operation manual - milco service/documentation awea/af 650... · 3.2.2 jog feedrate operation ......

TYPE：C-Type Series

CONTROLLER：FANUC 0iMD / 18iMB / 31iB

VERSION NO.：AFEQFI03

DATE：2012/05/03

AWEA MECHANTROINC CO., LTD NO.15,Keyuan 2nd Rd., Taichung City, Taiwan. 40763 TEL：886-4-2462-9698 FAX：886-4-2462-8002 http://www.awea.com E-mail:[email protected]

OPERATION MANUAL

CONTENTS

I

C O N T E N T S 1、 OPERATOR’S CONTROL ......................................................................................................1-1

1.1 OPERATOR’S CONTROL PANEL ...............................................................................................1-2 1.1.1 LCD/MDI Panel............................................................................................................1-2 1.1.2 Machine Operator's Panel .............................................................................................1-8 1.1.3 Magazine Operator's Panel .........................................................................................1-24

2、 POWER UP AND POWER DOWN.........................................................................................2-1 2.1 INSPECTION BEFORE OPERATION ...........................................................................................2-2

2.1.1 Checking before Power Up...........................................................................................2-2 2.1.2 Power Up ......................................................................................................................2-4 2.1.3 Checking After Power Up.............................................................................................2-5 2.1.4 Checking by Manual .....................................................................................................2-5

2.2 DOOR INTERLOCK SAFETY INSTRUCTION...............................................................................2-6 2.3 POWER DOWN........................................................................................................................2-7

2.3.1 Emergency Stop ............................................................................................................2-8 2.3.2 Other Stops....................................................................................................................2-9 2.3.3 Power Down ...............................................................................................................2-13

2.4 POWER ON PROCEDURE LIST................................................................................................2-14 2.5 POWER OFF PROCEDURE LIST..............................................................................................2-16

3、 OPERATION INSTRUCTION.................................................................................................3-1 3.1 MODE SELECTION..................................................................................................................3-2 3.2 MANUAL OPERATION .............................................................................................................3-4

3.2.1 Reference Point Return .................................................................................................3-4 3.2.2 Jog Feedrate Operation .................................................................................................3-5 3.2.3 Handle Wheel Operation...............................................................................................3-7 3.2.4 Spindle Manual Operation ............................................................................................3-8 3.2.5 Spindle Tool Unclamping Manual Operation ...............................................................3-9 3.2.6 Tool Magazine Manual Operation ..............................................................................3-11 3.2.7 Chip Conveyor Manual Operation and Trouble Shooting ..........................................3-12 3.2.8 Coolant Tank...............................................................................................................3-13

3.3 MDI OPERATION..................................................................................................................3-14 3.3.1 MDI Function .............................................................................................................3-14

3.4 AUTOMATIC OPERATION ......................................................................................................3-18 3.4.1 Executing Automatic Operation..................................................................................3-18 3.4.2 Block Skip...................................................................................................................3-19 3.4.3 Manual Absolute .........................................................................................................3-20 3.4.4 Program Restart ..........................................................................................................3-25

3.5 PROGRAM CHECK AND TEST ................................................................................................3-29 3.5.1 Machine Lock .............................................................................................................3-29 3.5.2 Z Axis Cancel..............................................................................................................3-29 3.5.3 Dry Run.......................................................................................................................3-29 3.5.4 Feedrate Override........................................................................................................3-30 3.5.5 Jog Override................................................................................................................3-30 3.5.6 Rapid Override............................................................................................................3-30 3.5.7 Spindle Speed Override ..............................................................................................3-31

3.6 TOOL SETTING .....................................................................................................................3-32 3.6.1 Tool Number Setting Initialization .............................................................................3-32

4、 TROUBLE SHOOTING...........................................................................................................4-1 4.1 TROUBLE SHOOTING GUIDE...................................................................................................4-2

CONTENTS

II

4.2 ALARM MESSAGE WITH REMEDIAL MEASURES .....................................................................4-3

4.2.1 Arm Type ......................................................................................................................4-3 4.2.2 Drum Type ....................................................................................................................4-9

4.3 RESET OF OVER TRAVEL ......................................................................................................4-13 4.3.1 Soft Limit Over Travel................................................................................................4-13 4.3.2 Hard Limit Over Travel ..............................................................................................4-14

4.4 THE SOLUTION PROCEDURES OF TOOL CHANGE INTERRUPTION..........................................4-15 4.4.1 Arm Type ....................................................................................................................4-15 4.4.2 Drum Type ..................................................................................................................4-16

5、 APPENDIX...............................................................................................................................5-1 5.1 INTRODUCTION OF APC .........................................................................................................5-2

5.1.1 Operations .....................................................................................................................5-2 5.1.2 APC Control .................................................................................................................5-2 5.1.3 Cautions ........................................................................................................................5-2

5.2 OPERATION MANUAL OF APC CONTROL PANEL BOARD ........................................................5-3 5.3 FUNCTIONS OF THE BUTTONS.................................................................................................5-4

5.3.1 APC Manual Mode Button ...........................................................................................5-4 5.3.2 Unclamp APC Pallet .....................................................................................................5-4 5.3.3 APC JOG Model ...........................................................................................................5-4 5.3.4 APC Pallet Lifts Up ......................................................................................................5-4 5.3.5 APC Pallet Goes Down APC ........................................................................................5-5 5.3.6 Rotate APC Pallet C.W.................................................................................................5-6 5.3.7 Rotate APC Pallet C.C.W .............................................................................................5-6 5.3.8 APC Door Interlock ......................................................................................................5-6 5.3.9 Complete Preparation of APC.......................................................................................5-6

5.4 ILLUSTRATION OF APC MANUAL OPERATION PANEL BOARD.................................................5-7 5.4.1 Use Occasion ................................................................................................................5-7 5.4.2 Cautions ........................................................................................................................5-7

5.5 TROUBLES SHOOTING ............................................................................................................5-8 5.5.1 Instructions of Warning Message..................................................................................5-8

5.6 M CODE LIST .......................................................................................................................5-10

CONTENTS OF FIGURE

III

C O N T E N T S O F F I G U R E Figure 1-1 LCD/MDI panel(18i-MB 10.4" color) ...................................................................... 1-2 Figure 1-2 Software operator's panel (18i-MB 10.4" color)......................................................... 1-4 Figure 1-3 Software operator's panel (0i-MD 8.4" color) ............................................................ 1-4 Figure 1-4 Software operator's panel (0i-MD 10.4" color) .......................................................... 1-4 Figure 1-5 Software operator's panel (31i-B 10.4" color) ............................................................ 1-5 Figure 1-6 Machine operator’s panel ........................................................................................ 1-8 Figure 1-7 Magazine operator’s panel .................................................................................... 1-24 Figure 1-8 Magazine operator’s panel .................................................................................... 1-26 Figure 3-1 Alarm message(18i-MB 10.4"LCD) ....................................................................... 3-34 Figure 3-2 Parameter setting screen(18i-MB 10.4"LCD) .......................................................... 3-34 Figure 3-3 PMC Control system screen(18i-MB 10.4"LCD) ..................................................... 3-35 Figure 3-4 PMCPRM screen(18i-MB 10.4"LCD) .................................................................... 3-35 Figure 3-5 PMC DATA screen(18i-MB 10.4"LCD).................................................................. 3-36 Figure 3-6 PMC G. DATA screen 1(18i-MB 10.4"LCD) ........................................................... 3-36 Figure 3-7 PMC G. DATA screen 2(18i-MB 10.4"LCD) ........................................................... 3-37 Figure 3-8 PMC G. DATA screen 3(18i-MB 10.4"LCD) ........................................................... 3-37 Figure 3-9 PMC G. DATA screen 4(18i-MB 10.4"LCD) ........................................................... 3-38 Figure 3-10 COUNTR screen(18i-MB 10.4"LCD)................................................................... 3-38 Figure 3-11 Alarm message(0i-MD 8.4"LCD) ......................................................................... 3-39 Figure 3-12 PMCMNT system screen(0i-MD 8.4"LCD) .......................................................... 3-39 Figure 3-13 PMCMNT DATA screen(0i-MD 8.4"LCD) ........................................................... 3-40 Figure 3-14 PMCMNT DATA screen 1(0i-MD 8.4"LCD)......................................................... 3-40 Figure 3-15 PMC DATA screen 2(0i-MD 8.4"LCD) ................................................................ 3-41 Figure 3-16 PMCMNT DATA screen 3(0i-MD 8.4"LCD)......................................................... 3-41 Figure 3-17 PMC DATA screen 4(0i-MD 8.4"LCD) ................................................................ 3-42 Figure 3-18 COUNTR screen(0i-MD 8.4"LCD) ...................................................................... 3-42 Figure 3-19 Alarm message(0i-MD 10.4"LCD) ....................................................................... 3-43 Figure 3-20 PMC MAINTE system screen(0i-MD 10.4"LCD).................................................. 3-43 Figure 3-21 PMC MAINTE DATA screen(0i-MD 10.4"LCD)................................................... 3-44 Figure 3-22 PMC MAINTE DATA screen 1(0i-MD 10.4"LCD) ................................................ 3-44 Figure 3-23 PMC MAINTE DATA screen 2(0i-MD 10.4"LCD) ................................................ 3-45 Figure 3-24 PMC MAINTE DATA screen 3(0i-MD 10.4"LCD) ................................................ 3-45 Figure 3-25 PMC MAINTE DATA screen 4(0i-MD 10.4"LCD) ................................................ 3-46 Figure 3-26 COUNTR screen(0i-MD 10.4"LCD) .................................................................... 3-46 Figure 3-27 Alarm message(31i-B 10.4"LCD) ........................................................................ 3-47 Figure 3-28 PMC MAINTE system screen(31i-B 10.4"LCD) ................................................... 3-47 Figure 3-29 PMC MAINTE DATA screen(31i-B 10.4"LCD) .................................................... 3-48 Figure 3-30 PMC MAINTE DATA screen 1(31i-B 10.4"LCD) ................................................. 3-48 Figure 3-31 PMC MAINTE DATA screen 2(31i-B 10.4"LCD) ................................................. 3-49 Figure 3-32 PMC MAINTE DATA screen 3(31i-B 10.4"LCD) ................................................. 3-49 Figure 3-33 PMC MAINTE DATA screen 4(31i-B 10.4"LCD) ................................................. 3-50 Figure 3-34 COUNTR screen(31i-B 10.4"LCD)...................................................................... 3-50 Figure 3-35 Remove the fixed teeth ....................................................................................... 3-56 Figure 3-36 Install gauge ...................................................................................................... 3-56 Figure 3-37 Tool magazine.................................................................................................... 3-57 Figure 3-38 Operator panel screen(18i-MB 10.4"LCD) ............................................................ 3-57 Figure 3-39 Operator panel screen(0i-MD 8.4"LCD) ............................................................... 3-58 Figure 3-40 Operator panel screen(0i-MD 10.4"LCD) ............................................................. 3-58

CONTENTS OF FIGURE

IV

Figure 3-41 Operator panel screen(31i-MD 10.4"LCD)............................................................ 3-59 Figure 3-42 Tool gauge......................................................................................................... 3-60 Figure 3-43 Magazine mounting plate .................................................................................... 3-60 Figure 3-44 Tool is within spindle.......................................................................................... 3-61 Figure 3-45 Rotate tool ......................................................................................................... 3-61 Figure 3-46 Parameter setting screen(18i-MB 10.4"LCD) ........................................................ 3-62 Figure 3-47 Parameter setting screen(0i-MD 8.4"LCD)............................................................ 3-62 Figure 3-48 Parameter setting screen(0i-MD 10.4"LCD) .......................................................... 3-63 Figure 3-49 Parameter setting screen(31i-B 10.4"LCD) ........................................................... 3-63 Figure 3-50 Parameter setting screen(18i-MB 10.4"LCD) ........................................................ 3-64 Figure 3-51 Parameter setting screen(0i-MD 8.4"LCD)............................................................ 3-64 Figure 3-52 Parameter setting screen(0i-MD 10.4"LCD) .......................................................... 3-65 Figure 3-53 Parameter setting screen(31i-B 10.4"LCD) ........................................................... 3-65 Figure 3-54 ATC JOG(18i-MB 10.4"LCD) ............................................................................. 3-66 Figure 3-55 ATC JOG & CCW(18i-MB 10.4"LCD)................................................................. 3-67 Figure 3-56 ATC JOG(0i-MB 8.4"LCD) ................................................................................. 3-68 Figure 3-57 ATC JOG & CCW(0i-MD 8.4"LCD) .................................................................... 3-69 Figure 3-58 ATC JOG(0i-MD 10.4"LCD) ............................................................................... 3-70 Figure 3-59 ATC JOG & CCW(0i-MD 10.4"LCD) .................................................................. 3-71 Figure 3-60 ATC JOG(31i-B 10.4"LCD) ................................................................................ 3-72 Figure 3-61 ATC JOG & CCW(31i-B 10.4"LCD).................................................................... 3-73 Figure 3-62 M6T1(18i-MB 10.4"LCD) .................................................................................. 3-76 Figure 3-63 M6T1(0i-MD 8.4"LCD)...................................................................................... 3-76 Figure 3-64 M6T1(0i-MD 10.4"LCD) .................................................................................... 3-77 Figure 3-64 M6T1(31i-B 10.4"LCD) ..................................................................................... 3-77 Figure 5-1 APC Control Panel Board ....................................................................................... 5-3

1、OPERATOR’S CONTROL

1-1

1、 OPERATOR’S CONTROL


1-2

1.1 Operator’s Control Panel

1.1.1 LCD/MDI Panel

LCD/MDI consisted of LCD (18i-MB 10.4" color) and keyboard, shown as Figure 1-1.

Figure 1-1 LCD/MDI panel(18i-MB 10.4" color)

A. Key function

The position push-button indicates the current position of the slides. The information is spread over pages.

In "EDIT" mode, the cursor can be moved any desired command by using the cursor Forward or Reverse. In "MDI" mode, the cursor can be input the data to the buffer memory. In "AUTO" mode the cursor can be displayed current commands.

The OFFSET push-button displays either the offset chapter or work shift chapter. Repeatedly pressing "OFFSET" push-button will alternately display on chapter or the other.

The button displays setting of the System Diagnostic data and System parameter data.

Graphic display function.

This button displays Alarm messages of interest to the operator in two chapters.


1-3

The software operator's panel is shown as following figure which can be determined by

the following procedure:

1. Press the Offset & Setting button.

2. Select the manual by pressing this button which located under the LCD.

OPR 3-1. Select the OPR soft-key by pressing the button located under the LCD(For 18i-MB 10.4" color LCD, 0i-MD 8.4" color LCD).

OPERAT PANEL

3-2. Select the OPERAT PANEL soft-key by pressing the button located under the LCD(For 0i-MD 10.4" color LCD).

4. Press the page button down, then the following picture will be displayed.


1-4

Figure 1-2 Software operator's panel (18i-MB 10.4" color)

Figure 1-3 Software operator's panel (0i-MD 8.4" color)

Figure 1-4 Software operator's panel (0i-MD 10.4" color)


1-5

Figure 1-5 Software operator's panel (31i-B 10.4" color)

PRG REST: "ON" indicates program restart function is effective. ATC JOG: "ON" indicates ATC turn forward.

ATC CCW: "ON" indicates ATC turn backward, ATC JOG need "ON". 4TH RUN: "ON" indicates the 4th axis is effective. MAN ABS: "ON" indicates Manual increment add on the absolute coordinate.

OVC.: "ON" indicates feedrate override is ineffective. AFL: "ON" means M, S, T code will be neglected.

TEACH: "ON" means teach-in function turns ON.

1. This key is used to shift the cursor a short distance in the reverse direction.

2. This key is used to shift the cursor a short distance in the forward direction.

Several pages are included in the chapter selected with each function button. The page is selected with PAGE button.

