TC-321n INSTRUCTION MANUAL8 BAY: 4 hee Le iF un pee aes osINTRODUCTION Correct usage of the machine is most critical to assure the expected machine capabilities and functions as well as operators’ safety. Read this Instruction Manual thoroughly before starting operation. “All ights reserved : No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form without prior permissian of the manufacturer “The contents of this Manual are subject to change without notice. “The contents of this Manual are compiled with utmost care. I you encounter any question or doubt, however, please contact us or your local dealer. © Copyright 1990 BROTHER INDUSTRIES, LTD. ALL RIGHTS: RESERVED.Chapter 1 Introduction 1-1 How to Read This Manual 1-2 Table of Contents1-1 How to Read This Manual This Manual is so designed as to enable operators to fully understand operation of the machine. Read the Manual carefully before starting operation. 1-1-1 Construction of Manual Explanation of each subject is basically composed of two spread pages so that a complete contents of subject can be referred to at one time without tuning pages. For example, subjects such as “Machine Specifications”, “Setting of Start Point’. eto. cover two pages respectively. However, note that there are some exceptions which exceeds 2 spread pages. In such a case, number (1) , 2)... is put after the title as follows. Relocation of Machine (1) Relocation of Machine (2) TITLE OF THE SECTION 9-6 SETTING PROCEDURE OF ‘THE MACHINING KENU SCREEN ON OPERATION “REFERENCE” PANEL HARK PAGE No.1-1-2 Mark indications ‘The marks used in this Manual indicate as follows : Mark Meanings cE | Precautions @) Reference items or Section No. to be referred to. : fed} ‘Warnings. Utmost care is required when this buzzer mak is used, 1-1-3 Quick Reference of Subject Il To see the explanation of functions etc. : See the “TABLE OF CONTENTS" page.1-2 Table of Contents Chapter 1. Introduction 1-1 1-2 How to Read This Manual.. 4-1-1 Construction of Manual 4-1-2. Mark Indications. 4-4-3 Quick Reference of Subject. Table of Contents... Chapter 2. General Cautions 2-4 2-2 General Precautions. nei 2-1-1 Mounting Tool Holders into Magazine. 2-1-2 Upward Axis Movement from Z zero position 244-8. Servo Motor Error. 2-1-4 During Memory Operation... For Safety Operation. 2-2-1 Before Power On. 2-2-2 Before Starting Operation. 2-2-3 During Operation 2-2-4 Troubles During Operation. 2:25 Before Power Off 2-2-6 Other Precautions Chapter 3. General System Description 3-1 Main Features of TC-321..... 3-1-1, Automatic Tool Changer (ATC) 3-1-2 Tapping Cycle.... 34-3 Spindle Headstock:.2. seen 3:1-4 Servo Mechanism (X.Y,Z Axes) 34-5 CNC Unit Basic Construction. 3-21 Basic Construction 3-2-2 Axis Movement (X,Y.2).3-3 O Machining Capability. 1 Safety Devices Name of Each Component.. 3-3-1 Machine Overall View. 3-3-2 Machine Back Sid Dimensional Drawings. Table Dimensions and Machining Range... 3-5-1 Table Dimensions .. 3-5-2 Machining Range... Machine Specifications. List of Accessories ‘3-7-1 Standard Accessories... 3-7-2 Optional Accessories... Specifications of CNC Unit..... Characteristics of Spindle Motor. 3-1-1, Main Satety Devices... 3-11-2 Location of Limit Switches. Chapter 4. Installation 4-1 Environmental Standards for Installation. 4-1-1 Environmental Conditions. 4-1-2 Notes for Installation... Floor Plan... Relocation of Machine (1)... 4-3-1 Relocation of Machine. Relocation of Machine (2) 4-4-1 Bringing Machine down from Fork Lift. 4-4-2 Leveling Work. wo 64 Wiring between Primary Power and Machine Power - 1 - 66 4-5-1 Opening/Closing CNC Unit Door. 4-5-2 Grounding Work. ‘4-5-3 Power Specifications for Wiring Wiring between Primary Power | and Machine Power - 2 - 4-6-1 Power Source at Customer's Factory is AC200V. 4-6-2 When Power Source at Customer's Factory is : (1) AC210-230V / (2) AC230-264V.. 5.Chapter 5. Maintenance 5-1 List of Regular Chec! 5-1-1 Maintenance 5-1-2 List of Regular Check 5-2 Lubrication : How to Replenish Grease 5-2-1. Interval for Refill. 5-2-2 Recommended Grease .... 5-2-3 Lubrication Repimishmer 5-3 Luburication : Where to Replenish Grease 5-3-1 Greasing Points. Chapter 6. Operation 6-1 Turning on Power... 6-1-1 Before Turning on Power 6-1-2 Tuming on Power 6-2 Turning off Power 6-2-1 Before Turning off Power 6-2-2 Tuming off Power... 6-3-1 Workpieces, Height of Fixture and Tool Length. 6-3-2 Setting of Conditions... 6-3-3 Checking of Interference .. 6-4 Mounting/Tools.... 6-4-1 Setting of Mounting Position 6-4-2 Mounting Tools... 6-5 Dismounting Tools. 6-6 Outline of Operation Panel 6-7 CRT Screen. 6-8 6-9 Operation Switch. Key Functions. Chapter 7. Manual Operation 7-1 Manual Operation. 7-2 Zero Position Return. ea 7-3 Return to Working Zero Position.7-4 Axis Feed... «0 @ (3) - Step Length.. 7-5 Rotating and Stopping Spindle. 7-6 Magazine Tool Change. 7-7 Magazine Rotation... Chapter 8. MDI Operation 8-1 MDI Operation 8-2 Data Setting (Block Operation). 8-3 Data Inputting for Operation (Example for Block Operation). 8-3-1 Setting of Work Coordinate System. 8-3-2 Outputting of External Signal....... 8-3-3 Tool Change. 8-3-4 Coolant Discharge and Stop... 8-3-5 Spindle Rotation and Stop. 8-3-6 Axis Feed... 8-3-7 Drilling Operation. 83-8 Tapping Operation 8-4 Data Input, Modification and Reference (2) - Specification of Auxiliary Code.. (8) ~ Setting of Too! Length... 8-6 Setting of Tool Pattern.. 8-7 Setting of Drill Dia for Tapping...... 8-8 Setting of Cutting/Tool Conditions....... 8-9 8-1 Setting of Parameter... 0 Tool Setting in Magazine.. a) (2) @ 2 8-11 Display of VO StatuChapter 9. Memory Operation 9-1 Cycle Operation and Single Operatioi 9-2 Single Operation...... 9-3 Cycle Operation... 9-4 Memory Operation Scree! 9-5 Dry Run Operatio: 9-6 Setting of Start Point. 9-6-1 Current Machining Psition for Setting Start Point. 9-6-2 Setting of Start Point... 9-63. Notes in Setting Start Poi 7 Schedule Program Operation. -8 Setting of Schedule Program Number 9 Temporary Stop and Resart. ec -10 Reset. Chapter 10 Alarm Message 10-1 Alarm Screen.. 10-2 Error Code List.=10-Chapter 2 General Cautions 2-1 General Precautions 2-2 For Safety Operation2-1 General Precautions Understand the following precautions in order to assure a safe machine operation. Failure to pay attention to these points is most likely to cause unnecessary breakdown of the machine. 2-1-1 Mounting Tool Holders into Magazine ‘When mounting tool holders into the magazine, make sure that the keyways of the tool holders and key positions of the gripper are properly fitted. (A click sound can be heard at this time.) Mounting of tool holder into magazine. ‘Make sure that the 3 parts - the key position of the pripper and the pin of the gripper (at2 points) - are securely fitted as shown on the sey right figure. ‘The above figure shows the case that a tool holder is comrectly fitted in the magazine! Er Postion En VERE PROPEELT aureneD, 2-1-2 Upward Axis Movement from Z Zero Position Before moving the Z axis upward from the zero position, the spindle must be properly positioned. Pressing [ATC] key once will execute automatic positioning of the spindle upon completion of zero return, Refer to 7-6 Magazine Tool Change for detailed operation of [ATC] key. pepressine fie] KEY2-1-3 Servo Motor Error ‘SO r-anis DIAL CAUCE 0, oe Liss & Wav To CHEE ‘TRE SPINDLE POSITION SPINDLE ROTATION STMUCTANEONS WOTION: 7 ATT NOVE-04H AND SPTHDLE ROTATION 2-1-4 During Memory Operation {including single operation) MAGAZINE ROTATION COLUMN TRAVERSE, TO 1/¥ ATES SIMULTANEOUS MOTION: MAGAZINE ROTATION AND COLUMN TRAVERSE TO X/Y axes If any servo motor is overloaded due to a tool interference with workpiece or fixture, a servo error is generated. Move each axis to the safety area first, then retum to the zero positioned. ‘Then check the relative positions of the spindle and the X/Y/Z axis in the following procedures. 1. Spindle position Positioning of the spindle is that the line connecting the both sides of the 2 keyways at the spindle nose is parallel with the Y-axis movement. (1) Press [MANU] key. (2) Press [ATC] key once and positioning the spindle. (3) Use a dial gauge and check that parallelism of the line connecting the both sides of the 2 keyways at the spindle nose and the ¥ axis is below 0.1mm. 2. X, ¥ and Z positions (1) Press [MEM] key. (2) Press [SINGL RUN] key and check the machining position. Note that the 2 motions as follows will be exe- ccuted at the same time in the memory operation including single operation). 1. Z-axis downward motion and spindle rotation 2. Magazine rotation and X/Y axes (column) movernent -13-2-2 For Safety Operation This section describes the basic points which should be fully understood for safety operation. Before starting operation, read it carefully to protect operators and the machine from troubles. | 2-2-1 Before Power On 1) Make sure that the door of control unit is closed and no obstacle is around the machine. 2) Check if somebody is in the machine movable range or close to the machine. 3) For power ON, tum the main power breaker control unit to ON, and then press [POWER ON] switch on the operation panel. 2-2-2 Before Starting Operation 1) Make sure that grease lubrication'to each guideway, etc. is sufficient. (Grease should be replenished every six months.) 2) Make sure that the inside of the spindle, spindle nose and tapered parts of the tool holders are clean and not damaged. Also, check them for tool wear. 3) Make sure that tool holders are securely set into the magazine, and the pullstuds are also tightened into the tool holders. 4) Turn off main power breaker when any ‘work - repair, maintenance, ete. is required. “ihe2-2-3 During Operation 1) Do not remove the splash guard from the machine. Also the door of the guard must be closed during operation, 2) When workpiece or fixture is reloaded or a new workpiece is machined, check each machine motion again by program to see if there is only interference with tools or workpiece, before starting operation. 3) During spindle rotating motion, tool change motion, axis feed motion, etc., follow the precautions for safe operation. 4) During spindle rotation, do not put your hand in the splash guard. . ~Do not put your hands on chips or workpice, ~Do not try to stop spindle rotation by hand or other material, 5) Make sure that workpieces are securely fixed on the table. 2-2-4 Troubles During Operation 1) For emergency stop, press the red [EMERGENCY] switch on the operation panel. The servo power is turned off immediatery and machine operation is stopped at once. For restart of the operation, return all the axes to the respective zero positions. 2) Check the cause of troubles carefully, and take necessary measures to solve the problem. 3) When more than one operators are working together, it is recommended to check each ‘one’s job in executing respective jobs. -15-2-2-5 Before Power Off 1) When itis necessary to register the data on the screen, execute the operation for data registration. 2) Press [POWER OFF] switch on the operation panel, and turn the main power breaker of control unit to OFF. 3) Main power must be always tured off when the machining is finished or operator leaves the machine. 