OPERATION MANUAL - Sharp Industries MANUAL I-SERIES-CAM SHARP MACHINERY CO.,LTD 1 INSTRUCTION HAND...

VERTICAL MACHINING CENTER

OPERATION MANUAL

I-SERIES-CAM

SHARP MACHINERY CO.,LTD

1

INSTRUCTION HAND BOOK

FANUC 18M、0I、18I、21I

10. 19, 2007


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FANUC 18M,0I,18I,21I 1. PREFACE .................................................................................................................................1-1 2. INSTALLATION AND POWER ON ......................................................................................2-1

2.1 Input power ON ..................................................................................................................2-2 2.2 Specifications of electric appliances ...................................................................................2-3 2.3The step of main power ON:................................................................................................2-5

3. OPERATOR’S PANEL ............................................................................................................3-1 3.1 Operator panel.....................................................................................................................3-5 3.1MDI keyboard functions: .....................................................................................................3-5 3.2 Soft operator's panel............................................................................................................3-7 3.3hine operator’s panel:...........................................................................................................3-8

4. ANUAL OPERATION...........................................................................................................4-16 4.1MANUAL REFERENCE POSITION RETURE ..............................................................4-16 4.2 MANUAL MOVEMENT OF 3-AXES: ...........................................................................4-16 4.3 OPERATION OF SPINDLE CLAMP/UNCLAMP:........................................................4-17 4.4 MANUAL MAGAZINE OPERATION : .........................................................................4-17 4.5 SPINDLE OPERATION: .................................................................................................4-17

5. EXPLANATION OF ATC .......................................................................................................5-1 5.1 HYDRAULIC TYPE ATC: ................................................................................................5-1 5.2 CAM TYPE ATC: ............................................................................................................5-12 5.3 CAROUSEL TYPE ATC: ................................................................................................5-27

6. EXPLANATION OF OTHER INSTALLATIONS................................................................6-35 6.1 LUBRICATION AND THE RELATED SETTING: .......................................................6-35 6.2 COOLER UNIT: ...............................................................................................................6-36 6.3 HYDRAULIC UNIT(HYD.) ............................................................................................6-37 6.4 CHIP CONVEYER (CHIP) ..............................................................................................6-37 6.5 WORK LIGHT/ALARM LIGHT.....................................................................................6-37 6.6 THERE LAYER ALARM LIGHT DESCRIPTION........................................................6-37 6.7 RS232 AC110V INTERFACE .........................................................................................6-37 6.8 HAND PASS SAFE DOOR INTER LOCK.....................................................................6-38

7. AUXILIARY FUNCTIONS:....................................................................................................7-1 7.1EXPLANATION OF M CODE: (THE MARKS “*” IS FOR OPTION FUNCTION) ......7-1

8. PLC SETTING..........................................................................................................................8-1 8.1SETTING OF TIMER: ........................................................................................................8-2 8.2 EXPANATION OF KEEP RELAY SETTING:.................................................................8-5 8.3TO MODIFY THE SETTING: ..........................................................................................8-17

9. THE TROUBLESHOOTING...................................................................................................9-1 9.1 LARGER TOOL MANAGEMENT ...................................................................................9-6


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1-1

1. PREFACE

This manual describes the operation and troubleshooting of SHARP’s vertical machining center (about auxiliary function for M code ,sequence for operation and some related items like TIMER, KEEP RELAY that also will be described at chapter 7, 8 ). The function of vertical machining center is not only decided by machine tools company, the CNC computer and servo system also have serious influence. In this manual we have tried as much as possible to describe all the various functions. Therefore, function which are not provide in your machine may be optional function. Do not modify the machine designing or add any electric device without our permitting, otherwise it may cause serious problem. Note: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


2-1

2. INSTALLATION AND POWER ON

When connecting the electric cabinet with the power.because the interior operation Of the cabinet is AC 220V.the user must use a transformer to switch the voltage In accordance with the specification of voltage where it is being used.Please refer To the diagram Fig 2-1 for connecting 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 electeic cabinet.

Fig 2-1


2-2

2.1 Input power ON Link power ON as show in fig 2.2 Note. Please make sure of power-off when connecting the power, and to cover lid

when it link completely. Be sure have ground connection to prevent the noise to the NC unit.

Fig 2-2


2-3

2.2 Specifications of electric appliances Vmc-650～1200 AC220v 60hz±10% 3φ supply wire 8m2 Vmc-1400～21100 AC220v 60hz±10% 3φ supply wire 14m2

VMC650～1200 distribution of consumption: AC220v

75(a)

AC220v

9.7(A) 34(A) 0.1(A) 6.5(A) 0.28(A) 4.2(A) 0.1(A)

AC110V AC110V 16.2(A) 1.4(A)

8.2(A)

(1.5A)

Control power 4 × SOL + 15 × relay + 1 × work light + 1 × revolving lamp = 4 × 1.1 + 15 × 0.0369 + 1 × 2.9 + 1 × 0.4 = 8.2 Non-fuse breaker= 9.7 + 34 + 16.2 + 0.1 + 6.5 + 0.28 + 4.2 +0.2 = 75 Transformer: A = N1/n2 = V1/V2 = 220/110 = 2 2 = A I2/I1 =9.7/I1 → I1 = 4.85(A)

4.85(A) × 220(V) = 1067(VA)

P.S.: If input voltage of environments is 380V, please use 23KVA transformer.

MAIN POWER SWITCH

75A

TRANSFORM

ER SPINDLE MOTOR OILER HYDRAULI

C UNIT HEAT EXCHANGE

ON CABINT SPINDLE COOLER SYSTEM MOTOR

FAN

POWER outPUT

CONTROL POWER

SEVO MOTORS FOR

3-AXES

COOLANT PUMP


2-4

VMC1400～21100 distribution of consumption: AC220V

96.18(A)

AC220V

9.7(A) 53(A) 0.1(A) 6.5(A) 0.28(A) 4.2(A) 0.1(A)

AC110V AC24V 22.2(A) 1.4(A)

8.2(A)

(1.5A)

Control power 4 × SOL + 15 × relay + 1 × work light + 1 × revolving lamp = 4 × 1.1 + 15 × 0.0369 + 1 × 2.9 + 1 × 0.4 = 8.2 Non-fuse breaker= 9.7 + 53 + 22.2 + 0.1 + 6.5 + 0.28 + 4.2 +0.2 = 96.18 Transformer: a = N1/N2 = V1/V2 = 220/110 = 2 2 = A = I2/I1 =9.7/I1 → i1 = 4.85(A)

4.85(A) × 220(V) = 1067(VA)

P.S.: If input voltage of environments is 380V, please use 30KVA transformer.

MAIN POWER SWITCH

75A

TRANSFORM

ER SPINDLE MOTOR OILER

HYDRAULIC UNIT

HEAT EXCHANGEON CABINT

SPINDLE COOLER SYSTEM FAN

POWER output

CONTROL POWER

SEVO MOTORS FOR

3-AXES

COOLANT PUMP


2-5

2.3The step of main power ON: Please use multi-meter to check if R.S.T. phases are shorted to ground connection? If machine oil tube is correct? And if the emergency stop button is pressed down that locates on operator panel? Be sure all those item that we mentioned are done, then turn main power ON. In this time the transformer, fan and the servo amp. are in stand-by state. You will see the power light on that displayed on the operator’s panel. After that please follow the step to turn main power ON:

(1) press power ON push button that locates 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 voice of hydraulic unit that starts to work. 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 then it will be restored.

We will fix each-axis (especially Z-axis) to ensure every axis are firmer to avoid displacement during delivery. After finishing power connection, be careful to remove all firmer and move all axes and back to home point. No matter start or stop the NC have to be on EMG situation. It means that start NC first then release EMG when you turn power ON, and press EMG first then stop NC when 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 checks the following items: (1) If each-axis has a normal?

(2) If oiler consumes oil and works normally? (3) If spindle orientation is correct?

(4) If z-axis tool change position is correct?

(5) If T code and magazine work correct? (6) If low/high gear changes smoothly

(7) Check other function like chip conveyer , coolant, work light, M30 light, Auto power out…


3-1

3. OPERATOR’S PANEL

8.4” Color LCD/MDI (Standard type, sheet key)

FANUC 18MC 8.4” COLOR LCD/MDI

10.4” Color LCD/MDI (Standard type, sheet key)

FANUC 18I 21IB 8.4” COLOR LCD/MDI


3-2

FANUC 18IB 21IB 10.4” LCD/MDI


3-3

FANUC 0I-C (Standard type, sheet key)

FANUC 0I-C 8.4＂ LCD/MDI


3-4

7.2＂ LCD/MDI


3-5

3.1 Operator panel

The operator panel is divided into two areas, the upper area is operator panel for MDI and CRT (please see page 3-1).

3.1MDI keyboard functions:

Item Description Function

1 Power ON/OFF key

Press this buttons to turn CNC ON and OFF

2 Rest key

Press this key to reset the CNC, to cancel an alarm, etc.

