank. Turn off the power first on the control panel with the emergency stop button and then at the main isolator before leaving the machine at end of the shift. XT series Heidenhain TNC640 Operating_ B (CE) Page 17/56

18 1.16 SAFETY DEVICES Make yourself aware of the locations of the emergency stop push buttons, which should be well known so that they can be operated at any time without the need to look for them. Test the push buttons periodically for their correct operation. The emergency stop push buttons are located on the main operator panel, ATC load door, chip conveyor (if fitted) and remote hand wheel (if fitted). Further safety devices are located at the following points around the machine: The front door and ATC load door have safety interlock switches with guard door locking. Stored stroke limit (Parameter setting): The control system will recognize when a move is requested that will take the motion beyond the end of the machine stroke. This move will not be allowed to start. Functional Explanation Emergency Stop Circuit A safety circuit is fitted in the machine through which the Emergency Stop Buttons are wired. If any one of Emergency Stop button is pressed, the machine will stop immediately and go into an Emergency Stop condition. CAUTION! Once the emergency condition has been safely resolved and the emergency stop buttons are released, the Power On button on the operator panel must be pressed to reset the safety relay into its normal condition. The CE button should then be pressed to clear any error messages within the control system. Servo & Spindle Power Disconnect Once the Emergency Stop button is pressed, the machine will stop and the power supply to the drives is removed. Door Safety Function The machine has interlocked doors, the main access door at the front of the machine and the toolchanger load station door at the left hand side of the machine. Both doors are shot bolted shut and can only be opened once the spindle is stationary and there is no program running. Power On Safety Circuit (Allows the operator to execute certain tasks whilst either door is open) Limited machine functionality is available to the operator whilst either door is open. The handwheel and jog keys are able to move the machine axes at feed rates of 2m/min and less when the mode select key switch is in the manual position. Selection of automatic program running is prohibited until the doors are shut and the mode select key switch is returned to the auto position. Rotation of the tool magazine is also prohibited until the doors are shut. XT series Heidenhain TNC640 Operating_ B (CE) Page 18/56

19 Door Interlock of Electrical Cabinet Safety Circuit When door interlock switch is in the 0 position and the cabinet doors are open, the power to the machine will be turned OFF. When door interlock switch is in the 1 position and the cabinet doors are open, the power to the machine will be kept ON WARNING: Only trained, skilled personnel should use this functionality. XT series Heidenhain TNC640 Operating_ B (CE) Page 19/56

20 2.1 TNC 640 VISUAL DISPLAY UNIT Header When the TNC is on, the current operating mode is shown in the header. Messages to the operator are also shown in this area. 2. Softkeys Various TNC functions are indicated on these soft keys. The displayed functions can be selected by pressing the keys directly below them. 3. Softkey selector keys. 4. Switch softkey rows. 5. Select screen layout. 6. Shift key to switch display between machining and programming modes. 7. Softkey selector keys for machine specific functions e.g. Toolchanger 8. Softkeys for various machine specific functions. The displayed functions can be selected by pressing the keys directly to the right. Further information on the use of and programming the Heidenhain control can be found at the following website address: XT series Heidenhain TNC640 Operating_ B (CE) Page 20/56

21 2.2 KEYBOARD AND CONTROL PANEL Spindle speed override knob Feedrate override knob M/C power on Emergency stop button Axis jog keys Spindle on/off Program start Program stop Mode select switch Standard coolant on/off Washdown on/off XT series Heidenhain TNC640 Operating_ B (CE) Page 21/56

22 2.3 CONTROLS ON THE TNC 640 Controls on the visual display unit Split screen layout Switch between machining or programming modes Softkeys for selecting functions in screen Switching for softkey rows Switching for softkey columns Program/file management Program Management Subprogram call MOD functions Help functions Pocket calculator Typewriter keyboard for entering letters and symbols Tool Functions Load tool offsets and activate ATC Machine operating modes Manual operation Electronic Handwheel Positioning with MDI Program run, single block Program run, full sequence Programming modes Programming and editing Test run Programming path movements Approach/depart contour Flexi Curve programming Linear move Circle centre/pole Circle move around CC Circle with radius Tangential circle Chamfer Corner rounding Moving the highlight, going directly to blocks, Cycles and parameter functions Move high-light Mode select switch Go directly to blocks, cycles and parameter functions XT series Heidenhain TNC640 Operating_ B (CE) Page 22/56

