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VERTICAL MACHINING CENTER
OPERATION MANUAL
I-SERIES-CAM
SHARP MACHINERY CO.,LTD
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INSTRUCTION HAND BOOK
FANUC 18M、0I、18I、21I
10. 19, 2007
SHARP MACHINERY CO.,LTD
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FANUC 18M,0I,18I,21I 1. PREFACE .................................................................................................................................1-1 2. INSTALLATION AND POWER ON ......................................................................................2-1
2.1 Input power ON ..................................................................................................................2-2 2.2 Specifications of electric appliances ...................................................................................2-3 2.3The step of main power ON:................................................................................................2-5
3. OPERATOR’S PANEL ............................................................................................................3-1 3.1 Operator panel.....................................................................................................................3-5 3.1MDI keyboard functions: .....................................................................................................3-5 3.2 Soft operator's panel............................................................................................................3-7 3.3hine operator’s panel:...........................................................................................................3-8
4. ANUAL OPERATION...........................................................................................................4-16 4.1MANUAL REFERENCE POSITION RETURE ..............................................................4-16 4.2 MANUAL MOVEMENT OF 3-AXES: ...........................................................................4-16 4.3 OPERATION OF SPINDLE CLAMP/UNCLAMP:........................................................4-17 4.4 MANUAL MAGAZINE OPERATION : .........................................................................4-17 4.5 SPINDLE OPERATION: .................................................................................................4-17
5. EXPLANATION OF ATC .......................................................................................................5-1 5.1 HYDRAULIC TYPE ATC: ................................................................................................5-1 5.2 CAM TYPE ATC: ............................................................................................................5-12 5.3 CAROUSEL TYPE ATC: ................................................................................................5-27
6. EXPLANATION OF OTHER INSTALLATIONS................................................................6-35 6.1 LUBRICATION AND THE RELATED SETTING: .......................................................6-35 6.2 COOLER UNIT: ...............................................................................................................6-36 6.3 HYDRAULIC UNIT(HYD.) ............................................................................................6-37 6.4 CHIP CONVEYER (CHIP) ..............................................................................................6-37 6.5 WORK LIGHT/ALARM LIGHT.....................................................................................6-37 6.6 THERE LAYER ALARM LIGHT DESCRIPTION........................................................6-37 6.7 RS232 AC110V INTERFACE .........................................................................................6-37 6.8 HAND PASS SAFE DOOR INTER LOCK.....................................................................6-38
7. AUXILIARY FUNCTIONS:....................................................................................................7-1 7.1EXPLANATION OF M CODE: (THE MARKS “*” IS FOR OPTION FUNCTION) ......7-1
8. PLC SETTING..........................................................................................................................8-1 8.1SETTING OF TIMER: ........................................................................................................8-2 8.2 EXPANATION OF KEEP RELAY SETTING:.................................................................8-5 8.3TO MODIFY THE SETTING: ..........................................................................................8-17
9. THE TROUBLESHOOTING...................................................................................................9-1 9.1 LARGER TOOL MANAGEMENT ...................................................................................9-6
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1. PREFACE
This manual describes the operation and troubleshooting of SHARP’s vertical machining center (about auxiliary function for M code ,sequence for operation and some related items like TIMER, KEEP RELAY that also will be described at chapter 7, 8 ). The function of vertical machining center is not only decided by machine tools company, the CNC computer and servo system also have serious influence. In this manual we have tried as much as possible to describe all the various functions. Therefore, function which are not provide in your machine may be optional function. Do not modify the machine designing or add any electric device without our permitting, otherwise it may cause serious problem. Note:1. The programming and maintenance of CNC︰please refer to the programming and maintenance manual of FANUC.
2. The installation and points for attention of machine︰ please refer to installation manual of SHARP
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2. INSTALLATION AND POWER ON
When connecting the electric cabinet with the power.because the interior operation Of the cabinet is AC 220V.the user must use a transformer to switch the voltage In accordance with the specification of voltage where it is being used.Please refer To the diagram Fig 2-1 for connecting instruction.Please connect the power to the Input terminal of transformer where the opposite voltage is and then connect the Output terminal(AC220V) to the NFB of the electeic cabinet.
Fig 2-1
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2.1 Input power ON Link power ON as show in fig 2.2 Note. Please make sure of power-off when connecting the power, and to cover lid
when it link completely. Be sure have ground connection to prevent the noise to the NC unit.
Fig 2-2
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2.2 Specifications of electric appliances Vmc-650~1200 AC220v 60hz±10% 3φ supply wire 8m2 Vmc-1400~21100 AC220v 60hz±10% 3φ supply wire 14m2
VMC650~1200 distribution of consumption: AC220v
75(a)
AC220v
9.7(A) 34(A) 0.1(A) 6.5(A) 0.28(A) 4.2(A) 0.1(A)
AC110V AC110V 16.2(A) 1.4(A)
8.2(A)
(1.5A)
Control power 4 × SOL + 15 × relay + 1 × work light + 1 × revolving lamp = 4 × 1.1 + 15 × 0.0369 + 1 × 2.9 + 1 × 0.4 = 8.2 Non-fuse breaker= 9.7 + 34 + 16.2 + 0.1 + 6.5 + 0.28 + 4.2 +0.2 = 75 Transformer: A = N1/n2 = V1/V2 = 220/110 = 2 2 = A I2/I1 =9.7/I1 → I1 = 4.85(A)
4.85(A) × 220(V) = 1067(VA)
P.S.: If input voltage of environments is 380V, please use 23KVA transformer.
MAIN POWER SWITCH
75A
TRANSFORM
ER SPINDLE MOTOR OILER HYDRAULI
C UNIT HEAT EXCHANGE
ON CABINT SPINDLE COOLER SYSTEM MOTOR
FAN
POWER outPUT
CONTROL POWER
SEVO MOTORS FOR
3-AXES
COOLANT PUMP
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VMC1400~21100 distribution of consumption: AC220V
96.18(A)
AC220V
9.7(A) 53(A) 0.1(A) 6.5(A) 0.28(A) 4.2(A) 0.1(A)
AC110V AC24V 22.2(A) 1.4(A)
8.2(A)
(1.5A)
Control power 4 × SOL + 15 × relay + 1 × work light + 1 × revolving lamp = 4 × 1.1 + 15 × 0.0369 + 1 × 2.9 + 1 × 0.4 = 8.2 Non-fuse breaker= 9.7 + 53 + 22.2 + 0.1 + 6.5 + 0.28 + 4.2 +0.2 = 96.18 Transformer: a = N1/N2 = V1/V2 = 220/110 = 2 2 = A = I2/I1 =9.7/I1 → i1 = 4.85(A)
4.85(A) × 220(V) = 1067(VA)
P.S.: If input voltage of environments is 380V, please use 30KVA transformer.
MAIN POWER SWITCH
75A
TRANSFORM
ER SPINDLE MOTOR OILER
HYDRAULIC UNIT
HEAT EXCHANGEON CABINT
SPINDLE COOLER SYSTEM FAN
POWER output
CONTROL POWER
SEVO MOTORS FOR
3-AXES
COOLANT PUMP
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2.3The step of main power ON: Please use multi-meter to check if R.S.T. phases are shorted to ground connection? If machine oil tube is correct? And if the emergency stop button is pressed down that locates on operator panel? Be sure all those item that we mentioned are done, then turn main power ON. In this time the transformer, fan and the servo amp. are in stand-by state. You will see the power light on that displayed on the operator’s panel. After that please follow the step to turn main power ON:
(1) press power ON push button that locates on the operator panel. (2) NC power ON
(3) NC starts and screen on (that indicates an alarm message of EMG. Stop).
If there is other alarm signal displayed in screen at this time. Please refer to alarm list of electric circuit. If NC alarm, then refer to operator’s manual of NC.
When releasing emergency stop button there should be no alarm message on screen. And you could hear the voice of hydraulic unit that starts to work. If the hydraulic pressure does not increase, it means that phase of the input power is wrong(please see fig 2.1). Please turn power OFF, and exchange R and S then it will be restored.
We will fix each-axis (especially Z-axis) to ensure every axis are firmer to avoid displacement during delivery. After finishing power connection, be careful to remove all firmer and move all axes and back to home point. No matter start or stop the NC have to be on EMG situation. It means that start NC first then release EMG when you turn power ON, and press EMG first then stop NC when you turn power OFF.
After you success to power ON at the first time, you have to remove all firmer, level the machine and test each-function one by one during this time to avoid some unknown damage from delivery. If there are any question for main power ON please contact with us or our agent.
After power ON, please checks the following items: (1) If each-axis has a normal?
(2) If oiler consumes oil and works normally? (3) If spindle orientation is correct?
(4) If z-axis tool change position is correct?
(5) If T code and magazine work correct? (6) If low/high gear changes smoothly
(7) Check other function like chip conveyer , coolant, work light, M30 light, Auto power out…
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3. OPERATOR’S PANEL
8.4” Color LCD/MDI (Standard type, sheet key)
FANUC 18MC 8.4” COLOR LCD/MDI
10.4” Color LCD/MDI (Standard type, sheet key)
FANUC 18I 21IB 8.4” COLOR LCD/MDI
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FANUC 18IB 21IB 10.4” LCD/MDI
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FANUC 0I-C (Standard type, sheet key)
FANUC 0I-C 8.4" LCD/MDI
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7.2" LCD/MDI
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3.1 Operator panel
The operator panel is divided into two areas, the upper area is operator panel for MDI and CRT (please see page 3-1).
3.1MDI keyboard functions:
Item Description Function
1 Power ON/OFF key
Press this buttons to turn CNC ON and OFF
2 Rest key
Press this key to reset the CNC, to cancel an alarm, etc.
3 HELP key
Press this key to use the help function when uncertain about the operation of an MDI key.(help function)
4 Soft key
The soft key have various functions, according to the Applications. The soft key functions are displayed at the bottom of the CRT screen.
5
Address and numeric keys
Press these keys to input alphabetic, numeric, and other characters.
6 Shift key
Some key have two characters on their keytop. Pressing the〈SHIFT〉key switches the characters. Then
the character indicated at the bottom right corner on the keytop can be entered.
7 INPUT key
When an address or a numerical key is pressed, the data is input to the buffer, and it is displayed on the CRT screen. To copy the data register input
tool offset memory by pressing key. This key is same as INPUT key of the soft keys, and either can be pressed to produce the same result.
8 Cancel key
Press this key to delete the last character or symbol.
ON OFF
RESET
HELP
SHIFT
INPUT
CAN
INPUT
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▲
PAGE
▼
PAGE
9 Program edit keys
Press these keys when editing the program
: Alteration
: Insertion
: Deletion
10 Function keys Press theses keys to switch display screens for each function.
: Press this key to display the position screen.
: Press this key to display the program screen
: Press this key to display the offset/setting screen
: Press this key to display the system screen
:Press this key to display the message screen
: Press this key to display the graphics screen
: Press this key to display the custom screen (conversational macro screen)
11 Cursor move keys
there are four different cursor move keys:
:This key is used to move the cursor to the right direction in a character distance
:This key is used to move the cursor to the left direction in a character distance
:This key is used to move the cursor to the downward direction in a character distance
: This key is used to move the cursor to the upward direction in a character distance
12 Page change keys :This key is used to changeover the page on the CRT screen in the forward direction.
: This key is used to changeover the page on the CRT screen in the reverse direction.
ALTER
INSRT
DELET
POS
PROG
OFFSET SETTING
SYSTEM
MESSAGE
GRAPH
CUSTOM
▼
▲
▲
▲
ALTER
INSRT
DELET
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3.2 Soft operator's panel
Push MDI board. To function button displayed
→ → → ﹝OPR﹞ to get into the screen of soft operator’s panel.
