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XYZ-1010

Please obey the description of contents and read this operation manual patiently and clearly. (When user is operating XYZ-1010 vertical machining center.)

CHIFA MACHINERY MANUFACTURER CO., LTD.

No. 44 MING CHUAN RD., SHENG KANG HSIANG, TAICHUNG HSIEN, TAIWAN TEL: +886-4- 25628747 FAX: +886-4-25614199

NOTICE

XYZ-1010

CONTENTS

CONTENT 1. Safety Operation rule

2. MECHNICAL INTRODUCTION

3. MECHINE OUTLOOK SIZE

4. Lubricating Oil/Coolant Control Scheme

5. PNEUMATIC SCHEME

6. ELECTRICAL SCHEME

7. CONTROL SOFTWARE

8. PART LIST

9. CALCULATION

10. TEST REPORT

11. LIST-STANDARD,BEALTH and SAFETY REQUIREMENT

12. HAZARD ASSESSMENT PROCEDURE

13.OPERATION MANUAL

14.SERIES PRODUCTION PROCEDURES

15.MISCELLANEOU

XYZ-1010

CONTENTS

XYZ-1010

General Safety Rules 1

Chapter 1. Safety Operation rule 1.1 General safety Notes

This machine had equipped with several safety equipments in order to keep away and protect operator from injury. However, this machine can be dangerous if operated under improper circumstances. Please read following safety notes and understand completely machine functions before starting to use the machine. 1.1.1 Danger Items Do not touch any electric equipment and operation panel with wet

hand, which could result in electric shock. Make sure no any loosed material or tools leaved on working table

before starting the machine. Do not try to touch or exchange anything while machine is on,

spindle is running and/or while machine is moving. Do not operate machine beyond the pre-set functional limitation. Make sure to keep the axis path way clear before starting machine. Do not operate machine under circumstance with explosive

materials around. 1.1.2 Warning Items

Keep working area floor dry & clean to prevent accident due to slippery. Keep machine and working area clean and organized. Provide machine a clean, dry and stable temperature environment. Make sure all of machine cover and doors are closed before starting

operation. Do not touch any unnecessary button while machine under normal

working cycle to prevent mechanical error situation. Make sure machine is completely stop and turn the main power OFF

before any fuss or major electrical parts exchange. Stop machine immediately while machine has any unexpected

movement occurred.

XYZ-1010


Make sure you know how to stop machine in correct process before starting to operate machine. When machine is running, set up a noticeable sign shown that

machine is running alive before operator leave working area. Prevent to operate machine without operator audit around. Make sure to wear proper working close and protecting devices

while operate machine. Keep any unauthorized person away from machine while machine is

running alive. Keep all contact surface of fixture and vise clean with minimum

lubricating oil. Make sure no any loosen materials or parts on table before staring

operate machine. Do not operate with exceed maximum working load and/or size

object. Do not remove any pre-installed safety devices during or before

operate machine. Make sure the tool on spindle is clean and no any cutting chips on it. Do not operate machine while any system alarm been turn on.

1.1.3 Things to remind If the supplied power voltage is not stable, an UPS system or voltage

equalizer needs to be added to the power system. Use factory recommended lubrication and coolant oil only. Use same character and specification fuss only. Do not change factory pre-settled parameters value without advised

by factory. Make sure to record all changes before and after process. Understand all switch function before using it. Safety device should be wear by operator all the time during

machine operating. Make sure all added fixture are compatible with machine

specification. Use only proper device with sufficient capacity to move machine. Do not use damaged tool to operate machine. Use tool with factory recommended limitation only.

XYZ-1010


Turn off the machine main power if machine will not be operate for longer time.

1.2 Machine movement safety The machine is built on a single base. Machine movement can be

very easy by remove the coolant tank first. The grouse weight of the VH series machine is around 5.35 ton. It is strongly recommended by factory to move machine with crane in order to keep reposition and accuracy. If to use folk lift is the only choice then following rules must be use.

1.2.1 Danger Items All movement devices must have certified loading capacity greater

than 6 ton to prevent machine and operator damage. Use only factory provide or recommended fixture to move machine

by crane. All cable and belt used need to have certified loading capacity more

than 6 ton.

1.2.2 Warning Items Any ways of machine movement must to make sure package are well

balanced before operate. Machine movement speed need to be as slow as possible to keep

object balance. Any person climb or stay on machine during machine movement is

strictly forbidden.

1.2.3 Things to remind Do not make any sudden stop and go during machine movement to

prevent exceeded momentum, which may cause lose balance. Allowed only certified operator to execute machine movement. 1.3 Electrical Safety Wiring: Use only certified electricity to connect power wire to

machine. Do not share breaker on power panel with any high signal

XYZ-1010


noise generate devices to prevent sudden voltage drop and noise. Ground: The minimum sectional-area curve of the grounding device

should be greater than l4 mm2. The impedance of the grounding resistance should be less than 100 . Make sure the NC machine has been grounded on individual grounding rod.

