operator’s manual - hardingeservice.com d-0009500-0392.pdf · operator’s manual quest® 6/42...
TRANSCRIPT
OPERATOR’S MANUAL
QUEST®
6/42QUEST 8/51QUEST 10/65
MULTI-TASKING CNC Lathes
Equipped with the
GE Fanuc 16i-T, 18i-T, or 21i-T Control
Revised: January 18, 2008
Manual No. M-392D Litho in U.S.A.Part No. M D-0009500-0392 June, 2007
TP6793
- NOTICE -
Damage resulting from misuse, negligence, or accident is not covered by theHardinge Machine Warranty.
Information in this manual is subject to change without notice.
This manual covers the operation of Hardinge QUEST® 6/42, 8/51, and10/65 Multi-Tasking CNC lathes equipped with the of the following GEFanuc controls:
16i-T18i-T21i-T
In no event will Hardinge Inc. be responsible for indirect or consequentialdamage resulting from the use or application of the information in this man-ual.
Reproduction of this manual in whole or in part, without written permissionof Hardinge Inc., is prohibited.
CONVENTIONS USED IN THIS MANUAL
- WARNINGS -
Warnings must be followed carefully to avoid the possibility of personal injuryor damage to the machine, tooling, or workpiece.
- CAUTIONS -
Cautions must be followed carefully to avoid the possibility of damage to themachine, tooling, or workpiece.
- NOTES -
Notes contain supplemental information.
- TRADEMARK NOTICE -
Windows is a registered trademark of Microsoft Corporation.
Hardinge Inc.One Hardinge Drive
P.O. Box 1507Elmira, New York 14902-1507 U.S.A.
www.hardinge.com
© 2007, Hardinge Inc. M-392D
READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATINGMACHINE, LOAD/UNLOAD AUTOMATION, OR BAR FEED SYSTEM
When this instruction book was printed, the information given was current. However, since we areconstantly improving the design of our machine tools, automation, and bar feed systems, it is possiblethat the illustrations and descriptions may vary from the machine, automation, or bar feed system youreceived.
- WARNING -
Occupational Safety and Health Administration (OSHA) Hazard Communica-tion Standard 1910.1200, effective May 25, 1986, and various state “employeeright-to-know laws” require that information regarding chemicals used withthis equipment be supplied to you. Refer to the applicable section of the Mate-rial Safety Data Sheets supplied with your machine when handling, storing, ordisposing of chemicals.
Machine should only be used with a bar feed approved by Hardinge Inc.
- SPINDLE TOOLING WARNING -
Hardinge HQC (Quick-Change) collets MUST NOT be used in applicationswhere the spindle is rotating without a bar or workpiece in the collet.
Rotating the spindle without a bar or workpiece in the collet can result in thecollet head being expelled from the spindle.
Failure to comply with this warning can result in serious injury or death.
HARDINGE SAFETY RECOMMENDATIONS
Your Hardinge machine is designed and built for maximum ease and safety of operation. However,some previously accepted shop practices may not reflect current safety regulations and procedures,and should be re-examined to insure compliance with the current safety and health standards.
Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and operators beadvised of the importance of safe maintenance, setup, and operation of machine tools. Our recom-mendations are described below. READ THESE SAFETY RECOMMENDATIONS BEFORE PRO-CEEDING ANY FURTHER.
READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation ormaintenance of the machine. Make certain that you understand all instructions.
DON’T ALLOW the operation or repair of equipment by untrained personnel.
CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.
WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When necessary,wear respirator, helmet, gloves, and ear muffs or plugs.
DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly performed andthe equipment is known to be in good working order.
WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and informa-tion. Do not remove them.
DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other safetydevice.
M-392D i
DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration oc-curs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any dam-aged parts.
REDUCE SPINDLE SPEED if vibration occurs. Bar stock straightness will have an effect on vi-bration and balance of the spindle system.
NEVER OPERATE THE MACHINE SPINDLE without a work-holding device if the draw tube isin the spindle.
TIGHTEN ALL DRAW TUBE SCREWS before beginning spindle operation.
MAKE CERTAIN that the equipment is properly grounded. Consult National Electric Code andall local codes.
DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.
ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electricalequipment.
DON’T REACH into any control or power case area unless electrical power is OFF.
DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wetsurface.
REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.
ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before re-starting the machine.
KEEP THE AREA AROUND THE MACHINE well lighted and dry.
KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment.
HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustiblematerial and keep chips clear of the work area.
DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.
MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors are closed and se-cured.
TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at theleft end of the machine. Make certain that the guard door is in place before starting the ma-chine.
DON’T OPEN GUARD DOORS while any machine component is in motion.
MAKE SURE chucks, closers, fixture plates, and all other spindle-mounted work-holding de-vices are properly mounted and secured before starting the machine.
MAKE CERTAIN all tools are securely clamped in position before starting the machine.
REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before operat-ing the machine. Always check the machine and work area for loose tools and parts especiallyafter work has been completed by maintenance personnel.
REMOVE CHUCK WRENCHES before starting the machine.
ii M-392D
BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that proper functionsare programmed and that all controls are set in the desired modes.
KNOW WHERE ALL stop push buttons are located in case of an emergency.
CHECK THE LUBRICATION OIL LEVEL and the status of the indicator lights before operatingthe machine.
MAKE CERTAIN that all guards are in good condition and are functioning properly before oper-ating the machine.
INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condi-tion and are functioning properly before the cycle is started.
CHECK THE POSITION of the tool top plate before pressing the Cycle Start push button.
CHECK THE POSITION of any load/unload automation before pressing the Cycle Start pushbutton.
CHECK SETUP, TOOLING, AND SECURITY OF THE WORKPIECE if the machine has beenOFF for any length of time.
DRY CYCLE a new setup to check for programming errors.
MAKE CERTAIN that you are clear of any “pinch point” created by moving slides before startingthe machine.
DON’T OPERATE any equipment while any part of the body is in the proximity of a potentiallyhazardous area.
DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain that allmachine movements have ceased.
BE CAREFUL of sharp edges when handling a newly machined workpiece.
DON’T REMOVE OR LOAD a workpiece while any part of the machine is in motion.
DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, neck-ties, or long hair not contained by a net or shop cap.
DON’T ADJUST tooling or coolant hoses while the machine is running.
DON’T LEAVE tools, workpieces or other loose items where they can come in contact with amoving component of the machine.
DON’T CHECK finishes or dimensions of workpiece near running spindle or moving slides.
DON’T JOG SPINDLE in either direction when checking threads with a thread gage.
DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.
ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge Inc.must be reviewed by a qualified safety engineer before installation.
USE CAUTION around exposed mechanisms and tooling especially when setting up. Be care-ful of sharp edges on tools.
DON’T USE worn or defective hand tools. Use the proper size and type for the job being per-formed.
M-392D iii
USE ONLY a soft-faced hammer on tooling and fixtures.
DON’T USE worn or broken tooling on machine.
MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.
INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operating con-dition. Replace any defective chuck before operating the machine.
Hardinge high speed spindles are balanced to an ISO G1.0 standard. High speed spindles re-quire a work-holding device balanced to G2.5 or better.
USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider weight, shape, andbalance of the workpiece.
USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece diam-eter that is larger than the gripping diameter.
DON’T EXCEED the rated capacity of the machine.
DON’T LEAVE the machine unattended while it is operating.
DON’T CLEAN the machine with an air hose.
KEEP TOTE PANS a safe distance from the machine. Don’t overfill the tote pans.
DON’T LET STOCK project past the back end of the collet closer or machine spindle withoutbeing adequately covered and properly supported.
FOLLOW each bar feed manufacturer’s guidelines. For performance and safe application, sizeand use feed tube bushings, pushers, and spindle liners according to bar feed information.
MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the barfeed is a floor-mounted type, it must be securely bolted to the floor.
DURING HIGH SPEED APPLICATIONS, the bar stock must be contained within the colletcloser and a bar feed not be used. Hardinge Inc. Recommends using a bar loader for feedingbar stock during high speed applications. Bar loaders feed the entire piece of bar stock into thespindle; then, the pusher is disengaged from the bar stock.
UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per-formed by one person. To avoid injury to yourself and others, be sure that all personnel areclear of the machine when opening or closing the coolant guard door and any access covers.
FOR YOUR PROTECTION - WORK SAFELY
iv M-392D
Table of Contents
CHAPTER 1 - OPERATOR CONTROL PANELS
Control Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Manual Data Input Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Special Key Functions for Windows Operation . . . . . . . . . . . . . . . . . . . . . . 1-7Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Control Interface Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Standard Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19PC-Based Operator Interface [Option] . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Stack Light [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21On-Line Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22P/S Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Methods of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Accessing the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Alarm Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Operation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Exiting the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
CHAPTER 2 - POWER-UP AND CONTROL STATUS
Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Machine Warm-Up Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Machine Warm-Up Program Structure . . . . . . . . . . . . . . . . . . . . . . . . 2-3QUEST® 8/51 Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3QUEST 8/51 Lathe with Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . 2-3QUEST 10/65 Lathe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4QUEST 10/65 Lathe with Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . 2-4
Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Standard Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5PC-Based Operator Interface [Option] . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Reviewing Control Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Position Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Program Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Offset Setting Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7System Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Message Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
M-392D v
CHAPTER 3 - OPERATIONAL MODES AND EDITING
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Single Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Word Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Word Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Editing a Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Altering a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Inserting a Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Deleting a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Deleting Up to an End of Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Deleting Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Deleting a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Edit Slow Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Continuous Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Incremental Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Manual Data Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Safe Start Subprograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Main Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Sub-Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Entering a Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . . . . 3-10Activating a Stored Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Running a Part Program for the First Time . . . . . . . . . . . . . . . . . . . . . . 3-11Stopping a Program Running in Automatic Mode. . . . . . . . . . . . . . . . . . . 3-12Restarting a Stopped Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Dry Run and Machine Lock Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Activating Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . 3-13Exiting Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Background Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Activating Background Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Editing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Creating a New Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . 3-14Ending Background Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Extended Part Program Editing [Option] . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Copy an Entire Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Copy Part of a Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Move Part of a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Merge a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Search and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Editing Machine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Displaying the Program Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
vi M-392D
CHAPTER 4 - VDI TURRET TOP PLATE TOOLING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Top Plate Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1QUEST® 6/42 & 6/42SP Lathe Turret Tooling Consideration. . . . . . . . . . . . . . . 4-2Tool Holder or Tool Station Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-4Tool Station Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Reversible Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Installing Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Tool Holder Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Installing Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Removing Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CHAPTER 5 - ESA TURRET TOP PLATE TOOLING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Top Plate Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Tool Holder or Tool Station Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . 5-1Tool Station Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Tool Station Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Reversible Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Installing Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Tool Holder Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Maximum Z Axis Tool Extension for Sub-Spindle Operation . . . . . . . . . . . . . 5-9Installing Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
M-392D vii
CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Square Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Main Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Qualified Tool Holders for Main Spindle Operation . . . . . . . . . . . . . . . . 6-1Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . 6-2Installing Square Shank Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Between-Center Turning on QUEST® 6/42 Lathes . . . . . . . . . . . . . . . . 6-4
Sub-Spindle Operation [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Cut-Off Tool Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Tooling Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Tooling Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Tool Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Tool Shank Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Mounting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Round Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Round Shank Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Tool Setting Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Installing Round Shank Tools for Main Spindle Operation . . . . . . . . . . . . . . 6-10Installing Round Shank Tools for Sub-Spindle Operation. . . . . . . . . . . . . . . 6-12
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
CHAPTER 7 - WORK SHIFT
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Manually Establishing Z Axis Work Shift . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
VDI or ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Hardinge Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
CHAPTER 8 - TOOL OFFSETS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Storing Tool Geometry Offsets in Memory . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Setting Tool Offsets for Non-Center Working Tools on the Turret . . . . . . . . . . 8-9Setting Tool Offsets for Center-Working Tools on the Turret . . . . . . . . . . . . . 8-12
Tool Probe [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Manual Tool Probe Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Semi-Automatic and Automatic Tool Probe Operation . . . . . . . . . . . . . . . . 8-16
Datuming the Tool Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16Tool Probe Datum Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Semi-Automatic Tool Probe Operation . . . . . . . . . . . . . . . . . . . . . . 8-19Automatic Tool Probe Operation . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Tool Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21Entering Tool Nose Radius Value and Orientation Code . . . . . . . . . . . . . . . . . 8-22Adjusting Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Adjusting X and Z Axis Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . 8-23Rules for Adjusting Wear Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
viii M-392D
CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1Spindle Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2Hydraulic Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Adjusting the Main Spindle Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . 9-2Main Collet Closer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Chucking Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6Switching the Chucking Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Cleaning the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Removing Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7Installing Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Collet or Step Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9Jaw Chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Spindle Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13Spindle Liner Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Boring a Bushing to Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14Installing or Removing the Spindle Liner . . . . . . . . . . . . . . . . . . . . . . . 9-14
CHAPTER 10 - TAILSTOCK
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2Tailstock Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Fixed Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Adjustable Home Position (Retract). . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Rapid-to-Feed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Overtravel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Tailstock Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Cycle Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Overtravel Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Tailstock Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Initiating Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5Stopping Manual Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Programmed Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6Initiating Programmed Movement . . . . . . . . . . . . . . . . . . . . . . . . . 10-6Stopping Programmed Movement. . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Checking and Adjusting Tailstock Feedrate . . . . . . . . . . . . . . . . . . . . . . . 10-8Checking and Adjusting Tailstock Force . . . . . . . . . . . . . . . . . . . . . . . . . 10-9Removing and Installing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Removing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10Installing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
M-392D ix
CHAPTER 11 - INPUT/OUTPUT DEVICES
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1Input/Output Device Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Standard Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1PC-Based Operator Interface [Option] . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Input/Output Device Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4I/O Channel 0, 1, or 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4I/O Channel 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Standard Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5PC-Based Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Selecting the Input/Output Device . . . . . . . . . . . . . . . . . . . . . . . 11-5RS-232 Serial Port (NC Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Data Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6Tape Parity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6Stop Bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Checking and Modifying Communications Parameters . . . . . . . . . . . . . . . . 11-7RS-232 Port Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Baud Rate Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8Stop Bit Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9RS-232 Serial Port (NC Data). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Uploading Data through the RS-232 Port . . . . . . . . . . . . . . . . . . . . . 11-9Uploading Control Parameters into Control Memory. . . . . . . . . . . . . . 11-9Uploading Part Programs into Control Memory . . . . . . . . . . . . . . . . 11-10Uploading Tool Offsets into Control Memory . . . . . . . . . . . . . . . . . 11-11
Downloading Data through the RS-232 Port . . . . . . . . . . . . . . . . . . . 11-12Downloading Control Parameters from Control Memory. . . . . . . . . . . . 11-12Downloading Part Programs from Control Memory . . . . . . . . . . . . . . 11-13Downloading Tool Offsets from Control Memory . . . . . . . . . . . . . . . 11-14
Integrated Input/Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15Standard Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15PC-Based Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
CHAPTER 12 - OPERATOR MAINTENANCE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Machine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Draining the Air Filter Bowls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Adjusting the Machine Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2Standard Hydraulic Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Filling the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2Hydrostatic Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Filling the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4Tramp Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5Chip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
x M-392D
CHAPTER 13 - OPTIONS AND MISCELLANEOUS FEATURES
Machine Run Time Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1Accessing the Run Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1Resetting the Run Time Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . 13-1
Machine Cycle Time Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1Accessing the Cycle Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Clock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2Resetting the Clock Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3Accessing the Parts Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . 13-3Resetting the Parts Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Thread Cutting Cycle Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4High Pressure Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4Bar Feed Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4English / Metric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Establishing English / Metric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5Axis Thrust Limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6Monitoring Axis Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6Accessing the Axis Servo Tune Page. . . . . . . . . . . . . . . . . . . . . . . . . 13-7Adjusting Axis Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Part Catchers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9Main Spindle Part Catcher [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9Typical Part Unload Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9Adjusting the Part Catcher for Part Length . . . . . . . . . . . . . . . . . . . . 13-10Adjusting the Part Catcher Extend / Retract Speeds . . . . . . . . . . . . . . . 13-10Adjusting the Part Basket Extend / Retract Speeds . . . . . . . . . . . . . . . . 13-11
Conveyor-Style Sub-Spindle Part Catcher [Option] . . . . . . . . . . . . . . . . . . 13-12Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12Part Catcher M Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14Part Catcher Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Boring the Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15Changing the Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Thru- Sub-Spindle Part Catcher [Option] . . . . . . . . . . . . . . . . . . . . . . . 13-17Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17Part Catcher Component Identification . . . . . . . . . . . . . . . . . . . . . . 13-18Selecting Part Catcher Components . . . . . . . . . . . . . . . . . . . . . . . 13-18Changing Part Catcher Components . . . . . . . . . . . . . . . . . . . . . . . 13-22Changing Sub-Spindle Draw Tubes . . . . . . . . . . . . . . . . . . . . . . . . 13-25
Installing the Standard Draw Tube. . . . . . . . . . . . . . . . . . . . . . . 13-25Installing the Part Catcher Draw Tube . . . . . . . . . . . . . . . . . . . . . 13-27
M-392D xi
Part Probe [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29Set-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29Datuming the Part Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31
Datuming the Part Probe on the X Axis . . . . . . . . . . . . . . . . . . . . . . 13-31Datuming the Part Probe on the Z Axis . . . . . . . . . . . . . . . . . . . . . . 13-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33Cleaning Probe and OMM Unit Windows . . . . . . . . . . . . . . . . . . . . . . . 13-34Changing the Probe Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35
Sub-Spindle Part Present Detector [Option] . . . . . . . . . . . . . . . . . . . . . . . 13-36Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36Extending the Part Present Detector . . . . . . . . . . . . . . . . . . . . . . . . . 13-37Range of Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
CHAPTER 14 - VDI LIVE TOOLING [Option]
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Types of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Adjustable Dead Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2Live Tooling Collets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
VDI 30 Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3VDI 40 Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Live Tooling RPM Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3Live Tooling Attachment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Mounting the Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5Installing / Removing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Live Tooling Attachment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-12Live Tooling Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Cross-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13End-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
VDI 30 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13VDI 40 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Setting Tool Offsets for Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 14-14Setting Offsets for End-Working Tools . . . . . . . . . . . . . . . . . . . . . . 14-14Setting Offsets for Cross-Working Tools . . . . . . . . . . . . . . . . . . . . . 14-16
Tool Nose Radius Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17Live Tooling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17Live Tooling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
Lubricating the Live Tooling Attachment . . . . . . . . . . . . . . . . . . . . . . . 14-18Lubricating the Live Tooling Pinion Gears . . . . . . . . . . . . . . . . . . . . . . 14-19
Lubrication Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19VDI 30 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19VDI 40 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19Lubricating the Turret Index Shaft and Live Tooling Drive Shaft . . . . . . . . . . . 14-20
xii M-392D
CHAPTER 15 - ESA LIVE TOOLING [Option]
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Types of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Live Tooling Collets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Live Tooling Attachment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Mounting the Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2Installing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4Tool Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Live Tooling Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6Cross-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6End-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6Setting Tool Offsets for Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Setting Offsets for End-Working Tools . . . . . . . . . . . . . . . . . . . . . . 15-7Setting Offsets for Cross-Working Tools . . . . . . . . . . . . . . . . . . . . . 15-9
Tool Nose Radius Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10Live Tooling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10Live Tooling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
CHAPTER 16 - TOOL LIFE MANAGEMENT
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1Tool Life Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Number of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1Amount of Machining Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Tool Life Management Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2Bar Feed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Determining Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . 16-3Verifying Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . 16-3Setting Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . . 16-3
Determining the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5Verifying the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5Switching the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Resetting a Tool Group Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
M-392D xiii
CHAPTER 17 - SUB-SPINDLE AND COLLET CLOSER [Option]
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Cycle Start Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Controlling Sub-Spindle Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Automatic, Manual Data Input, or Single Mode . . . . . . . . . . . . . . . . . . . . 17-2E Data Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2Feedrate Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3Axis Direction Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Feedrate Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3Rapid Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3Moving the Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Handwheel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3Moving the Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4Removing Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4Installing Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-6
Collet or Step Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-6Jaw Chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
Sub-Spindle Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10Hydraulic Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10
Adjusting the Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 17-11Sub-Spindle Collet Closer Operation . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12Chucking Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Switching the Chucking Mode . . . . . . . . . . . . . . . . . . . . . . . . . 17-12Main and Sub-Spindle Machining Set-Up and Operation. . . . . . . . . . . . . . . . . 17-13
Sample Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-14Set Up and Machine Main Spindle Operation . . . . . . . . . . . . . . . . . . . 17-14Set Up and Machine Sub-Spindle Operation . . . . . . . . . . . . . . . . . . . 17-15
APPENDIX ONE
Turret Travel SpecificationsX and Z Axes
VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1VDI 40 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3Hardinge Turret Top Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
Y Axis [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-5Tailstock Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-6Sub-Spindle Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-6Work Envelope
Machine Equipped with Tailstock and VDI 30 Turret Top Plate. . . . . . . . . . . . A1-7Machine Equipped with Tailstock and VDI 40 Turret Top Plate. . . . . . . . . . . . A1-8Machine Equipped with Tailstock and ESA Turret Top Plate . . . . . . . . . . . . . A1-9Machine Equipped with Tailstock and Hardinge Turret Top Plate . . . . . . . . . . A1-10Machine Equipped with Sub-Spindle and VDI 30 Turret Top Plate . . . . . . . . . . A1-11Machine Equipped with Sub-Spindle and VDI 40 Turret Top Plate . . . . . . . . . . A1-12Machine Equipped with Sub-Spindle and ESA Turret Top Plate . . . . . . . . . . . A1-13Machine Equipped with Sub-Spindle and Hardinge Turret Top Plate. . . . . . . . . A1-14
xiv M-392D
Sample Tooling Layouts10 Station VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1510 Station VDI 30 Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . A1-1612 Station VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1712 Station VDI 30 Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . A1-1816 Station VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1916 Station VDI 30 Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . A1-2010 Station VDI 40 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2110 Station VDI 40 Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . A1-2212 Station ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2312 Station ESA Turret Top Plate with Live Tooling . . . . . . . . . . . . . . . . . . A1-2412 Station Hardinge Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . A1-25
Spindle Torque and Horsepower CurvesMain Spindle
QUEST® 6/42 LathesStandard Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-26
QUEST 8/51 LathesStandard Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27High Speed Spindle Drive, High Speed Range . . . . . . . . . . . . . . . . A1-28High Speed Spindle Drive, Low Speed Range. . . . . . . . . . . . . . . . . A1-29
QUEST 10/65 LathesStandard Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-30High Speed Spindle Drive, High Speed Range . . . . . . . . . . . . . . . . A1-31High Speed Spindle Drive, Low Speed Range. . . . . . . . . . . . . . . . . A1-32
Sub-Spindle [Option]Standard Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33High Speed Spindle Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-34
Live ToolingVDI 30 and ESA Top Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-35VDI 40 Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-36
Spindle Draw Tube ConfigurationsQUEST® 6/42 Lathes with Standard Spindle Drive . . . . . . . . . . . . . . . . . . A1-37QUEST 8/51 Lathes with Standard Spindle Drive . . . . . . . . . . . . . . . . . . A1-38QUEST 10/65 Lathes with Standard Spindle Drive . . . . . . . . . . . . . . . . . . A1-39
APPENDIX TWO
G Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1M Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-15
M-392D xv
- NOTES -
xvi M-392D
CHAPTER 1 - OPERATOR CONTROL PANELS
CONTROL DISPLAY PANEL
The control display panel is shown in Figure 1.1. The panel consists of the display screen with as-sociated soft keys.
- NOTE -
The optional PC-based operator interface is equipped with a touch screen display.The operator can select Windows functions by touching the display screen.The operator can select CNC soft key functions through the use the soft keys or di-rectly by touching the soft key functions displayed on the screen.
SOFT KEYS
The ten unlabeled soft keys have various functions, depending on which function key isactive. The function keys are located on the Manual Data Input panel. The soft key functionsare displayed at the bottom of the control display screen.
LEFT-HAND SOFT KEY
This key is used to return to the initial state after a function has been accessed by press-ing a soft key.
RIGHT-HAND SOFT KEY
This key is used to display further soft key functions which are not currently displayed.
M-392D 1-1
Figure 1.1 - Control Display Panel(18i-T Control Shown)
TI4154
MANUAL DATA INPUT KEYBOARD
The available Manual Data Input panels are shown in Figures 1.2 through 1.5. This panel consistsof keys relating to data input, data editing, and monitoring control functions.
Refer to page 1-7 for information on special key functions relating to the Windows operating systemon machines equipped with the optional PC-based operator interface.
ALTER
This key permits changes to an existing entry in an active program while in Edit mode.Refer to Edit mode in Chapter 3.
This key is also used as the Tab key in the Windows environment on the optionalPC-based operator interface.
CAN (Cancel)
This key is used to cancel or delete the last character or symbol which has been enteredinto the input buffer. It is also used, together with the appropriate function key, to clear theData displayed on the screen.
This key is also used as the Backspace key in the Windows environment on the optionalPC-based operator interface.
CURSOR CONTROL KEYS
The � and � cursor control keys will shift the cursor forward or backward through theprogram one Data word at a time.
The � and � cursor control keys will shift the cursor forward or backward through theprogram one Data block (program line) at a time.
CUSTOM
This key has no function on the standard operator interface.
This key is used as the Control key in the Windows environment on the optional Windowsbased operator interface.
DATA INPUT KEYS
- NOTE -
Most alphabetic keys on the Manual Data Input keyboard are used to input morethan one character. The input from an alphabetic key is switched through the use ofthe Shift key.
These keys are used to manually enter Data into the control. These keys input alphabetic,numeric, and other characters. In addition to these keys, the Alter, Insert, Delete, Input, EOB(End of Block), and Cancel keys are active. Data entered with the Data input keys is indi-cated on a line near the bottom of the display screen.
1-2 M-392D
DELETE
This key causes the selected Data to be deleted. Refer to Edit mode in Chapter 3 for in-formation on using the delete function.
EOB
This key is used to input an End of Block (;) character.
GRAPH
This key is used to graphically display the tool path while the program is being executed.Machine motion will occur unless Machine Lock mode is active.
Refer to the GE Fanuc operator’s manual for a description of the graphics feature.
INPUT
This key is used to set Data, which has been entered into the input buffer area, into theappropriate area in the control memory. Refer to Manual Data Input mode in Chapter 3.
INSERT
This key allows additional commands to be inserted in a program line while in Edit mode.Refer to Edit mode in Chapter 3.
HELP
This key allows the operator to access the machine on-line help system. Refer to page1-22 for information relating to the on-line help system.
This key is also used as the Escape key in the Windows environment on the optionalPC-based operator interface.
MESSAGE
This key allows the operator to display alarm messages and operator messages issuedby the machine control due to NC programming errors or machine hardware failures.
OFFSET SETTING
This key allows the setting and display of offset values. Refer to:
Reviewing Control Status, in Chapter 2
Chapter 7 - Work Shift
Chapter 8 - Tool Offsets
M-392D 1-3
1-4 M-392D
Figure 1.2 - Manual Data Input Panel(Non-CE Mark Machines with Standard Operator Interface)
TI3818
Figure 1.3 - Manual Data Input Panel(CE Mark Machines with Standard Operator Interface)
TI3874
M-392D 1-5
Figure 1.4 - Manual Data Input Panel(Non-CE Mark Machines with Optional PC-Based Operator Interface)
TI4730
BlankKey
Figure 1.5 - Manual Data Input Panel(CE Mark Machines with Optional PC-Based Operator Interface)
TI4731
PAGE UP KEYS
PAGE DOWN KEYS
The Page keys are used to display information which requires more than one displaypage. Pressing Page � or Page � causes the control the display the previous or next page,respectively.
POS (Position)
Pressing the Position key will display the position Data in one of three ways:
1. In the absolute mode of the work coordinate system by pressing the Absolute soft key.
2. In the relative coordinate system by pressing the Relative soft key.
3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to go, bypressing the All soft key.
Use the Page keys to switch between the various position display screens. Refer toChapter 2 for more information on the position display screens.
PROG (Program)
The Program function key allows the operator to perform the following:
In Edit mode - Edit and display program memory.In Manual Data Input mode - Input and display Manual Data Input Data.In Automatic mode - Display the active part program.
RESET
This key can be activated any time while a part program is being executed. When the Re-set key is pressed, axis and spindle motion are stopped. The M and G codes are reset tothe power-up default status. The Reset key is also used to clear an alarm state after a faulthas been corrected.
- NOTE -
To return to the start of a main part program, select Edit mode and press Reset.
SYSTEM
This key allows the setting and display of parameters and diagnostic Data. Refer to Chap-ter 2 for more information on the diagnostic and parameter screens.
1-6 M-392D
SPECIAL KEY FUNCTIONS FOR WINDOWS OPERATION
- NOTE -
The descriptions in this section relate only to machines equipped with the optionalPC-based operator interface.
The functions described in this section are discussed in terms of how they relate to the use of theCNC Manual Data Input keyboard in the Windows environment. Refer to your Microsoft Windowsmanual for additional information relating to the Windows operating system.
Refer to Figures 1.4 and 1.5 for key locations.
Alter Key This key is used as the Tab key
Blank Key This key is used as the Alternate key
Cancel Key This key is used as the Backspace key
Custom Key This key is used as the Control key
Help Key This key is used as the Escape key
Shift + 1 Inputs the left brace symbol: {
Shift + 2 Inputs the right brace symbol: }
Shift + R Inputs the caret symbol: ^
Shift + S Inputs the backslash symbol: \
Shift + T Inputs the tilde symbol: ~
Shift + U Inputs the underscore symbol: _
Shift + Graph Access a Windows pop-up menu (equivalent to right click on a mouse)
Custom + Help Toggles between the CNC display screen and the Windows Start Menu
When using the Custom/Help key combination to toggle from the WindowsStart Menu back to the Fanuc CNC screen, press the “CNC Screen DisplayFunction” icon at the bottom of the display to clear the Windows tool bar.
M-392D 1-7
OPERATOR CONTROL PANEL
- NOTE -
The functions described in this section are listed according to location on the opera-tor control panel, from left to right. Refer to Figure 1.6.
SPECIAL MODES
BLOCK SKIP
Press this push button to alternately activate and deactivate Block Skip mode. When thismode is active, the control will ignore any Data block preceded by a slash (/) code. The indi-cator light is illuminated when Block Skip is active.
DRY RUN
- NOTE -
This mode must be OFF for normal machine operation.
Press this push button to alternately activate and deactivate Dry Run mode. When thismode is active, programmed feedrates are ignored and cutting moves are performed at aJog feedrate of 50 inches per minute. The indicator light is illuminated when Dry Run is ac-tive. Refer to Chapter 3 for information on using Dry Run mode.
G00
This push button is a momentary switch. Pressing this push button releases the Edit Slowfeature. Refer to Chapter 3 for information on Edit Slow mode.
MACHINE LOCK
- NOTE -
This mode must be OFF for normal machine operation.
Press this push button to alternately activate and deactivate Machine Lock mode. Whenthis mode is active, all axis and spindle motion is inhibited. M, S, and T functions are alsoinhibited. The indicator light is illuminated when Machine Lock is active. Refer to Chapter 3for information on using Machine Lock.
1-8 M-392D
OPTION STOP
- CAUTION -
It is the responsibility of the part programmer to program the appropriate com-mand to restart the spindle and coolant when program execution is resumedafter an Option Stop.
Press this push button to alternately activate and deactivate Option Stop mode. This func-tion causes the control to stop execution of the part program AFTER executing an activeblock which contains an M01 code. The M01 code is ignored when Option Stop is not ac-tive. This function may be activated before or during execution of the block containing theM01 code. The indicator light is illuminated when Option Stop is active. When a block con-taining an M01 code is encountered and this function is active, the following occurs:
The block is executed.
All slide motion and spindle motion stops.
The coolant pump turns OFF and Feed Hold turns ON.
Option Stop can be activated in Dry Run mode. To resume program execution, press theCycle Start push button. The Feed Hold push button light will turn OFF.
REPEAT MODE
Press this push button to alternately activate and deactivate Repeat mode. This functioncauses the active part program to cycle continuously. The indicator light is illuminated whenRepeat is active.
M-392D 1-9
TURRET STATION
INDEX
98
43
5
76
10
14
1213
11
AUXMACHBOTH
AUTOMATION
GE/Fanuc
-
0
+
TRAVRAPID
Z/E
X/Y
X/Y
Z/E
CYCLESTARTCLOSE
CLOSEOPEN/
OPEN/HOLDFEED
120
150
% FEED RATE OVERRIDE
1XLOW
% RAPID OVERRIDE
10X25
100X50
100
60
0%
20
40
80100
140
SUBFREE
MAINFREE
MAIN SUB
INC
CCW CW
DECDRYRUN
BLOCKSKIP
OPTION
REPEATMODE
STOPMACHINE
LOCK
G00
COOLANTON/OFF CATCHER
PART
PROBETOOL
AUX
MACHINE MODES
RAPIDREF
RAPID REF
EDIT
JOG
MDI
AUTO
SINGLE
MANUAL AXIS MOVEMENT
E
C2
Y
Z
X
C1
1
2 1516
0
MACHINEPOWER
0 11
PROGRAMPROTECT
10
1+21 2
1
1 2
2
F %F %
Figure 1.6 - Operator Control Panel TI4666A
A
BC
MISCELLANEOUS FUNCTIONS
AUX (Auxiliary)
No Function.
COOLANT ON/OFF
This push button controls standard coolant operation. If coolant flow has been activatedby a programmed M08 (Coolant ON), M13 (Spindle Forward/Coolant ON), or M14 (SpindleReverse/Coolant ON), pressing this push button will stop the coolant flow. If coolant flow hasnot been activated by the program, pressing this push button will start coolant flow eventhough an M08, M13 or M14 has not been programmed. However, if the program is re-peated the push button will not be active. The indicator light is illuminated when this functionis active.
PART CATCHER
This push button allows the operator to alternately extend and retract the main spindlepart catcher when the machine is in Jog mode. The indicator light is illuminated when thepart catcher is extended toward the spindle.
Refer to page 13-9 for additional information on the main spindle part catcher.
TOOL PROBE
This push button allows the operator to alternately deploy and stow the optional toolprobe when the machine is in Jog mode.
Refer to page 8-14 for additional information on the tool probe.
AUTOMATION
Option not available.
1-10 M-392D
SPINDLE CONTROL
MAIN SPINDLE / SUB-SPINDLE
When Jog mode is active, this switch allows the operator to select the main spindle orsub-spindle as the spindle to be controlled by the push buttons in the Spindle area of themachine control panel.
MAIN SPINDLE FREE
Press this push button to alternately activate and deactivate Main Spindle Free. WhenMain Spindle Free is activated, the spindle brake is released and the operator may rotatethe main spindle by hand when Cycle Start is NOT active. The indicator light is illuminatedwhen Main Spindle Free is active.
SPINDLE CCW / SPINDLE CW
This switch allows the operator to select the direction for non-programmed spindle mo-tion (as viewed from the main spindle end of the machine) when the machine is in Jogmode. The spindle speed is controlled with the Spindle Increase Override and SpindleDecrease Override push buttons. The push button indicator light is illuminated when one ofthese functions is active.
SPINDLE INCREASE OVERRIDE
SPINDLE DECREASE OVERRIDE
These push buttons have two applications:
1. Controlling spindle speed for non-programmed clockwise or counterclockwise spindle mo-tion:
a) Set the machine mode selector switch to Jog mode.
b) Use the Main Spindle / Sub-Spindle switch to select the appropriate spindle.
c) Use the Spindle CCW / Spindle CW switch to select the desired direction of rotation.
d) Initiate spindle rotation by pressing the Spindle Increase Override push button and releaseto begin spindle motion. The first time this switch is pressed and released, the spindlespeed will begin rotating at approximately 25 rpm.
Use the Spindle Increase Override push button to increase spindle speed. The spindlespeed will increase by approximately 25 rpm each time this key is pressed.
Press the Spindle Decrease Override push button to slow the spindle.
e) To stop spindle motion, press the Reset key or press and hold the Spindle DecreaseOverride push button until spindle motion ceases.
M-392D 1-11
1 2
1
2. Override programmed spindle speed while spindle is active in Auto mode:
Press the Spindle Decrease Override push button and release to decrease the spindlespeed in ten percent increments to a minimum of 50%. This push button is illuminatedwhen actual spindle speed is lower than the programmed spindle speed.
Press the Spindle Increase Override push button and release to increase the spindlespeed in ten percent increments to a maximum of 120%. This push button is illuminatedwhen actual spindle speed is higher than the programmed spindle speed.
Press the Spindle Increase Override and Spindle Decrease Override push buttons simul-taneously to cancel the override function. The spindle speed will return to the pro-grammed rate.
SUB-SPINDLE FREE
Press this push button to alternately activate and deactivate Secondary Spindle Free.When Secondary Spindle Free is activated, the spindle brake is released and the operatormay rotate the secondary spindle by hand when Cycle Start is NOT active. The indicatorlight is illuminated when Secondary Spindle Free is active.
1-12 M-392D
2
TURRET CONTROL
TURRET STATION
This rotary switch enables the operator to select the turret station to be indexed to the ac-tive position when the Turret Index push button is pressed.
INDEX
- CAUTION -
The operator must be sure no interference exists within the machine work en-velope before manually indexing the turret.
- NOTE -
The control must be in Jog mode to allow the Index push button to function.
Press the Index push button to command the turret to index to the station selected withthe Turret Station rotary switch.
MACHINE POWER
Switch “A”, Figure 1.6, turns the CNC control OFF when set to “0" and turns the CNCcontrol ON when set to ”1".
PROGRAM PROTECT
This switch is a two position, key operated switch. For normal operation, this switchshould be turned to the ON position. When this switch is turned to ON, parameters cannotbe edited and part programs cannot be edited or deleted. When this switch is turned toOFF, parameters can be edited and part programs can be edited or deleted. The key shouldbe removed except when part program or parameter editing is required. The key cannot beremoved from the switch when Program Protect is turned OFF.
M-392D 1-13
MANUAL AXIS MOVEMENT
- NOTE -
Refer to Figures 1.7 and 1.8 for illustrations showing axis definitions.
MANUAL AXIS MOVEMENT SELECTOR SWITCH
C1 Selects the C1 axis for manual axis control. The C1 axis is radial motion of the mainspindle.
Z Selects the Z axis for manual axis control. The Z axis is linear motion of the turret paral-lel with the spindle centerline.
X Selects the X axis for manual axis control. The X axis is linear motion of the turret par-allel with the spindle face and parallel with the machine bed.
Y Selects the Y1 axis for manual axis control. The Y1 axis is linear motion of the turretparallel with the spindle face and perpendicular with the machine bed.
E Selects the E axis for manual axis control. The E axis is linear motion of the tailstock orsub-spindle parallel with the spindle centerline.
C2 Selects the C2 axis for manual axis control. The C2 axis is radial motion of the sub-spin-dle.
1-14 M-392D
Figure 1.7 - E, X, and Z Axis Definitions(Shown with Optional Sub-Spindle)
TI4642A
+Z-Z
+X
-X
-E +E
Main Spindle Sub-Spindle
Turret
Z/E
The Z/E push buttons are momentary type switches that allow the operator to jog the se-lected axis in the indicated direction. The axis to be jogged is selected through the use ofthe Manual Axis Movement selector switch. Refer to Figure 1.7 for axis definitions. Active inJog mode.
X/Y
The X/Y push buttons are momentary type switches that allow the operator to jog the se-lected axis in the indicated direction. The axis to be jogged is selected through the use ofthe Manual Axis Movement selector switch. Refer to Figures 1.7 and 1.8 for axis definitions.Active in Jog mode.
RAPID TRAV (Rapid Traverse)
This push button is a momentary type switch. Pressing this push button while simulta-neously pressing one of the Jog directional push buttons causes the selected axis to moveat approximately 150 in/min [3800 mm/min]. Refer to Jog Mode, in Chapter 3.
MANUAL PULSE GENERATOR
Manual pulse generator “B”, Figure 1.6, allows the operator to jog the selected axis byspecific increments. The axis to be jogged is selected with the Manual Axis Movementswitch and the increment is selected with the Rapid Override switch.
M-392D 1-15
Figure 1.8 - X and Y Axis Definitions(Viewed from the Tailstock/Sub-Spindle End of the Machine)
TI4656
+Y
-Y
+X
-X
Spindle CenterlineM
achine
Bed
MACHINE MODES
AUTO
Automatic mode allows execution of the active part program and modification of part pro-grams using the Back Edit function. The indicator light is illuminated when automatic modeis active. Refer to Chapter 3 for an explanation of Automatic mode.
SINGLE (Single Block)
Single mode provides the operator with the ability to execute one block of Data each timethe Cycle Start push button is pressed. Canned cycles are executed one pass at a time. Theindicator light is illuminated when Single mode is active. Refer to the programmer’s manual(M-391) for descriptions of the Canned Cycles.
MDI (Manual Data Input)
Manual Data Input mode allows manual input of a temporary program block. The indicatorlight is illuminated when Manual Data Input mode is active. Refer to Chapter 3 for an expla-nation of Manual Data Input mode.
EDIT
Edit mode allows the operator or programmer to edit a stored program when the ProgramProtect key switch is in the OFF position. To deactivate Edit mode, select another operatingmode. The indicator light is illuminated when Edit mode is active. Refer to Chapter 3 for anexplanation of Edit mode.
RAPID REFERENCE
Rapid Reference mode allows the operator to move the machine axes to their respectivereference positions through the use of the Rapid Reference push button.
The X axis must be moved to the reference position before the Y1 or Z axis can be com-manded to the reference position through the use of the Rapid Reference push button.
The Rapid Reference push button allows the machine operator to move the selected axisto the reference position. The axis to be moved is selected through the use of the ManualAxis Movement selector switch. Active in Rapid Reference mode.
The X axis must be moved to the reference position before the Y1 or Z axis can bemoved to the reference position.
JOG
Jog mode allows non-programmed movement of the axes. The indicator light is illumi-nated when Jog mode is active. Refer to Chapter 3 for an explanation of Jog mode.
1-16 M-392D
% RAPID OVERRIDE
The Rapid Override switch has a dual function. Depending on which mode has been se-lected, the functions are as follows:
In Jog mode, the operator can select the jog increment to be active when moving anaxis with the manual pulse generator. The movement distance per division on the manualpulse generator is:
LINEAR AXES (E, X, Y1, Z)
X1 = .0001 inches [.001 millimeters]X10 = .001 inches [.01 millimeters]X100 = .01 inches [.1 millimeters]
ROTARY AXES (C1, C2)
X1 = .001 degreeX10 = .01 degreeX100 = .1 degree
In all other modes, the operator can modify the machine Rapid Traverse rate in stepsfrom Low to 100%. It is active in Positioning Mode (G00). The Rapid Override switch con-trols the E, X, Y, and Z axes.
% FEEDRATE OVERRIDE
The Feedrate Override switch has a dual function. Depending on which mode has beenselected, the functions are as follows:
In Jog mode, the jog feedrate can be modified in predefined steps from 0 - 50 in/min[1270 mm/min].
In all other modes, the operator can modify programmed feedrates from 0% - 150%. Asetting of “0" will stop G01, G02, & G03 motion.
M-392D 1-17
F %
%F
SUB OPEN / CLOSE
Pressing this push button while Cycle Start is NOT active will cause the work-holding de-vice in the secondary spindle to alternately open and close. The push button will be illumi-nated when the work-holding device is closed and will blink when the work-holding device isopen.
MAIN OPEN / CLOSE
Pressing this push button while Cycle Start is NOT active will cause the work-holding de-vice in the main spindle to alternately open and close. The push button will be illuminatedwhen the work-holding device is closed and will blink when the work-holding device is open.
FEED HOLD
This push button is a latching type switch that allows the operator to stop all programmedslide motion. However, the active spindle speed is not affected. Feed Hold can be activatedwhile in Automatic, Single Block, or Dry Run modes. Cycle Start turns OFF when Feed Holdis activated. To resume normal operation after a feed hold, press Cycle Start. This push but-ton is illuminated when Feed Hold is active.
CYCLE START
This push button is a latching type switch that initiates program execution when the con-trol is in Automatic mode or Single mode. An additional function of this switch is to executeManual Data Input commands. This push button is illuminated when Cycle Start is active.
EMERGENCY STOP
- CAUTION -
DO NOT use the Emergency Stop push button to stop spindle rotation unlessan emergency actually exists.
- NOTE -
The operator must wait approximately ten seconds from the time the EmergencyStop push button is pressed before attempting to clear the Emergency Stop.
Emergency Stop push button “C”, Figure 1.6, is a latching type switch. When pressed,programmed slide motion and spindle rotation are stopped. The message “Emergency Stop”is displayed on the control screen. To return to normal operation:
1. Correct the problem that prompted the Emergency Stop condition.
2. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.
1-18 M-392DRevised: January 18, 2008
2
1
CONTROL INTERFACE PORTS
STANDARD OPERATOR INTERFACE
The standard operator interface, shown in Figure 1.9, is equipped with 2 Data input/output ports:
• ATA Flash Card Port
• RS-232 Serial Port (25 pin)
Refer to Chapter 11 for information on using these input/output ports.
M-392D 1-19
Figure 1.9 - Data Input/Output Ports(Standard Operator Interface)
RS-232Serial Port
ATA FlashCard Port
TP4090
PC-BASED OPERATOR INTERFACE [Option]
- CAUTION -
It is recommended that the controlbe powered down before connectinga keyboard or mouse to the CNCcontrol.
- NOTE -
The universal serial bus (USB) portsare not active on machines using theMicrosoft Windows NT operating sys-tem.
The PC-based operator interface is equipped withthe following:
• ATA Flash Card Port
• RS-232 Serial Port (15 pin) for PC Data
• RS-232 Serial Port (25 pin) for NC Data
• Universal Serial Bus (USB) Ports
• Keyboard Port
• Mouse Port
Refer to Figure 1.10 for the location of the ATAflash card port and the RS-232 port used for NC Datainput/output.
Open the Data port cover, Figure 1.10, to gain ac-cess to the PC Data RS-232, universal serial, key-board, and mouse ports. Refer to Figure 1.11 for portidentification.
Refer to Chapter 11 for information on using theATA flash card and RS-232 serial ports.
1-20 M-392D
Figure 1.10 - Data Input/Output Ports(Overall View)
TP4623A
Data PortCover
RS-232 Portfor NC Data
ATA FlashCard Port
Figure 1.11 - PC and DataInput/Output Ports
TP4624A
USB Port 1
USB Port 2
Keyboard
Mouse
RS-232 Portfor PC Data
STACK LIGHT [Option]
The optional stack light, shown in Figure 1.12, is located at the left end of the lathe. The stack light isused to visually indicate the current status of the lathe.
