MB0120120108 HS-450i Operator's Manual

7/30/2019 MB0120120108 HS-450i Operator's Manual

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MB012012-01-08

HS-450i

Operators Manual


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HS-450i Operator's Manual

AVEREX Automation Co., Ltd.

Table of Content1 Safety Precautions 41.1 Potential Hazards 41.2 Safety Labels and Plates 51.3 Safety Devices 241.4 Safety Instructions 24

2 Controls and Operations 292.1 Electric Cabinet 292.2 Operation Console 312.3 Operation Panel 332.4 Other Controls and Pushbuttons 59

3 Starting and Ending Operation 663.1 Emergency Stop 663.2 Turning ON Power 663.3 Machine Warm-up 673.4 Turning OFF Power 693.5 After Turning Off Power 693.6 Measures in Power Failure 703.7 Weekly Timer 72

4 Manual Operation 744.1 Zero Point Return 744.2 JOG Feed 754.3 Rapid Traverse 764.4

Handle Feed 77

4.5 Insertion/Removal of Spindle Tool 784.6 Spindle Revolution and Stop 79

5 MDI Operation 805.1 MDI (Manual Data Input) Operation 805.2 Spindle Revolution in MDI 815.3 Spindle Orientation in MDI 825.4 ATC Magazine Indexing and Tool 835.5 Table Clamp/Unclamp in MDI Operation 84

6 Automatic Operation 856.1 Starting Automatic Operation 866.2 Stopping & Restarting Automatic 876.3 Door Safety Interlock 89

7 ATC Operation 927.1 Setting up ATC Magazine 927.2 Tool Registration 92

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7.3 Single Arm Manual Operation 987.4 Tool Exchange in MDI Operation 997.5 Tool Exchange in Automatic Operation 1017.6 Tool Data Screen 104

8 APC Operation 1068.1 Movement of APC 1068.2 Pallet Indexing Lever 1068.3 APC in Manual Operation 1088.4 APC in MDI Operation 1108.5 APC in Automatic Operation 111

9 Emergency Stop 1129.1 Cases of Emergency 1129.2 To Release Emergency Stop Status 112

10 Interference 11310.1 Workpiece Dimensions 11310.2 Travels of Axes 11410.3 Interference with Spindle 11710.4 Pallet Usable Area 12010.5 Limitation on Tools Dimensions 12110.6 Interference at ATC 12210.7 Pull Stud 124

11 Functions Codes (M Codes) 12511.1 M Code List 125

12 Alarm Message and Operator Message 12812.1 Alarm Messages 12812.2 Operator Message 132

13 Custom Macro Program 13514 Chip Conveyor 13614.1 Controls 13614.2 Alarm 137

15 Weekly Timer Setup 13815.1 Outline of Weekly Timer 13815.2 Same Operation Hours For Each Day 14115.3 Different Operation Hours For Different Day 14415.4 Operation Hours Span Over Multiple Days 149

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AVEREX Automation CO., Ltd.

1 Safety PrecautionsAlways keep this manual in a designated area, preferably nears by this

machine, so that every personnel can read it and thoroughly understand allsafety precautions.

1.1 Potential HazardsWhen a maintenance operation requires that machine enclosures beremoved or door interlocks be disabled, it creates a condition that personnel

are potentially exposed to hazards. In such situation, all personnel mustobserve the best safety practice to avoid the potential dangers.

During normal operations, door interlock devices must never be disabled or

bypassed, and enclosures must never be removed.

1.1.1 Electric ShockHS-450i has several subsystems powered by high voltage electricity. Theelectricity is usually not hazardous during most operations. However, if formaintenance purpose, the enclosures are removed or door interlocks are

disabled, the following few areas can endanger personnel with electric shock:

Electric cabinet Coolant pumps Lubrication pump Spindle Oil Chiller Motors

Read all applicable manuals and follow their warnings to avoid accidental

electric shock. Operators must never remove shields or panels, nor shouldoperators bypass or otherwise disable locks.

1.1.2 Moving Machine AreasBecause of the fast moving motions of the mechanisms, getting too close to

the machine in the following areas can result in serious bodily injury to thepersonnel.

Spindle head and column in motion.


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Spindle where a cutting tool in rotating motion. Nearby Automatic Tool Change Area where its mechanism is in motion. Nearby Automatic Pallet Change Area where its mechanism is in motion. Nearby Chip Conveyer in motion.

1.1.3 Sharp Edges on MaterialBe aware of potential dangers posed by sharp edges of materials or fixtures.

1.1.4 Cutting ToolsBe aware of potential dangers posed by the cutting tool(s) in the spindle or

in Automatic Tool Changer.

1.2 Safety Labels and Plates

These labels and plates are affixed on the enclosures of machine as depictedin the drawings. Some of these labels are used to emphasize the hazardous

situations that could result in serious injury or death when using the

machine. Read the warnings carefully and follow the instructions to avoidserious injury or death.



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1.2.1 Locations of Labels and Plates

Front Side



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Operator Side



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Tool Magazine Side

Top

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Back Side



Lifting Devices

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AVEREX Automation Co., Ltd.AVEREX Automation Co., Ltd.

Top View

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Tool Changer


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1) Tool Specification PlateBBT Tool



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CAT Tool



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2) Warning Moving Part Hazard

3) Warning Rotating Mechanism Hazard



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4) Warning Opened Door Hazard

5) M Code List



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6) Safety Instruction Plate

7) Machine Warm-up Instruction



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8) Warning - Electric Shock

9) Danger Electrical Shock Hazard

10)Manufacturer Plate



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11)Solenoid/Limit Switch



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12)Warning - Hot Surface

13)Maintenance Schedule



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14)Lubrication Points



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15)Lubrication Oil Instruction

16)Pneumatic Air Instruction

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17)Axial Directions

19)Oil Drain

Y+

X

Z+

18) (Reserved)

(Space reserved)

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20)Lifting Point

21)Oil Filler

22)Lifting Point Forklift

23)Main Power Switch

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1.3 Safety DevicesHS-450i is equipped with various types of safety devices that are designed

to protect personnel from accidental injuries. All personnel must learn touse these safety devices before operating or servicing the machine.

Safety Device Where Located

EMERGENCY STOP

pushbuttons

On the Operation Panel

On the side of the Pallet set-up door

On the side of the ATC door

Main Power Switch On the electric cabinet

Door Safety Interlock On the Pallet set-up door

On the Operator side doorOn the ATC door

Key Electric cabinet

Alarm Messages On the LCD display

1.4

Safety Instructions

Safety Instructions are classified into three categories, DANGERWARNING,

and CAUTION subjects to the degree of potential hazard to the personnel.

DANGER Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION Indicates a potentially hazardous situation which, if not avoided,may result in minor or moderate injury or property damage.



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1.4.1 General Instructions Wear proper apparel. Do not wear loose clothing, gloves, neckties,

rings, bracelets, or other jewelry that might be caught in moving parts

or areas of potential electric shock. Non-slip footwear is recommended.

Tie long hair back and wear protective hair covering to contain longhair.

Keep tools sharp and clean for best performance and to reduce the riskof injury. Follow instructions for lubrication and for changing

accessories. Use the proper tools. Do not use tools or attachments to perform a job

for which they were not designed for. Keep proper footing and balance at all times. Use a steady object for

support when reaching over the machine. Do not operate the machine in an unsafe environment. Do not use the

machine in damp or wet locations, or expose to rain. Keep the work area well lighted. The machine is not intended for use with flammable or harmful

substances.

Do not turn the machine on or try to operate it if there are explosiveor flammable gases present.

Use recommended accessories to avoid the risk of injury. Wipe up spills. Immediately cover with absorbent material and wipe up

coolant and oil spills around the machine. Correct the cause of the

leakage to prevent any hazards. The poly-carbonate viewing panels are an integral part of safety

enclosure for the machine. They must be inspected regularly for anysigns of reduced effectiveness (such as cracking or crazing) and

replaced immediately, if such signs or other indications of reducedeffectiveness are noticed.

1.4.2 Machine Installation

Only factory authorized individuals from Akari Seiki or distributors ofAkari Seki may install this machine.

Any electrical installation of the machine must be done by a qualifiedelectrician.

When used to install this machine, cranes, forklifts, and alike must beoperated by licensed operators.

Use appropriate equipments to handle heavy objects.