1.4 Mechanical safety Before turn on machine main power, check the power cable and

make sure it is in good condition. Make sure to clean all moveable parts and manually turn on the oil

pump several times in order to well lubricate every parts for a newly installed machine or machine which had not been use for a long time. Always wear safety shoes to operate machine. Make sure power supply is well enough for all machines within

machine shop. Check oil pump regularly, always fill the tank with factory

recommended oil. Check the coolant level meter on front side of the coolant tanks

regularly, fill it up when necessary and clean the filter regularly. Check system input power if voltage is correct, all buttons on control

panel are function normally. Check the pressed air supply and coolant pump pressure are sufficient and properly settled.

1.5 Warning signs on machine

XYZ-1010


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A. Do not open the front door during machine operation to prevent accident.

B. Do not put your hands close to spindle while it is ON.

C. Keep your hand away from ATC while it is ON.

D. Hold the tool on spindle firmly before using the manual tool release button.

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E. Main power switch, electrical shock warning sign.

F. High voltage warning sign.

G. Implemented M codes table, use properly to prevent damage machine.

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H. Do not open the back cover of the control panel to prevent electrical shock and/or damaging the control system.

I. Recommended lubrication and cooler oil: Use only following products.

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OIL USAGE RECOMMEND

REPLACE & ADD

PERIOD

VISCOSIT MOBIL SHELL ESSO CASTROL

LUBRICATION SYSTEM

DAILY ISO VG 68

VACTRA2

TONNA T68

MILLCO K68

MAGNA BDX 68

PNEUMATIC LUBRICATION

WEEKLY ISO VG 32

D.T.E LIGHT

TELLUSC32

AROX 22

HYSPIN AWS 46

SPINDLE COOLING SYSTEM

1000 RUNNING

HOURS

ISO VG 32

D.T.E LIGHT

TELLUSC32

TERESSO 32

HYSPIN AWS 46

HYDRAULIC SYSTEM

1000 RUNNING

HOURS

ISO VG 32

D.T.E 24

TELLUSC32

TERESSO 32

HYSPIN AWS 46

GEAR BOX 1000 RUNNING

HOURS

ISO VG 68

D.T.E HEAVY MEDIU

M

TURBO T68

TERESSO 38

MAGNA 68

ATC SYSTEM 1000 RUNNING

HOURS

ISO VG 32

D.T.E 24

TELLUSC32

TERESSO 32

HYSPIN AWS 46

AIR PRESSURE: 6 0.5 Kg/cm2 AIR COMPRESSOR: 200 l/min

XYZ-1010

MECHNICAL INTRODUCTION 1

Chapter 2. MECHNICAL INTRODUCTION 2.1 Mechanical structure outline The XYZ-1010 machining center is one of the best economic and efficient model within TWINHORN product line. The major parts of the machine includes base, column, head stock, saddle, working table, three axis motion control parts, air and oil pressure system, lubrication system, chip collecting device, safety cover, electrical control devices, operating control panel box and control units. The VH series is design to working on steel, iron, copper, alumni and various alloys or many advance modern 3D mold making materials. For any other materials like carbon and all kinds of particle or high evaporating materials process, user need to contact factory to provide necessary protecting device or advises. Do not modify the machine without consult with and have authority by factory to insure warranty and safety policy.

The XYZ-1010 series equipped with modern servo control system, which provides all of modern machining functions. With proper training and suitable tools the machine can be set up to operate fully automatically. All mechanical products has some certain level of possibility in dangerous. Operators need to fully understand the correct process to operate the machine. All Danger and Warning sign as well as safety rules need to be followed.

2.2 Noise The XYZ-1010 had been designed according the CNS standard under CNS4600 regulation to meet noise level below 75dBA during general operation situation. The actual noise level is largely depends on working materials, tools, programming code selecting and coolant quality. Operator should wear proper protecting devices to prevent hearing damage.

2.3 Machine Specification

XYZ-1010


Table size 1200x450 mm

Max. Load weight 450kgs

Working Table T slot #/wide/ and seperat

distance 5/75/18 mm

X axis 1010 mm

Y axis 500 mm

Z axis 520 mm Distance from spindle nose to

table 120~650 mm

Spindle center to Z axis guide

way 540 mm

Travel

Distance from Z axis guide way

to table center 290~790 mm

Max. spindle speed 8000 r.p.m

Spindle motor power 10HP

Spindle outer diameter 65 mm Head Stock

Spindle Tapper BT-40

Three axis rapid feed 15000 mm/min Axis travel rate

Three axis cutting feed 1~5000 mm/min

Machine Weight 5350 kgs

Machine size (L*W*H) 2508x2900x2700 mm

Packing size (L*W*H) 2788x2300x2450 mm

reposition 0.005/300 mm

Accurate 0.003mm

General Info.