3 HELP key

Press this key to use the help function when uncertain about the operation of an MDI key.(help function)

4 Soft key

The soft key have 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 Shift key

Some key have two characters on their keytop. Pressing the〈SHIFT〉key switches the characters. Then

the character indicated at the bottom right corner on the keytop can be entered.

7 INPUT key

When an address or a numerical 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 key. This key is same as INPUT key of the soft keys, and either can be pressed to produce the same result.

8 Cancel key

Press this key to delete the last character or symbol.

ON OFF

RESET

HELP

SHIFT

INPUT

CAN

INPUT


3-6

▲

PAGE

▼

PAGE

9 Program edit keys

Press these keys when editing the program

: Alteration

: Insertion

: Deletion

10 Function keys Press theses keys to switch display screens for each function.

: Press this key to display the position screen.

: Press this key to display the program screen

: Press this key to display the offset/setting screen

: Press this key to display the system screen

: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 downward direction in a character distance

: This key is used to move the cursor to the upward direction in a character distance

12 Page change keys :This key is used to changeover the page on the CRT screen in the forward direction.

: This key is used to changeover the page on the CRT screen in the reverse direction.

ALTER

INSRT

DELET

POS

PROG

OFFSET SETTING

SYSTEM

MESSAGE

GRAPH

CUSTOM

▼

▲

▲

▲

ALTER

INSRT

DELET


3-7

3.2 Soft operator's panel

Push MDI board. To function button displayed

→ → → ﹝OPR﹞ to get into the screen of soft operator’s panel.

OPERATOR’S 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 0.000 Y 0.000 Z 0.000 SO TO HAN

MACRO SETTING OPR

The function of operator’s 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 machine and 3 axes do not move. The coordinates value still varies in CRT. (NOTE:Be sure X,Y,Z axes have to back to home position after OFF)

(2)DNC MODE Data communication mode is used to transmit and execute simultaneously when the memory is for a large program. The program won’t exist 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’S MANUAL).

(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 may have wrong shape.)

OFFSETSSETTING

OFFSET WORK

OPR

SETTING

△ PAGE


3-8

(7) Handle inserts(HD.INT):For any mode it can control 3-axis’ movemant by

turnig hancl whed。

(8) 4、5 –AXIS BYPASSING：OFF indicates uses the 4/5 axis。

(4NG) ：ON indicate noglect the fnuction for 4/5 axis。

3.3hine operator’s panel:

This section is to explain the function of every button and switch of operator’s panel.

-4+

Y-Z

-Y+

4+

Z

+X

-X

OP

T2

OP

T3

OP

T4

OP

T5


3-9

(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 origination (re-zero).

(5) MODE SELECT: This switch is used to specify an operation mode. There are the explanation of each mode as below:

EDIT:This MODE is useed register,modify, add or delete of program and link personal computer to transfer parameter or program.

AUTO

MDI

EDIT


3-10

M.D.I.: This mode can execute the command in register. AUTO: This mode is used to execute a program stored in memory.

HANDLE: This mode can control 3-axes movement by turn hand wheel. The movement can be adjusted by incremental selector. JOG: In this mode, programmed of axis is controlled by FEEDRATE OVERRIDE

and JOG FEEDRATE and the feed rate is displayed on operator’s panel.

RPD: This mode is used to move axis in rapid traverse and is rapid speed adjusted by RAPID OVERRIDE %. ZRN: This mode is used to return 3-axes to machine zero and is moving speed 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.

ZRN MODE: To return 3-axes zero simultaneously.

SINGLE BLOCK MODE: To execute one block

(7) FEED HOLD: When this button is press, the program will pause automatically. Please notice that 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 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


3-11

(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 CRT. After release, Z-axis have to return zero. This button should be pressed at least 3 seconds for function Action 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 switch is ON, the controller will execute one block

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 works, the optional-stop will not be performed with only M01 code or with only this button on.


3-12

+Z+4 -Y

+Y-4

+X

-Z

-X

(19) CHIP CVYR: To ON/OFF chip conveyor. If safe door was opened or under maintenance mode

This button will be + press switch use functional

(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 can be chosen.(To reform rapid traverse by pushing AXIS FEED DIRECTION AND RAPID button simultaneously)

(22) INDEX: Push this button once for magazine rotating one step, hold this button for continuous rotating.(“INDEX” can only make a clockwise turn. If safe door was opened or under maintenance mode This button will be + press switch use functional

(23) 0. SP TOOL/1. STAND-BY: When this button is ON, 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:

Rapid travels of G00/G08/G30/G60 and canned cycle. The movement of RAPID” & “ZRN” MODE

%


3-13

x%

min

(25) JOG FEEDRATE & FEEDRATE OVERRIDE %:

To adjust the JOG FEEDRATE (a) Available in JOG & RUN mode (b) Range:0-1260mm/min The movement of PROGRAMMED FEEDRATE. (a)Available to F command that exists in program

(b)Available range:0-150% (c)unavailable in tapping cycle.

(26)SPINDLE OVERRIDE %: It can be adjusted in any mode.

The range:50%-120%。

(27) SPINDLE LOAD %: To display the actual load of spindle motor.

Please pay attention when LOAD 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 right side of machine)

0 150 ││││││││││││

x mm/min

%


3-14

L H

(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 states of ATC are OK.

(31) 4-AXIS UNCLAMP: To indicate the 4-axis is unclamped and can be operated.

(The lamp does not light when there is no 4th-axis)

(32) LUB ALARM: It lights when Lub tank is empty or pump malfunction.

(33) GEAR H/L: To show the spindle gear position H. lamp light when spindle gear on high position. L. lamp light when spindle gear on low position. (There are no GEAR H/L lamp for the spindle of belt type)

(34) MIRROR X/Y: “X” lamp will light during execute M71 command.

“Y” lamp will light during execute M72 command.

(35) AXIS FEED DIRECTION RAPID BUTTON: To quick move every axis by combining with AXIS FEED DIRECTION. When in ZRN mode, the light will indicate whether the ZERO-RETURN is performed.

4

X Y


3-15

(36) OP1 :For customer add option.(When use CE operator panel for ENABLE

button)

(37)OP2: The axis feed direction ENABLE button at JOG/RAP or ZER mode,When

use axis feed direction button must be enable OP2 button then can to move the axis.

(38)OP3: For customer add option.

(39)OP4: For customer add option.

(40) AIR BLOW(M07): Press this button to comply the M07 spindle side-flush

command If safe door was opened or under maintenance mode This button will be no functional


4-16

4. ANUAL OPERATION

4.1MANUAL REFERENCE POSITION RETURE

After NC power ON, the axes have to return to the reference position(home, zero). If not, the travel limit of the software will be useless for each axis. and it will cause machine in dangerous situation, and the RAPID traverse will not be available. There are two ways to return reference position as follows:

(1) In ZERO mode, press the OP2 button then press the push button of each axis to return ZERO. It works even push more than one buttons simultaneously. 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, this 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 indicate lamp of that axis will light. When 3 axes have returned reference position, the RAPID lamp will light too. Thereafter no matter 3 axes at any position just select zero mode and all RAPID lamp will light to remind customer that have overridden.

(2) In ZERO mode, press OP2 button tnen push CYCLE START button, Z-axis will move to reference position first. When Z-axis decelerates, the X, Y axes move to reference position in the same time. The detail action and time for lamps light-on are the same as above mentioned. Please note that:

(I) Before pushing the cycle start button, make sure that the limit switches of the 3 axes do not contact their dogs, and the 3 axes are not on the ZERO positions.

(II) 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 OP2 button then push AXIS DIRECTION SWITCH “+” or “-“ to move 3-axes, and to adjust the movement by FEEDRATE OVERRIDE & JOG FEEDRATE that is on operator’s panel.

(3) RPD OPERATION(rapid traverse): IN JOG/RPD mode, press OP2 button then push RAPID and AXIS DIRECTIO SWITCH “+” “-“ to move 3-axes, the movement


4-17

is adjusted by RAPID OVERRIDE % 4.3 OPERATION OF SPINDLE CLAMP/UNCLAMP:

VMC-1400~2185: There are CLAMP and UNCLAMP two push button at the metal of magazine, please select HANDLE mode, and push UNCLAMP to take off spindle tool. The CLAMP operation completion after push CLAMP to clamp tool.

VMC650～1100: There are only CLAMP/UNCLAMP button on the front of magazine, when press down this button is UNCLAMP and relieve it is CLAMP.

4.4 MANUAL MAGAZINE OPERATION :

(1) MAGAZINE RETURN HOME OPERATION: Select “ZRN” mode, push INDEX button that show on the panel. Then the magazine starts rotation until stopped at the position of 1. Stand by tool position. This function only available for VMC-1400 ~2185

(2) MAGAZINE ROTATIONG OPERATION: Select HANDLE mode, push INDEX button that show on the panel. Then moved one pot by clockwise move. If not relieve this button keep running.