OPERATOR’S PANEL M/C LOCK : OFF = ON DNC MODE : OFF = ON MEMO KEY : OFF = ON AUX LOCK : OFF = ON PRO RESET : OFF = ON MAN ABS : OFF = ON HD.INT : OFF = ON 4TH PASS : OFF = ON
ACTUAL POSITION (ABSOLUTE) X 0.000 Y 0.000 Z 0.000 SO TO HAN
MACRO SETTING OPR
The function of operator’s panel are as shown below: Operated mode ON、OFF by cursor move key to select
(1) M/C LOCK When the switch is set to ON position the machine and 3 axes do not move. The coordinates value still varies in CRT. (NOTE:Be sure X,Y,Z axes have to back to home position after OFF)
(2)DNC MODE Data communication mode is used to transmit and execute simultaneously when the memory is for a large program. The program won’t exist in the control’s memory.
(3) MEMO KEY Please set memory protect key to ON when you add, input, modify or delete program at EDIT MODE, even input or modify parameter at MDI MODE.
(4) AUX LOCK When the switch is set to ON position the M.S.T.A.B code will be directly by passed and skip to next block.
(5) PRO RESET Program restart(Option, please see FANUC’S SERIES 0-MC OPERATOR’S MANUAL).
(6) MAN ABS This switch decides whether the amount of manual movement is to be added to the absolute value. (Suggestion: Keep the switch ON, otherwise the workpiece may have wrong shape.)
OFFSETSSETTING
OFFSET WORK
OPR
SETTING
△ PAGE
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(7) Handle inserts(HD.INT):For any mode it can control 3-axis’ movemant by
turnig hancl whed。
(8) 4、5 –AXIS BYPASSING:OFF indicates uses the 4/5 axis。
(4NG) :ON indicate noglect the fnuction for 4/5 axis。
3.3hine operator’s panel:
This section is to explain the function of every button and switch of operator’s panel.
-4+
Y-Z
-Y+
4+
Z
+X
-X
OP
T2
OP
T3
OP
T4
OP
T5
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(1)POWER ON: This button turns the NC power ON.
(2)POWER OFF:This button turns the NC power OFF.
(3) EMERGENCY STOP: This button stops all machine motion in emergency
To release it , turn it clockwise.
(4) EMG RELEASE: This button prevents the over travel from wrong setting
of software limits or over travel situation of machine from wrong operation. When it works, the indicate light will on
and all motion are the same as E-STOP condition. The step of release: A: Check which axis(X 、Y、Z ) was over traveled. B: Select HANDLE MODE. C: Turn the axis switch to the over-traveled axis from hand wheel box, and press this button in the meanwhile. D: Press reset key to eliminate ALARM message, then re-execute 3-axes origination (re-zero).
(5) MODE SELECT: This switch is used to specify an operation mode. There are the explanation of each mode as below:
EDIT:This MODE is useed register,modify, add or delete of program and link personal computer to transfer parameter or program.
AUTO
MDI
EDIT
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M.D.I.: This mode can execute the command in register. AUTO: This mode is used to execute a program stored in memory.
HANDLE: This mode can control 3-axes movement by turn hand wheel. The movement can be adjusted by incremental selector. JOG: In this mode, programmed of axis is controlled by FEEDRATE OVERRIDE
and JOG FEEDRATE and the feed rate is displayed on operator’s panel.
RPD: This mode is used to move axis in rapid traverse and is rapid speed adjusted by RAPID OVERRIDE %. ZRN: This mode is used to return 3-axes to machine zero and is moving speed adjusted by RAPID OVERRIDE %.
(6) CYCLE START: Press this button, to start a program in auto mode and the lamp lights during the programmed operation. The function of CYCLE START for the following mode:
AUTO MODE: To continue executing program.
MDI MODE: To executed the input program of MDI.
ZRN MODE: To return 3-axes zero simultaneously.
SINGLE BLOCK MODE: To execute one block
(7) FEED HOLD: When this button is press, the program will pause automatically. Please notice that following situation:
Rigid tapping: “FEED HOLD” is not performed until tapping cycle is finished. ”FEED HOLD”: Could only stop the feed of 3-axes.
(8) SPINDLE CLOCKWISE(M03): In handle mode, it will start spindle clockwise by pressing this button and the speed will be decided by the S command in the register
(NC power ON must execute S command to use on MDI mode) (9) SPINDLE COUNTER CLOCKWISE(M04): In handle mode, it will start spindle counter clockwise by pressing this button. and the speed will be decided by the S command in the register (NC power ON must execute S command to use on MDI mode)
(10) SPINDLE STOP(M05): To stop spindle by pressing the switch, if not in HANDLE MODE, press “RESET” key to stop spindle
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(11) ORIENTATION: This switch will move the spindle to the orient position and then lock the spindle. To cancel the orientation, press M05.
(12) COOLANT: To switch ON/OFF coolant pump. If safe door was opened or under maintenance mode This button will be no functional
(13) WORK LIGHT: To switch ON/OFF work light.
(14) Z-AXIS LOCK: This function will lock Z-axis, the coordinate value of Z-axis still varies on CRT. After release, Z-axis have to return zero. This button should be pressed at least 3 seconds for function Action or release
(15) DRY RUN: When this button is ON, the feed and rapid traverse do not work, all movement is controlled by FEEDRATE OVERRIDE & JOG FEEDRATE. (16) SINGLE BLOCK: When the switch is ON, the controller will execute one block
and stop AUTO and MDI mode.
(17) BLOCK SKIP: When this button is ON, all block with slash ”/” are ignored.
(18) OPTION STOP: When this button is ON, the M01 code will works, the optional-stop will not be performed with only M01 code or with only this button on.
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+Z+4 -Y
+Y-4
+X
-Z
-X
(19) CHIP CVYR: To ON/OFF chip conveyor. If safe door was opened or under maintenance mode
This button will be + press switch use functional
(20) AUTO POWER OFF: When this button is ON, The main power of the machine
will be switched OFF after executing M30 or M02 command.
(21) AXIS FEED DIRECTION: There are “X” “Y” “Z” “4” 4 sets axis feed direction can be chosen.(To reform rapid traverse by pushing AXIS FEED DIRECTION AND RAPID button simultaneously)
(22) INDEX: Push this button once for magazine rotating one step, hold this button for continuous rotating.(“INDEX” can only make a clockwise turn. If safe door was opened or under maintenance mode This button will be + press switch use functional
(23) 0. SP TOOL/1. STAND-BY: When this button is ON, tool number of the stand by tool will be displayed at the tool number indicator. Otherwise the tool number of spindle tool will be shown.
(24) RAPID OVERRIDE %: To adjust the rapid travel speed, it is available in the following modes:
Rapid travels of G00/G08/G30/G60 and canned cycle. The movement of RAPID” & “ZRN” MODE
%
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x%
min
(25) JOG FEEDRATE & FEEDRATE OVERRIDE %:
To adjust the JOG FEEDRATE (a) Available in JOG & RUN mode (b) Range:0-1260mm/min The movement of PROGRAMMED FEEDRATE. (a)Available to F command that exists in program
(b)Available range:0-150% (c)unavailable in tapping cycle.
(26)SPINDLE OVERRIDE %: It can be adjusted in any mode.
The range:50%-120%。
(27) SPINDLE LOAD %: To display the actual load of spindle motor.
Please pay attention when LOAD is over 120%.
(28) TOOL NO.: This indicator displays the number of SP TOOL or STAND BY TOOL.
(29) MAIN POWER LIGHT (L1): To indicate the main power is ON (The main
power switch is located on right side of machine)
0 150 ││││││││││││
x mm/min
%
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L H
(30) ATC STAND-BY: The ATC does not work when the lamp does not light. When
ATC works, the lamp won’t light. The lamp lights when all
the states of ATC are OK.
(31) 4-AXIS UNCLAMP: To indicate the 4-axis is unclamped and can be operated.
(The lamp does not light when there is no 4th-axis)
(32) LUB ALARM: It lights when Lub tank is empty or pump malfunction.
(33) GEAR H/L: To show the spindle gear position H. lamp light when spindle gear on high position. L. lamp light when spindle gear on low position. (There are no GEAR H/L lamp for the spindle of belt type)
(34) MIRROR X/Y: “X” lamp will light during execute M71 command.
“Y” lamp will light during execute M72 command.
(35) AXIS FEED DIRECTION RAPID BUTTON: To quick move every axis by combining with AXIS FEED DIRECTION. When in ZRN mode, the light will indicate whether the ZERO-RETURN is performed.
4
X Y
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(36) OP1 :For customer add option.(When use CE operator panel for ENABLE
button)
(37)OP2: The axis feed direction ENABLE button at JOG/RAP or ZER mode,When
use axis feed direction button must be enable OP2 button then can to move the axis.
(38)OP3: For customer add option.
(39)OP4: For customer add option.
(40) AIR BLOW(M07): Press this button to comply the M07 spindle side-flush
command If safe door was opened or under maintenance mode This button will be no functional
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4. ANUAL OPERATION
4.1MANUAL REFERENCE POSITION RETURE
After NC power ON, the axes have to return to the reference position(home, zero). If not, the travel limit of the software will be useless for each axis. and it will cause machine in dangerous situation, and the RAPID traverse will not be available. There are two ways to return reference position as follows:
(1) In ZERO mode, press the OP2 button then press the push button of each axis to return ZERO. It works even push more than one buttons simultaneously. When the selected axis starts, the speed is controlled by RAPID OVERRIDE switch and the default direction are -X, +Y, +Z. When the limit switch of an axis contacts its dog, this axis will decelerate to a default low speed until LIMIT switch leaves dog and starts to finds ZERO signal of motor’s encoder. After that the axis will stop and the indicate lamp of that axis will light. When 3 axes have returned reference position, the RAPID lamp will light too. Thereafter no matter 3 axes at any position just select zero mode and all RAPID lamp will light to remind customer that have overridden.
(2) In ZERO mode, press OP2 button tnen push CYCLE START button, Z-axis will move to reference position first. When Z-axis decelerates, the X, Y axes move to reference position in the same time. The detail action and time for lamps light-on are the same as above mentioned. Please note that:
(I) Before pushing the cycle start button, make sure that the limit switches of the 3 axes do not contact their dogs, and the 3 axes are not on the ZERO positions.
(II) Set KEEP RELAY K4.7=1 (Please refer to chapter 9) 4.2 MANUAL MOVEMENT OF 3-AXES:
(1) MANUAL HANDLE OPERATION: In HANDLE mode, select AXIS DIRECTION SWITCH and control the movement of 3-axes by HAND WHEEL. The movement can be controlled by INCREMENTAL FEED SWITCH.
(2) JOG OPERATION (slow feed): In JOG/RPD mode, press OP2 button then push AXIS DIRECTION SWITCH “+” or “-“ to move 3-axes, and to adjust the movement by FEEDRATE OVERRIDE & JOG FEEDRATE that is on operator’s panel.
(3) RPD OPERATION(rapid traverse): IN JOG/RPD mode, press OP2 button then push RAPID and AXIS DIRECTIO SWITCH “+” “-“ to move 3-axes, the movement
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is adjusted by RAPID OVERRIDE % 4.3 OPERATION OF SPINDLE CLAMP/UNCLAMP:
VMC-1400~2185: There are CLAMP and UNCLAMP two push button at the metal of magazine, please select HANDLE mode, and push UNCLAMP to take off spindle tool. The CLAMP operation completion after push CLAMP to clamp tool.
VMC650~1100: There are only CLAMP/UNCLAMP button on the front of magazine, when press down this button is UNCLAMP and relieve it is CLAMP.
4.4 MANUAL MAGAZINE OPERATION :
(1) MAGAZINE RETURN HOME OPERATION: Select “ZRN” mode, push INDEX button that show on the panel. Then the magazine starts rotation until stopped at the position of 1. Stand by tool position. This function only available for VMC-1400 ~2185
(2) MAGAZINE ROTATIONG OPERATION: Select HANDLE mode, push INDEX button that show on the panel. Then moved one pot by clockwise move. If not relieve this button keep running.
