Operator’s Manual - Smithy Manual_0.pdf · Table of Contents I. Unloading Machine ... Operating Sequence ... operator’s manual for that machine and control type. 5) Never attempt

STL6 COMPACT TURRET LATHE Operator’s Manual

800-476-4849 | 170 Aprill Drive | Ann Arbor, Michigan 48103

TableofContentsI.UnloadingMachine.....................................................................................................................3

LiftingandTransporting.....................................................................................................4

UnloadingofMachine........................................................................................................4

II.DeliveryandTestRunning..........................................................................................................5

Installation..........................................................................................................................5

Cleaning..............................................................................................................................5

Levelling..............................................................................................................................5

EnvironmentalRequirements............................................................................................5

ElectricandAirRequirements............................................................................................6

III.SafetyGuidelines.......................................................................................................................6

Overview............................................................................................................................6

SafetyLabels.......................................................................................................................7

DangerandWarningLabelsDisplayedonMachine.....................................................7

SafetyCategoryGuidelines..........................................................................................7

BasicPointsofSafety–BeforeStartingtheMachine........................................................8

PersonalProtectiveEquipment(PPE)andSafety...............................................................9

ToolsandWorkHoldingBestPractices..............................................................................9

SafetyGuidelinesRelatedtoMaintenance......................................................................10

HazardControl.................................................................................................................11

IV.MachineToolOverview..........................................................................................................12

Characteristics..................................................................................................................12

ApplicationRange.............................................................................................................12

CNCControlSystem.........................................................................................................12

MachineComponents–X-andZ-axis..............................................................................13

WorkHolding....................................................................................................................13

AxesMotionDirection......................................................................................................13

WayLubeSystem.............................................................................................................13

PositiveDisplacementManifold.......................................................................................13

V.OperationBoard......................................................................................................................14

SystemOperationArea....................................................................................................14

Introduction................................................................................................................14

2

FurtherInformation....................................................................................................14

KeyCombinations.......................................................................................................16

ElementsontheMCP(MachineControlPanel)Front.....................................................18

Pre-DefinedInsertionStrips.............................................................................................18

CoordinateSystems..........................................................................................................19

MachineCoordinateSystem............................................................................................20

WorkpieceCoordinateSystem.........................................................................................21

RelativeCoordinateSystem.............................................................................................21

WorkpieceFixturing.........................................................................................................21

VI.SoftwareInterface..................................................................................................................21

ProtectionLevels..............................................................................................................24

ProtectionLevel1.......................................................................................................25

ProtectionLevel3-6...................................................................................................25

ProtectionLevel7.......................................................................................................25

VII.TurningonandReferencingMachine....................................................................................28

OperatingSequence.........................................................................................................28

VIII.SettingUpToolsandWorkOffsets.......................................................................................29

Overview..........................................................................................................................29

SettingUpTools...............................................................................................................29

CreateaNewCuttingEdge...............................................................................................30

EnteringToolOffsets........................................................................................................30

ActivatingtheToolandStartingSpindle..........................................................................31

SelectingtheHandwheel..................................................................................................32

MeasuringtheToolManually..........................................................................................33

IX.SettinguptheWorkpiece........................................................................................................36

MeasuringtheWorkpiece................................................................................................36

EnteringandModifyingData...........................................................................................38

SettingTimeCounter........................................................................................................39

SettingRParameters........................................................................................................40

Setting“Rel”CoordinateSystem......................................................................................42

SettingJogData................................................................................................................43

X.PartProgramming....................................................................................................................43

CreatingFilesorFolders...................................................................................................44

3

CreatingaProgramDirectory...........................................................................................44

EditingPartPrograms.......................................................................................................45

BlockEditingOptions.......................................................................................................44

SearchforStrings.............................................................................................................44

ManagingPartPrograms..................................................................................................47

RenamingPrograms.........................................................................................................47

ViewingandExecutingRecentPrograms........................................................................48

ContourProgramming......................................................................................................48

ProgrammingaContour...................................................................................................50

Undercuts.........................................................................................................................57

XI.AutomaticMachining..............................................................................................................60

Simulation........................................................................................................................61

XII.MachineToolSettingsandAdjustments................................................................................62

XIII.CommonFaults.....................................................................................................................63

Removal............................................................................................................................63

RestartMachineAfterMakingAdjustments....................................................................68

XIV.MachineMaintenance..........................................................................................................68

DailyMaintenance...........................................................................................................68

WeeklyInspection............................................................................................................68

MonthlyInspectionandMaintenance.............................................................................69

XV.M-CodeList............................................................................................................................69

XVI.PLCFunctionParameters......................................................................................................71

4

I. UnloadingMachine

LiftingandTransporting

1) Size,weightandcentralpositionaremarkedonthecrate(ifapplicable).

2) Besuretohaveaforkliftwithsufficientforklength,sizeandloadcapacity,inadditionto

asafety-mindedandwell-trainedoperator.Packagelifting:seeFigure2.1-liftsmoothly

andsteadily-avoiddamagetomachine,riggingequipment,orbystanders.

Figure2.1Lifting

UnloadingofMachine

1) Unloadmachine(s)asclosetotheinstallationsiteaspossible.

2) Ifthemachinecomesinacrate,removethetopfirst,thensides.Thoroughlylookover

machineandnoteanydamage.

3) Afterunloading,pleasechecktheconditionofmachine,ifthereareanyproblems,

pleasecontactrelateddepartmentofDetroitMachineToolsat1-800-476-4849.

4) Removeboxes,additionaloptions/accessories,andtoolingthataresecuredtothepallet

floor.

5) Removefasteninghardwarethatsecuresmachinetopallet.Typically,onamill,there

willbe4boltssecuringmachinetothepallet,andonalathe,4-6.

5

II. DeliveryandTestRunning

Installation

1) Afterplacingmachineinthedesignatedspot,pleasereadalltherelatedtechnical

documentscarefully.

2) Lookovertheconnectionsofanymechanicalandelectricalparts.

3) Makesurethatthefixedbracessecuringthecarriageandturrethavebeenremoved

beforeoperatingmachine.

4) Checkthepowersupply,lubricationsystem,coolantsystemandoillevel.Iftheoillevel

isnotsufficient,fillwithspecifiedwaylube.

Cleaning

1) Afterinstallation,cleantheanti-corrosivegreaseonmachine,tooling,andaccessories.

2) Applyaliberalcoatofoilonthemachineandtoolingtoavoidrustaftercleaning.

Levelling

1) Properlylevellingalatherequirestimeandamachinistlevelcapableof.0005”in8”or

better.Takeyourtimenowtosavehoursofaggravationlaterwhenyourtoolsare

cuttingunwantedtapers.

2) Levellingshouldbedonewhentemperatureinshophasstabilizedtoanormaloperating

temperature.

3) PlacemachinistlevelacrosswaysparalleltotheXaxis.Itiscriticalthatthisreadingbe

thesameonboththeheadstockandtailstockendoftheways.Thiswilleliminatetwist

ofthelathebedthuseliminatingtapers.LevellingparalleltoZisnotascritical,butthe

procedureisthesameasX.

EnvironmentalRequirements

1) Thetemperaturerangeshouldbebetween50°F-104°F.Toreachalevelofprecision

andrepeatabilitythemachinetoolenvironmentshouldbeaconsistent68°F.

2) Paycloseattentionwhenweldingequipmentisbeingoperatednearthemachinetool.

3) Therelativehumidityofconditionshouldbelessthan75%toprotectelectrical

componentsanddetectingelements.

6

ElectricandAirRequirements

1) Powersupplyis220V,60Hz,3-phase(differentcountrieswithdifferentrequirements),

voltagefluctuationcanbearound±10%.Ifthepowersupplyisnotstable,avoltage

regulatorshouldbeaddedtothelines.

2) Hydraulicoilshouldmeetspecificationsofhydraulicunitmanufacturer.

3) Ifyourmachineisequippedwithpneumaticcomponents,90P.S.I.ofcleandryair

shouldbesupplied.

III. SafetyGuidelines-ALWAYSREMEMBERSAFETYFIRST!

Overview1) Itisstronglyrecommendedthatyoureadthismanualtounderstandthoroughlythe

contents.Properusewillcreateasafeworkingenvironmentandprolongthelifeof

yourmachine.

2) Thismachineisprovidedwithvarioussafetydevicestoprotecttheoperatorand

machine,howeverthesecannotcoverallaspectsofsafety.Theoperatormust

thoroughlyreadandunderstandthecontentofthismanualbeforethemachineis

turnedonandoperated.

3) Theoperatorshouldalsotakeintoconsiderationsafetyaspectsrelatedtotheir

environmentalconditions,materialsandtools.

4) NeveroperateaCNCmachinewithoutpropertrainingorconsultingthespecific

operator’smanualforthatmachineandcontroltype.

5) NeverattempttoprogramaCNCmachinewithoutpropertrainingorconsultingthe

specificprogrammer’smanualforthatmachineandcontroltype.

6) Neitherthemanufacturer,itsrepresentativesnordealerscanassumeresponsibilityfor

anymishaps,damageorpersonalinjurywhichmayoccurasaresultofimproper

operation,orfromfailuretoobservethesafetyprecautionsmentionedinthismanual.

7

SafetyLabelsAlwaysobservethesafetyinstructionsinscribedonthenameplatesfixedtothemachine.DONOTremoveordamagethesenameplatesDONOTattempttooperateorturnonthemachineuntilyouhavereadandunderstoodthemanualssuppliedwiththemachine.

DangerandWarningLabelsDisplayedonMachine

SafetyCategoryGuidelinesThreecategoriesofsafetyguidelineshavebeenusedthroughoutthismanual.Pleasetakenoteofthesesymbolsandunderstandtheirmeanings.

Ifthisactionisnotavoided,itcouldresultinseriousinjuryorevendeath.Itmayalsocausepermanentdamagetoyourmachine.

Ifthisactionisnotavoided,itmaycausepotentialharmtoyourhealthresultinginseriousinjury.Thistoohasthepotentialtocauseseriousdamagetoyourmachine.

Ifthisactionisnotavoided,itmaycausepotentialharmtoyourhealthsuchasminortomoderateinjury.Notavoidingthisactioncouldresultindamagetoyourmachine.

8

BasicPointsofSafety–BeforeStartingtheMachine• MemorizethepositionoftheEMERGENCYSTOPBUTTONonthe

machinesothatyoucanpressitimmediatelyfromanypositioniscaseofemergencies.