The colors and definitions are listed below:
RED
Emergency Stop or alarm condition. Automatic cycle is stopped.
AMBER
The lathe is in Automatic mode, but automatic cycle is not active.
GREEN
Automatic cycle active. Normal operation.
M-392D 1-21
Figure 1.12 - Optional Stack Light
TP4955
ON-LINE HELP SYSTEM
GENERAL DESCRIPTION
The on-line help system provides information and instructions relating to P/S alarms, methods ofoperation, and parameter tables.
P/S Alarms
- NOTE -
Only the more difficult to understand P/S alarms are supported by the on-line helpsystem.
Information and remedies concerning specific P/S alarms is supplied.
Methods of Operation
Information concerning CNC machining operations.
Parameter Table
Displays ranges of parameter numbers based on parameter functions.
ACCESSING THE ON-LINE HELP SYSTEM
Press the HELP key to access the on-line help system. The following menu will be displayed:
1. Alarm Detail
2. Operation Method
3. Parameter Table
- NOTE -
When viewing “Operation Method” or “Parameter Table” screens, the help systemwill display two numbers in the upper right-hand corner of the screen; for example,“¼". The upper number indicates the current page number and the lower number in-dicates the total number of pages for that particular topic.
Alarm Detail
1. Press the “1 Alm” soft key.
2. Key in the alarm number and press the Select soft key. The alarm number and a detailed ex-planation will be displayed.
3. Repeat step 2 as needed.
4. Exit the on-line help system. Refer to “Exiting the On-Line Help System”.
1-22 M-392D
Operation Method
1. Press the “2 Opr” soft key.
2. Key in the topic number and press the Select soft key. The selected topic and a detailed ex-planation will be displayed.
3. Repeat step 2 as needed.
4. Exit the on-line help system. Refer to “Exiting the On-Line Help System”.
Parameter Table
1. Press the “3 Para” soft key. Page 1 of 4 will be displayed.
2. Use the page keys to view the various pages, as needed.
3. Exit the on-line help system. Refer to “Exiting the On-Line Help System”.
EXITING THE ON-LINE HELP SYSTEM
Press the Help key again or press any of the following function keys to exit the on-line help system:
- Message
- Offset / Setting
- Position
- Program
- System
M-392D 1-23
- NOTES -
1-24 M-392D
CHAPTER 2 - POWER-UP AND CONTROL STATUS
- CAUTION -
The recommended operating temperature range is 50° to 95° F [7° to 35° C].
POWER-UP PROCEDURE
- NOTE -
It is important that the power-up procedure is followed as described to ensure safe,accurate, and repeatable machine operation.
1. Turn main disconnect switch “A”, Figure 2.1, ON.
2. Turn the main air valve on pressure regulator “B”,Figure 2.2, ON.
- NOTE -
Refer to Chapter 12 for information ondraining the air filter bowls and refillingthe coolant tank.
3. Drain air filter bowls “C” and “D”.
4. Check the coolant level. If necessary, add coolant.
- CAUTION -
When turning the Control ON/OFFswitch to ON, DO NOT press anyother push buttons or keys until theposition or alarm screen is dis-played. Some push buttons and keysare used for control maintenance orspecial operation commands.
5. Turn the Control ON/OFF switch to ON and waituntil the CNC display screen is ON.
6. Pull the Emergency Stop push button out to thefirst detent, wait two seconds; then, pull the pushbutton out to the end of travel and release.
7. Verify that the coolant guard door is closed.
8. Set the Machine Modes selector switch to Jog.
9. Set the Axis Selector switch to “E”.
10. Press the right-hand Z/E push button to move thetailstock or optional sub-spindle to the referenceposition.
M-392D 2-1Revised: January 18, 2008
Figure 2.1 - Power Case Door
A
TP4109A
Figure 2.2 - Air Control AssemblyTP4101
B
C D
11. Open and close the coolant guard door to perform the guard door switch verification and clearthe verification alarm.
12. If the machine is equipped with a high-speed spindle and has been powered down for morethan 4 hours, proceed to Machine Warm-Up Program.
MACHINE WARM-UP PROGRAM
- CAUTION -
Factory-installed machine warm-up program O9000 will run the main spindleand sub-spindle (if equipped) for 3 minutes intervals at the following speeds:
QUEST® 8/51 Lathes: 2000, 4000, 6000, and 8000 rpm.QUEST 10/65 Lathes: 2000, 4000, and 6000 rpm.
If the tooling installed in the main spindle is NOT capable of these spindlespeeds, it will be necessary to copy and modify machine warm-up programO9000 to reduce the spindle speed to the maximum rating of the spindle tool-ing.
If the machine is NOT equipped with the optional Extended Part ProgramEditing, refer to page 3-10 for information on entering a program from the key-board.
If the machine is equipped with the optional Extended Part Program Editing,refer to page 3-15 for information on copying part programs.
Refer to page 3-2 for information on editing a program.
- NOTE -
The factory-installed machine warm-up programs begin on page 2-3.
The machine warm-up program is only used on a machine that is equipped with ahigh-speed spindle and has been powered down for more than 4 hours.
1. Set the Machine Modes selector switch to Automatic mode.
- NOTE -
The factory-installed machine warm-up program is O9000.
2. Select the machine warm-up program:
A) Key in:
“O9000” (Factory-installed machine warm-up program)
- or -
The number for the modified machine warm-up program (Refer to caution above)
B) Press the Cursor ê key.
3. Press the Cycle Start push button to execute the machine warm-up program.
2-2 M-392D
MACHINE WARM-UP PROGRAM STRUCTURE
- NOTE -
Refer to the appropriate warm-up program, based on the machine model and if themachine is equipped with the optional sub-spindle.
QUEST® 8/51 LATHE
O9000 (WARM UP Q51) ;
G97 M3 S2000 P1 ;
G4 X180. ;
S4000 ;
G4 X180. ;
S6000 ;
G4 X180. ;
S8000 ;
G4 X180. ;
M30 ;
QUEST 8/51 LATHE WITH SUB-SPINDLE
O9000 (WARM UP Q51 WITH SUB) ;
G97 M3 S2000 P1 ;
M33 S2000 P2 ;
G4 X180. ;
S4000 P1 ;
S4000 P2 ;
G4 X180. ;
S6000 P1 ;
S6000 P2 ;
G4 X180. ;
S8000 P1 ;
S8000 P2 ;
G4 X180. ;
M30 ;
M-392D 2-3
QUEST® 10/65 LATHE
O9000 (WARM UP Q65) ;
G97 M3 S2000 P1 ;
G4 X180. ;
S4000 ;
G4 X180. ;
S6000 ;
G4 X180. ;
M30 ;
QUEST 10/65 LATHE WITH SUB-SPINDLE
O9000 (WARM UP Q65 WITH SUB) ;
G97 M3 S2000 P1 ;
M33 S2000 P2 ;
G4 X180. ;
S4000 P1 ;
S4000 P2 ;
G4 X180. ;
S6000 P1 ;
S6000 P2 ;
G4 X180. ;
M30 ;
2-4 M-392D
POWER-DOWN PROCEDURE
STANDARD OPERATOR INTERFACE
1. Be sure “Cycle Start” is not active. The Cycle Start push button light will be OFF.
2. Be sure the program has been completed and that the spindle and slides are stationary.
3. Press the Emergency Stop push button.
4. Turn the Control ON/OFF switch to OFF.
5. Turn the main air valve on pressure regulator “B”, Figure 2.2, OFF
6. Turn main disconnect “A”, Figure 2.1, OFF.
PC-BASED OPERATOR INTERFACE [Option]
1. Be sure “Cycle Start” is not active. The Cycle Start push button light will be OFF.
2. Be sure the program has been completed and that the spindle and slides are stationary.
3. Press and hold the Custom key; then, press the Help key to display the Windows Start menu.
4. Release the Custom key.
5. On the touch screen, press “Shut Down” to display the shut-down menu.
6. Select “Shut Down the Computer”.
7. Press “Yes” and wait for the Windows shut-down to be completed. The following message willbe displayed:
“It is now safe to turn off your computer”
8. Press the Emergency Stop push button.
9. Turn the Control ON/OFF switch to OFF.
10. Turn the main air valve on pressure regulator “B”, Figure 2.2, OFF
11. Turn main disconnect “A”, Figure 2.1, OFF.
M-392D 2-5
REVIEWING CONTROL STATUS
The following descriptions refer to the control status displays. Refer to Chapter 1 for additional in-formation on the manual Data input keyboard:
POSITION KEY
There are three (3) pages of position display Data. After the Position key is pressed, the po-sition display page that was last active will appear on the control display screen. To access theother position display pages, press the appropriate soft key. The three position display pagesare as follows:
1. ALL (Overall Position Display): This page shows the active program number and block numberare displayed in the upper right-hand corner of the control display screen if the control is inAutomatic mode.
A) Relative: The axis position on the Relative Coordinate System. Position is displayed as Uand W coordinates.
B) Absolute: Axis position on the Work Coordinate System. After power-up, the origin of theWork Coordinate System is the intersection of the spindle face and the spindle centerline.Position is displayed as X and Z coordinates. This display can be modified by any one of thefollowing:
Active set of tool offsetsPosition Reset operationWork Shift offset
C) Machine: Displays the turret reference position in relation to the origin of the WorkCoordinate System, which is the intersection of the spindle face and the spindle centerline.
D) Distance to Go: This is the distance remaining between current axis position and theprogrammed axis position. This register is displayed only while the control is in Automatic orManual Data Input mode.
2. Absolute Position Display. Refer to part “b” under “ALL (Overall Position Display)”.
3. Relative Position Display. Refer to part “a” under “ALL (Overall Position Display)”.
PROGRAM KEY
Press the Program soft key to display the active program number, and active block se-quence number and eleven blocks of the active program on the control display screen. To dis-play other pages of the program, select Edit mode and use the page keys to read through theprogram.
During execution of the active part program, the cursor will be positioned under the se-quence number of the active block.
If necessary, press the Reset key to return to the start of the program.
2-6 M-392D
OFFSET SETTING KEY
When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed. From thefirst Offset Setting screen, press the soft key expansion key once to display the Macro soft key. Fromthe first Offset Setting screen, press the soft key expansion key twice to display the Work Shift softkey.
OFFSET SOFT KEY
Press the Offset soft key to access the geometry and wear soft keys.
One of the two chapters will be displayed on the control display screen. The displayed pagewill be the page which was active when the Offset display was last viewed. To display the otherchapter, press the corresponding soft key. Use the Page keys to view other pages within achapter.
The tool geometry and wear offset chapters display the following information:
X and Z Tool Offsets (32 pair)Tool nose radius valuesTool nose orientation numbers
SETTING SOFT KEY
Press the Setting soft key to access the system variables pages, which allows the operatoror programmer to assign the system variables listed below. To modify these variables, use thepage and cursor keys to move the cursor to the variable which is to be modified, enter the de-sired value, and press the Input key.
Parameter Write = _(0:Disable 1: Enable)TV Check = _(0:OFF 1:ON)Punch Code = _(0:EIA 1:ISO)Input Unit = _(0:MM 1:Inch)I/O Channel = _(0-4:Channel No.)Sequence No. = _(0:OFF 1:ON)Tape Format = _(0:No CNV 1:ON)Sequence Stop = _(Program No.)Sequence Stop = _(Sequence No.)
Parameter Write
This parameter allows the control parameters to be edited. When set to “0", parameterediting is disabled. When set to ”1", parameter editing is enabled. Refer to Chapter 3 forinformation on editing machine parameters.
TV Check
This parameter allows the activation or deactivation of parity checking. When set to “1",parity is checked from the beginning of each block to the beginning of the next block.When set to ”0", vertical parity checking is disabled.
M-392D 2-7
Punch Code
This parameter allows the selection of EIA or ISO Data input format through theRS-232 serial port. When set to “0", the Data input format is set to EIA. When set to ”1",the Data input format is set to ISO.
Input Unit
This parameter allows the selection of metric or inch operating mode. When set to “0",the operating mode is Metric. When set to ”1", the operating mode is set to Inch.
I/O Channel
This parameter allows the selection of the logical I/O to be used by the control. Thevalid selections for the I/O port assignments are 0, 1, 2, or 4.
I/O port assignments 0, 1, and 2 are used to select the RS-232 serial port andspecify the port configuration.
I/O port assignment 4 is used to select the ATA Flash Card port on the standardoperator interface.
I/O port assignment 4 is used to select the following group of input/output devicesprovided with the optional PC-based operator interface.
ATA Flash Card PortRS-232 Serial Port3½” Disk DriveInternal Hard DiskCD-ROM Drive
Refer to Chapter 11 for additional information on Data input/output.
Sequence No.
This parameter allows the selection of “automatic sequence number insertion”. Whenactive, sequence numbers will be automatically inserted into a program which is enteredinto memory from the manual Data input keyboard. When set to “0", automatic sequencenumber insertion is inactive. When set to ”1", automatic sequence number insertion is ac-tive.
Tape Format
Not Active
Sequence Stop (2 entries)
These two entries are used together to provide the machine operator with the capabil-ity of stopping automatic part program execution after the program block specified hasbeen completed.
The first entry (Program No.) identifies the program to be monitored.
The second entry (Sequence No.) identifies the sequence number (N word) of the lastblock to be executed by the CNC control during normal automatic operation. Once thisblock is executed, the CNC control will stop program execution.
Press the Cycle Start push button to resume program execution.
2-8 M-392D
MACROS SOFT KEY
Press the Macros soft key to display the macro variable registers.
WORK SHIFT SOFT KEY
Press the Work Shift soft key to display the work shift offset registers.
SYSTEM KEY
Press the System key to access the following information:
• Machine parameters and diagnostics
• PMC parameters, ladder, and diagnostics
• Control system configuration
One of four chapters will be displayed on the control display screen. The displayed page will be thepage which was active when the key was last deactivated. If necessary, press the soft key to displaythe desired chapter. Use the page keys to view other pages within a chapter.
PARAMETER SOFT KEY
Press the Parameter soft key to display machine parameters. These parameters establishmany of the characteristics, specifications, and functions of the machine tool. The page thatwas active when the parameter chapter was last exited will be displayed. To view other pageswithin the chapter, press the Page key to move to the desired page. Refer to Chapter 3 for in-formation on editing machine parameters.
DIAGNOSTIC SOFT KEY
Press the Diagnostic soft key to display the machine diagnostics chapter. The page that wasactive when the diagnostics chapter was last exited will be displayed. Use the Page keys toview other pages within the chapter.
PMC SOFT KEY
Press the PMC soft key to display the PMC information screen. The purpose of this screen isto view the PMC ladder, parameters, and diagnostics.
SYSTEM SOFT KEY
Press the System soft key to display the control system information screen.
M-392D 2-9
MESSAGE KEY
If “ALM” is displayed at the bottom right-hand corner of the control display screen during machineoperation, press the Message key. After the Message key is pressed, one of the three chapters will bedisplayed. To display one of the other chapters, press the appropriate soft key.
ALARM SOFT KEY
Alarm Message chapter. This chapter displays alarms that create a feed hold condition. Onealarm will be displayed on the control display screen at a time. The display is formatted to indi-cate which tool station has generated the alarm. Descriptions of each alarm are given in thealarm list in Appendix 2.
MESSAGE SOFT KEY
Operator Message chapter. Operator messages do not initiate a feed hold condition. Theycall the operator’s attention to a specific machine condition.
HISTORY SOFT KEY
The control is capable of storing the last 25 alarms generated by the machine control. Thereare a maximum of five pages, with up to five alarms per page. Use the Page keys to displaynext or previous page.
- NOTE -
Alarm and Operator messages caused by an error generated in Background Editmode will have no affect on a part program that is executing in the foreground.
2-10 M-392D
- NOTES -
M-392D 2-11
- NOTES -
2-12 M-392D
CHAPTER 3 - OPERATIONAL MODES AND EDITING
AUTOMATIC MODE
- CAUTION -
Before executing any part program in Automatic mode, it is recommended thatthe program be cycled through one time in Single mode. Refer to the instruc-tions for “Running a Part Program for the First Time”, page 3-11.
Automatic mode allows selection and execution of the active part program. When Automatic modeis active and the Program key is pressed, the following soft keys are displayed on the control displayscreen:
ProgramCheckCurrentNextOperator
Automatic mode is activated by the mode selector switch.
SINGLE MODE
Single mode allows the operator to execute one block of Data each time the Cycle Start push buttonis pressed. Canned cycles are executed one pass at a time. Single mode is activated by the mode se-lector switch.
Refer to the programmer’s manual (M-391) for descriptions of the Canned Cycles.
EDIT MODE
Edit mode allows creation of new part programs or modification of existing part programs held inmemory. There are two ways to search through the program: Word Scan and Word Search.
WORD SCAN
The Word Scan function permits the operator to search through the program one word or one line ata time.
- NOTE -
The cursor is displayed below the address character of the selected word.
1. Use the cursor� and� keys to move the cursor word by word on the screen.
2. Use the cursor � and � keys to move the cursor line by line on the screen.
3. Continue pressing the cursor keys to make a continuous search.
4. Press the Page� or Page� key to display the preceding or following pages and search for thefirst word of that page.
M-392D 3-1
WORD SEARCH
Word Search permits a specified word to be searched for from the current cursor position using thefollowing procedure:
1. Key in the Data word to be searched for.
2. Press the cursor � key to search forward or cursor � to search backward. If the Data wordentered in step 1 is located, the cursor will be displayed below the first character in the Dataword.
EDITING A PROGRAM
- NOTE -
When Edit mode is active and the Program Protect key is turned OFF, Edit Slowmode is automatically activated. Refer to page 3-4 for information on Edit Slowmode.
1. Set the mode selector switch to Edit mode.
- NOTE -
The Program Protect key MUST be turned to OFF to allow creating, editing, or delet-ing of part programs.
2. Turn the Program Protect key to OFF.
3. Press the Reset key.
4. Activate the program as follows:
a) Press the Program key.
b) Key in the letter “O” followed by the number for the desired program.
Example: O1111
c) Press the cursor� key.
5. Search for the word to be modified using the Word Scan or Word Search function.
6. Alter, insert, or delete the word/block/program as described in the sections that follow.
- CAUTION -
If the Reset key is not pressed before selecting Automatic mode and the partprogram is executed, the program will begin executing at the point in the pro-gram where the cursor was located when Edit mode was exited.
7. Press the Reset key to “rewind” the part program back to the beginning.
8. Turn the Program Protect key to ON.
3-2 M-392D
Altering a Word
- NOTE -
The cursor MUST be positioned under the word to be altered.
1. Use the Word Scan or Word Search function to locate the Data word to be changed.
2. Key in the letter address and the new value.
3. Press the Alter key.
Inserting a Word
- NOTE -
The cursor MUST be positioned under the word immediately preceding the locationof the new Data word.
1. Use the Word Scan or Word Search function to find the Data word or End of Block immedi-ately preceding the point in the program where the new Data word will be inserted.
2. Key in the Data word to be inserted.
3. Press the Insert key.
Deleting a Word
- CAUTION -
The cursor MUST be positioned under the word which is to be deleted.
1. Use the Word Scan or Word Search function to find the Data word which is to be deleted.
2. Press the Delete key.
Deleting Up to an End of Block
1. Position the cursor at the point where the deletion is to begin.
2. Press the EOB (End of Block) key; then, press the Delete key.
- NOTE -
The Data between the cursor and the next End of Block character will be deleted.The cursor will move to the address character of the next Data word in the program.
M-392D 3-3
Deleting Data Blocks
- NOTE -
In the procedure which follows, all Data from the cursor to, and including, the blockspecified by the sequence number will be deleted. The cursor will move to the nextsequence number in the program.
1. Position the cursor at the point where the deletion is to begin.
2. Key in the sequence number (N word) where the deletion is to end.
3. Press the Delete key.
Deleting a Program
1. Press the Program key.
2. Key in the letter “O” and the number of the program to be deleted.
Example: O1111
3. Press the Delete key. The selected program will be deleted.
EDIT SLOW MODE
Edit Slow mode disables the Rapid Override switch and forces G00 positioning moves to be per-formed at 39 in/min [990 mm/min]. This will occur whenever Edit mode is selected and the ProgramProtect key is in the OFF position.
This mode will remain active until the G00 push button is pressed or an M30 (End of Program) isread by the machine control
JOG MODE
- NOTE -
Refer to Spindle Control, beginning on page 1-11, for information on non-pro-grammed spindle motion.
The Y1 axis controls the optional Y axis on the turret.
The E axis controls the tailstock or optional sub-spindle.
Jog mode permits non-programmed movement of the axes. Jog mode is activated by setting themode selector switch to Jog. While in Jog mode, use the axis direction push buttons or the manualpulse generator to obtain the desired X, Y, Z, or E axis movement.
CONTINUOUS JOG
The Feedrate Override switch has a direct affect on the X, Y, Z, and E axis jog speeds. The jogfeedrate for the X, Y, Z, and E axes is approximately 25 in/min [635 mm/min] when the feedrate over-ride switch is set to 100% and approximately 37.5in/min [952 mm/min] when the corresponding switchis set to 150%. The Traverse push button will increase normal jog speeds. When the Traverse pushbutton is pressed along with one of the axis push buttons, the feedrate override switch is ignored andthe selected axis moves at approximately 236 in/min [6000mm/min]. Refer also to Incremental Jog.
3-4 M-392D
INCREMENTAL JOG
The manual pulse generator permits the cross slide or carriage to be moved incrementally when-ever Jog mode is active. The axis to be moved is selected by using the selector switch in the ManualAxis Movement section of the operator control panel. The movement increment is selected with theRapid Override switch. The selected axis will move incrementally when the handwheel is rotated. Thedirection and distance is determined by the direction and amount of rotation of the handwheel.
- NOTE -
When moving the X axis with the machine in diameter mode, physical axis motionwill be one half the selected increment.
EXECUTING AN INCREMENTAL JOG
1. Set the mode selector switch to Jog mode.
- NOTE -
The X/Y and Z/E axis direction keys are also active and may be used to jog theaxes. Refer to Continuous Jog.
2. In the Manual Axis Movement section of the operator control panel, use the selector to selectthe desired axis.
3. Set the Rapid Override switch to select the desired increment. Refer to Rapid Override, page1-17, for information on increment selection.
4. To view axis position on the control display screen:
a) Press the Position key.
b) Press the Page key until the desired position display appears on the control displayscreen.
5. Turn the handwheel in the desired direction (+ or -). Observe the axis position registers todetermine when the axis has been moved the required distance.
If the X axis was selected in step 2, turn the handwheel in the plus direction to move thecross slide away from the spindle centerline and turn the handwheel in the minus directionto move the cross slide toward the spindle centerline.
If the Y1 axis was selected in step 2, turn the handwheel in the plus direction to move theturret away from the machine bed and turn the handwheel in the minus direction to movethe turret toward the machine bed.
If the Z axis was selected in step 2, turn the handwheel in the plus direction to move thecarriage away from the face of the main spindle and turn the handwheel in the minus direc-tion to move the carriage toward the face of the main spindle.
If the E axis was selected in step 2, turn the handwheel in the plus direction to move thetailstock or sub-spindle away from the face of the main spindle and turn the handwheel inthe minus direction to move the tailstock or sub-spindle toward the face of the main spin-dle.
M-392D 3-5
MANUAL DATA INPUT MODE
Manual Data Input mode allows the operator to input a single block of non-stored Data into theManual Data Input memory. The Data can then be executed by pressing the Cycle Start push button.Once the Data in the Manual Data Input memory has been executed, it is erased from memory.
USING MANUAL DATA INPUT
- NOTE -
Pressing the Reset key clears the Manual Data Input buffer.
1. Set the mode selector switch to Manual Data Input mode.
2. Press the Program key.
3. Press the Reset key.
4. Enter the Data into the Manual Data Input buffer using the Data input keys. Each Data blockmust end with a valid End of Block character.
- NOTE -
If an error is made while keying in the Data and the Insert key has not been pressed,press the Cancel key and key in the correct Data.
5. Press the Insert key to input and display the Data from step 4 into the Manual Data Inputmemory.
- NOTE-
To alter Data after it has been entered into the Manual Data Input memory, place thecursor on the word, key in the correct Data, and press the Alter key. If it is necessaryto delete a word, place the cursor on the word and press the Delete key.
The collet closer must be in the closed position before an Manual Data Input com-mand can be executed.
6. Close the coolant guard door and press the Cycle Start push button to execute the Data.
3-6 M-392D
SAFE START SUBPROGRAMS
Safe Start subprograms O1, O2, O3, O4, O998, and O999 have been developed by Hardinge Inc.to provide machine safety and to help simplify programming. These programs are loaded perma-nently into the control memory. The purpose of these programs is to reactivate start-up modes, for ex-ample: positioning mode, deactivate Tool Nose Radius Compensation, establish ipm feed, and movethe turret to the safe index position.
Refer to the programmer’s manual (M-391) for more information on the Safe Start programmingformat.
- CAUTION -
If the machine is to be run in metric mode, the Z entry (pullback) insubprogram O2 must be converted to a metric value.
The operator should be aware that program O999 is used for the main spindleONLY. To avoid crash situations, program O998 must be used for thesub-spindle.
(Continued on next page)
M-392D 3-7
MAIN SPINDLE OPERATION
- CAUTION -
The Z axis coordinate defined in subprogram O999 MUST be programmed as aPOSITIVE number.
When machining on the main spindle, the safe index coordinates are defined by subprogram O999.The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe in-dex coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm].
Refer to Figure 3.1 or 3.2.
Subprogram O1 is used to exit the workpiece after performing an external machining operation onthe workpiece.
Subprogram O2 is used to exit the workpiece after performing an internal machining operation onthe workpiece.
Subprogram O999 is not called directly from the part program. Subprograms O1 and O2 callsubprogram O999, which is used to deactivate the tool offset and command the turret to the safe indexposition.
3-8 M-392D
Figure 3.1 - Z Axis Safe Index Valuefor Main Spindle Operations
(VDI Turret Top Plate)
TI4691
+X
Safe Index = Z + 1” [25.4 mm]
+Z
Z
Figure 3.2 - Z Axis Safe Index Valuefor Main Spindle Operations(Hardinge Turret Top Plate)
+X
+Z
Z
TI4743
Safe Index = Z + 1” [25.4 mm]
SUB-SPINDLE OPERATION
- CAUTION -
The Z axis coordinate defined in subprogram O998 MUST be programmed as aNEGATIVE number.
When machining on the sub-spindle, the safe index coordinates are defined by subprogram O998.The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe in-dex coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm].
Refer to Figure 3.3 or 3.4.
Subprogram O3 is used to exit the workpiece after performing an external machining operation onthe workpiece.
Subprogram O4 is used to exit the workpiece after performing an internal machining operation onthe workpiece.
Subprogram O998 is not called directly from the part program. Subprograms O3 and O4 callsubprogram O998, which is used to deactivate the tool offset and command the turret to the safe indexposition.
M-392D 3-9
Figure 3.3 - Z Axis Safe Index Valuefor Sub-Spindle Operations
(VDI Turret Top Plate)
TI4692
+X
Safe Index = Z + 1” [25.4 mm]
+Z
Z
Figure 3.4 - Z Axis Safe Index Valuefor Sub-Spindle Operations(Hardinge Turret Top Plate)
+X
+Z
Z
TI4744Safe Index = Z + 1” [25.4 mm]
PROGRAMS
ENTERING A PROGRAM FROM THE KEYBOARD
- NOTE-
Refer to Chapter 1 of the programmer’s manual (M-391) for a description of the Datawords used with this machine.
Refer to Chapter 11 of this manual for information on loading part programs fromtape, disk, or ATA flash card.
1. Set the mode selector switch to Edit mode.
2. Turn the Program Protect key to OFF.
3. Press the Program key.
4. Key in the letter and the program number at the Manual Data Input panel.
Example: O1111
5. Press the Insert key.
6. Press the EOB (End of Block) key.
7. Press the Insert key.
8. Enter each Data block as follows:
A) Key in the letter addresses and values.
B) Press the EOB (End of Block) key.
C) Press the Insert key.
9. Turn the Program Protect key to ON.
ACTIVATING A STORED PROGRAM
1. Set the mode selector switch to Automatic mode.
2. Press the Program key.
3. Key in the letter “O” followed by the number for the desired program.
Example: O100
4. Press the cursor � key.
3-10 M-392D
RUNNING A PART PROGRAM FOR THE FIRST TIME
- CAUTION -
Before executing any part program, be sure that all offsets are correct and thatno interference exists in the working area of the machine tool.
Operator should check and if necessary alter the coordinate values pro-grammed in Safe Index Subprogram O998 or O999 to be certain that they aresufficient. Refer to “Editing a Program”, page 3-2, for instructions to edit anactive program.
When Cut-off and Feed Stock are the first operations on bar work, the operatormust make certain that the stock face is placed flush with the collet face be-fore starting the cycle. This will ensure that the turret tooling will not come incontact with workpiece and cause damage to either the turret tooling or theworkpiece.
When testing an operation that uses a self-releasing tap or die holder, activateAutomatic mode immediately before the block containing the spindle reversal.After the Option Stop (M01) is read at the end of the tap or die operation, acti-vate Single mode to test the remainder of the program.
1. Press the Reset key.
2. Press the Program key.
3. Activate the desired program.
4. Set the mode selector switch to Single mode.
5. Close the guard door.
6. Press the Check soft key.
- NOTE -
Program Check displays the Absolute Position and Distance to Go to complete themove.
7. Press the Option Stop push button.
- NOTE -
Single mode is used for first part set up (Block-by-Block execution). Automatic modeis used to run part programs in automatic mode.
8. Turn the Rapid Override switch to LOW.
9. Turn the Feedrate Override switch to 10%.
- NOTE -
Setting the Rapid Override switch to LOW causes non-cutting linear moves (G00) tobe made at 39 in/min [990 mm/min].
Turning Feedrate Override switch to “0" stops X, Y, Z, and E axis motion. When theswitch is turned to another setting axis motion will resume.
10. Press the Cycle Start push button to execute each block of Data.
M-392D 3-11
STOPPING A PROGRAM RUNNING IN AUTOMATIC MODE
- CAUTION -
Pressing either the Reset key or the Emergency Stop push button while a pro-gram is running in Automatic mode will leave the tool against the workpiece ifperformed at the wrong time. DO NOT stop the program with a tool against theworkpiece unless absolutely necessary. Damage to the workpiece and/or tool-ing may result.
There are several ways to stop a program running in Automatic mode:
1. Program a stop command in the part program where it is to be stopped.
2. Press the Feed Hold push button.
- NOTE -
Automatic operation can be restarted by pressing the Cycle Start push button whenthe Feed Hold push button has been used.
3. Press the Reset key.
4. Press the Emergency Stop push button
RESTARTING A STOPPED PROGRAM
If the program was stopped by pressing the Emergency Stop push button, perform steps 1 through5.
If the program was stopped by pressing the Reset key, perform steps 4 through 6.
1. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.
2. Press the Reset key.
3. Key in the letter “O”; then, press the cursor � key. The control will go to the beginning of theprogram.
4. If it is necessary to restart the program at a point other than the beginning:
- CAUTION -
Be sure the block selected in the next step is a safe starting point for the de-sired operation.
A) Key in the letter “N” and the block number for the restart point. For example, “N5".
B) Press the cursor � key. The control will search the program for the block specified in theprevious step.
5. Press the Cycle Start push button. Program execution will resume at the block specified in step4.
3-12 M-392DRevised: January 18, 2008
DRY RUN AND MACHINE LOCK MODES
- CAUTION -
If Machine Lock is not activated with Dry Run, slide motion will occur at a jogfeedrate that is controlled using the Feedrate Override switch. The operatormust make certain that no interference exists between the tooling, workpiece,or spindle before running the machine in Dry Run.
- NOTE -
Feedrate override has a direct affect on the Dry Run feedrate. When Dry Run modeis active, axis motion will occur at a feedrate of 100 in/min [2540 mm/min] when thefeedrate override is set to 100%. When the feedrate override is set to zero, axis mo-tion and program execution are inhibited.
Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. Acti-vating Dry Run and Machine Lock modes together allows the operator to execute part programs with-out axis or spindle motion.
ACTIVATING DRY RUN AND MACHINE LOCK
1. Set the mode selector switch to Automatic mode.
2. Activate the program.
3. Press the Machine Lock push button and Dry Run push button.
4. Close the coolant guard door.
5. If it is desired to run the program block-by-block, set the mode selector switch to Singlemode.
- NOTE -
If Single mode is active, the Cycle Start push button must be pressed for each pro-gram block.
6. Press the Cycle Start push button.
EXITING DRY RUN AND MACHINE LOCK
1. Press the Machine Lock push button and Dry Run push button to deactivate Dry Run andMachine Lock modes.
2. Turn the control OFF, wait a few seconds; then, turn the control ON.
M-392D 3-13
BACKGROUND EDIT
The Background Edit function enables the operator or programmer to edit or create a part programwhile a second program is being executed by the machine tool. An alarm or warning in BackgroundEdit mode does not affect the program being executed in the foreground or vice-versa.
ACTIVATING BACKGROUND EDIT MODE
1. Turn the Program Protect key to the OFF position.
2. Press the Program key.
3. Press the Operator soft key.
4. Press the Background Edit soft key.
- NOTE -The editing functions which may be performed in Background Edit mode are the same as the fore-
ground editing functions. Descriptions of the foreground editing functions begin on page 3-3.
EDITING AN EXISTING PROGRAM
1. Activate Background Edit mode.
2. Key in the letter “O” and the desired program number.
3. Press the cursor� key.
CREATING A NEW PROGRAM FROM THE KEYBOARD
1. Activate Background Edit mode.
2. Key in the letter “O” and the desired program number.
3. Press the Insert key.
4. Press the EOB (End of Block) key.
5. Press the Insert key.
6. Refer to “Entering a Part Program from the Keyboard”, page 3-10.
ENDING BACKGROUND EDITING
- CAUTION -
If the Reset key is pressed while Background Edit is active, the part programthat is being executed will stop and the offset will be canceled. The operatormust escape Background Edit (Press the Background End soft key) to returnto the main program. With the main program displayed, the operator must jogthe turret to a safe area and restart the program at the beginning of the tooloperation.
1. Press the Background End soft key.
2. Turn the Program Protect key to the ON position.
3-14 M-392D
EXTENDED PART PROGRAM EDITING [Option]
INTRODUCTION
Extended Part Program Editing provides the following capabilities:
• Copy or move all or part of a program to another program
• Merge a program at any location within another program
• Search for or replace a Data word in a program
COPY AN ENTIRE PROGRAM
This procedure creates a new program by duplicating an existing program.
1. Select Edit mode.
2. Turn the Program Protect key to the OFF position.
3. Press the Reset key.
4. If necessary, activate the source program as follows:
a) Press the Program key.
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the Cursor� key.
5. Press the Operator soft key.
6. Press the right-hand soft key.
7. Press the Extended Edit soft key.
8. Press the Copy soft key.
9. Press the All soft key.
10. Key in only the number for the new program. DO NOT key in the letter “O”.
11. Press the Input key.
12. Press the Execute soft key.
13. If editing is complete, turn the Program Protect key to the ON position.
M-392D 3-15
COPY PART OF A PROGRAM
This procedure creates a new program by duplicating part of an existing program.
1. Select Edit mode.
2. Turn the Program Protect key to the OFF position.
3. Press the Reset key.
4. If necessary, activate the source program as follows:
a) Press the Program key.
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the Cursor� key.
5. Press the Operator soft key.
6. Press the right-hand soft key.
7. Press the Extended Edit soft key.
8. Press the Copy soft key.
9. Select the beginning of the range to be copied by moving the cursor to the beginning of therange and pressing the CRSL~ soft key.
10. Select the end of the range to be copied by:
Moving the cursor to the end of the range and pressing the ~CRSL soft key.
- or -
Pressing the ~BTTM soft key to indicate the end of the program as the end of the range tobe copied.
11. Key in only the number for the new program. DO NOT key in the letter “O”.
12. Press the Input key.
13. Press the Execute soft key.
14. If editing is complete, turn the Program Protect key to the ON position.
3-16 M-392D
MOVE PART OF A PROGRAM
This procedure creates a new program by extracting part of an existing program. The selectedrange will be removed from the original program.
1. Select Edit mode.
2. Turn the Program Protect key to the OFF position.
3. Press the Reset key.
4. If necessary, activate the source program as follows:
a) Press the Program key.
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the Cursor� key.
5. Press the Operator soft key.
6. Press the right-hand soft key.
7. Press the Extended Edit soft key.
8. Press the Move soft key.
9. Select the beginning of the range to be moved by moving the cursor to the beginning of therange and pressing the CRSL~ soft key.
10. Select the end of the range to be moved by:
Moving the cursor to the end of the range and pressing the ~CRSL soft key.
- or -
Pressing the ~BTTM soft key to indicate the end of the program as the end of the range tobe moved.
11. Key in only the number for the new program. DO NOT key in the letter “O”.
12. Press the Input key.
13. Press the Execute soft key.
14. If editing is complete, turn the Program Protect key to the ON position.
M-392D 3-17
MERGE A PROGRAM
This procedure inserts a copy of the specified existing program within the currently active program.
1. Select Edit mode.
2. Turn the Program Protect key to the OFF position.
3. Press the Reset key.
4. If necessary, activate the source program as follows:
a) Press the Program key.
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the Cursor� key.
5. Press the Operator soft key.
6. Press the right-hand soft key.
7. Press the Extended Edit soft key.
8. Press the Merge soft key.
9. Select the location where the specified program will be inserted by:
Moving the cursor to the position where the program is to be inserted and pressing the~CRSL soft key.
- or -
Pressing the ~BTTM soft key to indicate the end of the program as the position where theprogram is to be inserted.
10. Key in only the number for the program to be inserted. DO NOT key in the letter “O”.
11. Press the Input key.
12. Press the Execute soft key.
13. If editing is complete, turn the Program Protect key to the ON position.
3-18 M-392D
SEARCH AND REPLACE
This procedure locates or replaces the specified Data.
1. Select Edit mode.
2. Turn the Program Protect key to the OFF position.
3. Press the Reset key.
4. If necessary, activate the program as follows:
a) Press the Program key.
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the Cursor� key.
5. Press the Operator soft key.
6. Press the right-hand soft key.
7. Press the Extended Edit soft key.
- NOTE -
Be sure the cursor is located at the appropriate position in the program. The searchor replace function will begin at the cursor position.
8. Move the cursor to the desired position in the program.
9. Press the Change soft key.
- NOTE -
A maximum of 15 characters can be input when specifying the Before or After Data.
Data words specified as Before or After Data must be valid Data words.
10. Key in the Data word to be replaced.
11. Press the Before soft key.
12. Key in the new Data word.
13. Press the After soft key.
14. Press the Execute soft key to replace all occurrences of the specified Data word.
- or -
Press the Execute Single soft key to individually replace each occurrence the specifiedData word.
- or -
Press the Skip soft key to search for the first occurrence of the specified Data word.
15. When editing is complete, turn the Program Protect key to the ON position.
M-392D 3-19
EDITING MACHINE PARAMETERS
- CAUTION -
Use extreme caution when editing machine parameters. Making incorrectchanges in the parameter table may disable the machine or cause undesirablemachine behavior.
1. Press the Offset Setting key.
2. Press the Setting soft key.
3. If necessary, use the page up/down keys to display the Setting page that contains the Pa-rameter Write field.
4. If necessary, use the cursor keys to move the cursor to the Parameter Write field.
5. Set the mode selector switch to Manual Data Input mode.
6. Turn the Program Protect key to the OFF position.
7. Key in the number “1" to enable parameter editing.
8. Press the Input key.
- NOTE -
The control is placed in P/S alarm No. 100.
9. Press the System key.
10. Press the Parameter soft key.
11. Use the page and/or cursor keys to position the cursor on the parameter to be modified.
12. Key in the new parameter value.
13. Press the Input key.
14. Repeat steps 11 through 13 as needed.
15. Press the Offset Setting key.
16. Press the Setting soft key.
17. If necessary, use the page up/down keys to display the Setting page that contains the Pa-rameter Write field.
18. If necessary, use the cursor keys to move the cursor to the Parameter Write field.
19. Key in the number “0" (zero) key to disable parameter editing.
20. Press the Input key.
21. Turn the Program Protect key to the ON position.
3-20 M-392D
22. Press the Reset key to cancel P/S alarm No. 100 .
- NOTE -
Depending on which parameters have been modified, the control may output P/Salarm No. 000. If this alarm message is displayed, it will be necessary to re-initializethe control using the following procedure:
A) Press the Emergency Stop push button.
B) Press the Control OFF push button.
C) Wait approximately ten seconds.
D) Press the Control ON push button.
E) Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.
DISPLAYING THE PROGRAM DIRECTORY
Use the following procedure to display program memory:
1. Set the mode selector switch to Edit mode.
2. Press the Program key.
3. Press the Library soft key. The program library (directory) will be displayed.
M-392D 3-21Revised: January 17, 2008
- NOTES -
3-22 M-392D
CHAPTER 4 - VDI TURRET TOP PLATE TOOLING
INTRODUCTION
QUEST® series lathes are available with VDI ESA, or Hardinge turret top plates.
Refer to Chapter 5 for information on tooling for ESA turret top plates.
Refer to Chapter 6 for information on tooling for Hardinge turret top plates.
TOP PLATE CONFIGURATIONS
- CAUTION -
Refer to page 4-2 for information concerning turret tooling for QUEST 6/42 &6/42SP lathes equipped with the following combination of options:
• 12 or 16 station VDI 30 top plate
• Tool probe
• Sub-spindle part present detector
QUEST series lathes are available with the following VDI top plate configurations:
QUEST 6/42 & 6/42SP lathes
• 12 station VDI 30 top plate
• 10 station VDI 30 top plate
• 16 station VDI 30 top plate
QUEST 8/51, 8/51SP, 10/65 & 10/65SP lathes
• 12 station VDI 30 top plate
• 10 station VDI 30 top plate
• 10 station VDI 40 top plate
A live tooling option is available for the VDI top plate. Refer to Chapter 14 for information on livetooling for the VDI top plate.
M-392D 4-1
QUEST® 6/42 & 6/42SP LATHE TURRET TOOLING CONSIDERATION
- CAUTION -
A potential interference condition exists on QUEST 6/42 & 6/42SP lathesequipped with the following combination of options:
• 12 or 16 station VDI 30 top plate
• Tool probe
• Sub-spindle part present detector
The retract position of the sub-spindle part present detector on machines equipped with this combi-nation of options has been adjusted to avoid interference with the tool probe during part transfer be-tween the main spindle and the optional sub-spindle. Refer to Figure 4.1.
When machining on the sub-spindle, the new position of the part present detector could cause in-terference with the tool in the turret station immediately above the active turret station. It is possible toavoid this potential interference condition by doing either of the following:
• Install a short tool holder in the turret station immediately above the active turret stationif all turret stations are required for tooling
• Install a tool plug in the turret station immediately above the active turret station if allturret stations are not required
Refer to page 13-36 for additional information relating to the optional part present detector.
4-2 M-392D
M-392D 4-3
Figure 4.1 - Sub-Spindle Part Present Detector andTool Probe Viewed from Left End of Machine
TI5348
Part Present Detector Retracted(Standard Position)
Part Present Detector Retracted(Adjusted Position)
Active Turret Station
Potential Interferencewith this Tool Holder
Tool Probe Mountedon Machine Headwall
Turret Top Plate
Sub-Spindle
TOOL HOLDER OR TOOL STATION PLUG REMOVAL
- WARNING -
When removing a tool holder or tool station plug from a top plate, have a firmgrip on the tool holder or tool station plug while loosening the clamp screw inthe top plate.
The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The airpressure in the turret may cause the tool holder or tool station plug to begin moving out of the top platewhen the clamp screw is loosened.
TOOL STATION PLUGS
- CAUTION -
Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool.
DO NOT use the plastic tool station plugs when operating a machine equippedwith high pressure coolant.
All QUEST® series lathes are shipped with plastictool station plugs installed in the turret top plate.
Lathes equipped with the high pressure coolantoption are also supplied with steel tool station plugs.The steel tool station plugs must be used in place ofthe plastic plugs on machines equipped with highpressure coolant.
Install a tool station plug at each turret tool stationnot equipped with tooling. Refer to Figure 4.2 for an il-lustration of a tool station plug.
PLUG INSTALLATION
1. Thoroughly clean the top plate and tool stationplug.
2. Clean and check the O-ring on the tool stationplug to be sure the O-ring is in good condition.
3. Aligning tool station plug “B” with coolantbutton “C”, insert the plug into the turret topplate as shown in Figure 4.3.
4. Tighten clamp screw “A”.
4-4 M-392D
Figure 4.2 - Tool Station Plug
TI4263A
Figure 4.3 - Installing a Tool Station Plug
TI4681
B
C
A
LEFT-HAND / RIGHT-HAND TOOL SELECTION
Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing thecutting forces into the machine base will result in maximum tool life.
Making the selection between left-hand or right-hand tooling should be based on:
• the position of the tool in relation to the spindle
• the direction of spindle rotation
TOOL HOLDERS
Hardinge Inc. offers tool holders in various lengths as measured from the edge of the turret topplate. The standard tool holders can be mounted in any of the top plate tool positions; however, if themachine has the Y axis option and it is programmed to be moved below the spindle centerline, ashorter Y-axis tool holder MUST be mounted in the top plate tool position nearest the way cover tomaintain tooling clearance.
SQUARE SHANK TOOLS
BASIC CONFIGURATION
Square shank tool holders obtained from Hardinge Inc. that are designed for QUEST® series lathesare available for ¾", 1”, 20 mm, or 25 mm tooling.
Square shank tools are held in the tool holder by clamping block “G”, Figure 4.4. Clamp screws “D”and “F” apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw “E” isused to hold the clamp block in place when tension is removed from the clamping screws.
When installing or removing square shank tooling, do not remove spring-loaded screw “E”.Clamping block “G” is held in the tool holder by the spring-loaded screw.
REVERSIBLE TOOL HOLDERS
Square shank tool holders obtained fromHardinge Inc. that are designed for QUEST serieslathes are capable of using left-hand or right handtooling. Refer to “Left-Hand / Right-Hand Tool Selec-tion”, above.