For VMC-1400~2185: The control box at the lower of magazine have two buttons
for magazine forward CW and for magazine reverse.
Push button once for move one pot. If not relieve the button it will keep running. 4.5 SPINDLE OPERATION:
(1) In MDI mode, to start by key in M03 or M04 and speed S ,
after started the speed adjust by SPINDLE OVERRIDE 50% ~120%.
(2) In HANDLE mode, to start when executed M3 (M4) S indication. Only press
and then the spindle will rotate like S order that you have done
before.
IN PUT
MG. REV
MG. FOR
M3 M4
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5. EXPLANATION OF ATC
Please make sure that Z-axis reference position and spindle reference position are at the right point before execute M6 command. Especially, after you reinstalled Z-axis motor or orientation sensor.
The compensation parameter for Z-axis tool change point is No.1850
The compensation parameter for spindle orientation point is No.4031
There are HYDRAULIC TYPE ATC and CAM TYPE ATC for FANUC SYSTEM . The following are explanations for OPERATION AND TOOL-REGISTRATION.
5.1 HYDRAULIC TYPE ATC:
1) Note of operation:
I. ATC STAND-BY:
The ATC will be in STAND-BY state, except executing M06. If ATC is not stand-by, then M06 command won’t be executed and Z-axis will not move. When the STAND-BY LED indicate of ATC lights on, it means ATC is STAND-BY. When executing M06 the light is OFF.
II. TOOL CHANGE CYCLE
(1)TOOL CHANGE OF MDI MODE
To execute M06 or T code are available in MDI mode. In MDI mode, first
press , then key in M06 and press to execute M06. M19
(spindle orientation) will start automatically when execute M06. So it’s not necessary to execute M19 spindle orientation. When tool change is done, the ATC STAND-BY will light on.
In MDI mode, when Z-axis back to reference position using single movement to execute tool change is OK. But MDI single movement is only provide for ATC troubleshooting. During this time spindle tool and stand-by Tool doesn’t change in the tool table. So to reset tool table is necessary when finishing this command. Make sure all tool are correct.
PROGRAM
INPUT
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M codes for HYDRAULIC TYPE ATC:
M19 : SPINDLE ORIENTATION M82: POT. DOWN M83 : ARM 60 M84 : SPINDLE TOOL UNCLAMP M85 : ARM DOWN M86 : ARM CW180 M87 : ARM UP M88 : SPINDLE TOOL CLAMP M89 : ARM 0 M90 : POT. UP M91 : ARM180 , RACK RETURN (ARM DOES NOT MOVE)
In MDI mode, Z-axis must return reference position first when use M CODE for TOOL CHANGE,. and sequentially input M codes until ATC-STAND-BY lights on.
M codes for TOOL CHANGE is used on ATC troubleshooting. Please use M06 for tool change to prevent mistake in normal operation. The detail of ATC manual troubleshooting will explained on chapter 9.
(2) AUTO TOOL CHANGE MODE: To execute M06 tool change in AUTO MODE ( MACRO), it means when executing M06 in
program it will call the sub-program 09001 automatically. And after executed, it will return back to main-program. Do not modify or delete the program of 09001.
NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC 0M-C SYSTEM.
THE MOTION OF SUBPROGRAM:
Simultaneously executing Z-axis returning to reference position, POT DOWN, SPINDLE ORIENTATION (M19). The customer doesn’t have to write G91 G28 Z0 and M19 commands before M06. But if tool have interference, please check whether manual tool withdraw or spindle orientation are necessary.
Start tool change mechanism, and to execute the cycle of tool change: POT.DOWN ARM 60 SPINDLE UNCLAMP, AIR BLOW ARM DOWN ARM 180 ARM UP SPINDLE CLAMP ARM 0 POT UP CHECK ATC END M06 AFTER STAND-BY
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If M07 or M08 or M12 is applied, the code of M09 is not necessary to be written down. M07、M08、M12 will pause during executing M06 tool change, and start automatically when M06 finished.
If using MACRO for tool change in AUTO mode, M06 and T code are allowed to write
down at the same block.
Suggestion: Try not write them together in one block to save time for tool change.
(MODE 1) :
M06 T07; :
M06 T08; :
:
(MODE 2) : M06; T08;
:
M06 T09;
;
:
09001 is one block during executing M06. At this time press “FEED HOLD” key the program will stop after finishing the ATC tool changing.
CAUTION: Do not stop the process of tool change abnormally(like EMG STOP AIR-PRESSURE DROP AND UNUSUAL POWER OFF etc.). Please RESET, and use M code to set ATC STAND-BY, then re-execute tool change.
TOOL NO.7 MACHINING PROCESS
TOOL NO.7 MACHINING PROCESS
TOOL NO.8 MACHINING PROCESS
TOOL NO.8 MACHINING PROCESS
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2) TROUBLESHOOTING: (1) BRIEF INTRODUCTION FOR EVERY CONFIGURATION
HYDRAULIC TYPE ATC(FIGURE A、B、C、D)
L1:LOCK PIN IN ⎯ POSITION DETECT L2:POT IN POSITION DETECT L3:POT OUT POSITION DETECT L4:MAG. HOME POSITION DETECT L5:COUNT SENSOR A L6:COUNT SENSOR B L7 : ARM 60 L8 : ARM DOWN L9:ARM UP L10:SPINDLE CLAMP POSITION DETECT L11:SPINDLE UNCLAMP POSITION DETECT L12:SPINDLE HIGH GEAR POSITION DETECT L13:SPINDLE LOW GEAR POSITION DETECT L14:SPINDLE ORIENTATION SENSOR L17 : ARM 180 L18 : ARM -180 M1 :MAG MOTOR P1:MG FORWARD PUSH BUTTON P2:MG REVERSE PUSH BUTTON P3:SPINDLE CLAMP PUSH BUTTON P4:SPINDLE UNCLAM PUSH BUTTON
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(3) THE NECESSARY CONDITIONS FOR STAND-BY: To execute M06,the ATC must
be in STAND-BY situation, and has to satisfy the following conditions:
18MC
AIR PRESS. X1006.0 FOR VMC-1500-21100
LOOK PIN IN L1 ON X1005.4 POT IN L2 ON X1005.5 POT OUT L3 OFF X1005.6 TOOL CLAMP L10 ON X1005.0 TOOL UNCLAMP L11 OFF X1005.1 ARM 0 L4 ON X1007.1 ARM 60 L5 OFF X1007.2 ARM UP L6 ON X1007.3 ARM DOWN L7 OFF X1007.4 ARM CW 180 L8 OFF X1007.5 ARM CCW 180 L9 ON X1007.6
0I and 18I and 21I AIR PRESS. X6.0 FOR VMC-1500-21100
LOOK PIN IN L1 ON X5.4 POT IN L2 ON X5.5 POT OUT L3 OFF X5.6 TOOL CLAMP L10 ON X5.0 TOOL UNCLAMP L11 OFF X5.1 ARM 0 L4 ON X7.1 ARM 60 L5 OFF X7.2 ARM UP L6 ON X7.3 ARM DOWN L7 OFF X7.4 ARM CW 180 L8 OFF X7.5 ARM CCW 180 L9 ON X7.6
When the ATC STAND-BY lamp doesn’t light during maintenance, please use DGNOS to examine above items and make sure all limit switch are correct.(Please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction)
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FIG (A)
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FIG (B)
FIG (C)
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FIG (D)
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3) M06 CAN’T BE DONE: There are two situations as below:
I. Stop after POT DOWN:
(1) Z-axis has not returned HOME (2) Spindle orientation has not finished (3) POT OUT LIMIT has not ON (4) Tool search error(Tool registration has some mistake.) (5) Air pressure is not enough
Try to find the reason as mentioned items. Then use MDI to execute M90 (POT IN), and back to ATC STAND-BY. After it re-execute M06.
II. Stop during ATC ARM motion
(1) Reset NC (2) Remove the ATC sequence protection (SET K1.4=1). Also you could set K0.1=0 and
K1.3=1 when it is necessary. (3) In MDI mode, to perform reverse operation of M codes for tool change(please refer to
section 2.1.2) until arm returns 0 . (4) If ARM has already reached 180 , please do M91(RACK RETURN) (5) Recover the protection of manual ATC operation (Set K1.4.4=0) (6) ATC STAND-BY light ON (7) POWER OFF/ON
4) TO SET TOOL REGISTRATION:
Setting tool registration must be in MDI mode, and set write-down protection (PWE)= “1” , then set tool registration in DATA page. Please refer to ELECTIC CIRCUIT PAGE “N1”The addresses of tool registration. Here are descriptions for setting tool registration as below:
C01: To set the amount of tool. If magazine are 30 tools, set 30. If 24 tools just set 24(Be sure to set the right numbers, otherwise it will cause the machine to select the wrong tools)
The pot number in STAND-BY position: Setting at of counter screen of PMC
D10: Setting spindle tool number.
D11~D40:To set the tool number for POT No. 1~30, D11 is corresponding to Pot No. 1, etc. Be sure the tool number should not be bigger than 99 (for 24-tool magazine, D35~D40 should be kept empty).
If ATC has tool-selection mistake, please re-check the tool registration and correct
CURRENT
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the mistake. Otherwise there will be some alarm when executing T code.
5) USING & NEGLECTING OF MACRO FOR TOOL CHANGING:
MACRO 09001 is for M06 tool change, the benefit for using MACRO is as follows: 1. In AUTO mode, it will be able to execute M06 and T CODE in one block. 2. G91 G28 Z0 is not necessary before M06. 3. To reduce the time for tool change. Simultaneously executing POT-OUT & SPINDLE ORIENTATION AND Z-AXIS returning to the point of tool change.
For special reasons, if you don’t want using MACRO to execute tool changing. There is explanation of neglecting MACRO in the next section (1).
(1) Subprogram of tool change:
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% O9001(…..MO6 SUB-PROGRAM….) THE NUMBER OF PROGRAM AND EXPANATION.#3003=1 SINGLE BLOCK IS DISABLED. #3004=1 FEED HOLD IS DISABLED. T#4120 SEARCH T-CODE; IF[#1000EQ1] GOTO 70 TO DECIDE IF “T” IS SPINDLE TOOL IF[#1003EQ1] GOTO 10 TO DECIDE IF IN MDI MODE. N10 #103=#4003 SAVE THE CURRENT G-CODE OF THIRD GROUP
#1100=1 SPINDLE ORIENTATION AND POT DOWN G91G28Z0 Z-AXIS RETURNS HOME #1100=0 CANEL MACRO #1100 M06 EXECUTING TOOL CHANGING N70 G#103 #3003=0 SINGLE BLOCK IS AVAILABLE #3004=0 FEED HOLD IS AVAILABLE M99 RETURN TO MAIN PROGRAM
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(2) Neglect of MACRO tool change:
1. Select MDI mode
2. Press key parameter key set PWE=1
3. Change the setting of parameter 6071(No.6071=0 to neglect this MACRO, No.6071=6(M6) uses MACRO)
4. Set PWE=0 5.2 CAM TYPE ATC:
1) ATTENTION OF OPERATION:
(1). ATC STAND-BY: The ATC will be in STAND-BY state, except executing tool change. If ATC is not stand-by, then M06 won’t be executed and Z-axis will not move. When the LED(on operator’s panel) of ATC STAND-BY lights on, it means ATC is STAND-BY. When executing M06 the light is OFF.
(2.) TOOL CHANGE CYCLE
I. TOOL CHANGE OF MDI MODE
To execute M06 or T code are available in MDI mode. In MDI mode, first
press , then key in M06 and press to execute M06.
M19 (spindle orientation) will start automatically when execute M06. So it’s not necessary to execute M19 spindle orientation. When tool change is done, the ATC STAND-BY will light on.
II. MDI SINGLE BLOCK
In MDI mode, when Z-axis back to reference position using single block to execute tool change is OK. But notice that CAM single block method is only provide for ATC calibration. During this time spindle tool and standby Tool doesn’t change in the tool table.