• MakesurethatallsafetycoversarefittedandelectricalboxesareclosedandsecuredbeforethepowerisswitchedtoON.

• DONOTmodifythemachineinanywaythatwillaffectsafety.

• Checkallelectricalcablesfordamagebeforestartingmachine,everytime,topreventelectricalshock.Therearehighvoltageterminalsontheelectricalcontrolpanel,motors,junctionboxesandotherequipment.DONOTtouchanyofthesecomponentsunderanycircumstanceswhenthepowersupplyisON.

• DONOTEVERoperatethemachinewhileundertheinfluenceofdrugsoralcohol.

• DONOToperatethemachineifyousufferfromdizziness.________________________________________________________________________

• DONOTtoucharotatingtoolholderorworkpiecewhilethemachineisinoperationmode.

• Alwaysunplugthemainplugwhenthemachineisnotinuse.

• DONOTpaint,soil,damage,modifyorremoveanyofthesafetynameplates.Ifthedetailsbecomeillegibleorifthenameplateislost,obtainareplacementfromDetroitMachineToolsandmountitintheoriginallocation.

• Ifmorethanonepersonisoperatingthemachine,DONOTproceedtothenextstepwithoutinformingtheotheroperator(s)thatyouareabouttodoso.

________________________________________________________________________

• DONOTsubjectthemachine,controlbox,operatorpanel,orelectricalcontrolpaneltoahighvoltagesurge.

• Closeallcoversandjunctionboxesbeforerunningthemachine.DONOTremoveanysafetycoverswhilethemachineisinautomaticoperationmode.

9

PersonalProtectiveEquipment(PPE)andSafety• Alwaystiebacklonghairtoprevententanglingwithrotatingtools.• Alwayswearpersonalsafetyequipment–eye,ear,andother

protectiveequipment.• Alwayswearaprotectivemaskwhenmachiningmagnesiumalloys.• Neverwearlooseorbaggyclothingnorjewelrytopreventgetting

caughtinmovingparts.• Alwaysuseworkgloveswhenloadingandunloadingworkpiecesor

toolsandremovingchipsfromtheworkareatoprotectyourhandsfromsharpchipsandburnscausedbyheatgeneratedduringmachining.

• DONOThandlecoolantwithbarehandstoavoidirritation.

• Takecarenottoplaceanypartofyourbodyinpossiblepinchpoints

onthemachine.ToolsandWorkHoldingBestPractices

• Alwaysusepropercuttingtoolsandworkholdingclampssuitablefortheworkandwithinthespecificationsofthemachine.Neveruseblunttools.Alwaysreplaceworntoolsassoonastheyareidentified.

• DONOTstallthemachineduringcuttingduetoimproperfeedanddepthofcutsuitablefortheworkpiecematerial.

• DONOToperatethespindleabovetheratedspeedofthearbors/toolholdersandcuttingtoolsyouexpecttomountanduseinanymachiningoperation.

• DONOTremoveoradjustswitchestoincreaseaxistravelbeyondthemachinespecifications.

• Avoidcontactwithcuttingedgeswhenhandlingtoolsorchangingtoolsbyhand.

• Checkthatthemachineisnotoperatingwhenloadingatoolmagazine.

_____________________________________________________________________

10

• Checkthattheseatingsurfacesarecleanbeforeinstallingtoolsandthatthetoolsaresetcorrectly.Testtoolsbeforeuse.

• Donotextendbarstockoutofthechuckmorethantwotothreetimesthediameterwithoutpropersupport.

• Makesurethedrawbarandthetoolholdersaretightenedtothepropercuttingconditionsbeforeactualcuttingoperationsbegin.

• DoublecheckthatthecorrecttooldatahasbeeninputtedintotheCNCprogram.

• Makesurethatallworkandfixturesareclampedsecurelybeforestartingmachine.

• Onlyusetoolswithinthelimitsspecifiedbythemanufacturer.

• Onlytightentoolstorecommendedtorquevalue.

• Checkthatthespindledirectioniscorrectforright-handorleft-handoperation.

• Conductadryruntoensuretheprogramiscorrect.SafetyGuidelinesRelatedtoMaintenance

• Alwaysdisconnectthepowertothemachinebeforecarryingoutanymaintenancework.

• Afterthepowerhasbeenswitchedoffforaminimumof60minutes,checkvoltagewithamulti-meterorequivalentmetertomakesurethereisnoresidualvoltage.

• Maintenanceofelectricalandmechanicalcomponentsshouldonlybecarriedoutbyindividualswithworkingknowledgeofthemachinetool.

• DONOTremoveormodifyswitches._______________________________________________________________________

• DONOTallowchipstoaccumulateintheworkenvelope.DONOTwipetheworkpieceorclearawaychipswithyourhandoraragwhilethespindleisinoperation.

11

• Warmupthespindleandaxismotionbeforerunningthemachineinautomaticmode.

• DONOToperatethekeyboardoroperationpanelswitcheswhenwearinggloves.

• DONOTdisconnectthemainpowercablewithoutswitchingofftheCNCandPCconnections.

• Cleanthemachineareasaftermaintenanceiscompleted.

HazardControlThethreestepsinvolvedinrecognizinganddealingwithhazards:1) SpottheHazard-Ahazardisanythingthatcouldhurtyouorsomeoneelse,isunsafe,or

couldcauseanaccident.Useallyoursensestospothazards.Lookaround,listen,noticeanystrangesmells(likesmokeorchemicals)anduseyourknowledgeaboutthingsthatmightbedangerous.

2) AssesstheRisk-Figureouthowlikelyitisforthehazardtohurtsomeoneandhowbadly.Alwaystellsomeoneabouthazardsyoucannotfixyourselfandrememberitismoreurgenttomakethechangesifthehazardislikelytocauseseriousinjury.

3) MinimizetheRisk-Fixthehazardyourselfifyoucan,ortellsomeonewhoisabletofixit.Thebestwaytofixthehazardistogetridofit,butasthisisnotalwayspossible,therearesomewaysyoucanmakethehazardlessdangerous:

• Substituteitforalesshazardousmaterialoritem.• Isolateittoanareawhereit’sfurtheroutofharm’swaysuchasalockedroom.• Addsafeguards-forexample,putclearguardsaroundcuttingorslicing

equipmentorwarningsignsforpeopletosee.• Usepersonalprotectiveequipmentandclothinganytimeyouareworkingwith

hazardousmaterialsand/orequipment.• ElectricalHazards:Installelectricdroppersinsteadofusingextensioncords.• ToxicChemicals:Substitutelesstoxicmaterials(polishes,adhesivesetc).• Noises:Installcanopiestothenoisiestmachines.• Flyingparticles:Isolation,setasidespecificareasforgrinding.• Machiningdust:Engineercontrols,installandusedustextractionequipment.• Slip/Triphazards:Adoptbetterhousekeepingprocedures.• Fatigue:Rotatejobtasksamongworkers.• Newequipment:Trainallstaffoneverypieceofequipmenttoassisthazardous

breakdowns.

12

IV. MachineToolOverview

Characteristics

1) FlashFLserieslathesaredesignedtobehighlystable,whereaccuracy,easeofoperation,

operatorergonomics,installation,andtransportationarealltakenintoconsideration.

2) Thelathestructureiscastinaveryspecificcontrolledenvironmentthatproducesamore

durable, mechanically consistent and more stable iron than standard grey iron. This

processcastingwasdevelopedintheU.S.A,moreinformationcanbefoundHERE

3) Pre-loadedball screws/nut assemblies areequippedonbothX/Z axis. Pre-loadedaxis

assembliesprovidesuperiormovement,higheraccuracy,andlongerservicelife.

4) AutoMateCNCmachinesareequippedstandardwithanautomatic lubepump.Sliding

surfaces, screws, and bearings are all lubricated equally by means of the positive

displacementmanifolds.

ApplicationRange

TheFlashFLseriesmachinetoolisaflatbedlinearguideCNCmachinetool.Itiscontrolledbya

CNCsystem,withlinearinterpolation,arcinterpolation,threadinterpolation.Thismachinetool

canperformturning,drilling,boring,reaming,rigidtappingandthreadinginoneclamping.Our

machinetoolscanbefoundinvarious industries(auto,naval,aviation)aswellaseducational

settingsandhomeshops.

CNCControlSystem

AutoMateCNCmachines comestandardwith theSiemensSinumerik808DBasic, anewCNC

specificallydevelopedforbasicCNCmillingandturningcenters.

§ 808Dsupports3axis,plusspindle,i.e.positioningandCaxismovements

§ Minimummovementis1μmand0.1μmoptional,Max.cuttingspeedis100m/min.

§ CustomizablePLClogic.PLCladderdiagramcanbeonlineeditedandrealtimemonitored.

§ Partsprogramcanbeeditedbackgroundwhileotheroperationsarebeingcarriedout.

§ Onthe808dAdvanced,programfilescanbetransferredvianetworkcable.

§ Filetransfer,systemupdates,parameter/PlcchangescanbemadeviaUSBport

13

MachineComponents–X-andZ-axis

XandZaxismovementsarecontrolledbyACservomotorsdirectlycoupledtotheballscrews

viaspidercoupling.

WorkHolding

AutoMateCNCsuppliesmachineswithvariousworkholdingsolutions.Pleaseconsultyour

specificchuck/colletclosermanual,orcallatechnicianat800-476-4849.

AxesMotionDirection

XaxisTurret/GangPlateDirection–LathesWCSarethesameregardlessofwherethetool

positionis.

• Thespindlecenterlineispart0

• Movementawayfromcenteris(+)

• Movementtowardsthecenteris(-)

• ZaxisTurretleftandrightdirections

• Rightispositivedirection(+)

• Leftisnegativedirection(-)

Themechanicalzeroaxisisattheextremepositioninapositivedirection,andtheaxistravels

are according to machine specification 36100 POS_LIMIT_MINUS and 35110

POS_LIMIT_PLUS which limits the max travel. The Axis travels in positive and negative

directions.Theseareyoursoftlimits.Ifyoursimulatorseesavalueoutsideofthelimits,the

machinewillalarmout.

WayLubeSystem

Thismachinetoolisequippedwithautomaticlubepump.Thegearedrotationalpumpoffers

highperformanceandgoodvolumeefficiency.Allmachineshaveapositivedisplacement

manifoldensuringoilisdistributedevenlytoalllubricationpoints.Timingintervalandpurge

volumearecontrollable,andeachpumpisoutfittedwithalowlubelevelalarm.

PositiveDisplacementManifold

§ Waylubepumpisactivated,andoilispushedintomainoilline.