Air pressure 5kg/cm

2.4 Equipment

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2.4.1 Standard equipment Coolant system Floating tool clamp/unclamp system Working lamp Spindle nose air Full cover metal Leveling adjusting screw and pad Automatic lubricating system Rigid taping Adjusting tools and Tool box RS-232 interface Automatic power off function(M30)

2.4.2 Optional equipment

Spindle oil cooler Carousel ATC system (20 Tools) Arm type ATC system (24 Tools) Water curtain device 12000 rpm spindle speed 4th axis interface system Electrical cabin heat exchanger Spiral type chip conveyor and cart Belt type chip conveyor Coolant through tool holder 4th axis table Transformer CE standard construction Optional CNC controller

Mitsubishi 64S/65S Fanuc Oi-MB/21i-MB

2.5 Electrical Specification

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2.5.1 Voltage & Frequency Input voltage: 220 V Input Frequency: 60 Hz

2.5.2 Allowed power source

Allowed input voltage range: Between 85% ~ 110% of 220 V Allowed input frequency range: 60 HZ 2 Hz Allowed environment thermal change: 0C~45C (32F~113F) The environment humility change must be lower than 90% of

thermal change Environment requirement: Keep working area as stable as

possible.

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MACHINE OUTLOOK SIZE 1

Chapter 3 MACHINE OUTLOOK SIZE

3.1 MACHINE OUTLOOK SIZE

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3.1.1 Foundation construction plan

Leve

ling

1kg

Bolt

M24

P1.

511

0L

Nut

M12

1.2

5t1

0

Nut

M24

P1.

5t1

9

Foun

da

tion

Bolt

M12

500

L

CHI

P SH

APE

FORM

STY

REN

E

2 NO1345

BASE

SH

APE

PART

NA

ME

/ SP

ECIF

ICA

TION

88888

AA

1700

78870

818

708

2050

630

500

1200

1700800 500

30020

0480

568

450 45030 485

550 350

900

A-A

Vie

w (1

:X)

235

350

54

300

1 2 3

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3.1.2 Size of work table

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3.2 Main parts of machine

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3.3 Type of tool holder

3.3.1 Tool holder

TYPE: BT40

TYPE: DIN40 (Option)

TYPE: CAT 40

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3.3.2 Dimensions of pull stud

TYPE: BT 40

TYPE: DIN69871(DIN40)

TYPE: CAT 40

XYZ-1010

Lubricating Oil/Coolant Control Scheme 1

Chapter 4 Lubricating Oil/Coolant Control Scheme

4.1 Wasted oil collecting box: A. Fill the box with Coolant up to height before install it on

the backside of the machine base to collect cutting fluid. B. Adjusting the leveling screws on bottom of the box to a

proper position. C. Remove the collected wasted oil from box while full. D. Suggested Lubrication Oil Table

Oil Specification Items \ Brands MOBIL SHELL OTHERS

Lubrication System VACTRA 2 TONNA T68 CPC R68

Compressed Air Lub. System DTE-LIGHT TELLUS C32

Spindle Oil Cooler System DTE-LIGHT TELLUS C32

Two speed Gear Box System DTE-LIGHT TELLUS C32

Axis Ball screw Lub. System VACTRA 2 TONNA T68 CPC R68

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4.2 Automatic Lubrication System

YET-C2P2 Oil Pump

The oil pump had been set to operate every 15 min. and 15

Sec. Per each operation. If the daily operation time is 8 hour

then a full tank of oil will last about 4 days.

Normally, during operation, the pump pressure will raise up

to 15 Kgf before release oil to each lubrication portions. If the

pump can not accumulate pressure to 15 Kgf within 30 Sec.

which means there may be an oil pipe loosed or something

wrong on pump.

When the oil quantity within tank lower than the minimum

level, the system will enable the SINGLE BLOCK function,

light up the LED of the SINGLE BLOCK button and turn on

XYZ-1010


the RED NC alarm signal then stop the machine.

To reset the situation, one should fill the oil tank first then

press the RESET key on control panel and release the

SINGLE BLOCK key.

XYZ-1010

PENUMATIC SCHEME 1

Chapter 5 PNEUMATIC SCHEME

5.1 Pneumatic system 5.1.1 The pneumatic system elements control of

VH-650/850/1010, VH-650/850 L/L3 followings:

a. Air cylinder of GENEVA magazine (Armless type) b. Spindle clamp / unclamp c. Spindle air blast d. Chips air blowOption e. Cylinder of tool pot up & downArm type

5.1.2 Air unit a. Position & Name

b. Pressure adjustable valve turn C.W can increase pressure. We set the

range by manual from 46 /.

c. The recommend oil type CPC R12 spinning oil MOBIL Velocite 10

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PENUMATIC SCHEME 2

Castrol AWS 22 (Use the recommended or equivalent hydraulic oil, lubricate oil and grease all the time.)

d. Water release for every day by water release valve (3). e. Pressure Switch

We set the pressure gauge at 4.0 kg/cm2 of the air circuit. When air pressure below that 2.5 kg/ cm2 point, the ALARM on operators panel will light and the flash light will work but no emergency stop will be executed. (It will be very impractical to stop the machine every time when the air pressure starts to fall down), so the operator should be very careful when ALARM happened. He should find the cause of pressure low and shoot it in the shortest time. If can't be covered in 60 seconds, the NC system will FEED HOLD the machine.

f. The adjustment procedures of air pressure switch:

The following steps: 1. Turn C.C.W direction and take off set screw (1) of lock

plate. 2. Take off the lock plate (2) up.

