ace cnc lathe instruction manual - Metaalbewerking Zennewijnen

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ACE CNC LATHE
INSTRUCTION MANUAL
MACHINE : ACE CNC LATHE
MODEL : LT-20 CLASSIC MC
CONTROL SYSTEM : FANUC Oi-TC
IMPORTANT
Before operating the ACE CNC LATHE LT-20 CLASSIC MC this instruction
manual should be read carefully.
This instruction manual should be kept in a safe place where it is always easily
accessible during operation of ACE CNC LATHE.
While this manual has been compiled to give the general description and usage
of the machine, there may be changes owing to continuous design and development. Also some options that have been custom built for your company may not
be included in this manual. Such options will be separately given as a supplement.
Suggestions for improvement are always welcome.
96-104 MC / IM-03
June ’06
ACE CNC LATHE
INSTRUCTION MANUAL
MACHINE : ACE CNC LATHE
MODEL : LT-20 CLASSIC MC
CONTROL SYSTEM : FANUC Oi-TC
IMPORTANT
Before operating the ACE CNC LATHE LT-20 CLASSIC MC this instruction
manual should be read carefully.
This instruction manual should be kept in a safe place where it is always easily
accessible during operation of ACE CNC LATHE.
While this manual has been compiled to give the general description and usage
of the machine, there may be changes owing to continuous design and development. Also some options that have been custom built for your company may not
be included in this manual. Such options will be separately given as a supplement.
Suggestions for improvement are always welcome.
96-104 MC / IM-03
June ’06
Contents
Page No.
INTRODUCTION
1.
2.
3.
4.
5.
6.
7.
8.
Preface
Notes on safety
Basic points of safety
Clothing and personal safety
Safety aspects related to workpiece and tooling
Safety aspects related to maintenance
Safety aspects related to workplace
Safety equipment
1.1
1.1
1.2
1.3
1.5
1.6
1.7
1.7
PREPARATION
1.
2.
3.
4.
Preparation to be done by the customer
Foundation drawing for installation
Environmental conditions
Power source intake
2.1
2.2
2.3
2.4
INSTALLATION AND STARTUP
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Lifting method using ropes
Installation check points
Grounding
Cautionary details concerning installation
Power on / power off check points
Manual operation check points
Manual / automatic operation check points
Automatic operation check points
Levelling
Installation and maintenance of inter-machine connection
3.1
3.2
3.3
3.3
3.5
3.5
3.6
3.8
3.9
3.10
MACHINE SPECIFICATION
1.
2.
3.
Machine overall views
Machine specification
Power capacity chart
4.1
4.2
4.4
Contents
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Bed
Head stock
Spindle brake assembly
Spindle encoder assembly
Spindle speed characteristics : Alpha P22i, 50 - 3500 rpm
Spindle speed characteristics : Alpha P22i, 50 - 4000 rpm
Work holding
Z-axis assembly
X-axis assembly
Turret
Tailstock assembly
Hydraulic system
Lubrication system
Coolant system
Page No.
4.5
4.5
4.6
4.7
4.7
4.8
4.8
4.9
4.10
4.10
4.11
4.13
4.14
4.14
WORK HOLDING
1.
2.
3.
4.
5.
6.
7.
8.
9.
Standard chucks and cylinders
Chuck installation - Standard chuck
Chuck installation - Hollow chuck
Standard chucking cylinder
Operation and adjustment of hydraulic chuck unit
Soft jaw boring
Spindle speed and chucking force
Sample drawing
Spindle details
5.1
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
APPLICATION - 12 STATION TURRET
1.
2.
Machine movable range
Interference diagram
6.1
6.7
Contents
Page No.
CONTROL SYSTEM
1.
2.
3.
4.
Fanuc Oi-TC specifications
G Code list
M Code list
Operator messages
7.1
7.7
7.10
7.11
MACHINE CONTROL PANEL
1.
2.
Operator control panel-1 diagram
Operator control panel-1 details
Description of operator control panel-1
Operator control panel-2 diagram
Operator control panel-2 details
Description of operator control panel-2
8.1
8.2
8.3
8.7
8.8
8.9
MAINTENANCE
1.
2.
3.
4.
Daily maintenance
Periodic inspection
Lubrication
Head stock realignment
9.1
9.2
9.3
9.7
1. PREFACE :
Proper operational techniques and safety procedures will be explained in detail by our
technical staff. The general principles for safe operation of Ace CNC lathe are outlined in
this manual.
All Ace lathes have been engineered for operational safety. You will note, for example, that
all rotating parts are protected by specially designed covers and shields. The entire machine
is covered to eliminate damage by metal chips and cuttings and to prevent an insecurely
clamped workpiece from being thrown out during cutting operations. If the Ace lathe is
operated in accordance with the manufacturer’s instructions, it will provide you with reliable
service. However, with machines of this nature, serious accidents may occur owing to
improper or careless operation. Do not attempt to operate this equipment without having first
read and thoroughly understood the contents of this instruction manual. Not every example
of improper operation or unauthorized usage which may lead to malfunction or an accident
can be anticipated. If a particular operation is not documented in the manual as authorized
usage of the equipment, it should be assumed that this is an unauthorized or improper usage
with potential danger and should be avoided.
2. NOTES ON SAFETY :
1.
This machine is provided with various safety devices to protect the operator and the machine.
However, these cannot cover all aspects of safety, therefore the operator must thoroughly
read and understand this chapter before operating the machine. The operator should also take
into consideration other aspects of safety related to particular environmental conditions and
materials.
2.
Three categories of safety guidelines have been used throughout this manual :
DANGER, WARNING and CAUTION.
Their meanings are as follows :
DANGER :
Failure to observe these instructions could result in loss of life.
WARNING : Failure to observe these instructions could result in serious injury or substantial
damage to the machine.
CAUTION : Failure to observe these instructions could result in damage to the machine or
minor injuries.
1.1
3.
Always observe the safety instructions inscribed on the safety nameplates fixed onto the
machine. Do not remove or damage these name plates.
4.
Do not attempt to operate the machine until you have read the manuals supplied with the
machine and have understood each of the functions and operating methods.
3. BASIC POINTS OF SAFETY :
1. DANGER
There are high voltage terminals on the electrical control panel, transformer, motors, junction
boxes and other equipment.
DO NOT touch any of them under any circumstances, when the power supply is ON.
Make sure that all doors and safety covers are fitted before switching on the power. If any
door or safety cover is to be removed, first switch off the main circuit breaker.
2. WARNING
Memorize the position of the EMERGENCY STOP button so that you can press it immediately from any position.
Take care not to touch any of the switches accidentally while the machine is in operation.
Take care not to catch your fingers in the chuck .
Under no circumstances touch a rotating workpiece or the tool with your hands or any other
object.
To prevent incorrect operation of the machine, carefully check the position of the switches
before operation.
If in the slightest doubt about a procedure, ask the person in charge.
Always switch off the main circuit breaker before leaving the machine.
If more than one person is operating the machine, do not proceed to the next step without
indicating to the other operator(s) that you are about to do so.
Do not modify the machine in any way that will affect its safety.
1.2
3. CAUTION
Do not subject the CNC unit, the operator panel, or the electrical control panel to strong voltage
fluctuations.
Do not change the parameter values, volume values, or other electrical setting values without
good reason. If it becomes necessary to change a value, first check that it is safe to do so,
then make a note of the original value so that it can be reset if necessary.
Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details
become illegible or if the name plate is lost, obtain a replacement from Ace and mount it in
the original position.
Do not open any doors or safety covers while the machine is in automatic operation.
Stop all machine operations before cleaning the machine or any of the peripheral equipment.
After a job has been completed, set up each part of the machine so that it is ready to be used
for the next series of operation.
4. CLOTHING AND PERSONAL SAFETY :
1. DANGER
Tie back long hair which could become entangled in drive mechanisms.
Wear safety equipment (helmet, goggles, safety shoes, etc.) whenever possible.
Always wear a helmet if there are any overhead obstacles in the work area.
Always wear a protective mask when machining magnesium alloys.
Always use safety shoes with steel toecaps and oil-resistant soles.
Never wear loose or baggy clothes.
Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of
entanglement in drive mechanisms.
Do not operate the machine while under the influence of drugs with powerful effects,
unprescribed drugs or alcohol.
Do not operate the machine if you suffer from dizziness or fainting spells.
Always use gloves when loading or unloading workpieces or tools and when removing chips
from the work area to protect your hands from sharp edges and heat generated during
machining.
1.3
2. WARNING
Close all doors and covers of the CNC unit, operation panel, electrical control panel and
junction boxes to prevent damage from water, chips and oil.
Check all electrical cables for damage to prevent accidents due to current leakage or electric
shock.
Do not handle coolant with bare hands since it is likely to cause irritation.
Operators with allergies should take special precautions.
Do not operate the machine during violent thunderstorms.
Check the safety covers regularly to make sure that they are properly fitted and that they are
not damaged. Repair or replace any damaged covers immediately.
Always obtain assistance in handling loads beyond your capacity.
Do not operate fork lifts or cranes or carry out slinging work unless you have undergone
officially approved training.
When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of
these machines.
Always use wire rope or slings as per standards, suitable for the load to be supported.
Do not adjust the coolant nozzles while the machine is in operation.
Do not remove or otherwise interfere with safety devices such as actuating dogs, limit switches
or interlocks in order to increase axis travel.
When loading workpiece blank onto or unloading the finished product from the machine,
make sure that the tools are as far away as possible from the work area and the spindle is not
rotating.
Do not wipe the workpiece or clear away chips with your hand or with a rag while the spindle
is rotating. Always stop the machine and use a brush.
Do not operate the machine with any of the safety covers removed.
Always wear gloves and use a brush to clean chips off the tool tip. Never use bare hands.
Stop the machine before mounting or removing a tool.
Check slings, chains, hoists and other lifting gear for defects before use. Repair or replace
defective gear immediately.
1.4
3. CAUTION
Do not allow chips to accumulate during heavy-duty cutting since they will be hot and could
start a fire.