1. Carefully remove screw “E”, the spring, andclamp block “G”.
2. Remove clamp screws “D” and “F”.
3. Thoroughly clean the tool holder body and allcomponents that were removed.
4. Install clamp block “G”, the spring, and screw“E” on the upper or lower side of the tool holder,as needed.
5. Install clamp screws “D” and “F”.
M-392D 4-5
Figure 4.4 - Basic SquareShank Tool Holder
TI4158
D E F G
INSTALLING SQUARE SHANK TOOLS
- CAUTION -
Refer to the Maximum Tool Extension table shown below.
Refer also to Figures 4.5 and 4.6.
Maximum Tool Extension
Turret Top PlateConfiguration
Y Axis OptionMaximum Tool Extension
Inches [Millimeters]
VDI 30No 6.985 [177.4]
Yes 5.605 [142.4]
VDI 40No 7.575 [192.4]
Yes 6.195 [157.4]
- NOTE -
Hardinge recommends that tooling be selected that will direct all cutting forces intothe machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 4-5.
The recommended tool mounting position is to have the tool seated against the edgeof the tool holder, as shown in Figures 4.5 and 4.6.
1. Thoroughly clean the top plate, tool holders, and tooling.
2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.
- CAUTION -
Be sure the tool holder is mounted flush against the side of the turret topplate, as shown in Figure 4.8.
3. Aligning tool holder “H” with coolant button “I”, insert the tool holder shank into the turret topplate as shown in Figure 4.7.
- NOTE -
Maximum torque for the clamp screw is 17 lb-ft [23 N•m] on VDI 30 top plates and33 lb-ft [45 N•m] on VDI 40 top plates.
4. Tighten clamp screw “J”.
- CAUTION -
Be sure the tool sits squarely in the slot of the tool holder.
5. Mount the tool in the tool holder and tighten two clamp screws “K”, Figure 4.8.
4-6 M-392D
M-392D 4-7
Figure 4.5 - Square Shank Tool Installation(Main Spindle Operation)
TI4673A
Recommended ToolMounting Position
Maximum Tool Extension
TurretTop Plate
MainSpindle
Inches [Millimeters]
Standard Turret: 6.985 [177.4]Y-Axis Turret: 5.605 [142.4]
Figure 4.6 Square Shank Tool Installation(Sub-Spindle Operation)
TurretTop Plate
Inches [Millimeters]
Maximum Tool Extension
TI4684A
OptionalSub-Spindle
Standard Turret: 6.985 [177.4]Y-Axis Turret: 5.605 [142.4]
Recommended ToolMounting Position
4-8 M-392D
Figure 4.7 - Mounting a Square Shank Tool Holder
TI4674
H
J
I
Figure 4.8 - Square Shank Tool Holder with Tool(Viewed from the Main Spindle)
TI4675
K
Be sure the tool holder is flush againstthe side of the turret top plate.
ROUND SHANK TOOLS
TOOL HOLDER CAPACITIES
- NOTE -
Refer to the appropriate tooling catalog for information on tool holders and bushings.
Round shank tool holders for QUEST® series lathes are available from Hardinge Inc. in the follow-ing capacities:
Turret Top PlateConfiguration
EnglishCapacities
MetricCapacities
VDI 30
¾ inch 20 millimeters
1 inch 25 millimeters
1¼ inch 32 millimeters
VDI 40 1½ inch 40 millimeters
When using round shank tooling with a diameter equal to the capacity hole of the tool holder, thetool can be mounted directly in the tool holder. When using round shank tooling with a diameter otherthan the sizes specified above, it will be necessary to use a tool holder bushing.
INSTALLING ROUND SHANK TOOLS
- CAUTION -
When installing round shank tooling for sub-spindle operations, maximumtool extension is 8.375 inches [212.73 mm] from the centerline of the turret topplate tool mounting location. Refer to Figure 4.9.
1. 1Thoroughly clean the turret top plate, tool holders, and tooling.
2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.
3. If it is necessary to index the turret:
A) Move the turret to a safe index position.
B) Index the turret to the desired tool station.
C) Move the turret to a convenient position for installing tools.
- CAUTION -
Be sure the tool holder is mounted flush against the side of the turret topplate.
- NOTE -
Hardinge recommends that tooling be selected that will direct all cutting forces intothe machine base, resulting in maximum tool life. Refer to Left-Hand / Right-HandTool Selection, page 4-5.
4. Loosen two screws “M”, Figure 4.10.
M-392D 4-9
4-10 M-392D
Figure 4.9 - Maximum Round Shank ToolExtension for Sub-Spindle Operations
Inches[Millimeters]
Maximum Tool Extension
TurretTop Plate
OptionalSub-Spindle
TI4685A
6.997[177.73]
8.375[212.73]
Figure 4.10 - Mounting a Round Shank Tool Holder(Viewed from the Main Spindle)
TI4677
M
O
N
L
5. Aligning tool holder “L” with coolant button “N”, insert the tool holder shank into the turret topplate as shown in Figure 4.10.
6. Press the tool holder against the turret top plate and tighten two screws “M”.
- NOTE -
Maximum torque for the clamp screw is 17 lb-ft [23 N•m] on VDI 30 top plates and33 lb-ft [45 N•m] on VDI 40 top plates.
7. Tighten clamp screw “O”.
8. Place setting bar “S”, Figure 4.11 or 4.12, in the tool holder and tighten set screws “U” sothat there is a slight drag on the setting bar when it is rotated in the holder.
9. Loosen thumb screw “R” enough to allow locating bar “Q” to slide.
10. Place the machined side of tool setter support “P” flat against the side of the tool holder.
11. Rotate setting bar “S” until the machined flat is in line with the flat surface of locating bar “Q”,as shown in view #2.
12. Tighten thumb screw “R” when the following conditions are met:
a) The machined side of tool setter support “P” is flat against the side of the tool holder.
b) The flat on setting bar “S” is perpendicular to locating bar “Q”. Refer to view #2.
13. Loosen set screws “U” and remove gauge “S”.
14. If required, install the appropriate tool bushing in the round shank tool holder.
M-392D 4-11
Figure 4.11 - Tool Setting Gauge Oriented for Main Spindle Tooling
TI4678
U
R
Q P
S T U
Q P
R
S
T
VIEW #1 VIEW #2
15. Install and adjust the tool for length.
16. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder.
17. Tighten set screws “U” just enough to apply a slight drag on the tool shank.
18. Place the machined side of tool setter support “P” against the side of tool holder.
19. Rotate the tool until the tool tip touches locating bar “Q”.
20. Tighten set screws “U” to secure the setting.
21. Repeat steps 1 through 20 for additional tools, as necessary.
REMOVING ROUND SHANK TOOLS
- WARNING -
When removing a tool holder from a top plate, have a firm grip on the toolholder while loosening clamp screw “O”, Figure 4.10.
1. Loosen two screws “M”, Figure 4.10.
2. Loosen clamp screw “O”.
3. Remove the tool holder from the turret top plate.
4. Install a tool station plug if another tool holder is not to be installed. Refer to page 4-4 forinformation on tool station plugs.
5. Repeat steps 1 through 3 for additional tool holders, as necessary.
4-12 M-392D
Figure 4.12 - Tool Setting Gauge Oriented for Sub-Spindle Tooling
TI4686
U
R
QP
STU
QP R
S
T
VIEW #1 VIEW #2
- NOTES -
M-392D 4-13
- NOTES -
4-14 M-392D
CHAPTER 5 - ESA TURRET TOP PLATE TOOLING
INTRODUCTION
QUEST® series lathes are available with ESA, VDI, or Hardinge turret top plates.
Refer to Chapter 4 for information on tooling for VDI turret top plates.
Refer to Chapter 6 for information on tooling for Hardinge turret top plates.
TOP PLATE CONFIGURATION
The ESA turret top plate is a 12 station top plate.
A live tooling option is available for the ESA top plate. Refer to Chapter 15 for information on livetooling for the ESA top plate.
TOOL HOLDER OR TOOL STATION PLUG REMOVAL
- WARNING -
When removing a tool holder or tool station plug from a top plate, have a firmgrip on the tool holder or tool station plug when releasing the tool holder fromthe top plate.
The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The airpressure in the turret may cause the tool holder or tool station plug to begin moving out of the top platewhen the tool holder is released from the top plate.
M-392D 5-1
TOOL STATION PLUGS
INTRODUCTION
- CAUTION -
Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool.
Install a tool station plug at each turret tool station not equipped with tooling. Refer to Figure 5.1 foran illustration of a ESA tool station plug.
TOOL STATION PLUG INSTALLATION
1. Thoroughly clean the top plate and blanking plug.
2. Check the O-ring on the blanking plug to be sure the O-ring is in good condition.
3. Press and hold button "A", Figure 5.2.
4. Insert blanking plug "B" into the turret top plate as shown in Figure 5.2.
5. Release button "A" to clamp the blanking plug.
6. Tighten rear clamp screw "D", Figure 5.3.
7. Install and tighten four face screws “C”, Figure 5.2.
5-2 M-392D
Figure 5.1 - Blanking Plug
TI5413
M-392D 5-3
Figure 5.2 - Blanking Plug Installed on Top Plate
TI5435
C
A
C
B
Figure 5.3 - Rear Clamping Screw
D
TP7130
LEFT-HAND / RIGHT-HAND TOOL SELECTION
Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing thecutting forces into the machine base will result in maximum tool life.
Making the selection between left-hand or right-hand tooling should be based on:
• the position of the tool in relation to the spindle
• the direction of spindle rotation
SQUARE SHANK TOOLS
BASIC CONFIGURATION
Square shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST® serieslathes are available for ¾", 1”, 20 mm, or 25 mm tooling.
Square shank tools are held in the tool holder by clamping block “H”, Figure 5.4. Clamp screws “E”and “G” apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw “F” isused to hold the clamp block in place when tension is removed from the clamping screws.
When installing or removing square shank tooling, do not remove spring-loaded screw “F”.Clamping block “H” is held in the tool holder by the spring-loaded screw.
REVERSIBLE TOOL HOLDERS
Square shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST serieslathes are capable of using left-hand or right hand tooling. Refer to “Left-Hand / Right-Hand Tool Se-lection”, above.
1. Carefully remove screw “F”, the spring, andclamp block “H”.
2. Remove clamp screws “E” and “G”.
3. Thoroughly clean the tool holder body and allcomponents that were removed.
4. Install clamp block “H”, the spring, and screw“F” on the upper or lower side of the tool holder,as needed.
5. Install clamp screws “E” and “G”.
5-4 M-392D
Figure 5.4 - Basic SquareShank Tool Holder
TI5415
E F G H
MAXIMUM TOOL EXTENSION
- CAUTION -
When installing square shank tooling, the maximum X axis tool extensionmust not exceed the values listed in the table shown below. Refer also to Fig-ure 5.5.
Y Axis OptionMaximum Tool Extension
Inches [Millimeters]
No 3.639 [92.43]
Yes 2.259 [57.38]
M-392D 5-5
Figure 5.5 - Maximum Square Shank Tool Extension
TI5459
Maximum ToolExtension
Tool Oriented forMain Spindle Operation
Recommended ToolMounting Position
Recommended ToolMounting Position
Maximum ToolExtension
Tool Oriented forSub-Spindle Operation
5-6 M-392D
Figure 5.6 - Mounting a Square Shank Tool Holder
TI5418
I
Figure 5.7 - Square Shank Tool Holder with Tool
TI5419
J
K
INSTALLING SQUARE SHANK TOOLS
- NOTE -
Hardinge recommends that tooling be selected that will direct all cutting forces intothe machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 5-4.
The recommended tool mounting position is to have the tool seated against the edgeof the tool holder, as shown in Figure 5.5.
1. Thoroughly clean the top plate, tool holders, and tooling.
2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.
3. If it is necessary to index the turret:
A) Move the turret to a safe index position.
B) Index the turret to the desired tool station.
C) Move the turret to a convenient position for installing tools.
4. Press and hold button "I", Figure 5.6.
5. Insert the tool holder into the turret top plate as shown in Figure 5.6.
6. Release button "I" to clamp the tool holder.
7. Tighten rear clamp screw "D", Figure 5.3.
8. Install and tighten four face screws “J”, Figure 5.7.
- CAUTION -
Be sure the tool sits squarely in the slot of the tool holder.
Refer to the maximum tool extension table on page 5-5. Refer also to Figure5.5.
9. Mount the tool in the tool holder and tighten two clamp screws “K”, Figure 5.7.
10. Repeat as needed for additional tooling.
M-392D 5-7
ROUND SHANK TOOLS
TOOL HOLDER CAPACITIES
- NOTE -
Refer to the appropriate tooling catalog for information on tool holders and bushings.
Round shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST® serieslathes are available with the following maximum tool shank capacities:
English Tool Holder: 1¼ inches
Metric Tool Holder: 32 or 40 millimeters
When using round shank tooling with a diameter equal to the capacity hole of the tool holder, thetool can be mounted directly in the tool holder. When using round shank tooling with a diameter otherthan the sizes specified above, it will be necessary to use a tool holder bushing.
5-8 M-392D
MAXIMUM Z AXIS TOOL EXTENSION FOR SUB-SPINDLE OPERATION
- CAUTION -
DO NOT exceed the maximum Z axis tool extension defined in this section.
When installing round shank tooling for sub-spindle operations, the maximum Z axis tool extensionis 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location. Refer toFigure 4.9.
M-392D 5-9
Figure 5.8 - Maximum Round Shank ToolExtension for Sub-Spindle Operations
Inches[Millimeters]
TI5420A
5.481[139.22]
8.375[212.73]
INSTALLING ROUND SHANK TOOLS
- CAUTION -
When installing round shank tooling for sub-spindle operations, maximumtool extension is 8.375 inches [212.73 mm] from the centerline of the turret topplate tool mounting location. Refer to Figure 5.8.
1. Thoroughly clean the top plate, tool holders, and tooling.
2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.
3. If it is necessary to index the turret:
A) Move the turret to a safe index position.
B) Index the turret to the desired tool station.
C) Move the turret to a convenient position for installing tools.
- NOTE -
Hardinge recommends that tooling be selected that will direct all cutting forces intothe machine base, resulting in maximum tool life. Refer to Left-Hand / Right-HandTool Selection, page 5-4.
4. Press and hold button "L", Figure 5.9.
5. Insert the tool holder into the turret top plate as shown in Figure 5.9.
6. Release button "L" to clamp the tool holder.
7. Tighten rear clamp screw "D", Figure 5.3.
8. Install and tighten four face screws “M”, Figure 5.10.
9. Place setting bar “Q”, Figure 5.11 or 5.12, in the tool holder and tighten set screws “S” so thatthere is a slight drag on the setting bar when it is rotated in the holder.
10. Loosen thumb screw “P” enough to allow locating bar “O” to slide.
11. Place the machined side of tool setter support “N” flat against the side of tool holder "R".
12. Rotate setting bar “Q” until the machined flat is in line with the flat surface of locating bar “O”, asshown in view #2.
13. Tighten thumb screw “P” when the following conditions are met:
A) The machined side of tool setter support “N” is flat against the side of the tool holder.
B) The flat on setting bar “Q” is perpendicular to locating bar “O”. Refer to view #2.
5-10 M-392D
M-392D 5-11
Figure 5.9 - Mounting a Round Shank Tool Holder
TI5421
L
Figure 5.10 - Round Shank Tool Holder Mounted on Top Plate
TI5436
M
5-12 M-392D
Figure 5.11 - Tool Setting Gauge Oriented for Main Spindle Tooling
TI5437
S
P
O N
Q R S
ON
P
Q
R
VIEW #1 VIEW #2
Figure 5.12 - Tool Setting Gauge Oriented for Sub-Spindle Tooling
TI5438
S
P
ON
QRS
ON P
Q
R
VIEW #1 VIEW #2
14. Loosen set screws “S” and remove gauge “Q”.
15. If required, install the appropriate tool bushing in the round shank tool holder.
- CAUTION -
When installing tooling for sub-spindle operation, DO NOT exceed the maxi-mum tool extension specified on page 5-9.
16. Install and adjust the tool for length.
17. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder.
18. Tighten set screws “S” just enough to apply a slight drag on the tool shank.
19. Place the machined side of tool setter support “N” against the side of tool holder "R".
20. Rotate the tool until the tool tip touches locating bar “O”.
21. Tighten set screws “S” to secure the setting.
22. Repeat steps 3 through 21 for additional tools, as necessary.
M-392D 5-13
- NOTES -
5-14 M-392D
CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING
INTRODUCTION
QUEST® series lathes are available with ESA, VDI, or Hardinge turret top plates.
Refer to Chapter 4 for information on tooling for VDI turret top plates.
Refer to Chapter 5 for information on tooling for ESA turret top plates.
SQUARE SHANK TOOLS
MAIN SPINDLE OPERATION
Hardinge turret top plates are designed to use qualified square shank tool holders. Since thesetools are length, width, and height qualified, both set-up time and downtime due to tool replacementare greatly reduced.
Qualified Tool Holders for Main Spindle Operation
Qualified tool holder dimensions are held to ±.003 inch [.076 mm]. A left-hand square shank quali-fied tool holder is illustrated in Figure 6.1. Refer to Table 6.1 for qualified tool holder dimensions.
M-392D 6-1
Figure 6.1 - Qualified Tool Holder
TI2701A
A
B
C
F
E
H
Dimension English (in.) Metric (mm)
A 1.000 25.00
B 1.000 25.00
C 6.000 150.00
E 1.250 36.00
F 1.250 32.00
H 1.000 25.00
Table 6.1 - Qualified Tooling Dimensions
Left-Hand / Right-Hand Tool Selection
- CAUTION -
Read this section thoroughly before mounting square shank tooling for mainspindle operations on the turret top plate.
When using square shank tooling, Hardinge recommends the exclusive use of left-hand tools forthe following reasons:
1. The use of left-hand tools insures that allcutting forces will be directed into the machinebase and will result in maximum tool life.
2. In the event that a right-hand tool and aleft-hand tool are mounted in adjacent toolstations, as shown on Figure 4., aninterference situation is created. Both toolsWILL NOT be able to locate against the toolstop on the turret. Refer to the close-up inFigure 6.3. This could create a potential safetyhazard and MUST be avoided.
Right-hand tooling can be used IF A CHAMFER ISMACHINED ON THE CORNER OF THERIGHT-HAND TOOL HOLDER. Figure 6.4 showsthe location and minimum size of the chamfer re-quired to allow for safe use of right-hand tooling.
6-2 M-392D
Figure 6.2 - Tool Interference Illustration
TI2499
1.500[38.10]
1.500[38.10]
English[Metric]
Figure 6.3 - Interference Close-Up
English[Metric]
0.063[1.60]
TI2500
Figure 6.4 - Tool Shank Chamfer
English[Metric]
TI2501
0.063[1.60]
45� CH x 0.011 [2.8] Flat
Installing Square Shank Tools
- CAUTION -
The shank of the tool holder should be positioned firmly against the tool stopon the turret top plate, as shown in Figure 6.5. The notable exception is out-lined in “Between-Center Turning on QUEST® 6/42 Lathes”, on the next page.
- NOTE -
When using square shank tooling, Hardinge recommends the exclusive use ofleft-hand tools. This insures that all cutting forces will be directed into the machinebase, resulting in maximum tool life.
The wedge clamp can be located on either side of the tool slot centerline to accommodate bothright-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedgeshould bear against the tool shank with the arrow pointing toward the tool shank.
1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed.
2. Install the tool holder on the top plate and tighten the wedge clamp screws. This willautomatically set the tool tip to the correct height as long as qualified tooling is used.
M-392D 6-3
Figure 6.5 - Tool Shank PositionedAgainst the Tool Stop
TI4936
Tool Shank AgainstTool Stop
Figure 6.6 - Tool Clamp Orientation
TI1908
ToolShank
ToolShank
WedgeClamp
Between-Center Turning on QUEST® 6/42 Lathes
- CAUTION -
Read this section thoroughly beforemounting square shank tooling forbetween-center turning operations.
- NOTE -
The information in this section appliesonly to QUEST 6/42 lathes.
When using a standard live center for be-tween-center turning near the tailstock, a potential in-terference condition exists between the coolant ringon a Hardinge turret top plate and the tailstock enclo-sure. Refer to Figure 6.7.
The minimum diameter that can be turned is 218
inches [54 millimeters].
If it is necessary to turn a smaller diameter near thetailstock, two solutions are available:
1. Use an extended nose center, as shown inFigure 6.8.
- or -
2. Extend the tool away from the tool stop adistance equal to:
Tool Extension2.125 Finished Diameter
2�
�
Refer to Figure 6.9.
Example: Finished Diameter = 1.75 inches
Tool Extension2.125 1.75
2.1875�
��
6-4 M-392D
Figure 6.7 - Turning Near the Tailstockwith a Standard Live Center
TP4982
CoolantRing
TailstockEnclosure
Figure 6.8 - Turning Near the Tailstockwith an Extended Nose Live Center
TP4983
CoolantRing
TailstockEnclosure
Figure 6.9 - Extending the ToolAway from the Tool Stop
ToolExtension
TI4937
SUB-SPINDLE OPERATION [Option]
Maximum Tool Extension
- CAUTION -
Turret tooling for sub-spindle operation MUST NOT extend more than 4¼inches [108 mm] from the turret top plate on the X axis.
An interference condition can exist if sub-spindle turret tooling extends more than 4¼ inches[108 mm] from the turret top plate on the X axis. Be sure all sub-spindle turret tooling does not extendbeyond this limit
Cut-Off Tool Operating Limits
When using a cut-off tool during a cut-off and transfer operation from the main spindle to thesub-spindle, the following operating limits must be observed:
• the tip of the cut-off tool MUST extend 3.94 inches [100 millimeters] from theedge of the turret top plate.
• the face of the sub-spindle must be at least 1.80 inches [45.7 millimeters] fromthe face of the main spindle.
Refer to Figure 6.10.
Refer to the chart on the next page to identify the correct square shank cut-off tool holder.
M-392D 6-5
Figure 6.10 - Cut-Off Tool Operating Limits
TI4925
3.94[100]
1.80 [45.7]
Inches [millimeters]
TurretTop Plate
Main Spindle Optional Sub-Spindle
Square Shank Cut-OffTool Holder Required
Model Numbers for Square Shank Cut-Off Tool Holders
Machine Model English Top Plate Metric Top Plate
QUEST® 6/42 Lathe SG-CE SG-CEM
QUEST 8/51 & 10/65 Lathes CL-CE CL-CM
Tooling Configuration
Sub-spindle operations require ¾ inch square shank tooling on English top plates and 20 millimetersquare shank top plates on Metric machines.
Tooling Location
Square shank tooling for sub-spindle operations can only be mounted at odd numbers tool stations.
6-6 M-392D
Tool Mounting Position
Square shank tooling for main spindle operations is mounted on the -Z face of the turret top plateand square shank tooling for sub-spindle operations is mounted on the +Z face of the turret top plate.Refer to Figure 6.11.
M-392D 6-7
Figure 6.11 - Hardinge Turret Top Plate(Sub-Spindle Machines Only)
TI2737A
-Z Turret TopPlate Face
+Z Turret TopPlate Face
Square Shank ToolSlots for Main SpindleOperations
Square Shank ToolSlots for Sub-SpindleOperations(Odd Numbered ToolStations Only)
Toward Main Spindle Away from Main Spindle
Tool Shank Modification
- CAUTION -
Failure to modify the length of thetool holder shank may result in poorsurface finish.
The length of the tool slots used for sub-spindleoperations is 1-13/16 inches [46 mm]. Due to thelength of the tool slots, it will be necessary to shortenthe shank of the tool holder to position the tool tip at adistance of 1-1/4 inches [31.8 mm] from the edge ofthe turret top plate. The final length of the tool, aftermodification, will be 3-1/16 inches [77.8 mm] from thetool tip to the end of the tool shank. Refer to Figure6.12.
Mounting Tools
- NOTE -
When using square shank tooling for sub-spindle operations, Hardinge recommendsthe exclusive use of right-hand tools. This insures that all cutting forces will be di-rected into the machine base, resulting in maximum tool life.
The wedge clamp can be located on either side of the tool slot centerline to accommodate bothright-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedgeshould bear against the tool shank with the arrow pointing toward the tool shank.
1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed.
2. Install the tool holder on the top plate and tighten the wedge clamp screws.
6-8 M-392D
Figure 6.12 - Tool Length Modification
TI2774
1.81[46.0]
1.25[38.1]
English[Metric]
ROUND SHANK TOOLS
Round shank tools 1½ inches or 40 millimeters in diameter can be mounted directly into the op-tional English or Metric round shank tool holders, respectively. Round shank tools in specific sizesranging from 1/32 inch [1 millimeter] up to ¾ inch [20 millimeters] can be mounted in the round shanktool holders using the Hardinge Double-Angle Tool Holder Collet and Tool Holder System.
Round shank tools in specific sizes ranging from ½ inch [12 millimeters] up to 1¼ inch [32 millime-ters] can be mounted in the round shank tool holders using Hardinge HDC-12 bushings.
ROUND SHANK TOOL HOLDERS
QUEST® 6/42 LATHE
Hardinge drill holders are qualified at 1.250 inches [31.75 mm] from the hole center to theturret face. Hardinge boring bar holders are qualified at 2.000 inches [50.80 mm] from the holecenter to the turret face.
QUEST 8/51 and 10/65 LATHES
Hardinge drill holders are qualified at 1.500 inches [38.10 mm] from the hole center to theturret face. Hardinge boring bar holders are qualified at 2.813 inches [71.44 mm] from the holecenter to the turret face.
Refer to the appropriate Hardinge tooling catalog for additional information.
TOOL SETTING GAUGES
- NOTE -
Two separate tool setting gauges are supplied with QUEST series lathes. Onegauge is used to set tools for main spindle operation. The other gauge is used to settools for sub-spindle operation.
Tool setting gauges are used to place the tool nose of round shank tools such as boring bars and in-ternal threading tools on center with the spindle centerline.
The tool slot centerline of the active station and the spindle centerline are the same distance fromthe top surface of the machine ways. Therefore, if the tool nose is positioned on the tool slot centerline,it will be on center with the spindle centerline.
The tool setting gauge for main spindle operation mounts in the tool slot and provides aphysical projection of the tool slot centerline. Once the tool setting gauge is mounted on theturret, the tool is rotated to bring the tool nose against the gauge.
The tool setting gauge for sub-spindle operation is held against the side of the tool holderand provides a physical projection of the tool slot centerline. Once the tool setting gauge isproperly set up, the tool is rotated to bring the tool nose against the gauge.
M-392D 6-9
INSTALLING ROUND SHANK TOOLS FOR MAIN SPINDLE OPERATION
1. If not already installed, loosely mount wedge clamp “A”, Figure 6.13, on the top plate in thecorrect orientation for the tool to be installed.
2. Mount the round shank tool holder on the turret.
3. If required, install the appropriate tool cartridge in the round shank tool holder.
4. Insert the tool in the holder or tool cartridge and adjust the tool to length. Align the flat on theHardinge Double-Angle Tool Holder Collet or the slot in Hardinge HDC-12 bushings and the flaton the tool shank with one of the groups of three set screws “C”, Figure 6.14.
- NOTE -
Orientation of the gauge for setting left-hand tools is shown in Figure 6.13.
5. Insert tool setting gauge “B”, Figures 6.13 and 6.14, in the turret tool slot with one of thechamfered edges toward the bottom of the slot.
6-10 M-392D
Figure 6.13 - Tool Setting Gauge(Front View)
TI1908
A
B
Spindle Centerline
+X
+Y
Figure 6.14 - Tool Setting Gauge(Side View)
TI2410
B
C
6. Carefully position the tool setting gauge so the tool nose can be rotated to touch the inner faceof the gauge; then, tighten wedge clamp “A”, Figure 6.13.
- CAUTION -
Be careful not to damage the tool nose.
7. Rotate the tool until the tool nose touches the inner face of the tool setting gauge.
- CAUTION -
When the set screws are fully tightened there is the possibility that the toolmay rotate. This will damage the tool nose if it is against the tool settinggauge.
- NOTE -
To secure the tool, tighten the group of three set screws that align with the tool andtool holder as described in step 4.
8. Snug, but do not fully tighten any group of three set screws “C”, Figure 6.14, to hold the tool inplace.
9. Loosen wedge clamp “A”, Figure 6.13, swing the tool setting gauge out of the way, and tightenthe wedge clamp.
10. Fully tighten three set screws “C”, Figure 6.14, to secure the tool.
11. Loosen the wedge clamp and carefully position the tool setting gauge to check that the toolnose is still on center. If it has moved, repeat steps 6 through 10.
12. Remove the tool setting gauge from the turret and tighten the wedge clamp.
M-392D 6-11
INSTALLING ROUND SHANK TOOLS FOR SUB-SPINDLE OPERATION
- CAUTION -
DO NOT use round shank tool holder adapter plates on machines equippedwith the sub-spindle option. Use of the adapter plates may result in interfer-ence between the round shank tool holders and the sub-spindle.
The operator must make certain that no interference exists between the turrettooling and the main spindle, workpiece, or sub-spindle before manually in-dexing the turret.
Operating Limits
- CAUTION -
When installing round shank tooling for sub-spindle operations, maximumtool extension is 7.25 inches [184.1 mm] from the surface of the tool holder.
When installing a drill or boring bar for sub-spindle operation, the following operating limits must beobserved:
• maximum tool extension is 7.25 inches [184.1 millimeters] from the surface of thetool holder. Refer to Figure 6.15.
• tool extension must provide a minimum of 1.25 inches [32 millimeters] clearancebetween the tool holder and the face of the sub-spindle at the end of the cut. Re-fer to Figure 6.16.
6-12 M-392D
Figure 6.15 - Maximum Round Shank ToolExtension for Sub-Spindle Operations
Inches[Millimeters]
MaximumTool Extension
TurretTop Plate
OptionalSub-Spindle
TI4740A
7.25[184.1]
M-392D 6-13
Figure 6.16 - Minimum Tool Holder Clearancefor Round Shank Tool Holders
TI4926
1.25 [32.0]
Inches [millimeters]
OptionalSub-Spindle
TurretTop Plate
Tool Holder
Installation Procedure
1. Index the turret to the desired station.
2. Mount tool holder “E” on the turret, as shown in view #1 of Figure 6.17.
3. Refer to the illustration and complete steps 4 through 14.
4. Place setting bar “I” in the tool holder and tighten set screws “D” so that there is a slight drag onthe setting bar when it is rotated in the holder.
5. Loosen thumb screw “H” enough to allow locating bar “G” to slide.
6. Place the machined side of tool setter support “F” flat against the side of the tool holder.
7. Rotate setting bar “I” until the machined flat is in line with the flat surface of locating bar “G”, asshown in view #2.
8. Tighten thumb screw “H” when the following conditions are met:
A) The machined side of tool setter support “F” is flat against the side of the tool holder.
B) The flat on setting bar “I” is perpendicular to locating bar “G”. Refer to view #2.
9. Loosen set screws “D” and remove gauge “I”.
6-14 M-392D
Figure 6.17 - Tool Setting Gauge for Sub-Spindle Tooling(Hardinge Turret Top Plate)
TI2773
D
E FG
H
IE
I
F
H
G
VIEW #1 VIEW #2
+X
+Z
- CAUTION -
Be sure that there is sufficient clearance between the sub-spindle tooling andthe turret.
10. Place the tool in the tool holder at the desired length.
11. Tighten set screws “D” just enough to apply a slight drag on the tool shank.
12. Place the machined side of tool setter support “F” against the side of tool holder.
13. Rotate the tool until the tool tip touches locating bar “G”.
14. Tighten set screws “D” to secure the setting.
15. Repeat steps 1 through 14 for additional tools as necessary.
M-392D 6-15
- NOTES -
6-16 M-392D
CHAPTER 7 - WORK SHIFT
INTRODUCTION
The work shift offset shifts the origin of the work coordinate system. Work Shift values (Z) arestored in the Work Shift file. The value stored in this file is active at all times.
- CAUTION -
The Work Shift file contains an X and a Z shift register. The X axis register inthe Work Shift file should be set to zero at all times.
The value entered into the Z axis Work Shift file must be a negative number.
The values stored in the Work Shift file are added to the Absolute Position registers, thus shiftingthe origin of the work coordinate system by the amount stored in the Work Shift file. For example, if theZ axis is at 14 inches and the operator stores Z-2.5 in the Work Shift file, the Absolute Position regis-ters would then display Z11.5 [14 +(- 2.5)].
Immediately after a Work Shift value is stored, the control adds it to the Absolute Position registers.The registers will remain modified until the Work Shift offset values are set to zero by the operator orfrom the part program.
Typically, the part length is stored as the Z Work Shift offset and the X Work Shift offset IS NOTUSED (set to zero). Since the Work Shift value is added to the Absolute Position registers, the partlength is stored as a negative Z value. With the part length stored in the Work Shift file, the origin of theAbsolute coordinate system is the intersection of the part face and the spindle centerline.
- NOTE -
Refer to the programmer’s manual (M-391) for information on storing a work shiftfrom the part program.
M-392D 7-1
MANUALLY ESTABLISHING Z AXIS WORK SHIFT
VDI OR ESA TURRET TOP PLATE
- NOTE -
This procedure is used to set the work shift on QUEST® series lathes equipped witha VDI or ESA turret top plate. Refer to page 7-6 for the procedure that applies toQUEST series lathes equipped with a Hardinge turret top plate.
1. Load a workpiece into the collet or step chuck at the desired length.
2. Activate Jog mode.
3. Jog the turret to a safe position for indexing.
- CAUTION -
The machine operator must make certain that no interference exists betweenthe spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, orworkpiece before manually indexing the turret.
- NOTE -
If an square shank tool holder is not available, install a tool holder at any convenientstation.
4. Turn the Station switch to the number of a turret station equipped with a square shank toolholder.
5. Press the Turret Index push button to index the turret to the selected turret station.
6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jogfeedrate of approximately 37.5 in/min [952 mm/min].
7. Jog the tool holder to within 1 inch [25 mm] of the face of the workpiece.
8. Use the Manual Axis Movement switch to select the Z axis.
- NOTE -
Refer to page 1-17 for information on using the Rapid Override switch to selecthandwheel increments.
9. Use the Rapid Override switch to select the desired handwheel increment.
10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in theappropriate direction to move the turret toward the face of the workpiece until a slight drag is feltwhen moving the shim between the tool holder and workpiece. Refer to Figure 7.1, 7.2, 7.3, or7.4.
11. Press the Offset Setting key to display the offset pages.
12. Press the right hand soft key until the Work Shift soft key is displayed.
13. Press the Work Shift soft key to display the Work Shift registers.
7-2 M-392D
M-392D 7-3
Figure 7.1 - Establishing the Main Spindle Work Shift(VDI Turret Top Plate)
TI4682A
ShimThickness
Tool HolderOffset Value
Turret Position
Work Shift
MainSpindle
Figure 7.2 - Establishing the Sub-Spindle Work Shift(VDI Turret Top Plate)
TI4683B
Shim Thickness
Tool Holder Offset Value
Turret Position
Work Shift
MainSpindle
OptionalSub-Spindle
7-4 M-392D
Figure 7.3 - Establishing the Main Spindle Work Shift(ESA Turret Top Plate)
TI5443
ShimThickness
Tool HolderOffset Value
Turret Position
Work Shift
MainSpindle
Figure 7.4 - Establishing the Sub-Spindle Work Shift(ESA Turret Top Plate)
TI5444
Shim Thickness
Tool Holder Offset Value
Turret Position
Work Shift
MainSpindle
OptionalSub-Spindle
14. If not already set to “0" (zero), set the X value under Shift Value to ”0" as follows:
A) Use the cursor keys to move the cursor to the X Data field under Shift Value.
B) At the Manual Data Input keyboard, key in the number “0" (zero).
C) Press the Input key.
15. Use the cursor keys to move the cursor to the Z Data field under Measurement.
- NOTE -
The tool holder offset value is the Z axis distance from the tool station centerline tothe tool holder surface used to set the work shift.
Refer to the appropriate tooling catalog for the tool holder offset value.
16. If setting work shift at the main spindle, key in:
+(Tool Holder Offset Value + shim thickness)
If setting work shift at the sub-spindle, key in:
-(Tool Holder Offset Value + shim thickness)
17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register.
18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm]from the face of the workpiece.
19. Jog the turret to a safe position for indexing.
M-392D 7-5
HARDINGE TURRET TOP PLATE
- NOTE -
This procedure is used to set the work shift on QUEST® series lathes equipped witha Hardinge turret top plate. Refer to page 7-2 for the procedure that applies toQUEST series lathes equipped with a VDI or ESA turret top plate.
1. Load a workpiece into the collet or step chuck at the desired length.
2. Activate Jog mode.
3. Jog the turret to a safe position for indexing.
- CAUTION -
The machine operator must make certain that no interference exists betweenthe spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, orworkpiece before manually indexing the turret.
4. Turn the Station switch to the number of an empty turret station.
5. Press the Turret Index push button to index the turret to the selected turret station.
6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jogfeedrate of approximately 37.5 in/min [952 mm/min].
7. Jog the turret top plate to within 1 inch [25 mm] of the face of the workpiece.
8. Use the Manual Axis Movement switch to select the Z axis.
- NOTE -
Refer to page 1-17 for information on using the Rapid Override switch to selecthandwheel increments.
9. Use the Rapid Override switch to select the desired handwheel increment.
10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in theappropriate direction to move the turret toward the face of the workpiece until a slight drag is feltwhen moving the shim between the turret top plate and workpiece. Refer to Figure 7.5 or 7.6.
11. Press the Offset Setting key to display the offset pages.
12. Press the right hand soft key until the Work Shift soft key is displayed.
13. Press the Work Shift soft key to display the Work Shift registers.
14. If not already set to “0" (zero), set the X value under Shift Value to ”0" as follows:
A) Use the cursor keys to move the cursor to the X Data field under Shift Value.
B) At the Manual Data Input keyboard, key in the number “0" (zero).
C) Press the Input key.
7-6 M-392D
M-392D 7-7
Figure 7.5 - Establishing the Main Spindle Work Shift(Hardinge Turret Top Plate)
TI4733
ShimThickness
Turret Position
Work Shift
MainSpindle
Figure 7.6 - Establishing the Sub-Spindle Work Shift(Hardinge Turret Top Plate)
TI4734A
Work Shift
MainSpindle
OptionalSub-Spindle
Turret Position
Shim Thickness
4.7875 inches[121.603 mm]
15. Use the cursor keys to move the cursor to the Z Data field under Measurement.
16. If setting work shift at the main spindle, key in the shim thickness as a positive (+) value.
If setting work shift at the sub-spindle, key in:
-(4.7875” [121.603 mm] + shim thickness)
17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register.
18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm]from the face of the workpiece.
19. Jog the turret to a safe position for indexing.
7-8 M-392D
- NOTES -
M-392D 7-9
- NOTES -
7-10 M-392D
CHAPTER 8 - TOOL OFFSETS
INTRODUCTION
The Tool Offset file is made up of two types of offsets: Tool Geometry Offsets and Tool Wear Off-sets. The control has the capacity to store 32 sets of each offset type (Offsets 01 through 32) in sepa-rate files.
- NOTE -
Information stored in the Geometry and Wear Offset files is automatically convertedinto the correct units when a programmed G20 or G21 command is used to switchbetween inch and metric mode.
Tool offsets are illustrated in Figures 8.1 through 8.12.
Machines equipped with an ESA turret top plate have the same X axis reference po-sition and travel specifications as a machine equipped with a VDI 30 turret top plate.As indicated in Figures 8.5 through 8.8, the diameter of the ESA turret top plate is1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.
Refer to the programmer’s manual (M-391) for:
• a description of turret reference point and the tool nose reference point.
• information on activating and canceling tool offsets
The following information is stored in the Tool Geometry Offset file:
X Tool Dimension
Diameter distance from the X axis tool touch-off point to the turret X axis referencepoint. Sign is determined by the direction from the tool nose reference point to the turretreference point.
Z Tool Dimension
Distance from the Z axis tool touch-off point to the turret Z axis reference point. Sign isdetermined by the direction from the tool nose reference point to the turret referencepoint.
Tool Orientation:
The orientation code describes the location of the center of the tool nose in relation tothe tool nose reference point.
Tool Nose Radius Value:
The distance from the cutting edge to the center of the tool nose radius.
M-392D 8-1
8-2 M-392D
Figure 8.1 - Square Shank Tool Offsetsfor Main Spindle Operation (VDI Top Plate)
TI4679A
Turret Z Axis Reference Position
Z Axis Tool Offset
Turret X Axis Reference Position
Main Spindle
+X Axis Tool Offset+Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Figure 8.2 - Square Shank Tool Offsetsfor Sub-Spindle Operation (VDI Top Plate)
Turret Z Axis Reference Position
TI4687A
Z Axis Tool Offset
Turret X Axis Reference Position
OptionalSub-Spindle
+X Axis Tool Offset-Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
M-392D 8-3
Figure 8.3 - Round Shank Tool Offsetsfor Main Spindle Operation (VDI Top Plate)
TI4680A
Turret Z Axis Reference Position
Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position
Main Spindle
+X Axis Tool Offset+Z Axis Tool Offset
Figure 8.4 - Round Shank Tool Offsetsfor Sub-Spindle Operation (VDI Top Plate)
Turret Z Axis Reference Position
Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position
+X Axis Tool Offset-Z Axis Tool Offset
TI4688A
8-4 M-392D
Figure 8.5 - Square Shank Tool Offsetsfor Main Spindle Operation (ESA Top Plate)
TI5439A
Turret Z Axis Reference Position
Z Axis Tool Offset
Turret X Axis Reference Position(Refer to the note on page 8-1)
Main Spindle
+X Axis Tool Offset+Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
1.378 [35.00]
Inches [Millimeters]
Figure 8.6 - Square Shank Tool Offsetsfor Sub-Spindle Operation (ESA Top Plate)
Turret Z Axis Reference Position
TI5440A
Z AxisTool Offset
Turret X Axis Reference PositionRefer to the note on page 8-1)
OptionalSub-Spindle
+X Axis Tool Offset-Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
1.378 [35.00]
Inches [Millimeters]
M-392D 8-5
Figure 8.7 - Round Shank Tool Offsetsfor Main Spindle Operation (ESA Top Plate)
TI5441A
Turret Z Axis Reference Position
Z Axis Tool Offset
Main Spindle
+X Axis Tool Offset+Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position(Refer to the note on page 8-1)
1.378 [35.00]
Inches [Millimeters]
Figure 8.8 - Round Shank Tool Offsetsfor Sub-Spindle Operation (ESA Top Plate)
Turret Z Axis Reference Position
TI5442A
Z Axis Tool Offset
OptionalSub-Spindle
+X Axis Tool Offset-Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position(Refer to the note on page 8-1)
1.378 [35.00]
Inches [Millimeters]
8-6 M-392D
Figure 8.9 - Square Shank Tool Offsetsfor Main Spindle Operation (Hardinge Top Plate)
TI4736
Main Spindle
+X Axis Tool Offset+Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position
Z Axis Tool Offset
Turret Z Axis Reference Position
Figure 8.10 - Square Shank Tool Offsetsfor Sub-Spindle Operation (Hardinge Top Plate)
TI4737
Turret Z Axis Reference Position
Z Axis Tool Offset
Turret X Axis Reference Position
OptionalSub-Spindle
+X Axis Tool Offset-Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
M-392D 8-7
Figure 8.11 - Round Shank Tool Offsetsfor Main Spindle Operation (Hardinge Top Plate)
TI4738
Turret Z Axis Reference Position
Z Axis Tool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position
Main Spindle
+X Axis Tool Offset+Z Axis Tool Offset
Figure 8.12 - Round Shank Tool Offsetsfor Sub-Spindle Operation (Hardinge Top Plate)
TI4739
Turret Z Axis Reference Position
Z AxisTool Offset
This distance equals ½the X Axis Tool Offset
Turret X Axis Reference Position
+X Axis Tool Offset-Z Axis Tool Offset
The Tool Wear Offset file allows the operator to enter minor dimensional changes for each tool tocompensate for tool wear. The Tool Wear Offset files coincide with the Geometry Offset files. When atool offset is activated, the control looks at the corresponding Tool Wear offset and performs the nec-essary corrections to compensate for tool wear.
The Tool Offset files allow the operator to easily make corrections resulting from tool changes,eliminating the need for large-scale modifications to the part programs.
The Data word format for the T word is T4. Tool Offsets are activated by the last two digits in the Tword. The first two digits specify the turret station
8-8 M-392D
STORING TOOL GEOMETRY OFFSETS IN MEMORY
- NOTE -
Tool offset values can be entered using the following methods:
Manually from the keyboard.
Through the part program or a separate program. Refer to the programmer’smanual (M-391) for information on storing tool offsets from a program.
SETTING TOOL OFFSETS FOR NON-CENTER WORKING TOOLS ON THE TURRET
1. Load a workpiece of known diameter and length into the collet or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriateprocedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set thetool offsets.
3. Enter the work shift value into the Z axis work shift register.
4. Activate Jog mode.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before indexing aturret.
6. Jog the turret to a safe position for indexing.
7. Index the turret to the selected station.
8. Mount the tool holder and tool onto the turret.
9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle.
10. Place a shim or scale against the face of the workpiece and use the handwheel to move theturret on the Z axis to gently touch the tool tip to the shim so that a slight drag is felt whenmoving the shim, as shown in Figure 8.13 or 8.14.
11. Press the Offset Setting key.
12. Press the Offset soft key to access the Tool Offset pages.
M-392D 8-9
13. If not already displayed, press the Geometry soft key to display the Tool Geometry Offsetpages.
14. Use the page and cursor keys to position the cursor at the Z axis field for the desired offset.
15. If touching off on the main spindle, key in the letter Z and the thickness of the shim as a positivevalue.
If touching off on the optional sub-spindle, key in the letter Z and the thickness of the shimas a negative value.
8-10 M-392D
Figure 8.13 - Tool Touch-Off Points at Main Spindle(VDI Turret Top Plate Shown)
TI4689A
Workpiece
Shim
O.D. Tool
Workpiece
Shim
I.D. Tool
Figure 8.14 - Tool Touch-Off Points at Optional Sub-Spindle(VDI Turret Top Plate Shown)
TI4690A
16. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under theappropriate offset number, as selected in step 14.