1) For air blast unit, supply clean and dried air. 2) After the machine has been standing idle over three days, it must be warmed-up before starting operation. Warming-up time : About 15 min. Spindle speed + SOOrpm (mis) —> 1000rpm{min)-» Max.speed Axis feed : Full stroke on each axis ‘The warming-up should be executed on each motion such as ATC motion. 3) Do not use compressed air for cleaning machine, control unit, operation panel or removing cutting chips. 4) Operator must put on suitable working clothes with safety shoes, hat, protection glasses etc. 5) Always keep clean around the machine. 6) Do not handle switches by wet hand or material, 7) When the spindle is stuck with cutting chips, stop the spindle rotation and remove the chips. a6:al7=-18-3-1 3-2 3-3 3-4 3-5 3-6 3-7 38 39 Chapter 3 General System Description Main Features of TC-321 Basic Construciton Name of Each Component Dimensional Drawings Table Dimensions and Machining Range Machine Specifications List of Accessories Specifications of CNC Unit Characteristics of Spindle Motor 3-10 Machining Capability 3-11 Safety Devices3-1 Main Features of TC-321 Full understanding of machine features is most important to assure reliability of the machine. This section describes major features of TC-321's high machining performance. 3-1-1 Automatic Tool Changer (ATC) 1) The unique armless mechanism can realize simple and quick tool change motion, thus reducing non-cutting time. 2) The magazine rotates in either direction so that it can take the shorter way to reach the tool to be used. (Random access type) 3) Positioning (X/Y axes) during spindle rotation reduces non-cutting time, ‘Automatic tool changer (ATC) 3-1-2 Tapping Cycle 1 PIt Fully synchronized control of X axis feed and spindle rotation makes it possible to omit usage of tapping holder. This method reduces air cut time in conventional tapping operation as in drilling operation. (Max. spindle speed for tapping operation : 4000rpm(min*)) Fully synchronized feed of screw pitch and spindle rotation =20-3-1-3 Spindle Headstock 1) High precision spindle bearing maintains maximum rotating precision over a long time. 2) Itis grease-charged and requires no maintenance, |. 3) AC spindle servo motor adopted for the spindle offers wider speed range of up to 6-6000rpm(min*). Spindle structure 3-1-4 Servo Mechanism (X,Y,Z Axes) AC servo motor | 1) Brushless AC servo motor adopted to each axis | requires no maintenance. 2) Feed motors are directly connected to the high precision ball screws and linear motion bearings are used for guideways. It provides smooth feed motion without stick-slip or gear backlash. nilte3-1-5 CNC Unit 1) Brother's unique conversational programming system offers simplified and quick programming. ‘Operation panel3-2 Basic Construction This machine consists of the following units/accessories. 3-2-1 Basic Construction 1) Machine has a vertically-designed spindle headstock. 2) Column traverse : X/Y axes 3) Spindle headstock : Z axis > o®4) The unique armless Automatic Tool Changer (ATC) unit offers quick tool change motion. Unique armless mechanism! aA 5) Floor space is minimized due to built-in | } co control unit at the back side of the machine. q3-2-2 Axis Movement (X, Y, Z)3-3 Name of Each Component the total image of the machine. Check the names of components from the external view and understand 3-3-1 Machine Overall View op sie Spindle head Eth 1 Zaxis motor ATC magazine y : | Spindle | . - 3 > Table Leveling bott Columnist Bed Leveling plate ~:3-3-2 Machine Back Side Fan Main powier breaker ee) ica | Control unit = _ cont3-4 Dimensional Drawings Levelling) co~60) Unit : mm‘voge'xolddy 2392 «0 ate 2,3-5 Table Dimensions and Machining Range 3-5-1 Table Dimensions 0040.3 f Details of A Details of B Unit: mm3-5-2 Machining Range X AXIS (Table longitudinal direction) |. Shaded areas move in each axial direction.Y AXIS (Table cross direction) a ' rs{ oa | STROKE FRONT SIDE oer SPLASH GUARD Z.AXIS (Headstock up/down) SPINDLE NOSE (Unit : mm-35-3-6 Machine Specifications Item Unit Spec. Travel | X axis travel mm 700 (Colurnn longitudinal movement) Y¥ axis travel mm 300 (Column cross movement) Zaxis travel mm 250 (Headstock vertical movement) Table surface to spindle nose mm 450 Column front to table surface mm 265 Table | Table.work area mm 800x 300 Max. load on table kg 300 Table surface 12mm-T-slots (3 pes) Spindle | Spindle speed rpm(min') 66000 ‘Max spindle speed during tapping rpm(min’) 4000 Spindle taper hole 7/24 taper No.30 ID. of spindle bearing mm 4° Feedrate | Rapid traverse (X, Y) mm/min, 25000 Rapid traverse (Z) mm/min 20000 Cutting feedrate (X, ¥, Z) mm/min, 510000 Manual feedrate (X, ¥, Z) mm/min, '50~5000 (22 steps) Auto tool | Tool shank MAS BT30 changer 4002~15T Pallstud MAS P30 T-2(60") ‘Tool storage capacity (max.) pes. 10 Max. tool diameter mm 80 Max. tool length mm 100 Max. tool weight kg 3.0 Total tool weight kg 20 Tool selection Random access ‘Tool change time : Tool to Tool sec. 19 Chip to Chip sec. 45Item Unit Spec. Motor Spindle motor (30 min. rating) KW 41 ditto (Continuous rating) 3.1 Feed motor «, Y) KW 13 Feed motor @ KW 0.72 |Power Input power ¥ AC 200410% supply Hz 50/6081 | Power Continous rating KVA 7.0 (23.5A/phase) capacity |30 min. rating KVA —_|9.0 (29.4A/phase) «- | Moment rating KVA __|16.5(50.04/phase] ‘Air pressure source (When air blast for spindle taper is used) kgflom 46 N fnin, 500 (Air pressure)| Machine | Machine height (from bottom surface) mm 2075 size Required floor space (including opening space of mm 1900 x 3052 control unit door) ° Machine weight (including control unit) kg 2600 Accuracy | Positioning (JIS S B6338) mm +0.01300 (Positioning for X axis) mm (40.02/70) Repeatability (JIS B6338) mm £0,005 “i=3-7 List of Accessories 3-7-1 Standard Accessories Item aty. Splash guard I set Instruction Manual/ Programming Manual L copy Leveling bolt 4 pes. Leveling plate. Apes. Fuse 10A, 1 pce. Fase (8) 0.5A 1 pee. Fase (S) 1A L-poe. Fase (S) 2A -| 3pes. Fuse (S) 3A 1 pee. Fuse (S) 5A 2pes. Pd fuse 3A 1 pee. 4 fuse for spindle (1.3A)} 1 pee. -38-3-7-2 Optional Accessories Item Coolant unit (50 lit.) Solenoid valve for coolant unit Bubble memory unit Bubble cassette (128 KB) ‘Air blast unit for spindle taper Air pressure 0.4~ 0.5 MPa (4~Skgffem') Extemal Y/O unit (RS-232C interface, printer interface) Load meter Manual pulse generator Automatic door Work light Switch for door safety devices (sensor and lock release switch) Door lock ‘Work counter ‘Signal light (1-, 2- or 3-light) -39-3-8 Specifications of CNC Unit CRT display Decimal point input ‘MDI (Manual data input) Zero position return ‘Working zero position return Current position display Coordinate system setting Over travel Stroke limit Emergency stop Rapid feedrate Cutting (Jog) feedrate Step motion ‘Temporary stop Auto. acceleration/deceleration Synchronized tapping Function Contents Controlled axes 3 axes (X, Y, Z axes) Simultaneously controlled axes X,Y axes Least input increment 0.001mm Least command increment 0,001mm Programming method Absolute/incremental pragramming ‘Max. programmable dimension 4999,999mm, 9-inch CRT display Decimal point input is available for data input. To input NC program data by key-in operation, Automatic zero return by key-in opration. Automatic working zero position return by key-in operation. Display of current coodinate position of each axis and magazine status. Coordinate can be shifted and set to the specified positions on X-, Axial movement will stop instantaneously if each axis overrun limit switch is actuated. Movable range of each axis is set by parameter. All the commands and machine motion are immediately stopped. X/Y : 25mv/min, Z :20m/min. Cutting feedrate at S~ 10000mm/min. on each axis feed. 4-step movement for the entire range of 0.001~ 1.0mm, Z-axis. ‘Temporary stop for axis movement. By pressing [START] switch, the movement is restarted. Acceleration/deceleration is applied automatically toa movement command, Completely synchronized feed at one pitch per , spindle revolution.Function Contents. Interpolation function Canned eycle Setting of machining start point Pitch error compensation Dry run Dwell Tool function Spindle function Backlash compensation Tool length setting Automatic programming Background edit programming Program No. search Linear, circular interpolation A series of motions such as boring and tapping are available. Operation restarts from the middle of the program. Compensation of machanical error caused by pittch of ballscrew on X, Y, Z axis. Max. 50 compensation commands can be set at a fixed interval. Motion check at rapid feedrate is possible in the manual mode. . ‘Temporary stop is available for a specified time in the memory operation. According to the program, this function automatically specifies the necessary tool from the registered tools. This function specifies spindle speed automatically according to material, cutting condition and tool diameter already set. ‘Compensation for lost motion in mechanical system. ‘The compensation is available by the pulse in the range of 0 ~ 0.77mm on each axis. This function automatically memorizes the length of the tool mounted and measured on the spindle into tool menu data. ‘This function automatically makes program by selecting inputted data or conversationally programmed data. Program edit is possible during memory operation. Refer to Section 9-4 Memory Operation Screen for details. Memorized program can be called for with 4-digit program No. -41-FUNCTION CONTENTS Self-diagnose alarm ‘CNC unit performs various kinds of check and displays the status on CRT when any trouble is found, Extemal program/data search ‘Transfering or deleting extemal program/data can be performed by using the bubble memory unit (optional). Restart Repeated program operation in the memory mode is possible, Scheduled program ‘Max. 99 pes. of programs can be continuously operated in the memory mode. Motion program By registering the motion sequence which meets ‘customer's requirement, other machining patterns which have not been registered in the conversational programming can be executed. -42--4-3-9 Characteristics of Spindle Motor Chart of characteristics Rated output cw) 23100 Rated torque (kg.cm) 120 Torque Rated rotating speed rpm(min") 3000 (RG. CH) Rated voltage ~ 2140 or Rated current (a) 236 Max. rotating speed rpm(min‘) : 6000 Acceleration/deceleration range, TORQUE Cont. rating range 100 2000 3000 4000 5000) 000 ‘Speed mpm (min"t) “4-45-3-10 Machining Capability The machining conditions are largely affected by used tools, tool status, coolant setting, environmental conditions and other factors. Therefore, use the following machining data for your reference. Machining Conditions s4sc_| Fc20 | aDci2 Drilling | Diameter (mm) 7 20 25 Feed (mm/rev.) ois | 015 | 0.20 Tapping | Diameter (mm) mi4 | Mio | MIB Pitch (mmy/rev.) 2.0 2.0 25 End ailing | Cutting amount (emmin) | ¢ ¢ 2 o Dia 20mm Face milling | Cutting amount (cm?/min) | . 4 9 150 Dia 80mm-47-3-11 Safety Devices TC-321 has several kinds of safety devices for safety purpose of both operators and the machine itself. Any operation, however, must be done with greatest care without relying only upon the devices. 