For VMC-1400~2185: The control box at the lower of magazine have two buttons

for magazine forward CW and for magazine reverse.

Push button once for move one pot. If not relieve the button it will keep running. 4.5 SPINDLE OPERATION:

(1) In MDI mode, to start by key in M03 or M04 and speed S ,

after started the speed adjust by SPINDLE OVERRIDE 50% ～120%.

(2) In HANDLE mode, to start when executed M3 (M4) S indication. Only press

and then the spindle will rotate like S order that you have done

before.

IN PUT

MG. REV

MG. FOR

M3 M4


5-1

5. EXPLANATION OF ATC

Please make sure that Z-axis reference position and spindle reference position are at the right point before execute M6 command. Especially, after you reinstalled Z-axis motor or orientation sensor.

The compensation parameter for Z-axis tool change point is No.1850

The compensation parameter for spindle orientation point 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:

1) Note of operation:

I. ATC STAND-BY:

The ATC will be in STAND-BY state, except executing M06. If ATC is not stand-by, then M06 command won’t be executed and Z-axis will not move. When the STAND-BY LED indicate of ATC lights on, it means ATC is STAND-BY. When executing M06 the light is OFF.

II. TOOL CHANGE CYCLE

(1)TOOL CHANGE OF MDI MODE

To execute M06 or T code are available in MDI mode. In MDI mode, first

press , then key in M06 and press 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.

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.

PROGRAM

INPUT


5-2

M codes for HYDRAULIC TYPE ATC:

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 , RACK RETURN (ARM DOES NOT MOVE)

In MDI mode, Z-axis must return reference position 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 on chapter 9.

(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 09001 automatically. And after executed, it will return back to main-program. Do not modify or delete the program of 09001.

NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC 0M-C SYSTEM.

THE MOTION OF SUBPROGRAM:

Simultaneously executing Z-axis returning to reference position, POT DOWN, SPINDLE ORIENTATION (M19). The customer doesn’t have to write G91 G28 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 END M06 AFTER STAND-BY


5-3

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 write them together in one block to save time for tool change.

(MODE 1) :

M06 T07; :

M06 T08; :

：

(MODE 2) : M06; T08;

:

M06 T09;

；

：

09001 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.). Please RESET, and use M code to set ATC STAND-BY, then re-execute tool change.

TOOL NO.7 MACHINING PROCESS





5-4

2) TROUBLESHOOTING： (1) 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 -180 M1 ：MAG MOTOR P1：MG FORWARD PUSH BUTTON P2：MG REVERSE PUSH BUTTON P3：SPINDLE CLAMP PUSH BUTTON P4：SPINDLE UNCLAM PUSH BUTTON


5-5

(3) THE NECESSARY CONDITIONS FOR STAND-BY: To execute M06,the ATC must

be in STAND-BY situation, and has to satisfy the following conditions:

18MC

AIR PRESS. X1006.0 FOR VMC-1500-21100

LOOK PIN IN L1 ON X1005.4 POT IN L2 ON X1005.5 POT OUT L3 OFF X1005.6 TOOL CLAMP L10 ON X1005.0 TOOL UNCLAMP L11 OFF X1005.1 ARM 0 L4 ON X1007.1 ARM 60 L5 OFF X1007.2 ARM UP L6 ON X1007.3 ARM DOWN L7 OFF X1007.4 ARM CW 180 L8 OFF X1007.5 ARM CCW 180 L9 ON X1007.6

0I and 18I and 21I AIR PRESS. X6.0 FOR VMC-1500-21100

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

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

FIG (A)


5-7

FIG (B)

FIG (C)


5-8

FIG (D)


5-9

3) M06 CAN’T BE DONE: There are two situations as below:

I. Stop after POT DOWN:

(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 M06.

II. 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 0 . (4) If ARM has already reached 180 , please do M91(RACK RETURN) (5) Recover the protection of manual ATC operation (Set K1.4.4=0) (6) ATC STAND-BY light ON (7) POWER OFF/ON

4) TO SET 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 “N1”The addresses of tool registration. Here are descriptions for setting tool registration as below:

C01: 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: Setting at of counter screen of PMC

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).

If ATC has tool-selection mistake, please re-check the tool registration and correct

CURRENT


5-10

the mistake. Otherwise there will be some alarm when executing T code.

5) USING & NEGLECTING OF MACRO FOR TOOL CHANGING:

MACRO 09001 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. G91 G28 Z0 is not necessary before M06. 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).

(1) Subprogram of tool change:


5-11

% O9001(…..MO6 SUB-PROGRAM….) THE NUMBER OF PROGRAM AND EXPANATION.#3003=1 SINGLE BLOCK IS DISABLED. #3004=1 FEED HOLD IS DISABLED. T#4120 SEARCH T-CODE; IF[#1000EQ1] GOTO 70 TO DECIDE IF “T” IS SPINDLE TOOL IF[#1003EQ1] GOTO 10 TO DECIDE IF IN MDI MODE. N10 #103=#4003 SAVE THE CURRENT G-CODE OF THIRD GROUP

#1100=1 SPINDLE ORIENTATION AND POT DOWN G91G28Z0 Z-AXIS RETURNS HOME #1100=0 CANEL MACRO #1100 M06 EXECUTING TOOL CHANGING N70 G#103 #3003=0 SINGLE BLOCK IS AVAILABLE #3004=0 FEED HOLD IS AVAILABLE M99 RETURN TO MAIN PROGRAM


5-12

(2) Neglect of MACRO tool change:

1. Select MDI mode

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 5.2 CAM TYPE ATC:

1) ATTENTION OF 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’s 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 , then key in M06 and press 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 screen

PWE have to be set to 0. Otherwise, 100 P/S AL and MDI can’t work. There are steps for MDI single block as follows:

OFFSET SETTING

PROGRAM

INPUT

OFFSET SETTING


5-13

M19 : SPINDLE ORIENTATION

M82: POT. DOWN

M83 : ARM CW, M89: ARMCCW

M84 : SPINDLE TOOL UNCLAMP

M83 : ARM CW, M89: ARMCCW

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 are much 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 09001 automatically. And after executed, it will back to main-program. Do not modify or delete the program of 09001.

NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC 0M-C SYSTEM.


5-14


Simultaneously executing Z-axis returning to reference position, POT DOWN, SPINDLE ORIENTATION (M19). The customer doesn’t have to write G91 G28 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 => END M06 AFTER STAND-BY

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 will start automatically.


5-15

If use MACRO for tool change in AUTO mode, it is allowable M06 and T code in the

same black. Suggestion: Do not write them together in one block to save time for tool change.

(MODE 1) : M06 T07;

:

M06 T08; :

：

(MODE 2) : M06; T08;

:

M06; T09; ；

：

09001 is one block during executes M06 call sub-program 09001 in programming, At this time press “FEED HOLD” key the program will stop until l 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, and use M code to set ATC STAND-BY, then re-execute tool change.






5-16

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 (section 4.4) to see how to perform the movement of magazine.

4) TROUBLESHOOTING:

HYDRAULIC TYPE ATC(FIGURE A, B､C､D)

(1) BRIEF INTRODUCTION FOR EVERY 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 STAND BY 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 M2：CAM. MOTOR B1：CAM MOTOR FAN TROPELLER H1：CLUTCH FOR HANDLE BREAKER P1：MG FORWARD PUSH BUTTON P2：MG REVERSE PUSH BUTTON P3：SPINDLE CLAMP PUSH BUTTON P4：SPINDLE UNCLAMP PUSH BUTTON


5-17

(3) THE RELATED ITERS FOR STAND-BY: To execute M06,the ATC must be in

STAND-BY situation, and has to satisfy the following items:

18MC

AIR PRESS. X1006.0 FOR VMC-1500~21100

LOCK PIN IN L1 ON X1005.4 POT IN L2 ON X1005.5 POT OUT L3 OFF X1005.6 TOOL CLAMP L10 ON X1005.0 TOOL UNCLAMP L11 OFF X1005.1 CAM STOP L7 OFF X1007.2 CAM CHECK L8 ON X1007.3 CAM HOME L9 ON X1007.4 COUNTER A SENSOR L5 ON X1006.1 COUNTER B SENSOR L6 ON X1006.2 0I AND 18I 21I AIR PRESS. X6.0 FOR VMC-1500~21100

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 X7.2 CAM CHECK L8 ON X7.3 CAM HOME L9 ON X7.4 COUNTER A SENSOR L5 ON X6.1 COUNTER B SENSOR L6 ON X6.2


5-18

0IMATE

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)

FIG (E)

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 X26.2


5-19

FIG (F)


5-20


5-21

FIG (G)


5-22

FIG (H)

FIG (H)

5) M06 CAN’T BE DONE There are two situations as below:

I. Stop after POT OUT:

(1) Z-axis has not returned HOME (2) Spindle orientation has not finished (3) POT OUT LIMIT has not ON


5-23

(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 M06.