17. If touching off an O.D. working tool, jog the turret on the Z axis to clear the workpiece.
If touching off an I.D. working tool, use the handwheel to position the tool tip approximately.125 inch [3.2 mm] from the face of the workpiece.
18. Use the cursor keys to position the cursor at the X axis field for the desired offset.
19. If touching off an O.D. working tool, jog the turret on the X axis to place the tool tip beyond theO.D. of the part as shown in Figure 8.13 or 8.14.
20. If touching off an O.D. working tool, use the handwheel to move the turret on the Z axis until thetool tip is past the face of the workpiece.
21. Place the shim against the O.D. of the workpiece and turn the handwheel in the appropriatedirection until the tool tip gently makes contact with the shim, as shown in Figure 8.13 or 8.14.
22. Key in the diameter of the workpiece as a positive value.
Example: Diameter = 2.125
Input = X2.125
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.
23. Press the Measure soft key. The X axis offset value for the tool will now be displayed under theappropriate offset number.
24. Compensate for shim thickness:
If touching off an O.D. working tool and the control is set for diameter programming, entertwice the shim thickness as a negative (-) value and press the Input+ soft key.
If touching off an O.D. working tool and the control is set for radius programming, enter theshim thickness as a negative (-) value and press the Input+ soft key.
If touching off an I.D. working tool, no shim compensation is needed.
25. Jog the turret in the +X direction to clear the diameter of the workpiece by at least 1 inch [25mm] in the +X direction.
26. Jog the turret in the +Z direction to clear the face of the workpiece by at least 1 inch [25 mm] inthe +Z direction.
27. Jog the turret to a safe position for indexing.
28. Index the turret to the next tool station that is to be set.
29. Repeat steps 8 through 28 as required for other tools.
M-392D 8-11
SETTING TOOL OFFSETS FOR CENTER-WORKING TOOLS ON THE TURRET
- CAUTION -
This procedure is to be used for center-working tools such as drills, taps, andreamers ONLY.
The X axis Wear Offset must always set to zero for center-working tools.
1. Load a workpiece of known diameter and length into the collet or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriateprocedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set thetool offsets.
3. Enter the work shift value into the Z axis work shift register.
4. Activate Jog mode.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before indexing aturret.
6. Jog the turret to a safe position for indexing.
7. Index the turret to the selected station.
8. Mount the tool in the tool holder at the length desired.
9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle.
10. Place a shim against the face of the workpiece and use the handwheel to move the turret in theappropriate direction to gently touch the tool tip to the shim until a slight drag is felt when movingthe shim.
11. Press the Offset Setting key.
12. Press the Offset soft key to access the Tool Offset pages.
13. Press the Geometry soft key to access the Geometry Offset pages.
14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
8-12 M-392D
- NOTE -
Refer to the appropriate tooling catalog for information on tool holder dimensions.
15. If the control is set for diameter programming, enter twice the tool holder dimension as apositive (+) value and press the Input key.
If the control is set for radius programming, enter the tool holder dimension as a positive(+) value and press the Input key.
16. Use the cursor keys to position the cursor at the Z axis field for the desired offset.
17. Key in the letter Z and the thickness of the shim as a positive value.
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.
18. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under theappropriate offset number, as selected in step 14.
19. Move the turret in the appropriate Z direction to clear the workpiece.
20. Repeat steps 6 through 19 as required for other center-working tools.
M-392D 8-13
TOOL PROBE [Option]
INTRODUCTION
The tool probe allows the operator to set tool geometry offsets quickly and accurately. The toolprobe has been calibrated at the factory and is ready to use without further adjustment. Refer to “ToolProbe Calibration”, on page 8-21, for additional information.
The tool probe has three available operating modes:
• Manual Mode
• Semi-Automatic Mode
• Automatic Mode
MANUAL TOOL PROBE OPERATION
- NOTE -
The axis jog push buttons will not produce axis motion when the tool probe is acti-vated and deployed. Axis motion is obtained through the use of the manual pulsegenerator.
The optional sub-spindle must be at the E axis reference position before the toolprobe can be activated and deployed.
Once a tool has been probed, the X axis must be moved to the Reference Positionbefore the turret can be indexed.
This procedure assumes that all required turret tooling has been installed. Refer to:
Chapter 4 for information on installing tooling on a VDI turret top plate.
Chapter 5 for information on installing tooling on an ESA turret top plate.
Chapter 6 for information on installing tooling on a Hardinge turret top plate.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, tool probe, turret, turret tooling, or workpiece beforeindexing the turret.
1. Activate Rapid Reference mode.
2. Set the Manual Axis Movement switch to “X”.
3. Press the Rapid Reference push button to move the turret to the X axis reference position.
8-14 M-392D
4. If the machine is equipped with the sub-spindle option:
A) Set the Manual Axis Movement switch to “E”.
B) Press the Rapid Reference push button to move the sub-spindle to the reference position.
5. Activate Jog mode.
- CAUTION -
When the tool probe is turned ON, do not touch the probe with any objectother than the tool that is being set.
- NOTE -
Activating the tool probe will cause the control to automatically display the tool ge-ometry offset registers.
6. Press the Tool Probe push button to activate and deploy the tool probe.
7. Index the turret to the selected station.
8. Use the page and cursor keys to position the cursor at the desired offset number.
- CAUTION -
The machine operator must exercise care when approaching the tool probestylus with the tool. DO NOT impact the tool probe stylus with the tool.
9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe styluswith the tool.
10. Use the manual pulse generator to move the tool tip to a position near the appropriate side ofthe tool probe stylus.
11. Press the appropriate axis push button to choose which side of the tool probe stylus will beused. Refer to Figure 8.15.
12. Set the Rapid Override switch to the “1x” position for manual pulse generator control.
M-392D 8-15
Figure 8.15 - Axis Push Buttons
TI4716
X/Z
X/Z
X/Z X/Z
+X
ToolProbeStylus
+Z
CL
13. Turn the manual pulse generator one increment at a time to move the tool tip carefully againstthe tool probe stylus until the probe is tripped. The offset will register on the display screen
14. Move the tool away from the tool probe stylus.
15. Repeat steps 8 through 14 if touching the tool off on another axis.
16. Activate Rapid Reference mode.
17. Set the Manual Axis Movement switch to “X”.
18. Press the Rapid Reference push button to move the turret to the X axis reference position.
19. Activate Jog mode.
20. Repeat steps 7 through 19 if touching off additional tools.
21. Press the Tool Probe push button to deactivate and retract the tool probe.
SEMI-AUTOMATIC AND AUTOMATIC TOOL PROBE OPERATION
Datuming the Tool Probe
- CAUTION -
The tool probe must be correctly calibrated in manual mode before semi-auto-matic or automatic operation is performed.
All tools that are to be updated through semi-automatic or automatic toolprobe operation MUST have an offset value that is approximately equal to theactual tool offset Data. This can be accomplished by either of the followingmethods:
• Manually touching off the tools
• Using the tool probe in manual mode
- NOTE -
It is recommended that a standard turning tool be used to datum the probe.
The semi-automatic and automatic tool probe functions require that a master tool be used to datumthe probe prior to use. A master tool is defined as a tool that has known offset values defined in the tooloffset file.
The process of datuming the tool probe for semi-automatic or automatic operation is not to be con-fused with calibrating the probe for manual operation.
When the probe is calibrated for manual operation, parameters 5015 through 5018 areused to record the position of the probe stylus. Refer to “Tool Probe Calibration”, on page8-21, for additional information.
When the probe is datumed for semi-automatic or automatic operation, macro variables522 through 531 are used to record the position of the probe stylus. Refer to “Tool ProbeDatum Procedure”, on the next page.
8-16 M-392D
TOOL PROBE DATUM PROCEDURE
- NOTE -
Refer to “Entering a Program from the Keyboard”, page 3-10, for information on en-tering a program through the manual Data input keyboard.
1. Enter the following program into the control memory:
O____ (Datum Auto Tool Probe) ; Program Number (Operator Message)
#509=1 ; Specifies that Geometry and Wear Offsets are to be used
#530=.785 ;
#531=.3925 ;
G98 ; Inch/Millimeter per Minute Feedrate
M91 ; Enable Automatic Mode with Probe Extended
G65 P9011 K2. T_. H_. ; Call Macro Program 9011,K2. = Sets all Probe Faces for DatumT_. = Tool Station and Offset for Master Tool,H_. - Tool Quadrant (Tool Orientation Code)
M30 ; End of Program
2. Activate Rapid Reference mode.
3. Set the Manual Axis Movement switch to “X”.
4. Press the Rapid Reference push button to move the turret to the X axis reference position.
5. If the machine is equipped with the sub-spindle option:
A) Set the Manual Axis Movement switch to “E”.
B) Press the Rapid Reference push button to move the sub-spindle to the reference position.
6. Activate Jog mode.
7. Index the turret to the station with the master tool.
8. Press the Tool Probe push button to activate and deploy the tool probe.
- CAUTION -
The machine operator must exercise care when approaching the tool probestylus with the tool. DO NOT impact the tool probe stylus with the tool.
9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe styluswith the tool.
10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the cornerof the two sides of the probe stylus to be used for datuming.
11. Activate Automatic mode.
M-392D 8-17
- NOTE -
Refer to “Activating a Stored Program”, page 3-10, for information on activating aprogram.
12. Verify the datum program entered in step 1 is active.
13. Press the Cycle Start push button to datum the probe. After datuming is complete, the tool willreturn to the position it was jogged to in step 10.
14. Activate Rapid Reference mode.
15. Set the Manual Axis Movement switch to “X”.
16. Press the Rapid Reference push button to move the turret to the X axis reference position.
17. Press the Tool Probe push button to retract the tool probe.
8-18 M-392D
Semi-Automatic Tool Probe Operation
- CAUTION -
The tool probe must be correctly calibrated before semi-automatic operation isperformed.
The probe must be datumed before semi-automatic operation is performed.Refer to “Datuming the Tool Probe”, page 8-16 for information on datumingthe probe for semi-automatic operation.
- NOTE -
Refer to “Entering a Program from the Keyboard”, page 3-10, for information on en-tering a program through the manual Data input keyboard.
1. Enter the following program into the control memory:
O____ (Semi-Automatic Tool Probe Cycle) ; Program Number (Operator Message)
#509=1 ; Specifies that Geometry and Wear Offsets are to be used
G98 ; Inch/Millimeter per Minute Feedrate
M91 ; Enable Automatic Mode with Probe Extended
G65 P9011 T_. H_. ; Call Macro Program 9011,T_. = Offset Location for Tool Data (1 - 32),H_. - Tool Quadrant (Tool Orientation Code)
M30 ; End of Program
2. Activate Rapid Reference mode.
3. Set the Manual Axis Movement switch to “X”.
4. Press the Rapid Reference push button to move the turret to the X axis reference position.
5. If the machine is equipped with the sub-spindle option:
A) Set the Manual Axis Movement switch to “E”.
B) Press the Rapid Reference push button to move the sub-spindle to the reference position.
6. Activate Jog mode.
7. Index the turret to the selected station.
8. Press the Tool Probe push button to activate and deploy the tool probe.
- CAUTION -
The machine operator must exercise care when approaching the tool probestylus with the tool. DO NOT impact the tool probe stylus with the tool.
9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe styluswith the tool.
10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the cornerof the two sides of the probe stylus to be used for datuming.
11. Activate Automatic mode.
M-392D 8-19
- NOTE -
Refer to “Activating a Stored Program”, page 3-10, for information on activating aprogram.
12. Verify the program entered in step 1 is active.
13. Press the Cycle Start push button to probe the tool. After probing is complete, the tool will returnto the position it was jogged to in step 10.
14. Activate Rapid Reference mode.
15. Set the Manual Axis Movement switch to “X”.
16. Press the Rapid Reference push button to move the turret to the X axis reference position.
17. Press the Tool Probe push button to retract the tool probe.
- NOTE -
If probing additional tools, modify the values for the T and H words in programO3333 as needed for each tool to be probed.
18. Repeat steps 6 through 17, as needed, to probe additional tools.
Automatic Tool Probe Operation
- CAUTION -
The tool probe must be correctly calibrated before automatic operation is per-formed.
The probe must be datumed before automatic operation is performed. Refer to“Datuming the Tool Probe”, page 8-16 for information on datuming the probefor automatic operation.
Automatic tool probe operation can be performed by using either of the following methods:
• Execute automatic tool probe operation from within the part program
• Call a subprogram to execute automatic tool probe operation
Refer to the programmer’s manual (M-391) for information on programming automatic operation ofthe tool probe.
8-20 M-392D
TOOL PROBE CALIBRATION
The tool probe parameters are set at the factory when the probe is calibrated. Normally, it is notnecessary to re-calibrate the probe unless one of the following occurs:
• The probe tip has been replaced.
• The turning center is operating at a temperature that is significantly different than thatwhich the tool probe was calibrated at.
- NOTE -
The values for parameters 5015 and 5016 are set as diameter values.
Parameters 5015 through 5018 define the locations of the stylus contact surfaces used to set tooloffsets. Refer to Figure 8.16.
CALIBRATION PROCEDURE
1. Mount sufficient tooling on each turret to be able to probe all 4 surfaces on each tool probestylus.
2. Set tool offsets for the tooling installed in step 1 using the procedure outlined under “SettingTool Offsets for Non-Center Working Tools on the Turret”, starting on page 8-9.
3. Probe one of the tools installed in step 1 and observe any difference between the tool offsetobtained in step 2 and the tool offset established by the tool probe.
- NOTE -
Refer to Chapter 3 for information on editing machine parameters.
4. Modify the associated parameters (5015 through 5018) as needed to produce the same offsetusing both steps 2 and 3.
5. Repeat steps 2 through 4 as needed until identical results are obtained when using both steps 2and 3.
M-392D 8-21
Figure 8.16 - Tool Probe Parameter Definitions
TI4717A
Parameter 5018
+X
+Z
ProbeStylus
Parameter 5017
Parameter5015
Parameter5016
CL
ENTERING TOOL NOSE RADIUS VALUE AND ORIENTATION CODE
- NOTE -
If Tool Nose Radius Compensation is to be used, the tool nose radius value and thetool quadrant must be entered for each tool which uses Tool Nose Radius Compen-sation.
1. Press the Offset Setting key.
2. Press the Offset soft key to access the Tool Offset pages.
3. Press the Geometry soft key to display the tool geometry offsets.
4. Use the page and cursor keys to position the cursor at the R Data field for the desired offset.
5. Enter the tool nose radius value and press the Input key.
- NOTE-
The “T” value defines the orientation of the tool tip and has a range from 0 through 9.Refer to Figure 8.17.
6. Use the cursor keys to position the cursor at the T Data field for the desired offset.
7. Enter the tool orientation code number and press the Input key.
8. Repeat steps 4 through 7 for each tool, as required.
8-22 M-392D
Figure 8.17 - Tool Orientation Codes
TI2376
8
6
5 7
4 3
21
+X
+Z
Main Spindle Tailstock / Sub-Spindle
ADJUSTING TOOL WEAR OFFSETS
Tool wear offset adjustments are made by adding to or subtracting from an existing offset value us-ing positive or negative values and the Input+ soft key.
Tool Wear Offsets that are intended to adjust the position of the tool nose in the -X or -Z directionare entered as NEGATIVE values. Tool Wear Offsets that are intended to adjust the position of thetool nose in the +X or +Z direction are entered as POSITIVE values.
ADJUSTING X AND Z AXIS TOOL WEAR OFFSETS
1. Press the Offset Setting key to display the offset pages.
2. Press the Offset soft key to access the Tool Offset pages.
3. Press the Wear soft key to display the Wear Offset page.
4. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
5. Enter the X axis wear value as follows:
If the control is set for Diameter Programming, enter the wear offset as a diameter value.
If the control is set for Radius Programming, enter one half the measured (diameter) wearoffset value.
6. Press the Input+ soft key.
7. Use the cursor keys to position the cursor at the Z axis field for the desired offset.
8. Enter the Z axis wear value.
9. Press the Input+ soft key.
10. Repeat steps 4 through 9 for each tool as required.
RULES FOR ADJUSTING WEAR OFFSETS
1. Negative (-) offset values MUST be signed.
2. Wear Offset values may not exceed .5000 inch [12.700 mm].
M-392D 8-23
- NOTES -
8-24 M-392D
CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER
- WARNING -
Tighten all draw tube screws before beginning spindle operation.
- CAUTION -
Never operate the main spindle without a work-holding device if the draw tubeis in the spindle.
INTRODUCTION
The main spindle is equipped with a .875 inch [22.2 mm] stroke, hydraulically actuated collet closer.The hydraulic collet closer can be programmed for bar feed operation or it can be operated manuallyfor machine setup and chucking operations. If repairs to the collet closer assembly are required, theENTIRE ASSEMBLY must be removed and returned to the factory. Refer to the maintenance manual(M-393) for information on removing or installing the collet closer assembly.
SPINDLE CAPACITIES
- CAUTION -
When machining bar stock that extends back into the spindle draw tube on amachine equipped with a high-speed spindle, spindle liners MUST be usedwhen machining bar stock below the minimum size listed in the following ta-ble.
Refer to “Spindle Liners”, page 9-13, for additional information.
QUEST® series lathes have the following maximum through-spindle capacities:
MachineModel
Maximum Through-SpindleCapacity
Inch [Millimeter]
Minimum Bar StockDiameter for Operationwithout a Spindle Liner
QUEST 6/42 Lathe 1.625 [41.27] 1.500 [38.10]
QUEST 8/51 Lathe 2.000 [50.80] 1.875 [47.63]
QUEST 10/65 Lathe 2.500 [63.50] 2.375 [60.33]
M-392D 9-1
FREE SPINDLE
A “Free Spindle” condition allows the main spindle to be turned by hand. To obtain a free spindle,proceed as follows:
- NOTE -
To obtain a free spindle, the control must be ON and the spindle must not be rotat-ing.
1. Power up the machine as described in Chapter 2.
2. Press the control Reset key.
3. Press the Main Spindle Free push button.
HYDRAULIC PRESSURE CONTROL
The collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic pressure con-trols are located at the back of the machine.
Knob “A”, Figure 9.1, 9.2, 9.3, or 9.4 is used to adjust the hydraulic pressure applied to the colletcloser draw bar.
Gauge “B”, Figure 9.1, 9.2, 9.3, or 9.4 registers the collet closer hydraulic pressure in psig and bars.
Refer to Table 9.1, 9.2, or 9.3 to determine the approximate force that will be applied to the colletcloser draw bar for a given pressure.
A check valve system positively holds the closer open or closed, whichever is active, in the event ofan hydraulic pressure failure.
- CAUTION -
DO NOT exceed the maximum pressure setting, as shown in Tables 9.1, 9.2,and 9.3.
The collet closer hydraulic pressure should be maintained at 500 psi [34.5 bar]when operating at spindle speeds above 4,200 rpm.
- NOTE -
It is the responsibility of the machine operator or set-up person to properly adjust thecollet closer hydraulic pressure, based on the type of material to be machined andthe configuration of the workpiece.
ADJUSTING THE MAIN SPINDLE HYDRAULIC PRESSURE
1. Loosen the knurled lock nut behind adjustment knob “A”, Figure 9.1, 9.2, 9.3, or 9.4.
2. Turn the adjustment knob clockwise or counterclockwise to decrease or increase the colletcloser hydraulic pressure.
3. Tighten the knurled lock nut to secure the setting.
9-2 M-392D
M-392D 9-3
Figure 9.1 - Main Collet Closer Pressure Adjustment(Machine Equipped with Standard Spindle Drive and Tailstock)
A
B
TP4285
Figure 9.2 - Main Collet Closer Pressure Adjustment(Machine Equipped with Standard Spindle Drive and Sub-Spindle)
TP4196
B
A
9-4 M-392D
Figure 9.3 - Main Collet Closer Pressure Adjustment(Machine Equipped with High Speed Spindle Drive and Tailstock)
TP4815
A
B
Figure 9.4 - Main Collet Closer Pressure Adjustment(Machine Equipped with High Speed Spindle Drive and Sub-Spindle)
TP4816
A
B
M-392D 9-5
English Metric
Gauge Pressure(psig)
Draw Bar Force(lbs)
Gauge Pressure(bar)
Draw Bar Force(daN)
100 1,206 6.9 538
200 2,412 13.8 1,076
300 3,619 20.7 1,615
400 4,826 27.6 2,152
500 6,000 34.5 2,678
Table 9.1 - Main Spindle Collet Closer Draw Bar Force(QUEST® 6/42 Lathes)
English Metric
Gauge Pressure(psig)
Draw Bar Force(lbs)
Gauge Pressure(bar)
Draw Bar Force(daN)
100 2,000 6.9 890
200 4,000 13.8 1,780
300 6,000 20.7 2,670
400 8,000 27.6 3,560
500 10,000 34.5 4,450
Table 9.2 - Main Spindle Collet Closer Draw Bar Force(QUEST 8/51 Lathes)
English Metric
Gauge Pressure(psig)
Draw Bar Force(lbs)
Gauge Pressure(bar)
Draw Bar Force(daN)
100 2,533 6.9 1,127
200 5,066 13.8 2,253
300 7,599 20.7 3,380
400 10,132 27.6 4,507
500 12,665 34.5 5,634
Table 9.3 - Main Spindle Collet Closer Draw Bar Force(QUEST 10/65 Lathes)
MAIN COLLET CLOSER OPERATION
AUTOMATIC OPERATION
For automatic operation, program M21 to open the collet and M22 to close the collet. The M21(Open Collet) command may be executed while the spindle is running. M21 will remain active until it iscanceled by an M22 (Close Collet) command. While M21 is active, the Main Open/Close push buttonwill not be active. A programmed M22 (Collet Close) command will remain active until it is canceled byan M21 (Open Collet) command.
MANUAL OPERATION
- NOTE -
Manual operation of the collet closer is not possible while Cycle Start is active.
When the bar feed option is turned OFF, the collet closer can be manually operated in any mode.When the bar feed option is turned ON, the machine must be in Jog mode to manually operate the col-let closer. Use the Main Open/Close push button to operate the collet closer manually.
CHUCKING MODES
There is no default chucking mode. The current chucking mode will remain active until canceled bythe appropriate command (M27 or M28).
External chucking mode permits the use of work-holding fixtures that grip the workpiece externally.Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally.
SWITCHING THE CHUCKING MODE
1. Check to be sure the Main Open/Close indicator light is ON. Place a workpiece in the collet andpress the Main Open/Close push button, if necessary.
2. Activate Manual Data Input mode.
3. Press the Program soft key.
4. At the manual Data input keyboard:
Key in “M28” for External Chucking
Key in “M27” for Internal Chucking
5. Press the Insert key.
6. Press the EOB (End of Block) key.
7. Press the Insert key.
8. Close the machine guard door and press the Cycle Start push button.
9. Press the control Reset key. The selected chucking mode will be active
9-6 M-392D
CLEANING THE SPINDLE
As a general rule, the spindle and spindle draw tube should be cleaned between setups or monthlyif a long-run job is on the machine. However, when the machine is run more than one shift per day orcertain types of materials are being machined, it may be necessary to clean the spindle and spindledraw tube more often. Use the spindle tooling removal and installation procedures that follow forcleaning the spindle and draw tube.
SPINDLE TOOLING
- CAUTION -
Read and follow all safety recommendations and operating limits for anywork-holding device installed in the spindle. DO NOT EXCEED the rated ca-pacity of the work-holding device.
QUEST® series machines are available with a standard or high speed main spindle. The highspeed spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced toISO G2.5 or better.
All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limi-tations and balance specifications.
Hardinge Inc. offers chucks balanced to G2.5 or better for high speed applications.
REMOVING SPINDLE TOOLING
- CAUTION -
Do not operate the collet closerwhen a collet or step chuck ismounted in place without gripping apiece of stock or a plug of the cor-rect size.
1. Power the machine up using the procedureoutlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. If necessary, press the Main Open/Close pushbutton to open work-holding device in the colletcloser.
5. At the left end of the machine, remove drawtube access cover “C”, Figure 9.5.
6. If present, remove the plug from the end of thespindle draw tube.
M-392D 9-7
Figure 9.5 - Main Spindle DrawTube Access Cover
C
TP4088
7. Completely loosen six screws “D”, Figure 9.6.
- NOTE -
Six screws “D”, Figure 9.6, must becompletely disengaged from the colletcloser liner before draw tube nut “E”can be rotated.
Removal of a jaw chuck or step chuckmay require the assistance of a secondperson.
8. Rotate draw tube nut “E”, Figure 9.6,counterclockwise to disengage the draw tubefrom the work-holding device.
- WARNING -
Be prepared to accept the weight ofthe work-holding device.
9. Remove the work-holding device from thespindle.
10. If the machine is equipped with the optionalsub-spindle, cover the sub-spindle to protect it from chips while the main spindle is beingcleaned.
11. Close the main coolant guard door.
12. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of thespindle.
- WARNING -
The draw tube may be HOT when running aggressive duty cycles on machinesequipped with a high speed spindle.
13. Completely remove the draw tube from the back of the spindle.
14. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of thespindle a second time.
15. Clean the spindle and draw tube.
16. Lightly lubricate the bearing surfaces of the draw tube with Molylube® Anti-Seize grease.
17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp® SHC 32 grease.
18. Carefully replace the draw tube in the spindle.
19. If spindle tooling is to be installed at this time, proceed to “Installing Spindle Tooling”, beginningon page 9-9.
If spindle tooling is not to be installed at this time:
A) Replace the draw tube plug.
B) Replace draw tube access cover “C”, Figure 9.5.
9-8 M-392D
Figure 9.6 - Main Spindle Draw Tube Nut
TP4821
E
DF
INSTALLING SPINDLE TOOLING
- NOTE -
For the best surface finish and part roundness, the main spindle and draw tube havebeen balanced together at the factory. Although the spindle and draw tube can berun in other positions, the best balance is when etched mark “F”, Figure 9.6, andspindle drive button “G”, Figure 9.7, are aligned.
Two procedures are outlined in this section. The first procedure, which begins below, covers the in-stallation of collets and step chucks. The second procedure, beginning on page 9-11, covers the in-stallation of jaw chucks.
Collet or Step Chuck
This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”,beginning on page 9-7.
If previously used spindle tooling has just been removed, proceed to step 6.
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. Remove draw tube access cover “C”, Figure 9.5.
5. If present, remove the plug from the end of the spindle draw tube.
- NOTE -
The collet and spindle bore MUST be clean.
6. Clean the spindle bore and the collet or stepchuck and closer to be installed.
7. Press the Main Spindle Free push button torelease the spindle brake and allow the spindleto be rotated.
8. Manually position spindle drive button “G”,Figure 9.7, to the top dead center (12 o’clock)position.
9. Press the Main Spindle Free push button againto have the brake secure the spindle drivebutton at 12 o’clock.
M-392D 9-9
Figure 9.7 - Main Spindle Nose withDrive Button at Top Dead Center
G
TP4820
- WARNING -
To insure operator safety:- DO NOT use cast iron step chucks.- DO NOT use a step chuck without a step chuck closer.
- NOTE -
Installation of a step chuck may require the assistance of a second person.
10. If installing a step chuck in the spindle, place the step chuck closer against the spindle andinstall the mounting screws securely.
11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle untilit makes contact with the draw tube.
12. Carefully push the draw tube against the back of the collet while rotating the draw tubeclockwise to start the threads of the collet into the threads of the draw tube.
- NOTE -
Adjustment of the collet or step chuck may require the assistance of a second per-son.
13. Select the largest diameter workpiece which is to be chucked and position this part in the colletor step chuck.
14. Rotate draw tube nut “E”, Figure 9.6, clockwise until the workpiece is gripped tightly; then, backthe draw tube nut off ¼ to ½ turn.
15. Rotate the draw tube the shortest distance to locate etched mark “F” at top dead center (12o’clock) position.
16. Tighten six draw tube screws “D”.
17. Press the Main Open/Close push button to close the collet and test the gripping force on theworkpiece.
If the gripping force is satisfactory, then go to step 14.
If the gripping force is more or less than desired, adjust knob “A”, Figure 9.1, 9.2, 9.3, or9.4, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1, 9.2,or 9.3.
- CAUTION -
If the machine will not be operated with a bar feed system, the draw tube plugshould be installed in the end of the spindle draw tube to prevent coolant andchips from entering the spindle drive motor compartment.
18. Install the plug in the end of the spindle draw tube if a bar feed system will not be used.
19. Replace draw tube access cover “C”, Figure 9.5.
9-10 M-392D
Jaw Chuck
This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”,beginning on page 9-7.
If previously used spindle tooling has just been removed, proceed to step 6.
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. Remove draw tube access cover “C”, Figure 9.5.
5. If present, remove the plug from the end of the spindle draw tube.
- NOTE -
The jaw chuck and spindle bore MUST be clean.
6. Clean the jaw chuck and spindle bore.
7. Press the Main Spindle Free push button to release the spindle brake and allow the spindle tobe rotated.
8. Manually position spindle drive button “G”, Figure 9.7, to the top dead center (12 o’clock)position.
9. Press Main Spindle Free push button again to have the brake secure the spindle drive button at12 o’clock.
10. Place the chuck in the spindle and install the mounting screws securely.
11. Carefully push the draw tube against the back of the chuck while rotating the draw tubeclockwise to start the threads of the chuck into the threads of the draw tube.
12. Thread the draw tube onto the 3 jaw chuck as far as possible.
13. Rotate the draw tube counterclockwise to locate etched mark “F”, Figure 9.6, at top dead center(12 o’clock) position.
14. Tighten six draw tube screws “D”.
(Continued on next page)
M-392D 9-11
15. Place a workpiece into the chuck and press the Main Open/Close push button to close thechuck and test the gripping force on the workpiece.
If the gripping force is satisfactory, then go to step 12.
If the gripping force is more or less than desired, adjust knob “A”, Figure 9.1, 9.2, 9.3, or9.4, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1, 9.2,or 9.3.
- CAUTION -
If the machine will not be operated with a bar feed system, the draw tube plugshould be installed in the end of the spindle draw tube to prevent coolant andchips from entering the spindle drive motor compartment.
16. Install the plug in the end of the spindle draw tube if a bar feed system will not be used.
17. Replace draw tube access cover “C”, Figure 9.5.
9-12 M-392D
SPINDLE LINERS
INTRODUCTION
- CAUTION -
When machining bar stock that extends back into the spindle draw tube on amachine equipped with a high-speed spindle, spindle liners MUST be usedwhen machining bar stock below the minimum size listed in the table shownon page 9-1.
The spindle liner supports and aligns the bar stock in the spindle draw tube. Each spindle liner con-sists of four nylon spindle liner bushings, three spindle liner spacers, and one spindle liner nut. Borethe four spindle liner bushings to the appropriate size and install the spindle liner components in thespindle draw tube.
SPINDLE LINER BUSHING
- NOTE -
A spindle liner requires four spindle liner bushings bored to the same size.
A round capacity hole will always be used in the spindle liner bushing, regardless ofthe profile of the bar stock to be machined (round, square, hex, ...).
Referring to Figure 9.8, the dimensions of the spindle liner bushings are as follows:
MachineModel
Dimension “A”Inch [Millimeter]
Dimension “B”Inch [Millimeter]
Dimension “C”Inch [Millimeter]
QUEST® 6/42 Lathe 1.673 2.677 .250
QUEST 8/51 Lathe 2.080 3.203 .250
QUEST 10/65 Lathe 2.628 4.816 .468
M-392D 9-13
Figure 9.8 - Spindle Liner Bushing(Cross Section View)
TP4838
A
B
C
Boring a Bushing to Size
1. Install a 3 jaw chuck or step check in the machine spindle that will accommodate the O.D. ofthe spindle liner bushing.
2. Insert the spindle liner bushing into the selected work-holding device and press the MainOpen/Close push button to close the work-holding device.
- CAUTION -
If drilling the capacity hole for clearance purposes, be sure to drill the capacityhole undersize.
3. If necessary, use a drill to open up the capacity hole to accommodate the boring bar.
4. Bore the capacity hole in the spindle liner bushing to a diameter that is .020 inch [.5 millime-ter] larger than the bar stock to be machined.
INSTALLING OR REMOVING THE SPINDLE LINER
- NOTE -
The spindle, draw tube, and spindle liner components must be cleaned beforeinstallation.
1. Press the control Reset key.
2. Activate Jog mode.
3. If the collet closer is in the closed position, press the Main Open/Close push button to set thecollet closer to the open position.
4. On the machine, press the Emergency Stop push button.
5. On the bar feed unit or bar loader, press the Emergency Stop push button.
6. If necessary, move the bar feed unit or bar loader away from the machine.
7. Remove draw tube access cover “C”, Figure 9.5.
8. Install or remove the spindle liner bushings components. Refer to Figure 9.9.
Installation:
A) Install the spindle liner bushings and spacers.
B) Install the spindle liner nut and tighten the three screws.
Removal:
A) Loosen the three screws and remove the spindle liner nut.
B) Remove the spindle liner bushings and spacers.
9-14 M-392D
9. Replace draw tube access cover “C”, Figure 9.5.
10. Position the bar feed unit or bar loader in operating position.
11. Clear the Emergency Stop on the bar feed unit or bar loader.
12. Pull the Emergency Stop push button on the machine out to the first detent, wait two seconds;then, pull the push button out to the end of travel and release.
13. Press the control Reset key.
M-392D 9-15Revised: January 18, 2008
Figure 9.9 - Spindle Liner Components Installed in Spindle Draw Tube
TP4806
Spindle Liner SpacersSpindle Liner Nut
Spindle Liner Bushings
- NOTES -
9-16 M-392D
CHAPTER 10 - TAILSTOCK
INTRODUCTION
QUEST® series lathes feature a hydraulically operated, programmable tailstock. The hydraulicsystem is located at the rear of the machine. The tailstock gives added support when machining longparts and reduces part deflection. This allows for closer tolerances, better surface finishes, and higherspeeds and feeds than would otherwise be possible.
- WARNING -
Be sure all personnel are clear of the tailstock before initiating tailstock mo-tion.
- CAUTION -
Always make certain the turret is in a safe index position before moving thetailstock toward the machine spindle.
Check and, if necessary, adjust the tailstock feedrate before using thetailstock for machining operations. Refer to “Checking and AdjustingTailstock Feedrate”, page 10-8.
Check and, if necessary, adjust the tailstock force before using the tailstockfor machining operations. Refer to “Checking and Adjusting Tailstock Force”,page 10-9.
The tailstock assembly is advanced and retracted by means of a hydraulic cylinder. Tailstock mo-tion can be controlled automatically from the part program or manually using push buttons on the op-erator control panel.
There are two rates of motion:
• The rapid traverse rate (approximately 300 in/min [7620 mm/min])
• The adjustable feedrate.
The tailstock incorporates a “safety shear” feature to prevent damage to the tooling, turret,tailstock, and linear ways in the event that the turret contacts the tailstock. If contact is made betweenthe tailstock and turret, the “safety shear” feature allows the tailstock to be pivoted away from the tur-ret. Refer to the maintenance manual (M-393) for instructions on aligning the tailstock.
Tailstock overtravel protection in the forward direction is provided by macro program 9130. If thetailstock reaches the overtravel coordinate programmed in macro program 9130, tailstock motion willstop and the machine is put into a feed hold condition.
M-392D 10-1
TRAVEL SPECIFICATIONS
The tailstock travel specifications are shown in Figure 10.1. Tailstock Home (Retract) is a fixed po-sition. The forward (extend) position can be adjusted to suit the workpiece length.
10-2 M-392D
Figure 10.1 - Tailstock Travel Specifications
TI4651A
28.75 [730.3]
MainSpindle
CL
+X
+Z
Z0
7.25[184.2]
Dependent on Tailstock Center used
NOTE: All dimensions are shown in inches [millimeters]
Tailstock at FixedHome Position
Tailstock atForward Position
TAILSTOCK POSITIONS
Four tailstock positions are recognized by the control:
• Fixed Home Position
• Adjustable Home Position (Retract)
• Rapid-To-Feed Position
• Overtravel Position
- NOTE -
The programmer establishes the adjustable home, rapid-to-feed, and overtravel po-sitions, as needed, through macro program 9130. When the tailstock is commandedto one of these positions, the tip of the tailstock center will be moved to the com-manded position.
Refer to the programmer’s manual (M-391) for information on setting the adjustablehome, rapid-to-feed, and overtravel positions through macro program 9130.
FIXED HOME POSITION
The fixed home position is at the maximum tailstock travel away from the machine spindle. Refer to“Tailstock Movement”, page 10-5, for information on moving the tailstock to this position. This positionis NOT adjustable. Refer to Figure 10.1.
ADJUSTABLE HOME POSITION (RETRACT)
The adjustable home position is located between the rapid-to-feed position and the fixed home po-sition. This position is intended to minimize tailstock motion, resulting in lower cycle times.
When the tailstock is commanded to the adjustable home position, the tip of the live center is posi-tioned at the adjustable home position.
RAPID-TO-FEED POSITION
The rapid-to-feed position is the coordinate at which the rapid forward motion of the tailstock is re-duced to provide acceptable contact with the workpiece.
OVERTRAVEL POSITION
The overtravel position is the coordinate at which the forward motion of the tailstock is stopped andthe machine is put into a feed hold condition.
M-392D 10-3
TAILSTOCK SAFETY INTERLOCKS
There are two safety interlocks associated with the tailstock. These interlocks are designed to re-duce the possibility of crashes that result from incorrect tailstock positioning.
CYCLE START INTERLOCK
To activate Cycle Start while in Automatic, Manual Data Input, or Single mode, the tailstock MUSTbe in one of the following positions:
• Fixed Home position
• Adjustable Home Position (Retract)
• Forward Position (Any coordinate between the rapid-to-feed and the overtravel posi-tions)
If the tailstock is not in one of these three positions, an alarm will be generated by the control whenthe Cycle Start push button is pressed.
To clear the alarm, move the tailstock to the fixed home position. Refer to “Tailstock Movement”,page 10-5, for information on moving the tailstock.
OVERTRAVEL INTERLOCK
While in Automatic, Manual Data Input, or Single mode, M84 commands RAPID tailstock motiontoward the machine spindle. Macro program 9130 MUST be executed to set the rapid-to-feed positionso that the tailstock center will FEED onto the workpiece. If no workpiece is present, the tailstock willcontinue to move toward the machine spindle, resulting in an overtravel condition.
Tailstock overtravel protection in the forward direction is provided by the overtravel coordinate pro-grammed in macro program 9130. If the tailstock reaches the overtravel coordinate, an alarm will begenerated and the machine will be put into a feed hold condition.
To clear the alarm:
1. Press the control Reset key.
2. Press the right-hand Z/E push button to move the tailstock to the fixed home position at therapid traverse rate.
10-4 M-392D
TAILSTOCK MOVEMENT
- NOTE -
Refer to the programmer’s manual (M-391) for information on programming tailstockoperation.
Generally, the machine control must be in Jog mode to manually control tailstock motion. The nota-ble exception is during “between-center” work. If M30 (End of Program) is active while in Automaticmode, it is possible to manually jog the tailstock without switching to Jog mode. Be aware that activat-ing Jog mode will cancel this feature until another M30 is read by the control while in Automatic mode.
The Z/E push buttons are used to jog the tailstock in the indicated direction.
While in manual mode, the tailstock will always FEED toward the machine spindle and RAPIDaway from the machine spindle.
MANUAL MOVEMENT
Initiating Manual Movement
1. Activate Jog mode.
2. Set the Manual Axis Movement switch to “E” to select the tailstock.
3. Move the tailstock as follows:
TOWARD THE MACHINE SPINDLE
When the tailstock is to the right of the rapid-to-feed position:
Press the left-hand Z/E push button to FEED the tailstock toward the machine spindle(-Z direction).
Press the left-hand Z/E push button and the Rapid Traverse push button to RAPID thetailstock toward the machine spindle (-Z direction).
TOWARD THE FIXED HOME POSITION
Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.
Stopping Manual Movement
Manual tailstock motion can be stopped by pressing the Emergency Stop push button, Hold pushbutton, or control Reset key.
EMERGENCY STOP
To initiate tailstock motion after an Emergency Stop:
1. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.
2. Press the control Reset key.
3. Activate Jog mode.
4. Press a Z/E push button to move the tailstock in the desired direction.
HOLD or RESET
To initiate tailstock motion after a Hold or control Reset, press a Z/E push button to movethe tailstock in the desired direction.
M-392D 10-5Revised: January 18, 2008
PROGRAMMED MOVEMENT
Initiating Programmed Movement
- NOTE -
The machine control MUST be in Automatic, Manual Data Input, or Single mode tocommand tailstock motion using M codes.
M84 Tailstock Forward
When an M84 is read by the control, the tailstock will RAPID forward (toward the machinespindle) until the rapid-to-feed position is reached. At that point, the tailstock will slow tothe preset feedrate and feed onto the workpiece.
M85 Tailstock Retract
When an M85 is read by the control, the tailstock will move to the first home position en-countered at RAPID TRAVERSE rate.
M86 Tailstock Home
When an M86 is read by the control, the tailstock will move to the fixed home position atthe RAPID TRAVERSE rate.
Stopping Programmed Movement
Programmed tailstock motion can be stopped by pressing the Emergency Stop push button, FeedHold push button, or control Reset key.
EMERGENCY STOP
To initiate programmed tailstock motion after an Emergency Stop:
1. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.
2. Press the control Reset key.
3. Activate Jog mode.
4. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.
5. Reset the program to the beginning of the current operation.
6. Activate Automatic mode and press the Cycle Start push button.
10-6 M-392DRevised: January 18, 2008
FEED HOLD
To initiate programmed tailstock motion after a Feed Hold, press the Cycle Start push but-ton.
RESET
To initiate programmed tailstock motion after a control Reset:
1. Activate Jog mode.
2. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.
3. Reset the program to the beginning of the current operation.
4. Activate Automatic mode and press the Cycle Start push button.
M-392D 10-7
CHECKING AND ADJUSTING TAILSTOCK FEEDRATE
1. Activate Jog mode.
2. Press the right-hand Z/E push button to Home the tailstock.
3. Press the left-hand Z/E push button to move the tailstock toward the machine spindle andobserve the current tailstock feedrate. The tailstock will move toward the machine spindle at theadjustable feedrate.
4. If the tailstock feedrate needs to be changed, turn knob “C”, Figure 10.2 or 10.3, in the requireddirection to increase or decrease the feedrate as desired.
5. Repeat steps 2 through 4 until the desired feedrate is achieved.
10-8 M-392D
Figure 10.2 - Hydraulic System(Machine with Standard Spindle)
TP4285
A
B
C
Figure 10.3 - Hydraulic System(Machine with High Speed Spindle)
TP4815
A
B
C
CHECKING AND ADJUSTING TAILSTOCK FORCE
The force applied to the workpiece is controlled by hydraulic oil pressure which is regulated byvalve “A”, Figure 10.2 or 10.3. Gauge “B” indicates the force in pounds per square inch and bars. Ta-ble 10.1 lists the approximate force in pounds and dekanewtons which will be applied to the workpiecefor a given gauge pressure.
1. Activate Jog mode.
2. Use the left-hand Z/E push button to engage the tailstock with the workpiece.
3. Check the tailstock hydraulic pressure on gauge “B”, Figure 10.2 or 10.3.
If the tailstock hydraulic pressure needs to be adjusted, go to step 4.
If the tailstock hydraulic pressure does not need to be adjusted, go to step 6.
M-392D 10-9
English Metric
Gauge Pressure(psig)
Applied Force(lbs)
Gauge Pressure(bar)
Applied Force(daN)
200 630 13.8 280
300 940 20.7 420
400 1,260 27.6 560
500 1,570 34.5 700
Table 10.1 - Applied Tailstock Force
- CAUTION -
Recommended tailstock pressure is 350 psig (24 bars). For maximum operat-ing safety and to ensure that the hydraulic tailstock functions correctly, neverset the tailstock pressure below 200 psig [13.8 bars].
4. Loosen the knurled lock nut on valve “A” and turn the adjusting nut in the required direction untilthe desired pressure registers on gauge “B”. Refer to Table 10.1.
5. Tighten the lock nut on valve “A”.
6. Press the right-hand Z/E push button to move the tailstock to the fixed home position.
REMOVING AND INSTALLING A LIVE CENTER
REMOVING A LIVE CENTER
- NOTE -
Release nut "E", Figure 10.4, requires a 2 inch wrench, which is supplied with themachine. The wrench part number is QC 0009189.
Remove the live center by rotating release nut "E", Figure 10.4, outward to push live center "D" fromthe tailstock bushing.
INSTALLING A LIVE CENTER
1. Rotate the release nut inward before installing a live center.
2. Insert the live center into the tailstock bushing.
The live center will be seated in the bushing the first time it contacts a workpiece.
10-10 M-392D
Figure 10.4 - Live Centerand Release Nut
TI5362
D
E
- NOTES -
M-392D 10-11
- NOTES -
10-12 M-392D
CHAPTER 11 - INPUT/OUTPUT DEVICES
INTRODUCTION
QUEST® series lathes are available with either the standard operator interface or the optionalPC-based operator interface. When indicated, refer to the specific information relating to the appro-priate operator interface.
The purpose of this chapter is to explain the transfer of data between the various input/output de-vices and the CNC control.
INPUT/OUTPUT DEVICE LOCATIONS
STANDARD OPERATOR INTERFACE
- NOTE -
The RS-232 port supplied with the standard operator interface is a 25 pin connec-tion.
The standard operator interface is equipped with one ATA Flash Card port and one physicalRS-232 port, shown in Figure 11.1.
M-392D 11-1
Figure 11.1 - Data Input/Output Ports(Standard Operator Interface)
TP4090
RS-232Serial Port
ATA FlashCard Port
PC-BASED OPERATOR INTERFACE [Option]
- NOTE -
The RS-232 port supplied with the PC-based operator interface is a 15 pin connec-tion.
The PC-based operator interface is equipped with the following devices for data input/output:
• ATA Flash Card Port
• RS-232 Serial Port (15 pin) for PC Data
• RS-232 Serial Port (25 pin) for NC Data
• 3½” Disk Drive
• Internal Hard Disk
• CD-ROM Drive
Refer to Figures 11.2, 11.3, and 11.4.