Check that the belts have the correct tension before operating the machine.
Warm up the spindle and the axis motion mechanisms before operation.
Write the program for the warming-up operation so as to execute the functions of the full
range of the machine components.
Do not operate the operation panel switches while wearing gloves as this could lead to
incorrect operation or other mistakes.
Follow the sequence for switching off, press emergency switch off the power switch on the
CNC operation panel, switch off the machine circuit breaker, then switch off the factory power
supply.
5. SAFETY ASPECTS RELATED TO WORKPIECE
AND TOOLING :
1. WARNING
Always use tools suitable for the work and which conform to the machine specifications.
Replace the worn tools immediately, since badly worn tools are a cause of accidents or
damage.
Do not operate the spindle above the rated speed of the accessories mounted on it. Before
starting the spindle, check that any parts which are clamped onto it are properly secured.
If the centre hole on larger workpieces held between centres is too small, the work piece could
come off when cutting load is applied. Make sure that the hole is big enough and that is at
the correct angle.
Take care not to catch your fingers in the chuck.
Always use the correct lifting gear for heavy chucks and workpieces.
2. CAUTION
Make sure that the tool length is such that the tool will not interfere with fixtures or other
objects. Perform a test operation after mounting the tool.
After machining soft jaws, check if they grip the workpiece correctly and that the chuck
pressure is correct.
1.5
6.SAFETY ASPECTS RELATED TO MAINTENANCE:
1. DANGER
Always switch off the main circuit breaker before carrying out any maintenance work. This
will eliminate the possibility of the machinery being started inadvertently by someone else.
After the power has been switched off for a short while, check the voltage with a multimeter
or similar instrument to make sure that there is no residual voltage.
2. WARNING
Always switch off the main circuit breaker before replacing bulbs or other electrical equipment
and use products with the same specifications as the original.
Maintenance of electrical equipment must be carried out by qualified licensed electrical
engineers only.
Do not remove or modify overtravel limit switches, interlock limit switches, proximity
switches, or other safety devices.
When carrying out maintenance in high places, always use a suitable ladder or a service
platform and always wear a helmet.
Keep your fingers clear of belts and pulleys.
Do not start the machine until all the covers removed for maintenance have been refitted.
Wipe up any water or oil spills immediately and keep the maintenance area and the workplace
clean and tidy at all times.
3. CAUTION
Maintenance work should be carried out by qualified personnel in accordance with the
instructions of the person in charge.
Keep a stock of replacement parts.
Do not use compressed air to clean the machine or to remove chips.
Always use gloves when clearing away chips; never touch chips with bare hands.
Use only the specified grades of hydraulic oil, lubricating oil and grease or their equivalents.
When changing a fuse, check that the new fuse has the correct rating. (Using a fuse with too
high a rating could result in damage to the equipment).
Check the results of the maintenance work in the presence of the person in charge.
If one of the belts in a set has stretched beyond the prescribed limit, change the entire set.
Stop all machine operation before cleaning the machine or the surrounding area.
1.6
7. SAFETY ASPECTS RELATED TO THE WORK
PLACE:
1. WARNING
Immediately remove all water and oil spills from the floor and dry the floor to prevent
accidents.
Use strong service platforms only and make sure that nothing can slip off them. Keep
combustible materials well away from the work area or any other place where there are hot
chips.
Always provide sufficient working space and clear access to the machine and peripheral
equipment and store tools and other potential obstacles in a prescribed place away from the
machine.
Never place tools or other potentially dangerous objects on top of the headstock, turret or
covers.
Make sure that the nominal cross-sectional area of the power supply cable between the factory
power supply switch and the machine main circuit breaker is sufficient to enable a stable
supply for operation at the maximum output.
Protect all cables which will run along the floor from being damaged by chips, since this could
cause short-circuiting.
8. SAFETY EQUIPMENT :
This machine is provided with various safety devices to protect the operator and the machine.
The safety devices include interlock devices and emergency stop switches as well as doors
and covers. However it is absolutely necessary that the operator familiarises himself with the
instruction manual of the machine. It is essential that all operations be carried out in
accordance with these instructions. The manufacturer emphasises that it is the sole responsibility of the operator to ensure that all operations using the Ace CNC lathe are carried out
in complete safety.
Neither the manufacturer nor his representatives or dealers can assume responsibility
for any mishaps, damage or personal injury which may occur as a result of improper
operation or from failure to observe the safety precautions mentioned in this manual.
1.7
PREPARATION TO BE DONE BY THE CUSTOMER
PRIOR TO INSTALLATION OF THE MACHINE :
1.Environment (Machine side)
While installing the machine tool, avoid installing the machine in such places as mentioned
below.
a.
Places exposed to direct sunshine, close to heat sources and where temperature fluctuation is
considerable.
b.
Places where it is extremely humid.
c.
Places which are very dusty.
d.
Places close to sources of vibration.
e.
Places where the floor is not firm.
While installing the machine tool, the foundation should be firm and stable in order to maintain
the machining accuracy of the machine in the best condition. One of the recommended examples
of installation is shown on next page. However, as the foundation construction much depends
upon the condition of soil stratum supporting the floor of your shop, general counter measures for
the foundation of the machine tool should be taken.
When the floor of your shop is made of reinforced concrete having thickness of 300mm, it is
considered that the floor is firm enough to install this machine. The installing position should be
determined, considering the space around the machine so that the operator can remove the cover
for the maintenance of the machine, open and close the machine door and travel the carriage to
take out the cutting chips without contacting with other machines or bumping walls or the line.
Keep the environment around the machine clean at all times and do not install the machine where
it may be exposed to direct sunlight or heat source (heater).
FOUNDATION PROCEDURE FOR ISOLATING THE MACHINE
FROM SURROUNDING VIBRATIONS
In the case where the machine tool is installed out of necessity at a place close to vibration
sources, like hammers and presses, it is recommended to provide an isolated machine
foundation.
Please contact Ace Designers for further details.
2.1
2. FOUNDATION DRAWING FOR INSTALLATION
2.2
MACHINE INSTALLATION
1.
Place the machine on 25 mm thick M.S. pads positioned so as to have the anchoring bolt holes
over the grouting pockets.
2.
Place the 150 x 150 x 20 mm plates in position and insert the anchor bolt into the pocket
through the gap of the opening of pocket beyond the plate. Assemble the jack bolt, levelling
pad and the anchor bolt.
3. Prepare the grout and pour into the pockets
4.
After the specified time finish the floor around the pockets and remove the pads. (25 mm
thick M.S)
5.
Level the machine
In case machine is to be installed at a place where the ground is not firm, reinforce it by piling
work to prevent the installation from settling.
3. ENVIRONMENTAL CONDITIONS (NC SIDE)
a.
Ambient temperature :
During operation 00 to 450 C (320 to 1130 F)
b.
Humidity :
Relative humidity in normal cases, 75% or below. High humidity will cause deterioration of
insulation, leading to accelerated parts deterioration. There is no particular necessity for
dehumidification. However, avoid installing NC equipment in a humid place.
c.
Vibration
During operation: 0.5 G or less
During transportation: 3.5 G or less
2.3
4. POWER SOURCE INTAKE : (in INDIA)
Total Power capacity
: 27.11 KVA (For Alpha P22i Spindle motor)
Voltage
: AC 415 V, +10%, -15%, 3 phase
Frequency
: 50 Hz
Current
: 42 A
Power cable connection
: 10 mm2
POWER SOURCE INTAKE : (Export Machines)
Voltage
: AC 380V, +10%, -15%, 3 phase
Frequency
: 60 Hz
Current
: 46 A
: 10 mm2
Voltage
: AC 480V, +10%, -15%, 3 phase
Frequency
: 60 Hz
Current
: 36 A
: 10 mm2
Voltage
: AC 220V, +10%, -15%, 3 phase
Frequency
: 60 Hz
Current
: 79 A
: 25 mm2
2.4
1. LIFTING METHOD USING ROPES
The lifting arrangement of the machine is as shown in the figure. Remove the relevant covers
to sling the machine. Use a crane with capacity of at least 5 tons to lift the machine.
While lifting up, carefully check that the wire ropes do not touch the machine and provide
the portions where the ropes may touch with waste cloth or wooden pieces to prevent the
ropes from damaging the machine body.
NOTE : When lifting the machine, it is important to see that it is well balanced backwards
and forwards as well as to the right and left. Lift the machine a little above the floor and make
sure that it is well balanced before final lifting.
In case of lifting the machine by a group, proper co-ordination between the members of the
group has to be ensured.
3.1
2. INSTALLATION - CHECK POINTS
INSTALLATION SITE
The CNC machine should be properly installed in a location not exposed to direct sunlight. Care
should be taken to locate the installation site such that any chips, water, oil, or vibrations from
other equipments do not affect the lathe. Failure to observe these installation precautions may
result in serious malfunction of the machine. Improper installation can cause both numerical
control (CNC) error and loss of precision in machining operations.
Proper ambient temperature : 00 - 450 C.
Proper humidity : Below 75% Relative Humidity.
POWER SOURCE
The power source to the lathe should be free from any electrical noise produced by other equipment
such as electric welders or electrical discharging machines. Voltage drops and insufficient input
current can result in improper functioning of the CNC. An independent power source should be
provided if possible.
ELECTRICAL WIRING
a.
Connect the power line to the input terminals which are provided in the electrical cabinet of
the machine.
b.
The power source should be AC 415V, +10%, -15%, 50 Hz, 3 phase supply.(In India)
c.
Minimum gauge of the cable, from power source to the machine should be 10 mm2 . Separate
neutral and earth wires of 10 mm2 size are to be brought in.
Note : The machine should be earthed with an independent earth cable. We strongly insist
on the use of a 3Ø unbalanced voltage stabilizer at the incoming line.