II. 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 message for finished spindle orientation are mission.

(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 can’t be done. ii. Take off tools for safe reason iii. Be sure follow the below steps indeed:

(1) Troubleshooting by MANUAL: Please use this reliable and safe way to solve the problem If the engineer are 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).

iii) Release the device of motor breaker. Please refer to sketch(H1).(There are some mode’s breaker are different).

iv) In motor breaker released situation, use spanner to wrench CW or CCW until ARM back to 0 position. Be sure there are no tool on the ARM. Because of it will be very danger when spindle is on CLAMP while POWER OFF.

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 ARM JOG

K5.3 can execute each M83、M89 change that we mentioned as 5.2. 1)(2)II., but it is not suitable in ATC M06 can’t be done. Because this keep relay will


5-24

separated movement into three steps. So it is only use when ATC calibration.

There are keep relay for ARM JOG:K5.0=1 to star ARM JOG function

Operation: Please turn POWER OFF POWER ON EMG. To set K5.0=1 (Please refer to Chapter 8.3) setting screen 2,

PWE =0 otherwise, 100 P/S Al will cause MDI can’t be operating. NOTE: Don’t set K5.0 and K5.3 =1 at the same time or commands will no use at all.

Select HANDLE mode, lights ON means SPINDLE CLAMP

lights ON means SPINDLE UNCLAMP

Push , ARM JOG +

Push , ARM JOG −

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 D503.7 will automatic set =0 and ATC STAND-BY will light ON, otherwise M06 can’t be executing.

CYCLESTART

CYCLE START

FEED HOLD

FEED HOLD


5-25


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 “N1”The addresses of tool registration. Here are descriptions for setting tool registration as bellows:




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).

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.


MACRO 09001 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. G91, G28, Z0 is not necessary before M06. 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 5.1.5.1

CURRENT


5-26

(1) SUBPROGRAM OF TOOL CHANGE:

% O9001(…..MO6 SUB-PROGRAM….) THE NUMBER OF PROGRAM AND EXPANATION. #3003=1 SINGLE BLOCK IS DISABLED. #3004=1 FEED HOLD IS DISABLED. T#4120 SEARCH T-CODE; IF[#1000EQ1] GOTO 70 TO DECIDE IF “T” IS SPINDLE TOOL IF[#1003EQ1] GOTO 10 TO DECIDE IF IN MDI MODE. N10 #103=#4003 SAVE THE CURRENT G-CODE OF THIRD GROUP

#1100=1 SPINDLE ORIENTATION AND POT DOWN G91G28Z0 Z-AXIS RETURNS HOME #1100=0 CANEL MACRO #1100 M06 EXECUTING TOOL CHANGING N70 G#103 #3003=0 SINGLE BLOCK IS AVAILABLE #3004=0 FEED HOLD IS AVAILABLE M99 RETURN TO MAIN PROGRAM

(2) neglect of macro tool change:

1. Select MDI mode


3. Change the setting of parameter 6071(No.6071=0 to neglect this MACRO, No.6071=6(M6) uses MACRO)

4. Set PWE=0

OFFSET SETTING


5-27

5.3 CAROUSEL TYPE ATC:

1) ATTENTION OF 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 ,also in auto mode over 8 sec CRT will show “1004 ATC STAND-BY LS”message. When the LED(on operator’s 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

Carousel type ATC is use absoule pot of position ,the number 1 pot is put number 1 tool

,To execute M06 TX or T code are available in MDI mode. In MDI mode, first

press , then key in T_ CODE and press to execute tool change.

M19 (spindle orientation) will start automatically when execute T_code. 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 second reference position(G91G30Z0) using single block to execute tool change is OK. But notice that single block method is only provide for ATC calibration or troubleshooting. During this time spindle tool and standby Tool doesn’t change in the tool table.if finish the operation must be check tool table.

MDI single block as folloe:

M19 : SPINDLE ORIENTATION

M82: MAG. FORWARD

M83 : SPINDLE TOOL UNCLAMP

M84 : MAG. BACKWARD

M85 : SPINDLE CLAMP

In MDI mode using single block to execute tool change.Z axis back to second reference position (G91G30Z0).then according the M code to done.when it is finish ,the ATC STAND-BY will light on.

(2) TOOL CHANGE OF AUTO MODE: To execute T_CODE tool change in AUTO MODE ( MACRO), it means when executing

PROGRAM

INPUT


5-28

T_CODE in program it will call the sub-program 09000 automatically. And after executed, it will back to main-program. Do not modify or delete the program of 09000.

NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC SYSTEM.


Simultaneously executing Z-axis returning to second reference position, SPINDLE ORIENTATION (M19). The customer doesn’t have to write G91 G30 Z0 and M19 commands before T_code. But if tool have interference, please check that if tool withdraw and spindle orientation are necessary.

Start tool change mechanism to STAND-BY position (equate SPINDLE), and to execute the cycle of tool change: MAG. FORWARD SPINDLE UNCLAMP AIR BLOW

G91G28Z0 MAG.ROT.ST-BY TOOL G91G30Z0 SPINDLE CLAMP MAG.BACKWARD

When tool change finish the ATC STAND-BY will light o

If use MACRO for tool change in AUTO mode, it is allowable M06 and T code in the same black or only T_code. Suggestion: Do not write them together in one block.

(MODE 1) : T01;

:

T05; :

09000 is one block during executes T_code call sub-program 09000 in programming, At this time press “FEED HOLD” key the program will stop until l 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,




5-29

and use M code to set ATC STAND-BY, then re-execute tool change.

2) TROUBLESHOOTING:

CAROUSEL TYPE ATC(FIGURE

(1) BRIEF INTRODUCTION FOR EVERY CONFIGURATION

CAROUSEL ATC( FIGURE I,J )

L1 ：MAG.BACKWARD SENSOR POSITION DETECT L2 ：MAG.FORWARD SENSOR POSITION DETECT L3 ：MAG.COUNT SENSOR A L4 ：MAG.MOTOR

(2)THE RELATED ITERS FOR STAND-BY: To execute M06,the ATC must be in

STAND-BY situation, and has to satisfy the following items:

18MC

MAG.BACKWARD L1 ON X1005.5

MAG.COUNT A L3 OFF X1005.6 0I AND 18I 21I

MAG.BACKWARD L1 ON X5.5

MAG.COUNT A L3 OFF X5.6 0I-MATE

MAG. Backward sensor

MAG. Front sensor

L1

L2

ON

OFF

X25.5

X25.6

MAG. Counter sensor A. L3 OFF X26.1

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).


5-30

FIG I


5-31

FIG J


5-32

3)T_ M06 CAN’T BE DONE There are two situations as below:

I. Stop after MAG.FORWARD:

(1)MAG.FORWARD LIMIT not ON (2) Air pressure is not enough

Try to find the reason as mentioned items. Then use MDI to execute M85 (MAG. BACKWARD), and back to ATC STAND-BY. After it re-execute M06.


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 “N1”The addresses of tool registration. Here are descriptions for setting tool registration as bellows:




D11~D40:To set the tool number for POT No. 1~16, D11 is corresponding to Pot No. 1, etc. (For 16 tools set D11~D26,for 24 tools set D11~D34)Be sure the tool number should not be bigger than 99 .

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.


MACRO 09000 is for M06 tool change, the benefit for using MACRO is as follows: 1.In AUTO mode, it will be able to execute T_M06 or only T CODE . 2.G91, G30, Z0 is not necessary before T_M06. 3.To reduce the time for tool change. Simultaneously executing 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 .

CURRENT


5-33

(1)MACRO PROGRAM EXPANATION % O9000(T CODE SUB PROGRAMS) #3004=1 SINGLE BLOCK IS DISABLED #3003=1 FEED HOLD IS DISABLED #100=#4009 #101=#4007 #102=#4008 #103=#4003 #104=#4001 #105=#4120 SAVE T-CODE STATE #106=#1000 SAVE T = SB STATE #107=#1001 SAVE T = CHK STATE #1101=0 #108=0 #109=0 #110=#1005 Check Z lock PB IF【#110EQ1】GOTO20 CHECK Z LOCK PB OF ON/OFF STATE IF【#105GT100】GOTO30 CHECK T-CODE STATE WITH MAG. CAPACITY IF【#105GT16】GOTO10 IF【#105GT0】GOTO30 N10 #3000=1(TOOL CAN, T SEARCH) N20 #3000=2(PLEASE Z LOCK PB) N30 #1102=1 T#105 G04X0.5 #1102=0 #111=#1004 IF【#111EQ1】GOTO100 DECIDE T-CODE EQUAL SP TOOL N40 IF【#106EQ1】GOTO50 DECIDE STAND-BY POT EQUAL SP TOOL #1101=1 #106=#1000 GOTO40 N50 G91G00G30Z0M19 Z RETURN G91G30Z0 POS AND SP ORIENTATION M82 MAG. FORWARD M83 SP UNCLAMP #1100=1 Z INTER LOCK G91G28Z0. #105=#4120 IF【#105GT16】GOTO10 T#105 G91G30Z0 M84 SP CLAMP M85 MAG. BACKWARD #1100=0 G#104G#103G#102G#101G#100 TO RECOVER THE STATE OF G-CODE 3-GROUPN100 #3003=0 SIGNAL BLOCK IS AVAILABLE #3004=0 FEED HOLD AVAILABLE M99 RETURN TO MAIN PROGRAM %

(2) neglect of macro tool change:

SAVE G-CODE STATE


5-34

5. Select MDI mode


7. Change the setting of parameter 6001#5=0(No.6071=0 to neglect this MACRO, No.6001#5=1 uses MACRO)

8. Set PWE=0

OFFSET SETTING


6-35

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 LUBRICATION AND THE RELATED SETTING:

6.1.1 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 slideways is short for a long time, it will cause bad accuracy and servo motor vibration, noise, heat …etc. If serious, it will injure the slidewats.