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1.4.3 Before Powering OnBefore powering on the machine, check or inspect the following areas to

ensure safe operations:

All safety devices are functional. Lubrication tank has adequate lubrication oil. Coolant units have adequate coolant. Chips are not accumulated on the telescopic covers. No material or tool is left unintentionally in the machines moving

areas.

No damage in electrical wirings or components. Electrical cables and wires are connected securely. Electrical cabinet is securely closed and No leak in the pneumatic system. Only tools that meet the tool specifications are used

Note Read and understand the Operators Manual before operating this

machine.

1.4.4 Power On and Warming-up Any electrical installation of the machine must be done by qualified

electricians. Check that all protective devices and door interlocks are functional. All guards are firmly in place and show no damages. Follow the procedure and instructions described in the Operators

Manual to power on the machine.

Execute machine warm-up procedure as described in Section 3.3Machine Warm-up of HS-450i Operators Manual.

After the machine has been powered on, check the following items:

No alarm is displayed on the LCD screen No abnormal sound from the motors and gear boxes The cooling fans in the electrical cabinet have been turned on. Spindle and guide ways are adequately lubricated.



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1.4.5 During Machine Operation

Read the safety warnings supplied with all tooling. Keep doors closed while machining. Do not disconnect the front door safety switches. Under nocircumstances should the operator open the door before the spindle

stops rotating completely.

Wear ANSI or CE approved safety glassed at all times when operatingthe machine. Everyday glasses are not designed for protection. Only

ANSI or CE approved safety glasses have impact resistant lenses. Do not exceed the Manufacturers recommended maximum RPM for

the tool. When tools are placed in the spindle, verify the current RPMrecommended in the control before starting the spindle rotation.

Always check all parts for binding, breakage, and any other conditionthat may affect the proper operation of the machine and/or increase

the risk of injury. Damaged or missing parts must be repaired or

replaced BEFORE operating the machine. Do not operate the machine under the influence of drugs, alcohol, or

prescribed medication. Use proper safety gloves when handling sharp or jagged edges. Do

not wear gloves around rotating machinery. Use standard machining practices for holding the material that is to be

machined. Keep tools sharp and clean for best performance and reduction of the

risk of injury. Follow instructions for lubrication and for changing

accessories. Tools are designed to perform properly and safely at proper speeds. Take appropriate additional safety precautions and measures when

working with magnesium, wood, or other combustible materials. Hearing protection must be worn when operations exceed 90 (85 CE)

decibels.

Protection is recommended when cutting operations are dusty orexceed the permissible exposure limit.

Dust removal equipment is needed when working with dust-producingmaterials or procedures.



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1.4.6 Power Off Turn off the power to the machine before leaving the machine

unattended.

Never leave the machine until it has completely stopped.

1.4.7 After Powering Off

Keep work area clean. Good housekeeping practices encourage safety. Do not use air guns to blow away chips.

Always wear gloves when removing chips. Insert a dummy tool into the spindle to prevent debris from entering.

Be aware that the solenoid valves may remain hot for quite a while.

1.4.8 Maintenance Only qualified personnel are authorized to undertake maintenance

work on this machine. Use signs indicating Maintenance in progress to warn people not to

accidentally turn on the machine. Do not enter enclosure area for service or maintenance unless the machine has

been powered off.

Due to danger of slips or falls on a wet or oily surface, any table orenclosure floor that is to be used for maintenance access must be dry

and clean. Never damage, remove, or relocate any part of the limit switches, door

interlocks, or dogs. Wear a hard hat for maintenance or servicing. Always clean up the machine after maintenance work is done. Contact Akari Seiki or your local distributor for all repair parts and

service.


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2 Controls and OperationsHS-450i is built with the following controls to allow certain operations to beperformed by the operator:

Electric CabinetOperation Console

Pallet Operation Control

ATC Control

2.1 Electric Cabinet

CODE DESCRIPTION CODE DESCRIPTION

ACR AC Line Reactor MCP Motor Circuit Breaker

C Capacitor PSM Power Supply Module

D Bridge Rectifier SPM Spindle Amplifier Module

F Circuit Breaker SVM Servo Amplifier Module

G Switching Power Supply R Resistor

INV Inverter SK Surge Suppressor

K Relay T TransformerMC Magnetic Contactor TDON On-delay Timer

MCC Magnetic Contactor

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2.2 Operation Console

Green In the mode of Automatic Operation

Red AlarmYellow (lit) End of program executionYellow (blinking) Awaiting pallet setup to complete

Power lamp This lamp lights up whenever power is being supplied

to the operation box.

Main Power Switch This switch turns on or off the supply of the factorypower.

Operator PaneI

Fanuc Main Panel

Fanuc LCD Display

Manual Pulse Generator

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2.2.1 NC PushbuttonsNC Power ON Pushbutton (0)

When this button is pressed, NC is powered on and "NOT

READY" appears on the screen after a few seconds.

Note Power on the machine first before pressing NC Power ON pushbutton.

NC Power OFF Pushbutton (00)

When this button is pressed, NC is powered off and LCD

display disappears.

DANGER Always press Emergency Stop pushbutton before pressing NCOFF pushbutton.

DANGER Be sure to press NC OFF pushbutton before turning off Main

Switch of the electric cabinet. If not, NC can potentially bedamaged.

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2.3 Operation Panel

67

1 2 3 4

5 6 7 8

9 10 11

12 14 15

22

23

21

25

24

26

28 27

29 30 31

32 33 34

62

71

70

72

63

73

64 65

94 95 96

97 98 99

37 38 39 40 47 48

49 50 51 52 53 54

68 69

56 57

41 42 43

44 45 46

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1 EDIT Mode Pushbutton 41 Spindle CW Rotation Pushbutton

2 AUTO Mode Pushbutton 42 Spindle Stop Pushbutton

3 REMOTE Mode Pushbutton 43 Spindle CCW Rotation Pushbutton

4 MDI Mode Pushbutton 44 Spindle Speed Decrease Pushbutton

5 HANDLE Mode Pushbutton 45 Spindle Speed 100% Pushbutton

6 JOG Mode Pushbutton 46 Spindle Speed Increase Pushbutton

7 RAPID Mode Pushbutton 47 B-axis Table Clamp Pushbutton

8 Zero Point Return Mode Pushbutton 48 B-axis Table Unclamp Pushbutton

9 Single Block Pushbutton 49 Door Open Request Pushbutton

10 Optional Stop Pushbutton 50 Auto Power-off Pushbutton

11 Block Skip Pushbutton 51 Air Blow Pushbutton

12 Dry Run Pushbutton 52 Oil & Air System Lubrication Oil Pushbutton

13 (Reserved) 53 Fluorescent Lamp ON/OFF Pushbutton

14 Machine Lock 54 Tool Data Display Pushbutton

15 Program Restart 55 (Reserved)16 (Reserved) 56 Cycle Start Pushbutton

17 (Reserved) 57 Feed Hold Pushbutton

18 (Reserved) 58 Spindle Tool Clamp/Unclamp Pushbutton

19 (Reserved) 59 (Reserved)

20 (Reserved) 60 (Reserved)

21 X-axis Plus Feed Zero Return Pushbutton 61 (Reserved)

22 X-axis Minus Feed Pushbutton 62 Cutting/Jog Feed Override Switch

23 Y-axis Plus Feed Zero Return Pushbutton 63 Chip Auger Forward Pushbutton

24 Y-axis Minus Feed Pushbutton 64 Chip Auger Stop Pushbutton

25 Z-axis Plus Feed Zero Return Pushbutton 65 Chip Auger Reverse Pushbutton

26 Z-axis Minus Feed Pushbutton 66 (Reserved)

27 B-axis Plus Feed Zero Return Pushbutton 67 Emergency Stop Pushbutton

28 B-axis Minus Feed Pushbutton 68 NC Ready Pushbutton

29 Rapid Feed Override 0% Pushbutton 69 Safety Pushbutton

30 Rapid Feed Override 8% Pushbutton 70 Memory Protect Switch

31 Rapid Feed Override 15% Pushbutton 71 Pallet Manual Selection Switch

32 Rapid Feed Override 25% Pushbutton 72 Pallet Set-up Pushbutton

33 Rapid Feed Override 50% Pushbutton 73 Pallet Start Pushbutton

34 Rapid Feed Override 100% Pushbutton 94 F1DT Pushbutton

35 (Reserved) 95 PBLK Pushbutton

36 (Reserved) 96 HINT Pushbutton

37 Cutting Coolant Pushbutton 97 SUNC Pushbutton

38 Flood Coolant Pushbutton 98 JUNC Pushbutton

39 Shower Coolant Pushbutton 99 F2 Pushbutton

40 Spindle Through Coolant Pushbutton

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2.3.1 Mode Selection PushbuttonPushbuttons (1) to (8) are Mode selection pushbuttons. Press one of the

pushbuttons to enter its designated mode. When pressed, its lamp willcome on, and the machine will enter the selected mode until changed.