14

§ Asthepumpcontinuestopressurizeoil inthemainline,oil is forced intomanifold

compartment.

§ Whenpumpstopspurging,themanifoldvalveopensautomatically.Whenthevalve

isopen,volumeinthemachinelinesisnowbiggerthanthemainlinecreatingvacuum

andsiphoningoiltoalllubricationpoints.

Parameter Meaning Unit FactoryDefault

MD14510[24] Intervaltime min 30

MD14510[25] Lubricatetime S 10

V. OperationBoard

SystemOperationAreaIntroduction-ElementsonthePPU(PanelProcessingUnit)front

①VerticalandhorizontalsoftkeysCallsspecificmenufunctions

⑦On-boardassistantkeyProvidesstep-by-stepguidebasedoncommissioninginstructions

②Returnkey ⑧Helpkey

15

Returnstothenexthigher-levelmenu Callshelpinformation

③MenuextensionkeyReservedforfutureuse

⑨Cursorkeys*

④AlphabeticandnumerickeysToentertheuppercharacteronthekey,holddownthefollowingkey:

⑩Operatingareakeys*

⑤Controlkeys* ⑪USBinterface*

⑥AlarmcancellationkeyCancelsalarmsandmessagesthataremarkedwiththissymbol

⑫StatusLEDs*

Furtherinformation

Controlkeys

Deletesacharacterselectedtotheleftofthecursor

Deletestheselectedfileorcharacter

• Indentsthecursorbyseveralcharacters• Togglesbetweentheinputfieldandtheselectedprogramname

• Confirmsyourentryofavalue• Opensadirectoryorprogram

Cursorkeys

Reservedforfutureuse

Movesthecursortotheendofaline

Scrollsupwardsonamenuscreen

Scrollsdownwardsonamenuscreen

16

• Togglesbetweenentriesintheinputfield• Entersthe"Set-upmenu"dialogatNCstart-up

Operatingareakeys

Toopenthesystemdatamanagementoperatingarea,pressthefollowingkeycombination:

Enablesuser-definedextensionapplications,forexample,generationofuserdialogswiththeEasyXLanguagefunction.Formoreinformationaboutthisfunction,refertotheSINUMERIK808DFunctionManual.

StatusLEDs

LED"POK"Lightsupgreen:ThepowersupplyfortheCNCisswitchedon.

LED"RDY"Lightsupgreen:TheCNCisreadyforoperation.

LED"TEMP"Unlit:TheCNCtemperatureiswithinthespecifiedrange.Lightsuporange:TheCNCtemperatureisoutofrange.

USBinterface

ConnectstoaUSBdevice,forexample:

• AnexternalUSBmemorysticker,totransferdatabetweentheUSBstickerandtheCNC

• AnexternalUSBkeyboardwhichfunctionsasanexternalNCkeyboard

1.1 SINUMERIK808Doperatorpanels

KeyCombinationsKeyCombinations Description

<ALT>+<X Opensthemachiningoperatingarea:

<ALT>+<V Openstheprogrameditingoperatingarea:

+

>

>

17

<ALT>+<C > Openstheoffsetparametersoperatingarea:

<ALT>+<B Openstheprogrammanagementoperatingarea:

<ALT>+<M > Opensthediagnosticsoperatingarea:

· <ALT>+ <N> Opensthesystemdatamanagementoperatingarea:

· + <ALT>+<H > Callstheonlinehelpsystem<ALT>+<L> Enablesinputoflowercaseletters

<ALT>+<S ApplicableonlywhentheuserinterfacelanguageisChineseCallstheinputmethodeditorforenteringChinesecharacters

<=> Callsthepocketcalculator.Notethatthisfunctionisnotapplicablein"MDA"mode.

<CTRL>+< B> Selectstextinprogramblocks<CTRL>+< C> Copiestheselectedtext<CTRL>+< D> Showspre-definedslidesonthescreen<CTRL>+< P> Capturesscreens<CTRL>+< R> RestartstheHMI<CTRL>+< S> Savesstart-uparchives

>

>

18

ElementsontheMCP(MachineControlPanel)Front

①Emergencystopkey

Stopsallmachinemotionsimmediately⑥ User-definedkeys*

(allwithLEDstatusindicators)

②Handwheelkey(withLEDstatusindicator)Controlstheaxismovementwithexternalhandwheels

⑦ Axistraversingkeys*

③ ToolnumberdisplayDisplaysthecurrenttoolnumber

⑧ Spindlecontrolkeys

④Operatingmodekeys(allwithLEDstatusindicators)

⑨ Programstatekeys*

⑤ Programcontrolkeys*(allwithLEDstatusindicators)

⑩ FeedrateoverrideswitchTraversestheselectedaxisatthespecifiedfeedrateoverride

Pre-DefinedInsertionStripsTheMCPpackageincludestwosetsofpre-definedstrips.Onesetisformilling,theotherforturningIfyourcontrolsystemisoftheSINUMERIK808Dmillingvariant,replacethepre-insertedstripswiththemilling-specificstrips.

19

TheMCPpackagealsoincludesanA4-sizedblankplasticsheetwithdetachablestrips.Ifyouhavecustomizedcomponentsonyourmachine,replaceinsertionstripswithappropriatelabels.Inthe\04040000\examples\MCPfolderoftheToolboxDVDfortheSINUMERIK808D,thereisasymbollibraryfileandaninsertionstriptemplatefile.Tomakecustomizedinsertionstrips,followthestepsbelow:

1. Copythedesiredsymbolsfromthesymbollibraryfiletothedesiredlocationsintheinsertionstriptemplate.

2. PrintthetemplatetotheA4-sizedblankplasticsheet.3. Detachtheinsertionstripsfromtheblankplasticsheet.4. Pulloutthepre-insertedstripsfromtheMCP.5. InsertthecustomizedstripsonthebackoftheMCP.

CoordinateSystemsAsarule,acoordinatesystemisformedfromthreemutuallyperpendicularcoordinateaxes.Thepositivedirectionsofthecoordinateaxesaredefinedusingtheso-called"3-fingerrule"oftherighthand.Thecoordinatesystemisrelatedtotheworkpieceandprogrammingtakesplaceindependentlyofwhetherthetoolortheworkpieceisbeingtraversed.Whenprogramming,itisalwaysassumedthatthetooltraversesrelativetothecoordinatesystemoftheworkpiece,whichisintendedtobestationary.

20

Thefigurebelowillustrateshowtodeterminetheaxisdirections.

MachineCoordinateSystemTheorientationofthecoordinatesystemrelativetothemachinedependsonthemachinetype.Itcanberotatedindifferentpositions.Thedirectionsoftheaxesfollowthe"3-fingerrule"oftherighthand.Seenfromthefrontofthemachine,themiddlefingeroftheright-handpointsintheoppositedirectiontotheinfeedofthespindle.

Theoriginofthiscoordinatesystemisthemachinezero.Thispointisonlyareferencepointwhichisdefinedbythemachinemanufacturer.Itdoesnothavetobeapproachable.Thetraversingrangeofthemachineaxescanbeinthenegativerange.

90°90°

90°

<

21

WorkpieceCoordinateSystemTodescribethegeometryofaworkpieceintheworkpieceprogram,aright-handed,rightangledcoordinatesystemisalsoused.TheworkpiecezerocanbefreelyselectedbytheprogrammerintheZaxis.IntheXaxis,itliesintheturningcenter.RelativeCoordinateSystemInadditiontothemachineandworkpiececoordinatesystems,thecontrolsystemprovidesarelativecoordinatesystem.Thiscoordinatesystemisusedtosetreferencepointsthatcanbefreelyselectedandhavenoinfluenceontheactiveworkpiececoordinatesystem.Allaxismovementsaredisplayedrelativetothesereferencepoints.WorkpieceFixturingFormachining,theworkpieceisclampedonthemachine.Theworkpiecemustbealignedsuchthattheaxesoftheworkpiececoordinatesystemruninparallelwiththoseofthemachine.AnyresultingoffsetofthemachinezerowithreferencetotheworkpiecezeroisdeterminedalongtheZaxisandenteredinadataareaintendedforthesettableworkoffset.IntheNCprogram,thisoffsetisactivatedduringprogramexecution,forexample,usingaprogrammedG54command.

VI. SoftwareInterface Screenlayout

Statusarea Applicationarea

① Activeoperatingarea ⑧ Actualvaluewindow② Activeoperatingmode ⑨ T,F,Swindow③ Alarmandmessage④ promptarea ⑩Operatingwindowwithprogram

blockdisplay

⑤ Currenttimeanddate Tipandsoftkeyarea⑥ Programfilename ⑪ Informationline⑦ Programstatusindication ⑫ Horizontalsoftkeybar⑧ Activeprogramcontrol⑨ modes ⑬ Verticalsoftkeybar

Statusarea

22

Display Meaning

① Activeoperatingarea

Machiningoperatingarea

Systemdatamanagementoperatingarea

Programeditingoperatingarea

Programmanagementoperatingarea

Offsetparametersoperatingarea

Diagnosticsoperatingarea

② Activeoperatingmode

"REFPOINT"mode

"JOG"mode

Incrementaltraversein"JOG"mode

"MDA"mode

"AUTO"mode

Display Meaning

23

③

Alarmsandmessages

DisplaysactivealarmswithalarmtextThealarmnumberisdisplayedinwhiteletteringonaredbackground.Theassociatedalarmtextisshowninredlettering.Anarrowindicatesthatseveralalarmsareactive.Thenumbertotherightofthearrowindicatesthetotalnumberofactivealarms.Whenmorethanonealarmisactive,thedisplayscrollsthroughthealarmsinsequence.Anacknowledgementsymbolindicatesthealarmcancelcriterion.

DisplaysmessagesfromNCprogramsMessagesfromNCprogramsdonothavenumbersandappearingreenlettering.

④ Currenttimeanddate

⑤ Filenameofthecurrentpart

program

⑥

Programstate RESET Programcanceled/defaultstate

RUN Programisrunning

STOP Programstopped

⑦ Programcontrolin"AUTO"mode

Tipandsoftkeyarea

Screenitem Display Description

14

5

2 3

24

①

ReturnsymbolReturnstothenexthigher-levelmenuwiththefollowingkey:

② Informationline

Displaysnotesandinformationfortheoperatorandfaultstates

Screenitem Display Description

③ HMIstatusinformation

�/�

Lowercaseletterinputactive

RS232connectionactive

ConnectstoPLCProgrammingTool

④ Horizontalsoftkeybar

⑤ Verticalsoftkeybar

ProtectionlevelsTheSINUMERIK808Dprovidesaconceptofprotectionlevelsforenablingdataareas.Differentprotectionlevelscontroldifferentaccessrights.ThecontrolsystemdeliveredfromSIEMENSissetbydefaulttothelowestprotectionlevel7(withoutpassword).Ifthepasswordisnolongerknown,thecontrolsystemmustbereinitializedwiththedefaultmachinedata.Allpasswordsarethenresettodefaultpasswordsforthissoftwarerelease.