23 CONTROLS ON THE TNC 640 (cont.) Cycles, subprograms and program section repeats Define and call cycles Enter and call labels for Sub-programming and section repeats Program stop in a program Enter touch probe functions Co-ordinate axes and numbers: Entering and editing Select co-ordinate axes Numbers Decimal point Change arithmetic sign Polar co-ordinates Incremental co-ordinates Q parameter programming Actual position capture Skip dialog questions, delete words Confirm entry and resume dialog End block Clear numerical entry, or error message Abort dialog, delete program section XT series Heidenhain TNC640 Operating_ B (CE) Page 23/56

24 2.4 MODE SELECT SWITCH MODE-key set to MSO1 This is the normal operating condition which allows full machine functionality with all guard doors closed and locked shut. The general requirements of this manual and the Safety manual must be followed. Provided guard door is closed, any program can be started via CYCLE START when key is set in this mode. The key can be removed in this position by a Supervisor. When guard door is opened. All axes and spindle movement is disabled. MODE-key set to MSO2 This allows limited movement of the machine axes (<2m/min) with the main guard door open either by the hold-to-run jog keys on the main operating panel or the hold-to-run jog keys or electronic handwheel on the remote MPG in conjunction with the permissive keys for adjustment and/or setting purposes. There is a higher level of risk associated with any movement of the machine with the main guard door open (eg. crushing, shearing, cutting, ejection of material or mists etc) which could result in serious injuries or even death so, only specifically trained and authorised personnel are permitted to operate the machine in this condition and have access to the key switch which permits this mode. During any movement, all parts of the body should be kept away from the moving elements. The final responsibility for ensuring the safety of the operator in this mode of operation lies with the machine owner. If the operation can be carried out in MSO 1 with the main guard door closed, then that route should be selected in preference. MSO1 should be re-selected and the key switch removed as soon as all setting actions have been completed. The key should be kept in a safe place by the person authorised to use it. Machining is not permitted in MSO2 (Setting Mode). XT series Heidenhain TNC640 Operating_ B (CE) Page 24/56

25 2.5 MACHINE POWER ON AND REFERENCE Turn on Machine at the Isolator The isolator is located on the side of the machine. Turn the isolator switch "I" to the ON position, Figure A below. Rotate valve J of the main air switch, Figure B below, to the vertical position to turn the machine air supply ON. The machine will begin to power up, and the message Power Interrupted will be displayed. Press the key to clear this message and conclude boot-up sequence. Reference Machine 1. Ensure all Emergency stop buttons are out. 2. Press the Power ON button. Note: Due to safety checks it may be necessary to press the power on button twice. 3. Ensure that the feedrate override knob is set to 100%. 4. Press the Cycle Start button. 5. The machine will automatically Magazine reference out. 6. The ATC chain would rotate, but the other axes would be stationary. XT series Heidenhain TNC640 Operating_ B (CE) Page 25/56

26 2.6 MACHINE POWER OFF In order to prevent loss of data, the machine should be powered off using the following procedure: Press or to enter either Manual or Handwheel mode. Press key once to alter softkey display. Press softkey. The message What would you like to proceed? will be displayed. Confirm this by pressing the Shut down softkey. The machine will then power down. Note: It is also possible to set the machine to power off at the end of the program via the END PGM OFF softkey (See softkey operation section) Turn the main isolator switch I, Figure A, OFF. The main air switch valve J, Figure B, rotate the switch valve to horizontal position to turn the machine air supply OFF. I J OFF ON Figure A - Main Disconnect Switch Figure B - Main Air Valve XT series Heidenhain TNC640 Operating_ B (CE) Page 26/56

27 2.7 EMERGENCY STOP Pressing any Emergency stop button will cut the power supply to the axis drives, spindle drive and any other equipment on the machine (e.g. swarf conveyor). Emergency stop buttons are located in the following areas: Machine operator panel ATC manual operation panel (on side machine guard) Chip conveyor (if fitted) Remote MPG (if fitted) Power on Machine After an Emergency stop, the machine must be powered on before normal use can resume: Ensure all Emergency stop buttons are out. Press the Power ON button. Note: Due to safety checks it may be necessary to press and hold the power on button for a few seconds. Press the key to clear the emergency stop message. XT series Heidenhain TNC640 Operating_ B (CE) Page 27/56