3-11-1 Main Safety Devices 1. Protection cover (Splash guard) 2. Splash guard door sensor 3. Emergency stop switch 4, Display of alarm message 5, Limit switch (X-, Y-, Z-axis)3-11-2 Location of Limit Switches Front view CONTACT |WIRE No.| LIMIT SWITCH | POINT | NO T [+k Over-run Ls |: B 1.2 2 |X Reference LS A 3.4 3 |- Over-run LS a 5.6 Zt Left view -49- CONTACT |WIRE o.| LIMIT swiTcH | POINT | NO. 4 |-¥ over-run LS B 5.6 5 |+¥ Over-run LS a 1.2 6 |¥ zero point LS] A 3.4CONTACT [WIRE , | NO.) LIMIT swTrcH POINT | NO. T [+z Over-run LS B Tz 8 |Z zero paint Ls] & 3.4 9 |-2 Over-run Ls B 5.6 | | 10°}Z ate zero point] & 1.2 i Ls 11 |Z ATC area LS A 3.4 Right view-51-41 42 43 4-4 4-5 4-6 Chapter 4 Installation Environmental Standards for Installation Floor Plan Relocation of Machine (1) Relocation of Machine (2) Wiring between Primary Power and Machine Power -1- Wiring between Primary Power and Machine Power - 2 -4-1 Environmental Standards for Installation Accuracy of the machine is greatly affected by environmental conditions. Before installation, set the environmental conditions in your factory according to the following data. Contact your local dealer for further details. 4-1-1 Environmental Conditions Condition Note ‘Ambient temperature | 17°C~25°C ‘Acceptable range : 0°C-45°C (for machine operation) -20°C~60°C (for storage and transportation) Allowable 1.1°C or less per minute temperature change Humidity About 45%~75% (at 20°C) No dewing Vibration 0.5G or less * Unstable ambient temperature will deteriorate machining accuracy. To maintain the expected accuracy, keep the temperature difference within £2°C in a day. Installation area must be free from : 1) Direct sunlight -54-2) Excessive humidity 3) Excessive temperature change ore 4) Vibration -55-4-1-2 Notes for Installation 1) Keep the working area clean. Dust should be shut off from the control unit and the movable sections of the machine in particular. 2) Sufficient space for fully opening the control unit door is required behind the machine, 3) Supply dry clean air to the air blast unit. 4) Pay greatest attention to the air ventilation to maintain the most suitable temperature in the factory. 5) If excessive vibration is not evitable near the machine installation site due to other machines, streets, etc., it s recommended to relocate the machine or take necessary measures'such as vibrationproof wall, etc. 6) TC-321 cam be easily installed by using leveling bolts without any special foundation work. ‘When the foundation is not solid enough and there is a possibility of machine’s falling down, proper foundation work is recommended before installation, -56--57-4-2 Floor Plan If the floor is not strong enough, axis movement may affect the level on the machine table. Select most suitable place for installation in consideration of the machine weight. Unit : mm -58-After installation of the machine, remove the shipping bracket from the machine. ‘The bracket is clamped by bolts at 3 places. A ‘Standard machine specifications (,) K = ‘With parallel pallet changer4-3 Relocation of Machine (1) When the machine is to be relocated inside the factory for modification of layout, etc., take the following procedures. 4-3-1 Relocation of Machine BRING COLUMN TO FULL i Brn CLM euey 1) Before removing the power cable, move the (OPERATOR'S SIDE) _ column to its stroke end in the - ¥ direction (forward), and then in the X direction up to the a table center, These axis movements are for r i positioning the center of gravity in the middle Loy and to keep the machine balance. BRING Z AXIS! . _ DOWN. TOWARD * As for the machine equipped with PPC, move Oe : the column to its stroke end in the + direction. 2) Bring down the Z axis toward the table in the (-) direction as much as possible. 3) Shut off the power and remove the cord. 4) When various accessories are provided, Temove all those hoses and cords from the machine. Itis recommended to bundle the hoses and wires with tags as shown in the picture so that remounting will be much easier. Bundling of hoses5) Support the spindle headstock and the table by a shipping bracket and fixing bolts. When the machine is relocated inside factory, these bracket or fixing bolts are not required. 6) Insert the claws of the fork lift under the base and support the machine first. When transporting the machine, be sure that the machine is free from vibration or shock. Loosen the leveling bolts until before they come out from the machine bottom, but do not expose them from the machine base as it will damage the floor. “Transportation by for lift SEE The fork lft to be used should bear the machine weight and have claws long enough to hold the machine. Standard machine : 2600 kg Machine with PPC : 2900 kg -61-4-4 Relocation of Machine (2) This section describes the procedures of locating and leveling the machine. As leveling will greatly affect machining accuracy and machine life, utmost care must be taken at this time. 4-4-1 Bringing Machine down from Fork 1) Put the leveling plates, referring to the level- ing bott positions. When placing the leveling plates below the machine, put safety blocks first between the machine base and the floor and lay down the machine carefully in cooperation with other operators. Placing of leveling plate 2) Execute fine-adjustment of machine location. (The machine has casters for easy relocation.) 3) Loosen the fixing bolts used during transportation and remove the shipping bracket. 4) Connect all the cords and hoses to the machine. 5) Modify the thermal relay setting values for the coolant, motor/chip shower motor according to either 50 or 60Hz as used in your area, (Refer to the section of optional coolant unit for details.) 6) Connect the power of the machine to the © primary source in the factory, and turn it on,6) Tum on the main power breaker of the control ~ unit, * The main power breaker does not function when the handle lock key is set to A LOCK. 7) Tum on the power of the operation panel. -63-4-4-2 Leveling Work ‘Adjustment of level 1) Position the spindle in the center of the table by moving the X and ¥ axes. 2) As shown in the picture, set a level on the center of the table and check leveling. 3) Adjust leveling to 0,05mm/m or less in both X and ¥ axes by using the leveling bolts at the bottom of the machine. Fix the machine with Jock nuts after the required leveling accuracy is obtained. @ 1. Check if this level is maintained 1 = month after installation, and every 6 months afterwards. Check-up is| also required in case of excessive vibration such as earthquake, etc. 2. Use a leveling plate attached as a standard accessory.4-5 Wiring between Primary Power and Machine Power - I - Wiring work from primary power source to the control unit of TC-321 is to be executed by a customer in the following procedures. Before starting this work, make sure that all the machine power is turned off. 4-5-1 Opening/Closing CNC Unit Door Door lock key (at 2 points) | Opening of door Loosen the 2 door lock keys (upper and lower). After turning the main power breaker handle to the RESET/OPEN position, open the door. * The main power breaker does not function when the handle lock key is setto A LOCK. Closing of door After turning the main power breaker handle to the OFF position, close the door. Tighten the 2 door lock keys afterwards.4-5-2 Grounding Work | Connect the grounding by using a 4-core cabtyre cable (vinyl), ete. (Refer to your local safety standards in grounding work.) Grounding work should be done for 7 each unit independently, and make sure to avoid such grounding as shown in the figure as itis dangerous. ations for Wiring Item Specifications Input power AC200V 410%, 50/60Hz +1Hz Power capacity : - Continuous rating 7.0KVA — (23.SA/phase) ~30 min, rating 9.0KVA —(29.4A/phase) - Instantaneous rating 16.5KVA___(50.0A/phase) Wiring for power source | Nominal cross area Wiring distance $.Smm* Within 20m 8.0mm? Within 30m 14.0mm? Within 50m & Provide the exclusive wiring for TC-321 to avoid any electrical effect from other machines or equipments. The common use of a switchboard with other machines such as welding machine, induction hardening machine, press machine, etc. which generate a loud noise may cause malfunctioning of NC function. wie4-6 Wiring between Primary Power and Machine Power - 2 - Wiring work varies depending on the power supply voltage at customer's factory. Before starting the wiring work, check the power specifications at your factory. 4-6-1 Power Source at Customer’s Factory is AC200V ‘Transformer 2 | Transformer 1 | The power source of the machine is AC200Y, no | special wiring work is required any longer. (The | transformer connecting terminals are as shown in | the figure.) Position of transformers in control unit COMMECTING TERMIKAL| “FOR TRANSFORMER 1 A 1 A CONNECTING TERMINAL FOR TRANSFORMER 2 Wiring for AC200V4-6-2 When Power Source at Customer's Factory is: (1) AC210- 230V (2) AC230 - 264v Change the wiring of each connecting terminal of the transformer 1 and 2. (1) Transformer 1 : For power (2) Transformer 2 : For control EF Before changing the wiring of the E control transformer, tun the main power breaker to OFF, 1. Turn the main power breaker OFF. 2. Change transformer connecting terminals, Position of transformers in control unit -69-conWectrnG TERMTIAL FOR TRANSFORMER 2 1) WIRING FOR ACa46V~ 415V CONKECTING (om TERMTNAL OR TRANSFORMER 1 ff ’ CONNECTING TERMINAL FOR TRANSEORNEE 2] 2) WIRING FOR ACAOOV~ 440¥ -10-Chapter 5 Maintenance 5-1 List of Regular Check 5-2 Lubrication : How to Replenish Grease 5-3 Lubrication : Where to Replenish Grease5-1 List of Regular Check Check items described in this section must be observed periodically to keep the stable machining performance and to prevent machine from failures. Correct maintenance will also help the stabilization of entire machine operation. 5-1-1 Maintenance 1. After a daily operation is completed, clean inside and around the machine carefully, To use the air gun unit is not recommendable as it will blow off cutting chips and cause . malfunctions of the machine. 2. Check the cause of trouble immediately when the machine has any unusual noise or vibration. 3, Replenish lubrication oil according to Section 52, 4, When replacing parts, use the specified parts to avoid unnecessary troubles. *5-1-2 List of Regular Check Check the following items periodically. Check interval Check item Every day 1) Check the magazine rotating status and tool mountinig/dismounting status by [ATC] key. ( EJ) For details of [ATC] key, refer 07-6 Magazine Tool Change.) 2) Check if the control unit and the cooling fan work properly. 3) Check if the spindle nose and its tapered section are kept clean, and not damaged. 4) Check if the spindle rotates smoothly without any unusual noise. 5) Check the spindle position during its positioning motion. 6) Check if the chip pan is cleaned and without any chips left in it. 7) Check the oil level by oil gauge. Oil amount must be below the marked level on the gauge. Every mouth 1) Check that the power source voltage is AC200V +10% on a tester. 