XYZ-1010

PENUMATIC SCHEME 3

3. Take a screw -driver insert to pressure adjust button (3), turn and set the pressure meter (4) had show on 4 kg/cm2

4. Put back the lock plate (2), and attention the hex. socket

must be at the same position with adjust button . 5. Lock set screw of lock plate (1)

g. Main air pressure source supply The air compressor must be prepared by users, and the main air source pressure range we set under 5 / 2.

h. The maintenance of spindle pneumatic clamp / unclamp booster

In normal condition, the cup life of booster can use about 200000 times. In normal condition, fill the R68 lubricant to oil-orifice.

The lubricant checking frequency is 12 months. Its not good for the machine cause the oil not to replace for a long time. To look up the machine in good service conditions is necessary.

Its not in normal condition for oil cup at 2 or 3 days loose oil too fast, check the cup is break down or not and the joint leak or not. If the problem cant resolve contact us or your dealer.

5.1.3 The main points to make use of oily water to separate tank: A. Before to make use tank, fill coolant water about 1/2 height

of tank. Then put the tank behind to base. B. To adjust flatness of tank.

XYZ-1010

PENUMATIC SCHEME 4

C. Pour out refuse oil, when collection oil box full loaded.

5.2. Pneumatic Layout Diagram

5.2.1 Pneumatic Layout Diagram (Armless type 24T)

XYZ-1010

PENUMATIC SCHEME 5

5.2.2 Pneumatic Layout Diagram (Armless type 32T)

5.2.3 Pneumatic Layout Diagram (Non magazine assembly)

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ELECTRICAL SCHEME 1

Chapter 6 ELECTRICAL SCHEME 6.1 EfpIoModule

X402

X405

X404

X402

X404

X405

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ELECTRICAL SCHEME 3

SIEMENS

SIMODRIVE 611

X351

X404

X1

X5

X411

X305

X15

1

X302

X301

X304 X306X302

X301

X412

X413

X414

X415

X416

X405

X402

X404

X1

X5

X405

X402

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X411 s a

xisX414

z a

xis

X412

x a

xisX415

X413

y a

xisX416

4

th axis

X12

2 M

PI

X111 efp i/o m

odule X

3 IN

X305X304

X15

1

X12

1 ha

ndwhell

19

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SIEMENS

SIMODRIVE 611

X111

74

73.173.2

72

5.35.25.163996419

P24P15N15N24MMRESET

911248111213113

NS1NS2

I32.0

K1

KT1

X351

X12

1X14

1X16

1X17

1X17

2

B9

663AS2

AS1

IR READY

6.22 LubConnection_0

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Part List 1

Chapter 8 Part List

8.1 Base Combination

Base Combination (1) Part List

NO: PART No. PART NAME SPECIFICATION Q'TY REMARK

1 V2065080 02 LONG GUAED OF DOG HOUSING 1

2 V2065090 SHORT GUAED OF DOG HOUSING 1

3 V26X0800 LIMIT DOG 34 V210010A 08 BASE 15 BZ5120605 THRUST BEARING #51206 36 B20230150 01 LOCK NUT YSR-M30xP1.5 17 BZ6206ZZ0 BALL BEARING #6206zz 28 B20430150 LOCK NUT YSF-M30x1.5 19 B45253500 COUPLING T501-d25x35 110 B811AC120 ERVO MOTOR FUNAC-AC12 111 V26Y41L1 Y AXIS BALLSCREW 112 V26Y4200 Y AXIS TRANSMISSION BOX 113 V26X3100 01 PLATE OF TRANSMISSION MOTOR 1

14 V26Y4300 Z AXIS END BEARING HOUSING 115 VHB-604200 01 COLLAR 216 V2100200 01 ADJUSTABLE BOLT 817 V2100300 01 FOUNDATION NUT 818 VHB065210 01 Y AXIS CABLE CHAIN SUPPORT 1

19 KR94 CABLE PROTECT CHAIN KR94 2320 VLB-100400 01 LEVELLING PADS 821 V2065070 01 COVER OF TRANSMISSION BOX 1

22 V2061353 01 OIL GUIDE COVER 123

24

25

26

27

28

29

30

31

32

33

34

35

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Part List 2

Base Combination (1)

4

1

32

11

14

76

155

19

22

18

1221

13

9

10

8

16 17 20

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Part List 3

Base Combination (2) B

B (

1 :

2 )

C

V26

Y43

00

BZ5

1206

05B

Z620

6ZZ0

VH

B-60

4200

B20

2301

50

V21

0010

A

V26

Y420

0

B20

4301

50

B45

2535

00

V20

6507

0V

26X3

100

V206

1353

VLB

-100

400

V26

X08

00V2

0650

80V

2065

090

XYZ-1010

Part List 4

8.2 Column Combination

Column Combination (1) Part List

NO: PART No. PART NAME SPECIFICATIONQ'TY REMARK

1 V220010A 07 COLUMN 12 V26Z420A 02 Z AXIS DRIVE BEARING SEAT 13 BZ5120605 THRUST BEARING #51206 34 BZ6206ZZ0 BALL BEARING #6206zz 25 B20230150 01 LOCK NUT YSR-M30xP1.5 16 V26Z4301 01 Z AXIS END BEARING HOUSING 17 B20430150 LOCK NUT YSF-M30x1.5 18 B45253500 COUPLING T501-d25x35 19 B811AC120 SERVO MOTOR FUNAC-AC12 110 V26Z41L1 BALLSCREW OF Z AXIS 111 VHB-604200 01 COLLAR 212 V2210102 COUNTERWEIGHT HOUSING 113 V2210300 SHAFT OF CHAIN WHEEL 4