NOTE: The data displayed on the screen disappears when one of the function buttons and the "CAN" key are pressed. Thereafter, when either function button is pressed, the corresponding screen is displayed again. When the unit is not used with the long-term power turned on; then turn off the screen. This is effective to prevent the image quality from deteriorating.


1-6

B. Keyboard functions

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

Cursor shift keys:

1. This key is used to shift the cursor a short distance in the forward direction.

2. This key is used to shift the cursor a short distance in the

reverse direction. 3. This key is used to shift the cursor a short distance in the left

side direction. 4. This key is used to shift the cursor a short distance in the

right side direction.

Page change keys:

1. This key is used to change over the page on the LCD screen in the forward direction.

2. This key is used to change over the page on the LCD screen

in the reverse direction.

Program Editing Keys:

This button is used in Edit mode to alter a data word in an enabled program stored in memory.

INSERT

The "INSERT" button is used in Edit mode to insert data words, an entire block or several blocks of data, into an enabled part program stored in memory. It is also used when entering a part program into memory from the MDI keyboard.


1-7

DELETE

The "DELETE" button is used in edit mode to delete a data word, an entire block, or several blocks of data, from an enabled part program stored in memory. It is also used to delete a complete part program from the program Directory.

The "CAN" button is used to erase incorrect data entered on the MDI keyboard before "Insert" button is pressed. Character are erased singularly each time the button is pressed starting with the last character entered. That means when the address key or the numerical key is pressed next, the position where the alphabet or the numeral is inserted next is indicated by "-". When the cancel key is pressed, the character immediately before the "-" is canceled.

The “INPUT” button is used when entering information from the MDI keyboard. When an address or numerical key is pressed, the alphabet or the numeral is input once to the key input buffer, and it is displayed on the LCD screen. To set the data input to the key input buffer in the offset register, etc., press the Input key.

Address and alphabet and other symbol.

Softkeys: (special functions)

Left direction softkey: This key is used for returning to the previous status.

Right direction softkey: This key is used for returning to the next operation functions.


1-8

1.1.2 Machine Operator's Panel

AXIS AUX FUNCTION MANUAL POWER

X

Z

Z

F1

Y

Y V

V

XEND

SBK BDT M01

CCW

STOP

CW

ZLK

Z

MLKDRN

AUTO H.INT DOOR

AUTO MAN BLOW ON

OFF

APO

BACK

LIGHT

FORWDFORWD

CW CCW

1005025

F0

60

70

80

110

100

90

50 120

%

50

mm/min

150140

130120

110

3020

10

170

190180

40

6070

8090 100

160

0 200

% %

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

GO

REME

ENCYPTS

O

G E N Z A

REM

E

E S TRR

A

SCTN

NC X Y Z 4TH 5TH

ALARM STATUS HOMESPDMAG

F2

Figure 1-6 Machine operator’s panel


1-9

The description of Machine control panel will be as below:

A. Emergency stop:

GO

REME

ENCYPTSO

G E N Z A

REM

E

E S TRR

A

If you press the Emergency Stop button on the machine operator's panel, the machine movement stops in a movement, mechanical reference point will disappear. Spindle stops rotating automatically. The button is locked when pressed. The button can be unlocked by twisting it.

B. Rotary switches:

1. MODE selector:

EDIT It is used when editing a part program stored in memory; to add data to memory; to delete data from memory and to modify data in memory. To use this mode, Program Protect switch must in "OFF" position.

AUTO Press the cycle start button of the operating panel. The program in the AUTO operation memory will be executed. When pressed, automatically operation begin and cycle start lamp lights.

DNC Machine can be direct transfer the program while machine in auto operation.

MDI The common of the multiple blocks can be input from the LCD/MDI panel to the MDI operation buffer memory. The program in the MDI operation buffer memory can be edited in the same method as that for the program registered in the memory. Press the START key of the operating panels the program in the MDI operation buffers memory will be executed.

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

HANDLE can be used to move all axes manually. Select the axis to be moved by the axial selector, the selected axis can be moved by Manual Pulse Generator. Handle Multiplication can be set by actuating one of the three steps X1, X10, X100.


1-10

JOG operation can be moved selected axis and

moves in its directions (X+, X-, Y+, Y-, Z+, Z-), Feed rate can be set by Jog feed rate override switch. Actuate and hold the corresponding axis key, the machine axis moves continuously at the set traversing rate. Release the axis key held so far, the traverse movement will stop.

RAPID operation can be moved selected axis and moves in its directions, Feed rate can be set by Rapid feed rate override switch. Actuate and hold the corresponding axis key, the machine axis moves continuously at the set traversing rate. Release the axis key held so far, the traverse movement will stop.

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

ZRN set to the Home position, press the selected axis to be the reference point. The machine stops at the reference point return, lighting the Axes Home position LED. If 3 axes are selected simultaneously by three switches, three axes moves are allowed at the same time.

mm/min

4050

6070

8090 100

160

130120

110

3020

10

170180

190

150140

%

0 200

2. Cutting Feed rate Override: (1) With this dial, it is possible to override the feed rate

designated by the program. An override of 0 to 200% divide to 16 step, this switch provides to the feed rate of G01, G02, G03 and other G code which may using this feed rate for cutting.

(2) Jog Feed rate Override: With this dial, it is possible to

override the feed rate designated by the program. An override of 0 to 3,700 mm/min. divide to 16 step, this switch provides to the JOG or Dry RUN feed rate switch.

%

1005025

F0

3. Rapid Feed rate Override: The Rapid Override switch of 100%, 50%, 25% and F0 is

provided, when the rapid traverse rate is 20 m/min. and this dial is set to 50%, actual rate becomes 10 m/min. F0 is a constant value specified by the parameter. Rapid override is effective by the following functions: (1) by G00. (2) during canned cycle. (3) in G27 and G28. (4) Manual rapid traverse.


1-11

%

60

70

80

110

100

90

50 120

4. Spindle Speed Override: The spindle speed override switch allows the operator to modify programmed spindle speeds in steps of 10% from 50% to 120%. The actual spindle speed what you commended can be

seen on the LCD and displays current block "S". The switch is active in AUTO, MDI or Dry Run modes.

C. Key switches:

1. Program Protect switch: The Program Protect key-switch should be turned to the ON or EDIT position (left turn) and key removed except when part program editing is required. Part program can be deleted from memory or modified in any way when switch is in the OFF position (right turn). With this control, it can be operated by following process:

1) The program registered in memory and modified. 2) Re-setting the coordinate system. 3) Keying machine parameter by manual. 4) Setting the PC parameter and timer parameter.

2. SET/AUTO KEY: 1) Auto mode

A. The key is switched to the auto mode when the

interlocked movable guard is closed. a. All functions of electrical system including motor and

solenoid valve will be functional normally. b. The movements of spindle and servo axis will be

executed normally. c. The powered movements of machine will be operated

automatically. d. The movement of automatic tool change will be

executed. e. In the handle mode, the operator can control the

direction of axis directly by the use of handwheel. f. Machine maintenance will be not permitted under this

situation.

B. The key is switched to the auto mode when the interlocked movable guard is open. a. All functions of electrical system including motor and

solenoid valve will be not performed. b. The movements of spindle and servo axis will be

stopped.


1-12

c. The powered movements of machine will be stopped.d. The movement of automatic tool change will be

stopped. e. The handwheel will be disabled. f. Machine maintenance will be not permitted under this

situation. g. The power supply of servo system will be off after

delayed 4 seconds.

2) Setting mode

A. The key is switched to the setting mode, wherever the interlocked movable guard is closed or opened, the statements are the same as the following. a. All functions of electrical system including motor and

solenoid valve will be not performed. b. Spindle rotation will only be initiated by pressing two

buttons at the same time. One button is enabling device and the other is clockwise and counterclockwise of spindle. Spindle speed will not exceed 50 rpm. If the operator releases one of the two buttons, the spindle movement will be stopped immediately.

c. The movements of servo axis will only be initiated by pressing two buttons at the same time. One button is enabling device and the other is the direction of axis. Axis speed will not exceed 2m/min. If the operator releases one of the two buttons, the servo axis movement will be stopped immediately.

d. The powered movements of machine will be stopped. e. The movement of automatic tool change will be

stopped. f. The operator can control the direction of axis by

pressing the two enable buttons simultaneously on the handwheel.

g. Machine maintenance is permitted under this situation


1-13

D. Push-buttons:

CW

1. Spindle CW push-button (included red lamp): The spindle CW push-button is an illuminating, momentary type, push-button. The light must be "OFF" for spindle CCW mode operation. Effective by mode selected in Handle position (push-button illuminated). Spindle rotates in clockwise direction.

Note: After machine "ON", spindle speed must be keyed in the memory by MDI mode, then this button is effective for pressing.

CCW

2. Spindle CCW push-button (included red lamp): The spindle CCW push-button is an illuminating, momentary type, push-button. The light must be "OFF" for spindle CW mode operation. Effective by mode selected in Handle position (push-button illuminated). Spindle rotates in counterclockwise direction.

Note: After machine "ON", spindle speed must be keyin in the memory by MDI mode, then this button is effective for pressing.

STOP

3. (1) Spindle Stop push-button (including green lamp): In the HANDLE mode, press the button will stop the spindle

rotation. (2) Spindle Orientation push-button (including green lamp):

In the ZRN mode, press the button for spindle orientation.

4. Cycle Start push-button: The Cycle Start push-button is used to initiate programs in AUTO, MDI, Dry Run, and Machine Lock modes. It is illuminated while a data block is being executed. When control is in an End of Block, Feedhold or MDI condition, the button will not be illuminated. If Feedhold push-button is pressed during execution of a part program, Cycle Start light will turn "OFF".

5. Cycle Stop push-button: The button allows the operator to stop all axial motion during execution of an enabled part program. It is active in memory AUTO, MDI (Block by Block), Dry Run and Machine Lock modes. It is illuminated when active. It has no effect on active spindle speed. At M.S.T. operation continues up to the end of the block. Cycle Start light and Spindle CW or CCW button light will turn "OFF" when feed hold is activated. Normal operation maybe resumed by pressing Cycle Start push-button.


1-14

X

6. X + push-button: The X+ push-button is momentary type switch that allows the operator to jog the X axis in plus X direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position.

X

7. X - push-button: The X- push-button is momentary type switch that allows the operator to jog the X axis in minus X direction. It is enabled when mode is selected in JOG position.

Y

8. Y + push-button: The Y+ push-button is momentary type switch that allows the operator to jog the Y axis in plus Y direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position.

Y

9. Y - push-button: The Y- push-button is momentary type switch that allows the operator to jog the Y axis in minus Y direction. It is enabled when mode is selected in JOG position.

Z

10.Z + push-button: The Z+ push-button is momentary type switch that allows the operator to jog the Z axis in plus Z direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position.

Z

11.Z - push-button: The Z- push-button is momentary type switch that allows the operator to jog the Z axis in minus Z direction. It is enabled when mode is selected in JOG position.

12.4th + push-button: The 4th + push-button is momentary type switch that allows the operator to jog the 4th axis in CW direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position.

13.4th - push-button: The 4th - push-button is momentary type switch that allows the operator to jog the 4th axis in CCW direction. It is enabled when mode is selected in JOG position.


1-15

V

14. 5th + push-button: The 5th + push-button is momentary type switch that allows the operator to jog the 5th axis in CW direction. It is enabled when mode is selected in JOG position. Press the push-button to return to the reference point by mode selector in "HOME" position.

V

15. 5th - push-button: The 5th - push-button is momentary type switch that allows the operator to jog the 5th axis in CCW direction. It is enabled when mode is selected in JOG position.

SBK

16.Single Block push-button: The Single Block push-button is an illuminating, latch type switch push-button used to initiate AUTO, MDI, Dry Run and Machine Lock modes. It is illuminated while the push-button is being pressed. One block of the program is executed, and then the execution is stopped. If the cycle start button is pressed, the next block is executed and then the execution is stopped again. The Single Block push-button must be pressed a second time to be de-activated.

BDT

17.Block Skip push-button: The Block-Skip push-button is an illuminating, latching type that causes the control to ignore any block containing a Slash code ( / ). The function is active when the push-button is illuminated. When the push-button is not illuminated, the data block is executed. If the slash code is the first character in the block, all data to the EOB character will be ignored when the push-button is active. If the slash code is placed in the middle of a block, only data from the slash code to the EOB character will be ignored; while data proceeding the slash code will be executed. To exit from Block Skip, press push-button a second time. The push-button is active in Dry Run and Machine Lock.

DRN

18.Dry Run push-button: The Dry Run push-button is an illuminated, latch type switch that causes the control to execute of a program and running with feedrate of JOG OVERRIDE.


1-16

M01

19.Optional Stop push-button: The Optional Stop push-button is an illuminated, latch type switch that causes the control to stop execution of a part program after completing a block containing an M01 code. The function is active when the push-button is illuminated. An M01 code is ignored when the push-button is not illuminated. The push-button can be activated before or during a block containing an M01 code. When a block containing an activated M01 is completed, all slide motion and spindle rotation ceases, coolant pump turns OFF, Feed Hold push-button is illuminated and Optional Stop push-button flashes. The push-button is active in Dry Run and Machine Lock modes.

MLK

20.Machine Lock push-button: The push-button is an illuminating, latching type push-button. The light must be OFF for normal machine operation. When Machine Lock mode is active (push-button illuminated), all axes motion is inhibited. To exit from Machine Lock mode, press the push-button again.

APO

21.Auto power Off push button: The push-button is an illuminating, latching type push-button. M30 function will be active after this button has been depressed (push-button illuminated).

CW

22.Tool magazine index forward push-button: Press the button, magazine will be forwarding. (button is illuminated)

CCW

23.Tool magazine index reverse push-button: Press the button, magazine will be reversing. (button is illuminated)

BLOW

24.Air blower push-button: The air blower function will be active (button is illuminated) when this button is depressed.


1-17

END

25.Overtravel Release push-button: When the axes overtravel, set the mode selector in Handle position, press Overtravel button, in the mean time, release the axes by Manual Handwheel.

Caution: Machine may cause machine damage due to axis move to wrong direction while pressed the button and protection sensor bypass is active.

MAN

26.Coolant Manual push-button: Press the button, the coolant will be distributed. Press the button again, the coolant will be stopped.

AUTO

27.Coolant Auto push-button: The push-button is an illuminating push-button. Press the button, coolant will be distributed in accordance with M08, M13, M14, M28, M51 command in Automatic operation. When coolant is being distributed in Automatic operation, pressing this button again will stop coolant flow.

FORWD

28.Chip Conveyor forward push-button: The chip conveyor "ON" is active when the push-button is illuminated. When the push-button pressed a second time, the chip conveyor is always "OFF" regardless of operating mode.

BACK

29.Chip Conveyor Reverse push-button: The chip conveyor reverse "ON" is active when the push-button is illuminated. When the push-button pressed a second time, the chip conveyor is always "OFF" regardless of operating mode.

DOOR

30.Door open push-button: The push-button is an illuminating momentary type push-button. Press this button while the machine is stationary, the door will be opened.

H.INT

31.Handle Interruption push-button: Press the button, the axis can be moved by means of handwheel.


1-18

ZLK

Z

32.Z axis lock button: Press the button, Z axis will be locked (light is illuminated).

AUTO

33.Auto Home return button: Press the push-button (push-button light will come on), Z axis will move to its home position automatically. After Z axis is at its home position, Y axis will follow the Z axis procedure, and then the X axis.

ON

34.Power ON button: Press this button to turn the control ON.

OFF

35.Power OFF button: Press the button to turn the control OFF.

FORWD

36. Chip Screw ON button: Press the button to active the chip screw, to stop it by press the button once again.

LIGHT

37. Work light button: Press the button to turn the work lights ON, to press the button again, the lamp will be light out.