Before you use single block, first, set K5.3=1( please notice that setting K5.3=1 will have danger of operating). We suggest you take down of tools and turn POWER OFF then restart again when it finishes.( K5.3 will change to 0 automatically after POWER OFF and ATC STAND-BY lights ON.). We will explain
how to set K5.3=1 at chapter 8.3. When it is finished on the screen
PWE have to be set to 0. Otherwise, 100 P/S AL and MDI can’t work. There are steps for MDI single block as follows:
OFFSET SETTING
PROGRAM
INPUT
OFFSET SETTING
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M19 : SPINDLE ORIENTATION
M82: POT. DOWN
M83 : ARM CW, M89: ARMCCW
M84 : SPINDLE TOOL UNCLAMP
M83 : ARM CW, M89: ARMCCW
M88 : SPINDLE TOOL CLAMP
M90 : POT UP
Please turn POWER OFF and ON when finished otherwise STAND-BY light won’t lights ON.
Please execute M83 ARM CW if there are tools on spindle or POT. When execute M89 ARM CCW have to consider with if SPINDLE CLAMP/UNCLAMP finished.
Suggestion: don’t use tools during this time.
M03 and M89 could use alternately,
example: M83
ARM 60° M89 ARM 0°
M83 ARM 60° M83
ARM 180° UP M89
ARM DOWN 180° M89 ARM 0°
stop position (step 1.) (step 2.) (step 3.)
The above actions can operator by M83 or M89 in sequence. Please be careful to operate it, because this part are much different from HYDRAULIC TYPE ATC.
(3) TOOL CHANGE OF AUTO MODE:
To execute M06 tool change in AUTO MODE ( MACRO), it means when executing M06 in program it will call the sub-program 09001 automatically. And after executed, it will back to main-program. Do not modify or delete the program of 09001.
NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC 0M-C SYSTEM.
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THE MOTION OF SUBPROGRAM:
Simultaneously executing Z-axis returning to reference position, POT DOWN, SPINDLE ORIENTATION (M19). The customer doesn’t have to write G91 G28 Z0 and M19 commands before M06. But if tool have interference, please check that if tool withdraw and spindle orientation are necessary.
Start tool change mechanism, and to execute the cycle of tool change: POT.DOWN => ARM 60 => SPINDLE UNCLAMP, AIR BLOW => ARM DOWN => ARM 180 => ARM UP => SPINDLE CLAMP => ARM 0 => POT UP => CHECK ATC => END M06 AFTER STAND-BY
If M07 or M08 or M12 is applied, the code of M09 is not necessary to be written down. M07、M08、M12 will pause during executing M06 tool change, and will start automatically.
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If use MACRO for tool change in AUTO mode, it is allowable M06 and T code in the
same black. Suggestion: Do not write them together in one block to save time for tool change.
(MODE 1) : M06 T07;
:
M06 T08; :
:
(MODE 2) : M06; T08;
:
M06; T09; ;
:
09001 is one block during executes M06 call sub-program 09001 in programming, At this time press “FEED HOLD” key the program will stop until l ATC tool changing finished.
NOTE: Do not stop the process of tool change abnormally(like EMG STOP AIR- PRESSURE DROP AND UNUSUAL POWER OFF etc.). Please RESET, and use M code to set ATC STAND-BY, then re-execute tool change.
TOOL NO.7 MACHINING PROCESS
TOOL NO.7 MACHINING PROCESS
TOOL NO.8 MACHINING PROCESS
TOOL NO.8 MACHINING PROCESS
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3) TOOL SEARCH: The way for tool management (MAG) is random. The tool doesn’t correspond to any POT. When executing T code, first the controller decides the corresponding POT of tool, then starts magazine, uses the shortest path to decide MAG.CW or MAG.CCW , then puts tool on STAND-BY position. Do not stop ATC unusually during magazine rotation (Like EMG STOP, AIR-PRESSURE-DROP or UNUSUAL POWER-OFF). Otherwise tool counter will mistake. The tool registration have to be reset.( We will describe the way to reset registration at next chapter.) To search a tool is available for MDI or AUTO mode. In HANDLE mode, please refer to MANUAL MAGAZINE OPERATION (section 4.4) to see how to perform the movement of magazine.
4) TROUBLESHOOTING:
HYDRAULIC TYPE ATC(FIGURE A, B、C、D)
(1) BRIEF INTRODUCTION FOR EVERY CONFIGURATION
CAM ATC( FIGURE E、F、G、H )
L1 :LOCK PIN IN POSITION DETECT L2 :POT IN POSITION DETECT L3 :POT OUT POSITION DETECT L4 :MAG. HOME POSITION DETECT L5 :COUNT SENSOR A L6 :COUNT SENSOR B L7 :CAM STOP POSITION DETECT L8 :CAM CHECK POSITION DETECT L9 :CAM STAND BY POSITION DETECT L10:SPINDLE CLAMP POSITION DETECT L11:SPINDLE UNCLAMP POSITION DETECT L12:SPINDLE HIGH GEAR POSITION DETECT L13:SPINDLE LOW GEAR POSITION DETECT L14:SPINDLE ORIENTATION SENSOR M1:MAG. MOTOR M2:CAM. MOTOR B1:CAM MOTOR FAN TROPELLER H1:CLUTCH FOR HANDLE BREAKER P1:MG FORWARD PUSH BUTTON P2:MG REVERSE PUSH BUTTON P3:SPINDLE CLAMP PUSH BUTTON P4:SPINDLE UNCLAMP PUSH BUTTON
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(3) THE RELATED ITERS FOR STAND-BY: To execute M06,the ATC must be in
STAND-BY situation, and has to satisfy the following items:
18MC
AIR PRESS. X1006.0 FOR VMC-1500~21100
LOCK PIN IN L1 ON X1005.4 POT IN L2 ON X1005.5 POT OUT L3 OFF X1005.6 TOOL CLAMP L10 ON X1005.0 TOOL UNCLAMP L11 OFF X1005.1 CAM STOP L7 OFF X1007.2 CAM CHECK L8 ON X1007.3 CAM HOME L9 ON X1007.4 COUNTER A SENSOR L5 ON X1006.1 COUNTER B SENSOR L6 ON X1006.2 0I AND 18I 21I AIR PRESS. X6.0 FOR VMC-1500~21100
LOCK PIN IN L1 ON X5.4 POT IN L2 ON X5.5 POT OUT L3 OFF X5.6 TOOL CLAMP L10 ON X5.0 TOOL UNCLAMP L11 OFF X5.1 CAM STOP L7 OFF X7.2 CAM CHECK L8 ON X7.3 CAM HOME L9 ON X7.4 COUNTER A SENSOR L5 ON X6.1 COUNTER B SENSOR L6 ON X6.2
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0IMATE
When the ATC STAND-BY lamp doesn’t light during maintenance. please use DGNOS to examine above items. make sure that every limit switch is correct.(Please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction)
FIG (E)
AIR PRESS. X26.0
LOCK PIN IN L1 ON
POT IN L2 ON X25.5
POT OUT L3 OFF X25.6
TOOL CLAMP L10 ON X25.0
TOOL UNCLAMP L11 OFF X25.1
CAM STOP L7 OFF X24.3
CAM CHECK L8 ON X24.4
CAM HOME L9 OFF X24.5
SENSOR L5 ON X26.1
SENSOR L6 ON X26.2
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FIG (F)
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FIG (G)
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FIG (H)
FIG (H)
5) M06 CAN’T BE DONE There are two situations as below:
I. Stop after POT OUT:
(1) Z-axis has not returned HOME (2) Spindle orientation has not finished (3) POT OUT LIMIT has not ON
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(4) Tool search error(Tool registration has some mistake.) (5) Air pressure is not enough
Try to find the reason as mentioned items. Then use MDI to execute M90 (POT IN), and back to ATC STAND-BY. After it re-execute M06.
II. Stop during ATC ARM motion (1) POWER OFF during M06 tool change
(2) EMG emergency stop happened during M06 tool change (3) ARM not stop at right position
(4) ARM sensor L7、L8、L9 have malfunction
(5) TOOL CLAMP/UNCLAMP ( L10、L11) not finished
(6) The message for finished spindle orientation are mission.
(7) CAM motor overload (8) The breaker for CAM motor didn’t work.
There are a few ways to solve those problems but in any case have to observe the following principles: i. POWER OFF during M06 can’t be done. ii. Take off tools for safe reason iii. Be sure follow the below steps indeed:
(1) Troubleshooting by MANUAL: Please use this reliable and safe way to solve the problem If the engineer are not
familiar with logic of tool change. The steps are as below: i) POWER OFF(It only execute in POWER OFF situation)
ii) Take out the cover of CAM motor. Please refer to sketch (E)、(H).
iii) Release the device of motor breaker. Please refer to sketch(H1).(There are some mode’s breaker are different).
iv) In motor breaker released situation, use spanner to wrench CW or CCW until ARM back to 0 position. Be sure there are no tool on the ARM. Because of it will be very danger when spindle is on CLAMP while POWER OFF.
v) After ARM back to 0 position, wrench motor breaker to original place, then turn POWER ON again.
vi) To execute M90 POT UP In MDI mode. When ATC STAND-BY lights on.
then it’s done.
(2) Troubleshooting by ARM JOG
K5.3 can execute each M83、M89 change that we mentioned as 5.2. 1)(2)II., but it is not suitable in ATC M06 can’t be done. Because this keep relay will
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separated movement into three steps. So it is only use when ATC calibration.
There are keep relay for ARM JOG:K5.0=1 to star ARM JOG function
Operation: Please turn POWER OFF POWER ON EMG. To set K5.0=1 (Please refer to Chapter 8.3) setting screen 2,
PWE =0 otherwise, 100 P/S Al will cause MDI can’t be operating. NOTE: Don’t set K5.0 and K5.3 =1 at the same time or commands will no use at all.
Select HANDLE mode, lights ON means SPINDLE CLAMP
lights ON means SPINDLE UNCLAMP
Push , ARM JOG +
Push , ARM JOG −
In JOG procedure, If there are tool on ARM or POT please notice that spindle CLAMP/UNCLAM position and release all tools. You also would use MDI mode to execute M84( tool UNCLAMP)、M88(tool CLAMP)、 M82(POT DOWN)、M90(POT UP).
Use JOG moves ARM to 0° In MDI mode, to execute M90 POT UP then ATC will back to original position.
POWER OFF after ATC back to original position, then D503.7 will automatic set =0 and ATC STAND-BY will light ON, otherwise M06 can’t be executing.
CYCLESTART
CYCLE START
FEED HOLD
FEED HOLD
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6) TO SET TOOL REGISTRATION:
Setting tool registration must be in MDI mode, and set write-down protection (PWE)= “1” , then set tool registration in DATA page. Please refer to ELECTIC CIRCUIT PAGE “N1”The addresses of tool registration. Here are descriptions for setting tool registration as bellows:
C01: To set the amount of tool. If magazine are 30 tools, set 30. If 24 tools just set 24(Be sure to set the right numbers, otherwise it will cause the machine to select the wrong tools)
The pot number in STAND-BY position: Setting at of counter screen of PMC
D10: Setting spindle tool number.
D11~D40:To set the tool number for POT No. 1~30, D11 is corresponding to Pot No. 1, etc. Be sure the tool number should not be bigger than 99 (for 24-tool magazine, D35~D40 should be kept empty).
If ATC has tool-selection mistake, please re-check the tool registration and correct the mistake. Otherwise there will be some alarm when executing T code.
7) USING & NEGLECTING OF MACRO FOR TOOL CHANGING:
MACRO 09001 is for M06 tool change, the benefit for using MACRO is as follows: 1. In AUTO mode, it will be able to execute M06 and T CODE in one block. 2. G91, G28, Z0 is not necessary before M06. 3. To reduce the time for tool change. Simultaneously executing POT-OUT &
SPINDLE ORIENTATION AND Z-AXIS returning to the point of tool change.