Open the Data port cover, Figure 11.2, to gain access to the PC Data RS-232, universal serial, key-board, and mouse ports.
11-2 M-392D
Figure 11.2 - ATA Flash Card Portand Cover for RS-232 Port
(PC-Based Operator Interface)
TP4623A
Cover for3½” Disk Drive and
CD-ROM Drive
Data PortCover
ATA FlashCard Port
RS-232 Portfor NC Data
M-392D 11-3
Figure 11.3 - RS-232 Port(PC-Based Operator Interface)
TP4624A
RS-232 Portfor PC Data
Figure 11.4 - 3½” Disk Driveand CD-ROM Drive
(PC-Based Operator Interface)
3½” DiskDrive
CD-ROMDrive
TP4622
INPUT/OUTPUT DEVICE SELECTION
The input/output device to be used is selected through the I/O Channel setting, which is discussedon page 2-8. The valid settings for the I/O Channel are 0, 1, 2, and 4.
I/O CHANNEL 0, 1, OR 2
Three independent port assignments are available to allow the operator or programmer to estab-lish three different I/O port configurations for the same physical RS-232 port. These three configura-tions are designated as channels 0, 1, and 2.
Instead of changing the associated parameters to reassign the baud rate and stop bits, it is possibleto select a different I/O port configuration and have the changes implemented by the control automati-cally.
Setting the I/O Channel to 0, 1, or 2 selects the RS-232 port and selects which configuration will beactive.
Refer to page 11-6 for information on the RS-232 port.
Refer to page 11-8 for information on the RS-232 port parameter settings.
11-4 M-392D
I/O CHANNEL 4
Standard Operator Interface
Setting the I/O Channel to 4 selects the ATA Flash Card port. Refer to page 11-15 for information onusing the ATA Flash Card port.
PC-Based Operator Interface
Setting the I/O Channel to 4 allows the operator to select any of the following devices for data in-put/output:
• 3½” Disk Drive (Drive A:)
• Internal Hard Disk (Drive C: and D:)
• CD-ROM Drive (Drive E:)
• ATA Flash Card Port (Drive F:)
SELECTING THE INPUT/OUTPUT DEVICE
- NOTE -
If the ATA flash card is to be used on the PC-based operator interface, it must beplugged into the flash card port BEFORE the control is turned ON.
1. Press Shift + Graph.
2. Select “Data Input/Output Device” from the menu.
3. If the desired device is already selected, press OK
or
Proceed to step 4.
4. Press Browse.
5. Select the desired device (A, C, D, E, or F). Refer to the following device definitions:
A: 3½” disk driveC: hard disk, partition 1D: hard disk, partition 2E: CD-ROM driveF: ATA flash card port
6. Press OK to exit the device selection display.
7. Press OK to exit to the CNC display.
M-392D 11-5
RS-232 SERIAL PORT (NC DATA)
DATA COMMUNICATIONS PROTOCOL
Data communications protocol consists of three basic types of information: parity, baud rate, andstop bits. The baud rate and stop bits are controlled by parameters, which may be modified as re-quired.
Tape Parity Check
Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in eachcharacter and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number ofholes in each character. This characteristic of having an odd or even number of holes punched in ev-ery character is called parity.
The control accepts tape punched in either code, but each tape must be programmed in only one ofthe accepted codes.
The control automatically determines the particular type of coding by decoding the first End ofBlock (;) character on the tape. Each character is checked for parity as it is read by the tape reader orcomputer.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired par-ity.
Baud Rate
Baud rate is the speed at which data is transmitted from one device to another. To successfullytransmit data between two devices, it is necessary to have both devices set to the same baud rate.
The baud rate is set by three different parameters, depending on which I/O port is active. Refer tothe I/O setting on Setting Page #1 to determine which I/O port is active. Refer to ”Input/Output DeviceSelection”, page 11-4.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired baudrate.
Stop Bits
The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The numberof stop bits active in the machine control is controlled by three different parameters, depending onwhich I/O port is active. These parameters may be modified as required. Refer to ”Input/Output De-vice Selection”, page 11-4.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desirednumber of stop bits.
11-6 M-392D
CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS
Use the following procedure to check communications protocol parameters:
1. Press the System key.
2. Press the Parameter soft key.
3. Use the Page keys to display the parameter page to be viewed.
Use the following procedure to check and modify communications protocol parameters as needed:
1. Press the Offset Setting key.
2. Press the Setting soft key.
3. If necessary, use the Page keys to display the Setting page that contains the Parameter Writefield.
4. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
5. Activate Manual Data Input mode.
6. Key in the number 1 (one).
7. Press the Input key. Parameter editing will be enabled.
8. Press the System key.
9. Press the Parameter soft key.
10. Use the Cursor and Page keys to position the cursor on the parameter to be modified.
11. Key in the new parameter value.
12. Press the Input key.
13. Repeat steps 10 through 12, as needed.
14. Press the Offset Setting key.
15. Press the Setting soft key.
16. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
17. Key in the number 0 (zero).
18. Press the Input key. Parameter editing will be disabled.
M-392D 11-7
RS-232 PORT PARAMETER SETTINGS
Refer to “Checking and Modifying Communications Parameters”, starting on page 11-7, for infor-mation on modifying the parameter settings for the three I/O ports. These parameters may be modi-fied as required.
Baud Rate Parameter Settings
I/O Port Parameter Number
0 103
1 113
2 123
The valid parameter settings are as follows:
Setting Baud Rate
1 50
2 100
3 110
4 150
5 200
6 300
7 600
8 1200
9 2400
10 4800
11 9600
12 19200
Stop Bit Parameter Settings
I/O Port Parameter Number Bit Number
0 101 0
1 111 0
2 121 0
The valid parameter settings are “0" for 1 Stop Bit and ”1" for 2 Stop Bits.
- NOTE -
The Stop Bit parameter settings are displayed as one bit in an 8 bit binary number (0or 1). The bits are read “0" to ”7", from right to left.
11-8 M-392D
DATA TRANSFER
RS-232 SERIAL PORT (NC DATA)
Uploading Data through the RS-232 Port
UPLOADING CONTROL PARAMETERS INTO CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape reader or computer to the desiredcommunications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
4. Press the Offset Setting key.
5. Press the Setting soft key.
6. If necessary, use the Page keys to display the Setting page that contains the Parameter Writefield.
7. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
8. Activate Manual Data Input mode.
9. Key in the number 1 (one).
10. Press the Input key. Parameter editing will be enabled.
11. Press the System key.
12. Press the Parameter soft key.
13. Press the Operator soft key.
14. Activate Edit mode.
15. Press the soft key expansion key until the Read soft key is displayed.
16. Press the Read soft key.
17. Press the Execute soft key.
18. Set the tape reader or computer to transmit data to the machine control.
19. After the control parameters have been uploaded, activate Manual Data Input mode.
20. Press the Offset Setting soft key.
21. Key in the number 0 (zero).
22. Press the Input key. Parameter editing will be disabled.
M-392D 11-9
23. Remove power from the external device; then, disconnect the RS-232 cable from the machinecontrol.
24. Close the serial port cover.
25. Turn the control OFF and wait approximately 10 seconds.
26. Turn the control ON.
UPLOADING PART PROGRAMS INTO CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape reader or computer to the desiredcommunications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
4. Activate Edit mode.
5. Press the Program key.
6. Turn the Program Protect key to OFF.
7. Press the soft key expansion key until the Read soft key is displayed.
- NOTE -
If the program has no program number or if the program number is to be altered, keyin the letter “O” and the desired program number.
8. Key in the letter “O” and the program number. Example: O1111
9. Press the Read soft key.
10. Press the Execute soft key.
11. Set the tape reader or computer to transmit data to the machine control.
- NOTE -
When the program has been completely loaded into the control, it will appear as theactive program on the control display screen.
12. After the part programs have been uploaded, turn the Program Protect key to ON.
13. Remove power from the external device; then, disconnect the RS-232 cable from the machinecontrol.
14. Close the serial port cover.
11-10 M-392D
UPLOADING TOOL OFFSETS INTO CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape reader, or computer to the desiredcommunications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
4. Activate Edit mode.
5. Press the Offset Setting key.
6. Press the Offset soft key.
7. Press the Operator soft key.
8. Press the soft key expansion key until the Read soft key is displayed.
9. Press the Read soft key.
10. Press the Execute soft key.
- NOTE -
The offset data will load directly into the offset registers.
11. Set the tape reader or computer to transmit data to the machine control.
12. Remove power from the external device; then, disconnect the RS-232 cable from the machinecontrol.
13. Close the serial port cover.
M-392D 11-11
Downloading Data through the RS-232 Port
DOWNLOADING CONTROL PARAMETERS FROM CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape punch or computer to the desiredcommunications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
4. Connect the interface cable to the output device and the serial port on the control.
5. Set the tape punch or computer to receive data.
6. Activate Edit mode.
7. Press the System key.
8. Press the Parameter soft key.
9. Press the Operator soft key.
10. Press the soft key expansion key until the Punch soft key is displayed.
11. Press the Punch soft key.
12. Press the ALL soft key to download all parameters
- or -
Press the NON ZERO soft key to download only parameters with non-zero values.
13. Press the Execute soft key.
- NOTE -
To stop the parameters from downloading, press the Reset key. Once the Reset keyhas been pressed, it is not possible to download the remaining parameters. It will benecessary to download all of the parameters.
14. After the control parameters have been downloaded, remove power from the external deviceand disconnect the RS-232 cable from the machine control.
15. Close the serial port cover.
11-12 M-392D
DOWNLOADING PART PROGRAMS FROM CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape punch or computer to the desiredcommunications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
4. Connect the interface cable to the output device and the serial port on the control.
5. Set the tape punch or computer to receive data.
6. Activate Edit mode.
7. Press the Program key.
8. Key in the letter “O” and the program number. Example: O1111
9. Press the soft key expansion key until the Punch soft key is displayed.
10. Press the Punch key.
11. Press the Execute soft key.
- NOTE -
When outputting to a tape punch, the control will automatically output 3 feet of leaderand trailer tape. To shorten the leader or trailer length, press the Cancel push buttonwhile the leader or trailer is being punched, respectively.
To stop the part program from downloading, press the Reset key. Once the Resetkey has been pressed, it is not possible to download the rest of the part program. Itwill be necessary to download the entire part program.
12. After the part programs have been downloaded, remove power from the external device anddisconnect the RS-232 cable from the machine control.
13. Close the serial port cover.
M-392D 11-13
DOWNLOADING TOOL OFFSETS FROM CONTROL MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.
1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 11-7.
2. Refer to the appropriate manual to set the tape punch or computer to the desiredcommunications protocol.
3. Connect the interface cable from the tape reader or computer to the serial port.
4. Connect the interface cable to the output device and the serial port on the control.
5. Set the tape punch or computer to receive data.
6. Activate Edit mode.
7. Press the Offset Setting key.
8. Press the Offset soft key.
9. Press the Geometry soft key to display the Geometry offset page.
10. Press the Operator soft key.
11. Press the soft key expansion key until the Punch soft key is displayed.
12. Press the Punch key.
13. Press the Execute soft key.
- NOTE -
To stop the tool offsets from downloading, press the Reset key. Once the Reset keyhas been pressed, it is not possible to download the remaining tool offsets. It will benecessary to download all of the tool offsets.
14. After the tool offsets have been downloaded, remove power from the external device anddisconnect the RS-232 cable from the machine control.
15. Close the serial port cover.
11-14 M-392D
INTEGRATED INPUT/OUTPUT DEVICES
Standard Operator Interface
Machines with the standard operator interface are equipped with an integrated ATA Flash CardPort.
- NOTES -
Any flash card used must be an ATA Flash Card.
I/O Channel 4 must be selected. Refer to page 11-5 for information on selecting I/OChannel 4.
FILE MANAGEMENT
1. Insert the ATA flash card into the flash card port.
2. Set the I/O Channel to 4.
3. If copying a program to the machine control, turn the Program Protect key to OFF.
4. If copying parameters to the machine control:
A) Press the Offset Setting key.
B) Press the Setting soft key.
C) If necessary, use the Page keys to display the Setting page that contains the ParameterWrite field.
D) If necessary, use the cursor keys to position the cursor at the Parameter Write field.
E) Activate Manual Data Input mode.
F) Key in the number 1 (one).
G) Press the Input key. Parameter editing will be enabled.
5. Activate Edit mode.
6. Press the System key.
7. Press the soft key expansion key until the ALL IO soft key is displayed.
8. Press the ALL IO soft key.
9. Press the appropriate soft key, based on the type of file to be copied to the control memory:
Program: This function is used to transfer a program between the I/O device and controlmemory.
Parameter: This function is used to transfer a parameter file between the I/O device andcontrol memory.
Offset: This function is used to transfer an offset file between the I/O device and con-trol memory.
M-392D 11-15
10. Press the Operator soft key. The following soft key functions will be displayed:
FILESEARCH
This function is used to search the selected input/output device for a specificfile name.
A) Press the File Search soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of thefile listing.
FILEREAD
This function is used to copy the selected file from the input/output device tothe machine control.
A) Press the File Read soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. The selected file will be copied to the control memory.
PUNCH This function is used to copy the machine parameters, offset register data, orthe active program from the machine control to the input/output device
A) If necessary, activate the program to be copied. Refer to Chapter 3 for information onactivating programs.
B) Press the Punch soft key.
C) If a file name is to be assigned, key in the file name and press the File Name soft key.
D) If a program name is to be changed, key in the new program name and press the O Set softkey.
E) Press the Execute soft key. The selected file will be copied from the control memory to theinput/output device.
DELETE This function is used to delete a selected file from the input/output device.
A) Press the Delete soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. The specified file will be deleted from the input/output device.
11-16 M-392D
11. If a program was copied to the machine control, turn the Program Protect key to ON.
12. If control parameters were copied to the machine control:
A) Activate Manual Data Input mode.
B) Press the Offset Setting soft key.
C) Key in the number 0 (zero).
D) Press the Input key. Parameter editing will be disabled.
13. Press the Reset key.
14. Remove the ATA flash card and close the cover.
M-392D 11-17
PC-Based Operator Interface
Machines with the PC-based operator interface are equipped with the following integrated in-put/output devices:
• 3½” disk drive
• Internal Hard Disk
• CD-ROM Drive
• ATA Flash Card Port
- NOTES -
Any flash card used must be an ATA Flash Card.
I/O Channel 4 must be selected. Refer to page 11-5 for information on selecting I/OChannel 4.
If an ATA flash card is to be used, the flash card must be plugged into the flash cardport BEFORE the control is turned ON.
FILE MANAGEMENT
1. If the ATA flash card port is to be used, insert the ATA flash card into the flash card port beforethe control is turned ON.
2. Turn the machine control ON.
3. Set the I/O Channel to 4.
4. Select the input/output device to be used:
A: 3½” disk driveC: internal hard disk, partition 1D: internal hard disk, partition 2E: CD-ROM driveF: ATA flash card port
Refer to page 11-5 for information on the selecting the input/output device.
5. If copying a program to the machine control, turn the Program Protect key to OFF.
6. If copying parameters to the machine control:
A) Press the Offset Setting key.
B) Press the Setting soft key.
C) If necessary, use the Page keys to display the Setting page that contains the ParameterWrite field.
D) If necessary, use the cursor keys to position the cursor at the Parameter Write field.
E) Activate Manual Data Input mode.
F) Key in the number 1 (one).
G) Press the Input key. Parameter editing will be enabled.
11-18 M-392D
7. Activate Edit mode.
8. Press the System key.
9. Press the soft key expansion key until the ALL IO soft key is displayed.
10. Press the ALL IO soft key.
11. Press the appropriate soft key, based on the type of file to be copied to the control memory:
Program: This function is used to transfer a program between the I/O device and controlmemory.
Parameter: This function is used to transfer a parameter file between the I/O device andcontrol memory.
Offset: This function is used to transfer an offset file between the I/O device and con-trol memory.
12. Press the Operator soft key. The following soft key functions will be displayed:
FILESEARCH
This function is used to search the selected input/output device for a specificfile name.
A) Press the File Search soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of thefile listing.
FILEREAD
This function is used to copy the selected file from the input/output device tothe machine control.
A) Press the File Read soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. The selected file will be copied to the control memory.
M-392D 11-19
PUNCH This function is used to copy the machine parameters, offset register data, orthe active program from the machine control to the input/output device
A) If necessary, activate the program to be copied. Refer to Chapter 3 for information onactivating programs.
B) Press the Punch soft key.
C) If a file name is to be assigned, key in the file name and press the File Name soft key.
D) If a program name is to be changed, key in the new program name and press the O Set softkey.
E) Press the Execute soft key. The selected file will be copied from the control memory to theinput/output device.
DELETE This function is used to delete a selected file from the input/output device.
A) Press the Delete soft key.
B) Key in the number of the file, NOT a program name.
C) Press the File Set soft key.
D) Press the Execute soft key. The specified file will be deleted from the input/output device.
13. If a program was copied to the machine control, turn the Program Protect key to ON.
14. If control parameters were copied to the machine control:
A) Activate Manual Data Input mode.
B) Press the Offset Setting soft key.
C) Key in the number 0 (zero).
D) Press the Input key. Parameter editing will be disabled.
15. Press the Reset key.
16. Remove the ATA flash card and close the cover.
11-20 M-392D
- NOTES -
M-392D 11-21
- NOTES -
11-22 M-392D
CHAPTER 12 - OPERATOR MAINTENANCE
INTRODUCTION
Operator maintenance is normally confined to cleaning the machine and maintaining the hydraulicfluid and coolant levels. It is a good practice to check all fluid levels at the beginning of each shift. Theoperator should also check the cooling fans periodically to see that they are free of obstructions andfunctioning properly. Refer to the maintenance manual (M-393) for more extensive maintenance pro-cedures.
MACHINE AIR SYSTEM
The machine is equipped with a regulator and two-stage filter system to regulate and filter the in-coming air supply. The filter/regulator assembly is located at the back of the machine.
- CAUTION -
The air filter bowl should be drained at least once a day. If more frequentdraining is required, it may be necessary to install an air dryer in the air line.
DRAINING THE AIR FILTER BOWLS
1. Turn the main air valve on regulator “B”, Figure 12.1, ON.
2. Unscrew drain valve “C” only enough to drain the bowl of the standard air filter. Close the valvewhen the air filter bowl has finished draining.
3. Unscrew drain valve “D” only enough to drain the bowl of the coalescing air filter. Close thevalve when the air filter bowl has finished draining.
M-392D 12-1
Figure 12.1 - Air Filter/Regulator
TP4101
B
CD
A
ADJUSTING THE MACHINE AIR PRESSURE
Regulator “B”, Figure 12.1, is equipped with a pressure gauge that indicates the air pressure deliv-ered to the machine. The recommended range for machine air pressure is 70 psig [4.8 bars] to 90 psig[6.2 bars]. If necessary, adjust the regulator to set the machine air pressure to within the recom-mended range.
- NOTE -
The machine is equipped with an air pressure sensor that will force the machine intoEmergency Stop if the air pressure falls below 60 psig [4.1 bars].
1. Turn main air valve on regulator “B”, Figure 12.1, ON.
2. Lift knob “A”, then turn the knob clockwise or counterclockwise to increase or decreasemachine air pressure, respectively.
3. Press knob “A” down to lock the setting.
HYDRAULIC SYSTEM
STANDARD HYDRAULIC UNIT
- NOTE -
Use only Mobil® DTE-13M hydraulic fluid in the standard hydraulic unit.
The standard hydraulic unit provides hydraulic oil under pressure to operate the collet closer, spin-dle brake, and turret. The reservoir should be filled whenever the hydraulic fluid level drops belowsight gauge “E”, Figure 12.2 .
The reservoir should be drained, cleaned, and filled with fresh hydraulic fluid after every 1000 hoursof operation. Refer to the maintenance manual (M-393) for instructions on draining and cleaning thestandard hydraulic unit.
Filling the Oil Reservoir
- NOTE -
It is recommended that the machine notbe powered up for at least 10 minutesafter oil has been added to the hydrau-lic tank. This will allow any air bubblespresent in the oil to dissipate.
It is recommended that the hydraulic oilbe pre-filtered to 5 micron maximumparticle size before being added to thehydraulic tank.
1. Power down the machine as outlined inChapter 2.
2. Remove cap “F”, Figure 12.2, and SLOWLY fillthe reservoir with Mobil DTE-13M hydraulicfluid until sight gauge ”E” is filled.
3. Replace cap “F”.
12-2 M-392D
Figure 12.2 - Standard Hydraulic Unit(Shown with Cover Removed)
TP4105
FE
HYDROSTATIC HYDRAULIC UNIT
- NOTE -
The hydrostatic hydraulic unit is only used on machines equipped with theHydroGlide® hydrostatic linear guideway option.
Use only Mobil® DTE-18M® hydraulic fluid in the hydrostatic hydraulic unit.
The hydrostatic hydraulic unit provides hydraulic oil under pressure to the linear guideway trucks.The reservoir should be filled whenever the hydraulic fluid level drops below sight gauge “H”, Figure12.3.
The reservoir should be drained, cleaned, and filled with fresh hydraulic fluid after every 1000 hoursof operation. Refer to the maintenance manual (M-393) for instructions on draining and cleaning thehydrostatic hydraulic unit.
Filling the Oil Reservoir
- NOTE -
It is recommended that the machine not be powered up for at least 10 minutes afteroil has been added to the hydraulic tank. This will allow any air bubbles present inthe oil to dissipate.
It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particlesize before being added to the hydraulic tank.
1. Power down the machine as outlined in Chapter 2.
2. Remove cap “G”, Figure 12.3, and SLOWLY fill the reservoir with Mobil DTE-18M hydraulicfluid until sight gauge ”H” is filled.
3. Replace cap “G”.
M-392D 12-3
Figure 12.3 - Hydrostatic Hydraulic Unit(Shown with Cover Removed)
G
H
TP5765
COOLANT SYSTEM
Hardinge machine tools are designed using the latest technology and highest quality materialsavailable. However, due to the ever-increasing number of coolant selections available, it is importantto test material compatibility with each and every coolant. For additional information regarding coolantselection, coolant maintenance, and the coolant facilities on this machine, refer to the maintenancemanual (M-393).
- CAUTION -
Whenever water-soluble coolants are used, it is important to use the manufac-turer’s recommended mix ratio (concentration). It is also important to maintainthe coolant by keeping the proper concentration level when coolant is addedto compensate for evaporation. Another important factor is coolant pH (acid-ity). Typically, the coolant pH should be in the range of 8.5 to 9. When the pHdrops below 8.5 the rust inhibitors in the coolant start depleting, which can re-sult in corrosion of machine components. Also, the quality of the water shouldbe tested by the coolant manufacturer so that the proper coolant additives canbe administered. Failure to follow these recommendations could result in dam-age to the machine, seals, and paint.
If the coolant you have selected starts to react (cause material to rust, pit,swell, soften, crack, blister, etc.) with any portion of the machine tool,Hardinge suggests that you discontinue use and contact your coolant repre-sentative for alternative coolants.
It should also be noted that certain chemicals react with different metals.Hardinge recommends that you consult with your coolant representative to as-sure that the material you are cutting does not react with the coolant you haveselected.
The coolant level should not be allowed to fall below the sight gauge on the coolant tank. The cool-ant tank should be drained and cleaned at least every six months or whenever the type or brand ofcoolant is changed. More frequent cleaning may be required if the material being machined contami-nates the coolant. Refer to the maintenance manual (M-393) for instructions on draining and cleaningthe coolant system.
To fill the coolant tank, open the front coolant guard door and pour the required amount of coolantdirectly into the chip pan. Fill the coolant tank to the “FULL” line on the sight gauge tag. Either wa-ter-based or oil-based coolant may be used.
The coolant tank fluid capacity is 40 gallons [152 liters].
12-4 M-392D
TRAMP OIL PAN
- WARNING -
Dispose of waste oil in accordance with all applicable government guidelines.DO NOT introduce the waste oil into the hydraulic system.
- NOTE -
The tramp oil pan is only used on machines equipped with the HydroGlide® hydro-static linear guideway option.
The machine has been designed to keep contamination of the coolant by the oil used for the hydro-static linear guideways to a minimum. The oil drains from the machine and is collected in the tramp oilpan. The pan should be removed and emptied once a day. Empty the pan and place it back into posi-tion.
1. Slide tramp oil pan “I”, Figure 12.4, under the hydraulic units platform.
2. Insert the end of tramp oil return line “J”, Figure 12.5, into the pan.
M-392D 12-5
Figure 12.4 - Tramp Oil PanPartially in Position
I
TP5780
Figure 12.5 - Tramp Oil Pan Completely inPosition with Return line in Place(Viewed from Side of Machine)
J
TP5782
CHIP REMOVAL(Machines Without an Optional Chip Conveyor)
1. Power down the machine as outlined in Chapter 2.
2. If coolant was ON, wait a few minutes to allow any coolant that was in use to drain back into thetank.
3. Move the coolant tank as needed to gain access to the chips.
- WARNING -
Do not remove chips with your bare hands.
4. Rake or shovel the chips into a suitable container.
5. Return the coolant tank to its opening under the front of the machine.
6. Check inside the work area to make certain that coolant will drain back into the coolant tankproperly.
12-6 M-392D
- NOTES -
M-392D 12-7
- NOTES -
12-8 M-392D
CHAPTER 13 - OPTIONS ANDMISCELLANEOUS FEATURES
MACHINE RUN TIME COUNTER
The machine Run Time counter shows the total run time during automatic operation. The Run Timecounter does not count during a feed hold or programmed stop condition.
ACCESSING THE RUN TIME DISPLAY
Press the Position function key. The Run Time is displayed at the bottom of the page.
RESETTING THE RUN TIME COUNTER TO ZERO
1. Press the Offset Setting key.
2. If the Setting (Timer) page is not displayed:
A) Press the Setting soft key.
B) Use the page keys to display the Setting (Timer) page.
3. Activate Manual Data Input mode.
4. Turn the Program Protect key switch to the OFF position.
5. Press the Operator soft key.
6. Move the cursor to the number to be reset.
7. Key in “0" (zero) and press the Input key.
8. Repeat steps 6 and 7 as needed.
9. Turn the Program Protect key switch to the ON position.
MACHINE CYCLE TIME COUNTER
The machine Cycle Time counter shows the time of one automatic operation. The Cycle Timecounter starts counting when Cycle Start is pressed and stops counting when an End of Program(M02/M30) is encountered. The Cycle Time counter does not count during a feed hold or programmedstop condition.
The Cycle Time counter is automatically reset to zero when the Cycle Start push button is pressed,or when the control is turned OFF.
ACCESSING THE CYCLE TIME DISPLAY
Press the Position key. The Cycle Time is displayed at the bottom of the page.
M-392D 13-1
CLOCK FUNCTION
The clock function is displayed in the lower right corner of all screens. The clock function is dis-played as a 24 hour clock.
RESETTING THE CLOCK DISPLAY
1. Press the Offset Setting key.
2. If the Setting (Timer) page is not displayed:
A) Press the Setting soft key.
B) Use the page keys to display the Setting (Timer) page.
3. Activate Manual Data Input mode.
4. Turn the Program Protect key switch to the OFF position.
5. Press the Operator soft key.
6. Move the cursor to the number to be corrected.
- NOTE -
The display will not be updated if an invalid value is entered. Negative numbers areconsidered invalid values.
7. Enter the correct value and press the Input key. Refer to the following chart.
ITEM MAXIMUM VALUE
Year 2085
Month 12
Day 31
Hour 23
Minute 59
Second 59
8. Repeat steps 6 and 7 as needed.
9. Turn the Program Protect key switch to the ON position.
13-2 M-392D
PARTS COUNTER
The Parts Counter shows the total number of times a program has been run during automatic oper-ation. The Parts Counter is increased by one (1) each time an M97 command is read by the control.
- NOTE -
The Part Required register is located on the same display screen as the Parts Coun-ter register.
When Part Required is set to any non-zero number and the machine is running in Repeat mode,program execution will stop when the number in the Part Counter register is equal to the number in thePart Required register.
ACCESSING THE PARTS COUNTER DISPLAY
Press the Position key. The Parts Counter is displayed at the bottom of the page.
RESETTING THE PARTS COUNTER TO ZERO
1. Press the Offset Setting key.
2. If the Setting (Timer) page is not displayed:
A) Press the Setting soft key.
B) Use the page keys to display the Setting (Timer) page.
3. Activate Manual Data Input mode.
4. Turn the Program Protect key switch to the OFF position.
5. Press the Operator soft key.
6. Move the cursor to the number to be reset.
7. Key in “0" (zero) and press the Input key.
8. Repeat steps 6 and 7 as needed.
9. Turn the Program Protect key switch to the ON position.
- NOTE -
Part Required must be set to zero for continuous cycling of bar work.
M-392D 13-3
THREAD CUTTING CYCLE RETRACT
- NOTE -
Thread Cutting Cycle Retract is NOT functional during G32 Threadcutting.
This feature allows the operator to retract the tool from the workpiece during a threading pass. Thetool retracts to an X coordinate equal to the X coordinate of the start point of the threading cycle andmoves to the start point. The tool will follow the same basic retract movement that it would follow at theend of the thread.
To retract the tool, press the Feed Hold push button. The tool will be retracted from the workpiecewhen the current lead is completed. The tool will NOT finish the threading pass.
To restart the threading cycle, press the Cycle Start push button. The control will execute thethreading cycle as programmed. The tool will re-execute the pass which was interrupted by FeedHold.
The CNC control will synchronize the re-entry of the tool with the thread on the workpiece. This willassure the thread will be properly formed when the threading cycle is completed.
HIGH PRESSURE COOLANT SYSTEM
The High Pressure coolant system option is used when special coolant-fed tools are mounted onthe turret. When the High Pressure coolant system is operating, the standard machine coolant systemis disabled. The pump unit is located externally from the machine and draws coolant from the ma-chine’s coolant reservoir. The coolant is then pumped to the special tools when they are in the cuttingposition.
The spindle must be running before activating High Pressure coolant. When the option turned ON,the High Pressure coolant can be controlled manually by pressing the HP Coolant ON/OFF push but-ton. The High Pressure coolant can also be activated and deactivated from the part program using theM10 and M11 commands, respectively.
BAR FEED INTERFACE
- NOTE -
The bar feed interface must be activated for bar work and deactivated for slug work.
1. Press the Emergency Stop push button.
- NOTE -
The Block Skip push button indicator light will be ON when the bar feed interface isactivated.
2. Press and hold the Spindle Increase and Spindle Decrease push buttons.
3. Press the Block Skip push button to activate or deactivate the bar feed interface.
4. Release the Spindle Increase and Spindle Decrease push buttons.
5. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.
13-4 M-392DRevised: January 18, 2008
ENGLISH / METRIC MODE
One of the purposes of the Setting page is used to establish whether the control is to power-up andoperate in English mode or Metric mode. This section outlines the procedure for selecting the desiredoperating mode.
Through the use of the G20 (Inch Mode) and G21 (Metric Mode) commands, It is possible to oper-ate in either mode regardless of which mode has been selected on the Setting page. However, the useof these two G codes will not automatically adjust the position registers to display the position valuesin the proper units (inches vs millimeters).
- CAUTION -
Part programs should usually be written in the same format as selected on theSetting page. Programs not written in the same format as established on theSetting page MUST contain the appropriate English / Metric G code, G20/G21respectively. When required, this G code must be programmed by itself in thefirst Data block following the program number.
The work shift values are NOT automatically changed to the appropriate unitswhen the operating mode is changed.
- NOTE -
The tool offsets are automatically changed to the appropriate units when the operat-ing mode is changed.
ESTABLISHING ENGLISH / METRIC MODE
1. Press the Offset Setting function key.
2. Press the Setting soft key.
3. If necessary, use the Page keys to display the Setting page that contains the Input Unit field.
4. If necessary, use the cursor keys to position the cursor at the Input Unit field.
5. Activate Manual Data Input mode.
6. Key in the appropriate number (0:MM 1:INCH).
7. Press the Input key.
8. Turn the Control ON / OFF switch to OFF.
9. Wait a few seconds; then, turn the Control ON / OFF switch to ON and wait until the controldisplay screen is ON. The machine will power up in the desired operating mode.
M-392D 13-5
AXIS THRUST LIMITATION
INTRODUCTION
The E and Z axis servo drives are capable of delivering levels of thrust that exceed the limits of themachine tool. Therefore, axis thrust must be limited or machine life may be reduced. There is refer-ence material available for the programmer that provides approximate thrust values based on drill di-ameter, spindle speed, feedrate, and the type of material being machined. Hardinge Inc.recommends the MACHINING DATA HANDBOOK from Metcut Research Associates, Inc.
- NOTE -
Thrust limits are not easily exceeded unless large diameter twist drills are being runwith aggressive feedrates.
Axis thrust is limited to the following:
AXISTHRUST LIMIT
English (Pounds-Force) Metric (Newtons)
E 1,500 6,670
Z 2,250 10,000
MONITORING AXIS THRUST
It is possible to monitor axis thrust as a percentage of how much current the E or Z axis servo motoris drawing compared to the maximum amount of current that the motor should draw.
- CAUTION -
The percentage of maximum current must not exceed the following limits:
AXIS LIMIT VALUE
E 107
Z 132
If the percentage of maximum current on the E or Z axis exceeds the limit value, an alarmmessage will be displayed.
The percentage of maximum current is displayed under “CURRENT (%)” on the associated axisServo Tune page. Refer to the position indicator shown in Figure 13.1.
13-6 M-392D
ACCESSING THE AXIS SERVO TUNE PAGE
- CAUTION -
DO NOT modify any of the parameters displayed on the “Servo Setting” and“Servo Motor Tuning” screens. If any of the parameters are modified, reloadthe machine parameters from the diskette supplied with the machine tool. Re-fer to Chapter 11 for information on loading machine parameters.
1. Press the System key.
2. Press the Parameter soft key.
3. If necessary, press the right hand soft key to display the Servo Parameter soft key.
4. Press the Servo Parameter soft key.
5. Press the Servo Tune soft key.
6. If necessary, use the Page keys to access the appropriate “Servo Motor Tuning” screen.
7. Observe the value shown to the right of “CURRENT (%)”. Refer to the position indicator shownin Figure 13.1.
M-392D 13-7
S E RVO MOT OR T U NINGZ AXIS
O____ N____
FU NC. B ITL OOP GAINT U NING S TS E T P E R IODINT GAINP R OP. GAINF ILT E RVE L OC. GAIN
NU M.
(S V. S E T )
(PAR AME T E R )~~~~~~~~
AL AR M 1AL AR M 2AL AR M 3AL AR M 4AL AR M 5L OOP GAINP OS E R R ORCU R R E NT %
(MONIT OR )~~~~~~~
~S P E E D (R P M)AU T O
( )(S V. T U N) ( ) ( )
Figure 13.1 - Servo Tune Screen(Z axis page shown)
TI4179
ADJUSTING AXIS THRUST
- NOTE -
This procedure is to be performed during the operation that causes the axis over-load.
When performing machining operations where axis thrust is a concern, it is possibleto minimize cycle time by adjusting the programmed feedrate to bring the value un-der “CURRENT (%)” as close to the limit without exceeding the limit.
If the value displayed under “CURRENT (%)” on the appropriate axis Servo Tune page exceedsthe limit, reduce axis thrust according to the following procedure:
1. Turn the Feedrate Override switch down by 10%.
2. Run the operation that caused the axis overload and observe the value displayed under“CURRENT (%)” on the axis Servo Tune page.
If the value displayed under “CURRENT (%)” on the Servo Tune page still exceeds thelimit, repeat steps 1 and 2.
If the value displayed under “CURRENT (%)” on the Servo Tune page is under the limit,adjust the programmed feedrate in the part program according to the setting of the Feed-rate Override switch.
EXAMPLE
Assuming that the Feedrate Override switch had to be set to 80% to allow the operation to be per-formed:
1. Multiply the programmed feedrate by “.8".
2. Modify the programmed feedrate for the operation to match the number calculated in step 1.
13-8 M-392D
PART CATCHERS
MAIN SPINDLE PART CATCHER [Option]
Introduction
The main spindle part catcher is controlled from the operator panel through the use of the PartCatcher push button when the machine is in Jog mode.
The main spindle part catcher is controlled from the part program through the use of the following Mcodes:
M25 - PART CATCHER RETRACT
The M25 command rotates the part catcher arm to the spindle centerline for part pickup.
M26 - PART CATCHER EXTEND
The M26 command causes the following to occur:
1. The part catcher arm rotates toward the front of the machine and the part basket extends toreceive the part.
2. The part basket retracts after a fixed period of time.
Typical Part Unload Sequence
1. The part catcher arm rotates inward to a position under the spindle (M26).
2. The collet/chuck opens, ejecting the part onto the arm (M21).
3. The arm rotates outward and the basket extends to receive the part (M25).
4. The part falls from the arm into the basket.
5. The basket retracts.
6. The operator can open cover “A”, Figure 13.2, and remove the part from the basket by hand.
M-392D 13-9
Figure 13.2 - Main Spindle Part Catcher(External View)
A
B
TP4612
Adjusting the Part Catcher for Part Length
1. Loosen the screw in locking collar “C”, Figure13.3.
2. Slide the part catcher toward or away from themachine headwall to adjust the position, asneeded.
3. Tighten the screw in locking collar “C”.
Adjusting the Part CatcherExtend / Retract Speeds
The part catcher extend and retract speeds arecontrolled by separate flow control valves and can beadjusted independently.
Remove sheet metal cover “D”, Figure 13.4,from the front of the machine to gain access tothe part catcher flow control valves.
Flow control valve “E”, Figure 13.5, is used toadjust the speed at which the part catcher ex-tends (moves toward the spindle centerline).
Flow control valve “F” is used to adjust thespeed at which the part catcher retracts (movestoward the front of the machine).
Rotate the knob on a flow control valve clock-wise to reduce speed.
Rotate the knob on a flow control valve coun-terclockwise to increase speed.
13-10 M-392D
Figure 13.3 - Position AdjustmentLocking Collar
C
TP4610
Figure 13.4 - Front Cover
D
TP4158
Figure 13.5 - Part CatcherExtend/Retract Adjustments
F
E
TP4613
Adjusting the Part Basket Extend / Retract Speeds
The part basket extend and retract speeds are controlled by separate flow control valves and canbe adjusted independently.
Remove sheet metal cover “B”, Figure 13.2, to gain access to the part basket flow controlvalves.
Flow control valve “G”, Figure 13.6, is used to adjust the speed at which the part catcher ex-tends (moves toward the spindle centerline).
Flow control valve “H” is used to adjust the speed at which the part catcher retracts (movestoward the front of the machine).
Rotate the knob on a flow control valve clockwise to reduce speed.
Rotate the knob on a flow control valve counterclockwise to increase speed.
M-392D 13-11
Figure 13.6 - Part BasketExtend/Retract Adjustments
G H
TP4605
CONVEYOR-STYLE SUB-SPINDLE PART CATCHER [Option]
Introduction
The sub-spindle part catcher is a multiple axis part removal system designed to remove aworkpiece from the sub-spindle and deposit the workpiece on a conveyor, which will carry theworkpiece to an unload ramp located at the right end of the machine tool.
- NOTE -
It is the operator’s responsibility to provide a suitable container or surface to receivethe finished workpiece when it leaves the unload ramp.
The lower edge of the unload ramp, shown in Figure 13.7, is approximately 23¾ inches from thefloor.
13-12 M-392D
Figure 13.7 - Sub-Spindle PartCatcher Unload Ramp
(Covers Removed for Clarity)
TP4644
Part Catcher M Codes
The sub-spindle part catcher is controlled throughthe use of the following six M codes:
M221 PART CATCHER SLIDE EXTEND
M221 commands the part catcher to slideOUT from the sub-spindle headwall to thefixed part pick-up position.
Refer to Figure 13.8.
M222 PART CATCHER SLIDE RETRACT
M222 commands the part catcher to slideIN to the part drop-off position over the partconveyor.
M225 PART CATCHER ARM ROTATE DOWN
M225 commands the part catcher arm toswing down to allow the part catcher to be re-tracted.
M226 PART CATCHER ARM ROTATE UP
M226 commands the part catcher arm toswing up to the part retrieve position at thespindle centerline.
Refer to Figure 13.9.
M227 PART CATCHER GRIPPER CLOSE
M227 commands the part catcher gripper toclose and grip the workpiece.
M228 PART CATCHER GRIPPER OPEN
M228 commands the part catcher gripper toopen and release the workpiece.
M-392D 13-13
Figure 13.8 - Part Catcher Extended,Arm Rotated to Down Position
TP4654
Figure 13.9 - Part Catcher Extended,Arm Rotated to Up Position
TP4655
Interlocks
1. M221 must be active (Part Catcher Slide Extend) before M226 (Part Catcher Arm Rotate Up)can be commanded.
2. The sub-spindle must be at the reference position before M225 (Part Catcher Arm RotateDown) can be commanded.
3. M225 (Part Catcher Arm Rotate Down) must be active before M222 (Part Catcher SlideRetract) can be commanded.
Capacity
The part catcher has the following workpiece capacity:
Category English Units Metric Units
Maximum Length 6 inches 152.4 millimeters
Maximum Diameter 2.5 inches 63.5 millimeters
Maximum Weight 7 lb 3.18 Kg
13-14 M-392D
Part Catcher Gripper Pads
The part catcher grippers are designed to be equipped with nylon pads. The nylon pads are boredto the outer diameter of the workpiece to be machined.
BORING THE GRIPPER PADS
The gripper pad fixture, shown in Figure 13.10, is used to hold the gripper pads when they arebored to the required size.
1. Install a work-holding device capable of holding a 3½ inch workpiece in the machine spindle.
2. Insert blank gripper pads into the fixture and secure with four M3 x .5 x 10mm screws, suppliedwith the fixture.
3. Insert the gripper pad fixture into the spindle and close the work-holding device.
4. Bore the gripper pads to the required diameter.
5. Remove the gripper pad fixture from the spindle.
6. Remove the gripper pads from the gripper pad fixture.
7. Install the gripper pads on the part catcher gripper. Refer to “Changing the Gripper Pads”, page13-16.
M-392D 13-15
Figure 13.10 - Gripper Pad Fixturewith Blank Gripper Pads
TI4745
Gripper PadFixture
Gripper Pads
CHANGING THE GRIPPER PADS
1. If necessary, bore the gripper pads as outlined in the preceding section.
2. Close the guard door.
3. Activate Rapid Reference mode.
4. Set the Manual Axis Movement switch to “X”.
5. Press the Rapid Reference push button to move the turret to the X axis reference position.
6. Set the Manual Axis Movement switch to “E”.
7. Press the Rapid Reference push button to move the sub-spindle to the reference position.
- NOTE -
Refer to Chapter 3 for information on using Manual Data Input mode.
The guard door must be closed to execute commands in Manual Data Input mode.
8. Use Manual Data Input mode to:
A) Extend the part catcher slide (M221).
B) Rotate the part catcher arm to the up position (M226).
9. Open the guard door.
10. If necessary, loosen screws “I”, Figure 13.11,to remove the gripper pads currently installedon the grippers.
11. Clean the part catcher grippers.
12. Thoroughly clean the replacement gripperpads.
13. Install the replacement gripper pads.
14. Close the guard door.
15. Use Manual Data Input mode to:
A) Rotate the part catcher arm to the downposition (M225).
B) Retract the part catcher slide (M222).
13-16 M-392D
Figure 13.11 - Gripper PadMounting Screws
TP4656
I
THRU- SUB-SPINDLE PART CATCHER [Option]
- CAUTION -
Observe the sub-spindle operating limitations outlined in the programmer’smanual (M-391) when running a sub-spindle equipped with the thru- sub-spin-dle part catcher.
- NOTE -
The thru- sub-spindle part catcher is capable of handling parts with diameters thatfall within the following range:
� � �316 1" "
Introduction
The thru- sub-spindle part catcher provides the capability of feeding parts through the part catcherdraw tube, which is installed in the sub-spindle, and out the right end of the machine.
During part transfer from the main spindle to the sub-spindle, the part currently in the sub-spindlecollet is pushed from the collet by the part being delivered from the main spindle. As subsequent partsare delivered from the main spindle to the sub-spindle, the parts in the part catcher draw tube arepushed toward the right end of the machine, out the exit tube, and down the ramp to a receptacle pro-vided by the machine operator.
Refer to Figure 13.12 for an overall view of the thru- sub-spindle part catcher assembly.
M-392D 13-17
Figure 13.12 - Isometric View of Thru- Sub-Spindle Part Catcher Assembly
TI4788
Refer to Figure 13.17for close-up view.
Draw TubeAssembly
Part CatcherGuard
Part CatcherRamp
Safety Switch Clamp
Safety Switch
Collet andGuide Bushing
NOTE: Sub-spindle assembly not shown.
Exit Tube
Part Catcher Component Identification
COLLET GUIDE BUSHINGS
Three collet guide bushings, each machined for a different capacity, are supplied with thethru- sub-spindle part catcher. A collet guide bushing is always installed in the sub-spindle col-let when the thru- sub-spindle part catcher is to be used. Refer to “Selecting Part Catcher Com-ponents” for information on selecting the correct collet guide bushing.
One blank collet guide bushing is also included with the thru- sub-spindle part catcher. Theblank collet guide bushing can be used for the following:
• Replace a worn or damaged collet guide bushing
• Produce a custom size collet guide bushing for the part to be machined
PART CATCHER DRAW TUBE ASSEMBLY
One draw tube assembly is supplied with the thru- sub-spindle part catcher. This draw tubeassembly will replace the standard sub-spindle draw tube when the thru- sub-spindle partcatcher is to be used.
PART CATCHER DRAW TUBE LINERS
Two draw tube liners are supplied with the thru- sub-spindle part catcher. A draw tube linermust be installed in the part catcher draw tube when the thru- sub-spindle part catcher is to beused for parts that are 9/16 inch or less in diameter. Refer to “Selecting Part Catcher Compo-nents” for information on selecting the correct draw tube liner.
EXIT TUBES
Three exit tubes are supplied with the thru- sub-spindle part catcher. An exit tube is alwaysinstalled when the thru- sub-spindle part catcher is to be used. Refer to “Selecting Part CatcherComponents” for information on selecting the correct exit tube.
Selecting Part Catcher Components
The following part catcher components will be selected based on the diameter of the part to be ma-chined.