14 V2210202 CHAIN WHEEL 415 BZ6304ZZ0 BALL BEARING 6304ZZ 416 V2220200 FIXED SEAT OF COUNTER 217 V2220101 01 GUIDE RAIL OF COUNTERWEIGHT 2

18 V2220400 02 BOTTOM FIXED SEAT OF COUNTERWEIGHT GUIDE 2

19 V221050B COUNTERWEIGHT 120 V2210400 01 EYE BOLT 221 B18162410 HET NUT M16x2.0 222 V2065040 05 Z AXIS LIMIT SWITCH HOUSING 123 2-CONNECTING LIMIT SWITCH SN02R12-502M 124 V2700800 01 SET KEY OF ATC CONNECT BRACKET 2

25 BXA206010 01 COVER OF COLUMN 126 TRANSMISSION BOX27

28

29

30

31

32

33

XYZ-1010

Part List 5

Column Combination (1)

XYZ-1010

Part List 6

Column Combination (2)

B

C

V26

Z420

AB

Z620

6ZZ0

B20

4301

50

VH

B-6

0420

0

BZ5

1206

05

V22

0010

A

B20

2301

50

V26

Z430

1

V22

2040

0

V22

1050

B

V22

2010

1

V22

1010

2

V22

2020

0

BX

A20

6010

V22

1030

0

V22

1020

2

BZ6

304Z

Z0

B45

2535

00

XYZ-1010

Part List 7

8.3 SADDLE COMBINATION

Saddle Combination (1) Part List


1 B20230150 01 LOCK NUT YSR-M30xP1.5 12 B20430150 LOCK NUT YSF-M30x1.5 13 B45253500 COUPLING T501-d25x35 14 B811AC120 SERVO MOTOR FUNAC-AC12 15 B82NO2D12 2-CONNECTING LIMIT SWITCH SNO2D12-502 16 BZ5120605 THRUST BEARING #51206 37 BZ6206ZZ0 BALL BEARING #6206zz 28 V2065020 01 X AXIS LIMIT SWITCH SEAT 19 V2065030 Y AXIS LIMIT SWITCH SEAT 110 V2300400 ADJUSTMENT GIBS 211 V2300500 LEFT FIXED HOUSING 112 V2300600 RIGHT FIXED HOUSING 113 V2300700 WIPER (LEFT FRONT) 114 V2300800 WIPER (LEFT REAR) 115 V2300900 WIPER (RIGHT FRONT) 116 V2301000 WIPER (RIGHT REAR) 117 V2320101 SADDLE 118 V26X41L5 BALLSCREW OF X AXIS 119 V26X420A 06 X AXIS TRANSMISSION 1

BEARING HOUSING20 V26X430A 02 X,Y AXIS END BEARING HOUSING 121 V26Y4400 02 X,Y AXIS BALLSCREW NUT HOUSING 1

22 V2A06010 X CABLE CHAIN BRACKET 123 VHB-604200 01 COLLAR 224 VKC-301500 01 WIRING TANK OF Y AXIS 125 2-CONNECTING LIMIT SWITCH SN02R12-502M 126

27

28

29

30

31

32

33

34

XYZ-1010

Part List 8

Saddle Combination (1)

10

6

7

6

5

24

14

9

16 23

1

20

11

10

21

12

8

15

13

4

3

27

619

22

18

17

XYZ-1010

Part List 9

Saddle Combination (2)