For special reasons, if you don’t want using MACRO to execute tool changing. There is explanation of neglecting MACRO in next section 5.1.5.1
CURRENT
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(1) SUBPROGRAM OF TOOL CHANGE:
% O9001(…..MO6 SUB-PROGRAM….) THE NUMBER OF PROGRAM AND EXPANATION. #3003=1 SINGLE BLOCK IS DISABLED. #3004=1 FEED HOLD IS DISABLED. T#4120 SEARCH T-CODE; IF[#1000EQ1] GOTO 70 TO DECIDE IF “T” IS SPINDLE TOOL IF[#1003EQ1] GOTO 10 TO DECIDE IF IN MDI MODE. N10 #103=#4003 SAVE THE CURRENT G-CODE OF THIRD GROUP
#1100=1 SPINDLE ORIENTATION AND POT DOWN G91G28Z0 Z-AXIS RETURNS HOME #1100=0 CANEL MACRO #1100 M06 EXECUTING TOOL CHANGING N70 G#103 #3003=0 SINGLE BLOCK IS AVAILABLE #3004=0 FEED HOLD IS AVAILABLE M99 RETURN TO MAIN PROGRAM
(2) neglect of macro tool change:
1. Select MDI mode
2. Press key parameter key set PWE=1
3. Change the setting of parameter 6071(No.6071=0 to neglect this MACRO, No.6071=6(M6) uses MACRO)
4. Set PWE=0
OFFSET SETTING
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5.3 CAROUSEL TYPE ATC:
1) ATTENTION OF OPERATION:
(1). ATC STAND-BY: The ATC will be in STAND-BY state, except executing tool change. If ATC is not stand-by, then M06 won’t be executed ,also in auto mode over 8 sec CRT will show “1004 ATC STAND-BY LS”message. When the LED(on operator’s panel) of ATC STAND-BY lights on, it means ATC is STAND-BY. When executing M06 the light is OFF.
(2.) TOOL CHANGE CYCLE
I. TOOL CHANGE OF MDI MODE
Carousel type ATC is use absoule pot of position ,the number 1 pot is put number 1 tool
,To execute M06 TX or T code are available in MDI mode. In MDI mode, first
press , then key in T_ CODE and press to execute tool change.
M19 (spindle orientation) will start automatically when execute T_code. So it’s not
necessary to execute M19 spindle orientation. When tool change is done, the ATC
STAND-BY will light on.
In MDI mode, when Z-axis back to second reference position(G91G30Z0) using single block to execute tool change is OK. But notice that single block method is only provide for ATC calibration or troubleshooting. During this time spindle tool and standby Tool doesn’t change in the tool table.if finish the operation must be check tool table.
MDI single block as folloe:
M19 : SPINDLE ORIENTATION
M82: MAG. FORWARD
M83 : SPINDLE TOOL UNCLAMP
M84 : MAG. BACKWARD
M85 : SPINDLE CLAMP
In MDI mode using single block to execute tool change.Z axis back to second reference position (G91G30Z0).then according the M code to done.when it is finish ,the ATC STAND-BY will light on.
(2) TOOL CHANGE OF AUTO MODE: To execute T_CODE tool change in AUTO MODE ( MACRO), it means when executing
PROGRAM
INPUT
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T_CODE in program it will call the sub-program 09000 automatically. And after executed, it will back to main-program. Do not modify or delete the program of 09000.
NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC SYSTEM.
THE MOTION OF SUBPROGRAM:
Simultaneously executing Z-axis returning to second reference position, SPINDLE ORIENTATION (M19). The customer doesn’t have to write G91 G30 Z0 and M19 commands before T_code. But if tool have interference, please check that if tool withdraw and spindle orientation are necessary.
Start tool change mechanism to STAND-BY position (equate SPINDLE), and to execute the cycle of tool change: MAG. FORWARD SPINDLE UNCLAMP AIR BLOW
G91G28Z0 MAG.ROT.ST-BY TOOL G91G30Z0 SPINDLE CLAMP MAG.BACKWARD
When tool change finish the ATC STAND-BY will light o
If use MACRO for tool change in AUTO mode, it is allowable M06 and T code in the same black or only T_code. Suggestion: Do not write them together in one block.
(MODE 1) : T01;
:
T05; :
09000 is one block during executes T_code call sub-program 09000 in programming, At this time press “FEED HOLD” key the program will stop until l ATC tool changing finished.
NOTE: Do not stop the process of tool change abnormally(like EMG STOP AIR- PRESSURE DROP AND UNUSUAL POWER OFF etc.). Please RESET,
TOOL NO.1 MACHINING PROCESS
TOOL NO.5 MACHINING PROCESS
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and use M code to set ATC STAND-BY, then re-execute tool change.
2) TROUBLESHOOTING:
CAROUSEL TYPE ATC(FIGURE
(1) BRIEF INTRODUCTION FOR EVERY CONFIGURATION
CAROUSEL ATC( FIGURE I,J )
L1 :MAG.BACKWARD SENSOR POSITION DETECT L2 :MAG.FORWARD SENSOR POSITION DETECT L3 :MAG.COUNT SENSOR A L4 :MAG.MOTOR
(2)THE RELATED ITERS FOR STAND-BY: To execute M06,the ATC must be in
STAND-BY situation, and has to satisfy the following items:
18MC
MAG.BACKWARD L1 ON X1005.5
MAG.COUNT A L3 OFF X1005.6 0I AND 18I 21I
MAG.BACKWARD L1 ON X5.5
MAG.COUNT A L3 OFF X5.6 0I-MATE
MAG. Backward sensor
MAG. Front sensor
L1
L2
ON
OFF
X25.5
X25.6
MAG. Counter sensor A. L3 OFF X26.1
When the ATC STAND-BY lamp doesn’t light during maintenance. please use DGNOS to examine above items. make sure that every limit switch is correct.(Please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction).
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FIG I
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FIG J
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3)T_ M06 CAN’T BE DONE There are two situations as below:
I. Stop after MAG.FORWARD:
(1)MAG.FORWARD LIMIT not ON (2) Air pressure is not enough
Try to find the reason as mentioned items. Then use MDI to execute M85 (MAG. BACKWARD), and back to ATC STAND-BY. After it re-execute M06.
4) TO SET TOOL REGISTRATION:
Setting tool registration must be in MDI mode, and set write-down protection (PWE)= “1” , then set tool registration in DATA page. Please refer to ELECTIC CIRCUIT PAGE “N1”The addresses of tool registration. Here are descriptions for setting tool registration as bellows:
C01: To set the amount of tool. If magazine are 16 tools, set 16. If 24 tools just set 24(Be sure to set the right numbers, otherwise it will cause the machine to select the wrong tools)
The pot number in STAND-BY position: Setting at of counter screen of PMC
D10: Setting spindle tool number.
D11~D40:To set the tool number for POT No. 1~16, D11 is corresponding to Pot No. 1, etc. (For 16 tools set D11~D26,for 24 tools set D11~D34)Be sure the tool number should not be bigger than 99 .
If ATC has tool-selection mistake, please re-check the tool registration and correct the mistake. Otherwise there will be some alarm when executing T code.
5) USING & NEGLECTING OF MACRO FOR TOOL CHANGING:
MACRO 09000 is for M06 tool change, the benefit for using MACRO is as follows: 1.In AUTO mode, it will be able to execute T_M06 or only T CODE . 2.G91, G30, Z0 is not necessary before T_M06. 3.To reduce the time for tool change. Simultaneously executing SPINDLE ORIENTATION AND Z-AXIS returning to the point of tool change.
For special reasons, if you don’t want using MACRO to execute tool changing. There is explanation of neglecting MACRO in next section .
CURRENT
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(1)MACRO PROGRAM EXPANATION % O9000(T CODE SUB PROGRAMS) #3004=1 SINGLE BLOCK IS DISABLED #3003=1 FEED HOLD IS DISABLED #100=#4009 #101=#4007 #102=#4008 #103=#4003 #104=#4001 #105=#4120 SAVE T-CODE STATE #106=#1000 SAVE T = SB STATE #107=#1001 SAVE T = CHK STATE #1101=0 #108=0 #109=0 #110=#1005 Check Z lock PB IF【#110EQ1】GOTO20 CHECK Z LOCK PB OF ON/OFF STATE IF【#105GT100】GOTO30 CHECK T-CODE STATE WITH MAG. CAPACITY IF【#105GT16】GOTO10 IF【#105GT0】GOTO30 N10 #3000=1(TOOL CAN, T SEARCH) N20 #3000=2(PLEASE Z LOCK PB) N30 #1102=1 T#105 G04X0.5 #1102=0 #111=#1004 IF【#111EQ1】GOTO100 DECIDE T-CODE EQUAL SP TOOL N40 IF【#106EQ1】GOTO50 DECIDE STAND-BY POT EQUAL SP TOOL #1101=1 #106=#1000 GOTO40 N50 G91G00G30Z0M19 Z RETURN G91G30Z0 POS AND SP ORIENTATION M82 MAG. FORWARD M83 SP UNCLAMP #1100=1 Z INTER LOCK G91G28Z0. #105=#4120 IF【#105GT16】GOTO10 T#105 G91G30Z0 M84 SP CLAMP M85 MAG. BACKWARD #1100=0 G#104G#103G#102G#101G#100 TO RECOVER THE STATE OF G-CODE 3-GROUPN100 #3003=0 SIGNAL BLOCK IS AVAILABLE #3004=0 FEED HOLD AVAILABLE M99 RETURN TO MAIN PROGRAM %
(2) neglect of macro tool change:
SAVE G-CODE STATE
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5. Select MDI mode
6. Press key parameter key set PWE=1
7. Change the setting of parameter 6001#5=0(No.6071=0 to neglect this MACRO, No.6001#5=1 uses MACRO)
8. Set PWE=0
OFFSET SETTING
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6. EXPLANATION OF OTHER INSTALLATIONS
This chapter is to describe operation and explanation of other functions. Because the new software is updated too fast and there are many different requests from customers. Therefore, we only describe the standard function. About the optional functions, please refer to the attached information. 6.1 LUBRICATION AND THE RELATED SETTING:
6.1.1 The oil lubrication system is very important for machine tools. And the OILER is like the heart for oil lubrication system. If lubrication is not good it will cause servo motor a heavy load and abnormal current. If the oil supply of slideways is short for a long time, it will cause bad accuracy and servo motor vibration, noise, heat …etc. If serious, it will injure the slidewats.
When power ON, after releasing EMG the LUB will retain the pressure immediately at the first time. Retain pressure time is set by PLC TIMER D430. The standard value is 15 sec. After the pressure detecting time(D330,10 sec), If the pressure is still not enough, the LUB PRESSURE MISS alarm will be displayed. If the pressure is normal, the oil will start filling and the time intermittent counter will start to count. Same as the above condition, the pressure has to release within 10sec from filling oil. Otherwise 2010 ALARM will be displayed. When retain pressure and fill oil are all right, the time intermittent counter D435 and D315 will decide the time for next retain pressure. In auto mode, the intermittent time D435 is 10 minutes. In handle mode, the intermittent time D315 is 20 minutes.
As above description, The cycle for oiler is as follows:
ON RETAINS PRESSURE PRESSURE DETECTS FILLS OIL PRESSURE DETECTS INTERMITTENT RETAINS PRESSURE
(For the detail of setting PLC TIMER, please refer to page 8-1)
6. 1.2 HOW TO TAKE CARE OF THE OILER PROBLEMS:
If the machine does not ON for a long time. The slideways are dry. Please use MANUAL PUSH BUTTON to start oiler a few times after machine ON. About the question of OILER we will explain as following:
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1. ALARM 2009
ALARM 2009 is oil not enough. When ALARM happens, please fill oil within 30 minutes. If not, it will change to FEED HOLD. In auto mode, Single block is automatically engaged and the indicate lamp E4 will light. At this time, to fill oil and reset is the only way to solve this problem. If it still not works, maybe there are some other parts malfunctioned. Please ask the engineer of agent to help.