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 D430. The standard value is 15 sec. After the pressure detecting time(D330,10 sec), If the pressure is still not enough, the 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 2010 ALARM will be displayed. When retain pressure and fill oil are all right, the time intermittent counter D435 and D315 will decide the time for next retain pressure. In auto mode, the intermittent time D435 is 10 minutes. In handle mode, the intermittent time D315 is 20 minutes.

As above description, The cycle for oiler 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)

6. 1.2 HOW TO TAKE CARE OF THE OILER PROBLEMS:

If the machine does not ON for a long time. The slideways are dry. Please use MANUAL PUSH BUTTON to start oiler a few times after machine ON. About the question of OILER we will explain as following:


6-36

1. ALARM 2009

ALARM 2009 is oil not enough. When ALARM happens, please fill oil within 30 minutes. If not, it will change 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 2010

ALARM 2010 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 TIMER 330 and TIMER 430 (the maximum is 40 minutes). please notice that value of TIMER D300 should be larger than D430. If the problem still exists, it means the problem of 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 send 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. 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 phase of the input power is wrong.

For the rest of problems, the 1003 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’s and troubleshooting manual of 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.


6-37

6.3 HYDRAULIC UNIT(HYD.)

HYDRAULIC UNIT is to provide the power for hydraulic equipment of machine tools, including ATC､APC､AUTO DOOR AND COUNTER BALANCE for Z-AXIS(for some models) …etc.

When releasing EMG button, the hydraulic unit will start work and the pressure goes up. When pushing EMG button the hydraulic unit will stop. Basically, there is no electric controller which can control the pressure of hydraulic. But the work have to suit the EMERGENCY STOP CONTECTOR (ELECTRIC CIRCUIT C1). About the time for changing oil, to use what kind of oil and the adjustment of pressure please refer to maintenance manual.

6.4 CHIP CONVEYER (CHIP)

CHIP CONVEYER starts manually(a push button which shows on operator’s panel) or by M code (M68 ON and M69 OFF),please refer to chapter 7.

6.5 WORK LIGHT/ALARM LIGHT

The equipment for light is a 24V light (quartz), it locates beside head. It starts manually by the push button on the operator’s panel.

Alarm light not only lights on the end of M02､M30, when some ALARM happens it will light too. (Set K4.5=1)

6.6 THERE LAYER ALARM LIGHT DESCRIPTION

RED LAMP：Urgent situetion

YELLOW LAMP：Abnormal warning

GREEN LAMP：Programing in process or M30 programing ending signal incoming

6.7 RS232 AC110V INTERFACE

Only for power supply of the Notebook and prohiditted for other spare parts


6-38

6.8 HAND PASS SAFE DOOR INTER LOCK

When the machine is in the condition of power bisconnection or maintainance status

The inter lock in the status of (CLAMP) in case the maintenance person is closed in

The interior of the machine and can not open the safety door to get out as the power

Can not be operated to discharge the circuit of inter lock of the door. The way to get out is by usmg hand tools to open the door by force. As shown in the picture please

Find the component near by the inter lock and then turn the LOCK position to UNLOCK.

After the person left safely. Please remember to restore the inter lock to LOCK position on

Account of to prevent any person is endangered when the power is on because after the safety

Door was opened by force. It would stay at unlocked status.


6-39


7-1

7. AUXILIARY FUNCTIONS:

This chapter will describe the auxiliary functions. We follow the idiomatic usage to edit the common M codes(like M3、M4、M5、M19…etc.). About the other M codes we edit it as convenient as we can. Please refer to the list of this chapter or the ELECTRIC CIRCUIT MANUAL(page. M1).

If you have special request of M code, please contact with us. 7.1EXPLANATION OF M CODE: (THE MARKS “*” IS FOR OPTION

FUNCTION) M00 PROGRAM STOP

M01 OPTIONAL STOP, IT WORKS ONLY WHEN OPTION STOP BUTTON ON THE OPERAOR’S PANEL IS PRESSED.

M02/M30 END PROGRAM, IF COMBINING WITH AUTO POWER OFF BUTTON, THE NC WILL POWER OFF AUTOMATICLY. THE DIFFERENCE BETWEEN M2 AND M30 IS THAT M2 ONLY ENDS THE PROGRAM, M30 WILL END AND REWIND THE PROGRAM.

M03 SPINDLE CW ON

M04 SPINDLE CCW ON

M05 SPINDLE OFF

M06 IN MDI OR AUTO MODE, TO EXECUTE TOOL CHANGE.

*M07 MIST ON

M08 COOLANT ON

M09 MIST(M07),COOLANT(M08),THROUGH TOOL COOLANT(M12) OFF

*M10 THE 4TH CLAMP

*M11 THE 4TH UNCLAMP

*M12 THROUGH TOOL COOLANT ON

M14 APC TABLE A IN

M15 APC TABLE B IN

M16 AUTO APC CHANGE

M19 SPINDLE ORIENTATION

M21 SPINDLE SWITCH TO LOW GEAR

M22 SPINDLE SWITCH TO HIGH GEAR


7-2

*M68 CHIP ON


7-1

*M69 CHIP OFF

M70 CANCEL MIRROR FUNCTION

M71 X-AXIS MIRROR ON

M72 Y-AXIS MIRROR ON

M82 POT DOWN, Z-AXIS HAS TO RETURN ZERO AND ATC STAND-BY LIGHT ON

M83 ARM 60 . EXECUTE M82 AND M19 BEFORE THIS COMMAND.

M84 SPINDLE TOOL UNCLAMP

M85 ARM DOWN. EXECUTE TOOL UNCLAMP BEFORE THIS COMMAND.(FOR CAM ATC, M85,M86,M87 WILL COMBINED TO M85)

M86 ARM 180 CW. EXECUTE ARM DOWN BEFORE THIS COMMAND. (CAM ATC DOESN’T USE THIS COMMAND)

M87 ARM UP, ARM 180 CW AND SPINDLE UNCLAMP MUST HAVE DONE. (CAM ATC DOESN’T USE THIS COMMAND)

M88 SPINDLE TOOL CLAMP

M89 ARM 0 . FIRST, HAVE TO EXECUTE SPINDLE CLAMP

M90 POT. UP. FIRST, HAVE TO EXECUTE ARM 0

M91 ORIGINAL POSITION OF 180 RACK(ARM DOES NOT MOVE)

M98 SUB-PROGRAM CALL

M99 IF USED IN SUBPROGRAM IT WILL RETURN TO MAIN PROGRAM. IF USED IN MAIN PROGRAM IT WILL REPEAT EXECUTING THE PROGRAM

M82～M91: EACH M CODE IS ONE STEP FOR ATC OPERATION, THEY ARE ONLY USED DURING TROUBLESHOOTING. PLEASE USE M06 FOR TOOL CHANGE TO AVOID MACHINE DAMAGE.


7-2

M CODE LIST

CODE DESCRIPTION CODE DESCRIPTION

M00 PROGRAM STOP M68 CHIP CONVEYER ON

M01 OPTION STOP M69 CHIP CONVEYER OFF

M02 PROGRAM END M70 MIRROR IMAGE CAN

M03 SPINDLE FORWARD(CW) M71 X-MIRROR IMAGE

M04 SPINDLE REVERSE(CCW) M72 Y-MIRROR IMAGE

M05 SPINDLE STOP M82 POT OUT

M06 AUTOMATIC TOOL CHANGE ARM 60

M07 MIST ON

M83

M83 CAM ATC ARM CW(K5.3=1)

M08 COOLANT PUMP ON M84 SPINDLE TOOL UNCLAMP

M09 COOLANT PUMP OFF ARM DOWN

M10 4-AXIS CLAMP

M85

M85 CAM ATC NO USE

M11 4-AXIS UNCLAMP ARM CW 180

M12 DEEP DRILL ON

M86

M86 CAM ATC NO USE

M14 APC TABLE A IN ARM UP

M15 APC TABLE B IN

M87

M87 CAM ATC NO USE

M16 AUTO APC CHANGE M88 SPINDLE TOOL CLAMP

M19 SPINDLE ORIENT ARM 0

M21 SPINDLE L-GEAR

M89

M89 CAM ATC ARM CCW(K5.3=1)

M22 SPINDLE H-GEAR M90 POT IN

M25 EXTRA ADD 1M CODE ON M91 ORIGINAL POSITION

M26 EXTRA ADD 1M CODE OFF M98 CALL SUB-PROGRAM

M27 EXTRA ADD 2M CODE ON M99 END SUB-PROGRAM

M28 EXTRA ADD 2M CODE OFF

M30 PROGRAM STOP(AUTO POWER OFF)

M50 EXTRA ADD 3M CODE ON


M52 EXTRA ADD 4M CODE ON



8-1

8. PLC SETTING

The PLC setting are including TIMER and KEEP RELAY, the detail of to set TIMER and KEEP RELAY is described at section 3 in this chapter.