SCTN

38.Smoke exhaust button: Press the button to turn the smoke exhaust ON, to press the button again, the lamp will be light out.

39. Floor clean water button: Press the button to turn the floor clean water ON, to press the button again, the lamp will be light out.


1-19

40. Enabling device button:

A.Press the button and spindle CW push-button or spindle CCW push-button at the same time to start the spindle rotation. Spindle speed will not exceed 50 rpm. If the operator releases one of the two buttons, the spindle movement will be stopped immediately.

B.Press the button and manual feed axis direction selection button at the same time to initiate the axis movement. Axis speed will not exceed 2m/min. If the operator releases one of the two buttons, the axis movement will be stopped immediately.


1-20

E. LED Lamps:

1. X Axis Home position L.E.D. The X axis Home position light will be flashed whenever the X axis move to the reference points and will light up when the X axis returned to the HOME position.

2. Y Axis Home position L.E.D.

The Y axis Home position light will be flashed whenever the Y axis move to the reference points and will light up when the Y axis returned to the HOME position.

3. Z Axis Home position L.E.D.

The Z axis Home position light will be flashed whenever the Z axis move to the reference points and will light up when the Z axis returned to the HOME position.

HOME

X Y Z 4TH 5TH

4. 4th Axis Home position L.E.D. The 4th axis Home position light will be flashed whenever the 4th axis move to the reference points and will light up when the 4th axis returned to the HOME position.

5. 5th Axis Home position L.E.D. The 5th axis Home position light will be flashed whenever the 5th axis move to the reference points and will light up when the 4th axis returned to the HOME position.

ALARM

NC

a. NC alarm light b. Way lubrication abnormal indicator. c. Low air indicator.

STATUS

a. ATC ready indicator. b. M02 / M30 indicator. c. Spindle high gear indicator.


1-21

F. LED Display:

a. Tool number of spindle. Display current tool number of spindle.

b. Tool number of magazine.

Display current tool number of magazine.

SPDMAG


1-22

G. Manual Pulse Generator

1. Axial position selector Selecting which axis you want to move. (X, Y, Z,4th,5th)

X1: When switch is placed at X1 position each graduation the M.P.G. represents 0.001 mm.


2. Handle Multiplication Switch


3. Manual Pulse Generator

The feedrate can be adjusted precisely by using the Manual Pulse Generator. The incremental Jog handwheel allows the operator to jog a slide in increments when Mode Select Switch is in Handle position. The value of each handwheel increment depends on the setting of Handle Multiplication switch and the axis to be jogged depends on the setting of Axial Position Selector.

4. Enabling device button

Press the button and spindle CW push-button or spindle CCW push-button at the same time to start the spindle rotation. Spindle speed will be limited under 50 rpm. If the operator releases one of the two buttons, the spindle movement will be stopped immediately. Press the button and manual feed axis direction selection button at the same time to initiate the axis movement. Axis speed will not exceed 2m/min. If the operator releases one of the two buttons, the axis movement will be stopped immediately.

5. Emergency stop Press the button to immediately stop all actions machines.


1-23

H. Programming finish and alarm light:

Red lamp (R): It will be flashing every 0.5 second when machine alerts.

Yellow lamp (Y): It will be flashing every 0.5 second when program is finished.

Green lamp (G): It will be shining when machine is in normal

operation.

I. Open operation door, front door, side door:

1. All axes and spindle stop. 2. Program is not running.

3. Select mode switch to setting (SET) mode “ ”.

4. Press DOOR to open operation door “

DOOR

”.

5. The door is automatically locked after being closed. 6. Press DOOR to open the operation door. If one wants to open the other doors, press

DOOR again.


1-24

1.1.3 Magazine Operator's Panel

STOP

GRE

EM YCNE

TOOL SET NUMBER

TOOLNUMBER

CALL

MAGAZINE POST NUMBER

Figure 1-7 Magazine operator’s panel


1-25

A. Open Magazine door:

1. Select Key switch to HANDLE mode “ ”.

2. Switch Mode selector to the symbol DOOR” ”.

3. Press START button (ATC side) to open the ATC door” ”. 4. When ATC door is closed, it locks automatically. 5. If ATC door is not closed, the alarm occurs when switching to other modes.


1-26

Figure 1-8 Magazine operator’s panel

MANUALAUTO

1. MODE selector: AUTO: Can be auto tool change, and door of magazine lock. MANUAL: Not can auto tool change, and door of magazine unlock.

CW

2. Magazine index forward: Select "MANUAL" mode, press "Magazine (CW)" button, then magazine will be indexing reverse.

CCW

3. Magazine index reverse: Select "MANUAL" mode, press "Magazine (CCW)" button, then magazine will be indexing reverse.

2、POWER UP AND POWER DOWN

2-1

2、 POWER UP AND POWER

DOWN


2-2

2.1 Inspection Before Operation

Checking List to be followed before operation of the machine is as follows:

2.1.1 Checking before Power Up

The electric box, motor, transformer and relay boxes with a high-voltage mark have terminals of lethal voltage. Only electrical experts with official qualification are authorized to open their covers and doors. Cable and wire with damaged film can cause electric leakage or shock. Double-check that there is no damage on cable and wire. Failure to follow this warning will result in serious personal injury or death from electric shock.

Check point Check item Method RemarkAir filter unit‧ 1. Drain the water in reservoir? Check visually

2. Any lub. oil in reservoir? Check visually 3. Air pressure 5-7 kg/cm2? Check visually

Spindle Oil ‧

Cooler 1. Temperature setting value? Check visually

2. Oil sufficient? Check visually 3. Any leakage? Check visually

Chip conveyor‧ 1. Chips removed? Check visually Coolant Tank‧ 1. Chips removed? Check visually

2. Coolant sufficient? Check visually 3. Any leakage? Check visually

Chip collectors‧ 1. Chips removed? Check visually 2. Anything other than chips? Check visually

Slide cover‧ 1. Any chips accumulated? Check visually Magazine door ‧ 1. Any chips accumulated? Check visually Table‧ 1. Any chips accumulated? Check visually Spindle‧ 1. Spindle taper clean? Check visually

DANGER


2-3

Electric cabinet‧ 1. Door closed? Check visually

2. No damage or disconnection on external wiring or cables?

Check visually

3. Earth grounded? Check visually General‧ 1. Machine environment well sorted out? Check visually

2. No looseness of bolts on cover, etc.? Check visually


2-4

2.1.2 Power Up

DANGER ‧ DO NOT touch any switches or buttons when hands are wet.‧ CHECK the machine environment is clean so that convenient

for operation. ‧ CHECK cooler oil, coolant and pneumatic pressure are

sufficient to work.

CAUTION ‧ WARM UP the machine for approx. 15 minutes after turning the power ON ‧ WHEN setting the spindle speed above 3,000 rpm, pay the

closest attention.

Power-up procedure is a systematic method of safely turning on the control and the prepared machine for operation. The following are comprehensive descriptions of the 3 axes procedure:

1. Turn MAIN SWITCH and AIR SWITCH "ON".

2. Press POWER ON push-button.

When buzzer has beeped, that indicates that the control is in an EMERGENCY STOP condition. Press EMERGENCY STOP push-button in clockwise direction to make certain it is released; beep will be disappeared. Machine is ready for operation.

3. To Zero return axes: (a) Set Mode Selector at HOME position. (b) Set Rapid Override Switch at 50%.

(c)

Press Home position return push-button (push-button light will come on). Z axis will move to the Home position (positive direction). After Z axis Home position L.E.D. lights up showing the Z axis is at the reference zero position, then Y axis will follow up the Z axis procedure, and move to the Home position automatically until all axes Home position L.E.D. light up indicated that all axes are at their reference zero position.

(d) Procedure (c) can be operated by the manual push-button of each axis.

(e) Press and release X+ push-button, X axis will move to the positive side of Home position.

(f)

After X+ push-button light is out and X Home position L.E.D. lights up indicating that the X axis is at its reference zero position, press the Y+ and Z+ push-buttons. When the slides arrive at their reference zero position, Y+ and Z+ push-button lights will be out and Home position L.E.D. Y and Z will light up.

(g) Turn Rapid Override Switch to 100% and try procedure (e) again, to be sure this function is O.K.


2-5

2.1.3 Checking After Power Up

Check Point Check item Method Remark ‧Motor 1. No abnormal sound or heat? Check visually ‧Air unit 1. Air pressure (5-7kg/cm2)? Check visually 2. Hose leakage? Check visually ‧Coolant unit 1. Pump running perfect? Check visually ‧Hydraulic unit 1. System pressure (40 kg/cm2)? Check visually ‧LCD screen 1. No alarm displayed? Check visually ‧Operation panel 1. Warning lamp lights? Check visually

2.1.4 Checking by Manual

No Check item Check result 1. Each axis + direction? - direction? □Normal □Fault 2. Each axis over travel, + direction? - direction? □Normal □Fault 3. Each axis Home return? □Normal □Fault 4. Spindle rotation direction? Orient? Stop? Unclamp? □Normal □Fault 5. Tool magazine index direction in CW? CCW? □Normal □Fault


2-6

2.2 Door Interlock Safety Instruction

1. The following activities are not allowed when the door is opened. It could cause alarm. (1) Press the CYCLE START button to execute the program. (2) Moving X, Y, Z axis (JOG, RAPID or ZRN). (3) Manual coolant ON (Except wash gun). (4) Execute the manual tool magazine while magazine door opened.

2. The following activity will be ineffective when press the Door open button. (1) program is executing (2) spindle is rotating (CW, CCW, locating, or shift) or stalling (3) X, Y or Z axis is moving (Feedate, JOG, RAPID, ZRN) (4) chip conveyor is ON (clockwise, counterclockwise) (5) cooler is spraying

3. To force the door open without pressing the door open button will be cause the machine

in E-stop status. 4. Spindle speed will be limited in 50 rpm, and Feedrate will not be higher than 2,000

mm/min.


2-7

2.3 Power Down

All personnel must know the location of Emergency Stop buttons and how to use them in case of Emergency.

CAUTION ‧ ALWAYS lock the Main Switch by locker to protect

unauthorized personnel. ‧ DO NOT leave keys on the switches or lockers after

machine is turned off.

To prevent damage the controller, machine tool or drives during shutdown, follow the Power-Down procedure listed below:

1. Establish a condition which ensures that the machine tool will not be damaged when control is shutdown. Ideally, establish an end-of-program condition with all axes at Home position. If this can not be accomplished, a cycle stop is adequate, but try to position the axes clear of the workpieces.

2. Press Emergency Stop push-button. If rotating, spindle will dynamically brake to a stop. Any axis motion will also cease. Power is removed from axes drive motors and spindle drive motor, thus disabling axes and spindle.

3. Press Power OFF push-button.

4. Turn disconnect switch OFF and turn Air switch OFF.

Note: The machine is placed in E-Stop before the control is turned OFF is to remove power in two distinct steps; first from the drive motor, then from the drives. Removing all power at once can damage the machine.

CAUTION


2-8

2.3.1 Emergency Stop

In case of any emergency cases:

1. Press the emergency button which is nearest button as soon as possible. 2. Machine will be stopped immediately. 3. Screen will display the alarm message "Not ready". 4. After the emergency situation has solved, turn the switch clockwise to release the

emergency button. 5. Then the NC control is ready automatically.


2-9

2.3.2 Other Stops

There are several methods to stop machine during machine in AUTO or MDI operation. The descriptions are as below:

A. Program Stop (M00)

Stops program, stops spindle, turns coolant OFF, "Tool release" push-button is activated. "Feedhold" light flashes intermittently. Cycle operation is stopped after a block containing M00 is executed. When the program is stopped, all existing modal information remains unchanged as in single block operation. The cycle operation can be restarted by specifying a CNC start. It is the programmer's responsibility to program an M03, M04, M13, or M14 to restart spindle and turn coolant on when restarting the program after an M00 program stop.

B. Optional Stop (M01) Performs the same function as M00 but will not stop the cycle unless "Optional Stop" push-button is activated (illuminated) before the block containing the M01 is read by the control. If "Optional Stop" is not activated, the cycle will continue without stopping. When active, the "Cycle Start" light goes out, "Optional Stop" lights up and "Feed Hold" light is illuminated. This function is useful when it is necessary to gauge the workpiece during setup. Pushing "Cycle Start" push-button allows program to continue. It is the programmer's responsibility to program an M03, M04, M08, M13 or M14 to restart spindle and turn coolant on when restarting program after an M01 Optional Stop.

M01

ON: Press the button, button lamp will light up. Machine will be stopped after the block containing the M01 is read by the control. Machine will be restarted after release the Optional Stop push-button.

OFF: Release the button, button lamp will go out.

Machine will continue without stopping after the block containing the M01 is read by the control.

C. End Of Program (M02, M30)

The M02 or M30 is used at the end of the program. It is usually the last block programmed. It stop the spindle, and turns coolant off. "Cycle Start" light goes out and Feedhold light flashes intermittently. When entering a program in memory from MDI keyboard, placing M30 at end of Program will cause program to automatically return to stop when M30 is encountered in the enabled program.


2-10

D. Single Block

It is illuminated while the push-button is being pressed. One block of the program is executed, then machine will be hold on, the execution is stopped.

SBK

ON: It will be illuminated while the push-button is being pressed. One block of the program is executed, and then the execution is stopped. If the Cycle Start button is pressed, the next block is executed and then the execution is stopped again. At the end of each program block, the machine is placed in a Feed Hold condition.

OFF:

It will be de-activated while the bush-button is being released.

Rapid Traverse

Feedrate Traverse

Note 1: When G28 & G30 are in the same block, the execution will stop in G28 or G30 whatever which G code is executed.

Note 2: In Canned cycle, machine will stop at the end of point 1, 2 and 6 during Single Block is activated.

Note 3: When Single Block is activated, machine will not be executed during a block containing an M98P__; M99; and G65. But machine will be executed during a block containing an address other than O, N or P, and M98__, or M99.

Note 4: NC will be shifted into Single block status automatically when the mode selector change to EDIT or MDI mode while program is in executing.


2-11

E. Feedhold button

The axial movement will be feedhold temporary when this push button has been depressed while machine in operation at the mode of AUTO or MDI selection, but spindle and coolant will be active continuously. The light will light up when Feedhold button has been depressed.‧ The feed will be decelerated when machine axis is moving. ‧ Dwell will be cancelled when program is in G04 status. ‧ M.S.T or B action will be executed till end of single block.

Note 1: If mode selector turn to Handle mode while program is executing, the NC will be shift to machine block status.

Note 2: NC will be alert while program is executing, then NC will be shift to machine lock status.

If machine to be operated continuously, then push the Cycle start button once again.

F. Spindle Reset

STOP

The spindle can be stopped during machine in AUTO operation. Press Feed Hold button, machine will stopped, then push Spindle Stop button, the push-button will be illuminated. The spindle will be restarted after pressing Cycle Start button, all axes movement will be executed 1.5 sec. later on. The Spindle stop push-button can also be used to manually release the tool holder from the spindle, once pressed the button, the button light will be flashed then push the footswitch for tool unclamping which is located in front of the operator‘s door. The drawbar will stay in the open position as long as the button is held depressed. The button light will be flashed in 30 seconds valid for tool unclamping from Spindle. The spindle unclamping function will be invalid once light flashing stopped. This push-button is available only when spindle rotation is stopped and machine is out of cycle.