EDIT Mode Pushbutton (1)

Press this button to enter Edit mode. In this mode, programsteps can be modified, inserted, or deleted by using keys on

the NC keyboard.

AUTO Mode Pushbutton (2)

Press this button to enter AUTO mode. In this mode, theprogram stored in the memory can be executed; program

number search and sequence number search of the programin the memory are available.

REMOTE Mode Pushbutton (3)

Press this button to enter Remote mode. In this mode, theprograms read via RS232C interface can be executed.

MDI Mode Pushbutton (4)

Press this button to enter MDI mode. In this mode, data input

is available directly via keys on the NC Operators panel. Theprogram entered through NC Operators Panel can be started

HANDLE Mode Pushbutton (5)

by pressing Cycle Start pushbutton (56).

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Press this button to enter HANDLE mode. This mode is usedto provide minute feed with Manual Pulse Generator (82).

Once in this mode, Manual Pulse Generator (82) can be used

to control the movements of the axes.

On Manual Pulse Generator, Axis Selection Switch is used to

select a particular axis to move; Handle Feed Scale Selection

Switch is used set the amount scale of [x1 (=0.001 mm or0.001o), x10 (=0.01 mm or 0.01o), or x100 (=0.1 mm or

0.1o)].

While turning the handle of Manual Pulse Generator (82), theselected axis moves at selected minute feed rate.

JOG Mode Pushbutton (6)

Press this button to enter JOG mode. This mode can be used

to provide continuous feed by manual operation.

Press one of the Plus Direction Feed pushbuttons for X-axis

(21), Y-axis (23), Z-axis (25), or B-axis (27), the selectedaxis will move in the positive direction continuously until it is

released. Press one of the Minus Direction Feed pushbuttonsfor X-axis (22), Y-axis (24), Z-axis (26), or B-axis (28), the

selected axis will move in the negative direction continuouslyuntil it is released.

Note The feed rate can be changed with Feed Rate Override and JOG FeedSetting Switch (62).

In this mode, manual operations of ATC and APC are also allowed.

RAPID Mode Pushbutton (7)

Press this button to enter RAPID mode. This mode is used torun axis at a rapid traverse.

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Press one of the Plus Direction Feed pushbuttons for X-axis

(21), Y-axis (23), Z-axis (25), or B-axis (27), the selectedaxis will move in the positive direction at a rapid traverse rate

continuously until it is released. Press one of the Minus

Direction Feed pushbuttons for X-axis (22), Y-axis (24), Z-axis(26), or B-axis (28), the selected axis will move in thenegative direction at a rapid traverse rate continuously until it

is released.

Note The feed rate can be changed with Rapid Feed Override pushbuttons(29) to (34).

Zero Point Return Mode Pushbutton (8)

Press this button to enter Zero Point Return mode. Toexecute Zero Point Return:

1)Press and hold one of the Plus Direction Feed (ZeroReturn) pushbuttons for X-axis (21), Y-axis (23), Z-axis

(25), or B-axis (27).

2)Continue to hold down the pushbutton until its ZeroReturn Completion lamp is lit.

Note Rapid Feed Override pushbuttons (29) to (34) are available for use in

An absolute type encoder is used on each axis of the machine;

therefore, it is not required to execute Zero Point Return afterpowering on the machine.

If a Zero Point Return becomes necessary, it should be performed at

least 100 mm away from its Zero Point.

this mode. Refer to Section 4.1 "Zero Point Return".

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2.3.2 Program Execution PushbuttonsPushbuttons (9), (10), (11), and (12) are Program Execution pushbuttons.

Press one of the pushbuttons to enter one of program execution modes.When pressed, its lamp will come on, and the machine will enter that mode

until changed.

Single Block Pushbutton (9)

In AUTO or MDI mode, press this button to enter Single Block

program execution mode. In this mode, the machine stopsafter executing one block of the program. Each subsequent

press of Cycle Start pushbutton (56) results in executing onesingle block.

During G28, G29, or G30, the machine stops at an

intermediate point and Feed Hold pushbutton (57) lights up.

In the canned cycle, the machine stops at the end of the rapidtraverse to the point R and the lamp of Feed Hold pushbutton

(57) comes on. (Refer to FANUC's "Operator's Manual".)

During the time that the machine is temporarily stopped by a

single block; manual and MDI operations are still available tobe executed.

To restart the suspended program, press Cycle Start

pushbutton (56) in the original mode.

Note If a MDI operation is executed during automatic operation or viceversa, modal data affects the latter operation.

If a Single Block is commanded during operation, the machine stops

after it completes executing the current block.

Do NOT press [RESET] key. If [RESET] key is pressed, the next blockof information that has already been read into the buffer storage will

be lost and consequently skipped.

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Optional Stop Pushbutton (10)

When in automatic operation, pressing this button causes the

program execution to be in Optional Stop mode.

In this mode, cycle operation is stopped after a blockcontaining M01 is executed, and Program End Signal Light is

lit. To restart cycle operation, press Cycle Start pushbutton

(56).

Block Skip Pushbutton (11)

When in automatic operation, press this button for theprogram execution to enter Block Skip mode.

In this mode, any block beginning with "/" is ignored. If not in

this mode, any block beginning with "/" is executed.

Optional Block Skip is identified when "/" is read into the

buffer from the tape or memory.

Note If a block preceded by a slash has been read into the buffer beforeBlock Skip pushbutton (11) is pressed, it does get executed.

Dry Run Pushbutton (12)

Press this button for the program execution to enter Dry Run

mode. In this mode, all F codes specified in the program areignored. With that, cutting feed is no longer controlled by the

F code, but rather, determined by the JOG Feed rate which isset with Cutting JOG Feed Override switch (62).

In tapping cycle, pressing this button has no effect. In rapidtraverse cycle, this button usually is not in effect. However,

by changing some parameters, this button can be madeeffective for rapid traverse cycle.

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Note If operation is stopped in Dry Run, after all axes have completed theirmovements, press this pushbutton (12) again to exit Dry Run mode.

Machine Lock Pushbutton (14)

Pressing this pushbutton causes the machine to enter machine

lock state in which positional changes are displayed on thescreen without the actual axial movements.

When in Machine Lock state, M codes, T codes, and S codes

are still being accepted and can be executed.

Pressing the pushbutton (and Both Hands pushbuttonsimultaneously) again when in Machine Lock state will release

the axial movements from the lock state.

Note Machine Lock pushbutton and Both Hands pushbutton need to be

pressed simultaneously for machine lock to take place.

Note Never release the machine from the Machine Lock State while a

program is being executed.

Program Restart Pushbutton (15)

When a program execution has been stopped, pressing

pushbutton allows the program to continue its execution.

Note Program Restart pushbutton and Both Hands pushbutton need to bepressed simultaneously for program restart to take place.

2.3.3 Direction Feed and Zero Return PushbuttonPlus Direction

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X-axis: toward left (Column movement)

Y-axis: upward (Spindle head movement)Z-axis: toward front side (Table movement)

B-axis: clockwise direction (Table turn)

X-axis Plus Direction Feed and Zero Return Pushbutton (21)

This pushbutton can be used to move the X-axis in the

positive direction or to return the X-axis to zero point.

When the machine reaches X-axis zero points as a result ofthe execution of zero point return either by manual operation

or automatic operation (G28), the Zero Return CompletionLamp at the upper-right corner will light up.

X-axis Minus Direction Feed Pushbutton (22)

Pressing this pushbutton moves the X-axis in the negative

direction.

Y-axis Plus Direction Feed and Zero Return Pushbutton (23)

This pushbutton can be used to move the Y-axis in the

positive direction or to return the Y-axis to zero point.

When the machine reaches Y-axis zero points as a result ofthe execution of zero point return either by manual operation

or automatic operation (G28), Y-axis Zero Return CompletionLamp at the upper-right corner will light up.

Y-axis Minus Direction Feed Pushbutton (24)

Pressing this pushbutton moves the Y-axis in the negative

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direction.