28 2.8 SOFT KEY LAYOUT The machine functions accessible via softkey are split into 3 groups: Machine functions: e.g. coolant Spindle functions: e.g. rotation Toolchange functions: e.g. magazine loading The following pages contain an explanation of the functions available: XT series Heidenhain TNC640 Operating_ B (CE) Page 28/56

29 SOFT KEY LAYOUT (cont.) Machine Functions Cycle start Swarf conveyor on/off End of program power off Feed hold Swarf conveyor reverse (whilst key is pushed) Axis positive move Axis negative move Axis negative move Return to Main Menu Return to Main Menu XT series Heidenhain TNC640 Operating_ B (CE) Page 29/56

30 SOFT KEY LAYOUT (cont.) Spindle Functions Start spindle (cw) Through spindle coolant on/off (optional) Spindle stop Standard coolant on/off Jog spindle (cw) Washgun on/off (optional) Jog spindle (ccw) Orientate spindle to tool change position DRY RUN on/off Return to Main Menu Return to Main Menu XT series Heidenhain TNC640 Operating_ B (CE) Page 30/56

31 SOFT KEY LAYOUT (cont.) Toolchange Functions Manual tool load/unload function Jog tool changer magazine cw Tool unclamp Jog tool changer magazine ccw Enable tool changer magazine loading Return to Main Menu Return to Main Menu XT series Heidenhain TNC640 Operating_ B (CE) Page 31/56

32 2.9 MANUAL AXIS JOG Manual Axis jog via operator panel keys The Machine axes can be moved manually with the axis jog keys in either Manual Operation or Electronic Handwheel modes. Press or to enter the desired mode. A diagram of the axis jog keys is shown below: Press jog key relating to the desired axis and direction. The feedrate can be controlled using the feed override knob. To traverse at rapid feed press and the desired axis direction key. Note: The rapid jog feed will be reduced to 2m/min maximum when attempting to jog an axis with the guard door open, and it is only possible to move the axis individually. The mode select switch must be in the position. XT series Heidenhain TNC640 Operating_ B (CE) Page 32/56

33 HR 410 Permissive Buttons XT series Heidenhain TNC640 Operating_ B (CE) Page 33/56

34 2.10 ELECTRONIC HANDWHEEL The Machine axes can also be moved using the Manual Pulse generator (See Illustration) in Electronic Handwheel mode. Moving an Axis using Electronic Handwheel Press Select to enter Electronic Handwheel mode. the desired axis by pressing the relevant orange Axis key. Turn the Handwheel to move the axis. Setting the Interpolation factor Pressing the switch for handwheel. Selecting one of the three factor "SLOW", "MEDIUM","FAST". Note: The rapid jog feed will be reduced to 2m/min maximum when attempting to move an axis with the guard door open, and it is only possible to move the axis individually. The mode select switch must be in the XT series Heidenhain TNC640 Operating_ B (CE) position. Page 34/56

35 2.11 MANUAL TOOL LOAD/UNLOAD! WARNING Ensure adequate protection is used to prevent injury from sharp cutting tools. Press to enter manual mode. Press softkey to activate manual tool load/unload function. The message Tool Unclamping Please will appear. Open guard door of machine XT 630 5AX machine: Note: Whilst the TOOL RELEASE button on the machine head is pressed the tool in spindle is unclamped release button to clamp tool. While holding the tool, press the TOOL RELEASE button to release the tool in spindle. Replace tool then release the TOOL RELEASE button to clamp the tool in spindle Close guard door of machine The message TC quit, Please! will appear Press softkey to complete the manual tool load/unload function. XT series Heidenhain TNC640 Operating_ B (CE) Page 35/56

36 2.12 LOADING TOOL MAGAZINE VIA FRONT GUARD DOOR Press to enter manual mode. Press softkey to access toolchange menu. Press softkey to access load menu. To rotate the ATC magazine, press and hold the desired direction button until the magazine is in the required position (see picture). (Note: the magazine can only be rotated if the guard door is closed) Insert/remove tools from the carousel pockets, ensuring that they are correctly located. Press softkey to disable tool magazine loading. Press key to complete the operation. Press softkey to exit toolchange menu. Note: After manually changing the contents of the ATC magazine, check the pocket table to ensure the correct positioning. XT series Heidenhain TNC640 Operating_ B (CE) Page 36/56