2. ALARM 2010
ALARM 2010 IS PRESSURE DETECTION ERROR. It happens mostly with the problems of oil tube. If happens during retain pressure, it means the pressure can not retained in time. try to increase TIMER 330 and TIMER 430 (the maximum is 40 minutes). please notice that value of TIMER D300 should be larger than D430. If the problem still exists, it means the problem of oil tube or pressure switch or the pump.
6.2 COOLER UNIT:
COOLER UNIT is to provide cooling and lubrication to spindle head during high speed rotation. We have gear and belt type spindles which use different type cooler units. but the principle and motion are almost the same as below:
A pump withdraws warm oil from spindle head, and send it back to cooler. The detector will check whether the oil temperature is higher than the setting value. If yes, the compressor will start automatically to cool down the oil until the temperature is lower than the setting. The compressor will stop.
Because the cooling oil is a close-loop circulation system, the pump is non-stop, but the compressor works intermittently. The cooler unit starts work when power is ON and EMG is released. If alarm 1004 SPINDLE GEAR OIL AL is displayed at the first POWER ON, but cooler’s panel displays nothing. It means phase of the input power is wrong.
For the rest of problems, the 1003 ALARM will be displayed when cooler doesn’t work. If the problem is not same as the above, please check the panel’s display. and refer to the operation’s and troubleshooting manual of oil cooler unit.
Besides, the operation temperature range is also written in the manual of cooler unit. usually, the temperature setting is room temperature adds the value that we set. For example, now the room temperature is 25 , and the value is +5 , so the temperature is not over 30 . If over 30 , the compressor will start.
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6.3 HYDRAULIC UNIT(HYD.)
HYDRAULIC UNIT is to provide the power for hydraulic equipment of machine tools, including ATC、APC、AUTO DOOR AND COUNTER BALANCE for Z-AXIS(for some models) …etc.
When releasing EMG button, the hydraulic unit will start work and the pressure goes up. When pushing EMG button the hydraulic unit will stop. Basically, there is no electric controller which can control the pressure of hydraulic. But the work have to suit the EMERGENCY STOP CONTECTOR (ELECTRIC CIRCUIT C1). About the time for changing oil, to use what kind of oil and the adjustment of pressure please refer to maintenance manual.
6.4 CHIP CONVEYER (CHIP)
CHIP CONVEYER starts manually(a push button which shows on operator’s panel) or by M code (M68 ON and M69 OFF),please refer to chapter 7.
6.5 WORK LIGHT/ALARM LIGHT
The equipment for light is a 24V light (quartz), it locates beside head. It starts manually by the push button on the operator’s panel.
Alarm light not only lights on the end of M02、M30, when some ALARM happens it will light too. (Set K4.5=1)
6.6 THERE LAYER ALARM LIGHT DESCRIPTION
RED LAMP:Urgent situetion
YELLOW LAMP:Abnormal warning
GREEN LAMP:Programing in process or M30 programing ending signal incoming
6.7 RS232 AC110V INTERFACE
Only for power supply of the Notebook and prohiditted for other spare parts
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6.8 HAND PASS SAFE DOOR INTER LOCK
When the machine is in the condition of power bisconnection or maintainance status
The inter lock in the status of (CLAMP) in case the maintenance person is closed in
The interior of the machine and can not open the safety door to get out as the power
Can not be operated to discharge the circuit of inter lock of the door. The way to get out is by usmg hand tools to open the door by force. As shown in the picture please
Find the component near by the inter lock and then turn the LOCK position to UNLOCK.
After the person left safely. Please remember to restore the inter lock to LOCK position on
Account of to prevent any person is endangered when the power is on because after the safety
Door was opened by force. It would stay at unlocked status.
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7. AUXILIARY FUNCTIONS:
This chapter will describe the auxiliary functions. We follow the idiomatic usage to edit the common M codes(like M3、M4、M5、M19…etc.). About the other M codes we edit it as convenient as we can. Please refer to the list of this chapter or the ELECTRIC CIRCUIT MANUAL(page. M1).
If you have special request of M code, please contact with us. 7.1EXPLANATION OF M CODE: (THE MARKS “*” IS FOR OPTION
FUNCTION) M00 PROGRAM STOP
M01 OPTIONAL STOP, IT WORKS ONLY WHEN OPTION STOP BUTTON ON THE OPERAOR’S PANEL IS PRESSED.
M02/M30 END PROGRAM, IF COMBINING WITH AUTO POWER OFF BUTTON, THE NC WILL POWER OFF AUTOMATICLY. THE DIFFERENCE BETWEEN M2 AND M30 IS THAT M2 ONLY ENDS THE PROGRAM, M30 WILL END AND REWIND THE PROGRAM.
M03 SPINDLE CW ON
M04 SPINDLE CCW ON
M05 SPINDLE OFF
M06 IN MDI OR AUTO MODE, TO EXECUTE TOOL CHANGE.
*M07 MIST ON
M08 COOLANT ON
M09 MIST(M07),COOLANT(M08),THROUGH TOOL COOLANT(M12) OFF
*M10 THE 4TH CLAMP
*M11 THE 4TH UNCLAMP
*M12 THROUGH TOOL COOLANT ON
M14 APC TABLE A IN
M15 APC TABLE B IN
M16 AUTO APC CHANGE
M19 SPINDLE ORIENTATION
M21 SPINDLE SWITCH TO LOW GEAR
M22 SPINDLE SWITCH TO HIGH GEAR
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*M68 CHIP ON
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*M69 CHIP OFF
M70 CANCEL MIRROR FUNCTION
M71 X-AXIS MIRROR ON
M72 Y-AXIS MIRROR ON
M82 POT DOWN, Z-AXIS HAS TO RETURN ZERO AND ATC STAND-BY LIGHT ON
M83 ARM 60 . EXECUTE M82 AND M19 BEFORE THIS COMMAND.
M84 SPINDLE TOOL UNCLAMP
M85 ARM DOWN. EXECUTE TOOL UNCLAMP BEFORE THIS COMMAND.(FOR CAM ATC, M85,M86,M87 WILL COMBINED TO M85)
M86 ARM 180 CW. EXECUTE ARM DOWN BEFORE THIS COMMAND. (CAM ATC DOESN’T USE THIS COMMAND)
M87 ARM UP, ARM 180 CW AND SPINDLE UNCLAMP MUST HAVE DONE. (CAM ATC DOESN’T USE THIS COMMAND)
M88 SPINDLE TOOL CLAMP
M89 ARM 0 . FIRST, HAVE TO EXECUTE SPINDLE CLAMP
M90 POT. UP. FIRST, HAVE TO EXECUTE ARM 0
M91 ORIGINAL POSITION OF 180 RACK(ARM DOES NOT MOVE)
M98 SUB-PROGRAM CALL
M99 IF USED IN SUBPROGRAM IT WILL RETURN TO MAIN PROGRAM. IF USED IN MAIN PROGRAM IT WILL REPEAT EXECUTING THE PROGRAM
M82~M91: EACH M CODE IS ONE STEP FOR ATC OPERATION, THEY ARE ONLY USED DURING TROUBLESHOOTING. PLEASE USE M06 FOR TOOL CHANGE TO AVOID MACHINE DAMAGE.
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M CODE LIST
CODE DESCRIPTION CODE DESCRIPTION
M00 PROGRAM STOP M68 CHIP CONVEYER ON
M01 OPTION STOP M69 CHIP CONVEYER OFF
M02 PROGRAM END M70 MIRROR IMAGE CAN
M03 SPINDLE FORWARD(CW) M71 X-MIRROR IMAGE
M04 SPINDLE REVERSE(CCW) M72 Y-MIRROR IMAGE
M05 SPINDLE STOP M82 POT OUT
M06 AUTOMATIC TOOL CHANGE ARM 60
M07 MIST ON
M83
M83 CAM ATC ARM CW(K5.3=1)
M08 COOLANT PUMP ON M84 SPINDLE TOOL UNCLAMP
M09 COOLANT PUMP OFF ARM DOWN
M10 4-AXIS CLAMP
M85
M85 CAM ATC NO USE
M11 4-AXIS UNCLAMP ARM CW 180
M12 DEEP DRILL ON
M86
M86 CAM ATC NO USE
M14 APC TABLE A IN ARM UP
M15 APC TABLE B IN
M87
M87 CAM ATC NO USE
M16 AUTO APC CHANGE M88 SPINDLE TOOL CLAMP
M19 SPINDLE ORIENT ARM 0
M21 SPINDLE L-GEAR
M89
M89 CAM ATC ARM CCW(K5.3=1)
M22 SPINDLE H-GEAR M90 POT IN
M25 EXTRA ADD 1M CODE ON M91 ORIGINAL POSITION
M26 EXTRA ADD 1M CODE OFF M98 CALL SUB-PROGRAM
M27 EXTRA ADD 2M CODE ON M99 END SUB-PROGRAM
M28 EXTRA ADD 2M CODE OFF
M30 PROGRAM STOP(AUTO POWER OFF)
M50 EXTRA ADD 3M CODE ON
M51 EXTRA ADD 3M CODE OFF
M52 EXTRA ADD 4M CODE ON
M53 EXTRA ADD 4M CODE OFF
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8. PLC SETTING
The PLC setting are including TIMER and KEEP RELAY, the detail of to set TIMER and KEEP RELAY is described at section 3 in this chapter.
What is PLC ? It means control by LOGIC. That is to say, it is HUMAN INTERFACE. We try to modify PLC more user-friendly and safety for customer’s request. Because every company has different design. Please read the manual carefully for the best performance of the machine.
Before shipping the machine, we have checked an run machine completely, and the relative values are all set. To prevent missing the data, We copy it in ELECTRIC CIRCUIT(page L1~L3 and M1), and about the machine parameter we save in NC memory. Because the life of battery(lithium) is 5 years for machine (if machine are not works, the battery life only 3 months), if overtake the battery life the parameter will be lost. So we copy two set, one for the customer and one for us to ensure the parameter will not be lost. Please be careful to keep the items as blows:
ELECTRIC CIRCUIT
LADDER DIRGRAMM
THE DATA SHEET FOR SYSTEM PARAMETER
THE DATA SHEET FOR MACHINE PARAMETER
THE FLOPPY DISK FOR PARAMETER
In section 3 of this chapter we’ll mention about how to modify and setting PLC and machine parameter. But please be sure not to modify them without our approval.
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8.1SETTING OF TIMER:
8. 1.1 TIMER FOR LUB:
TIMER
NO.
DESCRIPTION STANDARD
VALUE
TMR 64 IN MANUAL MODE, THE TIME FOR
INTERMITTENCE.
1200000 (20 minutes)
TMR 62 THE TIME FOR DETECT THE PRESSURE
OF LUB.
10000 (10 seconds)
TMR 60 THE TIME FOR LUB MOTIONS AND FILLER 15000 (15 seconds)
TMR 61 IN AUTO MODE, THE TIME FOR
INTERMITTENCE.
600000 (10 minutes)
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8. 1.2 TIMER FOR HYDRAULIC TYPE ATC:
TIMER NO. DESCRIPTION STANDARD VALUE FOR
KFV-40
STANDARD VALUE FOR VMC-1400
TMR 9 MAGAZINE INDEX STOP 100 (0.1 sec.) 0
TMR 10 T CODE FINISH CHECK 100 (0.1 sec.) 0
TMR 11 MAGAZINE
ORIENTATION
150 (0.15 sec.) 150 (0.15sec.)
TMR 19 POT UP 200 (0.2 sec.) 200 (0.2sec.)
TMR 20 POT DOWN 200 (0.2sec.) 200 (0.2sec.)
TMR 21 SPINDLE CLAMP 150 (0.15sec.) 200 (0.2sec.)
TMR 22 SPINDLE UNCLAMP 300 (0.3sec.) 200 (0.2sec.)