• Collet Guide Bushing
• Part Catcher Draw Tube Liner
• Exit Tube
Part Size RangesCollet Guide Bushing
Capacity HoleDraw TubeLiner Size
Exit Tube Size
�3/16”, �5/16” Small Small Small
�5/16”, �9/16” Medium Medium Medium
�9/16”, �1” Large None Large
The three configurations are shown in Figures 13.13, 13.14, and 13.15.
13-18 M-392D
M-392D 13-19
Figure 13.13 - Section View Showing Componentsfor 1 Inch Maximum Part Diameter
TI4789
Anti-RotationBracket
Collet
Collet GuideBushing
Draw Tube Assembly
Exit Tube
Draw TubeRetaining Screws
Draw Tube Nut
1/16”[1.6 mm]
13-20 M-392D
Figure 13.14 - Section View Showing Componentsfor 9/16 Inch Maximum Part Diameter
TI4790
Collet
Draw Tube Assembly
Draw Tube Liner
Collet GuideBushing
Draw TubeLiner
Anti-RotationBracket
Exit Tube
Draw TubeRetaining Screws
Draw Tube Nut
1/16”[1.6 mm]
M-392D 13-21
Figure 13.15 - Section View Showing Componentsfor 5/16 Inch Maximum Part Diameter
TI4791
Collet
Collet GuideBushing
Draw Tube Assembly
Draw TubeLiner
Anti-RotationBracket
Exit Tube
Draw Tube Liner
Draw TubeRetaining Screws
Draw Tube Nut
1/16”[1.6 mm]
Changing Part Catcher Components
Part catcher components will be changed for either of the following reasons:
• Accommodate a different part size
• Replace a worn component
- CAUTION -
Do not operate the collet closer when a collet is mounted in place withoutgripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. If necessary, press the Sub Open/Close push button to open work-holding device in the colletcloser.
5. At the right end of the machine, pull safety switch clamp “K” to disengage safety switch “L”,Figure 13.16.
6. Loosen the mounting nuts and remove part catcher guard “J”.
7. Remove four thumbscrews “O” and tube clamps “P”, Figure 13.17.
8. Remove exit tube “Q”.
9. Remove two insert blocks “N”.
10. If a draw tube liner is in the draw tube:
A) Remove the two M4 screws and lock washers located at “T”.
B) Slide the liner out of the draw tube.
11. Remove the collet from the sub-spindle:
- NOTE -
The six draw tube retaining screwsmust be completely disengaged fromthe collet closer liner before draw tubenut can be rotated.
A) Using the T-handle hex wrench provided,completely loosen the six draw tuberetaining screws, shown in Figures 13.13,13.14, and 13.15.
B) Rotate the draw tube nut counterclockwiseto disengage the draw tube from the collet.
C) Remove the collet from the sub-spindle.
13-22 M-392D
Figure 13.16 - Part Catcher GuardTP4717
K
J
M
L
12. Remove the guide bushing from the collet.
13. Clean the collet and guide bushing; then, place in storage.
14. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned.
15. Close the main coolant guard door.
16. From the collet closer end of the draw tube, use an air line to blow any contaminants present outof the sub-spindle.
17. Press the Sub Open/Close push button to set the collet closer to the closed position.
M-392D 13-23
Figure 13.17 - Exit Tube Clamps and Anti-Rotation Bracket
TI4796
Refer to Figure 13.12 for an overall view of the part catcher.
W
S
O
P
Q
U
T
X
V
Y
R
N
18. If necessary, install the appropriate draw tube liner, based on the diameter of the part to beproduced, in the draw tube. Secure the draw tube liner with the two M4 screws and lockwashers provided.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information oncomponent selection.
19. Install two insert blocks “N”.
- NOTE -
There should be approximately 1/16” clearance between the end of the draw tube ordraw tube liner and the end of the exit tube. Refer to Figures 13.13, 13.14, and13.15.
20. Install the appropriate exit tube “Q”, based on the diameter of the part to be produced.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information oncomponent selection.
21. Install two exit tube clamps “P” and secure with four thumbscrews “O”.
22. Press the Sub Open/Close push button to set the collet closer to the open position.
23. Install the appropriate collet guide bushing, based on the diameter of the part to be produced, inthe collet to be used.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information oncomponent selection.
24. Install the collet in the sub-spindle using the basic information provided in “InstallingSub-Spindle Tooling”, beginning on page 17-6.
25. Replace part catcher guard “J”, Figure 13.16, and secure the mounting nuts.
26. Use clamp “K” to engage safety switch “L”.
27. Position a part receptacle under ramp “M”.
13-24 M-392D
Changing Sub-Spindle Draw Tubes
INSTALLING THE STANDARD DRAW TUBE
This procedure is used when it is necessary to change from the part catcher draw tube to the stan-dard draw tube.
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. If necessary, press the Sub Open/Close push button to open work-holding device in the colletcloser.
5. At the right end of the machine, pull safety switch clamp “K” to disengage safety switch “L”,Figure 13.16.
6. Loosen the mounting nuts and remove part catcher guard “J”.
7. Remove four thumbscrews “O” and tube clamps “P”, Figure 13.17.
8. Remove exit tube “Q”.
9. Remove two insert blocks “N”.
- CAUTION -
DO NOT remove two alignment blocks “R”.
10. Remove four screws “X” and two tube support blocks “Y”.
11. If a draw tube liner is in the draw tube:
A) Remove the two M4 screws and lock washers located at “T”.
B) Slide the liner out of the draw tube.
12. Clean all items removed in steps 7 through 11; then, place in storage.
13. Remove the collet from the sub-spindle:
- NOTE -
The six draw tube retaining screws must be completely disengaged before the drawtube nut can be rotated.
A) Completely loosen the six draw tube retaining screws, shown in Figures 13.13, 13.14, and13.15.
B) Rotate the draw tube nut counterclockwise to disengage the draw tube from the collet.
C) Remove the collet from the sub-spindle.
M-392D 13-25
14. Remove the guide bushing from the collet.
15. Clean the collet and guide bushing; then, place in storage.
16. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned.
17. Close the main coolant guard door.
18. From the collet closer end of the draw tube, use an air line to blow any contaminants present outof the sub-spindle.
19. Remove screw “W” and two bushings “V” from anti-rotation bracket “U”.
20. Completely remove the draw tube from the back of the sub-spindle.
21. Use an air line to blow any contaminants present out of the sub-spindle a second time.
22. Clean the sub-spindle, standard draw tube, and part catcher draw tube.
23. Lightly coat all exterior surfaces of the part catcher draw tube with Mobiltemp® SHC 32 grease;then, place in storage.
24. Lightly lubricate the bearing surfaces of the standard draw tube with Molylube® Anti-Seizegrease.
25. Lightly coat the remaining exterior surfaces of the standard draw tube with Mobiltemp SHC 32grease.
26. Carefully slide the standard draw tube into the sub-spindle.
27. If spindle tooling is to be installed at this time, install the tooling according to the procedureoutlined in “Installing Sub-Spindle Tooling”, beginning on page 17-6.
If spindle tooling is not to be installed at this time, install the draw tube plug.
28. Replace part catcher guard “J”, Figure 13.16, and tighten the mounting nuts.
29. Use clamp “K” to engage safety switch “L”.
13-26 M-392D
INSTALLING THE PART CATCHER DRAW TUBE
This procedure is used when it is necessary to change from the standard draw tube to the partcatcher draw tube.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. If necessary, press the Sub Open/Close push button to open work-holding device in the colletcloser.
5. At the right end of the machine, pull safety switch clamp “K” to disengage safety switch “L”,Figure 13.16.
6. Loosen the mounting nuts and remove part catcher guard “J”.
- NOTE -
Six screws “A”, Figure 13.18, must be completely disengaged before draw tube nut“B” can be rotated.
Removal of a jaw chuck or step chuck may require the assistance of a second per-son.
7. Completely loosen six screws “A”, Figure 13.18.
8. Rotate draw tube nut “B” counterclockwise to disengage the draw tube from the work-holdingdevice.
- WARNING -
Be prepared to accept the weight of the work-holding device.
9. Remove the work-holding device from the sub-spindle.
10. Clean the work-holding device; then, place in storage.
11. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned.
12. Close the main coolant guard door.
13. From the collet closer end of the draw tube, usean air line to blow any contaminants presentout of the sub-spindle.
14. Completely remove the draw tube from theback of the sub-spindle.
15. Use an air line to blow any contaminantspresent out of the sub-spindle a second time.
16. Clean the sub-spindle, standard draw tube,and part catcher draw tube.
17. Lightly coat all exterior surfaces of the standarddraw tube with Mobiltemp® SHC 32 grease;then, place in storage.
18. Lightly lubricate the bearing surfaces of thepart catcher draw tube with Molylube®
Anti-Seize grease.
M-392D 13-27
Figure 13.18 - Standard Draw Tube Nut
TP4133
A
B
19. Lightly coat the remaining exterior surfaces of the part catcher draw tube with Mobiltemp® SHC32 grease.
20. Carefully slide the part catcher draw tube into the sub-spindle.
- CAUTION -
Be sure bushings “V”, and screw “W” extend through the hole in bracket “S”.
21. Install two bushings “V”, and screw “W” into anti-rotation bracket “U”, as shown in Figure 13.17.Torque screw “W” to 60 lb-in [6.8 N•m].
22. Press the Sub Open/Close push button to set the collet closer to the closed position.
23. If necessary, install the appropriate draw tube liner, based on the diameter of the part to beproduced, in the draw tube. Secure the draw tube liner with the two M4 screws and lockwashers provided.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information oncomponent selection.
24. Thoroughly clean the two mounting surfaces for brackets “Y”.
25. Thoroughly clean two alignment blocks “R”.
- NOTE -
Locate brackets “Y” against alignment blocks “R” before securing with screws “X”.
26. Install two brackets “Y” using four screws “X”. Torque screws “X” to 25 lb-ft [33.9 N•m].
27. Install two insert blocks “N”.
- NOTE -
There should be approximately 1/16” clearance between the end of the draw tube ordraw tube liner and the end of the exit tube. Refer to Figures 13.13, 13.14, and13.15.
28. Install the appropriate exit tube “Q”, based on the diameter of the part to be produced.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information oncomponent selection.
29. Install two exit tube clamps “P” and secure with four thumbscrews “O”.
30. Press the Sub Open/Close push button to set the collet closer to the open position.
31. Install the appropriate collet guide bushing, based on the diameter of the part to be produced, inthe collet to be used.
Refer to “Selecting Part Catcher Components”, page 13-18, for additional information oncomponent selection.
32. Install the collet in the sub-spindle using the basic information provided in “InstallingSub-Spindle Tooling”, beginning on page 17-6.
33. Replace part catcher guard “J”, Figure 13.16, and secure the mounting nuts.
34. Use clamp “K” to engage safety switch “L”.
35. Position a part receptacle under ramp “M”.
13-28 M-392D
PART PROBE [Option]
INTRODUCTION
- CAUTION -
Although overtravel protection is built into the probe, the probing velocitymust not exceed 18 inches/minute to insure that the machine stopping dis-tance does not exceed the probe overtravel.
The optional part probe extends the versatility of the machines by providing automatic size check-ing and updating of tool offsets. Outside diameters, inside diameters, and lengths can be checkedwhen a cutting operation is not active.
The system consists of a measuring probe which is datumed in reference to a known surface. Theprobe is a multi-directional switch that is programmed to contact the workpiece at the desired inspec-tion point. Contact can be made from any direction. When the probe stylus makes contact, a signal isgenerated which is relayed to the interface where it is converted into a form the machine control willaccept. The control compares the inspection point to the calibration point and offsets are automati-cally corrected when required. The slide then backs off and a second signal is relayed to the interface,indicating the stylus has reseated and the probe is ready for the next measurement.
SET-UP PROCEDURE
- NOTE -
The probe holder installs in the same manner as a standard round shank tool holder.Refer to Chapter 4, 5, or 6 for information on installing tool holders.
1. Mount probe holder “F”, Figure 13.19 or 13.20, on the turret at the desired station.
2. Place OMP unit “E” in the probe holder and tighten mounting screws “G” just enough to hold theprobe in position.
3. Screw probe “A” into OMP unit “E” and tighten at “D” using the spanner wrench provided withthe probe.
4. Position the turret midway between the reference position and the spindle face and spindlecenterline.
M-392D 13-29
Figure 13.19 - Part Probe Mountedon a Hardinge Top Plate
TP4688
B
C D E FG
A
Figure 13.20 - Part Probe Mountedon a VDI Top Plate
TP4693A
F
G
5. Adjust OMP unit “E”, Figure 13.19, and OMM unit “I”, Figure 13.21, so that the optical windowon the OMP unit and the window on the OMM unit are aligned.
6. Tighten mounting screws “G”, Figure 13.19 or 13.20.
7. Tighten screw “H”, Figure 13.21.
- NOTE -
The probe stylus has a 360 degree rotational capability. However, it is important thatthe center of the stylus ball coincides with the X axis centerline of the turret.
8. Mount probe stylus “C”, Figure 13.19, on the probe with screw “B” so that the center of thestylus ball is approximately on line with the X axis center line of the turret top plate.
9. Index the turret to the station with the probe mounted on it.
10. Place a center in the spindle work-holding device.
11. Jog the turret to position the center of the stylus ball on center with the spindle centerline.
12. Adjust the probe stylus until the center of the ball is on the spindle centerline. This will place thecenter of the ball on the X axis centerline of the turret.
13. Tighten screw “B” using the wrench provided.
14. Datum the part probe, as outlined on the next page.
13-30 M-392D
Figure 13.21 - Part Probe OMM Uniton the Main Spindle Headwall
TP4689
H
I
DATUMING THE PART PROBE
- CAUTION -
The part probe must be correctly datumed before automatic operation is per-formed.
When the probe is datumed for automatic operation, macro variables 500 and 501 are used to re-cord the position of the probe stylus.
Datuming the Part Probe on the X Axis
- NOTE -
The program in step 1 is only an example to illustrate program structure. Turret sta-tion, tool offset, and coordinate Data may vary, depending on workpiece geometryand probe location on the turret top plate.
If necessary, refer to “Entering a Program from the Keyboard”, page 3-10, for infor-mation on entering a program through the manual Data input keyboard.
In this example, a piece of bar stock has been turned to a diameter of 1.7500 inches for the purposeof datuming the probe on the X axis.
1. Enter a program similar to the following into the control memory:
O____ (Radial Datum X Axis Part Probe) ; Program Number (Operator Message)
G10 P0 Z___ ; Set Work Shift, if Required
G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation,Inch/Millimeter per Minute Feedrate,Move Turret to Safe Index Position,Cancel Tool Offset
T0800 ; Index to Probe Station, No Tool Offset Active
X3. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset
M90 ; Part Probe ON
G4 X1. ; Dwell to Allow Probe ON
X1.76 Z-.375 ; Position Probe for X Axis Datuming as Required
G65 P9013 X1.75 ; Call Macro Program 9013,X1.75 = Known Diameter of the Bar stock
G0 X3. Z.5 ; Move to Clear Bar stock in Spindle
X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset
M30 ; End of Program
2. Activate Automatic Mode.
- NOTE -
Refer to “Activating a Stored Program”, page 3-10, for information on activating aprogram.
3. Verify the datum program entered in step 1 is active.
4. Press the Cycle Start push button to datum the probe on the X axis.
5. Proceed to “Datuming on the Z Axis”, on the next page.
M-392D 13-31
Datuming the Part Probe on the Z Axis
- NOTE -
The program in step 1 is only an example to illustrate program structure. Turret sta-tion, tool offset, and coordinate Data may vary, depending on the Z axis surface tobe used for datuming and probe location on the turret top plate.
If necessary, refer to “Entering a Program from the Keyboard”, page 3-10, for infor-mation on entering a program through the manual Data input keyboard.
In this example, the spindle face will be used for datuming the probe on the Z axis.
1. Enter a program similar to the following into the control memory:
O____ (Datum Z Axis Part Probe) ; Program Number (Operator Message)
G10 P0 Z___ ; Set Work Shift, if Required
G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation,Inch/Millimeter per Minute Feedrate,Move Turret to Safe Index Position,Cancel Tool Offset
T0800 ; Index to Probe Station, No Tool Offset Active
X5. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset
M90 ; Part Probe ON
G4 X1. ; Dwell to Allow Probe ON
X3.625 Z.05 ; Position Probe for Z Axis Datuming as Required
G65 P9017 Z0. T8. ; Call Macro Program 9017,Z0. = Known Z Position,T8. = Offset Location for Part Probe
G0 X5. Z.5 ; Move to Clear Spindle
X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset
M30 ; End of Program
2. Activate Automatic Mode.
- NOTE -
Refer to “Activating a Stored Program”, page 3-10, for information on activating aprogram.
3. Verify the datum program entered in step 1 is active.
4. Press the Cycle Start push button to datum the probe on the Z axis.
The probe is now datumed and is ready for automatic operation. Refer to the programmer’s manual(M-391) for information on programming automatic operation of the part probe.
13-32 M-392D
MAINTENANCE
- CAUTION -
Only a minimum amount of maintenance can be done by user. Dismantling ofRenishaw equipment is a highly specialized operation and must be carried outby an authorized service center. Equipment requiring repair that is still underwarranty should be returned to Hardinge Inc.
Adjustment to the stylus spring pressure may affect probe repeatability. Referto the Renishaw LP2 Probe document supplied with the probe.
Do not use sharp cleaning tools.
Do not use a degreasing agent when washing the probe cavity.
The probe system requires minimum maintenance. Approximately once a month the cavity be-tween front cap “K”, Figure 13.22, and inner seal “Q”, Figure 13.23, should be checked for contami-nants. A build-up of dirt or fine chips could eventually cause the probe to malfunction.
1. Use the hex pin wrench supplied with probe to remove screw “L” and stylus “J”, Figure 13.22.
2. Remove cap “K”, using spanner wrench supplied with the probe.
3. Remove seal “N”, Figure 13.23, and compression spring “O”.
4. Wash out cavity “P” and all parts with a jet of coolant.
M-392D 13-33
Figure 13.22 - Probe and Stylus Assembly
TP754
J K
L
Figure 13.23 - Probe Disassembled
TP751
MN O
P
Q
5. Check rear O-ring “R”, Figure 13.24, for damage or wear and replace if necessary.
6. If inner seal “Q”, Figure 13.23, is pierced or damaged, return the probe to Hardinge Inc.
7. Reverse the procedure to reassemble. Front cap “K”, Figure 13.22, need only be finger tight.
CLEANING PROBE AND OMM UNIT WINDOWS
The optical windows on the probe and OMM units should be checked several times during eachwork shift for any accumulation of dirt or chips which might interfere with probe operation. Use glasscleaner and a rag to clean the windows at least once per shift. More frequent cleaning may be requireddepending on the material being machined.
13-34 M-392D
Figure 13.24 - Rear O-Ring
TP755
R
CHANGING THE PROBE BATTERIES
- NOTE -
The probe unit is supplied with four 3 volt lithium batteries. Two 3 volt lithium batter-ies are required for probe operation.
1. Loosen screws “G”, Figure 13.19 or 13.20, and remove the probe assembly from probe holder“F”.
2. Remove cap “S”, Figure 13.25, using a coin or screwdriver.
3. Remove battery retractor “T” and the old batteries.
4. Install the battery retractor and two fresh batteries in the probe, positive end first. Refer toFigure 13.26 for the correct position of the battery retractor.
5. Install cap “S”.
6. Re-install the probe assembly on the top plate. Refer to page 13-29.
7. Re-calibrate the probe.
M-392D 13-35
Figure 13.25 - Battery Orientation
TP4694
S
T
Figure 13.26 - Battery Retractor Position
TP4695
Battery Retractor
SUB-SPINDLE PART PRESENT DETECTOR [Option]
- CAUTION -
Refer to page 4-2 for information concerning turret tooling for QUEST 6/42 &6/42SP lathes equipped with the following combination of options:
• 12 or 16 station VDI 30 top plate
• Tool probe
• Sub-spindle part present detector
INTRODUCTION
Sub-spindle part present detector "U", Figure 13.27, is commanded from the part program to checkthe sub-spindle for a part. Refer to the programmer’s manual (M-391) for an explanation of the Mcodes used to command the sub-spindle part present detector.
13-36 M-392D
Figure 13.27 - Part Present Detector
U
TP6968
EXTENDING THE PART PRESENT DETECTOR
An extension is provided in the event an application requires positioning the part present detectorarm further from the face of the sub-spindle.
- CAUTION -
Care must be used to avoid an impact between the part present detector andthe main machine headwall when the part present detector extension is in-stalled.
1. Note the radial position of part present detector arm "V", Figure 13.28.
2. Loosen two screws "W".
3. Remove the part present detector arm from main shaft "Z".
4. Thread extension "X" into the main shaft.
5. Tighten set screw "Y".
6. Install the part present detector arm and position radially as noted in step 1.
7. Tighten two screws "W".
RANGE OF MOTION
The range of motion for the part present detector is 120. Refer to View "B", Figure 13.28.
M-392D 13-37
13-38 M-392D
Figure 13.28 - Part Present Detector Extension and Range of Motion
TP5349
VIEW "A"
VIEW "B"
Extension Not Installed Extension Installed
V
X Y
120°
W Z
- NOTES -
M-392D 13-39
- NOTES -
13-40 M-392D
CHAPTER 14 - VDI LIVE TOOLING [Option]
INTRODUCTION
A live tooling option is available on QUEST® series lathes equipped with a VDI top plate. The livetooling attachments are not included with the machine tool and must be purchased separately.
VDI 30 live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at thetool tip, and can be operated at 30 percent of the total duty cycle at 8000 rpm.
VDI 40 live tooling attachments have a maximum spindle speed of 6000 rpm, as measured at thetool tip, and can be operated at 30 percent of the total duty cycle at 6000 rpm.
TYPES OF ATTACHMENTS
- CAUTION -
Live tooling attachments are available with or without through-tool coolant ca-pability.Live tooling attachments without through-tool coolant capability can be runwith or without coolant, as the machining process requires.Live tooling attachments with through-tool coolant capability MUST be runwith coolant turned ON.
Refer to page 14-3 for information on live tooling RPM limits for through-toolcoolant attachments, based on coolant pressure.
The live tooling attachments are identified by axis of operation and if they have internal (thru-tool)coolant.
VDI 30 live tooling attachments are designed to use ER 25 collets to grip the tools.
VDI 40 live tooling attachments are designed to use ER 32 collets to grip the tools.
Cross-Working Attachment:
This attachment locates the center of the drill or milling tool on the centerline of the tool sta-tion, with the spindle of the attachment aligned with the X axis.
End-Working Attachment:
This attachment locates the center of the drill or milling tool on the centerline of the tool sta-tion, with the spindle of the attachment aligned with the Z axis.
M-392D 14-1
ADJUSTABLE DEAD STOP
Each live tooling attachment is equipped with an adjustable dead stop. The dead stop can be ad-justed against the end of the tool to prevent the tool from sliding in the tool holder during high-thrustmachining operations.
The adjustable dead stop is threaded and can be adjusted using a small common-blade screw-driver.
The adjustable dead stop for all cross-working live tooling attachments is accessed through thefront of the tool holder. Refer to Figure 14.1.
The adjustable dead stop for end-working live tooling attachments equipped with internal coolant isaccessed through the front of the tool holder. The adjustable dead stop for end-working live tooling at-tachments NOT equipped with internal coolant is accessed through the back of the tool holder. Referto Figure 14.2.
14-2 M-392D
Figure 14.1 - Cross-Working Live Tooling Attachment
TI4811
Access toDead Stop
Figure 14.2 - End-Working Live Tooling Attachment
TI4812
Access to Dead Stop(Attachment without internal coolant)
Access to Dead Stop(Attachment with internal coolant)
LIVE TOOLING COLLETS AND CAPACITIES
- NOTE -
ER 25 and ER 32 collets conform to DIN 6499.
VDI 30 LIVE TOOLING
ER 25 collets are capable of employing English tools with a shank size from 0.02 inches up to andincluding 0.63 inches.
ER 25 collets are capable of employing Metric tools with a shank size from 0.5 millimeters up to andincluding 16 millimeters.
VDI 40 LIVE TOOLING
ER 32 collets are capable of employing English tools with a shank size from 0.04 inches up to andincluding 0.79 inches.
ER 32 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to andincluding 20 millimeters.
LIVE TOOLING RPM LIMIT
- CAUTION -
DO NOT exceed the RPM limits for through-tool coolant live tooling attach-ments, as indicated in graphs 14.1 and 14.2.
- NOTE -
The RPM limits DO NOT apply to live tooling attachments without through-tool cool-ant capability
Live tooling attachments with through-tool coolant capability are subject to an RPM limit, based onthe pressure of the coolant supplied to the attachment. The coolant pump delivers approximately 187psi [12.9 bar].
Refer to graphs 14.1 and 14.2 for RPM limits.
M-392D 14-3
14-4 M-392D
End-Working Toolholder
Internal Coolant
0
50
100
150
200
250
300
350
400
3000 4000 5000 6000 7000 8000
Spindle Speed, (RPM)
Ma
xim
um
Co
ola
nt
Pre
ss
ure
,
(PS
I)
Graph 14.1 - End-Working Attachments
TI4750A
Cross-Working Toolholder
Internal Coolant
050
100150200250300350400
1000 3000 5000 7000
Spindle Speed, (RPM)
Maxim
um
Co
ola
nt
Pre
ssu
re,(P
SI)
Graph 14.2 - Cross-Working Attachments
TI4751A
LIVE TOOLING ATTACHMENT INSTALLATION
- NOTE -
All turret tool stations can be used for live tooling applications.
MOUNTING THE ATTACHMENT
1. Power-up the machine according to the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before manually in-dexing the turret.
4. Move the turret to a safe position for indexing.
- WARNING -
Stay clear of the turret and turret tooling when indexing the turret. Physical in-jury can result.
5. Manually index the turret to position the desired tool station:
a) Set the Turret Station switch to the tool station to be indexed to the active position.
b) Press the Index push button.
6. Thoroughly clean the turret top plate and the live tooling attachment.
7. Clean and check the O-ring on the live tooling attachment to be sure the O-ring is in goodcondition.
8. If mounting an end-working attachment, loosen two screws “D”, Figure 14.4 or 14.6.
- CAUTION -
NEVER force the live tooling attachment into the turret top plate.
Be sure the live tooling attachment is mounted flush against the side of theturret top plate, as shown in Figure 14.3, 14.4, 14.5, or 14.6.
- NOTE -
When installing a VDI 40 live tooling attachment, the flats on the end of the driveshaft must be oriented 90° (perpendicular) to the gear rack on the shaft, as shown inFigures 14.5 and 14.6.
If necessary, rotate the spindle of the VDI 40 live tooling attachment to allow the at-tachment to seat properly.
9. Aligning live tooling attachment “A” with coolant button “C”, mount the live tooling attachmenton the turret top plate, as shown in Figure 14.3, 14.4, 14.5, or 14.6.
M-392D 14-5
10. If mounting an end-working attachment, press the tool holder against the turret top plate andtighten two screws “D”, Figure 14.4 or 14.6.
- NOTE -
Maximum torque for the clamp screw is 17 lb-ft [23 N•m] on VDI 30 top plates and33 lb-ft [45 N•m] on VDI 40 top plates.
11. Tighten clamp screw “B”.
12. If necessary, remove cap “E”, Figure 14.11, or cap “F”, Figure 14.12, and install the propercollet for the tool to be used. Replace the cap, but DO NOT TIGHTEN.
14-6 M-392D
M-392D 14-7
1
2
10
3
4
65
7
8
9
Figure 14.3 - Mounting a VDI 30 Cross-Working Live Tooling Attachment
TI4714A
C
A
B
1
2
10
3
4
65
7
8
9
Figure 14.4 - Mounting a VDI 30 End-Working Live Tooling Attachment
TI4872
A
B
D
C
14-8 M-392D
7
8
9
10
1
2
3
4
5
6
1
Figure 14.5 - Mounting a VDI 40 Cross-Working Live Tooling Attachment
TI47886
C
B
Be sure the tool holder is flush againstthe side of the turret top plate AGear Rack for
Clamp Screw
Note the Orientationof the Flats on theDrive Shaft
7
8
9
10
1
2
3
4
5
6
1
Figure 14.6 - Mounting a VDI 40 End-Working Live Tooling Attachment
TI4885
A
B
D
C
Be sure the tool holder is flush againstthe side of the turret top plate
Gear Rack forClamp Screw
Note the Orientationof the Flats on theDrive Shaft
INSTALLING / REMOVING TOOLS
Maximum Tool Extension
- WARNING -
DO NOT exceed these maximum tool extension values. Personal injury anddamage to the tooling and machine can result.
- NOTE -
All dimensions are shown in inches [millimeters].
Cross-working live tooling attachments have the following maximum tool extension from the edgeof the turret top plates:
VDI 30 Turret: 6.985 [177.4]
VDI 30 Turret with Y-Axis Option: 5.605 [142.4]
VDI 40 Turret: 7.575 [192.4]
VDI 40 Turret with Y-Axis Option: 6.195 [157.4]
Refer to Figures 14.7 and 14.8.
M-392D 14-9
Figure 14.7 - Maximum Tool Extensionfor VDI 30 Cross-Working Attachments
TI4715
MaximumTool
Extension
Inch [Millimeter]
Standard Turret: 6.985 [177.4]Y-Axis Turret: 5.605 [142.4]
Figure 14.8 - Maximum Tool Extensionfor VDI 40 Cross-Working Attachments
TI4715
MaximumTool
Extension
Inch [Millimeter]
Standard Turret: 7.575 [192.4]Y-Axis Turret: 6.195 [157.4]
End-working live tooling attachments oriented for sub-spindle operation have a maximum tool ex-tension of 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location.
Refer to Figures 14.9 and 14.10.
14-10 M-392D
Figure 14.9 - Maximum Tool Extensionfor VDI 30 End-Working Attachments(Oriented for Sub-Spindle Operation)
TI4704
Maximum Tool Extension
Inch [Millimeter]
8.375[212.73]
2.756[70.00]
6.997[177.73]
Maximum ToolExtension
Figure 14.10 - Maximum Tool Extensionfor VDI 40 End-Working Attachments(Oriented for Sub-Spindle Operation)
TI4704
Maximum Tool Extension
Inch [Millimeter]
8.375[212.73]
3.543[90.00]
6.997[177.73]
Maximum ToolExtension
Procedure
- NOTE -
Wrenches are supplied with the live tooling attachments.
1. Insert the tool into the attachment and set to length.
2. Secure the tool:
On cross-working attachments, mount a wrench on spindle “E”, Figure 14.11, and use asecond wrench to turn cap “F” in the clockwise direction to tighten.
On end-working attachments, mount a wrench on spindle “H”, Figure 14.12, and use aspanner wrench to turn cap “G” in the clockwise direction to tighten.
Reverse the procedure to remove the tooling.
M-392D 14-11
Figure 14.11 - Cross-Working Attachment
TI4209
EF
Figure 14.12 - End-Working Attachment
TI4210
H
G
LIVE TOOLING ATTACHMENT REMOVAL
- WARNING -
When removing a live tooling attachment from the top plate, have a firm gripon the attachment while loosening the clamp screw in the top plate.
The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The airpressure in the turret may cause the tooling attachment to begin moving out of the top plate when theclamp screw is loosened.
1. If removing an end-working attachment, loosen two screws “D”, Figure 14.4 or 14.6.
2. Loosen clamp screw “B”, Figure 14.3 or 14.4, 14.5, or 14.6.
3. Remove the tool holder from the turret top plate.
4. Install a tool station plug if another tool holder is not to be installed. Refer to page 4-4 for in-formation on tool station plugs.
5. Repeat steps 1 through 4 for additional tool holders, as necessary.
14-12 M-392D
LIVE TOOLING OFFSETS
Live tooling offsets are set in the same manner as standard tooling. However, there are some con-siderations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling at-tachments. These considerations are outlined below.
Refer to page 14-14 for information on setting live tooling offsets.
CROSS-WORKING ATTACHMENTS
Cross-working attachments are qualified on the Z axis. The centerline of the spindle in thecross-working attachment will always be located at the Z axis reference position of the turret topplates. Therefore, the Z axis tool offset will always be “0".
Figures 14.7 and 14.8 illustrate a cross-working drill/mill attachment mounted on the turret topplate.
END-WORKING ATTACHMENTS
End-working attachments are qualified on the X axis.
Figures 14.9 and 14.10 illustrate an end-working drill/mill attachment mounted on the turret topplate.
VDI 30 Attachments
The centerline of the spindle in the VDI 30 end-working attachment will be located 2.756 inches[70.0 mm] from the side of the turret top plate.
On machines set for diameter programming, this will result in an X tool geometry offset of 5.512inches [140.00 mm]. On machines set for radius programming, this will result in an X tool geometry off-set of 2.756 inches [70.00 mm].
VDI 40 Attachments
The centerline of the spindle in the VDI 40 end-working attachment will be located 3.543 inches[90.0 mm] from the side of the turret top plate.
On machines set for diameter programming, this will result in an X tool geometry offset of 7.086inches [180.00 mm]. On machines set for radius programming, this will result in an X tool geometry off-set of 3.543 inches [90.00 mm].
M-392D 14-13
SETTING TOOL OFFSETS FOR LIVE TOOLING
The live tooling feature allows milling, drilling, and tapping operations to be performed on either thediameter or face of the workpiece. The method used to establish the tool offset values for live toolingare similar to the method used for standard tooling. Live tooling attachments can be mounted at anytool station on the turret top plate.
Setting Offsets for End-Working Tools
- NOTE-
VDI 30 end-working live tooling attachments place the tool centerline 2.756 inches[70.0 mm] from the X axis turret face. When establishing tool offsets, this dimensionmust be doubled for machines that have been set for Diameter Programming.
VDI 40 end-working live tooling attachments place the tool centerline 3.543 inches[90.0 mm] from the X axis turret face. When establishing tool offsets, this dimensionmust be doubled for machines that have been set for Diameter Programming.
This procedure assumes that the live tooling attachment has already been mountedon the turret top plate and the tooling has been installed in the attachment. Refer topage 14-5 for information on installing live tooling attachments.
1. Load a workpiece of known diameter and length into the collet closer or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriateprocedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set thetool offsets.
3. Enter the work shift value into the Z axis work shift register.
4. Activate Jog mode.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before manually in-dexing the turret.
6. Jog the turret to a safe position for indexing.
7. Select the desired turret station using the Turret Station switch.
8. Press the Index push button to index the turret to the selected station.
9. Jog the tool to within 1 inch [25 mm] of the workpiece being held in the spindle.
14-14 M-392D
10. Place a shim against the part face and use the handwheel to move the turret on the Z axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.
11. Press the Offset Setting function key.
12. Press the Offset soft key to access the Tool Offset pages.
13. Press the Geometry soft key to display the Tool Geometry Offset pages.
14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
15. Key in the appropriate value from the following table:
ProgrammingMode
ProgrammingUnit
Value to Enter as Offset
VDI 30 Top Plate VDI 40 Top Plate
DiameterInch 5.512 7.086
Millimeter 140.00 180.00
RadiusInch 2.756 3.543
Millimeter 70.00 90.00
16. Press the Input key.
17. Use cursor keys to position the cursor at the Z axis field for the desired offset.
18. Press the Operator soft key.
19. Key in the letter Z and the thickness of the shim as a negative value.
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.
20. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under theappropriate offset number, as selected in step 14.
21. Turn the handwheel in the appropriate direction to clear the workpiece.
22. Repeat steps 6 through 21 for each tool as required.
M-392D 14-15
Setting Offsets For Cross-Working Tools
- NOTE -
Cross-working live tool attachments place the tool centerline at the Z axis turret ref-erence position. Therefore, the Z axis tool offset will be equal to “0” (zero).
This procedure assumes that the live tooling attachment has already been mountedon the turret top plate and the tooling has been installed in the attachment. Refer topage 14-5 for information on installing live tooling attachments.
1. Load a workpiece of known diameter and length into the collet closer or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriateprocedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set thetool offsets.
3. Enter the work shift value into the Z axis work shift register.
4. Activate Jog mode.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before manually in-dexing the turret.
6. Jog the turret to a safe position for indexing.
7. Select the desired turret station using the Turret Station switch.
8. Press the Index push button to index the turret to the selected station.
9. Jog the tool until it is positioned over the workpiece O.D.
10. Press the X push button.
11. Press the desired handwheel increment push button.
12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.
13. Press the Offset Setting key.
14. Press the Offset soft key to access the Tool Offset pages.
15. Press the Geometry soft key to display the Tool Geometry Offset pages.
14-16 M-392D
16. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
17. Key in the diameter of the workpiece as a positive value.
Example: Diameter = 2.125
Input = X2.125
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.
18. Press the Measure soft key.
19. Compensate for shim thickness:
If the control is set for diameter programming, enter twice the shim thickness as a negative(-) value.
If the control is set for radius programming, enter the shim thickness as a negative (-)value.
20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step 19.
21. Use the cursor keys to position the cursor at the Z axis field for the desired offset.
22. Key in “0" (zero).
23. Press the Input key.
24. Turn the handwheel in the appropriate direction to clear the workpiece.
25. Repeat steps 6 through 24 for each tool as required.
TOOL NOSE RADIUS COMPENSATION
For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool NoseRadius Compensation may be required for live tooling during C-Axis operations. Refer to the pro-grammer’s manual (M-391) for information on Tool Nose Radius Compensation or C-Axis.
LIVE TOOLING ALIGNMENT
The live tooling attachments are factory set to be on center and should require no further adjust-ment.
M-392D 14-17
LIVE TOOLING MAINTENANCE
LUBRICATING THE LIVE TOOLING ATTACHMENT
- NOTES -
Each live tooling attachment must be removed from the turret top plate at least onceper month to be inspected and lubricated.
1. Move the turret to a safe index position.
2. Index the turret top plate to a convenient position for removing the live tooling attachment.
3. Open the main coolant guard door.
4. Press the Emergency Stop push button.
5. Wipe coolant, chips, and other contaminantsfrom the live tool attachment and turret topplate.
6. Unthread the clamp screw just enough to beable to remove the live tooling attachment. Pullthe live tooling attachment straight out from thetop plate.
7. Inspect the live tooling attachment for wear andthe amount of grease on spline “I”, Figure14.13, or flats “K”, Figure 14.14.
8. Lightly coat spline “I” or flats “K” with Molylube®
Anti-Seize grease.
9. Check O-ring “J” or “L” to be sure that it is ingood condition.
10. Mount the live tooling attachment on the turrettop plate.
- NOTE -
Maximum torque for the clamp screw is17 lb-ft [23 N•m] on VDI 30 top platesand 33 lb-ft [45 N•m] on VDI 40 topplates.
11. Tighten the clamp screw.
12. Close the main coolant guard door.
13. Pull the Emergency Stop push button out to thefirst detent, wait two seconds; then, pull thepush button out to the end of travel andrelease.
14. Repeat steps 2 through 13, as needed, foradditional live tooling attachments.
14-18 M-392DRevised: January 18, 2008
Figure 14.13 - VDI 30 Cross-WorkingLive Tooling Attachment
TP4221
J
I
Figure 14.14 - VDI 40 End-WorkingLive Tooling Attachment
TP4864
K
L
LUBRICATING THE LIVE TOOLING PINION GEARS
Lubrication Frequency
VDI 30 TURRET
If the live tooling is generally run at less than 5000 rpm, the live tooling pinion gears must beinspected and lubricated every 500 hours of operation.
If the live tooling is generally run at 5000 rpm or faster, the live tooling pinion gears must beinspected and lubricated every 250 hours of operation.
VDI 40 TURRET
If the live tooling is generally run at less than 4000 rpm, the live tooling pinion gears must beinspected and lubricated every 500 hours of operation.
If the live tooling is generally run at 4000 rpm or faster, the live tooling pinion gears must beinspected and lubricated every 250 hours of operation.
Lubrication Procedure
1. Move the turret to a convenient position for accessing top plate cover “M”, Figure 14.15.
2. Open the main coolant guard door.
3. Press the Emergency Stop push button.
4. Wipe coolant, chips, and other contaminants from the turret top plate.
5. Remove six screws “N” and the associated lock washers to remove turret cover “M”.
6. Apply KLÜBER® ISOFLEX Topas NCA 152 grease to pinion gears “O”, Figure 14.16.
7. Replace turret cover “M” using lock washers and screws “N”, Figure 14.15. Torque screws“N” to 120 lb-in [162 N•m].
M-392D 14-19
Figure 14.15 - Turret Top Plate Cover(VDI 30 Turret Shown)
TP4227
N
M
Figure 14.16 - Live Tooling Pinion Gears(VDI 30 Turret Shown)
TP4218
P
O
Q
LUBRICATING THE TURRET INDEX SHAFT AND LIVE TOOLING DRIVE SHAFT
The turret index shaft and live tooling drive shaft must be inspected and lubricated every 2000hours of operation.
1. Move the turret to a convenient position for accessing top plate cover “M”, Figure 14.15.
2. Open the main coolant guard door.
3. Press the Emergency Stop push button.
4. Wipe coolant, chips, and other contaminants from the turret top plate.
5. Remove six screws “N” and the associated lock washers to remove turret cover “M”.
- CAUTION -
Use only a manually operated grease gun.
- NOTE -
A manually operated grease gun will require approximately 4½ strokes to deliver therequired amount of grease.
6. Using a manually operated grease gun, apply 4.0 cc of KLÜBER® ISOFLEX Topas NCA 15grease to grease fittings “P” and “Q”.
7. Replace turret cover “M” using lock washers and screws “N”, Figure 14.15. Torque screws“N” to 120 lb-in [162 N•m].
14-20 M-392D
- NOTES -
M-392D 14-21
- NOTES -
14-22 M-392D
CHAPTER 15 - ESA LIVE TOOLING [Option]
INTRODUCTION
A live tooling option is available on QUEST® series lathes equipped with a ESA top plate. The livetooling attachments are not included with the machine tool and must be purchased separately.
ESA live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at the tooltip, and can be operated at 30 percent of the total duty cycle at 8000 rpm.
TYPES OF ATTACHMENTS
- CAUTION -
Live tooling attachments are available with or without through-tool coolant ca-pability.Live tooling attachments without through-tool coolant capability can be runwith or without coolant, as the machining process requires.Live tooling attachments with through-tool coolant capability MUST be runwith coolant turned ON.
The live tooling attachments are identified by axis of operation and if they have internal (thru-tool)coolant.
Cross-Working Attachment:
This attachment aligns the centerline of the tool with the X axis.
End-Working Attachment:
This attachment aligns the centerline of the tool with the Z axis.
LIVE TOOLING COLLETS AND CAPACITIES
- NOTE -
ER 25 collets conform to DIN 6499.
ESA live tooling attachments are designed to use ER 25 collets to grip the tools.
ER 25 collets are capable of employing English tools with a shank size from 0.039 inches up to andincluding 0.629 inches.
ER 25 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to andincluding 16 millimeters.
M-392D 15-1
LIVE TOOLING ATTACHMENT INSTALLATION
- CAUTION -
Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool. Refer to page 5-2 for infor-mation on ESA tool station plugs.
- NOTE -
All turret tool stations can be used for live tooling applications.
MOUNTING THE ATTACHMENT
1. Thoroughly clean the top plate, live tooling attachments, and tooling.
2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.
3. If it is necessary to index the turret:
A) Move the turret to a safe index position.
B) Index the turret to the desired tool station.
C) Move the turret to a convenient position for installing tools.
4. Press and hold button "A", Figure 15.1.
5. Insert the tool holder into the turret top plate as shown in View B.
6. Release button "A" to clamp the tool holder.
15-2 M-392D
Figure 15.1 - Live Tooling Attachment Installation(Cross-Working Attachment Shown)
A
TI5451
B
VIEW ALive Tool AttachmentAligned for Installation
VIEW BLive Tool AttachmentInstalled on Top Plate
7. Tighten rear clamp screw "C", Figure 15.2.
8. Install and tighten four face screws “B”, Figure15.1.
9. If necessary, remove cap “D”, Figure 15.3, andinstall the proper collet for the tool to be used.Replace the cap, but DO NOT TIGHTEN.
M-392D 15-3
Figure 15.2 - Rear Clamping Screw
C
TP7130
Figure 15.3 - Collet Caps on Live Tool Attachments
D
D
TI5452
Cross-WorkingLive Tooling Attachment
End-WorkingLive Tooling Attachment
INSTALLING TOOLS
Maximum Tool Extension
- WARNING -
DO NOT exceed these maximum tool extension values. Personal injury anddamage to the tooling and machine can result.
- NOTE -
All dimensions are shown in inches [millimeters].
Cross-working live tooling attachments have the following maximum tool extension from the edgeof the turret top plates:
Standard Turret: 8.363 [212.42]
Turret with Y-Axis Option: 6.983 [177.37]
End-working live tooling attachments oriented for sub-spindle operation have a maximum tool ex-tension of 8.375 inches [212.73 millimeters] from the centerline of the turret top plate tool mounting lo-cation.
Refer to Figure 15.4.
15-4 M-392D
Figure 15.4 - Maximum Tool Extensions
Standard Turret: 8.363 [212.42]
Y-Axis Turret: 6.983 [177.37]
5.481[139.22]
8.375[212.73]Inch [Millimeter]
TI5453
Cross-Working Live Tooling Attachment End-Working Live Tooling AttachmentOriented for Sub-Spindle Operation
Tool Installation Procedure
- NOTE -
Wrenches are supplied with the live tooling attachments.
1. Insert the tool into the attachment and set to length.
2. Mount a spanner wrench on spindle “E”, Figure 15.5.
3. Use a wrench to tighten cap “F”.
M-392D 15-5
Figure 15.5 - Tools Installed in Live Tool Attachments
TI5454
Cross-WorkingLive Tooling Attachment
End-WorkingLive Tooling Attachment
F
E
F
E
LIVE TOOLING OFFSETS
Live tooling offsets are set in the same manner as standard tooling. However, there are some con-siderations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling at-tachments. These considerations are outlined below.
Refer to page 15-7 for information on setting live tooling offsets.
CROSS-WORKING ATTACHMENTS
Cross-working attachments are qualified on the Z axis. The centerline of the spindle in thecross-working attachment will always be located at the Z axis reference position of the turret topplates. The Z axis tool offset will always be “0".