37 2.13 TOOL TABLE Tool data, such as length, radius etc is stored in a centralised tool file. This file can be accessed from the following modes Manual Operation Electronic Handwheel Manual data input (MDI) Program run single block Program run full sequence In all modes, the tool table is accessed using the softkey. The tool table display is shown as below: Typical tool table fields are shown below. NAME L R R2 DL DR PLC Tool name. Tool length offset. Tool radius offset. Tool corner radius. Delta (wear adjustment) length offset. Delta (wear adjustment) radius offset. PLC information regarding the tool. There are four possible settings: Tool pocket will stay down after toolchange Tool pocket will retract after toolchange Editing tool table Press EDIT ON/OFF softkey so that ON is highlighted: Using cursor keys, highlight the desired field. Enter the new value. Exit tool table using the END soft-key or key. XT series Heidenhain TNC640 Operating_ B (CE) Page 37/56

38 2.14 POCKET TABLE The pocket table can be accessed from the tool table page using the softkey. The tool table display is shown below: The pocket table fields are shown below: Abbreviation Input Dialogue P Pocket number of the tool in the tool magazine (0 denotes spindle) POCKET NUMBER? T Tool number TOOL NUMBER? RSV Pocket reserved Pocket reserv.: Yes = ENT / No = NOENT ST F Special tool with a large radius requiring several pockets in the tool magazine. If your special tool takes up pockets in front of and behind its actual pocket, these additional pockets need to be emptied and locked (status L). Fixed tool number. The tool is always returned to the same pocket. SPECIALTOOL? Fixed pocket? Yes =ENT / No = NO ENT L Locked pocket Pocket locked? Yes =ENT / No = NO ENT DOC Display of the comment to the tool from TOOL.T Editing pocket table Press EDIT ON/OFF softkey so that ON is highlighted: Using cursor key, highlight the desired field. Enter the new value. Exit tool table using the END softkey or key. The pocket table can also be reset using the softkey. This will set the tool and pocket numbers the same, and remove any ST, F, L, DOC status. This should only be used if the magazine and spindle are empty. XT series Heidenhain TNC640 Operating_ B (CE) Page 38/56

39 2.15 ATC OPERATION IN MDI MODE Press key to enter MDI mode. Cursor to the end of the program using keys. Press key to begin a tool call line. Enter the new tool number using keys and press. Enter spindle axis as Z using orange key and press. Enter spindle rpm using keys and press. Conclude Tool Call line by pressing key. Ensure Tool Call line is highlighted using keys. Activate ATC cycle by pressing the green cycle start button. XT series Heidenhain TNC640 Operating_ B (CE) Page 39/56

40 2.16 M-FUNCTION CODES Function Effective at Beginning of Block End of Block M00 Stop program run/stop spindle M01 Optional program stop M02 Stop program run/stop spindle/return to program block 1 M03 Spindle on clockwise M04 Spindle on counter-clockwise M05 Spindle stop M07 Through spindle coolant on (where fitted) M08 Standard Coolant on M09 All Coolants off M10 Clamp axis M11 Unclamp axis M13 Spindle on CW and standard coolant on M14 Spindle on CCW and standard coolant on M19 Spindle orientation 0 degree M20 Spindle orientation selectable via Parameter M21 Spindle orientation cycle 13 M30 Stop program run/stop spindle/return to program block 1 M31 Working without M3/M4 M41 Wash down (chip-flush) coolant on M42 Wash down (chip-flush) coolant off M44 Unclamp axis 4 M45 Unclamp axis 5 M50 Chip conveyor stop M51 Chip conveyor forward M52 Chip conveyor reverse M56 Workpiece air-blast on M58 ATLM air-blast on M64 Clamp axis 4 M65 Clamp axis 5 M71 Axis limit 1 M72 Axis limit 2 XT series Heidenhain TNC640 Operating_ B (CE) Page 40/56