BC

VH

B-6

0420

0

BZ6

206Z

Z0

BZ5

1206

05

V26

X43

0A

B202

3015

0

V232

0101

V26X

420A

B204

3015

0

B45

2535

00

V20

6503

0V2

3008

00V2

3006

00V2

3004

00

VKC

-301

500

V26

Y440

0

B82

NO

2D12

V230

0500

XYZ-1010

Part List 10

8.4 Table Combination

Table Combination Part List


1 V2065110 X AXIS LIMIT FIXED PLATE 22 V2066001 02 X AXIS CABLE FLEXIBLE T=5mm. 1

PIPING BRACKET

3 V2420101 TABLE 14 V24202A0 MIDDLE WEDGE ADJUST BLOCK 2

5 V2420300 L&R WEDGE ADJUST BLOCK 2

6 V2420400 LEFT FRONT FIXED PLATE 1

7 V2420500 RIGHT FRONT FIXED PLATE 1

8 V2420600 LEFT REAR FIXED PLATE 1

9 V2420700 RIGHT REAR FIXED PLATE 1

10 V24211A0 MIDDLE GIB FIXED BLOCK 2

11 V2421300 TABLE WIPER(FRONT RIGHT) 1

12 V2421400 TABLE WIPER(FRONT LEFT) 1

13 V2421500 TABLE WIPER(REAR RIGHT) 1

14 V2421600 TABLE WIPER(REAR LEFT) 1

15 V26X0800 LIMIT DOG 316 V26X5601 01 LOCK KEY 217 V26Y4400 02 X.Y BALLSCREW NUT HOUSING 1

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

XYZ-1010

Part List 11

Table Combination

XYZ-1010

Part List 12

8.5 HEADSTOCK COMBINATION

HeadStock Combination Part List NO: PART No. PART NAME SPECIFICATION Q'TY REMARK

1 B811SA6000 SPINDLE MOTOR FANUC A6 12 V2065080 02 LONG GUAED OF DOG HOUSING 13 V2065100 LIMIT DOG PLATE OF Z AXIS 14 V2500300 MIDDLE ADHUSTABLE Gib 15 V2500400 MIDDLE ADHUSTABLE Gib 26 V2500500 FIXED PLATE OF EYE LEFT 17 V2500600 FIXED PLATE OF EYE RIGHT 18 V2500701 WIPER (LEFT UP) 19 V2500801 WIPER (RIGHT DOWN) 110 V2500901 WIPER (RIGHT UP) 111 V2501001 WIPER (LEFT DOWN) 112 V2550700 STOP BLOCK OF SPINDLE MOTOR SEAT 2

13 V2560110 HEADSTOCK 114 V2560220 03 COOLANT DISTRIBUTOR 115 V25661A2 02 SPINDLE MOTOR ADJUSTABLE PLATE 1

16 V26X0800 LIMIT DOG 317 FLUCTUATE PULL COMBINATION 1

17.1 V2564400 NOISE REDUCTION BLOCK 417.2 V2564500 SET COLUMN OF BOOSTER 417.3 V2564701 SET COLUMN BOLT OF BOOSTER 417.4 V2564610 PULL RING 217.5 B01100500 HEXAGON SOCKET HEAD SET SCREW M10xP1.5x50L 4

17.6 B15102120 COLLAR M10x21x2t 417.7 B15122130 COLLAR M12x21x2.5t 417.8 B41123520 COMPRESSION SPRING ID12;D2.3;L35L 417.9 B18121800 HEX NUT M12xP1.75 417.10 B25G40130 BOOSTER G-4000 117.11 VKA-520600 01 FIXED BOARD OF BOOSTER 1

18 CVH012104 VH SPINDLE 119

19

20

20

21

21

XYZ-1010

Part List 13

HeadStock Combination

XYZ-1010

Part List 14

CHIFAMACHINERY MAUFACTURER CO., LTD VH-1010

OPERATION MANUAL 1

CHAPTER 13 OPERATION MANUAL 13.1 Description of installation 13.1.1 POWER REQUIREMENTS OF VP SERIES VERTICAL MACHINING

CENTER: POWER SUPPLY VOLTAGE: AC 3 200 / 220V POWER SUPPLY FREQUENCY: 50 / 60 Hz TRANSFORMER: 15KVA~20KVA

13.1.2 POWER IMPORT MUST KEEP IN: RATED VOLTAGE -15% ~ +10% , RATED FREQUENCY 1 HZ

13.1.3 POWER REQUIREMENTS OF MOTOR

ITEM VH SERIES(HP) GENOVA ARM ATC

NC 0.5 KVA O O

ELECTRICAL CABINET 0.5 KVA O O

3 axis servo motor 3 KW * 3 O O

SPINDLE MOTOR (30min) 7.5 / 10 O O

COOLANT PUMP 1/2 O O

LUBRICATION PUMP 80W O O

MOTOR OF GENOVA 40W O X

ATC MOTOR 1/4 X O

ARMLESS MOTOR 1/2 X O

CHIP CONVEYOR MOTOR 1/4 OPTION OPTION

TOTAL POWER 15 KVA


OPERATION MANUAL 2

13.2 Mechanism to install 1) Ensure the leveling bolts and pads arrange on the correct place, adjust

all the pads position are balance and tight bolts on base. 2) Cleaning all the rust preventing oil device by cotton, then lubrication

them. 3) Ensure the correct specifications of main power supply and grounding

device for power input. 4) To install Z axis motor & motor seat. (To dismantle Z axis motor and

motor seat, when machine is shipping.) Adjust standing for coupling of Z axis servo motor. (According to mark line)

5) Power ON. 6) Air pressure adjustment: 6 kg/cm2 7) Select HANDLE mode, let Z axis go up 30mm by MPG. And then

take away the support bracket of spindle. 8) In HANDLE mode and move down Z axis till chains of

counterweight goes balance, then we can dismantlement the locked device of counterweight. (Loose the screws of fixed pipe in column and fine tuning Z axis with MPG let pipe take out easy.)

4

27

28

26


OPERATION MANUAL 3

29

20

4

Use for 32T magazine.

9) Ensure the wiring of coolant pump rotate direction CW & CCW. 10) To regulate the level of machine. 11) To correct proofs of machine. 12) Fill in the proper type lubrication oil.