Z-axis Plus Direction Feed and Zero Return Pushbutton (25)

This pushbutton can be used to move the Z-axis in the

positive direction or to return the Z-axis to zero point.

When the machine reaches Z-axis zero points as a result ofthe execution of zero point return either by manual operationor automatic operation (G28), Z-axis Zero Return CompletionLamp at the upper-right corner will light up.

Z-axis Minus Direction Feed Pushbutton (28)

Pressing this pushbutton moves the Z-axis in the negative

direction.

B-axis Plus Direction Feed and Zero Return Pushbutton (27)

This pushbutton can be used to move the B-axis in the

positive direction or to return the B-axis to zero point.

When the machine reaches B-axis zero points as a result ofthe execution of zero point return either by manual operation

or automatic operation (G28), B-axis Zero Return CompletionLamp at the upper-right corner will light up.

B-axis Minus Direction Feed Pushbutton (28)

Pressing this pushbutton moves the B-axis in the negative

direction.

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Note At the completion of 2nd zero point return for a particular axis, thecorresponding lamps will start blinking.

One absolute type encoder is used on each axis of the machine;therefore, there is really no need to execute Zero Point Return after

powering on the machine.

These lights will not come on except for the execution of zero pointreturn, even if the machine reaches to its zero point

At the completion of 2nd zero point return, the corresponding lamp willblink.

2.3.4 Rapid Feed Override PushbuttonRapid Feed Override 0% Pushbutton (29)

Pressing this pushbutton, in any mode, cancels RapidSpeed Override on any of the 4 axes.

Rapid Feed Override 8% Pushbutton (30)

In any mode, the selection of the Rapid Speed Override of8% on any of the 4 axes can be made by pressing this

pushbutton.


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In any mode, the selection of the Rapid Speed Override of

15% on any of the 4 axes can be made by pressing thispushbutton.



pushbutton.



pushbutton.



100% on any of the 4 axes can be made by pressing thispushbutton.

Note Cutting/JOG Feed Override Switch (62) is not available for Rapid Feed

Override.

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2.3.5 Coolant ON/OFF PushbuttonCutting Coolant Pushbutton (37)

Shower Coolant Pushbutton (38)Through Spindle Coolant Pushbutton (39)

Flood Coolant Pushbutton (40)

When any of these pushbuttons is pressed, its light comes onand its corresponding coolant pump is turned on. Subsequent

press of the same pushbutton turns off its coolant pump andlight.

These coolant pushbuttons are in effect regardless of mode

selection. It is therefore possible to turn off and on the flowof coolant during machining process in any mode.

During AUTO, MDI, or REMOTE mode, coolant can also be turned on and offby using M-codes.

Cutting Coolant

M08 cutting coolant starts

M09 cutting coolant stops, oil mist/air blow stops

Shower Coolant

M10 shower coolant startsM11 shower coolant stops

Spindle Through Coolant

M13 spindle through coolant starts

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M14 spindle through coolant stops

Flood Coolant

M15 flood coolant starts

M16 flood coolant stops

Note Shower coolant and flood coolant are automatically started when CycleStart pushbutton (56) is pressed.

Spindle through coolant is turned off when M6 or M106 is executed.

2.3.6 Spindle OperationSpindle Forward Rotation Pushbutton (41)

This pushbutton can only be used in JOG Mode. When it is

pressed, the spindle rotates clockwise. In any mode,whenever the spindle rotates forward, its lamp comes on.

Spindle Stop Pushbutton (42)

In HANDLE, JOG, RAPID or ZERO RETURN mode, when it ispressed, the spindle stops immediately.

Spindle Reverse Rotation Pushbutton (43)

This pushbutton can only be used in JOG Mode. When it is

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pressed, the spindle rotates counterclockwise. In any mode,whenever the spindle rotates in the reverse direction, its lamp

comes on.

Spindle Speed Decrease Pushbutton (44)

In any mode, each press of the pushbutton decreases the

spindle speed by 10% until the maximum deceleration, 50%,is reached.

Spindle Speed 100% Pushbutton (45)

By pressing this button, Spindle speed set by Spindle Speed

Deceleration pushbutton (44) or Spindle Speed Accelerationpushbutton (46) Spindle Speed is returned to its 100%.

Its lamp comes on, when this pushbutton is pressed.

Spindle Speed Increase Pushbutton (46)

In any mode, each press of the pushbutton increases thespindle speed by 10% until the maximum acceleration, 150%,

is reached.

2.3.7 B-axis Table Clamp/UnclampB-axis Table Clamp and B-axis Table Unclamp operations can only be donein JOG mode.

B-axis Table Unclamp Pushbutton (47)

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In JOG mode, pressing this button causes B-axis Table to be

unclamped. Its lamp comes on when B-axis Table isunclamped.

Note The B-axis Table can only be turned when it is unclamped.

B-axis Table Clamp Pushbutton (48)

In JOG mode, pressing this button causes B-axis Table to beclamped. Its lamp comes on when B-axis Table is clamped.

When clamped, the B-axis Table cannot be turned.

2.3.8 Chip Auger PushbuttonChip Auger Forward Pushbutton (63) (Option)

This pushbutton is used to turn Chip Auger so that it moves

the chips in the forward direction.

Chip Auger Stop Pushbutton (64) (Option)

This pushbutton is used to stop Chip Auger immediately.

Chip Auger Reverse Pushbutton (65) (Option)

This pushbutton is used to turn Chip Auger so that it movesthe chips in the reverse direction.

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2.3.9 Miscellaneous PushbuttonsDoor Open Request Pushbutton (49)

Before opening Operator Side Door, its necessary to pressDoor Open Request Pushbutton (49). When pressed, the lampis lit and the safety lock of the door is released.

To lock Operator Side Door again, close the door completely.When the door is closed, the door will be locked automatically

and this buttons lamp will go off.

Auto Power off Pushbutton (50)

Auto Power OFF function can be enabled by pressing AutoPower Off pushbutton (50). If pressed, its lamp will come on.

With Auto Power OFF turned on, when an automatic operationends (M30), the machine goes into the emergency stop state,

NC is powered off, and finally the main switch is turned off.

Note Remember to release this pushbutton, once the main power is turnedback on.

Air Blow (51)

In Manual Mode, when this pushbutton is pressed, Air Blow

starts and its lamp comes on. Subsequent press of thispushbutton stops Air Blow and its lamp to go off.

In MDI Mode or AUTO Mode, press this pushbutton to stop Air

Blow if it has been turned on; or press this pushbutton to startAir Blow if it has not been turned on.

Note In MDI Mode or AUTO Mode, M09 command can be used to turn off AirBlow; and M07 command can be used to turn on Air Blow.

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Oil & Air System Lubrication Oil Pushbutton (52)

When this button is pressed, lubrication oil is supplied to

ballscrews, linear guides, and the spindle for 6 seconds.

Note When NC is in ready state for operation, any axial movement or

spindle rotation will trigger lubrication oil and air to be automaticallysupplied to ballscrews, linear guides, and the spindle. Air is

continuously supplied whenever NC is in its ready state.

Oil lubrication cycle repeats itself as described below:

1)Lubrication oil is supplied for 20 seconds.2)Lubrication stops for 6 minutes.The lubrication oil can manually be turned on by pressing thispushbutton. Each press of this pushbutton triggers the oil lubricant to

be dispensed to ballscrews, linear guides, and the spindle for 20seconds.

Work Light ON/OFF Pushbutton (53)

This pushbutton is used to turn on/off the work light.

Tool Display Pushbutton (54)

Press this pushbutton to navigate the LCD display to Tool

Data.

As an example, in OPERATOR MESSAGE section, the following

tool information are displayed:

SPINDLE TOOL NO. = 2

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WAITING POT TOOL NO. = 1MAGAZINE POT TOOL NO. = 0

The data are interpreted as below:

Tool #2 in the spindle.

Tool #1 in the waiting pot.There is no tool in the magazine pot.

Safety Both Hands Pushbutton (69)

This pushbutton is needed for safety reason. Pressing

Machine Lock pushbutton or Program Restart pushbutton isonly effective when this pushbutton is also pressed at the

same time.

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2.3.10 Cycle Start Pushbutton

By pressing Cycle Start Pushbutton (56), an operation in

AUTO or MDI mode is started.

When a program is being executed, the lamp of Cycle Start

pushbutton will come on and stay on. The lamp will go off,once the program execution is ended, when FEED HOLD is

executed, or when the program execution is stopped orsuspended.