41 M73 Axis limit 3 M76 Workpiece air-blast off M78 ATLM air-blast off M80 Parts counter reset =0 M81 Parts counter +1 M82 Tool specific torque monitoring off M83 Tool specific torque monitoring on M180 Spare M-code 1 on M181 Spare M-code 1 off M182 Spare M-code 2 on M183 Spare M-code 2 off M184 Spare M-code 3 on M185 Spare M-code 3 off M186 Spare M-code 4 on M187 Spare M-code 4 off M188 Spare M-code 5 on M189 Spare M-code 5 off M190 Spare M-code 6 on M191 Spare M-code 6 off M192 Spare M-code 7 on M193 Spare M-code 7 off M194 Spare M-code 8 on M195 Spare M-code 8 off Notes: Certain M-codes are specific to a machine or Option fitted to machine. TOOL CALL must be used for toolchange command (M06* verifies without action) A comprehensive M-function list can be found in the Heidenhain TNC 640 manual supplied with the machine. XT series Heidenhain TNC640 Operating_ B (CE) Page 41/56

42 2.17 DATUM SETTING Preparation Clamp and align the workpiece. Load a tool of known radius and length into spindle. Ensure that the control is displaying actual (ACTL) position values. (to do this see the Heidenhain TNC 640 manual supplied with the m/c) For X and Y axis datum setting In manual operation or electronic handwheel mode, carefully move the tool until it touches the workpiece surface using the jog keys and the electronic handwheel. Press the softkey, and select the required axis using the orange axis keys. Enter the datum co-ordinates (taking tool radius in account where necessary) and confirm with the key. Repeat as necessary for other axis. For Z axis datum setting In manual operation or electronic handwheel mode, carefully move the tool until it touches the workpiece surface using the jog keys and the electronic handwheel. Press the softkey, and select the required axis using the orange axis keys. Enter the surface co-ordinate and confirm with the key. Please consult the supplied Heidenhain manual for information regarding this setting before use. XT series Heidenhain TNC640 Operating_ B (CE) Page 42/56

43 2.18 PROGRAM RUN Methods of program run Program run, single block - Each block of the program must be started individually with the Program start button. Used for program proving. Program run, full sequence- The program will run through automatically after the Program start button is pressed. Ensure workpiece is securely clamped and the datum and tools have been set. Enter the desired mode. (Note you can switch between modes during program execution) Select program to run Press to enter program management screen. Select the required program using the cursor keys and confirm with. The display will return to program run mode. Select block 0 by pressing. Begin program run by pressing the program start button. The program can be interrupted at any time by pressing the program stop (Feed hold) button. Program run can be resumed using the program start button, or ended by pressing the Internal Stop softkey. In addition, the machine can be manually moved via jog keys/handwheel by pressing the Manual Traverse soft key. Machining can be resumed by pressing the Restore Position soft key, followed by Cycle Start. Note: During program run, the spindle rpm and feedrate can be altered using the override knobs. When overriding spindle speed there may be a short feedrate hold to allow the spindle to alter speed. XT series Heidenhain TNC640 Operating_ B (CE) Page 43/56

44 2.19 MANUAL OPERATION OF SPINDLE The machine spindle can be manually activated in both manual operation and electronic handwheel mode: Press or to enter the desired mode. Ensure guard door is closed Activate Spindle Press softkey, and enter the desired spindle RPM. Confirm Spindle RPM by pressing the green cycle start key. Press softkey, and enter 3 (spindle on CW M code). Confirm spindle activation by pressing the green cycle start key. The Spindle will now begin to rotate at the programmed RPM. Deactivate spindle Press softkey, and enter 5 (spindle off M code). Confirm spindle deactivation by pressing the green cycle start key. The Spindle will now stop. Note: After loading the spindle RPM as described above, it is also possible to activate/deactivate the spindle using the spindle on/off buttons or the spindle on/off key XT series Heidenhain TNC640 Operating_ B (CE) Page 44/56

45 2.20 WASH GUN The machine is fitted with a manually operated coolant wash gun. To operate the wash gun: Ensure that the machine is stopped and the front guard door is open. Press the WASHGUN softkey. This will enable the wash gun and also activate the base wash down for a time period set in a parameter. The wash gun can now be operated by pulling the trigger on the gun body. If time out occurs to de-activate the wash gun press the WASHGUN softkey again Press the WASHGUN softkey again or close the front guard door to disable the wash gun. XT series Heidenhain TNC640 Operating_ B (CE) Page 45/56