TMR 23 ARM 60 200 (0.2sec.) 200 (0.2sec.)
TMR 24 ARM 0 150 (0.15sec.) 150 (0.15sec.)
TMR 25 MAGAZINE
ORIENTATION
600 (0.6sec.) 600 (0.6sec.)
TMR 26 ARM UP 200 (0.2sec.) 0
TMR 27 ARM DOWN 200 (0.2sec.) 0
TMR 28 ARM 180 200 (0.2sec.) 0
TMR 29 180 ORIGINAL
POSITION
200 (0.2sec.) 150 (0.15sec.)
TMR 32 CW COUNTER A 200 (0.2sec.) 0
TMR 33 MAGAZINE CW
COUNTER B
200 (0.2 sec.) 0
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8.1.3 TIMER FOR CAM ATC
TIMER NO. DESCRIPTION STANDARD VALUE FOR
KFV-40
STANDARD VALUE FOR VMC-1400
TMR 9 MAGAZINE INDEX STOP 0 0
TMR 10 T CODE STOP CHECK 0 0
TMR 11 MAGAZINE
ORIENTATION
0 150 (0.15sec.)
TMR 19 POT UP 200 (0.2sec.) 200 (0.2sec.)
TMR 20 POT DOWN 0 0
TMR 21 SPINDLE CLAMP 0 0
TMR 22 SPINDLE UNCLAMP 0 0
TMR 23 ARM 60 0 0
TMR 24 ARM 0 0 0
TMR 25 MAGAZINE
ORIENTATION
600(0.6sec.) 600(0.6sec.)
TMR 26 ARM DOWN & ARM 180
& ARM DOWN
0 0
TMR 32 MAGAZINE CW
COUNTER A
200 (0.2sec.) 0
TMR 33 MAGAZINE CCW
COUNTER B
200 (0.2sec.) 0
DO NOT CHANGE THE VALUE OF TIMER FOR ATC BY YOURSELF TO PREVENT MALFUNCTIONS.
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8. 1.4 TIMER FOR OTHERS :
TIMER NO. DESCRIPTION THE VALUE FOR
STANDARD
TMR 13 FLASH AT HOME POINT 1 500 (0.5 sec.)
TMR 14 FLASH AT HOME POINT FLASH 2 500 (0.5 sec.)
TMR 15 THE TIME FOR M02/M30 CALL
LIGHT
50 (0.05 sec.)
TMR 16 RIGID TAPPING 100 (0.1 sec.)
TMR 17 THE TIME FOR EMG STOP 50 (0.05 sec.)
TMR 18 M29 COMMAND DELAY 50 (0.05 sec.)
TMR 30 THE TIME FOR ONE SHOT(MAG) 350 (0.35sec.)
TMR 31 SPINDLE AIR BLOW 500 (0.5sec.)
TMR 5 BUZZER ON TIME 60000 (60sec)
8.1.5 TIMER FOR CAROUSEL ATC:
TIMER NO. DESCRIPTION THE VALUE FOR
STANDARD
TMR 10 MAG. START 50 (0.05 sec.)
TMR 11 MAG. STOP 150 (0.15 sec.)
TMR 9 T CODE STOP CHECK 150 (0.15sec.)
TMR 19 MAG. BACKWARD 150 (0.15sec.)
TMR 20 MAG. FORWARD 50 (0.05 sec.)
8.2 EXPANATION OF KEEP RELAY SETTING:
In according with different part of electric equipment or different control logic of customer. For convenience choice, there are some addresses we will design for KEEP RELAYS to control the different motion. Only the situation that mentions as below would change KEEP RELAY:
1. Lose NC control, reset KEEP RELAY。 2. To change KEEP RELAY to suit the electric equipment 3. Disable the protection when adjust ATC
4. to change the motion which is permitted to be selected
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Of cause in this kind of setting and modifying the operator should contact with our engineer to ensure the safety.
The meaning of KEEP RELAY will be described as below, but for the actual values, please refer to the page L1~L3 of electric circuit manual.。
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8.2.1 KEEPRELAY SET OF HYD ATC K0 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 1 1 0 0 1 0
ACTUAL SETTING
SAFE DOOR INTERLOCK SWITCH
W-60 POSITION MACHINE LOCK
NO USE
MN MODE
EACH MODE COOLANT ON
4-AXIS CLAMP USE M10 COMMAND
4-AXIS CLAMP USE EXTRANAL LIMIT SWITCH
NO USE
K1 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 0 1
ACTUAL SETTING
RIGID TAPPING M29 COMMAND NO USE S FUNCTION
RIGID TAPPING M29 COMMAND TIMER SPINDLE STOP
ARM0 M6 FINISH
Z-AXIS NO ZERO POINT RETURN
ATC OPERATOR SEQENCE CINTROL
POT UP KEEP RELAY
POT DOWN KEEP RELAY
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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ARM 60D KEEP RELAY
K2 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 1 0
ACTUAL SETTING
ARM-0D KEEP RELAY
ARM UP KEEP RELAY
ARM DOWN KEEP RELAY
ARM 180 CW KEEP RELAY
ARM 180 CWW KEEP RELAY
SPINDLE CLAMP KEEP RELAY
SPINDLE UNCLAMP KEEP RELAY
SPINDLE AIR CEL KEEP RELAY
K3 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 1 0 1 0 0 1
ACTUAL SETTING
0=1500-21100M/C 1:850~40
NO ATC UNIT
ATC OKI Z-AXIS ZERO RETURN G30 X0 Y0 POINT
NOT HIGH/LOW GEAR
0:USE LUB PRE DET FUNCTION
4-AXIS NEG
1=ZBK 0=CO BK
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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X-AXIS + ZERO PONIT
K4 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 1 0 0 0 0 0 0 0
ACTUAL SETTING
M25 FINISH BY X1008.3
M27 FINISH BY X1008.5
M50 FINISH BY X1008.6
M52 FINISH BY X1008.7
LUB. TYPE SELECT
ALARM CALL LIGHT
M00/M01 SPINDLE STOP
3-AXIS AUTO ZERO RETURN
K5 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 1 0
ACTUAL SETTING
1:USE ZF BOX
SPEED OVERRIDE SWITCH TYPE
NO USE
NO USE
NO USE
1:USE DATA MAG ONE PNP SENSOR
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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1:NO USE AIR PRESSURE CHECK
1:USE 3 M.P.G.
K6 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 1 0
ACTUAL SETTING
K7 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 1 0
ACTUAL SETTING
1:4/5 AXIS UNCLAMP SERVO OFF
1:5th AXIS BY PASS
1:M00/M01 LIGHT ON
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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K8 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 0 0
ACTUAL SETTING
K9 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 0 0
ACTUAL SETTING
1.USE AIR H/L GEAR CHANGE
1:OPT1 PB =+5 PB
1:OPT2 PB =-5 PB
1:AXIS MOVE BY PASS OPT2 PB
1:USE APO PB+OPT2 PB
1:USE M23(TOOL NO.RESET)
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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8.2.2 KEEP RELAY OF CAM ATC K0 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 1 1 0 0 1 0
ACTUAL SETTING
SAFE DOOR INTERLOCK SWITCH
W-60 POSITION MACHINE LOCK
PLAY BK (STEP MODE)
MN MODE
EACH MODE COOLANT ON
4-AXIS CLAMP USE M10 COMMAND
4-AXIS CLAMP USE EXTRANAL LIMIT SWITCH
SAFE DOOR OPEN SPINDLE STOP
K1 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 0 1
ACTUAL
1.NO.2=BIG TOOL
1.NO.4=BIG TOOL
1.NO.6=BIG TOOL
1.NO.8=BIG TOOL
1:USE M12 SP AIR
1:USE THE LUB ALARM COUNTER
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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SETTING
RIGID TAPPING M29 COMMAND NO USE S FUNCTION
RIGID TAPPING M29 COMMAND TIMER SPINDLE STOP
ARM0 M6 FINISH
Z-AXIS NO ZERO POINT RETURN
ATC OPERATOR SEQENCE CONTROL
POT UP KEEP RELAY
POT DOWN KEEP RELAY
K2 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 1 0
ACTUAL SETTING
SPINDLE CLAMP KEEP RELAY
SPINDLE UNCLAMP KEEP RELAY
SPINDLE AIR CEL KEEP RELAY
K3 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 1 0 1 0 0 1
ACTUAL SETTING
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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0=1500-21100M/C
NO ATC UNIT
ATC OK1 Z-AXIS ZERO RETURN G30 X0 Y0 POINT
NOT HIGH/LOW GEAR
0:USE LUB PRE DET FUNCTION
4-AXIS NEG
1=ZBK
X-AXIS + ZERO PONIT
K4 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 0 0
ACTUAL SETTING
M25 FINISH BY X1008.3
M27 FINISH BY X1008.5
M50 FINISH BY X1008.6
M52 FINISH BY X1008.7
LUB. TYPE SELECT
ALARM CALL LIGHT
M00/M01 SPINDLE STOP
3-AXIS AUTO ZERO RETURN
K5 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 1 1 0
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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ACTUAL SETTING
CAM ATC M83 M89 FUNCTION
SPEED OVERRIDE SWITCH TYPE
CHIP PUSH-BUTTOM TYPE
1:CAM STEP BY HAND MODE CY/FD
CAM SENSOR TYPE 1:NPN 0:PNP
1:USE DATA MAG ONE PNP SENSOR
1:NO USE AIR PRESSURE CHECK
NO USE
K6 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 0 0
ACTUAL SETTING
1:4/5 AXIS UNCLAMP SERVO OFF
1:USE 3MPG
1:5th AXIS BY PASS
1:M00/M01 LIGHT ON
1:USE “CYTEC”SP15000RPM
NO USE
1:使用”CYTEC”SP20000RPM
JOG/DRY OVERRIDE O~200%
K7 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD 0 0 0 0 0 0 1 0
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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SETTING ACTUAL SETTING
H/L GEAR RELAY NO KEEP ON
1: USE AIR H/L GEAR CHANGE
1: SP UNCLAMP NOT M19
1:OPT1 PB =+5 PB
1:OPT2 PB =-5 PB
1:AXIS MOVE BY PASS OPT2 PB
K8 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 0 0
ACTUAL SETTING
K9 ADDRESS NO 7 6 5 4 3 2 1 0STANDARD SETTING 0 0 0 0 0 0 0 0
1:USE SP H/L (Y-ΔOR Y-Y)
1:PROGRAM LED KEEP ON
1:USE CTRA-1 SENSOR(K TYPE)
1:USE APO PB+OPT2 PB
1:USE M23(TOOL NO.RESET)
1:KEEP0:UNKEEP
1:KEEP0:UNKEEP
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ACTUAL SETTING
8.3TO MODIFY THE SETTING:
When our engineer ask you to modify the setting on the telephone, please follows the method that we mentioned as below. Once again we’ll remind you to contact with service people before modify.
8. 3.1 MODIFY PLC
1. PRESS EMG STOP BUTTON 2. IN MDI MODE
3. AFTER PRESSING , THERE ARE(OFFSET),(SETTING)AND (WORK) SHOWING BELOW THE SCREEN.
4. PRESS SETTING KEY, 5. USE CURSOR KEY TO MOVE CURSOR TO PWE=0 (0:can not write
1:can write) 6. KEY IN ”1”
7. ,AT THIS TIME 100 P/S ALARM WILL HAPPENED
8.PRESS THERE ARE(PARAMATER)(DIAGNOS)(SYSTEM)WHICH
SHOWS BELOW THE SCREEN 9.PRESSED KEY, THERE ARE(PMCLAD)(PMCDGN)(PMCPRM) WHICH SHOWBELLOW THE SCREEN..
1.NO.2=BIG TOOL
1.NO.4=BIG TOOL
1.NO.6=BIG TOOL
1.NO.8=BIG TOOL
1:USE M12 SP AIR
1:USE THE LUB ALARM COUNTER
SYSTEM
OFFSET SETTING
INPUT
PMC
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10.PRESS KEY THERE ARE (TIMER)(COUNTER)(KEEPRL)
(DATA)(SETTING)WHICH SHOWBELLOW THE SCREEN.