END-WORKING ATTACHMENTS
- NOTE -
Machines equipped with an ESA turret top plate have the same X axis turret refer-ence position and travel specifications as a machine equipped with a VDI 30 turrettop plate. As indicated in Figure 15.6, the diameter of the ESA turret top plate is1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.
End-working attachments are qualified on the X axis. The centerline of the spindle in the end-work-ing attachment will be located 2.7559 inches [70.00 millimeters] from the X axis turret reference posi-tion.
On machines set for radius programming, the X tool geometry offset will be 2.7559 inches[70.00 millimeters].
On machines set for diameter programming, the X tool geometry offset will be 5.5118 inches[140.00 millimeters].
15-6 M-392D
Figure 15.6 - X Axis Tool Offset forEnd-Working Live Tooling Attachments
2.7559[70.0]
TI5455A
Inch [Millimeter]
1.378[35.00]
Turret X Axis Reference Position(Refer to the note on this page)
SETTING TOOL OFFSETS FOR LIVE TOOLING
The live tooling feature allows milling, drilling, and tapping operations to be performed on either thediameter or face of the workpiece. The method used to establish the tool offset values for live toolingare similar to the method used for standard tooling. Live tooling attachments can be mounted at anytool station on the turret top plate.
Setting Offsets for End-Working Tools
- NOTE-
ESA end-working live tooling attachments place the tool centerline 2.7559 inches[70.00 millimeters] from the X axis turret reference position. When establishing tooloffsets, this dimension must be doubled for machines that have been set for Diame-ter Programming.
This procedure assumes that the live tooling attachment has already been mountedon the turret top plate and the tooling has been installed in the attachment. Refer topage 15-2 for information on installing live tooling attachments.
1. Load a workpiece of known diameter and length into the collet closer or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriateprocedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set thetool offsets.
3. Enter the work shift value into the Z axis work shift register.
4. Activate Jog mode.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before manually in-dexing the turret.
6. Jog the turret to a safe position for indexing.
7. Select the desired turret station using the Turret Station switch.
8. Press the Index push button to index the turret to the selected station.
9. Jog the tool to within 1 inch [25 millimeters] of the workpiece being held in the spindle.
M-392D 15-7
10. Place a shim against the part face and use the handwheel to move the turret on the Z axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.
11. Press the Offset Setting function key.
12. Press the Offset soft key to access the Tool Offset pages.
13. Press the Geometry soft key to display the Tool Geometry Offset pages.
14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
15. Key in the appropriate value from the following table:
ProgrammingMode
ProgrammingUnit
Value to Enteras Offset
DiameterInch 5.5118
Millimeter 140.00
RadiusInch 2.7559
Millimeter 70.00
16. Press the Input key.
17. Use cursor keys to position the cursor at the Z axis field for the desired offset.
18. Press the Operator soft key.
19. Key in the letter Z and the thickness of the shim as a negative value.
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.
20. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under theappropriate offset number, as selected in step 14.
21. Turn the handwheel in the appropriate direction to clear the workpiece.
22. Repeat steps 6 through 21 for each tool as required.
15-8 M-392D
Setting Offsets for Cross-Working Tools
- NOTE -
Cross-working live tool attachments place the tool centerline at the Z axis turret ref-erence position. Therefore, the Z axis tool offset will be equal to “0” (zero).
This procedure assumes that the live tooling attachment has already been mountedon the turret top plate and the tooling has been installed in the attachment. Refer topage 15-2 for information on installing live tooling attachments.
1. Load a workpiece of known diameter and length into the collet closer or chuck.
2. If it has not already been done, determine the Work Shift Offset following the appropriateprocedure in Chapter 7.
- NOTE -
The work shift value must be in the Z axis work shift register to accurately set thetool offsets.
3. Enter the work shift value into the Z axis work shift register.
4. Activate Jog mode.
5. Set the Feedrate Override switch to the desired setting.
- CAUTION -
The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before manually in-dexing the turret.
6. Jog the turret to a safe position for indexing.
7. Select the desired turret station using the Turret Station switch.
8. Press the Index push button to index the turret to the selected station.
9. Jog the tool until it is positioned over the workpiece O.D.
10. Press the X push button.
11. Press the desired handwheel increment push button.
12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.
13. Press the Offset Setting key.
14. Press the Offset soft key to access the Tool Offset pages.
15. Press the Geometry soft key to display the Tool Geometry Offset pages.
M-392D 15-9
16. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.
17. Key in the diameter of the workpiece as a positive value.
Example: Diameter = 2.125
Input = X2.125
- NOTE -
Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.
18. Press the Measure soft key.
19. Compensate for shim thickness:
If the control is set for diameter programming, enter twice the shim thickness as a negative(-) value.
If the control is set for radius programming, enter the shim thickness as a negative (-)value.
20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step 19.
21. Use the cursor keys to position the cursor at the Z axis field for the desired offset.
22. Key in “0" (zero).
23. Press the Input key.
24. Turn the handwheel in the appropriate direction to clear the workpiece.
25. Repeat steps 6 through 24 for each tool as required.
TOOL NOSE RADIUS COMPENSATION
For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool NoseRadius Compensation may be required for live tooling during C-Axis operations. Refer to the pro-grammer’s manual (M-391) for information on Tool Nose Radius Compensation or C-Axis.
LIVE TOOLING MAINTENANCE
Refer to the maintenance manual (M-393) for information on live tooling maintenance.
LIVE TOOLING ALIGNMENT
Live tooling alignment is set at the factory and should require no further adjustment.
15-10 M-392D
- NOTES -
M-392D 15-11
- NOTES -
15-12 M-392D
CHAPTER 16 - TOOL LIFE MANAGEMENT
INTRODUCTION
The basic concept of Tool Life Management is that after a specific number of parts or a specificamount of machining time, the control will automatically begin using another tool in place of the cur-rent tool being used for a particular operation.
Tools are assigned to specific groups, as designated by the programmer. The control will monitorthe measurement value assigned to each tool group and automatically switch to the next tool in thegroup when the counter for that tool group reaches the measurement value specified by the program-mer.
TOOL LIFE MEASUREMENT UNITS
Tool life can be measured using one of the two following methods:
1. Number of parts (machined by the tool)
2. Amount of machining time (on the tool)
Only one of these methods may be used at a time. “Number of parts” will be the active measure-ment unit when the machine is shipped from the factory. Refer to Determining the Measurement Unit,page 16-5, for information on verifying or switching the active measurement unit.
An alarm message will be displayed when any tool group has reached its programmed tool life andan “M30" (End of Program) is read by the control. At that point, the machine operator will replace thetooling and reset the counter relating to the affected tool group. Refer to Resetting a Tool Group Coun-ter, page 16-6.
NUMBER OF PARTS
When this type of measurement is used, the control will increment the tool group counter for the ac-tive tool each time the tool group is called by the part program.
AMOUNT OF MACHINING TIME
When this type of measurement is used, the control will run the tool group counter for the currenttool whenever G01, G02, or G03 is active.
M-392D 16-1
TOOL LIFE MANAGEMENT PROGRAM
When using Tool Life Management, tools and offsets are assigned to specific groups. Thesegroups are established by the programmer through the use of a Tool Life Management program,which is independent of the part program. The Tool Life Management program will define the parame-ters required for Tool Life Management.
The Tool Life Management program defines the following parameters:
• Group numbers.
• Tool life value for each group.
• Tool stations and offsets for each group.
- CAUTION -
When the Tool Life Management program is executed, all Tool Life Manage-ment counters will be reset to 0 (zero).
When using Tool Life Management, the machine operator MUST load and execute the Tool LifeManagement program BEFORE executing the part program for the first time.
Refer to the programmer’s manual (M-391) for information on the Tool Life Management programand how to incorporate Tool Life Management information in the part program.
BAR FEED OPERATION
There are no special considerations for running bar jobs. When running a bar job and using ToolLife Management, the programmer will program an M30 at the end of the part program and the ma-chine operator will activate Repeat mode to cause the part program to loop.
Refer to page 1-9 for information on Repeat mode.
16-2 M-392D
OPERATION
DETERMINING MAXIMUM GROUPS AND GROUP SIZES
The maximum number of tool groups and maximum number of tools per group are established byparameter 6800, bits 0 and 1. Be sure that bits 0 and 1 are set to appropriate values to allow for thenecessary number of tool groups and tools per group to be programmed in the Tool Life ManagementProgram.
The bits in parameter 6800 are numbered as follows:
7 6 5 4 3 2 1 0
Set bits 0 and 1 according to the following chart:
Bit 1 Bit 0 Max No. of Groups Max Tools per Group
0 0 16 16
0 1 32 8
1 0 64 4
1 1 16 16
When the machine is shipped from the factory, the maximum number of groups and maximum toolsper group will be set to 16.
Verifying Maximum Groups and Group Sizes
1. Press the System key.
2. Press the Parameter soft key.
3. Use the Page keys to display the page that contains parameter 6800.
4. Compare bits 0 and 1 to chart above to determine the maximum groups and group sizes.
Setting Maximum Groups and Group Sizes
1. Press the Offset Setting key.
2. Press the Setting soft key.
3. If necessary, use the Page keys to display the Setting page that contains the Parameter Writefield.
4. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
5. Activate Manual Data Input mode.
6. Key in the number 1 (one).
M-392D 16-3
7. Press the Input key. Parameter editing will be enabled.
8. Press the System key.
9. Press the Parameter soft key.
10. Use the Page and Cursor keys to position the cursor at parameter 6800.
11. Record the current number in parameter 6800.
12. Key in the entire parameter value with bits 0 and 1 set to the appropriate values.
13. Press the Input key.
14. Press the Offset Setting key.
15. Press the Setting soft key.
16. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
17. Key in the number 0 (zero).
18. Press the Input key. Parameter editing will be disabled.
16-4 M-392D
DETERMINING THE MEASUREMENT UNIT
The two types of measurement units available are “Number of Parts” and “Amount of MachiningTime”. To verify which measurement unit is active, it is necessary to view parameter 6800, bit 2. Toswitch the type of measurement unit to be used with Tool Life Management, it is necessary to modifyparameter 6800, bit 2.
The bits in parameter 6800 are numbered as follows:
7 6 5 4 3 2 1 0
Verifying the Measurement Unit
1. Press the System key.
2. Press the Parameter soft key.
3. Use the Page keys to display the page that contains parameter 6800.
If parameter 6800, bit 2 is set to 0, “Number of Parts” is active.If parameter 6800, bit 2 is set to 1, “Amount of Machining Time” is active.
Switching the Measurement Unit
1. Press the Offset Setting key.
2. Press the Setting soft key.
3. If necessary, use the Page keys to display the Setting page that contains the Parameter Writefield.
4. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
5. Activate Manual Data Input mode.
6. Key in the number 1 (one).
7. Press the Input key. Parameter editing will be enabled.
8. Press the System key.
9. Press the Parameter soft key.
10. Use the Page and Cursor keys to position the cursor at parameter 6800.
11. Record the current number in parameter 6800.
12. Key in the entire parameter value with bit 2 set to the appropriate value.
13. Press the Input key.
14. Press the Offset Setting key.
15. Press the Setting soft key.
16. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
17. Key in the number 0 (zero).
18. Press the Input key. Parameter editing will be disabled.
M-392D 16-5
RESETTING A TOOL GROUP COUNTER
Resetting the control or turning the control OFF will have NO AFFECT on the tool group counters.When all of the tools in a tool group have reached the tool life specified in the Tool Life Managementprogram and an M30 “End of Program” is read, the following alarm message will be displayed:
1006 TOOL GROUP LIFE END
The expired tool groups will be listed near the bottom of the Tool Life Management screen on thecontrol display. The control can display more than one tool group number at a time, when applicable.Resetting the counter for the expired tool group(s) will clear the alarm and allow machine operation.
- NOTE -
It is not necessary to change machine modes to reset tool group counters.
Use the following procedure to reset the tool group counter(s):
1. Press the Offset Setting key.
2. Press the right-hand soft key.
3. Press the Tool Life soft key.
- NOTE -
Each time a cursor control key is pressed, the cursor will move to the next tool groupin the corresponding direction.
4. Use the cursor control keys to move the cursor to the desired tool group.
5. Press the Operator soft key.
6. Press the Clear soft key.
7. Press the Execute soft key. The tool group counter at the cursor position will be reset to 0(zero).
8. Repeat steps 4 through 7 to reset additional tool group counters, as needed.
16-6 M-392D
- NOTES -
M-392D 16-7
- NOTES -
16-8 M-392D
CHAPTER 17 - SUB-SPINDLE ANDCOLLET CLOSER [Option]
- WARNING -
Tighten all draw tube screws before beginning spindle operation.
- CAUTION -
Never operate the sub-spindle without a work-holding device if the draw tubeis in the spindle.
INTRODUCTION
The sub-spindle allows parts to be machined at both ends without stopping the machine toend-for-end the workpiece. This reduces cycle times by eliminating part handling by the operator.Drilling, boring, turning and facing operations can be performed on parts which are chucked in thesub-spindle.
Depending on the machining sequence which is selected, the first side of the workpiece is ma-chined in either the main spindle or the sub-spindle. The workpiece is then transferred to the otherspindle to complete machining of the second side. The sub-spindle travel specifications are shown inAppendix One.
CYCLE START SAFETY INTERLOCK
Cycle Start is inhibited when the main spindle and sub-spindle work-holding devices are both open.At least one work-holding device must be closed before Cycle Start can be activated.
FREE SPINDLE
A “Free Spindle” condition allows the sub-spindle to be turned by hand. To obtain a free spindle,proceed as follows:
- NOTE -
To obtain a free spindle, the control must be ON and the sub-spindle must not be ro-tating.
1. Power up the machine as described in Chapter 2.
2. Press the control Reset key.
3. Press the Sub Spindle Free push button.
M-392D 17-1
CONTROLLING SUB-SPINDLE MOVEMENT
AUTOMATIC, MANUAL DATA INPUT, OR SINGLE MODE
- NOTE -
When E axis motion is programmed by itself, the sub-spindle moves at the pro-grammed feedrate. When E axis motion is programmed with X and/or Z axis motion,the sub-spindle moves at a compensated feedrate to cause the sub-spindle to com-plete the move at the same time as the other axes.
Linear motion of the sub-spindle assembly, designated the E axis, is performed by a servo drivesystem that is controlled by the CNC control. The E Data word is used to command direction and dis-tance when moving the ball screw driven sub-spindle in Automatic, Manual Data Input, or Singlemode. The face of the sub-spindle is the sub-spindle reference point.
The maximum programmable feedrate (G01 active) is 394 in/min [10,000 mm/min].
The machine is forced into a Feed Hold condition when Automatic, Manual Data Input, or Singlemode is active and any interlocked door is opened or cover removed. The Feed Hold condition is re-leased when the door is closed or cover replaced. Press the Cycle Start push button to resume pro-gram execution.
E Data Word
The E Data word commands an absolute move referenced against the Z0 (zero) position of the ma-chine coordinate position. Positive E coordinates are to the right of Z0 and negative E coordinates areto the left of Z0. The Z0 position will be equal to the face of the main spindle unless modified throughthe Work Shift offset. Refer to Chapter 7 for information on the Work Shift offset.
Feedrate Override Switch
The Feedrate Override switch allows the machine operator to adjust the programmed feedrate ofthe sub-spindle from 0% to 150%, up to a maximum feedrate of 394 in/min [10,000 mm/min].
17-2 M-392D
JOG MODE
Axis Direction Keys
When a Z/E push button is pressed while Jog mode is active and the Manual Axis Motion switch isset to the E axis, the servo drive system causes the sub-spindle to move in the selected direction at ajog feedrate of 25 in/min [635 mm/min] when the Feedrate Override switch is set to 100%. Refer to“Feedrate Override Switch”, below.
FEEDRATE OVERRIDE SWITCH
The Feedrate Override switch allows the machine operator to adjust the jog feedrate ofthe sub-spindle from 0 to 37.5 in/min [952 mm/min].
RAPID TRAVERSE
The Traverse push button allows the machine operator to jog the sub-spindle on the Eaxis at approximately 150 in/min [3810 mm/min], regardless of the setting of the FeedrateOverride switch.
MOVING THE SUB-SPINDLE
1. Activate Jog mode.
2. Use the Manual Axis Motion switch to select the E axis.
3. Set the Feedrate Override switch to the desired setting.
4. Press the appropriate Z/E push button to jog the sub-spindle in the desired direction.
Handwheel Control
The handwheel can be used to move the sub-spindle incrementally on the E axis whenever CycleStart is not active. The E axis is selected with the Manual Axis Motion switch. The movement incre-ment is selected by with the Rapid Override switch. The sub-spindle will move incrementally when thehandwheel is rotated. The direction and distance is determined by the direction and amount of rotationof the handwheel.
MOVING THE SUB-SPINDLE
1. Activate Jog mode.
2. Use the Manual Axis Motion switch to select the E axis.
3. Use the Rapid Override switch to select the desired increment.
4. To view axis position on the control display:
A) Press the Position key.
B) Press the Page key until the desired position display appears on the control display.
5. Turn the handwheel in the desired direction (+ or -). Observe the axis position display todetermine when the axis has been moved the required distance.
• Turn the handwheel in the plus (+) direction to move the sub-spindle away fromthe face of the main spindle.
• Turn the handwheel in the minus (-) direction to move the sub-spindle toward theface of the main spindle.
M-392D 17-3
SUB-SPINDLE TOOLING
This section covers the removal and installation of spindle tooling, such as collets, step chucks,and jaw chucks.
- CAUTION -
Read and follow all safety recommendations and operating limits for anywork-holding device installed in the spindle. DO NOT EXCEED the rated ca-pacity of the work-holding device.
QUEST® series machines are available with a standard or high speed sub-spindle. The high speedspindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced to ISOG2.5 or better.
All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limi-tations and balance specifications. Hardinge Inc. offers chucks balanced to G2.5 or better for highspeed applications.
REMOVING SUB-SPINDLE TOOLING
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. If necessary, press the Sub Open/Close push button to open work-holding device in the colletcloser.
5. At the right end of the machine, remove draw tube access cover “A”, Figure 17.1.
6. If present, remove the plug from the end of the spindle draw tube.
7. Completely loosen six screws “B”, Figure 17.2.
17-4 M-392D
Figure 17.1 - Draw Tube AccessCover at Right End of Machine
TP4135A
A
Figure 17.2 - Spindle Draw Tube
TP4133A
B
D
C
- NOTE -
Six screws “B”, Figure 17.2, must be completely disengaged from the collet closerliner before draw tube nut “C” can be rotated.
Removal of a jaw chuck or step chuck may require the assistance of a second per-son.
8. Rotate draw tube nut “C” counterclockwise to disengage the draw tube from the work-holdingdevice.
- WARNING -
Be prepared to accept the weight of the work-holding device.
9. Remove the work-holding device from the spindle.
10. Cover the main spindle to protect it from chips while the sub-spindle is being cleaned.
11. Close the main coolant guard door.
12. From the collet closer end of the draw tube, use an air line to blow any contaminants present outof the spindle.
- WARNING -
The draw tube may be HOT when running aggressive duty cycles on machinesequipped with a high speed sub-spindle.
13. Completely remove the draw tube from the back of the spindle.
14. From the collet closer end of the draw tube, use an air line to blow any contaminants present outof the spindle a second time.
15. Clean the spindle and draw tube.
16. Lightly lubricate the bearing surfaces of the draw tube with Molylube® Anti-Seize grease.
17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp® SHC 32 grease.
18. Carefully replace the draw tube in the spindle.
19. If spindle tooling is to be installed at this time, proceed to “Installing Spindle Tooling”, beginningon page 17-6.
If spindle tooling is not to be installed at this time:
A) Replace the draw tube plug.
B) Replace draw tube access cover “A”, Figure 17.1.
M-392D 17-5
INSTALLING SUB-SPINDLE TOOLING
- NOTE -
For the best surface finish and part roundness, the sub-spindle and draw tube havebeen balanced together at the factory. Although the spindle and draw tube can berun in other positions, the best balance is when etched mark “D”, Figure 17.2, andspindle drive button “E”, Figure 17.3, are aligned.
Two procedures are outlined in this section. The first procedure, which begins below, covers the in-stallation of collets and step chucks. The second procedure, beginning on page 17-8, covers the in-stallation of jaw chucks.
Collet or Step Chuck
This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Sub-SpindleTooling”, beginning on page 17-4.
If previously used spindle tooling has just been removed, proceed to step 6.
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. Remove draw tube access cover “A”, Figure 17.1.
5. If present, remove the plug from the end of the spindle draw tube.
- NOTE -
The collet and spindle bore MUST be clean.
6. Clean the spindle bore and the collet or stepchuck and closer to be installed.
7. Press the Sub-Spindle Free push button torelease the spindle brake and allow the spindleto be rotated.
8. Manually position spindle drive button “E”,Figure 17.3, to the top dead center (12 o’clock)position.
9. Press the Sub-Spindle Free push button againto have the brake secure the spindle drivebutton at 12 o’clock.
17-6 M-392D
Figure 17.3 - Sub-Spindle Nose withDrive Button at Top Dead Center
E
TP5785
- WARNING -
To insure operator safety:- DO NOT use cast iron step chucks.- DO NOT use a step chuck without a step chuck closer.
- NOTE -
Installation of a step chuck may require the assistance of a second person.
10. If installing a step chuck in the spindle, place the step chuck closer against the spindle andinstall the mounting screws securely.
11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle untilit makes contact with the draw tube.
12. Carefully push the draw tube against the back of the collet while rotating the draw tubeclockwise to start the threads of the collet into the threads of the draw tube.
- NOTE -
Adjustment of the collet or step chuck may require the assistance of a second per-son.
13. Select the largest diameter workpiece which is to be chucked and position this part in the colletor step chuck.
14. Rotate the draw tube nut “C”, Figure 17.2, clockwise until the workpiece is gripped tightly; then,back the draw tube off ¼ to ½ turn.
15. Rotate the draw tube the shortest distance to locate etched mark “D” at top dead center (12o’clock) position.
16. Tighten six draw tube screws “B”.
17. Press the Sub Open/Close push button to close the collet and test the gripping force on theworkpiece.
If the gripping force is satisfactory, then go to step 14.
If the gripping force is more or less than desired, adjust knob “F”, Figure 17.4 or 17.5, toany setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 17.1.
- CAUTION -
If the machine will not be operated with a bar feed system, the draw tube plugshould be installed in the end of the spindle draw tube to prevent coolant andchips from entering the spindle drive motor compartment.
18. Install the plug in the end of the spindle draw tube if a bar feed system will not be used.
19. Replace draw tube access cover “A”, Figure 17.1.
M-392D 17-7
Jaw Chuck
This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Sub-SpindleTooling”, beginning on page 17-4.
If previously used spindle tooling has just been removed, proceed to step 6.
- CAUTION -
Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.
1. Power the machine up using the procedure outlined in Chapter 2.
2. Press the control Reset key.
3. Activate Jog mode.
4. Remove draw tube access cover “A”, Figure 17.1.
5. If present, remove the plug from the end of the spindle draw tube.
- NOTE -
The jaw chuck and spindle bore MUST be clean.
6. Clean the jaw chuck and spindle bore.
7. Press the Sub-Spindle Free push button to release the spindle brake and allow the spindle tobe rotated.
8. Manually position spindle drive button “E”, Figure 17.3, to the top dead center (12 o’clock)position.
9. Press the Sub-Spindle Free push button again to have the brake secure the spindle drivebutton at 12 o’clock.
10. Place the chuck in the spindle and install the mounting screws securely.
11. Carefully push the draw tube against the back of the chuck while rotating the draw tubeclockwise to start the threads of the chuck into the threads of the draw tube.
12. Rotate draw tube nut “C”, Figure 17.2, to thread the draw tube onto the 3 jaw chuck as far aspossible.
13. Rotate the draw tube counterclockwise to locate etched mark “D” at top dead center (12o’clock) position.
14. Tighten six draw tube screws “B”.
(Continued on next page)
17-8 M-392D
15. Place a workpiece into the chuck and press the Sub Open/Close push button to close the chuckand test the gripping force on the workpiece.
If the gripping force is satisfactory, then go to step 12.
If the gripping force is more or less than desired, adjust knob “F”, Figure 17.4 or 17.5, toany setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 17.1.
- CAUTION -
If the machine will not be operated with a bar feed system, the draw tube plugshould be installed in the end of the spindle draw tube to prevent coolant andchips from entering the spindle drive motor compartment.
16. Install the plug in the end of the spindle draw tube if a bar feed system will not be used.
17. Replace draw tube access cover “A”, Figure 17.1.
M-392D 17-9
SUB-SPINDLE COLLET CLOSER
The sub-spindle on QUEST® series lathes is equipped with a .5 inch [12.7 mm] stroke, hydraulicallyactuated collet closer. If repairs to the collet closer assembly are required, the ENTIRE ASSEMBLYmust be removed and returned to the factory. Refer to the QUEST series lathe maintenance manual(M-393) for information on removing or installing the sub-spindle collet closer assembly.
HYDRAULIC PRESSURE CONTROL
- NOTE -
The sub-spindle collet closer has an operational pressure range of 60 psig [4.14bars] to 500 psig [34.5 bars].
The sub-spindle collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulicpressure controls are located at the back of the machine. Sub-spindle collet closer pressure is con-trolled with adjustment knob “F”, Figure 17.4 or 17.5.
Gauge “G” registers the collet closer hydraulic pressure in psig and bars. Refer to Table 17.1, page17-11, to determine the force that will be applied to the collet closer draw bar for a given pressure. Acheck valve system positively holds the closer open or closed, whichever is active, in the event of a hy-draulic pressure failure.
- CAUTION -
DO NOT exceed the maximum pressure setting, as shown in Table 17.1 .
- NOTE -
It is the responsibility of the machine operator or set-up person to properly adjust thecollet closer hydraulic pressure, based on the type of material to be machined andthe configuration of the workpiece.
17-10 M-392D
Figure 17.4 - Sub-Spindle Collet Closer Pressure Adjustment(Machine with Standard Spindle Drive)
TP4196
FG
Adjusting the Hydraulic Pressure
1. Loosen the knurled lock nut behind pressure adjustment knob “F”, Figure 17.4 or 17.5.
2. Turn pressure adjustment knob “D” clockwise or counterclockwise to decrease or increase thecollet closer hydraulic pressure.
3. Tighten the knurled lock nut to secure the setting.
M-392D 17-11
English Metric
Gauge Pressure(psig)
Draw Bar Force(lbs)
Gauge Pressure(bar)
Draw Bar Force(daN)
100 1,206 6.9 538
200 2,412 13.8 1,076
300 3,619 20.7 1,615
400 4,826 27.6 2,152
500 6,000 34.5 2,678
Table 17.1 - Sub-Spindle Collet Closer Draw Bar Force
Figure 17.5 - Sub-Spindle Collet Closer Pressure Adjustment(Machine with High Speed Spindle Drive)
TP4816
F
G
SUB-SPINDLE COLLET CLOSER OPERATION
- CAUTION -
Do not operate the sub-spindle collet closer when a collet or step chuck ismounted in place without gripping a piece of stock or a plug of the correctsize.
Automatic Operation
For automatic operation, program M56 to open the collet and M57 to close the collet. The M56(Open Collet) and M57 (Collet Close) commands may be executed while the spindle is running. M56will remain active until it is canceled by an M57 (Close Collet) command. A programmed M57 (ColletClose) command will remain active until it is canceled by an M56 (Open Collet) command.
Manual Operation
The collet closer can be manually operated whenever the machine is in a Reset or program stop(M00, M01, or M30) condition. Use the Sub Open/Close push button to operate the sub-spindle colletcloser manually.
Chucking Modes
There is no default chucking mode. The current chucking mode will remain active until canceled bythe appropriate command (M68 or M69).
External chucking mode permits the use of work-holding fixtures that grip the workpiece externally.Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally.
SWITCHING THE CHUCKING MODE
1. Check to be sure the Sub Open/Close indicator light is ON. Place a workpiece in the collet andpress the Sub Open/Close push button, if necessary.
2. Activate Manual Data Input mode.
3. Press the Program soft key.
4. At the manual Data input keyboard:
Key in “M68” for External Chucking
Key in “M69” for Internal Chucking
5. Press the Insert key.
6. Press the EOB (End of Block) key.
7. Press the Insert key.
8. Close the machine guard door and press the Cycle Start push button.
9. Press the control Reset key. The selected chucking mode will be active
17-12 M-392D
MAIN AND SUB-SPINDLE MACHINING SET-UP AND OPERATION
Main and sub-spindle machining involves the following procedures:
• Set offsets and machine the first side.
• Set offsets and machine the second side.
- CAUTION -
WORK SHIFT When machining operations involving both spindles are per-formed, two work shifts must be called out through the part pro-gram. Both the main and sub-spindle work shifts must be recordedfor insertion into the part program.
Z AXIS VALUES For sub-spindle machining, negative Z values will be clearingmoves outside the workpiece face. Positive Z values will be insidethe workpiece face.
SAFE START ANDSAFE ENDPROGRAMS
The operator should be aware that programs O1 and O2 are usedfor the main spindle ONLY. To avoid crash situations, programsO3 and O4 must be used for the sub-spindle.O3 must be used to start all sub-spindle tool operations and to endall outside diameter work.O4 must be used to end all sub-spindle inside diameter work.
SAFE INDEXPROGRAMS
The operator should be aware that program O999 is used for themain spindle ONLY. To avoid crash situations, program O998must be used for the sub-spindle.
Prerequisites:
Control is turned ON and part program is loaded and active. Refer to Chapters 3and 11.
Safe Start and Safe End Programs O1, O2, O3, and O4 are loaded into thecontrol and are called out in the part program.
Safe Index Programs O998 and O999 are entered into the control.
Operator knows how to edit part programs. Refer to Chapter 3.
Work-holding device is installed on the main spindle and adjusted to grip theworkpiece properly. Refer to Chapter 9.
Work-holding device is installed on the sub-spindle and adjusted to grip theworkpiece properly. Refer to Chapter 17.
Tools are mounted on the turret top plate at the correct stations. Refer toChapter 4, 5, or 6.
Operator knows how to establish the work shift offset and tool offsets for themain spindle. Refer to Chapters 7 and 8.
Operator knows how to establish the work shift offset and tool offsets for thesub-spindle. Refer to Chapters 7 and 8.
M-392D 17-13
SAMPLE MACHINE SET-UP
The sample machine set-up on pages 17-14 through 17-16 illustrates how a machine could be setup for main spindle machining, followed by sub-spindle machining.
- CAUTION -
If the machine is to be operated in Metric mode, the Z pull back value in pro-gram O4 must be converted to the metric value.
When a bar feed is being used, the face of the bar should be flush with the col-let face since the program begins with a feed stock operation.
Set Up and Machine Main Spindle Operation
1. Place a workpiece of the correct size in the main spindle work-holding device at the desiredlength.
2. Press the Main Open/Close push button to close the work-holding device.
3. Establish the work shift offset for the main spindle. Record this dimension.
4. Find the tool geometry offsets for the turret tooling used for the main spindle.
5. Subtract the shim thickness and face stock to be removed from the value recorded in step 3 andrecord this dimension for insertion into the part program.
- CAUTION -
The X Safe Index coordinate defined in subprogram O999 should be equal theX Home position. The Z Safe Index coordinate should equal the LONGEST toolplus 1.000 inch [25.4 mm] minimum. Refer to Chapter 8 for additional informa-tion.
The Z Safe Index coordinate defined in subprogram O999 MUST be pro-grammed as a POSITIVE number.
6. Check the coordinates in Safe Index Sub-Program O999 to be sure that they are adequate.
If Then
Adequate Go to step 7.
Inadequate Edit sub-program O999 to provide extra clearance.Refer to Chapter 3.
7. If necessary, select the part program that is to be executed.
8. If a bar job is being run, press the Repeat Mode push button.
If a bar job is not being run, go to step 9.
17-14 M-392D
- CAUTION -
For safe operation, the main spindle work shift must be programmed at thestart of each main spindle operation.
9. Enter the work shift in the program at the start of each main spindle operation.
- NOTE -
The work shift is entered in the G10 P0 Z-____ block.
10. Press the control Reset key and make certain the program is at the beginning.
11. Press the Check soft key.
- NOTE -
This will cause the active program to be displayed as well as the Distance To Go tocomplete the move.
12. Set the Rapid Override switch to LOW.
13. Adjust the Feedrate Override switch to the desired percentage.
- CAUTION -
Do not use Single Block for a releasing Tap and Die Holder Operation.
14. Activate Single mode.
15. Press the Option Stop push button.
16. Close the guard door.
17. Press the Cycle Start push button for each block and machine the first side.
Set Up and Machine Sub-Spindle Operation
18. Execute the part transfer operation.
19. Establish the work shift offset for the sub-spindle. Record this dimension.
20. Establish the X and Z tool geometry offsets for the sub-spindle tooling on the turret.
- CAUTION -
To insure safe operation, the work shift for the sub-spindle must be entered atthe start of each Sub-Spindle operation.
The Z SHIFT VALUE defined in subprogram O998 must be programmed as aNEGATIVE value.
21. Subtract the shim or scale thickness and face stock from the value recorded in step 19.Program this dimension as the Z axis work shift at the beginning of each sub-spindle operation.
The work shift is entered in the G10 P0 Z-____ block.
M-392D 17-15
- CAUTION -
The X Safe Index coordinate defined in subprogram O998 should be equal theX Home position. The Z Safe Index coordinate should equal the LONGEST toolplus 1.000 inch [25.4 mm] minimum. Refer to Chapter 8 for additional informa-tion.
The Z Safe Index coordinate defined in subprogram O998 MUST be pro-grammed as a NEGATIVE number.
22. Check the Sub-Spindle Safe Index coordinates in subprogram O998.
They should read X19.5 Z-____ . Refer to page 3-7 for information on calculating the Zsafe index coordinate.
If the coordinates are: Then:
Correct Go to step 23.
Incorrect Edit the program to enter the correct values.
23. Press the Program key.
24. Activate the main workpiece program.
25. Press the control Reset key.
26. Press the Check soft key.
27. Activate Edit mode.
28. Key in the letter N and the sequence number of the first sub-spindle machining operation.
29. Press Cursor �.
30. Activate Single mode.
31. Press the Option Stop push button.
32. Set the Feedrate Override switch to the desired percentage.
33. Set the Rapid Override switch to LOW.
34. Close the guard door.
35. Press the Cycle Start push button to execute each block of data.
17-16 M-392D
- NOTES -
M-392D 17-17
- NOTES -
17-18 M-392D
APPENDIX ONE
M-392D A1-1
Figure A1.1 - Turret Travel Specifications: X and Z Axes(Lathes equipped with a VDI 30 Turret Top Plate)
TI4649A
0.500 [12.70] -Z Software Limit
25.630 [651.00] +Z Software Limit
25.380 [644.65] Z Axis Reference Position
Z0
+Z
+X
19.500 [495.30]X Axis
Reference Position
19.770 [502.15]+X Software Limit
4.870 [123.70]-X Software Limit
5.000 [127.00]
1.378 [35.00]
Turret Top Plate
MainSpindle
Ma
inS
pin
dle
He
ad
wa
ll
CL
NOTES:1. All dimensions are shown in inches [millimeters].2. All measurements for X are diameter values measured from the spindle centerline.3. All measurements for Z are measured from the face of the main spindle.4. Full programmable travel on the X axis is 14.900 [378.46], measured on the diameter.5. Full programmable travel on the Z axis is 25.130 [638.30].
A1-2 M-392D
Figure A1.2 - Turret Travel Specifications: X and Z Axes(Lathes equipped with a VDI 40 Turret Top Plate)
TI4881
0.500 [12.70] -Z Software Limit
25.125 [638.18] +Z Software Limit
25.000 [635.00] Z Axis Reference Position
Z0
+Z
+X
20.700 [525.78]X Axis
Reference Position
20.950 [532.13]+X Software Limit
6.050 [153.67]-X Software Limit
5.000 [127.00]
1.634 [41.50]
Turret Top Plate
MainSpindle
Ma
inS
pin
dle
He
ad
wa
ll
CL
NOTES:1. All dimensions are shown in inches [millimeters].2. All measurements for X are diameter values measured from the spindle centerline.3. All measurements for Z are measured from the face of the main spindle.4. Full programmable travel on the X axis is 14.900 [378.46], measured on the diameter.5. Full programmable travel on the Z axis is 24.625 [625.48].
M-392D A1-3
Figure A1.3 - Turret Travel Specifications: X and Z Axes(Lathes equipped with an ESA Turret Top Plate)
0.500 [12.70] -Z Software Limit
25.630 [651.00] +Z Software Limit
25.380 [644.65] Z Axis Reference Position
Z0
+Z
+X
19.500 [495.30]X Axis
Reference Position
19.770 [502.15]+X Software Limit4.870 [123.70]
-X Software Limit
5.000 [127.00]Turret Top Plate
MainSpindle
Ma
inS
pin
dle
He
ad
wa
ll
CL
1.378 [35.00](Refer to Note 6)
X and Z Axis Reference Position(Refer to Note 6)
NOTES:
1. All dimensions are shown in inches [millimeters].
2. All X axis travel specifications are diameter values measured from the spindle centerline.
3. All Z axis travel specifications are measured from the face of the main spindle.
4. Full programmable travel on the X axis is 14.900 [378.46], measured on the diameter.
5. Full programmable travel on the Z axis is 25.130 [638.30].
TI5430A
A1-4 M-392D
Figure A1.4 - Turret Travel Specifications: X and Z Axes(Lathes equipped with a Hardinge Turret Top Plate)
TI4735
0.250 [6.35] -Z Software Limit
22.910 [581.91] +Z Software Limit
22.660 [575.56] Z Axis Reference Position
Z0
+Z
+X
17.330 [440.18]X Axis
Reference Position
17.362 [441.00]+X Software Limit
2.316 [58.83]-X Software Limit
5.000 [127.00]Turret Top Plate
MainSpindle
Ma
inS
pin
dle
He
ad
wa
ll
CL
NOTES:1. All dimensions are shown in inches [millimeters].2. All measurements for X are diameter values measured from the spindle centerline.3. All measurements for Z are measured from the face of the main spindle.4. Full programmable travel on the X axis is 15.046 [382.17], measured on the diameter.5. Full programmable travel on the Z axis is 22.660 [575.56].
M-392D A1-5
Figure A1.5 - Turret Travel Specifications: Y Axis Option(VDI or ESA Top Plate)
(Viewed from the Tailstock/Sub-Spindle End of the Machine)
TI4643
0.126[3.18]
2.879 [73.13]
2.854 [72.50]
14.000[355.60]
SpindleCenterline
2.435[61.85]
7.450[189.23]
1.377[34.98]
2.000 [50.80]
NOTE: All dimensions are shown in inches [millimeters].
+X
-X
+Y
-Y13.780[350.00]
A1-6 M-392D
Figure A1.6 - Tailstock Travel Specifications
NOTE: All dimensions are shown in inches [millimeters].
TI4651A
28.75 [730.3]
CL
MainSpindle
7.25[184.2] Dependent on Tailstock Center used
Tailstock at FixedHome Position
Tailstock atForward Position
+X
+Z
Z0
Figure A1.7 - Sub-Spindle Travel Specifications
NOTE: All dimensions are shown in inches [millimeters].
23.25 [590.55] Reference Position
Z0
NOTE: All dimensions are shown in inches [millimeters].TI4650B
0.500 [12.70] Software Limit
CL
MainSpindle
+X
+Z
23.500 [596.90] Software Limit
23.25 [590.55] Reference Position
M-392D A1-7
Figure A1.8 - Work Envelope: Machine Equipped withTailstock and VDI 30 Turret Top Plate
TI4719
NOTES:
1. All dimensions are shown in inches [millimeters].2. All measurements for X are radius values.3. The work envelope is shown with NO tool offset active.4. The work envelope shown will be shifted by an active offset.5. The tailstock is shown at the Reference position.
25.130 [638.30](Z Axis Travel)
CL
+X Software Limit
5.500[139.70]
0.500 [12.70]
-X Software Limit
3.120 [79.25]
7.450[189.23]
(X Axis Travel)
TurretReferencePosition
Machine Reference Position
2.435 [61.85]
Main Spindle Headwall
-Z SoftwareLimit
+Z SoftwareLimit
A1-8 M-392D
Figure A1.9 - Work Envelope: Machine Equipped withTailstock and VDI 40 Turret Top Plate
TI4882
NOTES:
1. All dimensions are shown in inches [millimeters].2. All measurements for X are radius values.3. The work envelope is shown with NO tool offset active.4. The work envelope shown will be shifted by an active offset.5. The tailstock is shown at the Reference position.
24.625 [625.48](Z Axis Travel)
CL
+X Software Limit
5.500[139.70]
0.500 [12.70]
-X Software Limit
3.625 [92.08]
7.450[189.23]
(X Axis Travel)
TurretReferencePosition
Machine Reference Position
3.025 [76.84]
Main Spindle Headwall
-Z SoftwareLimit
+Z SoftwareLimit
M-392D A1-9
Figure A1.10 - Work Envelope: Machine Equipped withTailstock and ESA Turret Top Plate
25.130 [638.30](Z Axis Travel)
CL
7.450[189.23]
(X Axis Travel)
23.054 [585.57](Maximum Turn Length)
5.275[133.99]
1.250[31.75]
5.70[144.8]
Maximum Turn Diameter = 10.55 [267.9]
NOTES:
1. All dimensions are shown in inches [millimeters].
2. All measurements for X are radius values.
3. The turret is shown at the +X and +Z software limits.
TI5431A
A1-10 M-392D
Figure A1.11 - Work Envelope: Machine Equipped withTailstock and Hardinge Turret Top Plate
TI4741
NOTES:
1. All dimensions are shown in inches [millimeters].2. All measurements for X are radius values.3. The work envelope is shown with NO tool offset active.4. The work envelope shown will be shifted by an active offset.5. The tailstock is shown at the Reference position.
22.660 [575.56](Z Axis Travel)
CL
+X Software Limit
5.250[133.35]
0.250 [6.35]
-X Software Limit
5.840[148.34]
7.523[191.08]
(X Axis Travel)
TurretReferencePosition
Machine Reference Position
1.158 [29.41]
Main Spindle Headwall
-Z SoftwareLimit
+Z SoftwareLimit
M-392D A1-11
Figure A1.12 - Work Envelope: Machine Equipped withSub-Spindle and VDI 30 Turret Top Plate
TI4718A
NOTES:
1. All dimensions are shown in inches [millimeters].2. All measurements for X are radius values.3. The work envelope is shown with NO tool offset active.4. The work envelope shown will be shifted by an active offset.5. The sub-spindle is shown at the Reference position.
25.130 [638.30](Z Axis Travel)
CL
+X Software Limit
5.500[139.70]
0.500 [12.70]
-X Software Limit
2.380 [60.45]
7.450[189.23]
(X Axis Travel)
TurretReferencePosition
Machine Reference Position
2.435 [61.85]
Main Spindle Headwall
-Z SoftwareLimit
+Z SoftwareLimit
A1-12 M-392D
Figure A1.13 - Work Envelope: Machine Equipped withSub-Spindle and VDI 40 Turret Top Plate
TI4883
NOTES:
1. All dimensions are shown in inches [millimeters].2. All measurements for X are radius values.3. The work envelope is shown with NO tool offset active.4. The work envelope shown will be shifted by an active offset.5. The sub-spindle is shown at the Reference position.
24.625 [625.48](Z Axis Travel)
CL
+X Software Limit
5.500[139.70]
0.500 [12.70]
-X Software Limit
1.875 [47.63]
7.450[189.23]
(X Axis Travel)
TurretReferencePosition
Machine Reference Position
Main Spindle Headwall
-Z SoftwareLimit
+Z SoftwareLimit
3.025 [76.84]
M-392D A1-13
Figure A1.14 - Work Envelope: Machine Equipped withSub-Spindle and ESA Turret Top Plate
CL
25.130 [638.30](Z Axis Travel)
7.450[189.23]
(X Axis Travel)
3.006 [76.34]
5.275[133.99]
1.250[31.75]
23.054 [585.57](Maximum Turn Length)
0.196 [4.98]
Maximum Turn Diameter = 10.55 [267.9]
NOTES:
1. All dimensions are shown in inches [millimeters].
2. All measurements for X are radius values.
3. The turret is shown at the +X and +Z software limits.
TI5432A
A1-14 M-392D
Figure A1.15 - Work Envelope: Machine Equipped withSub-Spindle and Hardinge Turret Top Plate
TI4742
NOTES:
1. All dimensions are shown in inches [millimeters].2. All measurements for X are radius values.3. The work envelope is shown with NO tool offset active.4. The work envelope shown will be shifted by an active offset.5. The sub-spindle is shown at the Reference position.
22.660 [575.56](Z Axis Travel)
CL
+X Software Limit
5.250[133.35]
0.250 [6.35]
-X Software Limit
0.340 [8.64]7.523[191.08]
(X Axis Travel)
TurretReference Position
Machine Reference Position
1.158 [29.41]
Main Spindle Headwall
-Z SoftwareLimit
+Z SoftwareLimit
M-392D A1-15
Figure A1.16 - Sample Tooling Layout:10 Station VDI 30 Turret Top Plate
TI4710
10.66[270.76]Dia.
11.17[283.72]Dia.
11.10 [281.94] Dia.
Centerline at 88 mm
Centerline at 70 mm
Centerline at 70 mm
Centerline at 88 mmCenterline at 88 mm
Centerlineat 88 mm
Centerline at 70 mm
Centerlineat 70 mm
1.25
.88
11.17 [283.72] Dia.
11.17 [283.72] Dia.
11.17[283.72]Dia.
11.17 [283.72] Dia.
11.17 [283.72] Dia.11.17 [283.72] Dia.
11.53[292.86]Dia. 11.53 [292.86] Dia.
10.66[270.76]Dia.
9.84 [249.94] Dia.
11.47[291.34]
Dia.
11.76[298.70]
Dia.
Cut-Off Tool Holder
.750” ToolHolder
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
A1-16 M-392D
Figure A1.17 - Sample Tooling Layout:10 Station VDI 30 Turret Top Plate with Live Tooling
11.10 [281.94] Dia.
Centerline at 88 mm
Centerline at 70 mm
Centerline at 70 mm
Centerlineat 88 mm
1.25
.88
10.25 [260.35] Dia.