NOTICE

25

Beforeyoubootthecontrolsystemwithdefaultmachinedata,makesurethatyouhavebackedupyourdata;otherwise,alldataislostafterrebootingwithdefaultmachinedata.

Protectionlevel Lockedby Area

0 Siemenspassword Siemens,reserved

1 Manufacturerpassword Machinemanufacturers

2 Reserved

3-6 End-userpassword(Defaultpassword:"CUSTOMER")

Endusers

7 Nopassword Endusers

Protectionlevel1Protectionlevel1requiresamanufacturerpassword.Withthispasswordentry,youcanperformthefollowingoperations:

● Enteringorchangingallmachinedata

● ConductingNCcommissioning

Protectionlevel3-6Protectionlevel3-6requiresanend-userpassword.Withthispasswordentry,youcanperformthefollowingoperations:

● Enteringorchangingpartofthemachinedata

● Editingprograms

● Settingoffsetvalues

● Measuringtools

Protectionlevel7Protectionlevel7issetautomaticallyifnopasswordissetandnoprotectionlevelinterfacesignalisset.Theprotectionlevel7canbesetfromthePLCuserprogrambysettingthebitsintheuserinterface.Inthemenuslistedbelowtheinputandmodificationofdatadependsonthesetprotectionlevel:

● Tooloffsets

● Workoffsets

● Settingdata

26

● RS232settings

● Programcreation/programcorrection

Youcansettheprotectionlevelforthesefunctionareaswiththedisplaymachinedata(USER_CLASS...). 1.4.3 Thehelpsystem

TheSINUMERIK808Dcontrolsystemprovidescomprehensiveonlinehelp.Whenevernecessary,youcancallthehelpsystemfromanyoperatingarea.

Thehelpsystem

Pressthiskeyorthekeycombination<ALT>+<H>tocallthehelpsystemfromanyoperatingarea.Ifacontext-sensitivehelpexists,Window"①"opens;otherwise,Window"③"opens.

①Callsthecontext-sensitivehelpforthecurrenttopic:• Currentoperatingwindow• Alarmsselectedinthealarmspecificoperationarea• Machinedataorsettingdataselected

②CallstheOEM-developedPDFmanual

27

③Displaysallavailablehelpinformation:• Siemenshelpmanuals• OEM-developedhelpmanuals,ifany

SoftkeysinWindow"①"

UsethissoftkeytoselectcrossreferencesAcrossreferenceismarkedbythecharacters"≫...≪".Note:Thissoftkeyisdisplayedonlyifthecurrentpagecontainsacrossreference.

Searchesforaterminthecurrenttopic

Continuessearchforthenexttermthatmatchesthesearchcriteria

Exitsthehelpsystem

SoftkeysinWindow"②"

Zoomsinthecurrentview

Zoomsoutthecurrentview

Zoomsthecurrentviewtopagewidth

Jumpstothedesiredpage



Exitsthehelpsystem

SoftkeysinWindow"③"

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Expandshierarchicaltopics

Collapseshierarchicaltopics

Navigatesupwardsthroughthehierarchicaltopics

Navigatesdownwardsthroughthehierarchicaltopics

Openstheselectedtopicinthecurrenttopicrelevant

windowFunctionsthesameaspressingthefollowingkey:



Exitsthehelpsystem

VII. TurningonandReferencingMachineOperatingSequence

1. Switchonthepowersupplyforthecontrolsystemandthemachine.2. Releaseallemergencystopbuttonsonthemachine.3. Pressthecorrespondingaxistraversekeytoreferenceorhomethataxis

ByDefault,yourCNCmachinewillbein“Ref.Point”onbootup.

29

VIII. SettingUpToolsandWorkOffsetsOverviewInthischapter,wewilllearnhowto:

● Createthetoolsandcuttingedges.

● Enter/modifythetoolandworkoffsets.

● Enterthesettingdata.

SettingUpTools

OperatingSequence1. Selectthedesiredoperatingarea.

2. Openthetoollistwindow.

3. Openthelower-levelmenufortooltypeselection.

4. Selectadesiredtooltypewiththecorrespondingsoftkey.

5. Enterthetoolnumber(valuerange:1to31999;preferablyenteravaluelessthan100)andpositionofthecuttingedgeinthefollowingwindow.Thecontrolsystemsupportsamaximumof64toolsor128cuttingedges.

6. Usethissoftkeytoconfirmyoursettings.Thewindow

belowshowstheinformationofthenewtoolcreated.

30

CreateaNewCuttingEdge

1. Selectthedesiredoperatingarea.

2. Openthetoollistwindow.

3. Selectthetooltowhichyoudesiretoaddacuttingedge.

4. Openthelower-levelmenuforcuttingedgesettings.

5. Pressthissoftkeytocreateanewcuttingedgefortheselectedtool.Thecontrolsystemautomaticallyaddsthenewcuttingedgetothetoollist.

Notethatthemachinecanbeloadedwithamaximumof128cuttingedges,andamaximumofninecuttingedgescanbecreatedforeachtool.

6. Youcanenterdifferentlengthsandradiiforeachcuttingedgeaswell.

Otheroptionsforsettingupthecuttingedges: Resetall offsetvaluesoftheselectedcuttingedgetozero

Deletethe selectedcuttingedgeEnteringToolOffsetsThetooloffsetsconsistofthedatadescribingthegeometry,thewearandthetooltype.Eachtoolcontainsadefinednumberofcuttingedgeparametersdependentonthetooltype.

31

Besidesenteringthetooloffsetsinthetoollist,youcanalternativelydeterminethetooloffsetsbymeasuringthetoolmanually.


2. Openthetoollistwindowwhichcontainsalistofthetoolsandcuttingedgesthathavebeencreated.

3. Usethecursorkeystonavigateinthelist.

4. Enterthevaluesasrequiredintheinputfields(seetablebelowfortheparameterdescriptions).

5. Usethiskeyormovethecursortoconfirmyourentries.

ActivatingtheToolandStartingSpindle


2. Switchto"JOG"mode.

3. Openthe"T,S,M"window.

4. Enterthedesiredvaluesforthetoolnumber,cuttingedgenumberandspindlespeed(forexample,T1,D1and500rpm)inthe"T,S,M"window.


6. Selecttherotationdirectionofthespindleasrequired.

• M3:Spindlerotatesclockwise

• M4:Spindlerotatescounterclockwise

32

7. PressthiskeyontheMCPtoactivatethetoolandstartthe

SelectingtheHandwheel


2. PressthiskeyontheMCP.

3. Pressthedesiredaxistraversingkeywiththehandwheelicon.Thehandwheelisassigned.

Alternatively,youcanassignthehandwheelsusingthesoftkeys:


2. Openthemachinedatawindow.

3. Usethissoftkeytoopenthebasicmachinedatalist.Searchforthegeneralmachinedata"14512USER_DATA_HEX[16]"withcursorkeysorthefollowingsoftkeyandthenset14512[16].7=1.

+

33

4. Confirmyourinput.

5. Pressthisverticalsoftkeytoactivatethevaluechange.Notethatthecontrolsystemrestartstoacceptthenewvalue.

6. After the control system has booted, select the desiredoperatingarea.

7. PressthiskeyontheMCP.

8. Press this vertical softkey to open the handwheelassignmentwindow.

9. Select the desired handwheel number with the cursor

left/rightkey.

10. Presstherelevantaxissoftkeyforhandwheelassignment

ordeselection.

The symbol "☑" that appears in the window indicates ahandwheelhasbeenassignedtothespecificaxis.

MeasuringtheToolManuallyMeasuringthetoolintheXdirection



3. Openthemanualtoolmeasurementwindow.

34

4. PressthisverticalsoftkeytomeasurethetoolintheX

direction.

5. MovethetooltoapproachtheworkpieceintheXdirection.

6. Switchto"HANDWHEEL"mode.

7. Selectasuitableoverridefeedrate,andthenusethehandwheeltomovethetooltoscratchtherequiredworkpieceedge.

8. Entertheworkpiecediameterinthe"Ø"field(forexample,50mm).

9. SavethelengthvalueintheXaxis.Thetooldiameter,

radius,andcuttingedgepositionarealltakenintoaccount.

...

35

MeasuringthetoolintheZdirection



3. Openthemanualtoolmeasurementwindow.

4. PressthisverticalsoftkeytomeasurethetoolintheZdirection.

5. MovethetooltoapproachtheworkpieceintheZ

direction.



8. Enterthedistancebetweenthetooltipandtheworkpieceedgeinthe"ZØ"field,thatis"0".

9. SavethelengthvalueintheZaxis.

Repeattheaboveoperationsforothertoolsandmakesureyoumeasureallthetoolsbeforemachining,whichalsoeasesthetoolchangingprocess.

...

36

IX. SettinguptheWorkpieceAfterthemachineapproachesthereferencepoint,theactualvalueoftheaxiscoordinateisbasedonthemachinezero(M)ofthemachinecoordinatesystem.Amachiningprogram,however,isalwaysbasedontheworkpiecezero(W)oftheworkpiececoordinatesystem.Thisoffsetmustbeenteredastheworkoffset.Besidesmeasuringtheworkoffsetsbyscratchingtheworkpiecewiththetool,youcanalsoenterthevaluesasrequiredbyproceedingthroughthefollowingsteps.

OperatingSequence


2. Openthelistofworkoffsets.Thelistcontainsthevaluesofthebasicoffsetoftheprogrammedworkoffsetandtheactivescalingfactors,themirrorstatusdisplayandthetotalofallactiveworkoffsets.

3. Usethecursorkeystopositionthecursorbarintheinputfieldstobemodifiedandenterthevalues.

4. Confirmyourentries.Thechangestotheworkoffsetsare

activatedimmediately.

MeasuringtheWorkpieceYouneedtoselectthewindowwiththerelevantworkoffset(e.g.G54)andtheaxisyouwanttodeterminefortheoffset.ThefollowinggraphisanexampleabouthowtodeterminetheworkoffsetintheZaxis.