2) Check leveing of the machine by using a level gauge. (The level must be 0.0Smm/m or less in both X and Y directions.) 3) Check if the cooling unit fan in the control unit is dusty, and if inside the coolant tank is stained with oil. 4) Check if the coolant tank is kept clean. Every six months 1) Apply grease to each ball screw by using a grease gun. 2) Apply grease to each guideway by using a grease gun, -B-5-2 Lubrication : How to Replenish Grease Lubrication helps to maintain accuracy of each unit and assembly as well as to reduce abrasion on each section. Check and refill with grease periodically. 5-2-1 Interval for Refill Necessary grease lubrication is made on each part before shipment. After installation on customer's site, apply grease every 6 months. Application is also required whenever used grease is deteriorated. 5-2-2 Recommended Grease Grease name Supplier Use the specified grease to avoid unnecessary Licenia Gosanatola Shell O11 Co. | failures of the machine. Mobil Lux 2 Mobil Oil Co. ‘When higher machining accuracy Beacon 2 Esso Oil Co. is required, Maltemp LRL3 (Kyodoyushi) or its equivatent is +| recommended for the ball bear- ings. The above grease is sealed upon delivery. 5-2-3 Lubrication Replenishment Grease can be replenished either by spreading on the surface or by using a grease gun, When using a grease gun, supply grease until stained grease is extruded from the end of linear guideway or ball screw nuts due to grease supply pressure. Wipe off the stained grease by using a cloth. Do not wipe off the grease completely as it will affect a smooth lubrication, Ez When removing the machine rear cover for replenishment of grease, be sure to turn OFF the main breaker of the control panel first. Replenishment with grease gun <4.os5-3 Lubrication : Where to Replenish Grease Grease can be supplied from the 4 points either by spreading or by grease gun. 5-3-1 Greasing Points Rolling contact surface of plate cam (unctamp cam) Rolling contact surface of cam (spindle head) Zavis!S | Xe Wands | (1) Use a grease gun for replenishment of grease to the Z axis (between spindle and column). il inlet for Z axis Greasing points at A, Front side Forlinear guide For linear guide tuopertet), PREF ght! yd Bed Ps Nor nest Fortinesr guide ForZ- duide(lower right) (owertet) 2x8 ball sorew Column side Column side -16-Front side (2) Use a grease gun for replenishment of grease Column to the X/Y axis (from the machine rear side). Linear guide inear guide, Linear guide’ gan screw: Oil inlet for ¥ axis, Ollinietfor X axis; oy inlet for Yaris} FE Remove the machine rear cover for replenishment of grease. Rear side i Linear guide 7 near guid Tum OFF the main power breaker of ar guide | é a \inear guide: | the control box before removing the {_Hinear guide’ panscrew rear cover. Oil inlet for X axis Greasing area| (3) Spread grease on the rolling contact surface (on the upper part) of the plate cam (unclamp cam). (4) Spread grease on the rolling contact surface of the cam (spindle head).6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-9 Chapter 6 Operation Turning on Power Turning off Power Notes for Mounting Workpiece on Table Mounting Tools Dimounting Tools Outline of Operation Panel CRT Screen Operation Switch Key Functions6-1 Turning on Power 6-1-1 Before Turning on Power 1) Check that the main power breaker and the coolant motor switch are turned off. 2) Check that there are no obstacles around the machine, 3) Check that nothing is left on the machine table or the saddle. 4) Check that the door of CNC unit is securely closed. 5) Check that the tapered section of spindle nose is clean and there is no pitching or wear. Check that the pullstud is securely tightened, 7) Check that the tools are securely mounted on the magazine, and the pullstuds are securely tightened into the tool holders. 8) Check that the coolant tank is filled with sufficient amount of coolant, 9) Check that air supply source for the air blast is ready for operation. 6-1-2 Turning on Power 1) Connect the power cord of the machine to the “primary power source.~~ 2) Turn on the main power breaker for the control j unit on the rear side of the machine. Check that the lamp is ON at this time. -@ Bertsssoae 3) Tum on the power of the operation panel. When [POWER ON] button is pressed, the green lamp is lit and the initial screen is displayed on CRT screen, At the same time, the fan on the control unit will start rotating,and servo mechanism of X/¥/Z. ‘motors will be locked. Power ON ‘(Operation panef) -81-Fan on control unit 1. When power is once turned off, wait for minimum three seconds before turning on power again. 2. After power of CNC unit and operation panel has been turned on, make sure that the fan on the control unit is working properly. 3. Depending on the status of the machine, it may take about 1 5 seconds to display the CRT screen. Even if the initial screen is not displayed at this time, it is not abnormal.-83-6-2 Turning off Power 6-2-1 Before Turning off Power 1) Check that all the machine motions are stopped. 2) Check that all the operations such as program editing, data modification, input/output to/from external equipments, etc. have been finished. 6-2-2 Turning off Power 1) Press [POWER OFF] switch on the operation 2) Tum off main power breaker of the control unit.3) Disconnect the power cord or tum off the "power of the switchboard in the factory. 6-2-3 Power Failure If the machine stops due to power interruption, turn the main power breaker of the control unit off immediately. After the power is restored, turn on the power again according to the procedures as described in Section 6-1-2. -85-6-3 Notes for Mounting Workpiece on Table When mounting workpieces on the table, check workpieces, height of | fixtures and tool length, etc. first according to the following procedures. 6-3-1 Workpieces, Height of Fixtures and Tool Length T/C-321 execute a magazine rotation in automatic tool change as well as a table positioning motion at the same time to minimize non-cutting time during machine operation. Be sure to ‘check that a tool does not interfere with a workpiece of fixtures before mounting a workpiece. 6-3-2 Setting of Conditions Apply the dimensions of workpieces to be used to the sections such as LL, C, and H. LL: Max. length of wols in the magazine ! H ©: Zaxis wavel in parameter #2 H+ Max. height of workpiece and fixtures -86-6-3-3 Checking of Inteference ‘When the setting condition is HSC-LL-10mm ‘When the setting condition is H>C-LL- 10mm v o ‘Mount workpieces after checking conditions. -87- Depending on magazine rotating direction, tool mounting position or machining procéss, a tool may interfere with workpiece or fixtures. Check the interference before mounting the workpiece.6-4 Mounting Tools Mounting of tools can be done most effectively at the top part of the magazine. Rotate the gripper to be equipped with a tool by manual operation and move it to the upper limit. 6-4-1 Setting of Mounting Position 1) Press [MANU] key and select the manual operation mode. 2) Press [ATC] key. The Z axis will go up to the machine zero position and the spindle will be positioned as designated. 3) Press [ATC] key again. The ATC wil move to the ATC zero position. 4) Press [SINGL MAGAZ] key and rotate the magazine. Move the gripper to be equipped with a tool to the magazine top position, -88-6-4-2 Mounting tools Set the gripper key in the tool holder keyway, and the magazine pin to the tool holder V-groove firmly. Then insert the tool deeply into the | gripper and fix it securely. Tool holder keyway ‘When firmly set, Tool holder keyway Refer to the notes as described in 24-1,6-5 Dismounting Tools Tools can be dismounted most effectively at the top part of the magazine as in mounting of tools. ‘When dismounting a tool, take out the tool holder % in the direction of arrow while pushing it out. Refer to 6-4 "Mounting Tools" for details of magazine rotation. RENOVING TOOL HOLDER FROM MAGAZINERestrictions on tool holder. Tools to be used should satisfy the following conditions. & E 5 g 8 z MxL 180 (kgemm) whea : G : Center of gravity of whole tool M : Mass of whole tool L_ : Distance between gauge line and tool gravity center. -91-6-6 Outline of Operation Panel Operation panel consists of the NC operation panel and the machine operation panel. All the machine mmotions are controlled through this panel-93-6-7 CRT Screen This section describes how to display the EL screen on the operation panel. Program display area [~ @ata display area) baad ~L Data input area }— Teach data area (1) Program (data) display area Data and program contents required for the operation are displayed. (2) Data input area ‘When data is to be inputted, this area will show the necessary data contents. Input data by using numerical keys, select the required number from the list, etc. according to the instruction on the screen. (3) Teach data area Items to be selected for machine operation will be displayed.-95-6-8 Operation Switch This section describes functions of the switches on the NC operation panel, (1) POWER switch power 1) This switch is for tuming ON the power to the machine, The green lamp is lit oN when the power is ON. 2) This switch is for tuming OFF the power to the machine. When the input OFF voltage exceeds "Rated voltage + 15%", an alarm will occur and the red lamp fl on this switch is lit. (The power will be automatically turned off in such a case.) The alarm status can be released by turning OFF the main breaker switch. An alarm will be displayed on the CRT if the voltage becomes less than "Rated voltage - 15%". (2) START/STOP switch START ©! This switch is used for starting the MDI or memory operation, The START lamp will be on until after operation is completed. This switch is for stopping the X, Y and Z axes as well as operation momentarily during operation of program selected by MDI or by memory operation. The spindle rotation will not stop at this time, When this switch is pressed during tool change or tapping, the operation will not stop until after such motion is completely finished. The lamp is lit during motion stop. . Press [START] switch for restarting operation. (The STOP lamp will go off in such a case.) 96(3) COOLANT MOTOR switch COOLANT MOTOR OFF x (4) PROGRAM PROTECT switch EDIT Setting this switch to ON wall turn on the coolant motor. Unless this switch is set to ON, discharge will not be avail- able even when it is commanded in the MDI or program operation. Setting this switch to OFF will tum off the coolant motor. OFF ..... Editing of programs as well as inputting and modification of various data will be. available by setting this switch to OFF. Programs stored in memory as well as various data are protected and cannot be modified or deleted when this switch is set to ON. This switch should be set to ON unless program creation, memory data modifi- cation, deletion or addition is required.