2-12

G. Reset

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


2-13

2.3.3 Power Down

When the control loses power, either because of a power fail or because the Power Off push-button has been pressed, the control system disables all outputs, including the machine power permission control relay. If the control power is lost during any data entry operation, the correctness of the data being entered cannot be guaranteed and should be verified. All information previously entered into the system is retained; active information such as an operator entered MDI block is lost. There are some mechanical safety devices on the machine that can protect the operator or third party. A list is as below:

Safety Items Power ON Power Lost

Spindle Tool Power Drawbar Clamp Clamp

Spindle Tool Power Drawbar Unclamp Clamp

Spindle Motor Rotating Stop

All Axes Movement Moving Stop

Z Axial Brake Unclamp Clamp

Tool index for searching tool Indexing Stop

Power Switch On Off

Controller Power Unit On Off

Reset procedure after power lost: 1. Turn the main power OFF. 2. Depressed the E-Stop on the operator's panel. 3. Replace the workpiece or tools if necessary due to bad quality caused by the power

lost. After power returning back, power up by the procedure mentioned above. Returning all cutting conditions before power lost, then cycle start continuously.


2-14

2.4 Power on Procedure List

DANGER‧DO NOT touch any switches or buttons when hands are wet.‧CHECK the machine environment is clean so that

convenient for operation. ‧CHECK cooler oil, coolant and pneumatic pressure are

sufficient to work.

CAUTION‧WARM UP the machine for approx. 15 minutes after

turning the power ON. ‧WHEN setting the spindle speed over 3,000 rpm, pay the

closest attention.

1. Turn ON Air Switch.

2. Turn ON the Main Power Switch of electrical cabinet at the back of the machine.

ON

3. Press the Power On button on the machine operator’s panel to switch the numerical control on.

GO

REME

ENCYPTS

O

G E N Z A

REM

E

E S TRR

A

4. Release the Emergency Stop button.

5. Set the Mode Selector in Handle position. Move all axes away 200mm from Home position by Manual Pulse Generator.


2-15

6. To Zero return axes:

(a) Set the Mode Selector in ZRN position. (b) Set Rapid Feedrate Override Switch at 50%.

AXIS

X

Z

Z

F1

Y

Y V

V

XEND

(c.1) Manual: The Zero return procedure can be operated by the manual push-button of each axis. Press and release -X push-button, X axis will move to the Home position. Press the +Y and +Z push-buttons, Y axis and Z axis will move to the Home position.

AUTO

(c.2) Auto: Press the Auto Home return button, Z axis will move to its Home position automatically. After Z axis is at its Home position, X axis will follow the Z axis procedure and then the Y axis.

HOME

X Y Z 4TH 5TH

7. All axes Home position LED lamps will light up when all axes returned to the Home position.


2-16

2.5 Power Off Procedure List

CAUTION

ALWAYS lock the Main Switch by locker to protect ‧unauthorized personnel. DO NOT leave keys on the switches or lockers after ‧machine is turn off.

SBK

1. If the program is executing, the operator need to press the Single Block push-button. One block of the program is executed, and then the execution is stopped.

2. Press the RESET push-button to stop all machine movements.

GO

REME

ENCYPTS

O

G E N Z A

REM

E

E S TRR

A

3. Press the Emergency Stop button.

OFF

4. Press the Power Off button on the machine operator’s panel to switch the numerical control off.

5. Turn OFF the Main Power Switch.

3、OPERATION INSTRUCTION

3-1

3、 OPERATION INSTRUCTION


3-2

3.1 Mode Selection

According to the safety regulation whenever mode selection, all movement must be stopped. If mode exchange between AUTO / MDI and HANDLE / JOG / HOME, spindle, all axial movements will be stopped.

Returning to the mode of AUTO, press the CYCLE Start button, machine will be start. Returning to the HANDLE mode, it must be started from the beginning.

CAUTION

1. Returning to Auto mode for executing the program, and then spindle rotating will be remain the same as previous RPM & direction.

2. Turn the mode selection from AUTO to HANDLE mode

during program in executing, if each of axis displacement has been determined. It will affect the machine dimension when the program is executing continuously.

Whenever cancel or stop temporary to execute the program in AUTO mode, please follow the

regular procedure to avoid any mode exchange. 1. Cancel programming execution

(1) Push the E-stop button. (2) Press the Reset button.

2. Stop programming execution temporary

2-1 Feedhold: (1) Push FEED HOLD button. (2) To Returning back - Push CYCLE START button.

2-2 Feedhold; spindle stop: (1) Push FEED HOLD button, Axis movement will be stopped. Then push the Spindle

stop button, the spindle will be stopped. If the spindle stop is not depress after the axis movement has been completely stopped, then spindle will not be stopped.

(2) Push the CYCLE STOP button, the axial movement will be stopped, then the spindle will be stopped automatically.

(3) Returning back to the previous status - by pushing the CYCLE START button,then spindle will be returning to rotate, axial movement will be remain the same as before.


3-3

CAUTION

1. Normal programming edit at the end of the program will be M02 or M30 which means program to be ended and delete all information in the temporary storage.

2. If programming edit of M02 or M30 at the end of program was missing, then it is necessary to push the RESET button after program execution ending. Or press the RESET button before doing any operation on the machine.

3. If machine did not follow mentioned above regulation, then following condition will be happened:

At MDI mode:

O0000; M03 S300; %

<1> Key-in the sample program as mentioned left: a. Push the CYCLE START button, then spindle will be

rotating in 300 rpm in CW, then program M03 S300 will be disappeared.

b. Change the mode to HANDLE, spindle will be stopped.c. Mode selector turning back to MDI, then push the

CYCLE START button, spindle rotation will be ineffective.

d. Press the RESET button to end all procedure.

O0000; M03 S500 X500.; Z-300.; X-500.; Z300.; %

<2> Key-in the sample program as mentioned left: a. Push the CYCLE START button, then spindle will be

rotating in 300 rpm in CW, all axes will be moving normally.

b. Change the mode to HANDLE, the axis movement will be stopped first, spindle will be stopped few second later, the LCD will keep the same.

c. Mode selector turning back to MDI, then push the CYCLE START button, spindle rotation will be kept remain the same in 500 rpm, then axis movement will be remain the same as before. The program execution will be disappeared, but spindle will be rotating in 500 rpm because of there is neither M05 nor M02, M30 in the program.

d. Press the RESET button to ending all action.


3-4

3.2 Manual Operation

3.2.1 Reference Point Return

CAUTION

It is necessary to move each axis 200mm away from Home position by manual Handle mode before reference point return.

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

(1) Set the mode selector in HOME ZRN position. Home mode is selected, if X, Y, Z, or 4th are selected simultaneously by three or four push-buttons (X+, Y+, Z+, or 4th +), three or four axes moves are followed at the same time.

Note: Before Home return positioning, moves away min. 200 mm from Home position by using M.P.G. handwheel.

HOME

X Y Z 4TH 5TH

AXIS

X

Z

Z

F1

Y

Y V

V

XEND

(2) If press X- button, Z axis will move to its home position. After Z axis is at its home position, Z axis position will be reset in "0". There are three possibilities to interrupt the home return function: Press the Reset push-button on LCD/MDI panel. Turn the mode selector away from HOME position. Press the Emergency Stop button.

(3) After Z axis is at its home position, Y axis will follow the Z

axis procedure, and then the X axis 4th axis.

%100

5025F0

(4) Each selected axis will be moving to its HOME position with Rapid feedrate to the designed deceleration position, then move to the HOME position with 200 mm/min feedrate. The feedrate override switch can be adjusted while the axis is moving.


3-5

3.2.2 Jog Feedrate Operation

A. Jog Mode

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

(1) Set the mode selector in position. JOG mode is selected, X axis can be moved by pressing X+ momentary push-button (button is illuminated) that allows the operator to jog the X axis in the plus X direction with its Jog Override Feedrate. Axial movement will stopped by released the push-button. Depress X- push-button (button is illuminated) that allows the operator to jog the X axis in the minus X direction with its Jog Override Feedrate. Y, Z, 4th axes are the same as X axis procedure.

mm/min

4050

6070

8090 100

160

130120

110

3020

10

170180

190

150140

%

0 200

(2) Select JOG feedrate override switch With this dial, it is possible to override the feedrate designated by the program. An override of 0 to 3,600 mm/min. divide to 16 step, this switch provides to the JOG feedrate switch. Tolerance will be ±3%。

AXIS

X

Z

Z

F1

Y

Y V

V

XEND

(3) Select the axis what you want to move. JOG or RAPID mode is selected, all axis can be moved by pressing X+,X- or Y+, Y-, etc. momentary push-button (button is illuminated) that allows the operator to jog the X axis in the plus or minus X direction with its Jog Override Feedrate. Axial movement will stopped by released the push-button.


3-6

B. RAPID override mode

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

(1) Set the mode selector in position. RAPID mode is selected, X axis can be moved by pressing X+ momentary push-button (button is illuminated) and that allows the operator to move the X axis in the plus X direction with its Rapid Override Feedrate. Axial movement will stopped by released the push-button. Depress X- push-button (button is illuminated) and that allows the operator to move the X axis in the minus X direction with its Rapid Override Feedrate. Y, Z, 4th axes are the same as X axis's procedure.

%

1005025

F0

(2) Select the RAPID override switch The Rapid Override switch of 100%, 50%, 25%, and F0 is provided, when the Rapid traverse rate is 20 m/min. and this dial is set to 50%, actual rate becomes 10 m/min., F0 is a constant value specified by the parameter.

AXIS

X

Z

Z

F1

Y

Y V

V

XEND

(3) Select the axis what you want to move. JOG or RAPID mode is selected, all axis can be moved by pressing X+, X- or Y+, Y-, etc. momentary push-button (button is illuminated) and that allows the operator to move the X axis in the plus or minus X direction with its Rapid Override Feedrate. Axial movement will stopped by released the push-buttons.


3-7

3.2.3 Handle Wheel Operation

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

(1) Set the mode selector in HANDLE position. Select the axis to be moved by the axes selector, the selected axis can be moved by Manual Pulse Generator (M.P.G.). Handle Multiplication can be set by actuating one of the three steps X1, X10, X100.

(2) Set the Axis select mode The axis to be moved is selected by setting of Axis select mode. The Handle wheel allows the operator to move a slide in increments when Mode Select Switch is in X, Y, Z or 4th position.

(3) Set the Handle Multiplication Switch The value of each hand wheel increment depends on the setting of Handle multiplication switch and the axis to be jogged depends on the setting of Axis select Mode. A list of movement amount per degree is as below:

Input system X 1 X 10 X 100 Metric input (mm) 0.001 0.010 0.100 Inch input (inch) 0.0001 0.0010 0.0100

(4) Handle wheel To rotate the wheel in one turn (360°), it will create 100 pulse. Turn in CW direction, the axis will be moving in "＋" direction, Turn in CCW direction, the axis will be moving in "－" direction.

Note 1: If the Handle is rotated in excess of 5 turns /sec, there is a difference between the Handle rotation amount and the machine movement distance.

Note 2:

Rotating the Handle too fast when X100 is selected, moves the tool or table at a rate as fast as the rapid traverse rate. A sudden stop gives the machine tool a shock.


3-8

3.2.4 Spindle Manual Operation

Do not approach the spindle while it’s running. Stop the spindle before maintain the spindle.

CAUTION Be sure the tool clamping is secured before spindle running.

The spindle can be rotated by 4 push buttons when the mode at Manual mode selection (including Handle, Rapid, Jog). When the spindle is running, mode shift to Auto mode position, then the spindle will be stopped.

CW

Spindle CW push button: The spindle CW push-button is an illuminating, momentary type

push-button. The light must be OFF for spindle CCW mode operation. Effective by mode selected in Handle position, press the CW push-button. Spindle rotates in clockwise direction.

STOP

Spindle Stop push-button: Spindle can be stopped by the following methods:

(1)Press the Reset button in Handle mode, spindle will be stopped

immediately. The push-button will be illuminated whenever spindle is not in running.

(2)Commanded M05 when mode selector is in AUTO position.

(3)Press the push-button on the programmer's panel or Emergency

stop button.

The CW & CCW push-buttons will light out when spindle is stopped.

CCW

Spindle Counter Clockwise (CCW) push-button: The spindle CCW push-button is an illuminating, momentary type

push-button. The light must be OFF for spindle CW mode operation. Effective by mode selected in Handle position, press the CCW push-button. Spindle rotates in counter clockwise direction.


3-9

3.2.5 Spindle Tool Unclamping Manual Operation

CAUTION

DO NOT approach the spindle while it’s running. BE SURE that the power been turned off before servicing the spindle unit. CHECK AND MAKE SURE that the spindle is stopped while cleaning the spindle taper.

MUST STOP the axial movement while in spindle tool loading and unloading.

WARNING

MAKE SURE that there is no tool in the tool pockets of the magazine of whatever number is occupied on the spindle. IF the spindle has been occupied by a tool, DO NOT modify the spindle tool number at the value of "0". The tool must be performed by dimension check, clean and tightened pull stud before spindle loading. The tool to be mounted must meet the specified specifications as below:

BM-850 BM-1020 BM-1200 BM-1460

Max. tool dia./adjacent (mm) 90/150 90/150 90/150 90/150

Max. tool length (mm) 250 250 250 250

Max. tool weight (kg) 8 8 8 8


3-10

BM-1400 BM-1600 BM-1800 BM-2100




BM-2500

Max. tool dia./adjacent (mm) 130/250

Max. tool length (mm) 300

Max. tool weight (kg) 15

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

Set the mode selector at the Handle or Jog or Rapid position. Press Tool Unclamp push-button on the spindle head to let spindle unclamp. Press Tool Unclamp push-button on the spindle head to let spindle clamp.


3-11

3.2.6 Tool Magazine Manual Operation

WARNING MAKE SURE all items as mentioned below before tool loading at magazine.

(1) Before your requested tools are put into the

magazine, pre-check tool tips are in good condition and tighten and clean the tool holder.

(2) The tool to be mounted should meet the specified specifications as the list shown below.

(3) During mounting of your requested tools in the

magazine, Make sure that your expected tool pocket numbers are assigned by the controller.

A. Magazine index forward

CW

Select "HANDLE" mode, press "Magazine (CW)" button, then magazine will be indexing forward.

B. Magazine index reverse

CCW

Select "HANDLE" mode, press "Magazine (CCW)" button, then magazine will be indexing reverse.

C. Loading & Unloading from the Magazine

Be caution when loading the tool at the magazine:

1. Before your requested tools are put into the magazine, pre-check tool tips are in

good condition and tighten and clean the tool holder. 2. The specification of the tool must be as below:

BT40 BT50

Max. tool diameter 90 127

Max. tool length 250 300

Max. tool weight 8 15

3. Tool magazine door must be closed at all time. 4. During mounting of your requested tools in the magazine, make sure your expected

tool pocket numbers are assigned by the controller.


3-12

3.2.7 Chip Conveyor Manual Operation and Trouble Shooting

A. Operation

FORWD

Press this button on the operator panel, and then the chips shall be coming out from the conveyor. Users could stop the conveyor by pressing this button again.

FORWD

Press the button to active the chip screw, to stop it by press the button once again.

CAUTION DO NOT remove the chips by hands in order to avoid any injury.

B. How to remove the chip from the table?

1. Use brush or water gun to clean the chip to screw conveyor. 2. Turn the chip conveyor ON to remove the chip from screw conveyor.

C. Trouble shooting

1. Use hook to remove the chip from the conveyor. 2. Check the conveyor condition.

FORWD

Press this button once for forwarding

BACK

Press this button for reversing.

3. If it still does not move, it means the motor might be broken. Please contact with

your agency.


3-13

3.2.8 Coolant Tank

1. Manual operation

MAN

The cock must be turned on first. Press this button; the indicator will light up and the coolant will come out from spindle side. Press this button again; the indicator will black out and the coolant will stop.

2. Command

M08: Coolant ON M09: Coolant OFF

3. Water gun

MAN

The cock must be turned OFF. Press this button. The water gun will be enabled when the light illuminates. Press this button again, and the water gun will be stopped.