11USE CURSOR KEY TO MOVE CURSOR TO WHICH PARAMATER WANT
TO MODIFY, KEYIN THE VALUE THEN PRESS KEY FINISH THE MODIFY.
12.IF WANT TO MODIFY THE KEEPRELAY,ACCORDING THE STEP 10 TO PRESS (KEEPRL)KEY,THEN DEPEND STEP 11 TO MODIFY THE VALUE.BECAUSE THE KEEP RELAY IS THE BIT TYPE ,SO CAN ONLY MODIFY ONE BIT.
13.WHEN FINISHING MODIFYING, RETURN TO SETTING PAGE AND CHAGE PWE TO 0, SO 100 P/S ALARM CAN BE ELIMINATED AFTER RESETTING.
INPUT
PMCPRM
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8-1
8. 3.2 MODERFY PARAMETER
1. PRESS EMG STOP BUTTON 2. IN MDI MODE
3. AFTER PRESSING , THERE ARE (OFFSET) AND (SETTING) DESPLAYING BELOW THE SCREEN.
4. PRESS (SETTING), 5. USE CURSOR KEY TO MOVE CURSOR TO PWE=0 (0:can not write
1:can write) 6. KEYIN ”1”
7. ,AT THIS TIME 100 P/S ALARM WILL HAPPENED
8. PRESS (PARAMETER) WITCH SHOWS AT THE BOTTON OF THE SCREEN
9. PRESSED KEY, AND KEY IN THE NUMBER THAT YOU ARE GOING TO MODIFY.
10. AT NUMBER xxxx= , KEY IN THE NUMBER THAT YOU ARE GOING TO MODIFY
11.WHEN FINISHING MODIFYING, RETURN TO SETTING PAGE AND CHAGE PWE TO 0, SO 100 P/S ALARM CAN BE ELIMINATED AFTER RESETTING.
OFFSET SETTING
INPUT
NO
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8-2
TIMER SETTING LIST
TIMER NO. DESCRIPTION STANDRD VALUE ACTUAL VALUE
TMR1 LUB DEVICE ACTION INTERVAL TIMER(AUTO MODE) 600000
TMR2 LUB DEVICE ACTION TIMER 15000
TMR3 LUB DEVICE ACTION INTERVAL TIMER(HANDLE MODE) 1200000
TMR4 SPINDLE STOP TIMER 150000
TMR5 BZ STOP TIMER 60000
TMR6 0
TMR7 0
TMR8 0
TMR9 MAGAZING JOG STOP 100
TMR10 T-CODE STOP CHECK 100
TMR11 MAGAZING PIN ADJUSTMENT 150
TMR12 THE TIME WHEN LUB PRESSURE IS UNUSUAL 10000
TMR13 FLASH LAMP 1 500
TMR14 FLASH LAMP 2 500
TMR15 CALL HIGH RIUING TIMER 500
TMR16 RIGID TAPPING M29S COMMAND 100
TMR17 EMERGENCY STOP RELEASE POLSE 50
TMR18 M29 COMMAND DELAY TIMER 50
TMR19 POT UP 200
TMR20 POT DOWN 200
TMR21 SPINDLE CLAMP 150
TMR22 SPINDLE UNCLAMP 300
TMR23 W-ARM 60 200
TMR24 W-ARM 0 150
TMR25 MAGAZINE PIN ADJUSTMENT 600
TMR26 W-ARM UP 200
TMR27 W-ARM DOWN 200
TMR28 W-ARM CW 180 200
TMR29 W-ARM CCW 180 200
TMR30 ONE-SHOT TIMER 350
TMR31 SPINDLE AIR CELEAR 550
TMR32 MAGAZINE FOREARD PHASE 200
TMR33 MAGAZINE FOREARD PHASE2 200
TMR34 JOG/RAP/ZER MODE ENABLE TIMER 30000
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DATA TABLE SETTING
NO. ADDRESS DATA NO.
0000 D0010 SPINDLE NO.
0001 D0011 T1
0002 D0012 T2
0003 D0013 T3
0004 D0014 T4
0005 D0015 T5
0006 D0016 T6
0007 D0017 T7
0008 D0018 T8
0009 D0019 T9
0010 D0020 T10
0011 D0021 T11
0012 D0022 T12
0013 D0023 T13
0014 D0024 T14
0015 D0025 T15
0016 D0026 T16
0017 D0027 T17
0018 D0028 T18
0019 D0029 T19
0020 D0030 T20
0021 D0031 T21
0022 D0032 T22
0023 D0033 T23
0024 D0034 T24
*IF MAFAZINE TOOL CAPACITY 30 TOOLS SET DATA TABLE ADDRESS FOR D0035 TO D0040 (T25 TO T30)。
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8-4
MAGAZINE TOOL CAPACITY (30) SETTING
PMC DATA TBL CONTROL #001 GROUP TABLE COUNT=1
NO. ADDRESS PARAMETER TYPE DATA OF NO.
001 D0010 00000001 0 31
PC COUNTER MAGAZINE TOOL CAPACITY (30)
PMC PRM (COUNTER) #001
NO. ADDRESS PRESET CURRENT
001 C00 30 VARIABLE
*MAGAZINE TOOL CAPACITY 30 TOOLS SET 31 *CURRENT DATA VALUE IS STAND-BY TOOL POT NUMBER,IF YOU WANT RESET IT’S
COUNTENT,PLEASSE CHANGE THIS VALUE。
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9-1
9. THE TROUBLESHOOTING
When malfunction happened, please use this chapter trying to fix the basic problem. And gather the information as following items. We will do our best to recover the machine as soon as possible.
1. Machine serial number, Mode, Control system and delivery date?
2. The responded massage of machine: what is the alarm message and alarm number of servo? Does fuse fail? Is over load escaped?
3. What happens: In which mode? If it happens constantly? If it happens during executing some G code or M.S.T. code? If it happen at the particular machine coordinate? Are there any signs abnormally?
4. Check the frequency of occurrence: what is the frequency? When did the problem first occur? What did you do after malfunction?
5. Outline of environment: Is the voltage stable? Have you updated the program ? Have you changed the operator? Have you updated the tools and clampers? Is the temperature and quake of environment normal?
6. Before malfunction happened: have you edited program or changed auxiliary equipment? Do you adjust or remove the machine?
We hope to solve the problem immediately and completely. The above question is very helpful for us to find the problem. Any answer may be the key point to recover the machine. If during the telephone contact step, you could tell us the detail situation of machine. It will be more easier to find the reason of malfunction and recover it as soon as possible.
ALARM NUMBER
DESCRIPTION STEP OF RECOVER REMARKS
E1
MOL ALARM Motor for outside part have overload situation
1.Turn power OFF 2.Open the door of electric
cabinet and check the OVERLOAD.
3.Push the RESET BUTTON which is on overload.
Better waiting 2-3 minutes, usually it happens because of too much chips in chip -conveyor through.
E2
OIL ALARM Spindle coolant pressure detect alarm
1.Is filter too dirty? Use water, neutral cleaner or compressed air to clean up and air-dry in overcast.
2.if not work, please call the cooler maker。
the TEL of the cooler maker is on the cooler unit plate and the manuals of cooler unit.
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9-2
E3
SPINDLE ALARM heck it the feed rate and spindle speed are correct. 1.If not, turn power OFF and
RESET. 2. If yes, use a screwdriver to
open the door of electric cabinet (do not turn power OFF) and check the alarm number on the 7-segment decoder of spindle driver (at upper row, the second from the right side),and contact with the agent or FANUC.
E4
LUB ALARM LUB oil not enough
Please check the follow items: 1.Is the oil enough? 2.If yes, maybe the oil detector is
broken. please check in according to electric circuit manual.。
1002
SPINDLE DRIVER ALARM spindle driver overload alarm
same as E3
1003
EMERGENCY STOP ALARM
1.Overtravel: press the EMG RELEASE button on control panel. In EMG RELEASE mode: Switch to handle mode, use hand wheel to return original point, and RESET.
2.Motor overload(MOL. ALARM): the same as E1(RESET)
3.EMG not release
1004
SPINDLE GEAR OIL ALARM
the same as E2
1005
ATC STAND-BY LS ATC not at stand by situation
Please follows the chapter 5 or ATC stand-by instruction of electric circuit manual
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9-3
1007
SPINDLE CLAMP LS
Please check the following items: 1.Is spindle unclamping? 2.Does spindle clamp limit switch
touch the dog. 3.If yes, check if it have touched
exactly and stable.
2002
TOOL SEARCH ERROR
1.Are T code all right. 2.Check the tool registration.
2003
ARM 60 M/C LOCK
1.RESET NC. Turn ON manual operation of ATC. (K5.0=1)
2.In MDI mode, used M code to return ATC to stand-by situation step by step.
3.Turn manual operation of ATC. 4.Return Z-axis to ZERO
2004
SAFE DOOR INTERLOCK
1.Close safety door 2.If not works, please check if it is a problem of fuse.
2007
CHECK ZPZ POSITION
1. During ATC tool change, Z-axis does not return to original point .
2. Please return Z-axis back to original position.
2006
AIR PRESSURE MISS
Check whether the air pressure is miss? 2.If the pressure is enough, check
if the pressure switch is broken.
2008
CHECK SPINDLE OK LIST
1.Is spindle on clamp? Is ARM on 0 ? 2.Check if LIMIT switch are stable
that we mentioned before.
2009
SPINDLE LOAD TOO MUCH
1.Are feed-rate and spindle rate OK?
2.RESET NC
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9-4
2010
LUB OIL MISS The same as E4
2011
LUB PRESSURE MISS
1.Is pressure of LUB enough? If yes, please delay the time of pressure D330= 15000
2012
WAIT FOR RIGHT TOOL
1. May be the tool are not STAND BY 2.If the magazine keeping rotation, please call agent.
2013
GO G30 X0 Y0 FIRST
X、Y-axes must back to second reference points.
For VMC-650~800
2014
MAGAZINE PARITY ERROR
1. Check count A and count B Sensor
2015
SP NO TOOL CAN’T ROTATION
Please install tool then can start spindle
Only 10000rpmHigh speed sp
2016 SP “DA”AIR RELEASE PRESSURE NO OK
SP AIR PRESSURE RELEASE SIGNAL NO OK CHECK L.S
2017 SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN FIRST START SP
Please check sp tool,if ok press CYCLE START P.B to start sp warm up.
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9-5
2018
SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN SP STOP OVER 2 HOUR
SP stop over 2 hour please check sp tool,if ok press CYCLE START P.B to start sp warm up.
2020 2020 ADMONISH!THE Z AXIS LOCK P.B IS ON.ARE YOU SURE?YES,PLEASE HIT CYCLE START P.B TO CONTINUE.NO,PLEASE CHECK THE Z AXIS LOCK P.B.
Please check Z lock P.B in auto mode
2021 2021 PLEASE PUSH OP2 P.B TO ENABLE JOG/RAP/ZRN MODE
Push OP2 P.B to enable JOG/RAP/ZRN mode
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9-6
9.1 LARGER TOOL MANAGEMENT For user using the larger or special tools, we program 4 set tool store pot for “Larger Tool Management”. It could offer up to 4 set tool for processing. K9.0 1 Set up the tool store pot #2 as first large tool K9.1 1 Set up the tool store pot #4 as second large tool K9.2 1 Set up the tool store pot #6 as third large tool K9.3 1 Set up the tool store pot #8 as fourth large tool When using the “Large Tool Management” function, the 2 pot adjacent to large tool will be empty automatically. Example: when set up K9.0 1 that using the store pot #2 as the larger tool pot, controller won’t put the tool into first and third tool pot to avoid the danger of crash. PS. When using the “Larger Tool Management” function, user must be notice that you couldn’t insert any tool into adjacent pot in advance.