(6) EMERGENCY switch EMERGENCY ‘STOP ie This switch is used to stop the machine in case of ‘emergency or incorrect operation due to wrong data input. All the machine motions will instanta- neously stop with the message “EMERGENCY STOP" displayed on the CRT screen. Resetting : Tum [EMERGENCY] switch clockwise to release the button from the locked position, and press [RESET] key. The machine initial status right after power ON will be restored at this time. Check the current motion and return the machine to the zero position in the safest way at this time. BEE_ When power is turned onvottor after an emergency stop, the Z axis goes down by about 0.5mm. This distance will vary depending on brake, guide, ball screw or machine operating status. -98-(6) MAIN PWR lamp This lamp will tum to red when the main power ‘Pan | breaker on the control unit is tumed ON.6-9 Key Functions This section describes functions of each key on the operation panel. Key Functions f=] This key is for resetting the control unit to the initial status. * Displayed alarm will be deleted before reinputting when this key is pressed. (Alarms without any asteristk * or with only one asterisk can be deleted at this time.) * When this key is pressed during data inputting, all the inputted data becomes invalid. * When this key is pressed during the memory operation, all the motions| of X, ¥, Zaxes as well as the spindle will stop instantaneously. (If tapping or tool change is being executed at this time, it will not stop until after each cycle is completed.) . This key is used for releasing the magazine orientation or trouble with ATC motion. ‘This key is used for manual operation. The following operations will be available in the manual operation mode, * Zero position return * Working zero position return. * Automatic tool change * Magazine rotation * Rapid feedrate + Jog feedrate * Step length * Spindle normal/reverse rotation and stop -100-Key Functions za ‘This key is used for returning the X/Y/Z axes to the machine zero positions in the manual operation mode. ‘The coordinates after zero position return are as follows : x20 Z: -axis zero position as set by Parameter 2 lwzar ‘This key is used for returning the X/Y axes to the specified working zero positions and Z. axis to the machine zero position. are This key is used for tool change in the manual operation mode. ‘Tool change motion can be completed in the following sequence each time the key is pressed. 1) Z-axis zero retum + Spindle orientation 2) Z-axis positioning at ATC zero position 3) ATC rotation 4) ATC positioning at Z-axis zero position This key is used for rotating the magazine in the manual operation mode, ‘The magazine is rotated clockwise to the next indexing position cach time this key is pressed. The Z-axis should be moved up to the ATC zero position by [ATC] key at this time. This key is used for moving the X/Y/Z axes in either + or - direction ata high speed. ‘The max. rapid feedrate can be changed in the following 5 steps according to the setting of Parameter 2. 10%, 25%, 50%, 75%, 100% It is initially set to 10% when the power is turned ON. -101-Key Functions ‘This key is used for moving the X/Y/Z axes in either + or - direction at a low speed. “The speed can be changed in 22 steps in the range of 50 - 5000mm/min. for the X/Y/Z axes. Itis initially set to SOmm/min, when the power is tumed ON. [=] ‘This key is used for moving the X/Y/Z axes step by step (as specified) in either + of - direction. ‘The axis motion amount per step can be changed in the following 4 step: 0.001, 0.01, 0.1, 1.0mm Itis initially set to 0.001mm when the power is tumed ON. This key is used for rotating the spindle in the normal direction (CW rotation when viewed from the motor top.) ‘The speed can be set in 21 steps in the range of 100 - 6000 rpm(min* ). Itis initially set to 100 rpm(min! ) when the power is turned ON. This key is used for rotating the spindle in the reverse direction (CCW rotation when viewed from the motor top.) ‘The speed can be set in 21 steps in the range of 100 - 6000 rpm(mmin* ), Itis initially set to 100 rpm(min* ) when the power is turned ON. This key is used for stopping the spindle rotation in the manual operation mode. This key is used for increasing the setting value of a rapid feedrate, jog feedrate, step length and the spindle speed step by step in the manual operation mode. This key is used for decreasing the setting value of a rapid feedrate, jog feedrate, step length and the spindle speed step by step in the manual operation mode. -102-Key Functions xX EID Z ‘This key is used for moving the X, ¥, and Z axes in either the + or - direction in the manual operation mode. This key is used for selecting the MDI operation mode. The following operations will be available in this mode. * MDI block operation * Editing of data in the data bank (tool list, tool pattem, drill hole dia for tapping, cutting conditions, parameter) *Setting tool length (#8) This key is used for automatically measuring and inputting the length of tool mounted in the spindle while editing data in the tool list in the MDI operation mode. Ej This key is used for selecting the memory operation mode. Operation can be executed by calling the required program stored in the memory. @ This key is used for operating the program which is called in the memory operation motion by motion. (Cycle operation will be executed when the lamp is off.) ‘ony Rn This key is used for program check in the dry run operation. In this mode, a rapid feed and automatic tool change are executed as programmed and cutting feed is executed at a high speed in the manual operation, ‘The Z-axis is operated at a higher position by dry run offset amount as set by Parameter 1. -103-Key Functions This key is used for selecting the program edit mode. ‘The following operations are available in this mode. * Editing of machining data * Editing of motion programs * Editing of motion schedule programs * Memory display * Inputting/outputting of external programs (=) This key is used for setting the current X/Y coordinates as the working Ld zero position during machining data editing. This key is used for checking the cause when the tool specified during se program editing cannot be assigned from the tools registered in the Es tool list. 1, This key is used for automatically selecting the available tools from the tool list during tool assignment, ("ise 2. Items with [2] mark in the program are automatically calculated in oor tool assignment. 3. It is also used for starting communication with external equipments during external program inputting/outputting. This key is used for displaying the current X/¥/Z coordinates, remaining amount of each axis motion to the specified position as well as the number, name and length of tool mounted in the spindle, This key is used for displaying all the alarms currently occurring on the screen, while only a typical alarm can be displayed on the screen at one time in other cases. Up to 9 alarms are displayed by pressing this key. =104-Key Functions This key is for diplaying the block operation screen in the memory operation and MDI block operation for program editing. This key is for displaying the machine control status during trouble shooting. (This key is not required during operation.) This key is used for displaying the initial screen of the manual operation mode. Speed for each feed and spindle rotation can be set in the following ranges. .5 steps (10, 25, 50,75, 100%) * Jog feedrate .......22 steps (50, 62, 77, 95, 115, 140, 170, 205, 290, 340, 400, 500, 625, 700, 800, 1000, 1250, 1575, 2000, 3150, 5000mm/min.) * Step length 4 steps (0.001, 0.01, 0.1, 1.0mm) * Spindle speed ......21 steps (100, 125, 155, 190, 230, 280, 340, 410, 490, $80, 680, 800, 1000, 1250, 1400, 1600, 2000, 2500, 3150, 4000, 6000, xpm( min*)) This key is used for setting and displaying of the magazine pot num- bers for 60 tools registered in the tool list set in the data bank mode. ‘These operations are available only in the MDI mode. In other modes, current tool name and its pot number only can be displayed. ‘This key is used for setting of or referring to 5 kinds of data on tool list, tool pattern, drill hole dia for tapping, cutting conditions and pa- rameter. Select the MDI mode for inputting of data, and any other mode for referring to data. This key is used for deleting displays on the CRT screen. = 105-Functions ‘This key is used for shifting the cursor to the previous setting item. ‘This key is used for shifting the cursor to the next setting item. o ‘This key is used for scrolling the screen of programs and data to the ee previous page when they cannot be displayed at one time. ro) ‘This key is used for scrolling the screen of programs and data to Pe the next page when they cannot be displayed at one time. AOS ‘This key is used for inputting numerical data. This key is used for inputting the data in the data input area into the program display area. This key is used for cancelling the data in the data input area. (Once [ENTER] key is pressed, [CAN] key is not effective any longer.) ‘This key is used for deleting the programs and data stored in the memory. This key is used for adding data to the program already stored in the memory. i =106-= 108-1-6 7-7 Chapter 7 Manual Operation Manual Operation Zero Position Return Return to Working Zero Position Axis Feed Rotating and Stopping Spindle Tool Change Magazine Rotation7-1 Manual Operation This section describes manual operation for axis feed, spindle rotation, too! change and magazine rotation. After power is turned on or in the manual mode, the following screen (1) is displayed initially. ‘Screen (1) 2) By pressing [RAPID], [JOG], [STEP], [S.CW] [S.CCWJ, or [S.STOP] key, the cursor moves to the relative position. By pressing [CURSOR (DOWN)] key once, the cursor moves downward. -110-te7-2 Zero Position Return Each axis can be returned to the zero position in the following procedures. ‘The coordinate values at this time show 0 for X, Y axes, and the value as set in the parameter #2 for Z axis. Press [MANU] key and select the manual operation mode. 1) Press [AXIS] keys to move the X and Y axis so that the spindle may come to the center of the table, and move the Z axis, resulting in positioning the spindle nose 300mm above the table top. ‘Refer to Section 7-4 for details of axis feed. 2) Press [W.Z.RT] key. (The lamp on this key as well as that of START switch will be lit) After Z axis goes up and returns to the zero position, the X and ¥ axes simultaneously go back to the respective zero positions. -112-3) After the completion of the X/Y/Z-axis zero position return, the screen changes as shown oon the left. The lamps on both [M.Z.RTN] key and START switch will go off at this time. FEE (1) None of the 3 axis can excoed the stroke as set by parameter 2 after completion of zero position return. Ifitis necessary fo move any of the axes beyond the stroke| limit, press [AXIS] key while pressing [RELSE] key. (2) If any axis has exceeded the stroke limit and an overrun error occurred, return the relative axis to its zero position again. In case of overrun Press (1) [RESET] key and (2) [AXIS] key ([-X], [+X], FV]. [+¥]. 