46 2.21 USER PARAMETERS Some machine functions can be altered via the "OPTION BIT SETTING PAGE". Entering password "531122" can enter option bit setting page. Care should be used when altering these settings and it is recommended that the original values are noted before any alteration takes place. "OPTION BIT SETTING" page XT series Heidenhain TNC640 Operating_ B (CE) Page 46/56

47 2.22 SERVICE FUNCTION Activate SERVICE Function Ensure the all Machine guard doors are closed. Press the softkey after the "Jog" mode has been selected. [However this softkey will be turn to deactivate status (shading) other modes.] when operating in the Press the softkey and then the "SERVICE" function will be active. Using HELP Function Using the key of switching for softkey columns to select the desired function softkey e.g. : S TO TOOLCHANGE POSITION. Press the cycle start button to perform selected softkey function. When the function has been performed, the message 209 Function OK will be displayed. (A list of the softkey service functions available is shown on the next page.) When the maintain has been finished, press the function. softkey to exit the service (Note: It may be necessary to check the pocket table after service function about ATC arm exchange. See supplied Heidenhain TNC 640 manual.) XT series Heidenhain TNC640 Operating_ B (CE) Page 47/56

48 SERVICE FUNCTION (cont.) Service functions available: 1. The machine service softkey below is for a Double arm cam driven type ATC: XT series Heidenhain TNC640 Operating_ B (CE) Page 48/56

49 - Orientate the spindle to toolchange position - Move Z to Safety position - Move A to toolchange position - Move Z to toolchange position - Move Y to toolchange position - Move X to toolchange position - Swarf door open - Swarf door close - Unclamp tool in spindle - Clamp tool in spindle - Tool-pot down (towards spindle) - Tool-pot in (towards Mag.) - Move swing-arm to spindle - Move swing-arm to change tool - Move swing-arm to basic (home) - Move swing-arm to spindle - Move swing-arm to change tool - Move swing-arm to basic (home) - ATC recovery - Move magazine cw (right) - Move magazine ccw (left) - Move magazine to pocket 1 - Set spindle-tool status to tool 0 (DO NOT XT series Heidenhain TNC640 Operating_ B (CE) Page 49/56

50 2.23 ATC ARM RECOVERY WARNING: Please contact your local Hardinge Service Representative before using the toolchange recovery function. WARNING: Before executing ATC ARM RECOVERY procedure, check the spindle and Z axis tool change position. In the event of a toolchange error mid-toolchange, the ATC ARM RECOVERY function can be used to manually recover the machine. The machine happened E.M stop or power failed when ATC arm running. ATC ARM RECOVERY can make arm go to original. After machine power on, the alarm "88 ATC not on 0 degree position" will display on screen. Press ATC ARM go reference automatically XT series Heidenhain TNC640 Operating_ B (CE) Page 50/56

51 2.24 POCKET TABLE REFORMING WARNING: Please contact your local Hardinge Service Representative before using the pocket table reforming. PRESSING "TOOL TABLE" "POCKET TABLE" "EDIT ON" (highlighted) "RESET POCKET TABLE" "OK" XT series Heidenhain TNC640 Operating_ B (CE) Page 51/56

52 Note: There are some steps need you to pay attention after finished the tool recovery procedure as below: Step 1: Check what number of tool package is displayed on the main screen. Step 2: Setting the RSV value of this tool package to be "R" when you get the number of tool package from the main screen. (Example as Figure shown below: the number of tool package is "9" was shown up, then setting the XT series Heidenhain TNC640 Operating_ B (CE) Page 52/56

53 RSV value is "R" on the row of "1.9" tool package.) Step 3: Access to the "package table editing" mode screen and then setting the number of tool package to be "0" that you got from the main screen. (Example as Figure shown below: the number of tool package is "9" was shown up, then setting the number of tool package value is "9" on the row of tool package "0.0".) XT series Heidenhain TNC640 Operating_ B (CE) Page 53/56

54 2.25 STACK LIGHTS The stack lights will be flicking when power ON the machine firstly that allow the operator to carry on the stack lights checking as Figure at right-side shown. The colors and definitions are listed below: RED Emergency Stop or alarm condition. Automatic cycle is stopped. AMBER The machine is in Automatic mode, but automatic cycle is not active. GREEN Automatic cycle active. Normal operation. XT series Heidenhain TNC640 Operating_ B (CE) Page 54/56