37

OperatingSequence1. Selectthedesiredoperatingarea.

2.Switchto"JOG"mode.

3.Openthelistofworkoffsets.

4.Openthewindowformeasuringtheworkoffsets.Notethatthisverticalsoftkeyisactiveonlyin"JOG"mode.

5.Traversethetool,whichhasbeenmeasuredpreviously,toapproachtheworkpieceintheZdirection.



8. Selecttheoffsetplanetosavein(forexampleG54).

9. Pressthisverticalsoftkey.TheworkoffsetoftheZaxisis

calculatedautomaticallyanddisplayedintheoffsetfield.

Repeattheoperationtosetupthe“X”Axis.

...

38

EnteringandModifyingData


2. Openthesettingdatawindow.

3. Positionthecursorbarintheinputfieldstobemodifiedandenterthevalues(seetablebelowfortheparameterdescriptions).

Usethiskeyormovethecursortoconfirmyourentries.

① Thefeedratein"JOG"mode.Ifthefeedratevalueiszero,thecontrolsystemwillusethevaluestoredinthemachinedata.

⑤ Programmableupperspeedlimitationatconstantcuttingrate(G96).

② Thespeedofthespindle. ⑥ Thefeedratewhichcanbeenteredherewillbeusedinsteadoftheprogrammedfeedratein"AUTO"modeifthecorrespondingfunctionisselected.

12

345

6

7

39

③ A limitation of the spindle speed in theMax.(G26)/

⑦ Forthreadcutting,astartpositionforthespindleis

④ Min. (G25) fields can only be performedwithin the limit values defined in themachinedata.

SettingTimeCounter


2. Openthesettingdatawindow.

3. Openthetimecounterwindow.

4. Positionthecursorbarintheinputfieldstobemodifiedandenterthevalues(seetablebelowfortheparameterdescriptions).

5. Usethiskeyormovethecursortoconfirmyourentries.Parametersinthewindowfortimersandworkpiececounters

12345678

40

① Thetotalnumberofworkpiecesproduced(totalactual)

⑤ TheruntimeoftheselectedNCprograminsecondsThedefaultvalueis0eachtimeanewNCprogramstartsup.MD27860canbesettoensurethatthisvaluewillbedeletedevenifthereisajumptothebeginningoftheprogramwithGOTOSorintheeventofASUBS(usedfortoolchangein"JOG"and"MM+"modes)andPROG_EVENTsstarting.

SettingRParameters1. Selectthedesiredoperatingarea.

2. OpenthelistofRparameters.

3. Usethecursorkeystonavigateinthelist,andenterthevaluesintheinputfieldstobemodified.

Note:YoucansearchforyourdesiredRvariablewiththefollowingsoftkey.Bydefault,thefunctionsearchestheRnumber.

YoucanpressthefollowingsoftkeytoactivatetheoptionofsearchingbyRname.DefinetheRnameasdesired,ifnecessary.


41

Additional“JogMode”Settings

①Opensthe"T,S,M"windowwhereyoucanactivatetools,setspindlespeedanddirection,andselectaGcodeorotherMfunctionforactivatingthesettableworkoffset.

⑥Displaystheaxisfeedrateintheselectedcoordinatesystem.

②Switchesthedisplaytotherelativecoordinatesystem.Youcansetthereferencepointinthiscoordinatesystem.

⑦Displaystheaxispositiondataintherelativecoordinatesystem.

③Opensthetoolmeasurementwindowwhereyoudeterminethetooloffsetdata.Fordetailedinformationaboutthiswindow,refertoSection"Measuringthetool(manually)(Page33)".

⑧Displaystheaxispositiondataintheworkpiececoordinatesystem.

④Opensthe"ManualMachinePlus"userinterface.Thissoftkeyisvisibleonlyifthissoftwareoptionispreconfiguredbythemachinemanufacturer.Fordetailedinformationaboutthiswindow,refertothemanual"ManualMachinePlus(Turning)".

⑨Displaystheaxispositiondatainthemachinecoordinatesystem.

⑤OpensthesettingswindowwhereyoucansetJOGfeedrateandvariableincrementvalues.

42

①Displaystheaxesthatexistinthemachine

coordinatesystem(MCS),workpiececoordinatesystem(WCS),orrelativecoordinatesystem(REL).Ifyoutraverseanaxisinthepositive(+)ornegative(-)direction,aplusorminussignappearsintherelevantfield.Iftheaxisisalreadyintherequiredposition,nosignisdisplayed.

④DisplaysthecurrentlyactivetoolnumberTwiththecurrentcuttingedgenumberD.

②Displaysthecurrentpositionoftheaxesintheselectedcoordinatesystem.

⑤Displaystheactualaxisfeedrateandthesetpoint(mm/minormm/rev).

③Displaysthedistancetraversedbyeachaxisin"JOG"modefromtheinterruptionpointintheconditionofprograminterruption.Fordetailedinformationaboutprograminterruption,refertoSection"Startingandstopping/interruptingapartprogram(Page84)".

⑥Displaystheactualvalueandthesetpointofthespindlespeed(r.p.m.).

Setting“Rel”CoordinateSystem



3. Pressthissoftkeytoswitchthedisplaytotherelativecoordinatesystem.

4. Usethecursorkeystoselecttheinputfield,andthenenterthenewpositionvalueofthereferencepointintherelativecoordinatesystem.

43

SettingJogData



3. Pressthishorizontalsoftkeytoopenthefollowingwindow:

4. Entervaluesintheinputfieldsandconfirmyourentries.

5. Ifnecessary,pressthisverticalsoftkeytoswitchbetweenthemetricandinchdimensionsystems.

Pressthis softkeytoconfirmyourchange.

Pressthis softkeytoexit.

X. PartProgramming

1 StoresNCprogramsforsubsequentoperations

2 ManagesandreadsOEMCYCLES3 TransferfilesviaUSB4 TransferfilesviaRS2325 Backupmanufacturerfiles6 Backupuserfiles7 Showsrecentlyaccessedfiles8 ExecutescurrentProgram9 Createsnewfileordirectory10 Searchesfilesordirectories11 Selectsallfilesforsubsequentoperation12 Copiesselectfiles/folderstoclipboard13 Pastesfiles/foldersfromclipboard14 Restorestolastoperation15 Opensadditionalsoftkeys

44

CreatingFilesorFoldersTocreateapartprogram,followthesesteps:1. Selectthedesiredoperatingarea.

2. Enterthefolderforthenewprogramtobecreated.

3. Pressthisverticalsoftkey.

4. Pressthissoftkeytoactivatethewindowforcreatinganewprogram.

5. Enterthenameofthenewprogram.Ifyoudesiretocreateamainprogram,itisunnecessarytoenterthefileextension".MPF".Ifyoudesiretocreateasubprogram,youmustenterthefileextension".SPF".Thecharacterlengthofaprogramnameislimitedto24Englishcharactersor12Chinesecharacters.Itisrecommendedthatyoudonotuseanyspecialcharactersintheprogramname.

6. Pressthissoftkeytoconfirmyourentry,andthenewpartprogrameditorwindowopenssubsequently.Entertheblocksinthewindow,whicharesavedautomatically.Thenewprogramiscreatedsuccessfully.

CreatingaProgramDirectory

Tocreateaprogramdirectory,followthesesteps:1. Selectthedesiredoperatingarea.

2. Enteradesiredfolderforthenewdirectorytobecreated.

3. Pressthisverticalsoftkey.

4. Pressthissoftkeytoactivatethewindowforcreatinganewprogramdirectory.

5. Enterthenameofthenewdirectoryandpressthissoftkeytoconfirm.

45

EditingPartPrograms


2. Entertheprogramdirectory.

3. Usethissoftkeyorthecursorkeystoselecttheprogramfiletobeedited.

4. Pressthiskeytoopentheprogramfile.Thesystemswitchesovertotheprogrameditorwindow.

5. Edittheblocksinthewindowasrequired(seetablebelowforthedescriptionsofeditingoptions).Anyprogramchangesareautomaticallystored.

BlockEditingOptions

Replacestheblocknumberfromthecurrentcursortotheprogramend

Searchesforstrings

Selectsthetextsegmentbeforethecursor

Copiesthetextsegments

Pastesthetextsegments

46

SearchforStringsProceedthroughthefollowingstepstosearchforstrings:

1. Pressthissoftkeyintheopenedprogrameditorwindow.

2. Pressthissoftkeytosearchviatext.Alternatively,youcansearchwithagivenlinenumberbypressingthefollowingsoftkey:

3. Enterthesearchtextorlinenumberintheinputfield,andpressthiskeytoselectastartingpointforsearch.

4. Pressthissoftkeytostartthesearch,orotherwise,pressthefollowingsoftkeytocancelthesearch:

EditingPartProgramsinMDAMode

In"MDA"mode,youcancreatenewprogramsorloadexistingprogramsfromdirectoriesonthecontrolsystem.Proceedthroughthefollowingstepstoeditpartprograms:


2. Switchto"MDA"mode.

47

ManagingPartPrograms1. Selectthedesiredoperatingarea.

2. Selectthestoragemediuminwhichyouwishtoperformthesearch.

3. Pressthisverticalsoftkeytoopenthesearchwindow.

4. Enterthecompletenamewithextensionoftheprogramfiletobesearchedinthefirstinputfieldinthesearchwindow.Tonarrowyoursearch,youcanenterthedesiredtextinthesecondfield.

5. Usethiskeytochoosewhethertoincludesubordinatefoldersorobserveupper/lowercase.

6. Pressthissoftkeytostartthesearch,orotherwise,pressthefollowingsoftkeytocancelthesearch:

RenamingPrograms


2. Choosethedesiredstoragelocationandpositionthecursoronthefileordirectorywhichyouwouldliketorename.

3. Presstheextensionsoftkeytoaccessmoreoptions.

4. Pressthisverticalsoftkeytoopenthewindowforrenaming.

48

5. Enteradesirednewnamewiththeextensionintheinputfield.

6. Pressthissoftkeytoconfirmyourentry,orpressthefollowingsoftkeytocancel:

ViewingandExecutingRecentPrograms1. Selectthedesiredoperatingarea.

2. Pressthissoftkeytoopenthelistofrecentfiles.Notethateventhedeletedfilesarealsodisplayedinthelist.

3. Positionthecursoronafileandpressthisverticalsoftkeytostartexecutingtheprogram.

ContourProgrammingFreecontourprogrammingenablesyoutocreatesimpleandcomplexcontours.Acontoureditor(FKE)calculatesanymissingparametersforyouassoonastheycanbeobtainedfromotherparameters.Youcanlinktogethercontourelementsandtransfertotheeditedpartprogram.

