Ace Cnc Lathe Instruction Manual

Transcript

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) Total Power capacity : 27.11 KVA (For Alpha P22i Spindle motor) Voltage : AC 380V, +10%, -15%, 3 phase Frequency : 60 Hz Current : 46 A Power cable connection : 10 mm2 POWER SOURCE INTAKE : (Export Machines) Total Power capacity : 27.11 KVA (For Alpha P22i Spindle motor) Voltage : AC 480V, +10%, -15%, 3 phase Frequency : 60 Hz Current : 36 A Power cable connection : 10 mm2 POWER SOURCE INTAKE : (Export Machines) Total Power capacity : 27.11 KVA (For Alpha P22i Spindle motor) Voltage : AC 220V, +10%, -15%, 3 phase Frequency : 60 Hz Current : 79 A Power cable connection : 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 @ @ @ @ @ @ @ @ @ @ # @ @ @ @ @ @ @ @ @ # @ @ @ @ # # # # # @ @ 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 @ @ # @ # @ @ @ @ @ @ @ @ @ @ # # # 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 * @ @ $ @ @ @ # # # @ @ @ # # @ @ @ @ 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 1065 TOOL 2 WORNOUT, CHANGE INSERT 1066 TOOL 3 WORNOUT, CHANGE INSERT 1067 TOOL 4 WORNOUT, CHANGE INSERT 1068 TOOL 5 WORNOUT, CHANGE INSERT 1069 TOOL 6 WORNOUT, CHANGE INSERT 1070 TOOL 7 WORNOUT, CHANGE INSERT 1071 TOOL 8 WORNOUT, CHANGE INSERT 1072 TOOL 9 WORNOUT, CHANGE INSERT 1073 TOOL 10 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 1074 TOOL 11 WORNOUT, CHANGE INSERT 1075 TOOL 12 WORNOUT, CHANGE INSERT 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 2022 TOOL 2 GETTING WORNOUT 2023 TOOL 3 GETTING WORNOUT 2024 TOOL 4 GETTING WORNOUT 2025 TOOL 5 GETTING WORNOUT 2026 TOOL 6 GETTING WORNOUT 2027 TOOL 7 GETTING WORNOUT 2028 TOOL 8 GETTING WORNOUT 2029 TOOL 9 GETTING WORNOUT 2030 TOOL 10 GETTING WORNOUT 2031 TOOL 11 GETTING WORNOUT 2032 TOOL 12 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 At the start of the work through grease nipples. Tighten the jaws 3. Cutting tools Tighten the tool blocks, At the start of the work 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