What is PLC ? It means control by LOGIC. That is to say, it is HUMAN INTERFACE. We try to modify PLC more user-friendly and safety for customer’s request. Because every company has different design. Please read the manual carefully for the best performance of the machine.

Before shipping the machine, we have checked an run machine completely, and the relative values are all set. To prevent missing the data, We copy it in ELECTRIC CIRCUIT(page L1~L3 and M1), and about the machine parameter we save in NC memory. Because the life of battery(lithium) is 5 years for machine (if machine are not works, the battery life only 3 months), if overtake the battery life the parameter will be lost. So we copy two set, one for the customer and one for us to ensure the parameter will not be lost. Please be careful to keep the items as blows:

ELECTRIC CIRCUIT

LADDER DIRGRAMM

THE DATA SHEET FOR SYSTEM PARAMETER

THE DATA SHEET FOR MACHINE PARAMETER

THE FLOPPY DISK FOR PARAMETER

In section 3 of this chapter we’ll mention about how to modify and setting PLC and machine parameter. But please be sure not to modify them without our approval.


8-2

8.1SETTING OF TIMER:

8. 1.1 TIMER FOR LUB:

TIMER

NO.

DESCRIPTION STANDARD

VALUE

TMR 64 IN MANUAL MODE, THE TIME FOR

INTERMITTENCE.

1200000 (20 minutes)

TMR 62 THE TIME FOR DETECT THE PRESSURE

OF LUB.

10000 (10 seconds)

TMR 60 THE TIME FOR LUB MOTIONS AND FILLER 15000 (15 seconds)

TMR 61 IN AUTO MODE, THE TIME FOR

INTERMITTENCE.

600000 (10 minutes)


8-3

8. 1.2 TIMER FOR HYDRAULIC TYPE ATC:

TIMER NO. DESCRIPTION STANDARD VALUE FOR

KFV-40

STANDARD VALUE FOR VMC-1400

TMR 9 MAGAZINE INDEX STOP 100 (0.1 sec.) 0

TMR 10 T CODE FINISH CHECK 100 (0.1 sec.) 0

TMR 11 MAGAZINE

ORIENTATION

150 (0.15 sec.) 150 (0.15sec.)

TMR 19 POT UP 200 (0.2 sec.) 200 (0.2sec.)

TMR 20 POT DOWN 200 (0.2sec.) 200 (0.2sec.)

TMR 21 SPINDLE CLAMP 150 (0.15sec.) 200 (0.2sec.)

TMR 22 SPINDLE UNCLAMP 300 (0.3sec.) 200 (0.2sec.)

TMR 23 ARM 60 200 (0.2sec.) 200 (0.2sec.)

TMR 24 ARM 0 150 (0.15sec.) 150 (0.15sec.)

TMR 25 MAGAZINE

ORIENTATION

600 (0.6sec.) 600 (0.6sec.)

TMR 26 ARM UP 200 (0.2sec.) 0

TMR 27 ARM DOWN 200 (0.2sec.) 0

TMR 28 ARM 180 200 (0.2sec.) 0

TMR 29 180 ORIGINAL

POSITION

200 (0.2sec.) 150 (0.15sec.)

TMR 32 CW COUNTER A 200 (0.2sec.) 0

TMR 33 MAGAZINE CW

COUNTER B

200 (0.2 sec.) 0


8-4

8.1.3 TIMER FOR CAM ATC

TIMER NO. DESCRIPTION STANDARD VALUE FOR

KFV-40

STANDARD VALUE FOR VMC-1400

TMR 9 MAGAZINE INDEX STOP 0 0

TMR 10 T CODE STOP CHECK 0 0

TMR 11 MAGAZINE

ORIENTATION

0 150 (0.15sec.)

TMR 19 POT UP 200 (0.2sec.) 200 (0.2sec.)

TMR 20 POT DOWN 0 0

TMR 21 SPINDLE CLAMP 0 0

TMR 22 SPINDLE UNCLAMP 0 0

TMR 23 ARM 60 0 0

TMR 24 ARM 0 0 0

TMR 25 MAGAZINE

ORIENTATION

600(0.6sec.) 600(0.6sec.)

TMR 26 ARM DOWN & ARM 180

& ARM DOWN

0 0

TMR 32 MAGAZINE CW

COUNTER A

200 (0.2sec.) 0

TMR 33 MAGAZINE CCW

COUNTER B

200 (0.2sec.) 0

DO NOT CHANGE THE VALUE OF TIMER FOR ATC BY YOURSELF TO PREVENT MALFUNCTIONS.


8-5

8. 1.4 TIMER FOR OTHERS :

TIMER NO. DESCRIPTION THE VALUE FOR

STANDARD

TMR 13 FLASH AT HOME POINT 1 500 (0.5 sec.)

TMR 14 FLASH AT HOME POINT FLASH 2 500 (0.5 sec.)

TMR 15 THE TIME FOR M02/M30 CALL

LIGHT

50 (0.05 sec.)

TMR 16 RIGID TAPPING 100 (0.1 sec.)

TMR 17 THE TIME FOR EMG STOP 50 (0.05 sec.)

TMR 18 M29 COMMAND DELAY 50 (0.05 sec.)

TMR 30 THE TIME FOR ONE SHOT(MAG) 350 (0.35sec.)

TMR 31 SPINDLE AIR BLOW 500 (0.5sec.)

TMR 5 BUZZER ON TIME 60000 (60sec)

8.1.5 TIMER FOR CAROUSEL ATC:

TIMER NO. DESCRIPTION THE VALUE FOR

STANDARD

TMR 10 MAG. START 50 (0.05 sec.)

TMR 11 MAG. STOP 150 (0.15 sec.)

TMR 9 T CODE STOP CHECK 150 (0.15sec.)

TMR 19 MAG. BACKWARD 150 (0.15sec.)

TMR 20 MAG. FORWARD 50 (0.05 sec.)

8.2 EXPANATION OF KEEP RELAY SETTING:

In according with different part of electric equipment or different control logic of customer. For convenience choice, there are some addresses we will design for KEEP RELAYS to control the different motion. Only the situation that mentions as below would change KEEP RELAY:

1. Lose NC control, reset KEEP RELAY。 2. To change KEEP RELAY to suit the electric equipment 3. Disable the protection when adjust ATC

4. to change the motion which is permitted to be selected


8-6

Of cause in this kind of setting and modifying the operator should contact with our engineer to ensure the safety.

The meaning of KEEP RELAY will be described as below, but for the actual values, please refer to the page L1~L3 of electric circuit manual.。


8-7

8.2.1 KEEPRELAY SET OF HYD ATC K0 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 1 1 0 0 1 0

ACTUAL SETTING

SAFE DOOR INTERLOCK SWITCH

W-60 POSITION MACHINE LOCK

NO USE

MN MODE

EACH MODE COOLANT ON

4-AXIS CLAMP USE M10 COMMAND

4-AXIS CLAMP USE EXTRANAL LIMIT SWITCH

NO USE

K1 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 0 1

ACTUAL SETTING

RIGID TAPPING M29 COMMAND NO USE S FUNCTION

RIGID TAPPING M29 COMMAND TIMER SPINDLE STOP

ARM0 M6 FINISH

Z-AXIS NO ZERO POINT RETURN

ATC OPERATOR SEQENCE CINTROL

POT UP KEEP RELAY

POT DOWN KEEP RELAY

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-8

ARM 60D KEEP RELAY


ACTUAL SETTING

ARM-0D KEEP RELAY

ARM UP KEEP RELAY

ARM DOWN KEEP RELAY

ARM 180 CW KEEP RELAY

ARM 180 CWW KEEP RELAY

SPINDLE CLAMP KEEP RELAY

SPINDLE UNCLAMP KEEP RELAY

SPINDLE AIR CEL KEEP RELAY


ACTUAL SETTING

0=1500-21100M/C 1:850~40

NO ATC UNIT

ATC OKI Z-AXIS ZERO RETURN G30 X0 Y0 POINT

NOT HIGH/LOW GEAR

0:USE LUB PRE DET FUNCTION

4-AXIS NEG

1=ZBK 0=CO BK

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-9

X-AXIS + ZERO PONIT


ACTUAL SETTING

M25 FINISH BY X1008.3




LUB. TYPE SELECT

ALARM CALL LIGHT

M00/M01 SPINDLE STOP

3-AXIS AUTO ZERO RETURN


ACTUAL SETTING

1:USE ZF BOX

SPEED OVERRIDE SWITCH TYPE

NO USE

NO USE

NO USE

1:USE DATA MAG ONE PNP SENSOR

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-10

1:NO USE AIR PRESSURE CHECK

1:USE 3 M.P.G.