Thecontourcalculatorforturningtechnologyprovidesthefollowingfunctionsforthispurpose:

• Togglingbetweenradius/diameterprogramming(DIAMON,DIAMOF,DIAM90)• Chamfer/radiusatthestartandendofthecontour• Undercutsastransitionelementsbetweentwoaxiallyparallelstraightlines,whereone

runshorizontallyandtheothervertically(FormE,FormF,threadundercutacc.toDIN,generalundercut)

Proceedthroughthefollowingstepstoopenthecontoureditorwindow:

49


2. Enterthedesiredprogramfolder.3. Selectaprogramfile,andpressthiskeytoopenit

intheprogrameditor.

4. Pressthissoftkeytoopenthecontoureditorwindow.

① Anelementwasselectedusingthecursor

keys.Thissoftkeyenlargestheimagesectionoftheselectedelement.

⑤ Pressthissoftkeytotogglebetweentheselections.Thissoftkeyfunctionsthesameaspressingthefollowingkey:

② Zoomsthegraphicin/out/automatically. ⑥ Definesapoleforcontourprogrammingin

polarcoordinates.ThepolecanonlybeenteredinabsoluteCartesiancoordinates.

③ Whenyouselectthissoftkey,youcanmovetheredcross-hairwiththecursorkeysandchooseapicturedetailtodisplay.Whenyoudeactivatethissoftkey,theinputfocusispositionedinthecontourchainagain.

⑦ Exitsthecontoureditorandreturnstotheprogrameditorwindow,withouttransferringthelasteditedvaluestothemainprogram.

④ Ifyoupressthissoftkey,helpgraphicsaredisplayedinadditiontotherelevantparameter.Pressingthesoftkeyagainexitsthehelpmode.

⑧ Savesthesettingsforthestartpoint.

50

ProgrammingaContour1. Selectthedesiredoperatingarea.

2. Selectthissoftkey.

3. Selectaprogramwithcursorkeys.

4. Pressthiskeytoopentheprogram.

5. Pressthissoftkeytoopenthecontoureditor.

Recompile

Whentheprogrameditedinthecontoureditorisopenedintheprogrameditor,ifyoupositiontheeditorcursorinacommandlineofthecontourprogramandthenpressthissoftkey,themainscreenofthecontoureditoropensandyoucanrecompiletheexistingcontour.

SettingaStartPointWhenenteringacontour,beginatapositionwhichyoualreadyknowandenteritasthestartingpoint.

51

Selectthedesiredoperatingarea.Enterdesiredfolderbuypressingthe“Input”Key.

Selectfile,andpress“Input”keytoopenfileintotexteditorwindow.

Press“Cont.”keytoopenthecontoureditorwindow.

Pressingthe“Alternative”keywillallowusertotogglebetweenselections.

Youcandefineapoleforcontourprogrammingbypressingthissoftkey.

Pressthe“Accept”softkeytocreateastartingpoint.

ProgrammingContourElements

① OpenstheprogramforprogrammingaverticallineintheXdirection.

⑤ Accessadditionalsoftkey.

② OpenswindowforprogrammingintheZaxisdirection.

⑥ Returnstotheeditorwithoutacceptinganycurrentchanges.

52

③ Openswindowforangulardialog. ⑦ Acceptsdefinedcontour.

④ Opensthearcprogrammingwindow.

Pressthissoftkeytodisplayaselectionlistofalltheparametersfortheselectedcontourelement.Ifyouleaveanyparameterinputfieldsblank,thecontrolassumesthatyoudonotknowtherightvaluesandattemptstocalculatethesefromthesettingsoftheotherparameters.Thecontourisalwaysmachinedintheprogrammeddirection.

Inputswitchover

Thissoftkeyisdisplayedonlyincaseswherethecursorispositionedonaninputfieldwithseveralswitchoversettings.

Selectdialog

Someparameterconfigurationscanproduceseveraldifferentcontourcharacteristics.Insuchcases,youwillbeaskedtoselectadialog.Byclickingthissoftkey,youcandisplaytheavailableselectionoptionsinthegraphicdisplayarea.Selectthissoftkeytomakethecorrectselection(greenline).Confirmyourchoicewiththefollowingsoftkey:

Changeaselecteddialog

Ifyouwanttochangeanexistingdialogselection,youmustselectthecontourelementinwhichthedialogwasoriginallychosen.Bothalternativesaredisplayedagainwhenyouselectthissoftkey.

Clearaparameterinputfield

Youcandeletethevalueintheselectedparameterinputfieldwiththissoftkeyorthefollowingkey:

53

Saveacontourelement

Ifyouhaveenteredtheavailabledataforacontourelementorselectedadesireddialog,pressingthissoftkeyallowsyoutostorethecontourelementandreturntothemainscreen.Youcanthenprogramthenextcontourelement.

Appendcontourelement

Usethecursorkeystoselecttheelementinfrontoftheendmarker.Usethesoftkeystoselectthecontourelementofyourchoiceandenterthevaluesyouknowintheinputscreenforthatelement.Confirmyourinputswiththefollowingsoftkey:

Selectcontourelement

Positionthecursoronthedesiredcontourelementinthecontourchain,andselectitusingthiskey.Theparametersfortheselectedelementwillthenbedisplayed.Thenameoftheelementappearsatthetopoftheparameterizationwindow.Ifthecontourelementcanberepresentedgeometrically,itishighlightedaccordinglyinthegraphicdisplayarea,i.e.thecolorofthecontourelementchangesfromwhitetoblack.

Modifyingcontourelement

Youcanusethecursorkeystoselectaprogrammedcontourelementinthecontourchain.Pressthiskeytodisplaytheparameterinputfields.Theparameterscannowbeedited.

Insertacontourelement

Usethecursorkeysinthecontourchaintoselectthecontourelementinfrontofthepositionforthenewelement.Thenselectthecontourelementtobeinsertedfromthesoftkeybar.Afteryouhaveconfiguredtheparametersforthenewcontourelement,confirmtheinsertoperationbypressingthefollowingsoftkey:

Subsequentcontourelementsareupdatedautomaticallyaccordingtothenewcontourstatus.

54

Deletecontourelement

Usethecursorkeystoselecttheelementyouwishtodelete.Theselectedcontoursymbolandassociatedcontourelementintheprogramminggraphicarehighlightedinred.Thenpressthissoftkeyandconfirmthequery.

Closethecontour

Bypressingthissoftkey,youcanclosethecontourfromtheactualpositionwithastraightlinetothestartingpoint.

Undoaninput

Byselectingthissoftkeyyoucanreturntothemainscreenwithouttransferringthelasteditedvaluestothesystem.

Contoursymbolcolors

Themeaningofthesymbolcolorsinthecontourchainontheleftofthemainscreenisasfollows:

Icon Significance

Selected Symbolcolorblackonaredbackground->ElementisdefinedgeometricallySymbolcolorblackonalight-yellowbackground->Elementisnotdefinedgeometrically

Notselected Symbolcolorblackonagraybackground->ElementisdefinedgeometricallySymbolcolorwhiteonagraybackground->Elementisnotdefinedgeometrically

ParametersforContourElements

55

① Togglebetweenincremental/absolutepositioning.

④ Specifiesasidecontour.Graphicswindowwillreflectgeometrydata.

② Selectsachamferorradiusfortransitioningintonextelement

⑤ Graphicswindow.Pan/Zoom/Movetoviewgeometrydata.

③ Inputfieldfortypingindescriptivecomments.Allcommentsmustbeginwitha;atthebeginningofline.

⑥ Contourchainwindow.

① Directionofrotationofthecirculararc: ④ Absolute/IncrementalpositionsofcirclecenterpointinX/Zdirections.

56

② Radiusofcircle. ⑤ Contourchainthatincludesstartpointandallgeometryelements.

③ Absolute/Incrementalpositions ⑥ Graphicswindowwhichdisplaysgeometryelements

Transitions

Thefollowingadditionalparametersaredisplayedafteryoupressthissoftkey:

Parameter Description

α1 StartinganglewithreferencetoXaxis

α2 Angletoprecedingelement;tangentialtransition:α2=0

β1 EndanglewithreferencetoXaxis

β2 AngleofapertureofcircleAtransitionelementcanbeusedwheneverthereisapointofintersectionbetweentwoneighboringelements;thiscanbecalculatedfromtheinputvalues.Youcanchoosetoinserteitheraradius(RND),achamfer(CHR)oranundercutasthetransitionelementbetweenanytwocontourelements.Thetransitionisalwaysfixedtotheendofacontourelement.Youselecttransitionelementsintheparameterinputscreenfortherelevantcontourelement.

Radiusorchamferatthestartortheendofaturningcontour:Insimpleturningcontoursachamferorradiusmustoftenbeappendedatthestartandendofthecontour.Achamferorradiusterminatesanaxis-parallelcontoursectionontheblank:

Figure4-2 Contourwithradiusorchamfer

57

Youselectthedirectionoftransitionforthecontourstartinthestartingpointscreen.Youcanchoosebetweenchamferandradius.Thevalueisdefinedinthesamemannerasforthetransitionelements.Inaddition,fourdirectionscanbeselectedinasingleselectionfield.Youselectthedirectionofthetransitionelementforthecontourendintheendscreen.Thisselectionisalwaysproposed,evenifprecedingelementswereassignednotransition.ContourchainOnceyoucompleteorcanceltheprogrammingofacontourelement,youcannavigatearoundthecontourchain(leftonthemainscreen)usingthecursorkeys.Thecurrentpositioninthechainiscolor-highlighted.Theelementsofthecontourandpole,ifapplicable,aredisplayedinthesequenceinwhichtheywereprogrammed.Youcanselectanexistingcontourelementwiththefollowingkeyandreassignitsparameters:

Anewcontourelementisinsertedafterthecursorwhenyouselectoneofthecontourelementsontheverticalsoftkeybar;theinputfocusisthenswitchedtotheparameterinputontherightofthegraphicdisplay.Programmingalwayscontinuesaftertheelementselectedinthecontourchain.Youcandeletetheselectedelementfromthechainbyselectingthefollowingsoftkey:

GraphicswindowThegraphicswindowdisplaystheprogressofthecontourchainasyouconfiguretheparametersforthecontourelements.Theelementyouhaveselectedisdisplayedinblackinthegraphicswindow.Thecontourisdisplayedtotheextentitcanbeinterpretedbythecontrolonthebasisofparameterinputs.Ifthecontourisstillnotdisplayedintheprogramminggraphic,furthervaluesmustbeentered.Checkthecontourelementsyouhavealreadyprogrammed,ifrequired.Youmayhaveforgottentoenteralloftheknowndata.Thecoordinatesystemscalingisautomaticallyadaptedtochangesinthecompletecontour.Thepositionofthecoordinatesystemisdisplayedinthegraphicswindow.Anelementwasselectedusingthecursorkeys.Pressingthefollowingsoftkeyallowsyoutoenlargetheimagesectionoftheselectedelement:UndercutsTheformEandFundercutandformDIN76andgeneralthreadundercutfunctionsareonlyactivatedwhentheturningtechnologyisenabled.FormEandFundercutsaswellasthreadundercutsareavailableonlyiflevelG18isset.Undercutsarepermittedonlyoncontouredgesoftherotationalbody,whichruninthedirectionofthelongitudinalaxis(usuallyparalleltotheZaxis).Thelongitudinalaxisisidentifiedbythemachinedata.