3.2
3. GROUNDING
To prevent personal injury due to any abnormal current surges which may result from electrical
malfunction in other equipments, it is absolutely essential that all Ace CNC Lathes be grounded
independent of other equipment. If welding machines, electrical discharging machines, or the
like, are grounded to the steel framework of the building at the installation site, in no case should
any Ace CNC Lathe be grounded to the same steel framework. Malfunctions in electrical
equipment grounded in common with the Ace CNC Lathe may have adverse effects on the CNC’s
performance. Grounding wires should be as short and as thick as possible (use a grounding wire
of at least 10 mm2).
4. CAUTIONARY DETAILS CONCERNING
INSTALLATION
Provide a proper maintenance area.
1.
Make sure that all doors and panel coverings open and close freely without obstruction. Refer
to the appropriate installation diagram(s) in the manual provided with the Ace CNC Lathe.
2.
Make sure that the installation foundation is of sufficient strength and sturdiness. Refer to
the appropriate installation foundation diagram(s) in the manual.
3.
Ensure that the chip conveyor can be installed properly while accommodating the maintenance space. Refer to the appropriate installation diagram in the manual.
4.
All rust protective coatings on slideways which were applied for shipping should be
completely removed before beginning operations. Failure to do this can result in the actuation
of the servo-alarm when power is switched on.
5.
Before turning on the power, be sure to remove all fasteners and stoppers attached to the
carriage and the cross-slide during shipping.
6.
A number of internal cooling fans are fitted to each Ace CNC Lathe. It is imperative that the
installation site be located so as to prevent these fans from being clogged by dust or by mist
or spray from other equipment.
7.
When lifting the lathe, be sure to use only properly-rated cables, shackles and pipes. Refer
to the appropriate hoisting diagrams in the manual.
3.3
8.
After the lathe has been properly installed, use the Accuracy Test Results Chart shipped with
the equipment to ensure that it has been accurately levelled and adjusted so as to function at
a level of accuracy specified as being within the proper operating tolerances. Failure to do
so will result in serious loss of precision in machining operations.
Check the following before switching the power ON for the first time :
1.
Make sure that all bolts are properly tightened.
2.
Make sure that all high-pressure feed hosing and piping are securely fastened.
All Ace CNC Lathes are inspected and tested at the factory before being shipped to our
customers. However, possible mishandling or carelessness during shipment to the installation
site may result in misalignment or damage to the equipment. If left unchecked, this could
result in serious malfunctions later, such as vibration, CNC error, or oil leaks. To prevent the
possibility of this, it is essential to make a complete pre-operation inspection of the Ace CNC
Lathe.
3.
Power source:
Switch the power ON only after these points have been confirmed. At this time, once again,
check to make sure that all fastening and stoppers attached for shipping have been removed.
Do not begin operations immediately after switching the power ON. First operate the lub
pump manually to lubricate the slideways. Failure to provide proper lubrication can result in
seizing of the slideways.
After switching the power ON for the first time, check the following:
1.
Inspect for oil leaks. Make sure that all meters and gauges are functioning properly. Confirm
that the main pressure gauge is reading normally.
2.
Run the spindle, gradually increasing the RPM from low speed to maximum speed. This
should be separated into approximately five stages, operating at intermediate speeds at each
of the five stages for at least 20 minutes before eventually reaching the maximum allowable
RPM.
3.4
5. POWER ON / POWER OFF - CHECKPOINTS
The following checkpoints should be observed at all times during daily operations :
When switching the power ON, make a careful inspection of all the moving parts of the machine,
ensure that no one is standing close and that there are no obstructions. After switching ON the
power, check to make sure that the pressure gauges, lube pump, cooling fans, and other auxiliary
equipments are functioning properly. After the power is switched ON, do not begin operations
immediately. First operate the lube pump manually to lubricate the slideways and ballscrews.
Then activate each of the axes. Run the spindle for a period of approximately 15 minutes.
When turning OFF the power, observe the following order of operations:
1) Push the Emergency Stop Button
2) Turn OFF CNC
3) Shut OFF the machine power.
Do not leave the machine unattended with the power ON.
6. MANUAL OPERATIONS - CHECKPOINTS
The equipment should be operated only by one person at a time. It should never be operated by
anyone other than a trained operator who is familiar with the CNC Lathe.
If for example, one person is at the control panel operating the machine while another is replacing
the chuck jaws, the latter is liable to serious personal injury should the person at the control panel
inadvertently hit the wrong switch. If special circumstances make it unavoidable for two or more
persons to run the equipment, special care must be taken in co-ordinating activities to prevent
accidents.
Confirm that cutting tools and tool holders are securely fastened to the turret disc. Make sure that
these are fitted so as to be properly balanced and not to cause any interference or obstruction with
other parts of the equipment. Improper balance can have adverse effects on indexing cycle.
When performing set-up operations, be sure that the power is OFF. If it is absolutely necessary
to perform set-up operations with the power ON, take care before hand to set each switch located
on the control panel so as to prevent any accidents.
3.5
When using a scroll chuck, be sure to remove the chuck handle after using it to tighten the jaws.
Even if the spindle is stopped, the spindle will rotate slightly. This movement is more pronounced
on larger equipment. Be prepared for this rotation.
Always start rotating the spindle from minimum speed.
If any axis has moved beyond software overtravel, move the axis in the opposite direction and
then press the System Reset key. If any axis movement has actuated the Emergency limit, the
power to the drives will be shut off. Then keeping the Emergency over ride push button switch
pressed, jog the axis in the opposite direction till the emergency limit switch is released. Then
the emergency over ride push button can be released.
Optimum spindle speed should be calculated with due consideration to the specifications of the
particular chuck and chucking cylinder being used for the operation, and to the specific cutting
conditions.
7. MANUAL / AUTOMATIC OPERATIONS CHECK POINTS
Do not remove the protective covers or shields. Never attempt to insert a bar into the bore through
the spindle while it is rotating. This is an extremely dangerous practice with a high likelihood of
personal injury should the operator or portions of his clothing come into contact with the moving
parts of equipment and be drawn into the lathe.
When machining a bar, be sure to use the bar feeder and the guide bush. When a short bar is to
be machined, it must be of such length as to not protrude beyond the end of the spindle and the
guide bush must be used without fail. If the bar is longer than the spindle, it will be whipped
around violently with severe vibration.
3.6
Do not open the front guard or door while the spindle is rotating. Never open the front guard or
door to remove chips or cuttings or to gain access to the workpiece or the cutting tools while the
spindle is rotating.
Make sure that all rotating parts have come to a complete standstill before attempting to touch
them.
Never operate any Ace CNC Lathe with any of the safety devices removed. Be extremely careful
not to let loose clothing or hair get entangled in the moving parts of the machine. Be sure to wear
safety shoes or boots.
Be sure to keep the workpiece and cutting tools securely clamped at all times. Always begin
cutting operations at slow speeds and moderate cutting depths, gradually increase the feed and
depth of cut.
The operator should never stand in front of the spindle or other rotating parts. Particular care
should be taken during set-up operations or trial machining not to stand in front of the chuck since
there may be danger of the workpiece jumping out of the chuck jaws as a result of improper
clamping, and the cutting tool jumping out of the turret disc as a result of improper set-up.
During cutting operations, do not remove the chips by hand. Also, never attempt to touch the
chips directly with bare hands.
Never touch any of the switches or buttons with wet hands. This can cause short circuits or other
electrical malfunctions.
To prevent operational errors, operators should familiarize themselves thoroughly with the exact
positions of all the switches and push buttons.
3.7
8. AUTOMATIC OPERATIONS - CHECKPOINTS
When initiating operations for the first time under a new program, do not attempt to begin
continuous automatic operations at once. Keep the equipment in Single Block Operation (SBL)
mode and use other manual backup devices as appropriate to stop operations in progress as
necessary to check the effects of the program and to eliminate any bugs or undesirable machining
conditions found during trial runs.
Before replacing the workpiece with a new one, check that the Program-End lamp has turned ON
(indicating that the cutting cycle has been completed), and machining operations are actually
completed.
Be careful not to touch any of the push buttons or switches unnecessarily during automatic
operation.
3.8
9. LEVELLING
Before levelling, the machine base should rest on the levelling pads.
Fix the levelling bracket to the turret disc, as shown in the figure and place a spirit level on
the bracket.
Do a level check with the levelling bolts and foundation bolts tightened.
Level used
1 scale division
= 0.02 mm per meter.
Face size
= 150 x 55 mm
Keep the spirit level on the bracket.
Now, jog the Z-axis slide in both directions and adjust the levelling bolts so that the machine
is levelled both across and along the spindle axis. For levelling the machine across the spindle
axis keep the spirit level square to the spindle axis and repeat the same for different positions
of Z.
The bed should be levelled to get a reading within 2 divisions of the spirit level over the entire
axis length.
The level changes gradually depending on the condition of foundation, machine, etc. If the
above mentioned requirements are not satisfied the machining accuracy will be affected. So,
be sure to readjust the level atleast once every 6 months.
3.9
10. INSTALLATION AND MAINTENANCE OF
INTER-MACHINE CONNECTION
In order to maintain precision of machine for a long period of time and to operate it always
in the best condition, it is necessary to properly maintain the machine. Giving careful attention
to the operating state, conducting periodic inspection and replacing worn-out parts in their
early stage will prevent unexpected accident from happening.
1.
Maintenance immediately after installation
In the initial stage when the machine is installed, the machine is largely subject to change in
the bed level due to change in the foundation ground as well as to unstable solidification of
the ground, all of which have a serious influence on machine accuracy and at the same time
the machine itself undergoes initial wear and other changes. These changes possibly could
eventually affect the machine adversely.
While operating the machine, therefore, it is necessary to pay particular attention. Mentioned
below are points of caution as to the initial maintenance.
i)
Running in
After installation and when operating the machine for the first time, it is necessary to pay
particular attention to the machine before running in. Allow approximately 100 hours for the
running in. Avoid loading the machine heavily during the running in.
ii) Initial inspection of bed level
Check the bed level and the foundation for changes atleast once a month for a period of six
months after installation and, ensure correction of any disorder and always maintain the bed
level properly. After the six months, gradually extend the period between check as appropriate
depending on the changes observed, then carry out the check once or twice a year as it
stabilises.