621, [+Z]) while pressing [RELES] key to return the relative axis within the stroke limit. Then execute zero position return afterwards. -13-7-3 Return to Working Zero Position This section describes how to return each axis to the working zero position as set in the MDI mode or in the programs operated in the memory operation mode. qT /ork coodinates have to be determined before work zero position retum. Refer to 8-3 " Data inputting for operation.") Press [MANU] key and select the manual operation mode. 1) Press [POS] key. The current positions of the X, Y and Z axes will be displayed respectively. 2) Press [W.Z.RT] key. (The lamp will be lit) The lamp of [START] switch will be lit at the same time. <4.3) The Z axis moves up and returns to its zero position. 4) The X and Y axes return to the working zero positions as set in the MDI or memory operation mode. 5) After the completion of return to each working zero position, the lamp of the [W.Z.RT] key will go off. -115-7-4 Axis Feed (1) - Rapid Feedrate The X, Y and Z axes can be moved at a rapid feedrate by pressing respective [AXIS FEED] keys. ‘The feedrate can be selected from the following five steps - 10%, 25%, 50%, 75%, 100% - of the max. feedrate as set in parameter #2. Press [MANU] key and select the manual operation mode. ‘Then press [MANU COND] key. Ex. ) The max. feedrate set in parameter #2 is as follows: ‘The feedrate is set to 50%. 1) Press [RAPID] key. (The lamp is lit) Move the cursor to RAPID FEEDRATE. The rapid feedrate is set at 10% at this time. 2) Select “50%” by [INC] key. The X and ¥ axes move at 12,500mm/min, and Z axis moves at 10,000mm/min. at this time. -116-3) Press [POS] key. ‘The screen as shown on the left is displayed. 4) Move X, Y, Z axes in either the (+) or () direction by respective axis feed keys. To increase the max. rapid feedrate set in the parameter #2 is not possible. When the max. rapid feedrate by manual operation is set at 5,000mm/min. in the parameter #2 (for each axis), for example, each axis will not move at a higher speed than 5,000mm/min. even if the operator tries to. x.) When the feedrate is set at 25%, the feedrate of X axis is calculated as follows. 25,000 (mm/min.) x 0.25 = 6250 (mm/min.) The axis, however, will move at 5,000 (mm.min.) virtually. Reiter to 8-9 Parameter for details. -117-7-4 Axis Feed (2) - Jog Feedrate The X, Y and Z axes can be moved at an actual cutting speed as long as. respective Axis Feed keys are pressed. The jog feedrate can be selected from 22 steps - 50 ~ 5000mm/min. Select the manual operation mode first by pressing [MANU] key. Then press [MENU COND] key. When each axis, for example, is moved at 1,000mm.min. : 1) Press [JOG] key (the lamp is lit at this time.) and move the cursor to JOG FEEDRATE, 2) Select 1,000mm/min. by [INC] key. -118-3) Press [POS] key. ‘The screen as shown on the left will be displayed. 4) Move the X, Y and Z axes in either the (+) or () direction by respective Axis Feed key. -119-7-4 Axis Feed (3) - Step Length Feed in each axial direction is performed step by step at a designated amount each time the relative Axis Feed key is pressed. ‘Axis feed amount can be selected from the 4 steps - 0.001, 0.01, 0.1 and 1.0mm per step. Press [MANUJkey and select the manual operation mode. Then press [MANU COND] key. Ex.) Each axis is to be moved by 0.Imm/step. 1) Press [STEP] key (the lamp is lit.) and move the cursor to STEP LENGTH. 2) Select 0.1mmystep by [INC] key.3) Press [POS] key. The screen as shown on the left will be displayed. 4) The axes move by +0.1mm or -0.1mm each time the respective Axis Feed keys are pressed. -121-7-5 Rotating and Stopping Spindle The spindle can be stopped or rotated (CCW/CW) by manual operation. Spindle speed can be selected from the 21 steps in the range of 100~6000rpm(min" ). Select the manual operation mode by pressing [MANU] key and press [MANU COND] key. ‘When the spindle is to be rotated at 1,000rpm(min"!) 1) Move the cursor to SPINDLE SPEED by pressing [CURSOR] keys. 2) Select the spindle speed of 1,000rpm(min") by [INC] key. =122-3) By pressing [S.CW] key (the lamp is spindle will be rotated at 1,000rpm(min’ the CW direction. 4) in By pressing [S.CCW] key (the lamp is lit), the spindle will be rotated at 1,000rpm(min") in the CCW direction. By pressing [S.STOP] key (the lamp is lit), the spindle will be stopped. (The lamps on both [S.CW] and [S.CCW] keys will go off at this time.) E During the spindle rotation, DO NOT TOUCH THE SPINDLE BY HAND OR OTHER MATERIALS as it is dangerous. -123-7-6 Tool Change Change the tool in the position for replacement with the one in the spindle in the following 3 sequences. Press [MANU] key and select the manual operation mode. (A) Press [ATC] key. ‘The Z axis will return to the machine zero position, The spindle will be positioned at a designated point (spindle orientation-the two keyways in the spindle becomes parallel to the ¥ axis). (2) Press [ATC] key. The Z axis will move upward and be positioned at the ATC zero position. (3) Press [ATC]key. The magazine will rotate and index the next tool. (4) Press [ATC] key. The Z axis will go downward to the machine zero position. The operation is completed now. 1. Only one motion will be executed each time the key is pressed. Therefore, press the key after each motion is completed. 2. After the lamp of [ATC] key is off, the next motion is available.-125-7-7 Magazine Rotation Rotate the magazine for tool indexing. Press [MANU] key and select the manual operation mode. (1) Press [ATC] key. ‘The Z axis will return to the machine zero position, The spindle will be positioned at a designated point (spindle orientation - the two keyways in the spindle become parallel to the Y axis). (2) Press [ATC] key and move the Z axis to the ATC zero position. (3) Press [SINGL MAGAZ] key. ‘The magazine will rotate to index at the next station. Each time the key is pressed, the ‘magazine will rotate to the next station, (@ After this motion is completed, return the Z axis to the machine zero position. ped [SINGL MAGAZ] key is effective only when the Z axis is returned to the ATC zero position. -126--127--128-8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 Chapter 8 MDI Operation MDI Operation Data Setting (Block Operation) Data Inputting for Operation (Example for Block Operation) Data Input, Modification and Reference @ata Bank) Tool Registration Setting of Tool Pattern Setting of Drill Dia for Tapping Setting of Cutting/Tool Conditions Setting of Parameter 8-10 Tool Setting in Magazine 8-11 Display of YO Status8-1 MDI Operation The machine can be operated by directly inputting the necessary data. 1) Press [MDI] key. (The lamp will be lit at this time.) The CRT screen will display the screen as shown on the left, The cursor flickers at COORDINATE at this, time, 2) Press [CURSOR (NEXT)] key and move the cursor downward one by one. By pressing [START] switch, the operation is executed according to the inputted data. The cursor returns to COORDINATE upon completion of operation. 1. By moving the cursor, the menu displayed in the data input area is changed accordingly. 2. When several items are set, the items displayed on the initial screen will be ‘executed in order from the top one. -130--131-8-2 Data Setting (Block Operation) Axis feed or machining operation can be executed as one cycle motion by setting a single or several items. Press [MDI] key and display the block operation screen of the MDI mode. Display the block operation screen of MDI mode by pressing [MDI] key. Data on the item indicated by the flickering ccursor in the data input area can be set. Details of each item in the block operation will be described in the following pages. = 132-Item Description COORDINATE ‘Work zero positions for the X/Y axes are at the present machine coordinates, and work zero position for the Z. axis is at the position which is above the table top by the length of tool mounted in the spindle. EXT. SIGNAL Signals for operating such devices as signal light, automatic door, etc.. are outputted. These signals are usually set as customer's requirements, but the following signals are previously set upon delivery. * Machine interior code : 08 : Coolant valve ON 09 : Coolant valve OFF 05 : Spindle stop 19 : Spindle orientation jpindle orientation (0°) 21 : R/L pallets OUT (simultaneously) (for PPC specifications) 22 : Machine stop during pallet IN (for PPC specifications) 400 : Chip shower ON hip shower OFF + Signal code prohibited from setting : : Spindle CCW rotation 30 : Program end TOOL Tool change with the one in the specified pot number. COOLANT Setting of coolant valve open/close. SPINDLE Setting of spindle rotation/stop S. SPEED Spindle speed can be selected in the range of 6min.” through the max. value as set in the parameter #2. Set a tap rotation speed for tapping operation. -133-Item Description AXIS MOVE The X, ¥ and z axes can be moved to the machine zero positions, work x zero positions and other positions as requied. ¥ ‘The X and Y axes can be simultaneously moved, and the Y axis always Zz moves independently. FEED Select a required feed method for X, Y and Z axes from the followings. 0: POSITIONING Each axis moves at the max. rapid feedrate set in parameter #2. 1: CUTTING Each axis moves at the cutting feedrate selected by [JOG] key. 2: TAPPING . Feedrate for tapping is designated by the spindle speed and the used tool pitch. FEEDRATE Setting of the feedfate for cutting £ Spindle rotation and coolant discharge do not stop even if the machining operation is completed. To stop them, move the cursor to SPINDLE or COOLANT, and set the required data. -134--135-8-3 Data Inputting for Operation (Example for Block Operation) Machine can be started by inputting the necessary data in the MDI operation mode. 8-3-1 Setting of Work Coordinate System Press [MDI] key and display the block operation screen of the MDI mode. 1) The cursor flickers at COORDINATE. 2) Press [POS] key and check the current position of the spindle on the screen. JEG The current machine coordinates wil be the working zero postions for X and Y axes, and the table surface by the used too! length will be the working zero position for the Z axis. -136-3) When the displayed current position can be used as a work zero position, input [1] (1:ON) by the mumerical key and press [ENTER] key. If the current position cannot be used as a work zero position, move the axis to the required position in the manual operation mode. (Z]) Reterto 7-4 Axis Movement for "details. 