In the following cases, Cycle Start pushbutton is ignored:

Emergency stop is in effect. Mode selection is incorrect. Sequence number search is executing. Any alarm is not yet cleared. The numerical control system is not ready ("NC READY" is not displayed

on LCD) APC or ATC unit has not yet returned to its home position.

2.3.11 Feed Hold Pushbutton

This Feed Hold Pushbutton (57) is used to stop an automaticoperation in AUTO or MDI mode.

When this button is pressed, the followings occur:

The Cycle Start lamp goes off and the Feed Hold lampcomes on.

All axial movements are decelerated and subsequentlystopped.

Dwell is suspended. For M and S functions, the machine stops after executing

the current command. In the tapping cycle or counter tapping cycle, the machine

stops when the cycle reaches its end although Feed Holdpushbuttons lamp remains lit.

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If Feed Hold pushbutton is pressed during the movement

between the point R and the initial point, the movement stopsimmediately.

While Feed Hold is in effect, spindle rotation and coolantsystem are not stopped; thus, manual operation is stillpermitted.

While an automatic operation is being suspended, if themachine is operated manually, the axial positions may

possibly be shifted. Therefore, before restarting automaticoperation, return the axes to their prior positions.

Note To restart the operation, press Cycle Start pushbutton.

MDI command is not available if the machine is suspended with FeedHold.

2.3.12 Emergency Stop Pushbutton

Emergency Stop Pushbutton (67) is used to stop the machineimmediately in case of emergency. Once this button ispressed, it remains latched in the STOP position. To releasethe button, turn it clockwise. When an emergency stop takes

place, the power to the motors is interrupted, and all axialmovements and spindle rotation are stopped.

Note Be sure to remove the cause of emergency stop before releasingEmergency Stop button.

After releasing this button, pressing NC Ready pushbutton repeatedly

until EMG message disappears.

When the operation is restarted, all commands for axial movement orspindle rotation before the Emergency Stop occurred are lost.

CAUTION All personnel must know the locations of all Emergency Stop

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buttons and how to use them in case of emergency.

2.3.13 Feed Rate Override SwitchThis Feed Rate Override and JOG Feed Override Switch (62) can be used forsetting the feed rate override in JOG mode.

An override from 0 to 200%, at an interval of 10%, can be

applied to the feed rate specified by the F function inautomatic operation (AUTO, MDI). Normally, it is set to

100%.

Note: When Feed Rate Override switch is set at 0, no axial movement is

permitted.

NC Ready Pushbutton (68)

With NC powered on or emergency stop released, press thisbutton causes NC to enter its ready state. The lamp will light

up when both numerical control and mechanical system areready for operation.

2.3.14 Memory Protect Switch

locked to the mode previously selected; none of mode

OP LOCK (Operation Lock), the mode is temporarilyregistration or editing is prohibited. If the switch is set to

memory is protected from any modification, consequently,

this switch is set to "M LOCK" (Maintenance Lock), theregistration and editing of a program is allowed. WhenWhen Memory Protect Switch (70) is set to "CANCEL",

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selection pushbutton is functional.

The table below lists the operations allowed or disallowed according to the

mode selected by the Memory Protect Switch.

Cancel 1Op Lock M Lock

Program Edit/Transfer Yes Yes No

Tool Offset Yes Yes No

Workpiece Coordinate Offset Yes Yes No

Macro Variables Yes Yes No

Tool Life Management Yes Yes No

Mode Switch Yes No YesAxial Movement Yes No Yes

Tool Search/Tool Exchange Yes No Yes

Spindle Rotation Yes No Yes

Program Execution Yes No Yes

Peripheral Motor Action Yes No Yes

Message Display No Yes No

1Op Lock When Memory Protect Switch is set to Op Lock, the operations

listed in the table above are allowed only if Keep Relay K0.6 is

set to 1.

CAUTION Be sure to set this switch to "M LOCK" or OP LOCK after editing

or registering a program in memory.

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2.3.15 Pallet Control and PushbuttonsPallet Manual Selection Switch (71)

This switch is only meaningful in JOG mode. When Pallet

Start pushbutton (73) is pressed, the operation selected bythis switch is performed.

Note This switch is functional only when the machine is in the APC ready

position.

Pallet Set-up Pushbutton (72)

After workpieces have been set up on the pallet, press thisbutton to indicate to the machine that the workpieces on the

pallet are ready. When this button is pressed, its lamp comeson and stays on. At this point, the pallet is in a set-up state

and is awaiting the pallet change operation to start. When the

pallet is in set-up state, the front set-up doors are locked.

In AUTO mode, if the pallet is not in set-up state, the palletswill not be exchanged per any APC command; instead, the

pallet change operation is suspended until this button ispressed.

If the pallet is in already set-up state, press this button again

will cancel its set-up state and its lamp also goes off.

When pallets are exchanging, the lamp of Pallet Set-Uppushbutton will blink until the pallet change operation iscompleted. Once the pallet change operation is completed,

the locks on the set-up doors are released.

CAUTION Do NOT open the set-up door whenever the lamp of Pallet

Set-Up pushbutton is blinking.

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Pallet Start Pushbutton (73)

In JOG mode, pressing this button will start the operation

selected by Pallet Manual Selection Switch (71). When itslamp is lit, manual operations of APC are allowed.

2.3.16 Pushbuttons of OptionsF1DT Pushbutton (94)

To be designed.

PLBK Pushbutton (95)

To be designed.

HINT Pushbutton (96)

To be designed.

5UNC Pushbutton (97)

To be designed.

JUNC Pushbutton (98)

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To be designed.

F2 Pushbutton (99)

Reserved for future feature.

2.3.17 Manual Pulse Generator

In HANDLE mode, Manual Pulse Generator (82) is used to

move the axes at finer steps.

On Manual Pulse Generator, feed of 0.001 mm or 0.001o(x1), 0.01 mm or 0.01o (x10), 0.1 mm or 0.1o (x100) perscale can be selected.

To operate, select axis and scale, and then turn the handle.

One rotation of the handle is equivalent of 100 scales.

Note The handle should not be turned more than five rotations per second.

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2.4 Other Controls and Pushbuttons2.4.1 Spindle Tool Clamp/Unclamp PushbuttonSpindle Tool Clamp/Unclamp Pushbutton (58)

This pushbutton is on the enclosure panel next to the operators side doorfor easy access.

In JOG mode, when the spindle tool is clamped, pressing thisbutton causes the spindle tool to be unclamped. Similarly,

when the spindle tool is unclamped, pressing this buttoncauses the spindle tool to be clamped.

The lamp comes on when the spindle tool is in the unclampedstate.

Note Be sure to hold the tool by hand before unclamping it.

Press and hold the button for at least one second. If not, Spindle ToolClamp/Unclamp may not function properly.

The spindle tool cannot be unclamped while the spindle is rotating.

When the spindle is unclamping, it will clamp the tool if the hydraulicpressure suddenly drops because of either emergency stop or power-off.

If spindle rotation or spindle orientation is commanded while spindle

tool is unclamped, the machine will enter Feed Hold state.

The command for spindle rotation or spindle orientation should only be

submitted for execution when the spindle tool is clamped.

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2.4.2 Pallet Setting Side

Pallet Set-up Pushbutton (80)

Same function as Pallet Set-up pushbutton (72) on the

Emergency Stop Pushbutton (81)

Same function as Emergency Stop pushbutton (67) on the

80 81

machine operation panel. Refer to Section 2.3.15.


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2.4.3 ATC Magazine Side

Emergency Stop Pushbutton (75)

Same function as Emergency Stop pushbutton (67) on the

79

78

77

76

75


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ATC Manual Operation Switch (76)

In JOG Mode, the movement in ATC can be selectedwith this switch, followed by pressing ATC Manual

Start Pushbutton to execute the selected ATCoperation.

There are limitations imposed on the actions of ATC that can beselected with ATC Manual Operation Select switch:

Movements in (white) are available only in JOG Mode and when thespindle is in tool change position.

Movements in (grey) are available in Automatic operation modeprovided that ATC magazine has not been stopped.

Double Arm Chucking

ATC Shutter Open

Tool Unclamp

Initial PositionDouble Arm to

Tool Clamp

Counter ClockwiseDouble Arm Turn 180

ATC Shutter Close

180 ClockwiseDouble Arm Turn

Counter Clockwise

Magazine Rotate

Arm Side

Tool Pot to Double

ClockwiseMagazine Rotate

Magazine SideTool Pot to

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ATC Manual Start Pushbutton (77)

Pressing this pushbutton causes the operation selected by

the ATC Manual Operation Switch to be started rightaway.