3-14

3.3 MDI Operation

3.3.1 MDI Function

The MDI mode provides the operator with the means to manually enter and execute program information one block of information at a time. MDI blocks are executed independent of the Active NC program. Each MDI block is completely executed before the next MDI block can be entered.

The MDI mode is terminated by depressing one of the other mode keys. If an MDI block

is displayed in the MDI Block entry area when the MDI mode is terminated, the block is erased. The control state which was active when the MDI mode was entered is retained when the MDI mode is terminated, unless the state is changed from end of block to end of program while in the MDI mode, in which case the end of program state is retained.

Note: The MDI mode can not be terminated if the cycle of an MDI block has been started

and has not been completed (in cycle or suspended in the middle of the block).


3-15

A. Programming

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

Set the mode selector in MDI position. Press the PRGRM push-button, the LCD screen will displayed as below:

‧ The program No. O0000 will be inserted automatically. To program in MDI mode is the same as program editing.

‧ The length of a program which can be prepared is limited to one page of a LCD screen. In the above case, the longest program is 6 lines with specification of the parameter, if the mode is switched to that of no modal information display, up to 10 lines of program can be prepared. If the number of lines of program exceeds the limit, % will disappear and insertion and modification operation will become impossible.

‧ To delete a program by press the RESET push-button (when parameter no. 057 is set as MBCLR=1) or O「DELETE」.

About program editing, please refer to FANUC operation manual.


3-16

B. Program Execution

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


3-17

C. Cautions and others:

1.

Programs registered in the program memory can be called as subprogram. In this case, the nest of subprogram is up to 2-loops combined with automatic operation (AUTO) program. (If a caution macro option is provided, up to 4-loops combined is possible.)

2. If the custom macro option is provided, even in the MDI mode, custom macro program preparation and execution is possible. However, when a macro program which call another macro program, macro call is not possible.

3. A program to be prepared in the MDI mode uses program memory vacant area. If there is no vacancy in the program memory, program preparation in the MDI mode is not possible.

4. Program prepared in the MDI mode will be erased in the following cases: a. In MDI operation, if M02, M30 or % is executed. b. In AUTO mode, if memory operation is performed. c. In EDIT mode, if any editing is performed.

d. Background editing is performed.

5. The editing operation during the stop of MDI operation will start from the cursor position which makes start, but not from the current cursor position.


3-18

3.4 Automatic Operation

3.4.1 Executing Automatic Operation

The program which stored in memory can be executed in AUTO mode, only one program can be performed at the same time. To search the program number and enable it as follows:

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

(1) Set the mode selector in EDIT position. When once an expected program is selected, load the program by pressing the RESET push-button on the FANUC operator's panel.

(2) Set the mode selector in AUTO position. (3) Press the soft-key under the mode selection of MONITOR, the

programming O number will be showing up.

(1) Call the required program. (2) Press the CYCLE START push-button, the button light will come on.

After automatic operation is started, the following are executed:

(1) A one-block command is read from the specified program. (2) The block command is decoded. (3) The command execution is started. (4) The command in the next block is read. (5) Buffering is executed. That is, the command is decoded to allow immediate

execution. (6) Immediately after the proceeding block is executed, the execution of the next

block can be started because buffering has been executed. (7) Hereafter, automatic operation can be executed by repeating the steps (4) to

(6).


3-19

3.4.2 Block Skip

(1) ON: Depressed the push-button, button light will come ON. BDT

The function is active when the push-button is illuminated. The control will ignore any block containing a Slash code ( / ) when mode selector is in AUTO or MDI position.

(2) OFF: Released the push-button, button light will turn OFF.

When the push-button is not illuminated, the data block is executed, even any block containing a Slash code ( / ).

For example: N1 G54; N2 G90 G81 X50 .Z-20. R3 .F100; / N3 X30.; ( Slash code is in front of the block ) N4 X10.; N5 G80; M30;

Please refer to the FANUC Programming Manual for detail.


3-20

3.4.3 Manual Absolute

This ON/OFF soft-key selects whether the amount of manual movement is to be added to the absolute value.

For example: : N001 G01 G90 X100.0 Y100.0 F1000 ; N002 X200.0 Y150.0; N003 X300.0 Y200.0;

When block N002 has been executed after manual operation (X axis + 20.0, Y axis +100.0) at the end of movement of block N001.

(1)

Manual Absolute is OFF

Manual Absolue is ON

ManualOperation

( 220, 250 )

( 200, 150 )

( 100, 100 )

( 120, 200 )


3-21

When the Feed Hold button is pressed while block N002 is being executed, manual operation (Y axis +75.0) is performed, and the cycle start button is pressed and released.

(2)

Y Manual Absolute is OFF

Manual Absolute is ON

Manual Operation

(150, 200 )

(200, 225)

(200, 150)

(150, 125)(100, 100)

(300, 200)

(300, 275)

When the Feed Hold button is pressed while block N002 is being executed, manual operation (X axis +75.0) is performed, the control unit is reset with RESET button, and block N002 is read again.

(3)


Manual Absolute is ON

( 300, 275 )

( 300, 200 )

( 200, 150 )

( 200, 225 )

( 150, 200 )

( 100, 100 )

Manual Operation


3-22

(4)

When there is only one axis in the following command, only the commanded axis returns.

N1 G01 G90 X100.0 F500 ; N2 X200.0 ; N3 Y150.0;


Manual absolute is ON

ManualOperation

When the following commands are incremental commands, operation is the same as when the MANUAL ABSOLUTE push-button is OFF. NOTE:

The following conditions will be happened when manual operation is performed during cutter radius compensation.

A.The MANUAL ABSOLUTE push-button is OFF and cutter compensation is being performed.

After manual operation is performed with the Manual Absolute push-button in OFF position during cutter compensation, automatic operation is restarted then the tool moves parallel to the movement that would have been performed. If manual movement had not been performed, the amount of separation equals to the amount that was performed manually.

(5)

Manual Absolute is OFF - Tool Path

Tool Path

Program Path

ManualOperation


3-23

B.The MANUAL ABSOLUTE push-button is ON and cutter radius compensation is being performed.

Machine operation upon return to automatic operation after manual intervention with the manual absolute push-button in ON position during execution with an absolute command program in the cutter radius mode will be described. The vector, the remaining part of the current block and the beginning of the next block is shifted in parallel the amount of manual movement performed is included in the calculations of the vectors of the two blocks subsequent to the current block. This also applies when manual operation is performed during cornering. a. During block execution

Program path(Absolute command)

Tool Path(before manual operation)

Manual Operation

Example 1:

Assume that the Feed Hold was applied at point PH while moving from PA to PB of programmed path PA, PB, and PC and that the tool was manually moved to PH'. The block end point PB moves to the point PB' by the amount of manual movement, and vectors VB1 and VB2 at PB also move to VB1' and VB2'. Vectors VC1 and VC2 between the next two blocks PB - PC and PC - PD are discarded and new vectors VC1' and VC2' (VC2' = VC2 in the example above) are produced from the relation between PB' - PC and PC - PD. However, since VB2' is not a newly calculated vector, correct offset is not performed at block PB' - PC. Offset is correctly performed after PC.


3-24

Program Path(Absolute Command)

Manual Operation

Tool Path

VA1' Example 2:

This is an example when manual operation is performed during cutter radius cornering. VA2', VB1', and VB2' are vectors moved in parallel with VA2, VB1 and VB2 by the amount of manual movement. The new vectors are calculated from VC1 and VC2. Then correct cutter radius is performed for the blocks following PC. b. Manual operation was performed when execution of a block was terminated by single block stop.

Program Path(Absolute Command)

Tool Path

ManualOperation

Vectors VB1 and VB2 are shifted by the amount of manual operation. Sub-sequence processing is the same as case (a) described above. An MDI operation can also be intervened as well as manual operation. The movement is the same as that by manual operation.


3-25

3.4.4 Program Restart

This function specifies Sequence No. of a block to be restarted when a tool is broken down or when it is desired to restart machining operation after a day off, and restart the machining operation from that block. It can also be used as a high speed tape check function.

A. When a tool is damaged (P type):

a. Press Feed Hold to escape the tool, and replace it with a new one. Modify the offset

amount if it varies.

b. Press PRGRM to display the present program.

c. Turn the Mode selector in Handle or Rapid position in order to move Z, Y, or X axis to change the tool.

d. Depressed the Program Restart push-button on the machine control panel. The button light will come on.

e. Find the program head, press RESET push-button during memory operation. Selected AUTO mode position and press O and ↑.

f. Press P Sequence No. ↓, and search the block with Sequence No. to be restarted. When the same sequence No. appears many times, for example, when the subprogram is accessed several times in searching Sequence No. in the subprogram, specify the frequency of a block with its sequence No. in upper 4 digits, and specify Sequence No. in lower 4 digits as illuminated below. P 1 2 3 4 0 1 2 3 【↓】 └───┘└───┘ Frequency Sequence No. When the block is the first time, the upper 4 digits can be omitted. Further, the leading zero can be omitted expect Sequence No. when the frequency is specified.


3-26

g. After completion of block search, the LCD screen is changed to the program restart

screen. Please refer to the screen as below.

(DESTINATION) shows the position where the machining operation is restarted. (DISTANCE TO GO) shows the distance between the current tool position and the

machining restart position. The figure at the left side of the axis name shows the order (parameter setting) described later when the tool moves to the restart position.

M...Shows M code commanded recently 35 times in the past. T.....Shows T code commanded recently 2 times in the past. S.....Shows S code command in the last. B.....Shows B code command in the last.

Display the most previously commanded code in the head. Each code is cleared with the program restart command and the cycle start command in reset conditions.

h. Released Program Restart push-button, button light will turn off. At this time, the figure at the left side of axis name (DISTANCE TO GO) flickers as well as Restart message at the right side.

i. Check the screen, and if M, S, T or B code should be output, select the MDI mode and output M, S, T or B code from MDI. Each code in this case is not displayed on the program restart screen.

Selected “Handle” mode, push Spindle CW button to rotate which speed will be following the spindle speed executed by last block.

j. During memory operation, select AUTO mode and check that the distance of DISTANCE TO GO is correct, and the tool does not hit the workpiece or others. If it is about to collide with an obstacle, move the tool manually to the location where it does not collide, then press CYCLE START button. At this time, the tool moves to the machining restart position in the Dry Run mode by one axis in the order set to the parameters No. 0124 to 0127, thus restarting machining operation in succession.

Manual Absolute button must be depressed all the time.


3-27

PRPGRAM RESTART O0500 N0010 (DESTINATION) M033 010 011 020 015 X 100.000 019 034 056 050 044 Y 100.000 065 068 070 080 085 Z 100.000 077 082 092 022 015 A 0.000 032 044 040 055 *** *** *** *** *** *** (DISTANCE TO GO) *** *** *** *** *** 2 X 108.864 3 Y 103.001 T 0101 0202 4 Z 82.082 S 02000 1 A 0.000 B ****** 14:32:15 AUTO RSTR 【PRGRM】【CURRNT】【 NEXT】【CHECK】【RSTR】

B. When restarting machining operation after the following cases (Q type):

1. When power is turned OFF once. 2. When the emergency stop button is depressed once.

3. When the coordinate system is changed after automatic operation is previously stopped.

For example: (a) When G92 was set from MDI. (b) When the coordinate system was shifted. (c) When the automatic coordinate system was set by the reference point return. (d) When the coordinate system was modified by "RESET".


3-28

a. When power is turned ON or emergency stop is released, perform all necessary

operations at that time, including the reference point return.

b. Move the tool manually to the program starting point (machining start point), and keep the modal data and coordinate system in the same conditions as at the machining start.

c. If necessary, set and modify the offset amount.

d. Pressed the Program Restart push-button on the machine operator's panel. Button light will come ON.

e. Press PRGRM to display the program. When it is not the specified one, search the specified program.

f. Find the program head block. Press RESET During memory operation, select AUTO mode, and press O ↑.

g.

Press Q "sequence NO." ↓ and search a block with Sequence No. to be re-started. When the same sequence No. appears many times, specify the frequency of a block with its sequence No. in upper 4 digits, and specify Sequence No. in lower 4 digits.

h. Upon complete of block searching, the display on the LCD screen is changed to the Program Restart screen.

i. Release the Program Restart push-button, this function will be ineffective. At this time, the figure at the left side of axis name (DISTANCE TO GO) blinks.

j.

Check the screen, and select the MDI mode if there are M, S, T or B codes to be specified, and output M, S, T or B codes from MDI, In this case, each code is not displayed on the program restart screen.

k.

During memory operation, return the operation mode to "AUTO" mode, check that the distance (DISTANCE TO GO) is corrected, and that the tool does nor hit against a work and others when moving to the machining restart position. If it is likely to hit against an obstacle, move the tool manually to the position where it does not collide, then press the CYCLE START button, At this time, the tool moves to the machining re-start position in the DRY RUN mode by one axis in the order preset to the parameters (No.0124 to 0127).

For further details, please refer to the Section 4.5 PROGRAM RESTART of Chapter 4.AUTOMATIC OPERATION of FANUC OPERATOR’S MANUAL Volume 2.


3-29

3.5 Program Check and Test

3.5.1 Machine Lock

MLK

This function is used to check a program. When Machine Lock mode is active (push-button is illuminated), move command pulses are inhibited. Consequently the position display is updated as specified by the program, but the tool does not move. The M, S, and T are executed. Note: When a G27, G28 or G30 command is specified, the tool

does not go to the reference point and the reference point return completion led does not go on.

3.5.2 Z Axis Cancel

ZLK

Z

When the PLC switch # 11 setting up at ON position, the Z axis will not be moved while machine at Manual/Auto operation. When the Z axis Cancel push-button is pressed, button is illuminated, an Z axis command can be ignored during Manual or AUTO operation. Position display up dates as if the axis were moving. To exit Z axis cancel, press push-button a second time, button lamp will lights out.

3.5.3 Dry Run

DRN

When the Dry Run push-button is pressed (button is illuminated) during in MDI or AUTO position, the Feed-rate specified by the program is ignored. G00 will kept the same as Rapid Feedrate, G01 will becomes as Max. Jog Feedrate by JOG Feedrate override switch control (P1410). To exit this function, press the push-button a second time, button lamp will lights out.


3-30

3.5.4 Feedrate Override

3.5.5 Jog Override

3.5.6 Rapid Override

mm/min

4050

6070

8090 100

160

130120

110

3020

10

170180

190

150140

%

0 200

With this dial, it is possible to override the Feedrate designated by the program in MDI or AUTO mode. An override of 0 to 200 % can be applied to override all axes in G01 command. M48, M49 or Rigid Tapping function are always override 100%, this dial is not available.

mm/min

4050

6070

8090 100

160

130120

110

3020

10

170180

190

150140

%

0 200

JOG mode is selected, X axis can be moved by pressing X+ momentary push-button (button is illuminated) that allows the operator to jog the X axis in the plus X direction with its Jog Override Feedrate. Axial movement will stopped by released the push-button. Depress X- push-button (button is illuminated) that allows the operator to jog the X axis in the minus X direction with its Jog Override Feedrate. Y, Z, 4th axes are the same as X axis procedure.

%100

5025F0

The Rapid Override switch of 100%, 50%, 25% and F 0 is provided, when the rapid traverse rate is 18 m/min. and a G 00 is commanded in MDI or AUTO mode, this dial is set to 50%, actual rate becomes 9 m/min. F 0 is a constant value specified by the parameter. Rapid override is effective by the following functions: (1) by G00. (2) during canned cycle. (3) in G27 and G28. (4) Manual rapid traverse. (5) Rapid traverse in manual reference point return.


3-31

3.5.7 Spindle Speed Override

%

60

70

80

110

100

90

50 120

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


3-32

3.6 Tool Setting

3.6.1 Tool Number Setting Initialization

Tool Loading/Unloading & Tool Change Testing:

WARNING MAKE SURE all items as mentioned below before tool loading at magazine.