13.3 Leveling adjustable

The machinery level adjust is relationship about precision of machine. For keep precision of machine and decrease machinerys vibrate, to be sure to depend on following steps in doing level adjust.

1) Put level gage one L, R one F, B at table center. 2) To adjust bolts for four corner of base. 3) Precise level adjust of the X axis and Y axis, then adjust the other bolts let

the weight loaded average to distribute on bolts, but cant influence the level of a mechanism.

To keep precision and process quality of machine. We advise the level adjust for a mechanism one time per year at least


OPERATION MANUAL 4

13.4 To look over before POWER ON machine 1. The wiring & piping and joint are keep good conditions. 2. The voltage & frequency and phase of main power are correctly. 3. To pay attention to engineers whether workers to expose in danger area

or not. 4. To look up fans of spindle motor and electrics cabinet in normal

condition, when machine turn the main power on. 5. Following the standard operation procedures to power on mechanism.

Following the standard operation procedures to power off mechanism.


OPERATION MANUAL 5

13.5 Descriptions of machinery to transport A. The fork lift truck must be able to withstand load over 4 tons because

machine weight is about 3.8 tons. B. The size after packed is (VH-650/850/1010, 650/850 L/L3) 2788mm(L)

2300mm(W)2450mm(H) , Therefore you must pay attention to whether there are any blockage in moving path or not. Clear all of the blockages before moving.

C. Adjust the fork life truck to the right position and be aware of gravity centre of the machine after packed. Machine must be placed on the load center of fork life truck to avoid machine tilt that will damage and injure propel.

D. Be careful for the height of fork lift truck when lifting. Do not raise too high that will generate vibration because of the tilt of the machine. Have someone instruct the movement when moving machi

VMC-1050/1250 MAX: 98,000 KG

15 TON

2450mm

2300mm

2788mm


OPERATION MANUAL 6

13.5.1 Fixed layout plan of machinery to transport

13.5.2 Fixed layout plan of GENEVA magazine

Fixed block magazine to slide .To dismantle before machine is running.


OPERATION MANUAL 7

13.5.3 To dismantle Z axis servo motor layout plan

The painting mark line.

The painting mark line.


OPERATION MANUAL 8

13.6 To add to the option magazines reserved electrics interface & Electrics contact and connection diagram

13.6.1 Armless type 16T / 20T (GENEVA)

U14

V14

W14

PE

16T / 20T OF GENEVA MOTOR

GENOVA TYPE TERMINAL DESCRIPTIONFANUC

1

240

2

MELDAS

32

207

Remark

47

46

L26

SQ5

L16

46

45

L26

L16

SQ3

SQ6SQ4

Function

Magazine counter

Signal no. for PC board

220v power

Limit switch cable

13.6.1 24T ARM type II 24T

U13 V13 W13U14

V14

W14PE

PE

ATC MOTOR 24T MAGAZINE MOTOR

CAM II TYPE TERMINAL DESCRIPTION

3

Magazine in position (normal open)

8

10

9

7

6

4

5

Reserved

Pot down

Pot up

Home position

Brake point

60 position

Reserved

No.

2

1

Negative electricity

Positive electricity

Function

212 245

222 238

204

205

241

242

207

-

213

214

240

-

244

243

FANUCMELDAS

2

3

2

1

Remark


OPERATION MANUAL 9

13.7 To add to the 4TH axis installation and electrics interface 1. The 4th axis wiring cable is according the 4th axis specification and

type for different supply company.

2. The magnetic valve power for 4th axis depends on different company. We also have supply 3 kinds type of magnetic valve for customer in CHIFA. The magnetic valve type: 24V, 110V, 220V.

3. The operation procedures and notices for 4th axis are depends on

different controller. 13.7.1 To make use 4th axis of a point for attention MELDAS

controller.

OPERATION NOTICE FOR 4TH AXIS METHODS OF OPEN 4TH AXIS:

1. Change screen display to [PLC SWITCH] Change followings: [TOOL PARAM]-->[MENU]-->[PLC SWITCH]

2. Set forth item of switch: 4TH AXIS ENABLE Fifth item: open "ROT_TAB ENABLE". This is the function for 4TH axis has used.

3. Manual input M11 in main display screen, let 4TH axis "UNCLAMP" 4. Be sure this motion is correct, then change to "Zero reference mode" and push "-" direction button till 4TH axis return to Zero reference point.

5. In this moment the 4TH axis still remain to "UNCLAMP". When machine is programming, the command "M10" must be executed in programming and let 4TH axis "CLAMP".

METHODS OF CLOSE 4TH AXIS: 1. Change screen display to [PLC SWITCH] 2. Set forth item of switch: 4TH AXIS ENABLE

Fifth item: close "ROT_TAB ENABLE". This is the function for 4TH axis unused.