Note Make sure the door of ATC magazine is closed before pressingATC Manual Start pushbutton.

Single Arm Manual Operation Switch (78)

In JOG mode, a Single Arm manual operation can

be selected with this switch, followed by pressingSingle Arm Manual Start pushbutton (79) to start

the operation.

Note Manual continuous operation can be started in any operation

mode.

Continuous Operation

Tool from Waiting pot to Magazine pot

Tool from Magazine pot to Waiting pot

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Single Operation

Tool chucking at Magazine pot

Tool chucking at Waiting pot

Grippers locked and Tool removed

Single arm from Magazine pot to Waiting pot

Single arm from Waiting pot to Magazine pot

Tool inserted and Grippers unlocked

Single arm to the initial position

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Single Arm Manual Start Pushbutton (79)

The operation that is currently selected by the Single Arm

Manual Operation Switch can be started by pressing thisbutton.

Note After the machine is powered on, make sure there is adequatehydraulic pressure before manually operating the single arm.

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3 Starting and Ending OperationBefore starting any operation, check the machine to ensure all safety

regulations are enforced. (Refer to Safety Precautions)

3.1 Emergency StopEmergency Stop is used to stop the machine operation immediately.

Emergency Stop is used to stop the machine operation

immediately in case of emergency. There are three

3.2 Turning ON PowerFollow the procedure below to turn on the machine:

Make sure factory power is supplied to the electric cabinet.

Turn on Main Power switch on the electric cabinet.

Power Lamp on the electric cabinet comes on. Ventilation fans in the electric cabinet are turned on. Spindle motor fan is turned on.

Release all Emergency Stop pushbuttons (67), (75), and (81).

Emergency Stop buttons (67), (75), and (81). Thesebuttons are effective in any mode.

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Press NC Power ON pushbutton (0)

The lamp of NC Power ON pushbutton lights up. The LCD displays System Configuration screen and NC is

now powered.

Press NC Ready pushbutton (68) and hold for a few seconds.

The lamp of NC Ready pushbutton lights up. The machine is now ready for operation.

Items to check after the machine is powered on are:

Items Check ForMotors Abnormal heat or noise

LCD screen Alarm display

3.3 Machine Warm-upMachine warm-up is mandatory in order to ensure smooth and properoperations of every component of the machine, and to minimize the effect of

heat expansion on the machine accuracy.

Lubrication

After the machine is powered on, oil is automatically supplied to spindle,ballscrews, and linear guides, etc., where lubrication are needed.

However, immediately after the machine is turned on, the spindle bearings

are not sufficiently lubricated. In order to ensure that these parts are notdamaged unintentionally, the following rules must be strictly enforced:

If the machine has been turned off for less than 48 hours, do NOT turnthe spindle for at least 20 minutes after the machine is powered on.

If the machine has been turned off for more than 48 hours, do NOT turnthe spindle for at least 40 minutes after the machine is powered on.

Air unit Adequate air pressure (0.6 MPa)

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CAUTION Spindle can be damaged if it is rotated before its spindle

bearings are adequately lubricated.

Hydraulic Circuit

To warm up of the oil in the hydraulic circuit, use the following two Mfunctions to increase the oil temperature:

M83 - When room temperature is in the range of 5C~15C(40F~60F).

M84 - When room temperature is less than 5C (40F)Note The oil in the hydraulic circuit, when it is cold, has high viscosity which

can cause problems in certain operations, such as spindle tool

clamp/unclamp.

Grease

Grease also needs to be warmed up so that it can permeate the parts and

the components. For example, insufficient lubrication on the clamp pins ofthe double arm may result in a tool chucking problem.

Warm-up Procedure without using Weekly Timer

Two warm-up programs, O8930 and O8931, are installed on the machine

before delivery. The elapsed time since the last power-off of the machinecan be used to determine which one of the two programs to execute.

If the machine has been powered off for more than 48 hours, execute warm-

up program O8931. If the machine has been powered off for less than 48

hours, execute warm-up program O8930.

The execution time for O8930 is approximately 50 minutes. The executiontime for O8931 is approximately 60 minutes.

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3.4 Turning OFF Power

Make sure that the light of Cycle Start pushbutton (56) is off.

If the light of Cycle Start pushbutton is not off, press FeedHold pushbutton (57).

Press Emergency Stop pushbutton (67).

Press NC Power OFF pushbutton (00).

Turn off Main Power switch.

3.5 After Turning Off PowerAny cleanup work should only be carried out after the machine has beenturned off.

DANGER Be sure to turn off all power supply to the machine and to thedevices such as chip conveyor before cleaning them.

Chips are flushed by coolant toward the chip pan sitting at the front ofthe machine. Make sure that chips are not over-accumulated in the chip

pan. Chips left on the covers should be brushed off with soft brushes. Do NOT use air gun to blow chips away from the covers.

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Remove chips and wipe clean coolant left on the covers. Coolant andchips infiltrate underneath the covers can potentially damage machinecomponents such as spindle bearings or ballscrews.

Always wear gloves to clean chip debris. Be aware that solenoid valves will remain hot after the machine is

powered off. Refrain from touching them for a while. If the machine will not be operated for a long time, insert a tool into the

spindle to prevent foreign matters from entering.

3.6 Measures in Power FailureWhen power failure occurs during machine operation, the NC unit and theelectrical control units are all powered off; the machine goes into the

emergency stop state. As a result, the commands stored in the NC buffer orinput through the operation panel are cleared and lost.

Below are the steps to take immediately following a power failure:

Press Emergency Stop pushbutton (67).

Turn off Main Power switch.

Below are the steps to take after power is restored:

Turn on Main Power switch on the electric cabinet. Refer to

Release all Emergency Stop pushbuttons (67), (75), and

(81).

Section 3.2 Turning ON Power.

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Press NC Power ON pushbutton (0)

Press NC Ready pushbutton (68) and hold for a few seconds.

Troubleshoot and remove the causes of alarms if any.

Restore the machine, with manual operations, to theconditions before power failure.

WARNING Corrective actions after power is restored must be carried outwith manual operations. This is because the remaining

pneumatic/hydraulic motion may be continued unexpectedly

when these circuits are turned back on.

After power to the machine is restored, the states of the machine should beas follows:

Before Power Failure After Power is Restored

Spindle tool clamped Spindle tool clampedSpindle tool unclamped Spindle tool unclamped

Spindle rotating Spindle stoppedSpindle stopped Spindle stopped

X/Y/Z/B axis feed Unchanged

ATC motion Stopped/UnchangedAPC motion Stopped/Unchanged

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3.7 Weekly TimerThis machine is equipped with a weekly timer. This weekly timer can be

enabled or disabled by the key switch located on the door of the electriccabinet.

By using the weekly timer, the machine can be automatically turned on and

off at preset times.

If the weekly timer is used to turn on the machine, warm-up programs ofthe spindle and other movable components will be automatically performed.

ON Operation

1)At the preset ON time, AC power is supplied to the power supply moduleof the machine.2)NC is turned on.

3)The machine gets in the Ready state for operation. (All emergency stopbuttons must be released.)

4)Twenty minutes later, a spindle warm-up program (installed at factory) isstarted. It will take about 25 minutes to warm-up the 15,000 rev/minspindle.

5)When the spindle warm-up is finished, the machine warm-up program willbe started.

Note The key switch for the weekly timer must be set to ON (enabled) and

the day selection switch for that day is set to ON.

OFF Operation

1)At the preset OFF time, the machine goes into the emergency stop state.Note If a program is being executed at preset OFF time, the machine will

wait until the program complete its execution before entering the

emergency stop state.

2)NC is turned off.3)AC power supply to the power supply module is shut off, but the main

power switch stays ON.

Prepare Weekly Timer for Next Day

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Check the following items before the Weekly Timer turns off the machine:

The weekly timer is correctly set for the next operation day. All emergency stop buttons are released. AUTO Mode is selected. Single block switch on the operation panel is set to OFF. Make sure that no tool is in the spindle. This is important because if

there is a tool in the spindle, it may cause problems during the nextautomatic spindle warm-up procedure.