(1) Before your requested tools are put into the magazine,

pre-check tool tips are in good condition and tighten and clean the tool holder.

(2) The tool to be mounted should meet the specified specifications.

(3) Tool magazine door must be closed all the time.

BM-850 BM-1020 BM-1200 BM-1460




BM-1400 BM-1600 BM-1800 BM-2100




BM-2500

Max. tool dia./adjacent (mm) 130/250

Max. tool length (mm) 300

Max. tool weight (kg) 15


3-33

WARNINGMAKE SURE ALL FOLLOWING ITEMS MUST BE CORRECT BEFORE TOOL CHANGE.

BE SURE that the tool number in the spindle and magazine are relative to each other. MAKE SURE that there is no tool in the tool pocket of the magazine when the tool is in the spindle. IF the spindle has been occupied by a tool, DO NOT modify the spindle tool number at the value of "0". The tool must be performed by dimension check, clean and tightened pull stud before spindle loading.

WARNINGTool loading number must meet the required T# executed while tool table initialization.

Following procedure is prohibited while tool initialization:

Tool number initialization is no bigger than the maximum tool number of the machine.

After tool initialization/modified, all process must be reconfirmed.

The spindle tool number must be at the pocket where is empty in order to be sure that the tool returning back will not damage the tool magazine.


3-34

A. Arm Type

a. ATC Arm Type Tool Installation & Data Setting(18i-MB 10.4"LCD)

1. Push down the emergency stop button (Figure 3-1);

Figure 3-1 Alarm message(18i-MB 10.4"LCD)

2. Press SYSTEM key; then push the soft key "PMC" to enter next screen (Figure 3-2);

Figure 3-2 Parameter setting screen(18i-MB 10.4"LCD)


3-35

3. Press the soft key "PMCPRM" (Figure 3-3);

Figure 3-3 PMC Control system screen(18i-MB 10.4"LCD)

4. Press the soft key "DATA" (Figure 3-4);

Figure 3-4 PMCPRM screen(18i-MB 10.4"LCD)


3-36

5. Press down the soft key "G. DATA" (Figure 3-5);

Figure 3-5 PMC DATA screen(18i-MB 10.4"LCD)

(1) If the parameter K900#7 = 1, the figure 3-5, PMC DATA screen, is not displayed.

(2) If the parameter K900#7 = 0, the figure 3-5, PMC DATA screen, is displayed.

6. When tools are dislocated or in the initial setup, it will need to reset the data values from address D0001~D0099 (Figure 3-6);

Figure 3-6 PMC G. DATA screen 1(18i-MB 10.4"LCD)


3-37

7. During the initial installation, please make sure the initial values of the address D00101 to D00199 are tool state code. (Figure 3-7);


8. If there are not the large diameter tools, set the initial values of D0201~D0216 are 0

(Figure 3-8);



3-38

9. Setting the total pockets number of tool magazine in D0300 (Figure 3-9);


NOTE:Please turn the "ATC JOG" function on and turn it off while changing D300.

10. Change to the “COUNTR” screen and rotate the tool magazine pocket to No.1

position. Setting C028[CURRENT]=0 (Figure 3-10);

Figure 3-10 COUNTR screen(18i-MB 10.4"LCD)


3-39

b. ATC Arm Type Tool Installation & Data Setting(0i-MD 8.4"LCD)


Figure 3-11 Alarm message(0i-MD 8.4"LCD)

12. Press SYSTEM key; then push the soft key "PMCMNT" to enter next screen (Figure

3-12);

Figure 3-12 PMCMNT system screen(0i-MD 8.4"LCD)


3-40


Figure 3-13 PMCMNT DATA screen(0i-MD 8.4"LCD)

14. When tools are dislocated or in the initial setup, it will need to reset the data values

from address D0001~D0099 (Figure 3-14);

Figure 3-14 PMCMNT DATA screen 1(0i-MD 8.4"LCD)


3-41

15. During the initial installation, please make sure the initial values of the address

D00101 to D00199 are tool state code. (Figure 3-15);

Figure 3-15 PMC DATA screen 2(0i-MD 8.4"LCD)


(Figure 3-16);

Figure 3-16 PMCMNT DATA screen 3(0i-MD 8.4"LCD)


3-42


Figure 3-17 PMC DATA screen 4(0i-MD 8.4"LCD)




Figure 3-18 COUNTR screen(0i-MD 8.4"LCD)


3-43

c. ATC Arm Type Tool Installation & Data Setting(0i-MD 10.4"LCD)


Figure 3-19 Alarm message(0i-MD 10.4"LCD)

20. Press SYSTEM key; then push the soft key "PMC MAINTE" to enter next screen

(Figure 3-20);

Figure 3-20 PMC MAINTE system screen(0i-MD 10.4"LCD)


3-44


Figure 3-21 PMC MAINTE DATA screen(0i-MD 10.4"LCD)



Figure 3-22 PMC MAINTE DATA screen 1(0i-MD 10.4"LCD)


3-45





(Figure 3-24);



3-46






Figure 3-26 COUNTR screen(0i-MD 10.4"LCD)


3-47

d. ATC Arm Type Tool Installation & Data Setting(31i-B 10.4"LCD)


Figure 3-27 Alarm message(31i-B 10.4"LCD)

28. Press SYSTEM key; then push the soft key "PMC MAINTE" to enter next screen

(Figure 3-28);

Figure 3-28 PMC MAINTE system screen(31i-B 10.4"LCD)


3-48


Figure 3-29 PMC MAINTE DATA screen(31i-B 10.4"LCD)



Figure 3-30 PMC MAINTE DATA screen 1(31i-B 10.4"LCD)


3-49





(Figure 3-32);



3-50






Figure 3-34 COUNTR screen(31i-B 10.4"LCD)


3-51

Executing “M6 T_” to install tools into magazine.

NOTE: G.. DATA (NO) 0001~ (NO) 0099 = tool pocket number (DATA) 0001~ (DATA) 0099 = actual tool number (random) (DATA) 0101~ (DATA) 0199 = tool state code 33: standard tool (diameter: Φ79 mm) 66: large diameter tool (diameter: Ф80~ Ф100 mm) 99: forbid using this pocket

00 or 0:tool pocket is empty; it is preparative to install new tool

(DATA) 0300 = the total of tool magazine pockets a. When (DATA) 0300 = 24;

(DATA) 0201~ (DATA)0212 = the range of inputting large diameter tool numbers b. When (DATA) 0300 = 30;

(DATA) 0201~ (DATA)0215 = the range of inputting large diameter tool numbers

ADDRESS PRESET CURRENT

C000 tool magazine pocket number present pocket number

C028 tool magazine pocket number present spindle tool number

Table 1. "COUNTR"


3-52

Example1: The totality of tool magazine pockets: 24 All tools are in different normal size diameters. (Table 2 & Table 3)

Address Data D0000 99 D0001 1 D0002 2 : : D0024 24 : : D0100 99 D0101 33 D0102 33 : : D0124 33 : : D0200 99 D0201 0 : : D0216 0 Table 2. "DATA" 1 Address Preset Current C0000 24 1 C0028 24 0

Table 3. "COUNTR" 1


3-53

Example2: The totality of tool magazine pockets: 24 No. 23 Pocket is a large diameter tool set. No. 22 & No. 24 must set the value in "0" state, because the No.23 pocket is set in a large diameter tool. (Table 4 & Table 5)

Address Value D0000 99 D0001 1 D0002 2 : : D0022 0 D0023 23 D0024 0 : : D0100 99 D0101 33 : : D0121 33 D0122 99 D0123 66 D0124 99 : : D0200 99 D0201 23 : : D0216 0 Table 4 "G. DATA" 2 Address Preset Current C0000 24 1 C0028 24 0

Table 5 "COUNTR" 2

No. 23 Pocket is a large diameter tool set.


3-54

Example3: The totality of tool magazine pockets: 24 There are two large diameter tools separately within 2 pockets: No.21 & No.23. No. 20, No.22 and No. 24 must set in "0" state, because each of No.21 and No.23 is set in a large diameter tool (Table 6 & Table 7).

Address Value D0000 99 D0001 1 D0002 2 : : D0020 0 D0021 21 D0022 0 D0023 23 D0024 0 D0100 99 D0101 33 D0102 33 : : D0120 99 D0121 66 D0122 99 D0123 66 D0124 99 D0200 99 D0201 21 D0202 23 D0203 0 : : D0216 0 Table 6 "G. DATA" 3 Address Preset Current C0000 24 1 C0028 24 0 Table 7 "COUNTR" 3


3-55

CAUTION It can not be assigned the tool pockets in continuous numbers, if there are two large diameter tools or more in the magazine.

The following table presents 5 conditions with the result:

Large diameter tool pocket No. Result

No.23, No.22, No.21 Wrong



No.23, No.21, No.19 OK

No.23, No.21, No.15 OK

If there is one large diameter tool pocket defined; then we must set in "no using" pockets state for the both-side, last and next, pockets of the defined large diameter tool pocket.


3-56

e. ATC Arm Type Tool Magazine Adjustment

1. Magazine position adjustment:

Remove the fixed teeth of spindle (Figure 3-35), and mark them to make for restoring to original position after completing the installation.

Figure 3-35 Remove the fixed teeth

2. Install the gauge to spindle and arm separately (Figure 3-36).

Figure 3-36 Install gauge


3-57

3. Use the tool wrench to manually change the arm (Figure 3-37) or turn on the “ATC JOG” function (18i-MB 10.4"LCD Figure 3-38, 0i-MD 8.4"LCD Figure 3-39, 0i-MD 10.4"LCD Figure 3-40, 31i-B 10.4"LCD Figure 3-41); then press the CYCLE STRAT button.

Figure 3-37 Tool magazine

Figure 3-38 Operator panel screen(18i-MB 10.4"LCD)


3-58

Figure 3-39 Operator panel screen(0i-MD 8.4"LCD)



3-59



3-60

4. Until the arm rotates to the side of spindle, use the tool to correct the center points are all in same position (Figure 3-42).

Figure 3-42 Tool gauge

5. Make sure the magazine position and angle are correct, screw the nut, and then set 2

pins in each location (Figure 3-43).

Figure 3-43 Magazine mounting plate


3-61

6. Clamp a tool in spindle (Figure 3-44).

Figure 3-44 Tool is within spindle

7. Rotate the arm to catch the tool which is in spindle. Then, adjust spindle Z position

to rotate the tool smoothly (Figure 3-45).

Figure 3-45 Rotate tool


3-62

8. Switch to machine coordinate screen, at the Step 7 we need to lift Z axis up 0.5mm.

Then, input this machine coordinate value to PARAMETER 1241.


Figure 3-47 Parameter setting screen(0i-MD 8.4"LCD)


3-63


Figure 3-49 Parameter setting screen(31i-B 10.4"LCD)


3-64

9. Set the spindle orientation angle: -4095 to 4095 in PARAMETER 4077.




3-65


Figure 3-53 Parameter setting screen(31i-B 10.4"LCD)


3-66

f. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(18i-MB 10.4"LCD)

1. MANUAL ARM CW FOR OPERATION

SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPR OPERATION’S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON

Figure 3-54 ATC JOG(18i-MB 10.4"LCD)

(1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND POCKET TOOL)


3-67

2. MANUAL ARM CCW FOR OPERATION

SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPR OPERATION’S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS

Figure 3-55 ATC JOG & CCW(18i-MB 10.4"LCD)

(1) SWITCH TO "HANDLE" MODE (2) PRESS CYCLE START PUSH BUTTON (3) MANUALLY UNCLAMP & CLAMP TOOL (4) MUST CHECK TOOL LIST (SPINDLE TOOL AND PACKET TOOL)


3-68

g. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(0i-MD

8.4"LCD)

1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPR OPERATION’S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON

Figure 3-56 ATC JOG(0i-MB 8.4"LCD)



3-69


SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPR OPERATION’S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS

Figure 3-57 ATC JOG & CCW(0i-MD 8.4"LCD)



3-70

h. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(0i-MD

10.4"LCD)

1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPERAT PANEL OPERATION’S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON

Figure 3-58 ATC JOG(0i-MD 10.4"LCD)



3-71


SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPERAT PANEL OPERATION’S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS

Figure 3-59 ATC JOG & CCW(0i-MD 10.4"LCD)



3-72

i. ATC Arm Type Trouble Shooting of the Interrupted Arm Action(31i-B

10.4"LCD)

1. MANUAL ARM CW FOR OPERATION SETING PMC PRM (KEEP RELAY) OPERATION SETTING RIGHT PUSH-BUTTON OPERAT PANEL OPERATION’S PANL MOVE CURSOR ADDRESS OPTION ATC JOG ON

Figure 3-60 ATC JOG(31i-B 10.4"LCD)



3-73


SETING DATA TABLE OPERATION SETTING RIGHT BUTTON OPERAT PANEL OPERATION’S PANL OPTION ATC JOG ON (USE DOWN PUSH-BUTTON MOVE ATC CCW ON) AS FOLLOWING SCREEN SHOWS: TURN ON THE "ATC JOG" & "ATC CCW" FUNCTIONS

Figure 3-61 ATC JOG & CCW(31i-B 10.4"LCD)



3-74

B. Drum Type

1. COUNTER SET: (1) PRESS [SYSTEM] (2) [PMC] (3) [PMCPRM] (4) [COUNTR]

NO. ADDRESS PRESET CURRENT

1 C000 # ＊

2 C004 12 1

3 C008 20 0

4 C012 0 0

5 C016 0 0

6 C020 0 0

7 C024 0 0

8 C028 20 0

9 C032 8 0

10 C036 0 0 #AMOUNT OF TOOL ＊CURRENT TOOL POT NO.

2. G-DATA SET:

(1) PRESS [SYSTEM] (2) [PMC] (3) [PMCPRM] (4) [COUNTR] (5) [DATA] (6) [G-DATA]

NO. ADDRESS DATA

0 D0010 ■

1 D0011

2 D0012

3 D0013

4 D0014

5 D0015

6 D0016

7 D0017

■ =SPINDLE TOOL NUMBER


3-75

1. It is necessary to make sure all tool pockets are empty. 2. Set spindle tool number in DATA of address D0010. The spindle tool number can

not be 0.

NO. ADDRESS DATA

0 D0010 ■

1 D0011

2 D0012

3 D0013

4 D0014

5 D0015

6 D0016

7 D0017

■=SPINDLE TOOL NUMBER

3. If tool pocket number 1 is at the ready position, press the tool magazine index

forward push-button, tool pocket number 1 will move forward and tool pocket number 2 will at the ready position. Pressing the tool magazine index reverse push-button, tool pocket number 2 will move backward and tool pocket number 1 will at the ready position.

4. Set 20 in # if there are 20 tools. Set 1 in ＊if the tool pocket number 1 is at the ready position.

NO. ADDRESS PRESET CURRENT

1 C000 # ＊

2 C004 12 1

3 C008 20 0

4 C012 0 0

5 C016 0 0

6 C020 0 0

7 C024 0 0

8 C028 20 0

9 C032 8 0

10 C036 0 0 #AMOUNT OF TOOL ＊CURRENT TOOL POT NO.


3-76

5. Key in M06T1 then make sure HD.T=1 and NX.T=1 displayed as the following

screen.

Figure 3-62 M6T1(18i-MB 10.4"LCD)

Figure 3-63 M6T1(0i-MD 8.4"LCD)


3-77

Figure 3-64 M6T1(0i-MD 10.4"LCD)

Figure 3-65 M6T1(31i-B 10.4"LCD)

6. Manually load the tool number 1 in the spindle.

7. Key in M06T2, then the tool number 1 which was held in the spindle will be put in the tool pocket number 1. HD.T=2 and NX.T=2 is displayed on the screen. Manually load the tool number 2 in the spindle. Key in M06T3 to M06T20 to repeat steps 5 and 6 until 20 tools are put in the tool pockets.