4) Work coordinates as displayed on the left screen will be set by pressing [POS] key and [START] switch. Setting of work zero position is completed nov. ‘The screen as shown on the left is displayed by pressing [POS] key. bed Before starting the MDI operation, set the work coordinates first. -137-8-3-2 Outputing of External Signal When the extemal signal 5 is to be outputted : Press [MDI] key and display the block operation screen of the MDI mode. 1) Move the cursor to EXT. SIGNAL by pressing [CURSOR (NEXT)] key.” 2) Input [5] by the numerical keys, and press [ENTER] key as well as [START] switch. (The lamp on [START] switch is lit) 3) After the completion of the above operation, the lamp on [START] switch will go off, -138-Signals are sent to the output terminals by the BCD 2 code. CODE 2 (2-8) (2=4) (2'=2) (2=1) BCD 0 0 1 0 Terminal block es Moa M22 Mot Output signal e CODE 54H) (2-8) (2=4) (2=2) (2=1) BCD 0 1 Oo 1 Terminal block Mia M14 Mi2 Mit Output signal e e (Output singals in the NC unit are sent to the position with @ mark in the above table. -139-8-3-3 Tool Change ‘When the tool in the Pot No. 3 is to be mounted in the spindle : Press [MDI] key and display the block operation screen of the MDI mode. 1) Move the cursor to TOOL by pressing [CURSOR (UP)] key. 2) Input the Pot No. [3] by the numerical keys, and press [ENTER] key and [START] switch. (The lamp on [START] switch is lit)3) The Z axis returns to the machine zero position and the magazine rotates to set the tool in the Pot No. 3 in the spindle. (The magazine rotates by random access selection system at this time.) 4) After the completion of the above operation, the lamp on [START] switch will go off. FER + During magazine rotation, do not touch it or get inside ofthe motion range. 2. Before starting a tool change operation, make sure that the tools are securely mounted into the magazine pot. =i8-3-4 Coolant Discharge and Stop ‘Tur the coolant motor switch on the operation panel to ON. Press [MDI] key and display the block operation screen of the MDI mode. 1) Move the cursor to COOLANT by pressing [CURSOR (DOWN)] key. 2) Input [1] (1 : ON) by the numerical key, and press [ENTER] key and [START] switch. (The lamp on [START] switch is lit at this time) -142-3) Coolant is discharged. 4) Move the cursor to COOLANT again by [CURSOR (DOWN) key. Input [0] @: OFF) by the numerical key, and press [ENTER] key and [START] switch. 5) Coolant discharge stops. FE 1. Betore the above operation, turn the coolant motor switch on the operation panel to ON. 2. When coolant is not used, turn the coolant motor switch to OFF. -143-8-3-5 Spindle Rotation and Stop ‘When the spindle is to be rotated at 4,000rpm(min') in the CW direction : Press [MDI] key and display the block operation screen of the MDI mode. 1) Move the cursor to SPINDLE by [CURSOR (DOWN)] key. 2) Input [1] (1 : CW) by the numerical key, and press [ENTER] key. (The cursor moves to $. SPEED at this time.) -144-3) Next, input [4000] by the numerical keys, and press [ENTER] key and [START] switch. 4) Spindle rotates at 4,000rpm(min.~) in the CW direction. 5) Move the cursor again to SPINDLE. Input [0] (0: Stop) and press [ENTER] key and [START] switch. 6) The spindle rotation stops. - 1458-3-6 Axis Feed ‘When the X axis is to be moved to the position -150,000mm away from the working zero position or the current position. : Display the block operation screen of MDI mode by pressing [MDI] key. 1) Press [POS] key. Check the current position of X axis on the left screen. 2) Press [PRGRM] key and display the block operation screen. Move the cursor to AXIS MOVE by pressing [CURSOR (DOWN) key. - 146 -3) Input [0] (0 : DESIGNATE POS) by pressing the numerical key for axis movement to the designated position, and press [ENTER] key. 4) Check that the cursor flickers at X. Then, input [-150] by the numerical keys, and press [ENTER] key. Be sure to input a decimal point. [-150,] = -150mm [-150] > -0.150mm -147-5) Move the cursor to FEED by [CURSOR (DOWN)] key. Input [0] (0: Positioning) and press [ENTER] key and [START] switch. ©) The X axis moves to the specified position. Check the position by pressing [POS] key. -148-8-3-7 Drilling Operation roars CurREWT PostrIoN 215mm} ie ECE uercHT Ora Spindle : CW rotation, 2000min.* Feeddrate : 200mm/min. Tool No. : Drill No, 2 (4.9mm) Drilling of hole (3.9) in the aluminum material is to be performed. : ‘The Z axis moves to 130.0 on the work coordinate ata feedrate of 200mm/min. and spindle speed of 2000min.*, Drill No. 2 is curently mounted in the spindle. gz 1. Check that the work coordinate ” and coolant status are correctly set. ” 2. Move the Z axis (tool end position) to 155mm away in advance. Display the program operation screen of the MDI mode by pressing [MDI] key. 1) Move the cursor to SPINDLE by [CURSOR (DOWN)) key. Input [1] (1 : CW) by the numerical key and press [ENTER] key. -149-2) Check that the cursor flickers at S. SPEED. Input the spindle speed [2000] and press [ENTER] key. 3) Check that the cursor flickers at AXIS MOVE. Input [0] (0: DESIGNATE POS) by the numerical key and press [ENTER] key. -150-4) Move the cursor to Z by [CURSOR (DOWN)] key. Input work coordinates [130.] by the numerical keys and press [ENTER] key. | Do not input numerical values for the X and Y axes and skip by pressing [ENTER] or [CURSOR (DOWN)] key. 5) Check that the cursor flickers at FEED. Input [1] (1: Cutting) by the numerical key and. press [ENTER] key. = 151+6) Check that the cursor flickers at FEEDRATE. Tnput [200] by the numerical key and press [ENTER] key and [START] switch. 7) The Z axis starts to move at JOG feedrate. Display the current position screen by pressing [POS] key, and check that the Z axis is at 130. The spindle does not return to the zero position even if the Z axis coordinates becomes 130.0 as designated. It keeps rotating at the same position until the next commandis given. Command to move the X or ¥ axis or to change tools should be avoided while the spindle is at this position. -152-8) Select the MDI mode by pressing [MDI] key and return the Z axis to a higher position than the machining start point. Peter to 7-4 Axis Feed for details. 9) Select the MDI mode by pressing [MDI] key and stop the spindle rotation. Refer to 7-5 Rotating and Stopping | Spindle for details. * -153-8-3-8 Tapping Operation ‘Tapping under the following conditions is to be performed. waceraru M343 rout Pitch 0.75 No. 4 - tap is mounted in the spindle currently. : 1. Check that the work coordinates Spindle +2,000epmin’) and coolant status are correctly Tool No. No. 4P- Tap a SEO ERO EN 2. Move the Z axis to 155mm away from the table surface. Display the program screen of the MDI mode by pressing [MDI] key. 1) Move the cursor to S. SPEED by pressing [CURSOR (DOWN) key. Input [2000] by the numerical keys and press [ENTER] key. -154-2) Check that the cursor is flickering at AXIS MOVE, Input [0] (0 : DESIGNATE POS) by the numerical key and press [ENTER] key. 3) Move the cursor to Z by [CURSOR(DOWN)] key. Input [130.0] by the numerical keys and press [ENTER] key. -155-4) Check that the cursor is flickering at FEED. Input [2] (2 : Tapping) by the numerical key and press [ENTER] key and [START] switch, 5) Zaxis starts tapping operation. After the completion of tapping operation, the Z axis automatically returns to the tapping start point. 1. Start operation after mounting a tap in the spindle. 2. In the tapping cycle, the spindle is synchronously fed according to the tapping pitch as set in the tool menu list. 3. Tapping step is done by a reducing step method. (Step ratio : 100%) -156--157-8-4 Data Input, Modification and Reference (Data Bank) Various kinds of the data required for conversational programming and machine operation are stored in the data bank. 1) Press [DATA BANK] key. ‘The screen as shown on the left is displayed as the screen of the data bank menu. = Various data in the data bank can be modified and registered in the MDI mode. In other modes, however, only reference is available and modification cannot be done. Select the MDI mode before registration or modification of data. Refer to Chapter 6 "Tool Pattern" or Chapter 7 “Cutting Condition" in Programming Manual. - 158+ 159-8-5 Tool Registration (1) This section describes how to register names, dimensions, shapes and expected life of tools to be used for the operation. ‘There are 20 kinds of tools, and max. 60 tools can be registered. (19 kinds of tools are available for the memory operation.) Press [MDI] key and select the MDI mode. Display the screen of the data bank menu by pressing [DATA BANK] key. 1) Set PROGRAM PROTECT switch to OFF. 2) Input [1] (1 : Tool Menu) by the numerical key and press [ENTER] key. The cursor flickers at TOO! at this time, 3) Move the cursor to the number of tool to be registered by [PAGE] and [CURSOR] keys. Or input the tool No. directly by the numerical key for this purpose. -160-4) The cursor moves to TOOL by pressing [F1] key (Tool setting), 20 kinds of tools are displayed in the teach data area at this time. Data setting is ready now. | 1. 20 kinds of tools cannot be ' displayed at one time in the teach data area. Undisplayed tools can be shown on the screen by pressing [NEXT] key. ‘ealh 2. The contents of the finctions keys ==" can be checked by pressing [FUNC] key. 5) Select the required tool, and input the tool No. by the numerical key and press [ENTER] key. When [2] (Drill) is to be selected, for example, input [2] and press [ENTER] key. -161-6) According to the selected tool, items to be inputted are displayed. Input the data on tool dimensions and shape by the numerical keys and press [ENTER] key. 7) After data setting is completed, press [Fo] key (Editend). According to the message in the teach data area, terminate the operation, Press [Fo] key (Edit end) to register the inputted data.8) The screen of the data bank menu will be displayed again. The tool registration is completed and the data is registered. 9) Turn PROGRAM PROTECT switch to OFF. HEB +- When the tool cimensions or shapes are changed, the data must be also modified. In this case, check the relative programs by assigning the tools to see if the data are correctly modified. 2. Be sure to register the tool dimensions or shape correctly. If the contents of the data registered in the tool menu differ from those actually mounted in the magazine, it will cause a damage on tools, workpieces or fixtures. 3. Itis recommneded to put the numbers on the tools so that the registered tool data and the actual tools can be in conformity. 4. 