There is no tool or part unintentionally left in the machining area. All machine doors are closed (Door Open Request pushbutton is OFF). Feed rate override switch/pushbutton is set appropriately. The waiting pot is positioned at the spindle side (normal position), The main power switch is set to ON.Note Do not use the Auto Power Off function. Auto Power Off causes the

main power switch to be turned off.

The key switch for the weekly timer must be set to ON (enabled).

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4 Manual Operation4.1 Zero Point Return

In this machine, every axis is equipped with an absolute type encoder fortracking its positions. Therefore, it is not required that the zero point return

be executed after the machine is powered on. However, if any servo motorloses its zero point data because of low battery, executing the zero point

return will become necessary for all axes.

The zero point return procedure for B-axis is slightly different from that of X,

Y, or Z axis.

For X, Y, and Z axes, please refers to Section 11.6 Zero Point Setting ofAxes in HS-450i Maintenance Manual.

For B axis,

Press Zero Point Return Mode pushbutton (8).Its lamp comes on.

Select an appropriate rapid feed rate with one of

Rapid Feed Override pushbuttons, 8%, 15%, 25%, 50%,

Press and hold B-axis Plus Direction Feed and Zero ReturnPushbutton (27) until its completion lamp is lit which

indicates that B-axis has reached its zero reference point.

or 100% (30) to (34).

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When over-travel fault occurs, follow the steps outlined below to resolve the

error:

1)Move every axis to the center of its travel path by manual operation.2)Press the NC Power OFF pushbutton (00).3)While pressing [P


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Note Over-travel alarm is triggered whenever any axis travels past its

over-travel limits. Axis itself cannot travel past its travel limits ineither automatic mode or manual mode.

To resolve Over-travel alarm, move the axis in the opposite direction

in manual operation, and then press RESET button.

4.3 Rapid TraverseRapid traverse is to move each axis continuously at a rapid traverse rate.Override of 0, 25, 50 and 100% can be selected.


0%, 8%, 15%, 25%, 50% and 100% on any of the 4 axescan be made by pressing the corresponding pushbutton.

Press RAPID Mode pushbutton (7) to put the Machine inRAPID Traverse mode. Its lamp will be lit.

RAPID Mode

Select the desired rapid feed speed of 0%, 8%, 15%, 25%,

50% and 100% by pressing one of the Rapid Feed Overridepushbuttons, (29) to (34).

Press one of the Plus Direction Feed and Zero Return

Pushbutton, (21), (23), (25) or (27), to move the selectedaxis in the positive direction.

Or press one of the Plus Direction Feed pushbuttons (22),

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(24), (26), or (28), to move the selected axis in the negativedirection.

When one of these pushbuttons is pressed, the selected axis

moves continuously at the rapid traverse rate selected in the

previous step.

4.4 Handle FeedHandle feed is to move each axis little by little using the Manual Pulse

Generator (82). On Manual Pulse Generator (82), feed rate of 0.1, 0.01, or

0.001 mm/scale is available for X, Y and Z axes, while 0.1, 0.01, or 0.001per scale is available for B axis.

Each revolution of the dial equals 100 scales. The dial should only be turned

at a speed less than 5 revolutions per second.

Press HANDLE Mode pushbutton (5) to enter Handle

mode. Its lamp will be lit.

Select 1 (0.001mm), 10 (0.01mm), or 100 (0.1mm)

using the Handle Feed Selection switch on Manual PulseGenerator (82).

Select an axis to move with the Axis Selection switch onManual Pulse Generator (82).

Whilst the pushbuttons (21), (23), (25), and (27) on

Operation Panel are functional in HANDLE mode, the lamp

of the selected axis using Axis Selection Switch will be lit.

Turn the handle of Manual Pulse Generator (82) to movethe selected axis.

The amount of movement is calculated according to the

number of turns and the selected handle feed rate.

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Note Manual Pulse Generator is only used in HANDLE Mode.

4.5 Insertion/Removal of Spindle ToolTo insert a tool into the spindle or to remove a tool from the spindle, followthe steps below:

1) Move spindle head toward the operator side using handle feed.2) Press Door Open Request button (49) to open the door.3) Press JOG Mode pushbutton to enter JOG mode.

Tool Removal

While holding the spindle tool firmly by hand, press Spindle

Tool Insertion

Insert a tool into the spindle, then press Spindle ToolClamp/Unclamp button (58) again. The tool is clamped in the

spindle and the lamp of Spindle Tool Clamp/Unclamp buttonwill go off to indicate as such.

Note Be sure to hold the spindle tool firmly by hand before pressing thisbutton to unclamp it.

When pressing the button, keep it pressed securely for at least onesecond. If not, this button may not function correctly.

and can be removed from the spindle.Tool Clamp/Unclamp button (58). The tool will be unclamped

Press Spindle Tool Clamp/Unclamp button (58). The lamp

position.

will come on indicating that the spindle is in an Unclamp

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When the spindle is in the unclamp state, it does not execute spindlerotation or spindle orientation command.

WARNING Do not touch the cutting edge of tools by hand. Be sure to stayaway from a rotating spindle.

4.6 Spindle Revolution and Stop

Press JOG Mode pushbutton (6) to enter JOG mode. Its lampwill be lit.

Press Spindle CW Rotation pushbutton (41) to rotate thespindle clockwise, or press Spindle CCW Rotation pushbutton(43) to rotate the spindle counter-clockwise.

When Spindle CW Rotation pushbutton (41) or Spindle CCW

Rotation pushbutton (43) is pressed, the spindle rotates atthe speed specified in the "S" command that was executed

previously in MDI or AUTO mode.

If not a single MDI or AUTO operation has been executed

since the machine was powered on, the spindle will not rotate

because the spindle speed is undetermined.

To resolve this, execute a spindle speed command in MDI

mode before issuing any spindle rotation command.

To change spindle speed, the speed override of 50% to 150%

can be achieved using Spindle Speed Decrease pushbutton(44) or Spindle Speed Increase pushbutton (46).

Press Spindle Stop pushbutton (42) to stop the spindlerotation.

Note Spindle Stop pushbutton (42) is only functional in HANDLE, RAPID, or

JOG mode.

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5 MDI Operation5.1 MDI (Manual Data Input) Operation

In MDI mode, commands can be entered into MDI operation buffermemory through LCD/MDI panel.

Press MDI Mode pushbutton (4) to enter MDI mode. Thelamp of MDI Mode pushbutton comes on and MDI screen

is displayed on the LCD.

If any other screen is displayed, press [PROG] key or MDIsoft key to navigate the display to MDI screen.

Enter a block of commands and then press [EOB] key,followed by [INSERT] key.

Move the cursor to the top of the program or to theposition where the program should start.

Program starts from the top of block where the cursor is.

Press Cycle Start pushbutton (56).

Note On the LCD screen, one page of program, up to 10 blocks, canbe executed in the same manner as the normal program.

While a program is being executed, to stop execution of the

program immediately, press Feed Hold pushbutton (57).

Program No. "O0000" is automatically added at the top of theprogram created in MDI mode.

To clear the program created on the LCD, input "O" then press[DELETE] key. By parameter setting, [RESET] key can clear the

program.

PROG

EOB INSERT

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For the first time the program is executed, it will start from thetop of the block regardless of the cursor position. After the first

run, however, it will start from wherever the cursor is.

A program created in MDI mode can call sub-programs, but not

macro programs.

MDI operation is allowed only if there is enough memory to storethe program.

A MDI program is automatically deleted after the program

execution reaches %. However, a MDI program is not deletedif it includes M02, M30 or M99 in the program.

A MDI program in the memory is deleted under the following

situations:

EDIT Mode pushbutton (1) is pressed Background editing is completed Automatic operation is started.

5.2 Spindle Revolution in MDI

Press MDI Mode pushbutton (4) to enter MDI mode. The

lamp of MDI Mode pushbutton will come on.

Press [PROG] key on NC keyboard.

To specify the spindle speed in the command, key in S,followed by the desired spindle speed, then press[INSERT] Key.

To request for spindle rotation in the command, key inM03 (Forward) or "M04" (Reverse), and [EOB], then[INSERT].

For example: To rotate the spindle at 900 rpm forward,

enter:

PROG

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[S][9][0][0][INSERT]

[M][0][3][EOB][INSERT]Press Cycle Start pushbutton (56). As a result of the

execution of the commands entered previously, thespindle will rotate at the specified speed in the specified

direction.

Note During ATC operations or when the spindle tool is unclamped,Spindle Revolution command is ignored.