4、TROUBLE SHOOTING

4-1

4、 TROUBLE SHOOTING


4-2

This chapter is describing how to find and fix the problems coming out from the PMC

(Programmable Machine Controller), other than Alarms from NC or Servo system may describe by FANUC manual. Check the following items, if the machine still can not function properly; then please contact our Representative or our Office in your territory and give the following particulars: (1) Machine Model; (2) Serial No. (All are on the machine nameplate); (3) Condition of the machine (as much detail as possible).

4.1 Trouble Shooting Guide

In case of any short circuit or thermal break caused by any mechanical overloaded or mis-operation, when electrical malfunction occurs, a prior knowledge of the components governing the various machine functions can be very useful in isolation the problem to a specific area of the control circuit.

Once the problem area has been defined, the electrical components controlling that function should be checked for proper operation. The coils of any of the electrically held control devices included within the problem area should be checked to see if they are in the proper state; energized or de-energized as specified in the electrical diagrams. This can be accomplished by checking the state of the indicating mechanism on the control device. If a coil is found to be in the incorrect state, then the components and related circuitry controlling the state of that component must be checked using a volt-ohm meter or similar checking device. First checks to be certain that 220 Volt supply is being delivered to the problem area. The circuit components will generally operate within a range of 198 to 240 volts. If the supply voltage is below the minimum value, it may be inadequate to energize the circuit components. In this case, check the transformer output to see if it is within the prescribed range (220 Volt ±10%). If not, check the power source to see if line voltage is being delivered to the electrical system. If the power source and transformer outputs appear to be adequate but the voltage being delivered to the problem area is low, there is probably a “short” somewhere in system between the transformer and the problem area.

With the proper voltage being supplied to the problem area, check across each of the circuit components until a loss of voltage is detected, thereby indicting the component causing the problem.

It is quite possible that the coil of the electrically held control device is in the proper state but a system malfunction still exists. In this case, the related circuit components controlling the state of that coil would appear to be functioning properly electrically, thereby indicting that it is not necessary to check out the circuit as previously described. In this situation, the contacts should be inspected for mechanical binding, welded contacts, dirt, dust, corrosion or similar abnormality.

If the components previously checked appear to be functioning properly and a malfunction still exists, check the electrical circuit for such abnormalities as defective motor, stuck solenoid, broken or loose wiring, short circuit, etc.

Some common component problems and their possible cause and cures are listed on the Trouble shooting guide.


4-3

4.2 Alarm Message with Remedial Measures

4.2.1 Arm Type

WARNINGONLY qualified person is authorized to service followings. Failure to do so will result in serious injury or death

No. Alarm Message Correction

1001 SPINDLE HEAD COVER INTERLOCK The alarm message is cancelled.

1002 3 AXES NOT HOME (ATC) Make sure that all axes have been HOME returned correctly.

1003 Z AXIS NOT 2ND HOME (ATC) Run the program of G91G30Z0.

1004 SPINDLE OIL COOLER ALARM

(1) Check the spindle oil cooler unit whether there are any of abnormal. Please correct it.

(2) Check the wiring of the unit whether there are any damaged or shortage.

1005 EMERGENCY STOP Release all E-stop on the machine.

1007 AIR ALARM Make sure the switches & wiring for the air loop and pressure are correct.

1010 ATC NOT READY

(1) Make sure the limit switches for spindle clamping & unclamping are corrected.

(2) Make sure the tool magazine is packing at the neutral position.

1011 OIL COOLER FAILURE

(1) Check the spindle oil cooler unit whether there are any of abnormal. Please correct it.

(2) Check the wiring of the unit whether there are any damaged or shortage.

1012 ONE OF MOTORS OVERLOAD

(1) Make sure that the fan of the motor is free air inlet.

(2) Turn the power OFF and open the electric cabinet to check the thermal relay and its switch are in good condition without jumping out. If any of them is jumped out, please wait for a few minute later and reset the thermal relay. Refer to the electric diagram to be sure of the set value is corrected.

(3) Close the electric cabinet and start to operate the machine.

1013 5TH AXIS CLAMPED Make sure the 5th axis is unclamped.


4-4


1014 CHIP A MOTOR OVERLOAD





1016 COOLANT MOTOR OVERLOAD




1020 AIR ALARM CANNOT CYCLE START

Make sure the leveling gauge switches of the lubrication oil loop and oil leveling gauge are corrected.

1023 NO. OF PARTS REACHED Reset the workpieces counter.

1024 X AXIS OVERTRAVEL OR EMG. STOP

(1) Press the END button on the machine operator’s panel; then move X axis to the safe position.

(2) Check the limit switch of X axis.

1025 Y AXIS OVERTRAVEL

(1) Press the END button on the machine operator’s panel; then move Y axis to the safe position.

(2) Check the limit switch of Y axis.

1026 Z AXIS OVERTRAVEL

(1) Press the END button on the machine operator’s panel; then move Z axis to the safety position.

(2) Check the limit switch of Z axis.

1036 NEED PMC K6.3=1 Set the parameter K6.3=1 for Coolant through spindle purpose.

1050 ATC OPERATION ERROR Make sure the limit switches of the spindle clamping & unclamping are corrected.

1051 ATC L.S. FAULT (ATC) Make sure the limit switches of the spindle clamping & unclamping are corrected.


4-5


1052 ATLM FAULT Make sure the limit switches & electric circuit of the ATLM are corrected.

1054 SENSOR OF SWING POCKET FAULT

(1) Check the air pressure is corrected. (2) Check the Solenoid & piping of the tool

pocket for up & down are corrected. (3) Check the sensors of the tool pocket for 3

upper & bottom side are corrected.

1055 T NO. OVER RANGE The value of T code is greater than the maximum tool number of magazine.

1056 SP. TC UNIT ALARM Check if the line of spindle thermal compensation card is loose.

1060 TIMEOUT MONITOR TOOL MAGAZINE

Make sure the sensor & its wiring of the tool magazine counting are corrected.

1064 T COMMAND ＞ 98 T CODE has been exceeded permitted range, so please correct the T#.

1065 POCKET IS OCCUPIED BY OV. SIZE TOOL

Check tool data setting. The tool is over the right size.

1066 T NO. NOT REGISTERED T CODE number is not in the tool table, so please correct it.

1067 M6T0 CAN’T BE TOGETHER M6 & T0 can not be at the same block. 1072 TOOL NO. DUPLICATED Check the tool data setting.

1074 POCKET/COUNT 1 NO. NO ATC & COIN.

This alarm message means that the tool pocket is not at the tool change position of tool magazine under automatic tool change operation. Check if the tool pocket is stuck and the counter of tool pocket is normal.

1075 MAG. POCKETS ARE FULL All tool pockets of tool magazine are filled with tools. Don’t load another tool in the tool pocket.

1082 GEAR CHANGE NOT END

(1) Make sure the pressure for the gear shift is corrected.

(2) Make sure the limit switches for the high/low gear are corrected.

1093 SOFT KEY #3 ON

Turn the SOFT KEY #3 ATC CCW ON only for maintenance, test, and adjustment purposes. Turn the SOFT KEY #3 ATC CCW OFF in the AUTO mode.

1094 PMC K12.0=1 (1) Set K12.0=1 will cause the detection signal

of tool arm position is ignored. (2) Set K12.0=0 in normal condition.

2000 DOOR INTERLOCK Make sure the door is closed.

2006 3 AXES NEED HOME (FOR RAPID 100%)

Make sure that all axes has been HOME returned correctly.

2017 LUBRICATION PRESSURE LOW

Check the lubrication circuit and level switch with its circuit.


4-6


2030 SUCK PUMP OVERLOAD


(2) Turn the power OFF and open the electric cabinet to check the thermal relay and its without jumping out. If any of them is jumped out, please wait for a few minute later and reset the thermal relay. Refer to the electric diagram to be sure of the set value is corrected.


2031 MAIN TANK LOW LEVEL Make sure the leveling gauge and its wiring of the coolant tank are corrected.

2032 SUB TANK OVERFLOW Make sure the switches & wiring for the high level of the main coolant tank are corrected.

2033 C.T.S. PUMP OVERLOAD




2034 C.T.S. FILTER DIRTY Clean the filter of the coolant tank.

2035 MAIN TANK MIDDLE LEVEL Make sure the switches & wiring of the main coolant tank leveling are corrected.

2036 LUBRICATION LEVEL LOW Check if the amount of lubricant is enough. 2037 BOTH TANK OVERFLOW Reducing the coolant from the tank.

2038 COOLANT LOW LEVEL Make sure the switches & electric circuit of coolant quantity and its leveling are in right condition.

2039 SET PMC K2#5=1 The machine has CE mark. Set 1 in K2#5 of keep relay of PMC PRM.

2040 HANDLE INTERRPUPT MODE ENABLED

In the AUTO mode, the button has been pressed, so the axis could be moved by means of handwheel.

2041 M,S,T CODES ARE LOCKED (1) The AFL switch of the software operator’s

panel is turned on. (2) M, S, T code will be neglected.

2045 SETTING MODE This mode allows operator to check workpiece in work area. Meanwhile, the protect condition in Spindle/Rapid will be limited.


4-7


2046 WARNING! K0.2 AND K12.2 CANNOT BE SET IN “1” AT THE SAME TIME

This alarm occurs when K0.2 and K12.2 both turn to on. K0.2 enable Y-D function. And K12.2 is used in Y connection only. The bit-select function are at below: SP with gear box:K0.0=1,K0.2=0,K12.2=0 SP_Y-D control with belt/direct: K0.0=0,K0.2=1,K12.2=0 SP_Y-D in Y with belt/direct: K0.0=0,K0.2=0,K12.2=1 SP_Y-D in Y with gear box: K0.0=1,K0.2=0,K12.2=1

2047 TOOL UNCLAMP ERROR Please make sure if the sensor is unbroken and the position of sensor is proper.

2048 TOOL CLAMP ERROR Please make sure if the sensor is unbroken and the position of sensor is proper.

2062 NEED CYCLE START (DOOR INTERLOCK) Please press the CYCLE START button.

2073 POCKET/COUNT 1 NO. CANNONT CYCLE START & COINCIDENCE

This alarm message means that when press the Cycle Start button, the tool pocket is not at the tool change position of tool magazine. Check if the tool pocket is stuck and the counter of tool pocket is normal.

2076 MAGAZINE MOTOR OVERLOAD




2077 ARM MOTOR OVERLOAD





4-8


2080 CHECK POCKET NO. / COUNT 1 NO.

This alarm message means that when pressing the Cycle Start button, the tool pocket is not at the tool change position of tool magazine. Check if the tool pocket is stuck and the counter of tool pocket is normal.

2083 GEAR POSITION ERROR

(1) Check the pressure is corrected. (2) Check the solenoid & its piping of the high

gear / low gear shift are corrected. (3) Check the limit switches of the high

(bottom) / low (upper) gear shift are corrected.

2090 SOFT KEY ATC JOG ON

Turn the SOFT KEY #2 ATC JOG ON only for maintenance, test, and adjustment purposes. Turn the SOFT KEY #2 ATC JOG OFF in the AUTO mode.

2092 PMC K13.6=1

Set K13.6=1 only for maintenance purpose will cause the signals of ATC and tool clamp/unclamp are ignored. It may cause hazard. Set K13.6=0 in normal condition.

2095 PMC K6.7=1 Set K6.7=1 only for maintenance purpose will cause the detection of air pressure is ignored. Set K6.7=0 in normal condition.

2096 PMC K7.6=1 K7.6=1 means the zero return operation is not performed compulsorily. If K0#6=0, the zero return operation is performed.

2097 PUT SPRAY GUN BACK Make sure the spray gun is put back when machine is operating.


4-9

4.2.2 Drum Type


1001 SPINDLE ALARM Be sure that the sensors for the spindle clamping & unclamping or gear shift are corrected.

1002 3 AXES NEED HOME Make sure that all axes have been HOME returned correctly.

1003 Z AXIS NOT 2ND HOME Make sure the Z axis has been second reference point returned.

1004 AIR PRESSURE TOO LOW Make sure the air loop and pressure switch with its circuit are corrected.

1005 ATC NOT READY

(1) Make sure the limit switches for spindle clamping & unclamping are corrected.

(2) Make sure the tool magazine is packing at the neutral position.

1006 MOTOR OVERLOAD




1007 SPINDLE COOLER UNIT FAILURE

(1) Check the spindle oil cooler unit whether there are abnormal or not. Please correct it.

(2) Check the wiring of the unit whether there are any damage or shortage.


1009 AIR ALARM CANNOT CYCLE START

Make sure the switches & wiring for the air loop and pressure are corrected.

1012 EMERGENCY STOP Release all E-stop on the machine.


4-10


1013 GEAR SHIFT ERROR

High / low-speed winding of motor shift Check if the electromagnetic contact of high-speed winding / low-speed winding of spindle motor is active and the signal line of high-speed winding / low-speed winding is loose. Gear shift (1) Check if the gear of high/low gear is

stuck. (2) Check if the solenoid valve of high/low

gear is active. (3) Check if the signal line of high/low gear

is loose and the detection of high/low gear is normal.

1014 GEAR POSITION ERROR Be sure the spindle shifter position is corrected.

1017 TOOL UNCLAMP FAILED DURING TOOL CHANGE Remove the spindle and unclamp the tool.

1056 SP. TC UNIT ALARM Check if the line of spindle thermal compensation card is loose.

2000 MAIN DOOR INTERLOCK Make sure the door is closed.

2010 LUBRICATION PRESSURE LOW

Make sure the air pressure is right; then user could try press the “FEED” or “RESET” button for recovering alarm condition.

2011 LUBRICATION ALARM CANNOT CYCLE START

Check the lubrication circuit and level switch with its circuit.

2015 BOTH TANKS OVERFLOW Reducing the coolant from the tank. 2016 C.T.S. FILTER DIRTY Clean the filter of the coolant tank.

2017 MAIN TANK LEVEL LOW Make sure the switches & wiring of the main coolant tank leveling are corrected.

2018 SUB TANK OVERFLOW Make sure the switches & wiring of the sub-coolant tank leveling are corrected.

2021 EMERGENCY BUTTON IS RELEASED

Press the E-stop button and then release it again.

2022 SPINDLE IS EMPTY CANNOT UNCLAMP TOOL MANUALLY

Spindle is in empty status, and to insert a tool manual is forbidden.

2023 HANDLE INTERRUPT MODE ENABLED

Machine is in HANDLE INTERRUPTION mode.

2024 SPINDLE NOT ORIENTATED Make sure the spindle orientation is made.

2025 SPINDLE IS ROTATING CANNOT RELEASE TOOL

Spindle is rotating that can not be tool released manually.

2026 MAGAZINE LIMIT SWITCH FAULT

Make sure the tool magazine sensors are in normal condition.


4-11


2027 SPINDLE LIMIT SWITCH FAULT

Make sure the signal sensor of the spindle is corrected.

2028 SPINDLE UNCLAMP CANNOT ORIENTATE

Spindle orientation while spindle is unclamping the tool, is forbidden.

2029 M,S,T CODES FUNCTION ARE LOCKED AFL mode is in position.

2030 MAGAZINE. RIGHT MOVE ERROR

(1) Check the solenoid valve of magazine right sensor.

(2) Check if the detection of magazine right sensor is normal and the signal is correct.

2031 MAGAZINE LEFT MOVE ERROR

(1) Check the solenoid valve of magazine left sensor.

(2) Check if the detection of magazine left sensor is normal and the signal is correct.

2032 MAGAZINE ROTATION ERROR

(1) Check the sensor of the magazine indexing is corrected.