11.17 [283.72] Dia.
9.82 [249.43] Dia.
11.47[291.34]
Dia.
11.76[298.70]
Dia.
Cut-Off Tool Holder
.750” ToolHolder
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
TI4711
Centerlineat 70 mm
11.17 [283.72] Dia.
10.66 [270.76] Dia.
10.63[270.00]Dia.
9.99[253.75]Dia.
11.17[283.72]Dia.
End Mill/Drill Attachment
Cross Mill/Drill Attachment
End Mill/DrillDouble SpindleAttachment
M-392D A1-17
Figure A1.18 - Sample Tooling Layout:12 Station VDI 30 Turret Top Plate
9.36 [237.74] Dia.
Centerline at 88 mm
Centerline at 70 mm
1.25
.88
8.71 [221.23] Dia.8.71
[221.23]Dia.
9.18 [233.17] Dia.
9.39[238.51]
Dia.
9.18[233.17]Dia.
Cut-Off Tool Holder
.750” ToolHolder
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
TI4712
9.46 [240.28] Dia.
9.18 [233.17] Dia.
Centerline at 70 mm
Centerline at 70 mm
Centerline at 88 mm
9.46 [240.28] Dia.
9.18 [233.17] Dia.
Centerline at 70 mm
Centerlineat 88 mm
9.18[233.17]Dia.
Centerlineat 70 mm
9.18[233.17]Dia.
Centerlineat 88 mm
Centerline at 88 mm
9.18 [233.17] Dia.
A1-18 M-392D
Figure A1.19 - Sample Tooling Layout:12 Station VDI 30 Turret Top Plate with Live Tooling
9.36 [237.74] Dia.
Centerlineat 88 mm
Centerline at 70 mm
1.25
.88
8.70 [220.98] Dia.
8.06[204.72]
Dia.
8.13 [206.50] Dia.
9.41[239.01]
Dia.
9.18[233.17]Dia.
Cut-Off Tool Holder
.750” ToolHolder
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
TI4713
8.72 [221.49] Dia.
Centerline at 70 mm
Centerline at 88 mm
9.18 [233.17] Dia.
9.18 [233.17] Dia.
End Mill/Drill Attachment
Cross Mill/Drill Attachment
End Mill/DrillDouble SpindleAttachment
9.18[233.17]Dia.
8.53[216.66]Dia.
Centerlineat 70 mm
8.32 [211.33] Dia.
9.66[245.36]
Dia.
Centerlineat 88 mm
9.18[233.17]Dia.
End Mill/Drill Double Spindle Attachment
7.90 [200.66] Dia.
M-392D A1-19
Figure A1.20 - Sample Tooling Layout:16 Station VDI 30 Turret Top Plate
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
TI4832
6.63[168.40]Dia.
6.61[167.89]Dia.
8.19 [208.03]Dia.
6.46[164.08]Dia.
6.76[171.70]
Dia.
6.29[159.77]
Dia.
8.29[210.57]
Dia.
6.95[176.53]
Dia.
6.69[169.93]
Dia.
1.25[31.75]
¾” SquareTurning Tool
1-1/4” Boring Bar
40mm Boring Bar
1” SquareTurning Tool
A1-20 M-392D
Figure A1.21 - Sample Tooling Layout:16 Station VDI 30 Turret Top Plate with Live Tooling
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
TI4833
6.55[166.37]
Dia.
6.67[169.42]Dia.
7.82[198.63]Dia.
6.46 [164.08] Dia.
27.80 [706.12] Dia.Swing-Over Way CoverNon-Y Axis
6.41[162.81]Dia.
7.70[195.58]
Dia.
6.68[169.67]
Dia.
6.69 [169.93] Dia.
1.79 [45.47]
End-WorkingLive Tool
1-1/4” Boring Bar
¾” SquareTurning Tool
6.69 [169.93] Dia.
40mm Boring Bar
6.68[169.67]
Dia.
Cross-WorkingLive Tool
3.19 [81.03]
25.00 [635.00] Dia.Swing-Over Way CoverY Axis
M-392D A1-21
Figure A1.22 - Sample Tooling Layout:10 Station VDI 40 Turret Top Plate
TI4879
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
12.80 [325.1]Dia.
21.80 [553.7]Dia.
19.75[501.7]Dia.
9.35 [237.5]Dia.
18.30 [464.8]Dia.
20.20 [513.1]Dia.
8.90 [226.1]Dia.
10.80 [274.3]Dia.
9.45 [240.0]Dia.
2” Boring Bar
1-9/16” Drill
1” Square Turning Toolwith 1-1/4” Overhang
25” Diameter MaximumSwing over Way Cover
10.80 [274.3]Dia.
10.90 [276.9]Dia.
1” Square AxialTurning Tool
36°
1.25
A1-22 M-392D
Figure A1.23 - Sample Tooling Layout:10 Station VDI 40 Turret Top Plate with Live Tooling
TI4880
36°
8.90 [226.1] Dia.
9.45 [240.0] Dia.
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
2” Boring Bar
10.35 [262.9]Dia.
1” End Mill
25/32” DrillLive Tool
1-9/16” Drill
1” Square Turning Toolwith 1-1/4” Overhang
18.30 [464.8]Dia.
2-1/2” Face MillLive Tool
25” Diameter MaximumSwing over Way Cover
¾” DrillLive Tool
10.45 [265.4]Dia.
21.80 [553.7]Dia.
11.85 [301.0]Dia.
12.80 [325.1]Dia.
10.80 [274.3]Dia.
1.25
M-392D A1-23
Figure A1.24 - Sample Tooling Layout:12 Station ESA Turret Top Plate
TI5433
Ø 8.88 [225.6]
Ø 8.96 [227.6]
Ø 9.57 [243.1]
Ø 11.02[280.0]
Ø 9.48 [240.8]
Ø 9.48 [240.8]
Ø 9.14 [232.2]
Ø 9.06 [230.1]
0.88 [22.4]
Ø 8.85 [224.8]
Ø 8.85 [224.8]
Ø 9.46 [240.3]Ø 9.46 [240.3]
Ø 9.46 [240.3]
Ø 20.7087 [526.0]
Cut-OffTool Holder
0.75 TurningTool
1.25 [31.8]
Ø 1.25 Drill
Ø 1.25Boring Bar
Ø 0.63 Drill in ER Collet
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
A1-24 M-392D
Figure A1.25 - Sample Tooling Layout:12 Station ESA Turret Top Plate with Live Tooling
TI5434
Ø 20.7087 [526.0]
Ø 19.2915 [490.0]
0.75 TurningTool
Ø 8.96 [227.6]
Ø 1.25 Boring Bar
0.88 [22.4]
Ø 9.49 [241.0]
Cut-Off Tool Holder
Ø 11.19 [284.2]
End-Working Mill/Drill Attachment
Cross-Working Mill/Drill Attachment
End-Working Mill/Drill Attachment
End-Working Mill/Drill Attachment
Ø 0.63 Drill in ER Collet
Ø 1.25Drill
Ø 9.46 [240.3]
Ø 9.48[240.8]
Ø 9.48[240.8]
Ø 9.47[240.5]
Ø 9.25 [235.0]
Ø 9.27 [235.5]
Ø 9.26 [235.2]
Ø 8.86 [225.0]
Ø 9.10 [231.1]
Ø 9.11 [231.4]
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
M-392D A1-25
Figure A1.26 - Sample Tooling Layout:12 Station Hardinge Turret Top Plate
1.438
1.125
8.859 [225.02] Dia.
9.510[241.55]
Dia.
9.514[241.66]
Dia.
9.510[241.55]
Dia.
.060Past Center
NOTES:
1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].
TI4732
9.510 [241.55] Dia.
8.530 [216.66] Dia.
Centerline at 1.500
8.530 [216.66] Dia.
Centerlineat 2.813
9.046 [229.77] Dia.
9.510[241.55]Dia.
9.510[241.55]Dia.
9.510 [241.55] Dia.
F = 1.250(Worst Case)
8.567[217.60]
Dia.
A1-26 M-392D
Quest 42 Belted (cont.)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0
300
600
900
1200
1500
1800
2200
2500
2800
3100
3400
3700
4000
4300
4600
4900
5200
5500
5800
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.27 - Main Spindle Torque/Horsepower Curves,Standard Drive, Continuous Rating (QUEST® 6/42 Lathe)
TI4630
Quest 42 Belted (30 min.)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
0
300
600
900
1200
1500
1800
2200
2500
2800
3100
3400
3700
4000
4300
4600
4900
5200
5500
5800
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.28 - Main Spindle Torque/Horsepower Curves,Standard Drive, 30 Minute Rating (QUEST 6/42 Lathe)
TI4831
M-392D A1-27
Quest 51 Belted (cont.)
0.02.0
4.06.0
8.010.0
12.014.0
16.0
030
060
090
012
0015
0018
0022
0025
0028
0031
0034
0037
0040
00
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.020.0
40.060.0
80.0100.0
120.0140.0
160.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.29 - Main Spindle Torque/Horsepower Curves,Standard Drive, Continuous Rating (QUEST® 8/51 Lathe)
TI4752
Quest 51 Belted (30min)
0.0
5.0
10.0
15.0
20.0
25.0
030
060
090
012
0015
0018
0022
0025
0028
0031
0034
0037
0040
00
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
50.0
100.0
150.0
200.0
250.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.30 - Main Spindle Torque/Horsepower Curves,Standard Drive, 30 Minute Rating (QUEST 8/51 Lathe)
TI4753
A1-28 M-392D
Quest 51 Wrap HS winding (cont.)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
0
500
1000
1500
2100
2600
3100
3600
4100
4600
5100
5600
6100
6600
7100
7600
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.31 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,High Speed Range, Continuous Rating (QUEST® 8/51 Lathe)
TI4760
Quest 51 Wrap HS winding (30min)
0.0
5.0
10.0
15.0
20.0
25.0
050
010
0015
0021
0026
0031
0036
0041
0046
0051
0056
0061
0066
0071
0076
00
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.32 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,High Speed Range, 30 Minute Rating (QUEST 8/51 Lathe)
TI4761
M-392D A1-29
Quest 51 Wrap LS winding (cont.)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
0 100 200 300 450 500 600 700 800
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.33 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,Low Speed Range, Continuous Rating (QUEST® 8/51 Lathe)
TI4762
Quest 51 Wrap LS Winding (30min)
0.0
5.0
10.0
15.0
20.0
25.0
0 100 200 300 450 500 600 700 800
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
50.0
100.0
150.0
200.0
250.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.34 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,Low Speed Range, 30 Minute Rating (QUEST 8/51 Lathe)
TI4763
A1-30 M-392D
Quest 65 Belted (cont.)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
030
060
090
012
0015
0018
0022
0025
0028
0031
0034
00
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
50.0
100.0
150.0
200.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.35 - Main Spindle Torque/Horsepower Curves,Standard Drive, Continuous Rating (QUEST® 10/65 Lathe)
TI4754
Quest 65 Belted (30min)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
0
200
400
600
857
1000
1200
1400
1600
1800
2100
2300
2500
2700
2900
3100
3300
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
50.0
100.0
150.0
200.0
250.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.36 - Main Spindle Torque/Horsepower Curves,Standard Drive, 30 Minute Rating (QUEST 10/65 Lathe)
TI4755
M-392D A1-31
Quest 65 Wrap HS winding (cont.)
0.02.0
4.06.0
8.010.0
12.014.0
16.0
040
080
012
0016
0021
0025
0029
0033
0037
0041
0045
0049
0053
0057
00
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.37 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,High Speed Range, Continuous Rating (QUEST® 10/65 Lathe)
TI4768
Quest 65 Wrap HS winding (30min)
0.0
5.0
10.0
15.0
20.0
25.0
040
080
012
0016
0021
0025
0029
0033
0037
0041
0045
0049
0053
0057
00
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.38 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,High Speed Range, 30 Minute Rating (QUEST 10/65 Lathe)
TI4769
A1-32 M-392D
Quest 65 Wrap LS winding (cont.)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
0 100 200 300 450 500 600 700 800
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
50.0
100.0
150.0
200.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.39 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,Low Speed Range, Continuous Rating (QUEST® 10/65 Lathe)
TI4770
Quest 65 Wrap LS Winding (30min)
0.0
5.0
10.0
15.0
20.0
25.0
0 100 200 300 450 500 600 700 800
Speed (RPM)
Ho
rsep
ow
er
(HP
)
0.0
50.0
100.0
150.0
200.0
250.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.40 - Main Spindle Torque/Horsepower Curves, High-Speed Drive,Low Speed Range, 30 Minute Rating (QUEST 10/65 Lathe)
TI4771
M-392D A1-33
Standard Speed Sub-Spindle (Continuous)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
040
080
012
0016
0021
0025
0029
0033
0037
0041
0045
0049
0053
0057
0061
0065
0069
0073
0077
00
Speed
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.41 - Standard Speed Sub-Spindle Torque/Horsepower Curves,Continuous Rating
TI4758
Standard Speed Sub-Spindle (30 Minute)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
040
080
012
0016
0021
0025
0029
0033
0037
0041
0045
0049
0053
0057
0061
0065
0069
0073
0077
00
Speed
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.42 - Standard Speed Sub-Spindle Torque/Horsepower Curves,30 Minute Rating
TI4759
A1-34 M-392D
High Speed Sub-Spindle (Continuous)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.00
500
1000
1500
2100
2600
3100
3600
4100
4600
5100
5600
6100
6600
7100
7600
8100
8600
9100
9600
Speed
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.43 - High Speed Sub-Spindle Torque/Horsepower Curves,Continuous Rating
TI4869
High Speed Sub-Spindle (30 Minute)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0
500
1000
1500
2100
2600
3100
3600
4100
4600
5100
5600
6100
6600
7100
7600
8100
8600
9100
9600
Speed
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.44 - High Speed Sub-Spindle Torque/Horsepower Curves,30 Minute Rating
TI4870
M-392D A1-35
Quest VDI 30 and ESALive Tooling (cont.)
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0 300
600
900
1200
1500
1800
2200
2500
2800
3100
3400
3700
4000
Speed (RPM)(Q65SP is limited to 3429)
Ho
rsep
ow
er
(HP
)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.45 - Live Tooling Torque/Horsepower Curves,Continuous Rating (VDI 30 and ESA Top Plates)
TI4766A
Quest VDI 30 and ESALive Tooling (30min)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 300
600
900
1200
1500
1800
2200
2500
2800
3100
3400
3700
4000
Speed (RPM)(Q65SP is limited to 3429)
Ho
rse
po
we
r(H
P)
0.0
5.0
10.0
15.0
20.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.46 - Live Tooling Torque/Horsepower Curves,30 Minute Rating (VDI 30 and ESA Top Plates)
TI4767A
A1-36 M-392D
Quest VDI 40 Live Tooling (cont.)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
030
060
090
012
0015
0018
0022
0025
0028
0031
0034
0037
0040
00
Speed (RPM)(Q65SP is limited to 3429)
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
To
rqu
e(f
tlb
s)
HP (cont)
Torque (cont)
Figure A1.47 - Live Tooling Torque/Horsepower Curves,Continuous Rating (VDI 40 Top Plate)
TI4764
Quest VDI 40 Live Tooling (30min)
0.01.02.03.04.05.06.07.08.0
030
060
090
012
0015
0018
0022
0025
0028
0031
0034
0037
0040
00
Speed (RPM)(Q65SP is limited to 3429)
Ho
rsep
ow
er
(HP
)
0.0
5.0
10.0
15.0
20.0
25.0
30.0
To
rqu
e(f
tlb
s)
HP (30 min.)
Torque (30 min)
Figure A1.48 - Live Tooling Torque/Horsepower Curves,30 Minute Rating (VDI 40 Top Plate)
TI4765
M-392D A1-37
Figure A1.49 - Spindle Draw Tube Configuration:QUEST® 6/42 Lathe with Standard Spindle Drive
A1-38 M-392D
Figure A1.50 - Spindle Draw Tube Configuration:QUEST® 8/51 Lathe with Standard Spindle Drive
M-392D A1-39
Figure A1.51 - Spindle Draw Tube Configuration:QUEST® 10/65 Lathe with Standard Spindle Drive
- NOTES -
A1-40 M-392D
APPENDIX TWO
G CODES
G Code Group Definition
G00 1 Rapid Traverse Positioning Mode
G01 1 Linear Interpolation
G02 1 Clockwise Circular Interpolation
G03 1 Counterclockwise Circular Interpolation
G04 0 Dwell
G10 0 Offset Value Setting
G17 16 X,C Work Plane Selection
G18 16 X,Z Work Plane Selection
G19 16 Z,C Work Plane Selection
G20 6 Inch Data Input
G21 6 Metric Data Input
G22 9 Stored Stroke Limits ON
G23 9 Stored Stroke Limits OFF
G28 0 Return to Reference Position
G31 0 Skip Function
G32 1 Threadcutting Routine (Constant Lead)
G34 1 Threadcutting Routine (Variable Lead)
G40 7 Cancel Tool Nose Radius Compensation
G41 7 Tool Nose Radius Compensation (Part Right)
G42 7 Tool Nose Radius Compensation (Part Left)
G50 0 Maximum RPM Limit for Constant Surface Speed
G65 0 User Macro Call
G70 0 Automatic Finishing Cycle
G71 0 Automatic Rough Turning Cycle
G72 0 Automatic Rough Facing Cycle
M-392D A2-1
G Code Group Definition
G73 0 Automatic Rough Pattern Repeat Cycle
G74 0 Automatic Drilling Cycle
G76 0 Automatic Threading Cycle
G80 10 Cancel G80 Series Cycle
G83 10 Z Axis Drilling Cycle
G84 10 Z Axis Tapping Cycle
G85 10 Z Axis Boring Cycle
G87 10 X Axis Drilling Cycle
G88 10 X Axis Tapping Cycle
G89 10 X Axis Boring Cycle
G90 1 Canned Turning Cycle
G92 1 Canned Threading Cycle
G94 1 Canned Facing Cycle
G96 2 Constant Surface Speed
G97 2 Direct RPM Programming
G98 5 Inches/mm per Minute Feedrate
G99 5 Inches/mm per Revolution Feedrate
G107 0 Activate Cylindrical Interpolation
G112 21 Activate Polar Interpolation
G113 21 Cancel Polar Interpolation
A2-2 M-392D
M CODES
M Code Definition Standard / Option
M00 Program Stop Standard
M01 Option Stop Standard
M03 Main Spindle Forward Rotation Standard
M04 Main Spindle Reverse Rotation Standard
M05 Main Spindle Stop / Coolant OFF Standard
M07 Spindle Phase Synchronization Option
M08 Coolant ON Standard
M09 Coolant OFF Standard
M10 High Pressure Coolant ON Option
M11 High Pressure Coolant OFF Option
M13 Main Spindle Forward Rotation / Coolant ON Standard
M14 Main Spindle Reverse Rotation / Coolant ON Standard
M15 Thru-Spindle Coolant ON, Main Spindle Option
M16 Thru-Spindle Coolant OFF, Main Spindle Option
M20 Speed Arrival Check ON Standard
M21 Main Spindle Collet / Chuck Open Standard
M22 Main Spindle Collet / Chuck Close Standard
M23 Main Spindle Contouring Mode ON Option
M24 Main Spindle Contouring Mode OFF Option
M25 Part Catcher Retract Option
M26 Part Catcher Extend Option
M27 Main Spindle Internal Chucking Mode Standard
M28 Main Spindle External Chucking Mode Standard
M29 Rigid Tapping Mode Standard
M30 Program End, Optional Auto Door Open Standard
M32 Spindle Synchronization Option
M33 Sub-Spindle Forward Rotation Option
M-392D A2-3
M Code Definition Standard / Option
M34 Sub-Spindle Reverse Rotation Option
M35 Sub-Spindle Stop Option
M36 Main Spindle Air Blast ON Option
M37 Main Spindle Air Blast OFF Option
M38 Auto Door Open Option
M40 Low Speed Range Option
M41 High Speed Range Option
M42 No Corner Rounding - Exact Stop Standard
M43 Corner Rounding Standard
M44 Enable Turret Bi-Directional Index Standard
M45 Disable Turret Bi-Directional Index Standard
M46 Sub-Spindle Air Blast ON Option
M47 Sub-Spindle Air Blast OFF Option
M48 Enable Feedrate and Spindle Override Standard
M49 Disable Feedrate and Spindle Override Standard
M51 Live Tooling Rotation Option
M52 Live Tooling Rotation Option
M53 Live Tooling Rotation / Coolant ON Option
M54 Live Tooling Rotation / Coolant ON Option
M55 Live Tooling Stop / Coolant OFF Option
M56 Sub-Spindle Collet / Chuck Open Option
M57 Sub-Spindle Collet / Chuck Close Option
M58 Feed Bar Stock Option
M59 Cancel Feed Bar Stock Option
M60 Speed Arrival Check OFF Standard
M61 Bar Change Option
M62 Activate C Axis Spindle Synchronization Option
M63 Cancel C Axis Spindle Synchronization Option
A2-4 M-392D
M Code Definition Standard / Option
M64 Spindle Feedback from Main Spindle (Default) Standard
M65 Spindle Feedback from Sub-Spindle Option
M66 Spindle Feedback from Live Tool Spindle Option
M68 Sub-Spindle External Chucking Mode Option
M69 Sub-Spindle Internal Chucking Mode Option
M70 Spindle Orient Commands to Sub-Spindle Option
M71 Spindle Orient Commands to Main Spindle Option
M72 Chamfering OFF Standard
M73 Chamfering ON Standard
M76 Sub-Spindle Drive OFF Option
M77 Sub-Spindle Drive Low Torque Option
M78 Sub-Spindle Drive Normal Torque Option
M80 Check Part Missing Option
M81 Check Part Present Option
M84 Tailstock Advance Standard
M85 Tailstock Retract Standard
M86 Tailstock Retract to Fixed Home Position Standard
M90 Part Probe ON Option
M91 Tool Probe Enable Option
M92 Tool Probe Deploy Option
M93 Tool Probe Stow Option
M97 Increment Part Counter Standard
M98 Sub-Program Call Standard
M99 Return from Sub-Program Standard
M215 Thru-Spindle Coolant ON, Sub-Spindle Option
M216 Thru-Spindle Coolant OFF, Sub-Spindle Option
M221 Sub-Spindle Part Catcher Slide Extend Option
M222 Sub-Spindle Part Catcher Slide Retract Option
M-392D A2-5
M Code Definition Standard / Option
M223 Sub-Spindle Contouring Mode ON Option
M224 Sub-Spindle Contouring Mode OFF Option
M225 Sub-Spindle Part Catcher Arm Rotate Down Option
M226 Sub-Spindle Part Catcher Arm Rotate Up Option
M227 Sub-Spindle Part Catcher Gripper Close Option
M228 Sub-Spindle Part Catcher Gripper Open Option
A2-6 M-392D
ALARM MESSAGES
1000 Air Pressure Low
Low air pressure to machine. The control is put in an alarm condition and the machine inE-stop.
Increase the air pressure to within the recommended range and press Reset to clear thealarm.
1002 Verify Operator Door Switch
Machine Power-Up Message. Open and close the main guard door to verify interlock switchoperation.
1006 Tool Group Life End
All of the tools in one or more tool groups have reached the tool life specified in the Tool LifeManagement program and an M30 “End of Program” has been read by the control.
Refer to Chapter 16 for instructions on resetting the tool group counter(s).
1007 Barfeed Fault Powerdown
The automatic power down feature of the machine has been selected and the conditions forshutdown have been met.
1013 Tool Probe Arm Timeout
The tool probe arm remained in between the active and stowed positions for more than tenseconds. Clear any obstruction. Select Jog mode. Move the probe arm to one position or theother using the probe push button. Press Reset to clear the alarm.
1014 Tool Probe Not Enabled
Program M91 to enable the tool probe when it is deployed for use with the machine inAutomatic mode. Failing to enable the probe with M91 causes this alarm to be displayed whenthe machine moves. Press Reset to clear the alarm.
1015 Tool Probe Switch Fault
Both the probe stowed and probe active limit switches are activated. This may indicate that aswitch has failed. When the problem is fixed, press Reset to clear the alarm.
1016 Spindle Fault
The spindle coolant chiller temperature is too high or too low, spindle coolant chiller flow istoo low, or the collet drain overflow sensor indicates the collet drain pump has failed. When oneof these conditions has been true for four minutes or more, the machine will stop. When theproblem is fixed, press Reset to clear the alarm.
M-392D A2-7
1026 Hydraulic Pressure Too Low
The hydraulic pressure switch indicated that the pressure was too low for machine operation.To restart, press the Emergency Stop push button to put the machine in emergency stop state.After a few seconds, clear the Emergency Stop. If the pump starts and stays ON, press Reset toclear the alarm.
1035 Hydraulic Pump Overload
The hydraulic pump motor overload has tripped. Reset the overload to restart the motor andclear this message.
1036 Hydraulic Fan Overload
The hydraulic fan motor overload has tripped. Reset the overload to restart the motor andclear this message.
1050 X1 Torque Limiter Fault
The X axis torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.
Refer to the maintenance manual (M-393) for information on resetting the torque limiter.
1051 Z1 Torque Limiter Fault
The Z axis torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.
Refer to the maintenance manual (M-393) for information on resetting the torque limiter.
1053 E Torque Limiter Fault
The E axis torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.
Refer to the maintenance manual (M-393) for information on resetting the torque limiter.
1056 Live Tool Torque Limit
The live tool torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.
Refer to the maintenance manual (M-393) for information on resetting the torque limiter.
1057 Live Tool Fault
The live tooling disengaged proximity switch does not give the expected signal. The livetooling spline may have failed to engage or the live tooling disengaged proximity switch may befaulty. Press Reset to clear the alarm.
A2-8 M-392D
1060 Turret Fault
Turret index was interrupted by Reset or Emergency Stop.
To clear the fault:
1. Reset Emergency Stop.
2. Select Jog mode.
3. Select a station and press the Turret Index push button.
4. The turret will index to the selected station.
1061 Turret Unclamped
The turret top plate is not properly seated. Turret index time exceeds two seconds. Turretproximity switch may be faulty. The control is put in an alarm condition.
1062 Please Press Reset
Turret index is not allowed when the live tool drive is engaged. Press Reset to disengage thelive tool drive. Try to index the turret.
1063 Turret Unclamped Switch
The turret unclamp solenoid is energized but the turret unclamped switch has not beenactivated. Either the turret has failed to unclamp or the unclamped switch has failed.
1067 Turret Station Switch Fault
The turret station selector switch indicates an invalid station. The control is put into an alarmcondition.
1072 Please Turn Off Power
After operating the machine with the Machine lock feature active, power down is required toreset the machine position. Power OFF the machine, wait a few seconds, and then restart themachine.
1075 Bar Feed Fault
Bar feed signals a fault. The control is put in an alarm condition.
Adjust the bar feed and press Reset to clear the alarm.
1076 End of Bar
End of bar condition exists. The control is put in an alarm condition.
Press Reset to clear the alarm.
1082 T Code Invalid
The T word exceeds the maximum number of turret stations on the top plate.
T word format error.
M-392D A2-9
1083 M Code Invalid
M word is programmed for an option not available/enabled on the machine.
M word is not defined in the control.
M word format error.
Press Reset to clear the alarm.
1085 B Code Invalid
B word orient angle is invalid.
B word is programmed for an option not available/enabled on the machine.
B word format error.
Press Reset to clear the alarm.
1100 Part Catcher Must be Retracted
The main spindle part catcher must be retracted before starting a program in Automaticmode or deploying the optional tool probe in any mode.
Press Reset to clear the alarm.
1110 Left Collet Access Door
The main spindle collet access door is open. Automatic mode is inhibited. Close the door andpress Reset to allow machine operation.
1111 Right Collet Access Door
The sub-spindle collet access door is open. Automatic mode is inhibited. Close the door andpress Reset to allow machine operation.
1113 Main Collet Limit Switch
One or both of the main collet Open/Close pressure switches are faulty. Both switchesindicate the same state. The control is put into an alarm condition.
1114 Main Spindle Orient Fault
Spindle orient failed to complete in five seconds. Press Reset to clear the alarm.
1115 Main Spindle Brake Fault
Main spindle brake switch input contradicts the state of the solenoid valve.
1120 Tailstock Past Limit Position
The tailstock has traveled past the position defined by the A word in macro program 9130.
Refer to the programmer’s manual (M-391) for information on macro program 9130.
A2-10 M-392D
1121 Move Tailstock to Mid or Home
The tailstock is out of position. Move the tailstock to either the mid-point or the fixed Homeposition. Cycle Start is inhibited.
1123 Please Home Tailstock
Power Up Message. Home the tailstock.
Refer to Chapter 10 for information on homing the tailstock.
1131 Main Collet Reservoir Full
Hydraulic fluid has filled the overflow reservoir. This indicates that a fault may exist in themain spindle collet drain pump system. Possible causes are:
• Level sensor in the overflow reservoir is faulty
• Faulty air valve on the drain pump
• Drain pump is faulty
Refer to Appendix Three of the maintenance manual (M-393) to identify the collet reservoirpump.
1140 Part Catcher Must Be Retracted
The sub-spindle part catcher slide is not retracted and program execution was attempted.Retract the sub-spindle part catcher slide and press Reset to clear the alarm.
1170 Hydraulic Temperature Too High
- NOTE -
This alarm applies only to machines equipped with HydroGlide® hydrostatic linearguideways.
The fluid temperature in the hydraulic unit for the HydroGlide hydrostatic linear guidewaysexceeds the high limit. Possible causes for hydraulic fluid high temperature are:
• Ambient temperature is in excess of the recommended maximum operatingtemperature, which is 95°F [35°C]
• Hydraulic unit pump motor is running hot
• Hydraulic unit heat exchanger fan has malfunctioned
• Hydraulic unit heat exchanger coils need to be cleaned
1174 Hydrostatic Pressure Fault
Hydrostatic pressure is too low to support the slides. Emergency stop is applied. Determinethe cause of the problem. Restart the machine and Press Reset to clear this message.
M-392D A2-11
1180 CH1 Temperature Out of Range
This message applies to Super-Precision® machines only.
Thermocouple channel 1 indicates an improbable value. The thermocouple needs to bereplaced. Refer to Appendix Three of the maintenance manual (M-393) for thermocouplelocations.
1181 CH1 Thermocouple Disconnected
This message applies to Super-Precision machines only.
Thermocouple channel 1 appears to be open-circuited. Check the thermocouple connection.Refer to Appendix Three of the maintenance manual (M-393) for thermocouple locations.
1182 CH3 Temperature Out of Range
This message applies to Super-Precision machines only.
Thermocouple channel 3 indicates an improbable value. The thermocouple needs to bereplaced. Refer to Appendix Three of the maintenance manual (M-393) for thermocouplelocations.
1183 CH3 Thermocouple Disconnected
This message applies to Super-Precision machines only.
Thermocouple channel 3 appears to be open-circuited. Check the thermocouple connection.Refer to Appendix Three of the maintenance manual (M-393) for thermocouple locations.
1184 Cold Junction Compensation Fault 1
This message applies to Super-Precision machines only.
The temperature measurement system has a fault. Refer to the GE Fanuc temperaturemeasurement system documentation.
1185 Thermocouple System Fault 1
This message applies to Super-Precision machines only.
The temperature measurement system has a fault. Refer to the GE Fanuc temperaturemeasurement system documentation.
1186 Thermocouple Module Fault 1
This message applies to Super-Precision machines only.
The temperature measurement system has a fault. Refer to the GE Fanuc temperaturemeasurement system documentation.
A2-12 M-392D
1187 Temperature Compensation Out of Range
This message applies to Super-Precision® machines only.
The temperature compensation calculated by the control is too large. Temperaturecompensation is disabled.
1190 CH2 Temperature Out of Range
This message applies to Super-Precision machines only.
Thermocouple channel 2 indicates an improbable value. The thermocouple needs to bereplaced. Refer to Appendix Three of the maintenance manual (M-393) for thermocouplelocations.
1191 CH2 Thermocouple Disconnected
This message applies to Super-Precision machines only.
Thermocouple channel 2 appears to be open-circuited. Check the thermocouple connection.Refer to Appendix Three of the maintenance manual (M-393) for thermocouple locations.
1192 CH4 Temperature Out of Range
This message applies to Super-Precision machines only.
Thermocouple channel 4 indicates an improbable value. The thermocouple needs to bereplaced. Refer to Appendix Three of the maintenance manual (M-393) for thermocouplelocations.
1193 CH4 Thermocouple Disconnected
This message applies to Super-Precision machines only.
Thermocouple channel 4 appears to be open-circuited. Check the thermocouple connection.Refer to Appendix Three of the maintenance manual (M-393) for thermocouple locations.
1194 Cold Junction Compensation Fault 2
This message applies to Super-Precision machines only.
The temperature measurement system has a fault. Refer to the GE Fanuc temperaturemeasurement system documentation.
1195 Thermocouple System Fault 2
This message applies to Super-Precision machines only.
The temperature measurement system has a fault. Refer to the GE Fanuc temperaturemeasurement system documentation.
M-392D A2-13
1196 Thermocouple Module Fault 2
This message applies to Super-Precision® machines only.
The temperature measurement system has a fault. Refer to the GE Fanuc temperaturemeasurement system documentation.
1210 Part Missing
The sub-spindle part detector did not find a part in the sub-spindle.
1211 Part Present
The sub-spindle part detector found a part in the sub-spindle.
1212 Part Detector Failed to Retract
The sub-spindle part detector is actuating the extended switch or not actuating the homeswitch.
1213 Opposite Collet Limit Switch
One or both of the sub-spindle collet Open/Close pressure switches are faulty. Both switchesindicate the same state. The control is put into an alarm condition.
1214 Opposite Spindle Orient Fault
Sub-spindle orient failed to complete in five seconds. Press Reset to clear the alarm.
1215 Opposite Spindle Brake Fault
Sub-spindle brake switch input contradicts the state of the solenoid valve.
1231 Opposite Collet Reservoir Full
Hydraulic fluid has filled the overflow reservoir. This indicates that a fault may exist in thesub-spindle collet drain pump system. Possible causes are:
• Level sensor in the overflow reservoir is faulty
• Drain pump is faulty
Refer to Appendix Three of the maintenance manual (M-393) to identify the collet reservoirpump.
1400 Part Catcher, See Message
The sub-spindle part catcher has a fault. Refer to the message display for detailedinformation.
A2-14 M-392D
OPERATOR MESSAGES
2001 1000 Hour Lube Required
Machine lubrication is required every 1000 hours of machine ON time. Cycle Start is inhibitedwhile this message is displayed.
Refer to the maintenance manual (M-393) for information on machine lubrication.
After lubricating the machine, press the Reset and Feed Hold push buttons at the same timeto clear this message.
2005 New Tool Used on this Part
A tool in the currently active tool group has reached the tool life specified in the Tool LifeManagement program. The next tool in the active tool group has been selected.
Press Cycle Start or Reset to clear this message.
2021 Lamp Output Disconnected
An output module driving the panel lamps is overloaded. Turn the machine OFF to clear thismessage.
2022 Operator Door Open
The coolant guard door is open. Cycle Start is inhibited until the guard door is closed.
2023 Battery Low
Low voltage condition on control memory battery back-up. DO NOT POWER DOWN THEMACHINE!
Refer to the maintenance manual (M-393) for instructions to replace the battery.
2024 Part Probe Battery Low
The part probe battery is nearly discharged.
Refer to Chapter 13 for instructions to replace the battery. After the battery is replaced, pressReset to clear this message.
2030 Coolant Pump Overload
The coolant pump motor overload on the coolant pump contactor in the machine power casehas tripped. Repeat mode is canceled.
Correct the cause of the overload. Locate the coolant pump contactor in the power case andreset the overload. When the overload is reset, press Reset to clear this message.
M-392D A2-15
2031 Coolant Chiller Flow
The flow switch in the coolant chiller unit has opened, indicating low coolant flow. This maybe due to a clogged coolant filter.
After proper coolant flow is restored, press Reset to clear this message.
2034 X Scale Air Purge Pressure Fault
This message applies to Super-Precision® machines only.
The scale air purge pressure switch indicates a loss of pressure. Repeat mode is canceled.Cycle Start is inhibited.
Correct the cause of the pressure loss and press Reset to clear this message.
2047 Air Conditioner Fault
The optional air conditioner has failed. Machine operation can continue unless the machinegets too hot. The user must decide if it is cool enough in the shop to run the machine without theair conditioner.
2054 E Axis Thrust Limit Exceeded, Please Adjust Feedrate
The E axis thrust limit has been exceeded. The machine is put into a feed hold condition.
Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until themessage clears. Adjust the feedrate in the part program by the percentage that was required toclear the message.
2055 Turret Thrust Limit Exceeded, Please Adjust Feedrate
The Z axis thrust limit has been exceeded. The machine is put into a feed hold condition.
Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until themessage clears. Adjust the feedrate in the part program by the percentage that was required toclear the message.
2071 Y Too Low to Jog E1 or Z1
The turret is positioned below Y0. Move the turret to Y0 before attempting to move the E1 orZ1 axis.
2077 Open Collet Only in Jog Mode
For machines equipped with the bar feed option and the option is turned ON, the control mustbe in Jog mode to manually open the collet or chuck. Press Reset or select Jog mode to clearthis message.
2086 Part Count Satisfied
The part count specified has been completed. Repeat mode is canceled. Press Cycle Startor Reset to clear this message.
A2-16 M-392D
2090 Turret Must be at X Axis Home Position
The tool probe was commanded to deploy and the turret is not at the X axis referenceposition. Move the turret to the X axis reference position before deploying the tool probe.
When the tool probe is deployed, the turret can only be indexed when it is positioned at the Xaxis reference position.
2091 Opposite Spindle Must be at Home Position
The tool probe was commanded to deploy and the sub-spindle is not at the referenceposition. Move the sub-spindle to the reference position before deploying the tool probe.
2092 Tailstock Must be at Home Position
The tool probe was commanded to deploy and the tailstock is not at the reference position.Move the tailstock to the reference position before deploying the tool probe.
2093 Tool Probe Must be Stowed
The tool probe is not stowed and Cycle Start was pressed with Automatic mode active. Thetool probe must be stowed to start a part program in Automatic mode.
The tool probe is not stowed and the part catcher was commanded to extend. The tool probemust be stowed before the part catcher can be extended in any mode.
2096 Spindle Chiller Temperature
The spindle chiller temperature is too high or low or the spindle coolant chiller flow is too lowon machines equipped with built-in spindle motors. This fault cancels Repeat mode. Themachine will stop with alarm 1016 after four minutes. Press Reset to clear this message.
2097 Collet Drain Pump Fault
The collet drain reservoir overflow sensor indicates the main or sub-spindle collet drain pumphas failed. Repeat mode is canceled. The machine will stop with alarm message 1016 after fourminutes. Press reset to clear this message.
2101 Part Catcher Timeout
The main spindle part catcher took too much time to complete the commanded motion. Thearm or basket may be stuck or obstructed. Press Reset to clear this message.
M-392D A2-17
2102 Part Catcher Limit Switch Fault
One of the following conditions exists:
• The main spindle part catcher arm extended and retracted limit switches areboth activated.
• The main spindle part catcher basket extended and retracted limit switchesare both activated.
• This may indicate that one of the limit switches has failed.
Refer to the maintenance manual (M-393) for information on replacing limit switches.
2103 Please Close Part Catcher Cover
The main spindle part catcher cover is open. Program execution is inhibited. Close the coverto allow program execution.
2133 Main Collet Open
The main spindle collet/chuck is open. Cycle Start and manual spindle operation areinhibited. Close the Collet/chuck to allow Cycle Start and manual spindle operation.
Press Reset to clear this message
2134 Main Spindle Contouring Mode
The manual axis movement selector switch is set to C1 and the operator is attempting tomanually operate the main spindle through the use of the spindle control functions on theoperator panel.
Set the manual axis movement selector switch to another setting.
2141 Opposite Spindle Part Catcher Timeout
The sub-spindle part catcher took too long to complete the commanded motion. The slide,arm, or gripper may be stuck. Correct the problem and press Reset to clear the alarm.
2142 Opposite Spindle Part Catcher Limit Switch Fault
The sub-spindle part catcher slide, arm, or gripper limit switches indicate the same state.This may indicate that one of the switches has failed. Correct the problem and press Reset toclear the alarm.
2143 Opposite Spindle Part Catcher Slide Must be Extended
The sub-spindle part catcher slide must be extended before the arm can be rotated up to thespindle centerline.
2144 Opposite Spindle Must be Home
The sub-spindle must be at the reference position before the sub-spindle part catcher armcan be rotated up or down.
A2-18 M-392D
2145 Opposite Spindle Part Catcher Arm Must be Down
The sub-spindle part catcher arm must be rotated down before the part catcher slide can beretracted.
2146 Opposite Spindle Parts Catcher Gripper Fault
The parts catcher grippers are closed without gripping a part.
2147 Part Conveyor Motor Overload
The part conveyor motor overload in the machine power case has tripped.
Correct the cause of the overload. Reset the overload in the power case. When the overloadis reset, press Reset to clear this message.
2150 High Pressure Coolant Filter Clogged
The high pressure coolant filter pressure drop is too high. This message cancels Repeatmode, but allows machine operation. Check the condition of the filter.
Press the Reset key to clear this message from the screen.
2151 High Pressure Coolant Motor Overload
The high pressure coolant motor is overloaded. Correct the cause of the problem.
Press the Reset button on the high pressure coolant unit to reset the alarm.
Press the control Reset key to clear this message from the screen.
2152 High Pressure Coolant Level Low
The level switch in the high pressure coolant tank indicates that the coolant level is too low.Check the operation of the pump. Find and correct the cause of the problem.
Press the Reset button on the high pressure coolant unit to reset the alarm.
Press the control Reset key to clear this message from the screen.
2153 One Spindle Must be Running
The active spindle must be running before the high pressure coolant pump can be started.The active spindle is selected by M64 or M65. The main spindle is the default.
Revise the part program is necessary.
Press Reset to clear this message.
M-392D A2-19
2154 High Pressure Coolant Not Ready
The high pressure coolant unit is not ready.
Verify the high pressure coolant unit is ON.
Check the fuses in the machine power case.
Find and correct the cause of the problem.
Press Reset to clear this message.
2155 Lower Axis Thrust Limit
The lower axis thrust limit has been exceeded. The machine is put into a feed hold condition.
Press Cycle Start or Reset to clear this message.
2170 Hydrostatic Fluid Level too Low
The hydrostatic fluid level is below the full mark. The machine goes into Emergency Stop. Fillthe tank and restart the machine. Press Reset to clear this message.
2171 Hydrostatic Fluid Level Low, Refill
The hydrostatic fluid level is below the full mark. The tank should be filled soon. Filling thetank clears this message.
2172 Hydrostatic Pump Overload
Hydrostatic pump circuit breaker tripped. Determine the cause of the problem. Reset thecircuit breaker and press Reset to clear this message.
2173 Hydrostatic Fan Overload
Hydrostatic cooling fan circuit breaker tripped. Determine the cause of the problem. Resetthe circuit breaker and press Reset to clear this message.
2175 Hydrostatic Temperature Fault
Hydrostatic temperature is too high. Determine the cause of the problem and correct it. PressReset to clear this message.
2176 Excessive Flow
Hydrostatic fluid flow is excessive. Determine the cause of the problem and correct it. PressReset to clear this message.
2200 Parameter Write Fault 1: Please Turn Off Power and Restart Machine
The control has failed to write a parameter correctly. Restarting the machine may clear theproblem. Contact the Hardinge Service Department if necessary.
A2-20 M-392D
2201 Parameter Write Fault 2: Please Turn Off Power and Restart Machine
The control has failed to write a parameter correctly. Restarting the machine may clear theproblem. Contact the Hardinge Service Department if necessary.
2220 Axis Thrust Limit X Axis
The optional programmable X axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.
2221 Axis Thrust Limit Y Axis
The optional programmable Y axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.
2222 Axis Thrust Limit Z Axis
The optional programmable Z axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.
2223 Axis Thrust Limit E Axis
The optional programmable E axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.
2233 Opposite Collet Open
The sub-spindle collet/chuck is open. Cycle Start and manual spindle operation are inhibited.Close the Collet/chuck to allow Cycle Start and manual spindle operation.
Press Reset to clear this message
2234 Opposite Spindle Contouring Mode
The manual axis movement selector switch is set to C2 and the operator is attempting tomanually operate the sub-spindle through the use of the spindle control functions on theoperator panel.
Set the manual axis movement selector switch to another setting.
2240 Door Closed Switch Fault — Shorted
One of the two door closed switch contacts is ON all the time or the two contacts are shortedtogether. Cycle Start is inhibited. Check the switch wiring.
When the problem is corrected, press Reset to clear this message.
2241 Door Closed Switch Fault — Open
One of the two door closed switch contacts is disconnected. Cycle Start is inhibited. Checkthe switch wiring.
When the problem is corrected, press Reset to clear this message.
M-392D A2-21
2242 Door Locked Switch Fault — Shorted
One of the two door locked switch contacts is ON all the time or the two contacts are shortedtogether. Cycle Start is inhibited. Check the switch wiring.
When the problem is corrected, press Reset to clear this message.
2243 Door Locked Switch Fault — Open
One of the two door locked switch contacts is disconnected. Cycle Start is inhibited. Checkthe switch wiring.
When the problem is corrected, press Reset to clear this message.
2246 Please contact Hardinge at 800/635-0192 extension 2227, or [email protected], and provide the key code shown below.You will be given a four digit password. You have 45 Days Toobtain your password. Key Code: [Xxxx]
Contact Hardinge Inc. as instructed.
2247 Your warning period has expired. Please contact Hardinge at800/635-0192 extension 2227, or at [email protected], and providethe key code shown below.Key Code: [Xxxx]
Contact Hardinge Inc. as instructed.
5305 Illegal Spindle Number
A spindle command (S word) was issued without an active P word. Program P1, P2, or P3 tospecify the active spindle.
Refer to the programmer’s manual (M-391) for information on programming the P word forspindle selection.
A2-22 M-392D
- NOTES -
M-392D A2-23
Hardinge Inc.
Elmira, New York 14902-1507 USAPhone: 607-734-2281 Fax: 607-734-8819
www.hardinge.com