3.10
2.
Inspection of inter-machine connection
Inspection of the state of electrical connections among respective units of the NC equipment,
the machine proper, the hydraulic unit, the control panel, etc.
i)
Loosened connectors
Check each connecting portion for loosening and tighten if so.
ii) Loosened screws at each terminal
Check electrical terminals of machine relay regions and each operation panel for loosened
screws, and tighten them as required.
iii) Check terminal screws and mounting screws of micro-switches for loosening and tighten
them.
3.
Inspection of electrical control panel
When inspecting the electrical control panel, be sure to turn off the main circuit breaker before
performing each check.
i)
Terminal screws and soldered portions
Check terminal screws of each electrical component for loosening and tighten them if
loosened. Lightly pull soldered portions of relay panel to check soldering strength.
ii) Cleaning
Dust and chips in the electrical control panel will lead to accidents. So vacuum clean them
with care.
3.11
1. ACE LT-20 CLASSIC MC - OVERALL VIEWS
4.1
2. MACHINE SPECIFICATIONS
Description
Standard
Swing over bed
Ø550
mm
Swing over carriage
Ø290
mm
Distance between centres
650
mm
Maximum machining diameter
Ø250
mm
Maximum longitudinal travel (Z)
600
mm
Maximum transverse travel (X)
193
mm
Maximum power requirement
27
KVA
Approximate weight
4500
Kg
Spindle centre height from floor
1050
mm
Spindle nose
A2 - 6
Bore through spindle
Ø63
mm
Ø86 mm
Maximum bar capacity
Ø51
mm
Ø75 mm
Front bearing I.D.
Ø100
mm
Ø120 mm
Spindle speed
50 - 4000 rpm
3500 rpm
Spindle motor (A.C. Motor)cont./30min
Fanuc Alpha P22i, 11/15 kW
Tailstock quill diameter
Ø80
Tailstock taper in quill
MT - 4
Tailstock quill stroke
120
mm
Tailstock base travel
425
mm
Thrust (Maximum recommended)
500 kg @ 20 kg/cm2
Cross slide inclination
300
Number of turret stations
12
X&Z
Standard cutting tools
25 x 25
Axes
Ball screw diameter X-axis
Ø32 mm; Pitch=10 mm
Ball screw diameter Z-axis
Ø40 mm; Pitch=10 mm
Feed motor X-axis
Fanuc AC12Bi, 12 Nm
Feed motor Z-axis
Fanuc AC12Bi, 12 Nm
Capacity
Spindle
Tailstock
Optional
A2-8
mm
mm
4.2
TURNMILL SPECIFICATIONS
Turret specification
:
Duplomatic BSVN-200
Driven tool System
:
ODTN 20
Type of Tooling
:
VDI 40
Rotary tool motor power cont. / 30 min
:
3.7 kW / 5.5 kW
Motor Specification
:
Fanuc Alpha 3i
4.3
3. MACHINE POWER CAPACITY CHART
MACHINE : LT-20 CLASSIC MC
CNC System : FANUC 0i-TC
CNC Package : Alpha C12Bi (Feed motor - 2 Nos.), Alpha P22i (Spindle) with PSM26i.
Elements used
Power required (KVA)
Spindle & Servo drives
22.42
Electrical control unit
1.00
Hydraulic pump motor
1.40
Coolant pump motor
0.94
Lubricant pump motor
0.15
Chip conveyor
0.20
Cooling unit
1.00
Total
27.11 KVA
4.4
4. BED :
The Bed is of box type construction made of cast iron grade 25. It is designed for high
rigidity with suitable cross section and ribs. The bed undergoes natural seasoning and stress
relieving before assembly.
5. HEAD STOCK ASSEMBLY (A2-8) :
The head stock aasembly features cartridge type construction. The spindle assembly consists
of three angular contact ball bearings of P4 class accuracyin the front of 2TB construction
and double row cylindrical roller bearing with taper bore NN30K (Super precision class) in
the rear. The bearings are grease lubricated for life. The spindle drive is thro’ a set of SPA
series wedge belts.
4.5
6. SPINDLE BRAKE ASSEMBLY :
The spindle brake mounting assembly is as shown in figure. The brake is actuated hydraulically
and it locks the spindle in the oriented position.
4.6
7. SPINDLE ENCODER ASSEMBLY :
The spindle speed feed back is through an incremental rotary optical encoder which is driven
by a timing belt.
8. SPINDLE SPEED CHARACTERSTICS :
4.7
9. SPINDLE SPEED CHARACTERSTICS :
10. WORK HOLDING :
The work holding mounted on the spindle front end and the chucking cylinder at the rear are
connected by a drawbar. The clamping and declamping is achieved by the actuation of the
draw bar.
Any standard work holding and chucking cylinder can be mounted on the spindle with suitable
adaptors.
4.8
11. Z-AXIS ASSEMBLY :
The Z-axis slide moves over a pair of hardened & ground guide strips. The sliding surfaces
are lined with Turcite for anti stick slip properties. An AC servo motor drives the ball screw
through a timing belt. The pretensioned ball screw arrangement takes care of the expansion
effect due to temperature variation.
The axis system is provided with overload safety clutch to protect the machine against
application of excessive motor torque on to the elements in case of accidents.
The feedback for the Z-axis motion is through the encoder built into the motor.
For setting the machine co-ordinates in the Z-axis a set of actuating dogs and limit switches
are provided. Machine reference and emergency positions can be set with these limit switches.
4.9
12. X-AXIS ASSEMBLY :
The X-axis slide moves over a pair of hardened & ground guide strips. The sliding surfaces
are lined with Turcite for anti stick slip properties. An AC servo motor drives the ball screw
through a timing belt. The pretensioned ball screw arrangement takes care of the expansion
effect due to temperature variation.
The axis system is provided with overload safety clutch to protect the machine against
application of excessive motor torque on to the elements in case of accidents. An electromagnetic brake is provided on the axis for added safety. The feedback for the X-axis motion
is through the encoder built into the motor.
For setting the machine co-ordinates in the X-axis a set of actuating dogs and limit switches
are provided. Machine reference and emergency positions can be set with these limit switches.
13. TURRET
Refer to Duplomatic Rotary Tool Turret Manuals.
4.10
14. TAILSTOCK ASSEMBLY :
The tailstock assembly consists of hardened quill sliding in a honed cast iron housing. The
housing which is adjustable crosswise is mounted on a cast iron base which moves on V and
flat guide ways. The tail stock quill can be advanced and retracted hydraulically using the
foot switch. The whole tailstock body can be moved after loosening the clamp bolts. The
bullet can be removed from the centre assembly by a wedge.
The quill is provided with MT-4 taper in the front to facilitate mounting of add-on revolving
centre, with MT-2 bullet.
The tailstock is also offered with built-in revolving centre with MT-2 bullet as an option.
4.11
Tailstock revolving centre - Load diagram
Example : Admissible load of centre at 1000 rpm
Axial load = 480 Kgf and Radial load = 320 Kg workpiece
4.12
15. HYDRAULIC SYSTEM :
The power pack is mounted at the rear side of the bed. A variable displacement vane pump
supplies oil to the manifold block mounted at the front of the machine. The various control
elements are mounted on the manifold block and the settings of these can be done from the
front of the machine. A gauge isolator with pressure gauge is provided to read the different
pressure settings. From the manifold blocks A & B lines of the actuators are connected
through flexible hoses. The leakage line from the chucking cylinder is connected back to the
power pack through a PVC wire braided hose. Pressure switches provided in the circuit enable
interlocking features to ensure clamping. The spindle locking in oriented position is achieved
by a hydraulic actuated brake.
4.13
16.
LUBRICATION SYSTEM
1.
Pump
7.
Float switch
2.
Motor
8.
Oil filler cum breather
3.
Relief valve
9.
Suction strainer
4.
Pressure gauge dampner
10.
Pressure reducing valve
5.
Pressure gauge
11.
Feed valve
6.
Pressure switch
12.
Reservoir
The machine is built with an automatic centralized lubrication system which supplies a
metered quantity of lubricant at a set regular interval to the guide ways and the ball screw
nuts. The quantity of the lubricant is regulated by metering cartridges and the time interval
through a PLC timer. The lubrication system monitors the build up of pressure and oil level
and gives suitable signals to the operator. An oil collector collects the spent lubricant which
is to be disposed off at regular intervals. For lubricant system details refer to the annexure.
17.
COOLANT SYSTEM :
The machine has got a coolant tank of 130 litres capacity. The coolant pump mounted on the
tank delivers the coolant to the tool tip through each of the turret station and tool disc assembly.
The coolant which flows out through the turret, drains back to the tank. The machine guarding
is designed to protect the drive elements from coolant splash and chips and to facilitate easy
maintenance. A sight glass with safety grill is provided for viewing the machining
operation with the front doors closed.
4.14
1. STANDARD CHUCKS AND CYLINDERS
Standard 3 jaw / 2 jaw chucks (GMT)
Hollow 3 jaw / 2 jaw chucks (GMT)
Standard chucking cylinders (PRAGATI)
2. STANDARD CHUCK
DISMOUNTING AND INSTALLING PROCEDURE
If the machine is supplied with a standard chuck (GMT 3B/2B x 200), follow the procedure
given below to dismount the chuck.
a.
Put the chuck in clamping condition.
b.
Remove the jaws.
c.
Remove the centre piece.
d.
Remove the chuck mounting screw.
e.
Actuate the draw bar in out position. The chuck slides out from mounting flange.
f.
Hold the chuck firmly.
g.
Use the special Allen (or box spanner) supplied along with the chuck to loosen the draw bolt
completely. The chuck will slide out. Avoid hammer blows on the Allen key.
While following the above procedure it is suggested that the hydraulics be put OFF.
HOLLOW CHUCK : Insert a suitable rod inside the draw bar and unscrew the draw nut of
the chuck
FOR REINSTALLING FOLLOW THE STEPS GIVEN BELOW:
a.