(2) Check the wiring circuit of the tool magazine indexing is corrected.

2033 TOOL UNCLAMP ERROR

(1) Check the sensor of the spindle unclamping is in normal condition.

(2) Check the electric circuit of the spindle unclamping is in normal condition.

2034 TOOL CLAMP ERROR

(1) Check the sensor of the spindle clamping is in normal condition.

(2) Check the electric circuit of the spindle clamping is in normal condition.

2035 CHECK TOOL NO. Check the spindle T#, Tool magazine T# is corrected.

2036 LUBRICATION LEVEL LOW Check if the amount of lubricant is enough.

2037 ATLM LIMIT FAULT

(1) Check the electric circuit of the ATLM (AUTO TOOL LENGTH MEASURE) is in good condition.

(2) Check the activity of the ATLM is corrected.

2038 PMC K0#6 SET 1 K0#6=1 means the zero return operation is not performed compulsorily. If K0#6=0, the zero return operation is performed.

2039 SET PMC K2#5=1 The machine has CE mark. Set 1 in K2#5 of keep relay of PMC PRM.

2041 SOFT KEY ATC JOG ON Soft key ATC JOG ON means the automatic movement of ATC is not permitted during maintenance.

2044 MOVE MAGAZINE TO LEFT BY M27 CODE

Refer to the Chapter 5.4.2 The Solution Procedures of Tool Change Interruption for Drum Type in the operation manual.


4-12


2045 SETTING MODE

The alarm message means that the Set/Auto key is switched to the Setting mode for maintenance and test of the machine. Set the Set/Auto key in the Auto mode, and the powered movements of machine will be operated automatically.

2046 WARNING! K10.5 AND K12.2 CANNOT BE SET IN “1” AT THE SAME TIME

This alarm occurs when K10.5 and K12.2 both turn to on. K10.5 enable Y-D function. And K12.2 is used in Y connection only. The bit-select function are at below: SP with gear box:K0.0=1,K10.5=0,K12.2=0SP_Y-D control with belt/direct: K0.0=0,K10.5=1,K12.2=0 SP_Y-D in Y with belt/direct: K0.0=0,K10.5=0,K12.2=1 SP_Y-D in Y with gear box: K0.0=1,K10.5=0,K12.2=1

2047

CAUTION! SPINDLE TOOL CLAMPED AND UNCLAMPED LIMIT SWITCH SIGNALS ARE IN THE SAME STATE

Please check if the limit switch is broken or not, and make sure the limit switch is in correct position.

2097 PUT SPRAY GUN BACK Make sure the spray gun is put back when machine is operating.


4-13

4.3 Reset of Over Travel

There are two travel limits at both ends of the axes: one is setting by Software parameter setting, and another is setting by Hardware setting.

4.3.1 Soft Limit Over Travel

When the axes movement over travel to its soft limit, machine will be alert and displayed as below:

"OVER TRAVEL" Machine will stop immediately. In this case, please move the axis in its reverse direction by press axial movement push-button and press the reset button, and machine will be ready for operation.


4-14

4.3.2 Hard Limit Over Travel

When the axes movement over travel to its hard limit, machine will be alert and displayed as below:

"NOT READY" To solve this alarm, please refer to the following procedure:

EDIT

AUTO

MDI

RAPID

HANDLE

JOG

ZRN

DNC

MODE

1. Turn the mode selector in Handle position.

END

2. Press Over travel button, in the mean time, release the axes as following procedure.

3. Move the axes to its reverse direction by M.P.G.

END

4. Release the Over travel button.

RESET

5. Press the Reset button on the FANUC panel to cancel the alarm message.


4-15

4.4 The Solution Procedures of Tool Change Interruption

4.4.1 Arm Type

The tool change interruption solution procedures are as follows:

1. The tool arm is stopped beside the spindle during tool change operation. Step 1: Press the Emergency Stop button. Step 2: Keeps the Z axis at the second reference point. Step 3: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “ON” Step 4: Set the mode selector in HANDLE position. Step 5: Keep pressing the Cycle Start button on the machine operator’s panel until the tool arm move to its home position. Step 6: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “OFF” Step 7: After the tool arm move to its home position, please check the spindle tool number, current tool pocket number, and current tool number in the pocket. Step 8: Reference Point Return operation is performed.


4-16

4.4.2 Drum Type

The tool change interruption solution procedures of different conditions are as follows: 1. The tool magazine is stopped beside the spindle during tool change operation.

The Z axis is at the second reference point under spindle clamping condition. Step 1: Press the Emergency Stop button. Step 2: Be sure the air pressure is adequate. Step 3: Turn the key switch to the SETTING mode. Step 4: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “ON” Step 5: Set the mode selector in MDI position. Step 6: Key in M27 command then the tool magazine will move to its home

position. Step 7: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “OFF” Step 8: After the tool magazine move to its home position, please check the spindle

tool number and current tool pocket number. Step 9: Reference Point Return operation is performed.

The Z axis is at the second reference point under spindle unclamping condition. Step 1: Press the Emergency Stop button. Step 2: Be sure the air pressure is adequate. Step 3: Turn the key switch to the SETTING mode. Step 4: Move up the Z axis to the top by the use of the handwheel. Step 5: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “ON” Step 6: Turn the key switch to the AUTO mode. Step 7: Set the mode selector in MDI position. Step 8: Key in M27 command then the tool magazine will move to its home

position. Step 9: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “OFF” Step 10: After the tool magazine move to its home position, please check the spindle

tool number and current tool pocket number. Step 11: Reference Point Return operation is performed.


4-17

The Z axis is not at the second reference point. Step 1: Press the Emergency Stop button. Step 2: Be sure the air pressure is adequate. Step 3: Turn the key switch to the SETTING mode. Step 4: Move up the Z axis to the top by the use of the handwheel. Step 5: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “ON” Step 6: Turn the key switch to the AUTO mode. Step 7: Set the mode selector in MDI position. Step 8: Key in M27 command then the tool magazine will move to its home position. Step 9: Press the buttons on the LCD/MDI panel.

【OFFSET SETTING】 Pages 【OPR】 ATC JOG “OFF” Step 10: After the tool magazine move to its home position, please check the spindle tool number and current tool pocket number. Step 11: Reference Point Return operation is performed.

5、APPENDIX

5-1

5、 APPENDIX

5、APPENDIX

5-2

5.1 Introduction of APC

1. APC (Auto Pallet Changer) is an accessory of machine. Please read user’s manual before action.

2. Please follow the illustration in APC operation manual. 3. If any problems or breakdown occurred, please refer to following instruction to get the

problem fixed.

5.1.1 Operations

The following section illustrates the instructions of pallet change.

5.1.2 APC Control

M code function list 2. M106

Change pallet A to preparation area. 3. M107

Change pallet B to preparation area.

5.1.3 Cautions

Before pallet change, make sure no tools on the spindle; otherwise, the warning message “ERROR 3061” will occur.

The instruction code of tool return is stated as following: G91G30Z0； T0； DO NOT forget to add “G91G30Z0；T0；” in the end of processing program input.

5、APPENDIX

5-3

5.2 Operation Manual of APC Control Panel Board

STOP

GRE

EM YCNE

MAN UP DOWN

JOG

CW CCW

READYDOOR

Figure 5-1 APC Control Panel Board

5、APPENDIX

5-4

5.3 Functions of the Buttons

K18#1=1 can be managed APC panel.

5.3.1 APC Manual Mode Button

MAN

1. Light on “MAN” first, the rest of function buttons on APC panel can be managed (“DOOR OPEN” button and “READY” button are excluded).

2. “MAN” only works in HANDEL mode.

5.3.2 Unclamp APC Pallet

1. “Unclamp” light on indicates APC pallet unclamping. 2. “Unclamp” light off indicates APC pallet clamping. 3. “Unclamp” only works in HANDLE mode as “MAN” is on.

5.3.3 APC JOG Model

JOG

1. “JOG” works for pallet lifting up, going down, and rotating. 2. “JOG” only works in HANDLE mode as “MAN” is on. (This model is

used for maintenance and malfunction operations)

5.3.4 APC Pallet Lifts Up

UP

1. “UP” light on indicates APC pallet lifting up. 2. “UP” only works in HANDEL mode as “MAN” is on and pallet is

unclamped. 3. As “JOG” lights on, pallet goes up in JOG mode.

5、APPENDIX

5-5

5.3.5 APC Pallet Goes Down APC

DOWN

1. “Down” light on indicates APC pallet going down. 2. “Down” only works in HANDEL mode as “MAN” is on and pallet is

unclamped. 3. As “JOG” lights on, APC pallet goes down in JOG mode.

5、APPENDIX

5-6

5.3.6 Rotate APC Pallet C.W

CW

1. “CW” light on indicates pallet A is ready in preparation area (APC of servo).

2. “CW” flashed indicates pallet A is changing to preparation area; “CW” light on indicates pallet A is changed and ready in preparation area (APC of hydraulic)

3. APC rotates CW in HANDEL mode as “MAN” is on and pallet is unclamped and is lifted up.

5.3.7 Rotate APC Pallet C.C.W

CCW

1. “CCW” light on indicates pallet B is in preparation area (APC of servo). 2. “CCW” flashed indicates pallet B is changing to preparation area;

“CCW” light on indicates pallet B is changed and ready in preparation area (APC of hydraulic).

3. APC rotates CCW in HANDEL mode as “MAN” is on and pallet is unclamped and is lifted up.

5.3.8 APC Door Interlock

DOOR

1. “DOOR” light on indicates APC electric door interlock is locked. 2. This function works only if door interlock is electric controlled.

5.3.9 Complete Preparation of APC

READY

1. This button stands for a full ready of preparation area. 2. “READY” light on indicates a full ready of preparation area and pallet

change can be performed.

5、APPENDIX

5-7

5.4 Illustration of APC Manual Operation Panel Board

The following section illustrates the use occasion and caution notes of APC Manual Operation Panel Board. Please DO follow the instruction below.

5.4.1 Use Occasion

Operation manual of APC Control Pane Board is used to exclude or modulate error or breakdown when facing malfunction.

5.4.2 Cautions

Please keep an eye on the following two points when manually modulate the panel board to do pallet change:

1. Check pallet first. It must be at the bottom dead center. 2. X, Y, and Z axes must be in the 4th reference position. The instruction code is stated

as follows: G91G30P4X0.Y0.Z0.

5、APPENDIX

5-8

5.5 Troubles Shooting

5.5.1 Instructions of Warning Message

Warning Message PALLET NOT READY FOR RLS/CLP(A10.1)

Cause Pallet is not in the right position.

Trouble Shooting

1. Make sure pallet is in the 4th reference position (exchange position). 2. Make sure APC of servo is in the right position (between

-0.5°~+0.5° or +179.5°~+180.5°) 3. Check pallet A/B, and make sure sensor works well..

Warning Message APC DOOR OPEN/UNLOCK(A10.2)

Cause APC door is not closed.

Trouble Shooting 1. Make sure APC door is locked. 2. If APC door is locked, check if the signaling system of door lock is

functioning well. Warning Message PALLET A NOT IN WORK AREA(A10.3)

Cause Pallet A is not in working area.

Trouble Shooting 1. Incorrect M code input. 2. Make sure pallet A is in working area. 3. Make sure pallet is at the bottom dead center.

Warning Message PALLET B NOT IN WORK AREA(A10.4)

Cause Pallet B is not in working area.

Trouble Shooting 1. Incorrect M code input. 2. Make sure pallet B is in working area. 3. Make sure pallet is at the bottom dead center.

Warning Message AIR NOT TIGHT(A10.5)

Cause Air is not fully tight.

Trouble Shooting

1. Make sure if APC connection block is hooked entirely on pallet as pallet moves up to the top dead center.

2. Make sure if APC pallet is positioned well in the pallet support as pallet moves down to the bottom dead center.

3. Make sure there is no interference in APC connection block and APC support.

4. Make sure if airtight sensor pressure reaches 0.2MPa. 5. Make sure airtight sensor works well.

5、APPENDIX

5-9

Warning Message APC NOT READY(A10.6)

Cause APC is not completely ready.

Trouble Shooting 1. Make sure “READY” is on. 2. Make sure “READY” is functioning well.

Warning Message PALLET A/B NOT INPOSITION(A10.7)

Cause Pallet A/B is not in the right position.

Trouble Shooting 1. Make sure pallet is right in confirmation position. 2. Make sure pallet A/B sensor works well.

Warning Message PALLET UP/DOWN NOT INPOSITION(A11.0)

Cause Pallet UP/DOWN is not in the right position.

Trouble Shooting

1. Make sure pallet is in the right position—at the top dead center and at the bottom dead center.

2. Make sure pallet is not stuck. 3. Make sure if pallet UP/DOWN sensor works well.

Warning Message APC MANUAL MODE(A11.1)

Cause APC is in manual operation mode.

Trouble Shooting 1. Make sure if APC is in manual operation mode. 2. Cancel the manual operation mode, If APC is in that mode

Warning Message APC NEED MANUAL HOME(A11.2)

Cause Once APC pallet changes abnormally, APC has to back to original position.

Trouble Shooting

1. Exchange APC into JOG mode and then rotate the 4th axis (C axis) to the position (0 or 180) with manual pulse generator.

2. Make sure if APC support is in the 4th reference position. 3. Move pallet down to the support manually. 4. Manually clamp pallet. 5. If problem still exists after running above mentioned instructions,

please make sure if pallet A/B sensors works well. Warning Message PALLET RELEAS SIGNAL ERROR(A11.3)

Cause Oil pressure of pallet went wrong.

Trouble Shooting 1. Make sure oil pressure pump works well, such as providing with oil

and reaching pressure level (35~45kg/cm2). 2. Make sure oil pressure sensor works well.

5、APPENDIX

5-10

5.6 M Code List

M code Function

M00 Program Stop

M01 Optional Stop

M02 End of Program

M03 Spindle Forward

M04 Spindle Reverse

M05 Spindle Stop

M06 Automatic Tool Change

M07 Air Blow ON

M08 Coolant ON

M09 All Coolant OFF (Cancel M07, M08, M28, M51)

M10 4th Axis Unclamp

M11 4th Axis Clamp

M13 Spindle Forward - Flood Coolant ON

M14 Spindle Reverse - Flood Coolant ON

M15 ATC Door Open

M16 ATC Door Close

M19 Spindle Orientation

M21 Tool Pocket Down & Magazine Move in

M23 Spindle Unclamp

M25 Spindle clamp

M27 Arm Up & Magazine Move Out

M28 Flood Coolant ON (OPTION)

M29 Rigid Tapping Mode ON

M30 End of Program

M39 Retraction For Rigid Tapping

M45 5th Axis Unclamp

M46 5th Axis Clamp

M48 Override Cancel On

M49 Override Cancel Off

5、APPENDIX

5-11

M code Function

M51 Coolant Through Spindle ON (OPTION)

M56 ATLM & Air Clean ON

M57 ATLM & Air Clean OFF

M59 TS27R Start

M60 OMP60 Start

M61 Chip Wash Pump ON

M62 Chip Conveyor ON

M63 Chip Screw ON

M64 Chip Remove System OFF

M65 APC Clean ON

M66 APC Clean OFF

M70 Mirror Cancel

M71 X Axis Mirror Effective

M72 Y Axis Mirror Effective

M73 Z Axis Mirror Effective

M74 4th Axis Mirror Effective

M75 Counter OFF

M76 Counter ON

M78 APC Ready Check Finish

M79 RECTIFICATION TOOL

M80 APC Ready Check ON

M81 Smoke Exhaust ON

M81 Smoke Exhaust OFF

M85 Oil Mist ON

M86 Oil Mist OFF

M87 Air Extraction ON

M88 Air Extraction OFF

M98 Call Sub-program

M99 Return to Main Program

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