5.3 Spindle Orientation in MDI

Press MDI Mode pushbutton (4) to enter MDI mode. Thelamp of MDI Mode pushbutton will come on.


Key in "M19" (orientation), [EOB], and[INSERT]


Note Spindle Orientation does not get executed when the spindle isunclamped.

Spindles orientation is released when any ATC movement iscompleted and a Spindle Revolution command is executed.

PROG

M

SP

1 9

EOB INSERT

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5.4 ATC Magazine Indexing and Tool

Press MDI Mode pushbutton (4) to enter MDI mode. The

lamp of MDI Mode pushbutton will come on.

Registration for instructions.


Key in the tool No. to be indexed.

For example, to index tool No. 1, press [T] [0] [1] [EOB][INSERT].

Press Cycle Start pushbutton (56). The tool is nowindexed at ATC position.

For ATC, move spindle head to ATC position.

Key in [M] [6] [EOB] [INSERT].

Press Cycle Start pushbutton (56). The spindle tool isexchanged with the indexed tool.

Note T** commands and M6 must be executed in different blocks.

PROG

INSERTEOB

1

SP

M

%

T

6

EOB INSERT

0

To register tools, please refer to Section 7.2 "Tool

(Refer to Section 7.4 "Tool Exchange in MDI Operation.)

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5.5 Table Clamp/Unclamp in MDI OperationIn MDI operation, M61 can be used to command the B-axis to be clamped,

while M62 and M63 can be used to command the B-axis to be unclamped.

M61

This is the only command to can be used for B-axis clamping.

M62

When M62 is executed in MDI mode, B-axis rotary table will be unclamped;it will be automatically clamped again once B-axis completes the rotation.

This Auto-clamp function in AUTO/REMOTE mode works the same way as in

MDI mode.

Note If B axis is stopped by Feed Hold, it will remain unclamped.

M63

M63 is a single command for B-axis unclamping. M63 doesn't executeAuto-clamp function after B-axis completes its rotation.

After M63 command is executed, M61 needs to be executed in order to

clamp the B-axis. M62 can be used to clamp the B-axis if it is executed inthe same block as the table rotation command.

Note Even if the table is unclamped by M63, machining process can still

continue, although, with inferior precision. For heavy cutting or

cutting accurate, make sure the table is clamped.

Note In Handle mode, when Manual Pulse Generators axis selection is setto 4, pressing either B-axis Plus Feed Zero Return Pushbutton or B-

axis Minus Feed pushbutton (28) causes B-axis to be unclamped.

When B axis is in the unclamped state, switching into Auto mode orMDI mode will cause B-axis to be clamped again, however, switching

into JOG mode or Zero Return mode, B-axis will remain unclamped.

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6 Automatic OperationBefore entering automatic operation

Check that the program is correctly entered. Check that all switches and pushbuttons are correctly set. Check that all doors are closed and that all covers are properly set. Check that no part of human body is and will be in the machine

movable area. Check that no interference is and will be introduced between tools and

workpieces or fixtures. Be sure to avoid any possibility of catching fire.

During automatic operation

Never open any door or any cover. Be sure that someone is ready to press Emergency stop pushbuttons

in case of an emergency.

After automatic operation

Before opening any door or any cover, check to make sure that theautomatic operation has stopped, and that all movements have

completely stopped.

Alarms

If an alarm appears and the machine has stopped, be sure to removethe cause of the alarm before restarting the operation. Failure to reactto these warnings may result in serious bodily injury to personnel or

serious damage to the machine.

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6.1 Starting Automatic OperationMemory Operation (AUTO)

Press AUTO Mode pushbutton (2). Its lamp should comeon.Press [PROG] key on NC keyboard.

The program edit screen will be displayed on the LCD.

Invoke a program with the following steps:

1. Press address key [O].2. Key in the program number with numerical keys. For

example, press [0], [1], [3] and [2] or just [1], [3]

and [2] for Program No. 0132.3. Press DOWN cursor key. The program will be

displayed on the LCD.4. Press [RESET] key.Check that the program is correctly entered, and then

press Cycle Start pushbutton (56) to execute theprogram.

Its lamp is lit and the program is executed.

Remote Mode Operation

Setup a tape reader or a program transfer device using theRS232C interface so that program can be retrieved from these

devices.

Press REMOTE Mode pushbutton (3) to enter Remote mode.

Its lamp should be lit.

Press Cycle Start pushbutton (56). Its lamp is lit. The

program is retrieved from the external device and thenexecuted, although its blocks are not displayed on the LCD

screen.

PROG

1O)

3 2

RESET

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6.2 Stopping & Restarting Automatic

Feed Hold (Halt)

Feed Hold pushbutton (57) is used to put the operation on atemporary stop.

Feed Hold lamp lights up and the lamp of Cycle Startpushbutton (56) goes off.

All movements are stopped. The dwell execution is halted. Immediately after the execution of M code or S code

commands is completed, the machine stops.

Feed Hold does not stop the spindle or coolant.

Single Block Stop

Single Block pushbutton (9) is used to execute one block of

program at a time. Press Single Block pushbutton causes itslamp to come on.

When an operation stops, the lamp of Cycle Startpushbutton (56) goes off.

With this pushbutton (9) ON, each press of Cycle Startpushbutton (56) executes the next one block and stops theoperation.

Suspension of Automatic Operation

Manual operation is allowed if automatic operation is stoppedby Feed Hold.

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MDI operation is allowed if automatic operation is stopped bySingle block.

Restart of Automatic Operation

Press AUTO Mode pushbutton (2) to put the machine back inautomatic mode.


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6.3 Door Safety InterlockOperator Side Door

The operator side door has built-in safety lock.

Open the Door

To open this door during automatic operation,

Press Single Block Pushbutton (9). The lamp of Cycle Start

pushbutton should go off.

Press Door Open Request Pushbutton (63). Its lamp comeson.

The door can now be opened.

Note Pressing Door Open Request causes the spindle to stop, if it was

running, and the coolant pumps to stop pumping.

It may take a while before the spindle stops completely. The door canonly be opened after the spindle has completely stopped.

To Restart the Operation

Close the door. The lamp of Door Open Request should go

off. The door is locked.

In Auto mode, press Cycle Start Pushbutton (56).

The spindle and the coolant systems are restarted.

Press Cycle Start Pushbutton (56) again.

The program resumes from where it was stopped.

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Note The safety lock is fully engaged and functional even if the main power

switch is off.

The spindle restart is cancelled if RESET button is pressed, EmergencyStop button is pressed, or the power is turned off.

ATC Magazine Door

The ATC magazine door is equipped with a safety lock. The door cannot beopened when

ATCs double arm or single arm is in motion. The tool pot magazine is rotating.Unlike to open the operator side door, pressing Door Open Request

pushbutton is not needed in order to open the ATC magazine door.

Note When this door is open, no operation of ATC double arm, ATC singlearm, or tool pot magazine is permitted.

The safety lock is fully engaged and functional even if the main power

switch is off.

Set-up Doors

The set-up doors of this machine are equipped with safety locks.

These doors are locked when:

Pallet change operation is in process. The lamps of Pallet Set-up pushbuttons (72) and (80) are lit.Note In Auto mode or Manual mode, pallet change is allowed even if the

set-up doors are open or not locked. However, it is advised that pallet

change operation only be done with these doors closed.

The safety lock is fully engaged and functional even if the main power

switch is off.

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Summary of Door Interlocks

When Operator door is open

MODE

ACTION Auto and MDI Handle/Jog/Rapid/Zero Return

Axis Movement No Yes

Spindle Revolution No No

Tool clamp/unclamp No Yes

ATC Double arm No No

Tool magazine No Yes

APC Pallet change No No

Pallet clamp/unclamp No Yes

When ATC magazine door is open

ACTION Auto and MDI

Axis Movement Yes

Spindle Revolution Yes

Tool clamp/unclamp Yes

ATC Double arm No

Tool magazine No

APC Pallet change YesPallet clamp/unclamp Yes

When Set-up doors are open

ACTION All Modes

Axis Movement Yes

Spindle Revolution Yes

Tool clamp/unclamp Yes

ATC Double arm YesTool magazine Yes

APC Pallet change No

Pallet clamp/unclamp Yes

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7 ATC Operation7.1 Setting up ATC MagazineInserting tools into the tool pots or removing tools from the tool pots

can be done using ATC Man

Documents

MB0120120108 HS-450i Operator's Manual