Clean the chuck mounting surfaces with lint free cloth.
b.
If the chuck to be installed is a new one, it has to be dismantled, cleaned and greased as per
the recommended instructions of the manufacturer. Then the chuck assembly without the
hard/soft jaws and centre piece is to be mounted on the face plate.
c.
It is assumed that the relevant chucking cylinder and the corresponding drawbar is already
installed on the machine. If it is not done, the appropriate chucking cylinder flange and the
drawbar are to be fitted on to the chucking cylinder after cleaning the mounting surfaces.
5.1
Provisions for mounting the chucking cylinder flange exists on the face of the pulley on the
spindle. Clean the surface well and mount the chucking cylinder together with the flange
and the drawbar onto this surface. Check the alignment of mounting by dialling the reference
surface at the rear of the chucking cylinder. The total indicated reading (TIR) should be
preferably less than 0.04 mm to keep the spindle vibrations to the minimum.
Connect hoses to the input lines. The drain line should be directed downward and held in
that position to avoid tilting, thereby preventing overflow of oil from the drain chamber.
d.
Switch on the hydraulics and actuate the chuck clamp, the draw bar will be drawn in. Mount
the chuck in this condition. Engage the draw bar bolt into the draw bar and rotate the draw
bolt till the chuck is seated on the face plate. Insert the mounting bolts and tighten them
uniformly.
To set the clamping stroke, operate the foot pedal to release the chuck. Loosen the draw bar
till it just meets the resistance. This is the fully opened position of the jaws. Now tighten
the draw bolt by half a turn. Now the full stroke of the master jaws is available for clamping.
Operate the clamp/declamp switch/foot pedal to ensure the above. Then insert the centre
piece and fix it. Mount the hard/soft jaws suitably.
3. HOLLOW CHUCK INSTALLING PROCEDURE
This is almost similar to the mounting and dismounting of a standard chuck.
Following are the differences:
The draw bar is hollow and threaded to the piston of the chucking cylinder, and is prevented
from loosening by applying suitable thread locking compounds, which also prevents coolant
seeping through the threads.
The chuck being hollow, a draw nut is provided in it to fasten the draw bar. The draw nut
needs a special tool to rotate it (supplied by chuck manufacturer).
The chucking cylinder is provided at the rear with a coolant collector, (connected to the
housing) and a face seal is provided to seal coolant entry in to the chucking cylinder.
The chuck flange is not the same as that of a standard solid chuck.
5.2
4. STANDARD CHUCKING CYLINDERS(PRAGATI)
The hydraulic cylinders are suitable for operation of power chucks or collets. The cylinder
is mounted on the rear of the lathe spindle, and operates the job holding device through a
draw bar.
These cylinders have been designed with a hole through the entire assembly. The through
hole can be used to supply air or coolant to the work holding fixture. It is also possible to
use a length stop rod fitted from the rear of the cylinder to provide axial location for the
workpiece. This rod rotates with the spindle, but always remains axially stationary with
respect to the spindle, thus providing a positive reference point for job location.
The cylinders incorporate a non-contacting type of rotary joint, which is virtually free from
maintenance problems. This type of rotary joint gives a certain amount of leakage. The
leakage return tube should be of generous size and should be connected directly to the tank.
Cylinders should be mounted in the HORIZONTAL position, with leakage oil connection
pointing downward.
5.3
5. OPERATION AND ADJUSTMENT OF
HYDRAULIC CHUCK UNIT
The hydraulic chuck is opened by depressing the foot pedal and closed by depressing it again.
a.
If reduced jaw opening is desired then the draw bolt has to be adjusted after removing the
centre piece. The centre piece should be put back again after adjustment. For large
adjustments, the jaws have to be shifted on the serration on the master jaw.
b. Jaw change :
For jaw change, clean the serration of the master jaw and jaws, and the jaw nut fitting part
carefully, and then install with the same serration engagement as at the time of jaw
boring/turning.
c.
Adjustment of the clamping force :
Adjustment is done with the pressure reducing valve on the hydraulic power pack. Adjust
while observing the pressure gauge. After the adjustment, it must be locked with the lock
nut. The chuck pressure adjustment range is from 5 to 30 kg/cm2.
d. Change between Chuck Clamp / Declamp (by M codes).
To be used in MDI mode only and spindle should be OFF.
1. Select MDI mode
2. Enter M11 for chuck clamping
3. Enter M10 for chuck declamping
4. Press cycle start. The selected mode will be retained even after power OFF.
NOTE :
1.
For execution of M03 and M04 ensure that chuck is clamped properly before starting the
cycle.
2.
Change over from internal to external clamping should be done through I.D./O.D. selection
M codes i.e M16 for I.D. and M18 for O.D.
5.4
6. SOFT JAW BORING SEQUENCE FOR
EXTERNAL CLAMPING
1.
Install the soft jaws on the chuck.
2.
Set the hydraulic chuck internal clamping by parameter (M11).
3.
Use an inner diameter cutting tool to cut a hole (d) about 8 mm smaller than the workpiece
clamping diameter (D) into the soft jaws installed in the chuck.
4.
Set the hydraulic chuck external clamping by parameter (M10).
5.
Clamp a blank (outer diameter d-1 mm, length about 6 mm) in the hole (d) of the machined
soft jaws.
6.
Bore the soft jaws according to the clamping diameter (D) of the workpiece and remove the
blank after boring.
7.
Remove burrs.
NOTE : For detailed explanations regarding the hydraulic chuck, refer to the instructions
issued by the chuck manufacturer.
5.5
7. SPINDLE SPEED AND CHUCKING FORCE
1) Maximum chuck operating force :
The chucking force of the chuck may be decreased by the influence of centrifugal force in
proportion to the spindle speed in case of O.D. chucking. However, in general, the maximum
speed is defined as that speed at which the dynamic chucking force becomes a half of the
static chucking force when the standard jaw is used under ordinary condition and chucked
with a suitable cylinder.
2) Spindle speed and chucking force :
The decrease of chucking force against operational speed is shown in figure. The top jaw
is the standard jaw and at the maximum operating position. This value is, however, the
normal case and care must be taken because it generally varies depending on the adjusting
position of top jaws, size of jaw and cutting conditions.
5.6
8. SAMPLE DRAWING
Drg. No. 97-108 / 74-0-3
5.7
9. SPINDLE DETAILS (A2-8)
Drg. No. 96-104 / 0165-0
5.8
1. MACHINING RANGE
96-104 / M371
6.1
2. MACHINING RANGE
96-104 / M372
6.2
3. MACHINING RANGE
96-104 / M373
6.3
4. MACHINING RANGE
96-104 / M375
6.4
5. MACHINING RANGE
96-104 / M376
6.5
6. MACHINING RANGE
96-104 / M374
6.6
7. INTERFERENCE DIAGRAM
96-104 / M36
6.7
1.
FANUC Oi-TC SPECIFICATIONS
ITEM
SPECIFICATIONS
Machine
controlled axes
CONTROLLED AXIS
Controlled path
Controlled axis
Simultaneous controlled axes
Axis control by PMC
Cs contouring control
1 path
2 axes
4 axes (Including Cs axis)
Max. 4 axes
Max. simultaneous 4 axes,
(Not available on Cs axis)
1 axis
In case of G code system A, basic 2
axes are X and Z, Additional axes are
optional from Y, A, B, and C.
Axis name
In case of G code system B/C, basic
2 axes are X and Z, Additional axes
are optional from Y, U, V, W, A, B,
and C.
2 units
Spindle
Simple synchronous control
Least input increment
0.001mm, 0.001deg, 0.0001inch
0.0001mm, 0.0001deg,
0.00001inch
Optional DMR
Increment system 1/10
Flexible feed gear
Fine Acc & Dec control
Servo HRV control
Inch / Metric conversion
HRV3
All axes / each axis / each direction /
block start / cutting block start.
Interlock
Machine lock
Emergency stop
Overtravel
Stored stroke check 1
Stored stroke check 2, 3
Chuck & Tailstock barrier
Mirror image
Follow-up
Servo off
Chamfering on/off
Backlash compensation
Backlash compensation for each rapid traverse and
cutting feed
Stored pitch error compensation
Position switch
Unexpected disturbance torque detection function
All axes / each axis
Each axis
Oi-TC
@
@
#
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
7.1
' @ ' = Standard,
' # ' = Optional
OPERATION
Automatic operation (memory)
DNC operation
MDI operation
Schedule function
Program number search
Sequence number search
Sequence number comparison and stop
Program restart
Manual intervention and return
Buffer register
Dry run
Single block
JOG feed
Manual reference position return
Reference position setting without DOG
Reference position setting with mechanical stopper
Manual handle feed
Manual handle feed rate
Manual handle interruption
Incremental feed
Jog and handle simultaneous mode
Reader/puncher interface is required
1 unit / each path
2 units
x 1, x 10, x m, x n,
m: 0~127, n: 0~1000
x 1, x 10, x 100, x 1000
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
INTERPOLATION FUNCTIONS
Positioning
Linear interpolation
Circular interpolation
Dwell
Polar coordinate interpolation
Cylindrical interpolation
Threading, synchronous cutting
Multiple threading
Threading retract
Continuous threading
Variable lead threading
Polygon turning
Skip
High-speed skip
Torque limit skip
Reference position return
Reference position return check
2nd reference position return
3rd / 4th reference position return
G00 (Linear interpolation type
positioning is possible)
G01
G02 / G03 (Multi-quadrant)
G04
G31
G28
G27
G30
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
7.2
FEED FUNCTION
Rapid traverse rate
Rapid traverse override
Feed per minute
Feed per revolution
Tangential speed constant control
Cutting feedrate clamp
Automatic acceleration/deceleration
Rapid traverse bell-shaped acceleration /
deceleration
Linear acceleration/deceleration after cutting feed
interpolation
Feedrate override
Jog override
Override cancel
Manual per revolution feed
Error detection
Rapid traverse block overlap
External deceleration
PROGRAM INPUT
Tape code
Label skip
Parity check
Control in / out
Optional block skip
Max. programmable dimension
Program number
External memory & sub program calling function
Sequence number
Absolute / incremental programming
Decimal point programming / pocket calculator type
decimal point programming
Input unit 10 time multiply
Diameter / radius programming (X-axis)
Plane selection
Rotary axis designation
Rotary axis roll-over
Coordinate system setting
Automatic coordinate system setting
Coordinate system shift
Direct input of coordinate system shift
Workpiece coordinate system
Workpiece coordinate system preset
Direct input of workpiece origin offset value
measured
Manual absolute on and off
Direct drawing dimension programming
G code system
Chamfering / corner R
Programmable data input
Sub program call
Custom macro B
Addition of custom macro common variables
Max. 240 m/min (1 µ m)
Max. 100 m/min (0.1 µ m)
F0, 25, 50, 100%
Rapid traverse, linear cutting feed,
exponential.