58

ThemachinedataMD20100$MC_DIAMETER_AX_DEFforturningmachinescontainsthenameofthetransverseaxis(usuallyX).TheotheraxisinG18isthelongitudinalaxis(usuallyZ).IfMD20100$MC_DIAMETER_AX_DEFdoesnotcontainanameorcontainsanamethatdoesnotconformtoG18,therearenoundercuts.Undercutsonlyappearoncornersbetweenhorizontalandverticalstraightlines,includinganystraightlines,whichareat0°,90°,180°or270°.Atoleranceof±3°isrequiredhere,sothatconicalthreadsarealsopossible(theseundercutsdonotmeetthestandardinthiscase).SelectinganundercutformWhenyouchoosethetransitionelementinthecontourprogrammingwindow,youcanusethefollowingsoftkeytoselectanundercutasatransitionelement:

Youcansubsequentlydefinetheundercutformbytogglingbetweentheselectionsinthecorrespondinginputfields.

Inthecaseofstandardthreadundercuts,thecharacteristicsizeofthethreadpitchisP.Thedepth,lengthandtransitionradiusoftheundercutarecalculatedaccordingtotheDINstandard.The(metric)threadpitchesspecifiedinDIN76canbeused.Theentryanglecanbefreelyselectedinthe30°-90°range.Ifthediameterisknownwhenselectingtheundercut,anappropriatethreadpitchissuggested.FormsDIN76A(externalcontrol)andDIN76C(internalcontrol)areavailable.Theprogramdetectsthetwoformsautomaticallyusingtheirgeometryandtopology.BasedonthethreadundercutaccordingtoDIN,youcanusethegeneralundercuttypetocreatespecificundercuts,e.g.forinchthreads.SpecifyingContourElementsUsingPolarCoordinatesThedescriptiongivenaboveofdefiningthecoordinatesofcontourelementsappliestothespecificationofpositionaldataintheCartesiancoordinatesystem.Alternatively,youhavetheoptiontodefinepositionsusingpolarcoordinates.Whenprogrammingcontours,youcandefineapoleatanytimepriortousingpolarcoordinatesforthefirsttime.Programmedpolarcoordinatessubsequentlyrefertothispole.Thepoleismodalandcanbere-definedatanytime.ItisalwaysenteredinabsoluteCartesiancoordinates.ThecontourcalculatorconvertsvaluesenteredaspolarcoordinatesintoCartesiancoordinates.Positionscanbeprogrammedinpolarcoordinatesonlyafterapolehasbeenspecified.ThepoleinputdoesnotgenerateacodefortheNCprogram.

59

PoleThepolarcoordinatesarevalidinthelevelselectedwithG17toG19.Thepoleisacontourelementthatcanbeedited,whichitselfdoesnotcontributetothecontour.Itcanbeenteredwhenthestartingpointofthecontourisdefinedoranywherewithinthecontour.Thepolecannotbecreatedbeforethestartingpointofthecontour.Thissoftkeyallowsyoutospecifyapoleandcanonlybeenteredinabsolute

Cartesiancoordinates.Thissoftkeyisalsopresentinthestartingpointscreen.Thisenablesthepoletobeenteredatthestartofacontour,sothatthefirstcontourelementcanbeenteredinpolarcoordinates.FurthernotesIfthestraightlinethatwasgeneratedwithclosecontourislinkedtothestartelementofthecontourwitharadiusorchamfer,theradiusorchamfermustbespecifiedexplicitlyasfollows:

● Closecontour,inputkey,enterradius/chamfer,acceptelement.Theresultthencorrespondsexactlytowhatwouldoccuriftheclosingelementweretobeenteredwiththeradiusorchamfer.

Closecontourcanonlybeusedforenteringcontourelementsinpolarcoordinatesifthestartingpointofthecontourwassettopolarandthesamepoleisstillvalidwhenthecontourisclosed.Inputswitchover:Cartesian/polarThefollowingcontourelementscanbeenteredoptionallyinpolarcoordinatesonlyafterapolehasbeendefined,whetherthiswasdoneattheoutsetorlaterintheprocess:

● Circulararcs,● Straightlines(horizontal,vertical,anydirection)

ToswitchoverbetweenCartesianandpolarcoordinates,additionaltogglefieldsaredisplayedintheprogrammingwindowsforthecontourelementsofobliquelinesandcirculararcs.Atogglefieldisnotdisplayedifnopoleexists.InputfieldsanddisplayfieldsarethenonlyavailableforCartesianvalues.Absolute/incrementalinputAbsoluteandincrementalpolarcoordinatescanbeinputfor"polar/Cartesian".Theinputfieldsanddisplayfieldsarelabeledinkandabs.Absolutepolarcoordinatesaredefinedbyanabsolutedistancetothepolethatisalwayspositiveandanangleintherangeof0°...+/-360°.Whenabsolutedimensionsarespecified,theangularreferenceisbasedonahorizontalaxisoftheworkingplane,e.g.XaxiswithG17.Thepositivedirectionofrotationrunscounter-clockwise.Ifthereareseveralinputpoles,thedefinitivepoleisalwaysthelastpolebeforetheinputoreditedelement.Incrementalpolarcoordinatesrelatetoboththedefinitivepoleandtheendpointoftheprecedingelement.

60

Foranincrementalinput,theabsolutedistancetothepoleiscalculatedusingtheabsolutedistancefromtheendpointoftheprecedingelementtothepoleplusthelengthincrementthatwasentered.Theincrementcanbepositiveornegative.Theabsoluteangleiscalculatedaccordinglyusingtheabsolutepolarangleoftheprecedingelementplustheangularincrement.Hereitisnotnecessaryfortheprecedingelementtohavebeenenteredaspolar.Incontourprogramming,thecontourcalculatorconvertstheCartesiancoordinatesoftheprecedingendpointusingthedefinitivepoleintopolarcoordinates.Thisalsoappliesiftheprecedingelementhasbeengiveninpolarcoordinates,sincethiscouldrelatetoanotherpoleifapolehasbeeninsertedinthemeantime.

Polechangeexample

XI. AutomaticMachiningPressingthe“Machine”and“Auto”softkeyontheMCUpanel

61

1. Zoomsintheactualvaluewindow. 6. DisplayscurrentG/Mcodes2. Selectprogramtest,dryrun,Optional

stop,andblockskipping7. Displaysauxiliaryfunctions.

3. Searchfordesiredblocklocation 8. Displayscurrentfeedrate.4. Activatessimulation 9. Displayscycletimes/partcounter5. Fixesincorrectprogramblocks SimulationByusingthebroken-linegraphics,theprogrammedtoolpathcanbetraced.Beforetheautomaticmachining,youneedtoperformthesimulationtocheckwhetherthetoolmovesintherightway.

Selectthedesiredoperatingarea.

Movecursortoselectprogramforsimulation.Press“Input”keytoopenprogram.

Switchto“Auto”mode.

Pressthissoftkeytoentersimulationmode.

Pressthiskeytostartstandardsimulation.

Ifyouarenotcurrentlyin“Auto”mode,youwillseetheabovemessage.Pressthe“Auto”softkey,andhitcyclestartagain.

ProgrammingUsingSiemensDialect ForfurtherprogramminginstructionsonusingSiemenscycles,pleaseclickthelinkbelow.

62

ClickPictureorHEREtodownload.pdfmanual.

ProgrammingUsingISOGCodeLanguageForfurtherprogramminginstructionsonusingSiemenscycles,pleaseclickthelink

below.

ClickPictureorHEREtodownload.pdfmanual.

63

XII. MachineToolSettingsandAdjustments

Themachinehaspassedqualifiedcommissionandinspectioninourfactory,theuserdoesnot

have to readjust. After the machine has been in service for an extended period of time,

adjustmentstotheballscrewassemblymaybenecessary.Followtheprocedurebelow:

• JogCarriagetomiddleoftravel

• Powerdownmachine

• Removecablesfromaxismotor

• Removescrewssecuringmotortolathecasting

• Pullmotorinthedirectionofballscrew

• Removejamnutsonbothendsofballscrew

• Tightenprecisionlocknutsatbothends

• Retorquejamnuts

XIII. CommonFaultsRemoval

IfyourCNCmachinetoolhasafault,checktoseeifsupplyvoltage,airsupplyifnecessary,and

breakersareinanoperablestate.Pleasegiveusacallifyouhavequestions.

Commonfaultitems,andfaultcausesandhandlingmethodslistedbelow.

Number CommonFault FaultCause HandlingMethods

Spindle

1

Beltneeds

adjustment

Adjustorreplacethebelt

Figure8-1:BallScrewStructure

64

Spindlerunning

noise

Beltpulleyofmain

motorisloose

Adjustlocknutontaper-lock

Spindlebearingshave

beenworndown

Replacebearings

2 Spindlespeed

inaccurate

Spindledrivewith

problem

Checkspindledrivesystem,check

faultcodesonspindledrive

3 Spindleorientation

inaccurate

Timingpulleyisloose. Adjustlocknutontaper-lock,

reorientation

Spindledriveerror Checkspindledrivesystem,correct

output,reorientation

Axes

4

Axispositionnot

returningtozero

FaultyLimitSwitch

Checklimitswitchintegrity.Limit

switchesmustbefreeofdebrisand

coolant

Tripdogneeds

adjustment.

Checkandadjustzeroposition

5 Backlash Spidercouplerloose Tightensetscrewssecuringnutto

ballscrew,andnuttoaxismotor

Ballscrewnutsloose Checkscrewsintegrity,adjustwhen

necessary.