20 kinds of tools cannot be all displayed in the teach data area at a time. The tools which are not displayed can be referred to by pressing [NEXT] key. -163-Contents of the function keys can be checked during editing by pressing [FUNC] key. Contents of the function keys in tool menu (Fo) : End edit The mode for terminating editng is available. When this mode is selected, the contents of the function keys are automatically displayed in the teach data area. Terminate editing according} to the instructions of the functionkeys. [F\] : Tooltoo! No. setting [Fo] : [Fe]: IF: (Fol ] [Fe] Data bank menu screen This key is for selecting the tool number setting mode for shifting the cursor to the specified number in the tool list or tool setting mode for inputting the tool kind and dimensions. When the tool list is selected from the data bank menu screen, the tool number setting mode will be displayed firstly. Set the tool number for editing and press [F] key to enter the tool kind and dimensions. Edit end Edited data is registered in the memory. Cancel edit Edited data becomes ineffective and cannot be registered in the memory. Edit mode Editing is available again. -164-Mi Contents of Data Registration Item Contents Tool Registration ‘TOOL NO. Registration No. of tools Max. 60 tools from 1 - 60 can be registered. TOOL Required tools can be selected from 20 kinds in the teach data area POINT ‘Angle of tool end Center dull, Drill, Cabide dell, ANGLE : Chamfer drill, Stepped drill, Drill tap, Drill reamer SMALL OD of tool end Center drill, Chamfer tool, Counter- DIA.:d boring tool, Chamfer drill, Stepped drill, Drill tap, Drill reamer, Chamfer milling tool, Centering tool SMALL Length of tool end Center drill, Counter boring tool, DL: Chamfer drill, Stepped drill, Drilll tap, Drill reamer ANGLE : 6 Large dia. angle of center drill Center drill, Chamfer tool, Chamfer or end part angle of chamfering drill, Chamfer milling tool tool and chamfering milling tool -165-tem Contents Tool Registration INEF.L.:Lo | Chamfer length Spiral tap, Point tap, Hand tap, Rolled * For tapping, specify the pitch | tap, Drill tap, Reamer, Drill reamer, ‘or number of threads. Chamfer tool DIAMETER | OD of tool All tools except centering tool :D * For tapping, specify the thread type and size (O.D) PCH For tap: Sprial tap, Point tap, Hand tap, THR/:P Pitch Mt Rolled tap, Drill tap NW 1 inch Metric ‘Threads NW Inch No. of threads per inch FLUTE:L | Length of cutter flute Drill, Carbide drill, Sprial tap, Point tap, Hand tap, Rolled tap, Counter boring tool, Chamfer drill, Stepped drill, Drill tap, Reamer, Drill reamer, End mill R, End mill F, Carbide end mill R, Carbide end mill F = 166-Item Contents Tool Registration TORSION | Direction of thread. Select the Sprial tap, Point tap, Hand tap, direction (right or left) in the teach Rolled tap data area. FLUTE No. of cutter flute for end mill or End mill R, End mill F, Carbide chamfer milling tool end mill R, Carbide end mill F, Chamfer milling tool OVERALL | Tool length from tool holder gauge line | All tools L:LL to tool end TOOL LIFE | Setting of life time for the registered All tools except centering tool min, tool Setting is made by “minute”. When the expected life as registered is expired during MEMORY operation, a spare tool specified in the magazine is called ut, and machine continues operation. When the spare tool is not specified, an alarm occurs. -167-Ml List of the Required Items for Too! Registration Tools 1239 4 5 9 10 tems | POINT ANGLE a | SMALLDIA. d ofofo]-[+i-[-]- | : | ° SMALL DL. ole faleleiel.fololo ANGLE - of-|-]-}-:-]-]-]o qc INEF. L Lo Sey tsb oaddé eyiye DIAMETER D ° °o ° ° ° ° ° ° ° ° PCH THRM Pp . . *|[olotofo]« [-. : FLUTEL OL sfolololefolo}-folo TORSION direction | + | « | « | o | co: oflot+ets |]. FLUTE sfefelete iste}. hoy. OVERALL L Lu ° ° ° o1o ° oO ° | ° ° TOOLLIFE min, olololoje ololololeo (1) Center ail (6) Hand tap (2) Drill (7) Folled tap (3) Carbide aril (8) Chamier tool (4) Spiral tap (9) Counterboring too! (©) Point tap (10) Chamter drill 168 -Tools 11012 «13:«14«15 «16 «17:«18«19° «20 Items POINTANGLE a olol«lol«el«le]-e|ed SMALLDIA. d stal«~tal~|2lele lel SMALL D.L. oflo}-lol-ie]}-]-]- ANGLE ‘ efede fe flit yl pite INEF. L Lo spotofots [syste] e DIAMETER | olofotclolojo! PCH THRII P [eur irist ris | eds FLUTEL =k ester ele epee TORSION direction |} to 6 | ololo i PUITE: ofolojo ofolololo} OVERALLL =—oLL clofoflololololojo| TOOLUFE min. (11) Stepped dil (17) Carbide end mill R (12) Drill tap (for rough finish) (13) Reamer (18) Carbide end mill F (14) Drill reamer (for finish) (15) End mill R (19) Chamter mill (for rough finish) (20) Centering too! (16) End mill F (for finish) -169-fl indication of Tool Shape and Dimensions 1, Center drill d=0 a -——-—} eno 2. Drill 3. Carbide drill5. Point tap Right or left 6. Hand tap Right or left -171-8. Chamfer tool 9. Counterboring tool Q 10. Chamfer drill -1n-Right or left 13. Reamer 14, Drill reamer -173-15. End mill R (for rough finish) 16. End mill F (for finish) 17. Carbide end mill R (for rough finish) 18. Carbide end mill F (for finish) Zo < L . of teeth 19. Chamfer mill -(ol> Be No. of teeth -174-20. Centering tool Tool length -195-8-5 Tool Registration (2) - Specification of Auxiliary Code When the same kinds of tools are used, they can be specified by auxiliary codes 1-9. Press [MDI] key and select the MDI mode. Then, display the intial screen of the data bank by pressing [DATA BANK] key. When the auxiliary code 1 is used to specify a drill : 1) Set PROGRAM PROTECT switch to OFF. 2) Input [1] (1 : Tool Menu) by the numerical key, and press [ENTER] key. 3) Move the cursor to the tool No. for registration of an auxiliary code by using [PAGE] and [CURSOR] keys or inputting the tool No. by the numerical key, and press [F1] (Tool setting) key for data setting. The contents of function keys can be checked by pressing [FUNC] key. -176-4) Setting of the drill with an auxiliary code is completed. The left screen shows that a drill is set in the tool No. 32 and the auxiliary code [1] is being specified. Input [2] (Drill) [ - ] [1] and press [ENTER] key. Register the tool dimensions, shape, etc. according to the registration method in the tool menu. 5) Press [Fo] key, and terminate editing as indicated by the function key (end mode). 6) Turn EDIT switch to OFF. FE_ 1- Inputing by the numerical keys incicate as below. : to 7 ot Tool name Auniliary code 2. By setting an auxiliary code in the tool menu and using the same code for tool registration in the Cutting Conditions 1 and 2, the tool specified by the auxiliary code will be selected in the tool assignment. -177-8-5 Tool Registration (3) - Setting of Tool Length From the current position and the tool length offset amount set in the parameter #1, length of the tool mounted in the spindle is calculated, and automatically registered in the tool list. Press [MDI] key and select the MDI mode. 1) Tum EDIT switch to ON. 2) Press [MAGAZ] key and check the screen to see that the tool mounted in the magazine and the one displayed on the screen are identical. Refer to 8-10 Tool Setting in Magazine (1). Mount the tool to be measured in the spindle. wi x fe) Refer to 8-3-3, Tool Change. -178-3) Display the initial screen of data bank by pressing [DATA BANK] key. Input [5] (5: Parameter) by the numerical key, and press [ENTER] key. The screen of parameter menu will be displayed. 4) Input [1] (1 : Switeh) by the numerical key and press [ENTER] key. The parameter 1 switch menu will be displayed. -179-5) Move the cursor to TOOL LENGTH OFFSET VALUE by pressing [CURSOR (DOWN)] key. Input the dimensions of [A] (Height of the height presetter) as in Fig. 1 (P. 151) and press [ENTER] key. The tool length offset value is set accordingly. The left screen shows that the tool offset amount has been set at 50. 6) After the completion of setting, press [Fo] key and terminate editing as indicated by the function key in the teach data area. a The contents of function keys can be checked by pressing [FUNC] key. -180-7) Press [MANU] key and select the manual operation mode. Move the Z axis downward so that it may slightly touch the height presetter surface at the tool length measuring position, || Referto Fig. 1 (P. 178) 8) Press [MDI] key and select the MDI mode. Then press [DATA BANK] key to display the ‘menu screen of the data bank, Input[1] (1 : Tool Menu) by the numerical key and press [ENTER] key. The screen shows a case that a length of tool (02 Drill) is set to 150.000. 9) Press [TOOL OFSET] key and display the screen of tool length setting. 10) Check the tool length displayed on the screen. Press [FO] key for setting the tool length and press [F1] key for not setting. By pressing either of the keys, the screen of tool list will be displayed again. 11) Select the edit end mode by pressing the function key and terminate tool length set- ting. 12) Tum the PROGRAM PROTECT switch to ON. -181-GAUGE LINE Z-axis machine coordinate Fig. 1 HEIGHT PRESETTER (or BLOCK) Value for (B-A) is set asa tool length. SEE Check that the tool mounted in the magazine is the same as the one displayed on the screen. If they are not identical, it may cause a machine damage, etc. -182-=183-8-6 Setting of Tool Pattern This section describes how to set names and sequence of tools to be used for the machining process. For one machining process, a machining pattem can be selected from 2 kinds - “With Chamfer” and “Without Chamter”, ‘The tool pattern required for each machining process is automatically set in tool assignment. Press [MDI] key and select the MDI operation mode. Then press [DATA BANK] key and display the menu screen of data bank. 1) Tum PROGRAM PROTECT switch to OFF. 2) Input [2] (2 : Tool Pattern) by the numerical key and press [ENTER] key. Move the cursor to the position to be modified by pressing [PAGE] and [CURSOR] keys. [Delete] Deleting of tool indicated by the cursor is available. 3) Press [DELET] key. The left screen shows that 1. C. DRILL with “HOLE” and “W/ CHAMFER’ is to be deleted. ‘The tool indicated by the flickering cursor is deleted, and the next data is available.Replacement of tool indicated by the cursor with the another tool is available, 4) Select the tool to be replaced from the teach data area. Input the tool number by the numerical key and press [ENTER] key. By pressing [NEXT] key, the tools No. 13~17 will be displayed in the teach area. The left screen shows that 2, DRILL with “TAP" and “W/CHAMFER” is to be replaced with 3. CRDRILL in the teach data area. In put [3] @ : CBDRILL) and press [ENTER] key at this time. a 17 kinds of tools cannot be displayed at one time in the teach data area. Undisplayed tools can be shown on the screen by pressing [NEXT] key. 5) The tool is replaced with another one. -185-[Insert] Inserting a new tool into the tool data currently displayed withon the screen. The new tool is in- serted right before the line indicated by the flickering cursor at this time. 6) Press [INSRT] key. Select the tool to be in serted from the teach data area. Input the tool No. by the numerical key, and press [ENTER] key. “C. DRILL” is inserted before “1. DRILL” as shown on the left screen. 7) By inserting of the selected tool, the following data move down one by one.8) After the completion of setting, press [Fo] key (end mode), and terminate the setting operation as instructed by the function key. | The contents of function keys can be checked by pressing [FUNC] key. 9) Turn the [PROGRAM PROTECT] switch to ON. BEE 1 Tools are automaticaly selected by the intial setting pattem in general, but the pattern must be changed depending on the machining method. Refer to the previous pages for changing patterns. 2. Total 17 kinds of tools are displayed in the teach data area, but they cannot be displayed at atime. To see the tool names which are not displayed, press [MENU] key. =187-Contents of the function keys in tool pattern editing When checking the contents of the function keys during esiting, press [FUNC] key. [Fo] : END MODE Mode for terminating editing will be available. [Fi] : PREVIOUS PATTERN The cursor will move to the beginning of the previous machi [F2] : NEXT PATTERN The cursor will move to the beginning of the next machining process. i i process. Contents of the function keys in the edit end mode in tool pattern editing. [Fo] : EDIT END Contents after being edited are registered in the memory. [Fe] : CANCEL EDIT Contents after being edited become ineffective and are not registered in the memory. [Fs EDIT MODE Editing is available again. Fo Fz] Screen of data bank menu ~ 188 -