@
@
@
@
@
@
@
@
@
@
0 ~ 150%
0 ~ 150%
@
@
@
@
@
@
@
EIA RS244 / ISO840
@
@
@
@
@
@
@
@
@
@
Horizontal and Vertical parity
9
± 8 digit
O4 digit
N5 digit
Combined use in the same block.
@
G17, G18, G19
G52 ~ G59
@
@
@
@
@
@
@
@
@
@
@
@
A/B/C
G10
4 folds nested
#100 ~ #199, #500 ~ #999
@
@
@
@
@
@
@
@
Pattern data input
Interruption type custom macro
Canned cycles
Multiple repetitive cycle
Multiple repetitive cycle II
Canned cycles for drilling
Circular interpolation by R programming
Tape format for FANUC series 10/11
Conversational programming with graphic function
Macro executor
AUXILLIARY / SPINDLE SPEED FUNCTION
Auxilliary function
2nd auxilliary function
Auxilliary function lock
High speed M / S / T / B interface
Multiple command of auxilliary function
Spindle speed function
Spindle serial output
spindle analog output
Constant surface speed control
Spindle override
Actual spindle speed output
Spindle speed fluctuation detection
1st spindle orientation
1st spindle output switching function
2nd spindle orientation
2nd spindle output switching function
Spindle synchronous control
Multi spindle control
Spindle positioning
Rigid tapping
TOOL FUNCTION / TOOL COMPENSATION
Tool function
Tool offset pairs
Tool offset
Y-axis offset
Tool nose radius compensation
Tool geometry/wear compensation
Tool life management
Tool offset value couunter input
Automatic tool offset
Direct input of tool offset value measured
Direct input of tool offset value measured B
Pocket profile
Graphic display circuit is required.
512 KB / 2MB / 4MB
M8 digit
B8 digit
3
S5 digit, binary output
S5 digit, serial output (1st & 2nd)
S5 digit, analog output
0 ~ 120%
T7 + 1/T6 + 2 digits
± 6 digit, 64 pairs
@
@
@
@
@
@
@
@
#
#
@
@
@
@
#
@
$
$
@
@
@
@
#
#
#
#
#
#
#
#
@
@
@
@
@
@
@
@
@
@
@
EDITING OPERATION
Part program storage length
Number of registerable programs
Part program editing
Program protect
Background editing
Extended part program editing
Password function
Playback
320 m (equivalent to 128KB)
640 m (equivalent to 256KB)
400
*1
*1
@
@
@
@
@
@
@
@
@
SETTING AND DISPLAY
Status display
Clock function
Current position display
Program display
Parameter setting and display
Self-diagnosis function
Alarm display
Alarm history display
Operator message history display
Operator history display
Remote diagnostic
Operation history display
Help function
Run hour and parts count display
Actual cutting feedrate display
Display of spindle speed and T code at all screens
Directory display of floppy cassette
Graphic function
Servo setting screen
Spindle setting screen
Servo waveform display
Display of hardware and software configuration
Software operator's panel
Software operator's panel general purpose switch
Multi-language display
Data protection key
Erase CRT screen display
Program name 31 characters
Machine remote diagnosis package &
Ethernet card are required.
Display unit with graphic is required
Only for serial interface
English
Japanese (Chinese character)
Chinese (Traditional Chinese)
German / French / Italian / Polish
Spanish / Korean / Portuguese
Swedish / Czech / Hungarian
4 types
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DATA INPUT/OUTPUT
Reader/puncher interface
Reader / puncher (Ch. 1)
Reader / puncher (Ch. 2)
Data server
External I/O device control
DNC2 control
External tool offset
External message
External machine zero point shift
External data input
External key input
External program input
External workpiece number search
External program number search
Memory card input/output
Power mate CNC manager
INTERFACE FUNCTION
Ethernet
Profibus DP
Device Net
Including above 3 items
9999
1 ~ 9999
For maintenance
Ethernet board is required
Master / slave
Master / slave
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OTHERS
Status output signal
Control unit incorporated display unit
PMC
SYSTEM
PMC-SA1
PMC-SB7
I/O card
I/O Link
Machine operator's panel
Operator's panel I/O module
Manual pulse generator
DI / DO : 48 / 32 points
Alpha 2/5000i, 4/5000i, 8/3000i,
12/3000i, 22/3000i, Alpha C4/3000i,
C8/2000i, C12/2000i, C22/2000i.
Connectable servo motor
Connectable servo amp.
Position detector interface (for full-closed control)
Alpha is series (SVM)
Pulse coder/optical scale (2 phase
pulse interface)
Alpha 3i, 6i, 8i, 12i, Alpha C2i, C3i,
C6i, C8i, C12i, Alpha P8i, P12i,
P15i, P18i, P22i, P30i, P40i.
Connectable spindle motor
Connectable spindle amp.
Input power supply
Alpha is series (SPM)
DC 24V ±10%
At operating : 0°C ~ 58°C
At non-operating : -20°C ~ 60°C
Normally : 75% RH or less Short term
(within one month) : 95% RH or less
(No dew, nor frost allowed).
At operating : 0.5G or less
At non-operating : 1G or less
Ambient temperature of unit
Ambient relative humidity
Vibration
' @ ' = Standard,
NC ready, servo ready, automatic
operation, automatic operation start
lamp, feed hold, reset, NC alarm,
distribution end, rewinding, inch input,
cutting, in-position, thread cutting,
tapping , etc.
7.2" monochrome LCD/MDI
Horizontal type.
2 slots, 400(W)x200(H)x120(D) mm.
Basic instruction: 5 µ sec/step Max.
step number ladder: 5000
Basic instruction: 0.033 µ sec/step
Max. step number ladder: 24000
DI / DO : 96 / 64
' # ' = Optional
*
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7.6
' $ ' = Standard alternative, ' ' = Function included in other option
*1 The value might change according to the registered number of programs and the program sizes.
2. G CODES
M00
M01
M02
M03
M04
M05
M06
M07
M08
M09
M10
M11
M12
M13
M14
M15
M16
M17
M18
M19
M20
M21
M22
M23
M24
M25
M26
M27
M28
M29
M30
M31
M32
M33
M34
M35
M36
M37
M38
M39
M40
M41
M42
M43
M44
M45
M46
M47
M48
M49
M-code list for Classic MC
Program stop
Optional stop
End of program
Spindle rotation CW
Spindle rotation CCW
Spindle stop
Coolant ON
Coolant OFF
Chuck declamp
Chuck clamp
Live tool rotation cw
Live tool rotation ccw
Live tool stop
Chuck clamp on I.D.
Chuck clamp on O.D.
End of main program
T.S. quill forward
T.S. quill retract
Parts catcher fwd
Parts catcher ret
M50
M51
M52
M53
M54
M55
M56
M57
M58
M59
M60
M61
M62
M63
M64
M65
M66
M67
M68
M69
M70
M71
M72
M73
M74
M75
M76
M77
M78
M79
M80
M81
M82
M83
M84
M85
M86
M87
M88
M89
M90
M91
M92
M93
M94
M95
M96
M97
M98
M99
Turret Zero cycle ON
T.S. quill override ON
Chuck signal override ON
T.S. quill interlock ON
T.S. quill interlock OFF
Cs contour mode ON
Cs contour mode OFF
Spindle brake ON
T.S. body forward
T.S. body retract
T.P. arm forward
T.P. arm retract
Sub program call
Sub program end
7.9
M-code list for Classic MC
M00
M01
M02
M03
M04
M05
M06
M07
M08
M09
M10
M11
M12
M13
M14
M15
M16
M17
M18
M19
M20
M21
M22
M23
M24
M25
M26
M27
M28
M29
M30
M31
M32
M33
M34
M35
M36
M37
M38
M39
M40
M41
M42
M43
M44
M45
M46
M47
M48
M49
Program stop
Optional stop
End of program
Spindle rotation CW
Spindle rotation CCW
Spindle stop
Coolant ON
Coolant OFF
Chuck declamp
Chuck clamp
Live tool rotation cw
Live tool rotation ccw
Live tool stop
Chuck clamp on I.D.
Chuck clamp on O.D.
End of main program
T.S. quill forward
T.S. quill retract
Parts catcher fwd
Parts catcher ret
M50
M51
M52
M53
M54
M55
M56
M57
M58
M59
M60
M61
M62
M63
M64
M65
M66
M67
M68
M69
M70
M71
M72
M73
M74
M75
M76
M77
M78
M79
M80
M81
M82
M83
M84
M85
M86
M87
M88
M89
M90
M91
M92
M93
M94
M95
M96
M97
M98
M99
Turret Zero cycle ON
T.S. quill override ON
Chuck signal override ON
T.S. quill interlock ON
T.S. quill interlock OFF
Cs contour mode ON
Cs contour mode OFF
Spindle brake ON
T.S.
T.S.
T.P.
T.P.
body forward
body retract
arm forward
arm retract
Sub program call
Sub program end
7.9
[qtmc-01]
NO.