6

Axisrunningwith

noise

Lackoflubricationoil Stopmachinetocheckthe

lubricationoilsupplydelivery

system.

Ballscrewbearingis

broken

Stopmachinetocheck,repairor

replace

Ballscrewnutis

broken

Stopmachinetocheck,repairor

replace

65

Guidewayisbroken Stopmachinetocheck,repairor

replace

AutoLubricationSystem

7

Nolubrication

pressure

Pumpisnotworking Checkcontrolcircuitandpump,

repairandreplace

Oilcircuitwithair

bubbles

Removeoillinesandmanually

operatepumptoremoveairfrom

withinlines.

Oilfracturesorloose Checkandtightenalloilpipeand

replacebrokenlines

Debriswithinoil Replacewithcleanoilasrequired

CoolantSystem

8 Nocoolantflow Directionofcoolant

pumpmotorrotation

iswrong

Swaplegsoncoolantmotorlines

U/V/W

Lowcoolantlevel Fillunitwithspecifiedcoolant.

ProcessingQualityProblem

9

Machiningoutside

specifiedtolerance

Ballscrewplayistoo

large

Checktheplayinballscrewoutlined

above

Checktooloffset

library

Checkwear/radialvaluesorcorrect

Ballscrewlocknuts

loose

Checklocknuts,andtightenif

necessary

10

T.I.R.outof

tolerance

Spindlebearingsloose Indicatespindleboreandcheck

T.I.R.Tightenbearings

Spindlebearings

damaged

Replacebearings

66

11 Taperofwork

pieceisoutof

tolerance

Parallelismofspindle

centerlineandZaxis

isoutoftolerance

Checkbedfortwistwithamachinist

level

Misalignmentof

spindleandZaxisis

outofalignment

Adjustmisalignmentquantityof

spindleaxisandZaxis

12

Inaccuratethreads Mainbeltloose Tensioningmainbelt

Processprogram Checkprocessprogram

Settingofsystem

servoparameter

Optimizeservoparameter

13

Breakingtaps

inconsistent

Thechoiceofcutting

fluid

Choosesuitablecuttingfluidin

accordancetomaterial.

Wrongfeeds/speeds Choosesuitablecuttingspeed

Processprogram Chooserigidtappingprogramming

The choice of tool

holder

Choosededicatedtappingholder

Setting of system

parameter

Adjusttappingparameter

TurretIndexing

14 Turretremains

unlockedafter

indexing,even

aftermotorstops

running,still

withoutcirculate

finishedsign

SSR(solidstaterelay)

fault

ReplaceSSR(solidstaterelay)

Turretcontrolsystem

fault

Checkwhetherthemotorpower

switchisclosedin5milliseconds

afterproximityswitchsendsout

signal,itcanbecheckedwith

oscilloscope

Proximityswitchfault Replaceproximityswitch

67

15

Turretspinspast

specifiedtool

position

Encoderfault Turnturretcrankandcheckencoder

signal,ifitisinvalid,replace

encoder

Proximityswitchfault Turnturretcrankandcheck

proximityswitchsignal,ifitis

invalid,replaceproximityswitch

Controlcircuitfault Checkdifferentsignals(suchastool

request,encoder,feedback,

proximityswitch,etc.),whether

theyareinthecorrectorder,and

whethertheyareavailableinthe

righttime

16 Indexingwith

abnormalnoise

Looseconnections Torquefastenerstospecsoutlined

inturretmanual

17 ToolrotationIs

rough

Loadofturretdiscis

imbalance

Repositiontoolstoimprovebalance

18 Turretmotor

overheatingalarm

Indexingcycletoo

frequently

Decreaseindexingcycletimesper

minute(Maximum10times/min)

Powersupplyisoutof

balance

Checkthe3-phasevoltage,change

orafterifitnecessary

Communication

19

Unabletouse

RS232

communication

Operation Checkrelatedsystemoperation

manuals

Parameter Checkwhethertheparametersof

thetransmissionsoftwareare

unifiedwiththerelatedsystem

transmissionparameters.

Transmissioncable CheckwhethertheRS232serialport

iscorrect,checkwhetherthe

68

operationboxRS232interfaceto

thesystemofattachmentiscorrect

Systemfault Checksystemalarm

RestartMachineAfterMakingAdjustments

1) Afterrepairandadjustment,cleanandremovevarioustoolsandremovetrashfrom

workplace.

2) BeforerunningthemachineinAUTOmode,operatethemachineinmanualmodeto

makesureeverythingisfunctioningproperly.

3) RechecktoolandworkoffsetsbeforerunninginAUTOmode.

XIV. MachineMaintenanceDailyMaintenance

1) LubricationSystem--Checkwhethertheoilsupplypressureofthelubricationsystemis

innormalstate,ifaproblemarises,adjusttonormalrequirements.Keepthewaylube

oilintheoptimaloperatingrange.Oilreservoirisclearlymarked.

2) Theoperatorshouldcleanmachineattheendofday.Removecoolantanddebrisfrom

waycovers,carriage,andATC/toolblocksanddisposeasnecessary.

3) Ifusingawashdownhose,donotdirectsprayintoelectricalcabinetoraxismotors.

4) Donotusehighpressureairtocleanmachinetool.

WeeklyInspection1) ElectricControlCabinetofMachineTool–Checkthecontrolsystemandelectrical

componentsintheelectriccabinet,makesuretheyarecleanandwithoutdust.Check

theworkingconditionoftheelectricalcabinetfansandcleanfilterswhennecessary.

2) MotorsandLimitSwitches–Checkifthereisanydust,chipsandsludgegatheredonthe

motorandswitches,cleanasnecessary.

3) CoolingSystem–Checkwhetherthecoolantinsystemisinthenormalcondition.

Agitate,replaceoradjustconcentrationwhennecessary.

69

MonthlyInspectionandMaintenance1) GuideWaysandBallScrews–Overanextendedperiodoftime,debrisandcoolantcan

collectbelowtheaxiswaycovers.Removethewaycoversandcleanwaysandscrewsas

necessary.Donotusecompressedair.Simplywipedownslidingsurfacesandscrews,

andlubricatewithfreshwaylubewhenfinished.

2) ElectricalDevices

a. Checktheoperationofallelectricalsafetydevicesincludingthelowlevelalarmon

thelubricationsystem,limitswitch,homingswitchandsoon.

b. Checkallthecables,conduitlines,checkingforwearanddamage.

c. Checkthegeneraloperationandcleanlinessoftransformerandmotor.Note:ifany

problemsarefound,fixasnecessaryorcallourtechnicaldepartmentforguidance.

XV. M-CodeListM00 ProgramStop

M01 OptionalStop

M02 ProgramEnd

M03 SpindleClockwise

M04 SpindleCounter-clockwise

M05 SpindleStop

M06 AutomaticToolChange

M08 CoolantOn

M09 CoolantOff

M10 ChuckClamp

M11 ChuckRelease

M19 SpindleOrientation

M30 ProgramStop

M66 RobotArmSignal

70

PLCWarningInformationPleasereferencethePLCmanualfromSiemensforfurtherinformation.Belowisapartiallistof

PLCalarmsthataremanufacturespecific.

700002 Programmedtoolpositiondisagreeswithactual

Description Toolnumberdoesnotmatchrequiredtool

Solution 1.T.S.MchangedtotoolNo.1

2.Checkservomodule,turretmotorencoderandtheconnection

betweenmotorandturret.

700003 Lowwaylubepumppressure

Description Press lubrication start button, lubrication pump unit pressure

detectionswitchnotclosed

Solution Checkpumpcirculationcircuitfortrappedairordebris

700004 Waylubelevellow

Description Upperleveldetectionswitchoflubricationpumpunitnotclosed

Solution 1.Checkcapacityinsideoiltank

2.Checkliquidlevelswitch

700006 Coolantpumpmotoroverload

Description Waterpumpcircuitbreakerinsideelectricalcabinettripped

Solution Check if breaker set overload current matches with coolant

pump,andcheckifmotorisoverload.

700016 Drivernotready

Description PPUandservomodulenotready

Solution Checkthetwomodulesanditswiring

700031 MCPpanelfailure

Description Machineoperationpanelfailure

Solution Checkpanelandassociatedwiring

700032 Turretinunlockstate

Description Remindermessage

Solution

71

700033 Turrethandwheelisactive

Description Remindermessage

Solution

700034 Closechuckbeforeoperation

Description Reminderinformation.

Solution Closechuckandresumeoperation

700035 SafetyDoorisopen

Description Closedoorandresumeoperation

Solution Closedoorandresumeoperation

700036 Guarddooropen,cannotoperate

Description Reminderinformation

Solution Operateitafterclosingguarddoor

700037 ChuckUnclamped,


Solution Closechuck,resumeoperation

700038 Xaxishandwheeliseffective


Solution

700039 Zaxishandwheeliseffective


Solution

XVI. PLCFunctionParametersCNC Machine PLC

Parameter

Meaning

MD14510[20] =0Withoutguarddoor

72

=1Withguarddoor

MD14510[21] =0Withoutlivetooling

=1Withlivetooling

MD14510[22] =0Withouthydraulictailstock

=1Withhydraulictailstock

MD14510[24] Lubricationintervalunit:Min.(setvalue30min)

MD14510[25] Lubricationtimeunit:MS(Setvalue10ms)

MD14510[26] =0Footswitchtype1(Note1)

=1Footswitchtype2(Note1)

MD14510[27] =0Withoutrobot(Robotarm)

=1Withrobot(Robotarm)

MD14510[28]

=1Turretjogbuttoneffective;Turrethandwheeleffective

=0Turretjogbuttoninvalid;TurrethandwheelinvalidT

=0,andMD14510[21]=1;Livetoolingeffective

MD14512[0]:

Bit0 =0Withouthydraulictailstockrelease/clamp

=1Withhydraulictailstockrelease/clamp

Bit1 =0Withouthydraulictailstocksleevepositiondefectiveswitch

=1Withhydraulictailstocksleevepositiondefectiveswitch

Bit2 =0Servoturret

=1Hydraulicturret

Bit3 =012-stationservoturret

=18-stationhydraulicturret

Bit4 =012-stationhydraulicturret

=18-stationhydraulicturret

Bit5 =0Withoutchipconveyor

=1Withchipconveyor

Documents

Operator’s Manual - Smithy Manual_0.pdf · Table of Contents I. Unloading Machine ... Operating Sequence ... operator’s manual for that machine and control type. 5) Never attempt