ACTUAL SETTING


ACTUAL SETTING

1:4/5 AXIS UNCLAMP SERVO OFF

1:5th AXIS BY PASS

1:M00/M01 LIGHT ON

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-11


ACTUAL SETTING


ACTUAL SETTING

1.USE AIR H/L GEAR CHANGE

1:OPT1 PB =+5 PB

1:OPT2 PB =-5 PB

1:AXIS MOVE BY PASS OPT2 PB

1:USE APO PB＋OPT2 PB

1:USE M23(TOOL NO.RESET)

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-12

8.2.2 KEEP RELAY OF CAM ATC K0 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 1 1 0 0 1 0

ACTUAL SETTING

SAFE DOOR INTERLOCK SWITCH

W-60 POSITION MACHINE LOCK

PLAY BK (STEP MODE)

MN MODE

EACH MODE COOLANT ON

4-AXIS CLAMP USE M10 COMMAND

4-AXIS CLAMP USE EXTRANAL LIMIT SWITCH

SAFE DOOR OPEN SPINDLE STOP


ACTUAL

1.NO.2＝BIG TOOL

1.NO.4＝BIG TOOL

1.NO.6＝BIG TOOL

1.NO.8＝BIG TOOL

1：USE M12 SP AIR

1:USE THE LUB ALARM COUNTER

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-13

SETTING

RIGID TAPPING M29 COMMAND NO USE S FUNCTION

RIGID TAPPING M29 COMMAND TIMER SPINDLE STOP

ARM0 M6 FINISH

Z-AXIS NO ZERO POINT RETURN

ATC OPERATOR SEQENCE CONTROL

POT UP KEEP RELAY

POT DOWN KEEP RELAY


ACTUAL SETTING

SPINDLE CLAMP KEEP RELAY

SPINDLE UNCLAMP KEEP RELAY

SPINDLE AIR CEL KEEP RELAY


ACTUAL SETTING

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-14

0=1500-21100M/C

NO ATC UNIT

ATC OK1 Z-AXIS ZERO RETURN G30 X0 Y0 POINT

NOT HIGH/LOW GEAR

0:USE LUB PRE DET FUNCTION

4-AXIS NEG

1=ZBK

X-AXIS + ZERO PONIT


ACTUAL SETTING





LUB. TYPE SELECT

ALARM CALL LIGHT

M00/M01 SPINDLE STOP

3-AXIS AUTO ZERO RETURN


1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-15

ACTUAL SETTING

CAM ATC M83 M89 FUNCTION

SPEED OVERRIDE SWITCH TYPE

CHIP PUSH-BUTTOM TYPE

1:CAM STEP BY HAND MODE CY/FD

CAM SENSOR TYPE 1:NPN 0:PNP

1:USE DATA MAG ONE PNP SENSOR

1:NO USE AIR PRESSURE CHECK

NO USE


ACTUAL SETTING

1:4/5 AXIS UNCLAMP SERVO OFF

1:USE 3MPG

1:5th AXIS BY PASS

1:M00/M01 LIGHT ON

1:USE “CYTEC”SP15000RPM

NO USE

1:使用”CYTEC”SP20000RPM

JOG/DRY OVERRIDE O~200%

K7 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD 0 0 0 0 0 0 1 0

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-16

SETTING ACTUAL SETTING

H/L GEAR RELAY NO KEEP ON

1: USE AIR H/L GEAR CHANGE

1: SP UNCLAMP NOT M19

1:OPT1 PB =+5 PB

1:OPT2 PB =-5 PB

1:AXIS MOVE BY PASS OPT2 PB


ACTUAL SETTING


1:USE SP H/L (Y-ΔOR Y-Y)

1：PROGRAM LED KEEP ON

1:USE CTRA-1 SENSOR(K TYPE)

1:USE APO PB＋OPT2 PB

1:USE M23(TOOL NO.RESET)

1:KEEP0:UNKEEP

1:KEEP0:UNKEEP


8-17

ACTUAL SETTING

8.3TO MODIFY THE SETTING:

When our engineer ask you to modify the setting on the telephone, please follows the method that we mentioned as below. Once again we’ll remind you to contact with service people before modify.

8. 3.1 MODIFY PLC

1. PRESS EMG STOP BUTTON 2. IN MDI MODE

3. AFTER PRESSING , THERE ARE(OFFSET),(SETTING)AND (WORK) SHOWING BELOW THE SCREEN.

4. PRESS SETTING KEY, 5. USE CURSOR KEY TO MOVE CURSOR TO PWE=0 (0:can not write

1:can write) 6. KEY IN ”1”

7. ，AT THIS TIME 100 P/S ALARM WILL HAPPENED

8.PRESS THERE ARE(PARAMATER)(DIAGNOS)(SYSTEM)WHICH

SHOWS BELOW THE SCREEN 9.PRESSED KEY, THERE ARE(PMCLAD)(PMCDGN)(PMCPRM) WHICH SHOWBELLOW THE SCREEN..

1.NO.2＝BIG TOOL

1.NO.4＝BIG TOOL

1.NO.6＝BIG TOOL

1.NO.8＝BIG TOOL

1：USE M12 SP AIR

1:USE THE LUB ALARM COUNTER

SYSTEM

OFFSET SETTING

INPUT

PMC


8-18

10.PRESS KEY THERE ARE (TIMER)(COUNTER)(KEEPRL)

(DATA)(SETTING)WHICH SHOWBELLOW THE SCREEN.

11USE CURSOR KEY TO MOVE CURSOR TO WHICH PARAMATER WANT

TO MODIFY, KEYIN THE VALUE THEN PRESS KEY FINISH THE MODIFY.

12.IF WANT TO MODIFY THE KEEPRELAY,ACCORDING THE STEP 10 TO PRESS (KEEPRL)KEY,THEN DEPEND STEP 11 TO MODIFY THE VALUE.BECAUSE THE KEEP RELAY IS THE BIT TYPE ,SO CAN ONLY MODIFY ONE BIT.

13.WHEN FINISHING MODIFYING, RETURN TO SETTING PAGE AND CHAGE PWE TO 0, SO 100 P/S ALARM CAN BE ELIMINATED AFTER RESETTING.

INPUT

PMCPRM


8-1

8. 3.2 MODERFY PARAMETER

1. PRESS EMG STOP BUTTON 2. IN MDI MODE

3. AFTER PRESSING , THERE ARE (OFFSET) AND (SETTING) DESPLAYING BELOW THE SCREEN.

4. PRESS (SETTING), 5. USE CURSOR KEY TO MOVE CURSOR TO PWE=0 (0:can not write

1:can write) 6. KEYIN ”1”

7. ，AT THIS TIME 100 P/S ALARM WILL HAPPENED

8. PRESS (PARAMETER) WITCH SHOWS AT THE BOTTON OF THE SCREEN

9. PRESSED KEY, AND KEY IN THE NUMBER THAT YOU ARE GOING TO MODIFY.

10. AT NUMBER xxxx= , KEY IN THE NUMBER THAT YOU ARE GOING TO MODIFY

11.WHEN FINISHING MODIFYING, RETURN TO SETTING PAGE AND CHAGE PWE TO 0, SO 100 P/S ALARM CAN BE ELIMINATED AFTER RESETTING.

OFFSET SETTING

INPUT

NO


8-2

TIMER SETTING LIST

TIMER NO. DESCRIPTION STANDRD VALUE ACTUAL VALUE

TMR1 LUB DEVICE ACTION INTERVAL TIMER(AUTO MODE) 600000

TMR2 LUB DEVICE ACTION TIMER 15000

TMR3 LUB DEVICE ACTION INTERVAL TIMER(HANDLE MODE) 1200000

TMR4 SPINDLE STOP TIMER 150000

TMR5 BZ STOP TIMER 60000

TMR6 0

TMR7 0

TMR8 0

TMR9 MAGAZING JOG STOP 100

TMR10 T-CODE STOP CHECK 100

TMR11 MAGAZING PIN ADJUSTMENT 150

TMR12 THE TIME WHEN LUB PRESSURE IS UNUSUAL 10000

TMR13 FLASH LAMP 1 500

TMR14 FLASH LAMP 2 500

TMR15 CALL HIGH RIUING TIMER 500

TMR16 RIGID TAPPING M29S COMMAND 100

TMR17 EMERGENCY STOP RELEASE POLSE 50

TMR18 M29 COMMAND DELAY TIMER 50

TMR19 POT UP 200

TMR20 POT DOWN 200

TMR21 SPINDLE CLAMP 150

TMR22 SPINDLE UNCLAMP 300

TMR23 W-ARM 60 200

TMR24 W-ARM 0 150

TMR25 MAGAZINE PIN ADJUSTMENT 600

TMR26 W-ARM UP 200

TMR27 W-ARM DOWN 200

TMR28 W-ARM CW 180 200

TMR29 W-ARM CCW 180 200

TMR30 ONE-SHOT TIMER 350

TMR31 SPINDLE AIR CELEAR 550

TMR32 MAGAZINE FOREARD PHASE 200

TMR33 MAGAZINE FOREARD PHASE2 200

TMR34 JOG/RAP/ZER MODE ENABLE TIMER 30000


8-3

DATA TABLE SETTING

NO. ADDRESS DATA NO.