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0011
0012
0013
0014
0015
0016
0017
0018
0019
0020
0021
0022
0023
0024
0025
0026
0027
0028
0029
0030
0031
0032
0033
0034
0035
0064
0065
0066
0067
0068
0069
0070
0071
0072
0073
0074
4. OPERATOR MESSAGES
ADDRESS
A000.0
A000.1
A000.2
A000.3
A000.4
A000.5
A000.6
A000.7
A001.0
A001.1
A001.2
A001.3
A001.4
A001.5
A001.6
A001.7
A002.0
A002.1
A002.2
A002.3
A002.4
A002.5
A002.6
A002.7
A003.0
A003.1
A003.2
A003.3
A003.4
A003.5
A003.6
A003.7
A004.0
A004.1
A004.2
A007.7
A008.0
A008.1
A008.2
A008.3
A008.4
A008.5
A008.6
A008.7
A009.0
A009.1
MESSAGE
1000 LOW LUB OIL LEVEL, CYCLE INTERRUPT
1001 LOW LUB PRESSURE, CYCLE INTERRUPT
1002 CHUCK ACTUATION FAILURE
1003 T.S. BODY UNCLAMP FAULT
1004 T.S. BODY ACTUATION FAILURE
1005 T.S. QUILL NOT IN POSITION, CYCLE INTERRUPT
1006 SPINDLE POSITIONING ABORTED
1007 PRG CNTL SW OPRTD, RST & HOME X & Z AXES
1008 TURRET CLAMP SIGNAL FAULTY
1009 T.S. QUILL POSITION LOST, SET DOGS & RESET
1010 T.S. QUILL ACTUATION FAIL
1011 SPN O/L, CHK TOOL TIP, DEPTH OF CUT & F/R
1012 X-AXIS CLUTCH TRIPPED, REFER MANUAL
1013 Z-AXIS CLUTCH TRIPPED, REFER MANUAL
1014 TOOL WORNOUT, REPLACE THE INSERT
1015 TURRET INDEX ABORTED
1016 TURRET NOT IN SAFE ZONE, GO X-HOME
1017 TURRET MOTOR OVER HEATED
1018 TOOL NUMBER HIGH
1019 TURRET UNCLAMPED, FEED OFF
1020 PARTS CATCHER ACTUATION FAILURE
1021 DOOR ACTUATION FAILURE
1022 SPINDLE ORIENTATION ABORTED
1023 AIR PRESSURE LOW
1024 T.P ACTUATION FAILURE
1025 LUB MOTOR/PR SW CONTINUOUSLY ON
1026 HOMING FAILURE
1027 CANCEL CSS BEFORE T-COMMAND
1028 SPINDLE BRAKE ACTUATION FAIL
1029 RUN ZERO CYCLE AND THEN INDEX
1031 BAR FEEDER NOT READY
1032 CHIP CONVEYOR TH TRIP/LS OPEN
1033 PARTS MACHINED = PARTS SET
1064 TOOL 1 WORNOUT, CHANGE INSERT
1
[qtmc-01]
NO.
0075
0076
0077
0078
0079
0080
0081
0082
0083
0084
0085
0086
0087
0088
0089
0090
0091
0092
0093
0094
0095
0104
0105
0106
0107
0108
0109
0110
0111
0112
0113
0114
0115
0116
OPERATOR MESSAGES
ADDRESS
A009.2
A009.3
A009.4
A009.5
A009.6
A009.7
A010.0
A010.1
A010.2
A010.3
A010.4
A010.5
A010.6
A010.7
A011.0
A011.1
A011.2
A011.3
A011.4
A011.5
A011.6
A012.7
A013.0
A013.1
A013.2
A013.3
A013.4
A013.5
A013.6
A013.7
A014.0
A014.1
A014.2
A014.3
MESSAGE
2009 COOLANT CONTACTOR NOT ON
2001 CHUCK POSITION FAULT
2015 CHUCK NOT CLAMPED, SPINDLE INHIBIT
2000 TOOL IS WEARING OUT
2100 CHUCK CLAMPED ON O. D.
2101 CHUCK CLAMPED ON I.D.
2002 CHUCK IN EXTREME END POSITION
2003 AXES NOT REFERENCED, HOME X & Z
2004 HOME X BEFORE Z
2005 HOME Z BEFORE X
2006 CLAMP CHUCK BEFORE SPINDLE START
2007 DOOR NOT CLOSED, CLOSE BEFORE CY START
2008
2010 TOOL PROBING INCOMPLETE,PROBE OTHER AXIS
2021 TOOL 1 GETTING WORNOUT
2
1.
OPERATOR CONTROL PANEL
The above operator panel is only for the user reference. For exact description of operator
panel for the machine supplied refer to the relevant operator panel drawing supplied with
the machine interface manual.
8.1
OPERATOR CONTROL PANEL-1 DETAILS
1.
Emergency stop push button
2.
CNC OFF/ON push button
3.
Emergency override push button
4.
+X jog push button
5.
-X jog push button
6.
+Z jog push button
7.
-Z jog push button
8.
Rapid override push button
9.
Cycle start push button
10.
Feed hold push button
11.
Spindle CW/CCW push button
12.
Spindle stop push button
13.
Feed override rotary switch
14.
Rapid override rotary switch
15.
Handle/Step feed rotary switch
16.
Mode selection rotary switch
17.
Spindle speed override rotary switch
18.
Optional stop switch
19.
Block delete switch
20.
Dry run switch
21.
Machine lock switch
22.
Program check switch
23.
Program protect OFF/ON key switch
24.
RS 232C port
8.2
DESCRIPTION OF OPERATOR CONTROL PANEL-1
1.
EMERGENCY STOP PUSH BUTTON
Machine will be in emergency state if this push button is pressed. After pressing the CNC
ON push button, if the emergency push button is released hydraulic gets ON and machine
will reset, automatically. In emergency state, power to the drives and hydraulics are
removed and not ready message is displayed on the screen.
2.
CNC ON/OFF PUSH BUTTON
After the main supply is switched ON, CNC system can be switched ON by pressing CNC
ON push button. After a few seconds delay the CRT display will come ON showing
software version number and PMC number. The CNC can be switched OFF by pressing
CNC OFF push button.
3.
EMERGENCY OVERRIDE PUSH BUTTON
During machine operation if any slide actuates the end limit switch, the machine will come
to emergency stop state. Jog keys become ineffective unless the emergency override push
button is pressed. Keeping emergency override push button pressed jog the axis in opposite
direction till the end limit switch is released. Then emergency override push button should
be released. After this jog switches will remain effective.
4.
+X JOG PUSH BUTTON
If this key is pressed in jog mode then X-slide will move in positive direction at a feed rate
depending upon the feed override selected. When in reference mode, this key can be used
for X-axis homing.
5.
-X JOG PUSH BUTTON
If this key is pressed, in jog mode then X-slide will move in negative direction at a feed
rate depending upon the feed override selected.
8.3
6.
+Z JOG PUSH BUTTON
If this key is pressed in jog mode then Z-slide will move in positive direction at a feed rate
depending upon the feed override selected. When in reference mode and X-axis reference
is completed then with this key Z-axis homing is possible.
7.
-Z JOG PUSH BUTTON
If this key is pressed in jog mode then Z-slide will move in negative direction at a feed rate
depending upon the feed override selected.
8.
RAPID OVERRIDE PUSH BUTTON
When this push button is pressed along with any of the jog push buttons, the respective
slide moves in rapid rate set for that slide. This push button is effective only after axes are
referenced. Rapid rate can be set using the rapid override rotary switch.
9.
CYCLE START PUSH BUTTON
This push button is effective in Auto single and MDI modes of operation
10. FEED HOLD PUSH BUTTON
Auto cycle is interrupted when this push button is pressed.
11. SPINDLE CW/CCW PUSH BUTTON
In jog mode spindle direction of rotation can be selected using these two push buttons.
The spindle speed can be selected using S command in MDI mode.
12. SPINDLE STOP PUSH BUTTON
In jog mode spindle is disabled using this push button.
13. FEED OVERRIDE ROTARY SWITCH
Feed can be varied from 0-150% of the set feed rate.
14. RAPID OVERRIDE ROTARY SWITCH
Rapid rate can be varied from 0-100% in steps of 25%.
8.4
15. HANDLE/STEP FEED ROTARY SWITCH
In handle/step mode without MPG option, this rotary switch can be used to move the slides
to a distance ranging from one micron to one millimeter using X or Z keys. With MPG
option in handle/step mode, with every incremental rotation of the MPG, slides can be
moved to a distance ranging one micron to 100 microns depending upon the position of
handle/step rotary switch.
16. MODE SELECTION ROTARY SWITCH
Modes of operations such as EDIT, AUTO-SINGLE, AUTO CONT, MDI, HANDLE/STEP, JOG, ZRN can be selected using this switch.
17. SPINDLE SPEED OVERRIDE ROTARY SWITCH
Spindle speed can be varied from 50% to 120% of set speed in turns of 10% step.
18. OPTIONAL STOP SWITCH
For M01 code to be effective, this switch is to be pre selected.
19. BLOCK DELETE SWITCH
For skipping the part program blocks this switch is to be pre-selected. ’/’ mark has to be
inserted before the block. If this switch is selected during the execution of auto cycle in
single block then system indicates the error alarm "PRGM CONT SW OPRATD, RST &
HOME".
20. DRY RUN SWITCH
This switch can be used to enable DRN signal. When the DRN signal turns ON, the feed
rate command commanded in Auto or MDI mode is ignored and the machine operates at
the feed determined by the feed override dial. Dry run for rapid traverse can be enabled
or disabled by parameter setting.
8.5
21. MACHINE LOCK SWITCH
The slide movement will only be effective with this switch OFF. This switch is not
effective with auto cycle ON in auto continuous mode. If this switch is selected during
the execution of auto cycle in single block then system indicates the error alarm "PRGM
CONT SW OPERATED, RST & HOME".
22. PROGRAM CHECK SWITCH
Program check switch in combination with the machine lock switch can be used to check
the part program using graphic option. (Graphic simulation)
23. PROGRAM PROTECT OFF/ON KEY SWITCH
Program protection is possible only when this switch is in ON position. In order to edit
the part program in edit mode this switch must be in OFF position.
24. RS 232C PORT
This port can be used to upload or download the PLC program, part program or machine
parameters from CNC system to the computer or other Fanuc system compatible peripheral
devices.
8.6
2. OPERATOR CONTROL PANEL-2
The above operator panel is only for the user reference. For exact description of operator
panel for the machine supplied refer to the relevant operator panel drawing supplied with
the machine interface manual.
8.7
OPERATOR CONTROL PANEL-2 DETAILS
1.
Cycle start push button
2.
Coolant on/off selector switch
3.
Turret index on push button
4.
Turret unclamp override push button
5.
Machine reset push button
6.
Lub inch push button
7.
Conveyor forward/reverse spring return selector switch
8.
Door open/close push button
9.
Turret tool station display unit
10.
Spindle load meter
11.
LED indicators
a.
X-reference LED
b.
Z-reference LED
c.
Turret clamp LED
d.
Tailstock quill forward LED
e.
Tailstock quill home LED
f.
Chuck clamp LED
g.
Chuck declamp LED
h.
Lub. ON LED
i.
Lub. fault LED
8.8
DESCRIPTION OF OPERATOR CONTROL PANEL-2
1.
CYCLE START PUSH BUTTON
This push button is effective in Auto continuous/Auto single and MDI modes of operation
2.
COOLANT ON/OFF SELECTOR SWITCH
Coolant can be switched ON and OFF using coolant ON and OFF selector switch in jog
mode. In auto mode, for coolant ON, M07 to be commanded along with coolant ON
selection. Coolant can be made OFF by M09 or machine reset or coolant OFF selection.
3.
TURRET INDEX ON PUSH BUTTON
In the jog mode the turret can be indexed forward direction by pressing this push button
provided turret is in safe zone and turret clamp signal is present.
4.
TURRET UNCLAMP OVERRIDE PUSH BUTTON
If the turret is unclamped the axes can’t be moved. This can be overridden by pressing
this switch.
5.
MACHINE RESET PUSH BUTTON
This push button can be used to reset M, S or T functions when in execution. This push
button can also be used to reset PLC messages and spindle alarm.
6.
LUB INCH PUSH BUTTON
Once this push button is inched lub motor will be ON for three seconds. Lubrication
inching is possible only when the machine is not under emergency and sufficient oil is
present in the lubrication tank.
7.
CHIP CONVEYOR FORWARD/REVERSE SPRING RETURN
SELECTOR SWITCH
In jog mode chip conveyor can be run forward/reverse, by using spring return selector
switch. In auto mode chip conveyor works in forward direction.
8.9
8.
MACHINE DOOR OPEN/CLOSE PUSH BUTTON
This push button can be used to open or close the door in Jog, MDI or Auto mode, when
the auto cycle is not ON.
9.
TURRET TOOL STATION DISPLAY UNIT
This can be used to indicate the turret station number of the tool being used.
10. SPINDLE LOAD METER
This meter indicates the load conditions of the spindle motor as a percentage of full load
(0 to 120%). This indication is independent of the direction of rotation of the spindle.
Continuous load should be within 100% irrespective of spindle speed.
8.10
1. DAILY MAINTENANCE
1.
Lubrication system
Check for oil level, pressure
(Alarm signal)
build up & film on sliding
At the start of the work
surfaces
2.
Chuck
Greasing the master jaws
through grease nipples.
Tighten the jaws
3.
Cutting tools
Tighten the tool blocks,
tools and inserts
4.
Hydraulic oil level
Check for level
Replenish if needed
5.
Pressure gauge
Check system pressure
30 Kg/cm2
Check for chuck pressure
As per requirement
Replenish if needed
6.
Coolant level
Check for level
7.
Tubing and machine
Check for leakage and
surroundings
cleanliness
External wiring and
Check for disconnections and
cables
damage to sheath
Cleaning
Clean the work holding, turret
8.
9.
At the end of the work
and sliding guards to remove
chips and coolant
9.1
2. PERIODIC INSPECTION
Coolant
Check for condition
Replace as required
Hydraulic system
Return line filter replacement
6 months
Check condition of oil and replace
1 year
Clean power pack and surroundings
1 year
Clean suction strainer
1 year
Check proper working of
6 months
accumulator
Lubricating system
Check for proper working
1 month
Check for oil lubrication lines
1 month
V belts and timing belts
Check for condition and tension
1 month
Motors
Check for rigid (proper) mounting
6 months
Chuck
Overhaul the chuck
1 month
Chucking cylinder
Check for leakage across the piston
3 months
Electrical cabinet
Vacuum clean the CNC and the
3 months
electrical cabinets
Electrical contacts
Check for discolouration in the
3 months
contacts
Electrical elements
Check for proper working of push
3 months
button switches
Limit switches
Check for proper signals
3 months
Axes backlash
Check and compensate
6 months
Foundation
Check for level and relevel
6 months
Headstock
Clean labrynth holes
1 month
Turret
Check for alignment and correct
As required
9.2
3. LUBRICATION
Lubrication is very important for machine tools since it greatly affects machine life. Use
only recommended lubrication oils which can clean and free foreign matter. Periodically
clean the tank and filter, inspect equipment or piping for damages to ensure optimum machine
operation.
a.
SPINDLE
The headstock houses the spindle in bearings which are lubricated for life with high grade
grease (KLUBER ISOFLEX NBU-15). This grease can withstand low and high temperatures (-60o C to +130o C).
Spindle should be warmed up for approximately one hour when the machine has been
stopped for a long period (e.g. five days or more on account of holidays etc.).
See Cautionary details concerning Installation
b.
TAILSTOCK
The tailstock quill is connected to the central lubrication system. If the tailstock contains a
built-in live centre, then it is lubricated for life with KLUBER ISOFLEX NBU-15 grease.
It needs to be changed when the bearings are to be changed. If the machine is with add-on
revolving centre there is no lubrication required.
3.1 COOLANT
A tank serving both as a coolant tank and a chip tray (or optional chip conveyor) is installed
in the front side of the bed. It can be removed from the front side of the machine. Therefore,
it is easy to clean the inner part of the tank and to dispose chips. (Capacity 130 litres)
9.3
3.2
CHUCK
Selection of grease depends on the chuck used. Never fail to supply grease once a day to
the slideway of master jaw.
For GMT Chucks, it is recommended to lubricate the chuck once every shift. Use DOW
CORNING GN PLUS, MOSIL BRB 100, MOLYKOYTE BR 2 GREASES.
DO NOT USE OIL FOR LUBRICATION.
3.3 CENTRALISED LUBRICATION
The X & Z slideways, ballscrews and the tailstock quill are lubricated by automatic
centralised lubrication. Each point of lubrication is connected through a metering cartridge
of 0.25cc capacity/stroke. The provision for manual or automatic selection of lubrication is
provided on the control panel, and the lubrication interval is usually set at once for three
seconds for every 30 minutes.
It is recommended to supply enough number of lubrication shots by manual means before
starting a machine which has been shut down for a long time. The number of shots required
to fill the drained out lubrication lines after the lubrication metering cartridge depends upon
the distance from the metering cartridge to the lubrication point.
For further details see annexure - Centralised Lubrication.
3.4
DAILY INSPECTION
By opening the rear door the lubrication oil distributor mounted beside the X-axis feed motor
is monitored. Visual inspection of the distributor is not sufficient, so check oil at places
where oil is distributed (such as slideways). (e.g. Touch the slideways to check for an oil
film.)
Especially when the machine has been stopped for an extended period, the distributing pipe
gets drained. There are cases when the oil does not flow even though the pipe is filled with
oil. In such a case, check for oil flow by disconnecting the pipe.
If the machine is operated without supplying the lubricating oil to the sliding surfaces, it will
cause seizure of the sliding surface. Be sure to perform the above mentioned inspection
every day.
9.4
3.5 OIL GUIDE TABLE
Lubrication point Lubrication system
Recomm. oil grade
Head stock
KLUBER ISOFLEX NBU-15
Grease
Quantity
Ball screws,
Guideways,
Centralised lubrication
ISO VG-68
3 Litres
ISO VG-68
45 Litres
Tailstock
Hydraulic
Coolant
130 Litres
NOTE : Do not use oil other than the above mentioned.
Also, do not use the mixture of oils of different makes.
9.5
3.6
STARTING CHECK TABLE
Check item
1.
Lubrication oil level
Check
a. Centralised lubrication unit tank
2.
Grease injection
a. Check master jaw (Once every day)
3.
Oil flow
Check
a. Slideway
4.
Oil leak from each part
a. Hydraulic unit
b. Chucking cylinder
c. Peripheral area of machine
5.
Abnormal noise from spindle drive system
a. Head stock
b. Motors
6.
Electrical system
a. Check for each indication
b. Check for each switch function
9.6
4. HEAD STOCK REALIGNMENT
In case of axis misalignment of the spindle with respect to the Z-axis, follow the method given
below for resetting:
1.
Remove the chuck, chucking cylinder etc.
2.
Mount the inspection mandrel.
3.
Open the left hand guard covering the head stock.
4.
Loosen the mounting bolts of the head stock slightly and use the screws provided to align
the axis with respect to the Z-axis.
5.
Tighten the clamping bolts and recheck the alignment in both primary and secondary planes
of the Z-axis.
6.
Shift the tailstock also if necessary in the appropriate direction (use a mandrel between
centres for this task).
7.
Refix the covers.
9.7
REVISION RECORD
ACE CNC LATHE CLASSIC MC - INSTRUCTION MANUAL
Revision
Date
96-104 MC / IM-01
Apr. ’ 02
96-104 MC / IM-02
July ’ 03
Contents
Fanuc Oi-TB System
Updated pages 4.2, 4.3, 4.4
Fanuc Oi-TB specifications, G-Code,
M-code, Operator Messages.
96-104 MC / IM-03
June ’ 06
Fanuc Oi-TC System
System Specifications, G-Code

ace cnc lathe instruction manual - Metaalbewerking Zennewijnen

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