0000 D0010 SPINDLE NO.

0001 D0011 T1

0002 D0012 T2

0003 D0013 T3

0004 D0014 T4

0005 D0015 T5

0006 D0016 T6

0007 D0017 T7

0008 D0018 T8

0009 D0019 T9

0010 D0020 T10

0011 D0021 T11

0012 D0022 T12

0013 D0023 T13

0014 D0024 T14

0015 D0025 T15

0016 D0026 T16

0017 D0027 T17

0018 D0028 T18

0019 D0029 T19

0020 D0030 T20

0021 D0031 T21

0022 D0032 T22

0023 D0033 T23

0024 D0034 T24

*IF MAFAZINE TOOL CAPACITY 30 TOOLS SET DATA TABLE ADDRESS FOR D0035 TO D0040 (T25 TO T30)。


8-4

MAGAZINE TOOL CAPACITY (30) SETTING

PMC DATA TBL CONTROL #001 GROUP TABLE COUNT=1

NO. ADDRESS PARAMETER TYPE DATA OF NO.

001 D0010 00000001 0 31

PC COUNTER MAGAZINE TOOL CAPACITY (30)

PMC PRM (COUNTER) #001

NO. ADDRESS PRESET CURRENT

001 C00 30 VARIABLE

*MAGAZINE TOOL CAPACITY 30 TOOLS SET 31 *CURRENT DATA VALUE IS STAND-BY TOOL POT NUMBER，IF YOU WANT RESET IT’S

COUNTENT，PLEASSE CHANGE THIS VALUE。


9-1

9. THE TROUBLESHOOTING

When malfunction happened, please use this chapter trying to fix the basic problem. And gather the information as following items. We will do our best to recover the machine as soon as possible.

1. Machine serial number, Mode, Control system and delivery date?

2. The responded massage of machine: what is the alarm message and alarm number of servo? Does fuse fail? Is over load escaped?

3. What happens: In which mode? If it happens constantly? If it happens during executing some G code or M.S.T. code? If it happen at the particular machine coordinate? Are there any signs abnormally?

4. Check the frequency of occurrence: what is the frequency? When did the problem first occur? What did you do after malfunction?

5. Outline of environment: Is the voltage stable? Have you updated the program ? Have you changed the operator? Have you updated the tools and clampers? Is the temperature and quake of environment normal?

6. Before malfunction happened: have you edited program or changed auxiliary equipment? Do you adjust or remove the machine?

We hope to solve the problem immediately and completely. The above question is very helpful for us to find the problem. Any answer may be the key point to recover the machine. If during the telephone contact step, you could tell us the detail situation of machine. It will be more easier to find the reason of malfunction and recover it as soon as possible.

ALARM NUMBER

DESCRIPTION STEP OF RECOVER REMARKS

E1

MOL ALARM Motor for outside part have overload situation

1.Turn power OFF 2.Open the door of electric

cabinet and check the OVERLOAD.

3.Push the RESET BUTTON which is on overload.

Better waiting 2-3 minutes, usually it happens because of too much chips in chip -conveyor through.

E2

OIL ALARM Spindle coolant pressure detect alarm

1.Is filter too dirty? Use water, neutral cleaner or compressed air to clean up and air-dry in overcast.

2.if not work, please call the cooler maker。

the TEL of the cooler maker is on the cooler unit plate and the manuals of cooler unit.


9-2

E3

SPINDLE ALARM heck it the feed rate and spindle speed are correct. 1.If not, turn power OFF and

RESET. 2. If yes, use a screwdriver to

open the door of electric cabinet (do not turn power OFF) and check the alarm number on the 7-segment decoder of spindle driver (at upper row, the second from the right side),and contact with the agent or FANUC.

E4

LUB ALARM LUB oil not enough

Please check the follow items: 1.Is the oil enough? 2.If yes, maybe the oil detector is

broken. please check in according to electric circuit manual.。

1002

SPINDLE DRIVER ALARM spindle driver overload alarm

same as E3

1003

EMERGENCY STOP ALARM

1.Overtravel: press the EMG RELEASE button on control panel. In EMG RELEASE mode: Switch to handle mode, use hand wheel to return original point, and RESET.

2.Motor overload(MOL. ALARM): the same as E1(RESET)

3.EMG not release

1004

SPINDLE GEAR OIL ALARM

the same as E2

1005

ATC STAND-BY LS ATC not at stand by situation

Please follows the chapter 5 or ATC stand-by instruction of electric circuit manual


9-3

1007

SPINDLE CLAMP LS

Please check the following items: 1.Is spindle unclamping? 2.Does spindle clamp limit switch

touch the dog. 3.If yes, check if it have touched

exactly and stable.

2002

TOOL SEARCH ERROR

1.Are T code all right. 2.Check the tool registration.

2003

ARM 60 M/C LOCK

1.RESET NC. Turn ON manual operation of ATC. (K5.0=1)

2.In MDI mode, used M code to return ATC to stand-by situation step by step.

3.Turn manual operation of ATC. 4.Return Z-axis to ZERO

2004

SAFE DOOR INTERLOCK

1.Close safety door 2.If not works, please check if it is a problem of fuse.

2007

CHECK ZPZ POSITION

1. During ATC tool change, Z-axis does not return to original point .

2. Please return Z-axis back to original position.

2006

AIR PRESSURE MISS

Check whether the air pressure is miss? 2.If the pressure is enough, check

if the pressure switch is broken.

2008

CHECK SPINDLE OK LIST

1.Is spindle on clamp? Is ARM on 0 ? 2.Check if LIMIT switch are stable

that we mentioned before.

2009

SPINDLE LOAD TOO MUCH

1.Are feed-rate and spindle rate OK?

2.RESET NC


9-4

2010

LUB OIL MISS The same as E4

2011

LUB PRESSURE MISS

1.Is pressure of LUB enough? If yes, please delay the time of pressure D330= 15000

2012

WAIT FOR RIGHT TOOL

1. May be the tool are not STAND BY 2.If the magazine keeping rotation, please call agent.

2013

GO G30 X0 Y0 FIRST

X､Y-axes must back to second reference points.

For VMC-650～800

2014

MAGAZINE PARITY ERROR

1. Check count A and count B Sensor

2015

SP NO TOOL CAN’T ROTATION

Please install tool then can start spindle

Only 10000rpmHigh speed sp

2016 SP “DA”AIR RELEASE PRESSURE NO OK

SP AIR PRESSURE RELEASE SIGNAL NO OK CHECK L.S

2017 SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN FIRST START SP

Please check sp tool,if ok press CYCLE START P.B to start sp warm up.


9-5

2018

SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN SP STOP OVER 2 HOUR

SP stop over 2 hour please check sp tool,if ok press CYCLE START P.B to start sp warm up.

2020 2020 ADMONISH!THE Z AXIS LOCK P.B IS ON.ARE YOU SURE?YES,PLEASE HIT CYCLE START P.B TO CONTINUE.NO,PLEASE CHECK THE Z AXIS LOCK P.B.

Please check Z lock P.B in auto mode

2021 2021 PLEASE PUSH OP2 P.B TO ENABLE JOG/RAP/ZRN MODE

Push OP2 P.B to enable JOG/RAP/ZRN mode


9-6

9.1 LARGER TOOL MANAGEMENT For user using the larger or special tools, we program 4 set tool store pot for “Larger Tool Management”. It could offer up to 4 set tool for processing. K9.0 1 Set up the tool store pot #2 as first large tool K9.1 1 Set up the tool store pot #4 as second large tool K9.2 1 Set up the tool store pot #6 as third large tool K9.3 1 Set up the tool store pot #8 as fourth large tool When using the “Large Tool Management” function, the 2 pot adjacent to large tool will be empty automatically. Example: when set up K9.0 1 that using the store pot #2 as the larger tool pot, controller won’t put the tool into first and third tool pot to avoid the danger of crash. PS. When using the “Larger Tool Management” function, user must be notice that you couldn’t insert any tool into adjacent pot in advance.

Date post:	10-Mar-2018
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