OPERATION MANUAL 10

13.8 FANUC i SYSTEM OPERATION MANUAL

13.8.1 Operation Box

FANUC I SYSTEM (For FANUC System)


OPERATION MANUAL 11

13.8.2 Descriptions Of CNC Controller

Operating panel of FANUC i serial

RAPID

AUTOPOWER OFF

RAPID

BLOWAIR

COOLANT1 2

COOLANT

120

110100

90

80

70

60

50

100

EMS/OTRELEASE

WORKLAMP

SPINDLESTOP

RAPID

CWSPINDLE

RAPIDOVERRIDE

80

60

40

20

0

150

140

120

STOPOPTION

OPENDOOR

3COOLANT

YX 4Z

PROTECTPROGRAM

X Y Z 4

BLOCKSINGLE

SKIPBLOCK

RESTARTPROGRAM

LOCKMACHINE

LOCKZ AXIS

RUNDRY

ABSMANUAL

5

OVERRIDE

OVERRIDE OVERRIDE

FEEDFEEDHOLDHOLD START

CYCLECYCLE


OPERATION MANUAL 12

13.8.3 Function descriptions of mechanical operating panel:

No. Switch Name Descriptions

1

POWER ON/OFF

Power switch for CNC control unit. How to set up machine ready, Proceeding as follows: 1. Push power switch on button. 2. Release emergency stop button.

2

E-STOP

1. Turn the rest button by arrowhead direction to release the emergency stop.

2. Push rest button for emergency stop. Warring: Applying the emergency stop,

there is a possibility that each axis or magazine position may slip. Therefore, never fall to make the reference point return.

3

DOOR OPEN (OPTION)

Its the door interlock device. When machine is turning and in manual mode, please set this switch to be effective. Light on: open front door enable. Light off: front door disable. Warning: keep the door interlock effective

is necessary for safety.

4

O.T. RELEASE

While machine is operating or programming, one of three axes over travel alarm display. Please keep press this button and move the over travel axis away from limit switch by M.P.G simultaneously, then the alarm will be release.

5

SPINDLE ON

1. Select the MDI mode. 2. Input S code command, then press

cycle start button. 3. Select HANDLE mode. 4. Press the spindle on button turn on

the spindle, then the spindle rotation CW direction and the speed is according to the S xxxx code at the MDI mode.

6

SPINDLE STOP

When spindle is rotating. Press this button, the spindle stop and the Spindle on key lights off.


OPERATION MANUAL 13


7

SPINDLE SPEED OVERRIDE

This switch is used to control the spindle speed (rpm) percentage from 50% to 120% in 10% step increments.

8

FEEDHOLD

When machine is programming, the program has paused by press this button. Then released this key the program will be execute continue.

9

CYCLE START

Set the mode to AUTO. Press the cycle start button on the operating panel to start the selected program.

10

FEED OVERRIDE

During automatic operation, use command in the program to specify feed rate. The range can be varied from 0% to 150% in 10% step increments. (G01 in AUTO mode or JOG in HANDLE mode)

11

MODE SELECTION

MODE SELECTION SWITCH These switches are used for selecting the operation modes. A. As shown on top figure EDIT, AUTO, TAPE, MDI modes are used for automatic operations. The HANDLE, JOG, REF modes are used for manual operations. B. When this switch is set at automatic mode, all manual modes become ineffective. Also the tool selection switch and spindle rotation switch are not effective. When this switch is set at manual mode all automatic modes become ineffective. C. Set the mode selection switch at the mode before executing.


OPERATION MANUAL 14


EDIT

1. Thats for inputting the new program commands into the computer memory. 2. Thats for calling the memorized exist program for editing alternation, insert, delete, or check programs.

DNC (AUTO)

For executing DNC program command. In this mode, that we can transmission programs by RS-232 interface.

MEMORY (AUTO)

For executing the program memorized in the CNC controller. In this mode, that we can call program and auto execute program from memory.

MDI (AUTO)

This MDI mode is used to input the temporary programs by manual control. Programs input through MDI can be used one time only. After the programs have been executed, they disappear automatically. Input programs again when repeat execution is required.

MPG (Manual)

When the mode selection switch is set at this position, the manual pulse generator is effective. This mode provides three magnifications for choice: X1, X10, X100

JOG (Manual)

When the mode selection switch is set at this position, move the axial by using

axis direction keys. Stroke travels at a rate set by the JOG FEEDRATE OVERRIDE switch.

11

HOME / REF (manual)

This mode is used for returning the 3 axes to the reference position in X, Y or Z axis direction.


OPERATION MANUAL 15


12

X- AXIS Button

Turn the mode switch to HANDLE mode, and press +X or -X button to control the movement direction of X axial.

Left, Right

13

Y- AXIS Button

Turn the mode switch to HANDLE mode, and press +Y or -Y button to control the movement direction of Y axial.

front, back

14

Z- AXIS Button

Turn the mode switch to HANDLE mode, and press +Z or -Z button to control the

movement direction of Z axial. up,

down

15

4TH-AXIS JOG (OPTION)

Depend on the 4TH functions.

CW, CCW

16

Manual Pulse Generator ( M.P.G)

M.P.G is only available at HANDLE mode. The axial movement and distance are according with three magnifications rate for choice. Unit is feed rate / pulse. p : pulse

Input 1 10 100

Metric 0.001/p 0.01/p 0.1/p

Inch 0.0001/p 0.001/p 0.01/p


OPERATION MANUAL 16


17

RAIPD OVERRIDE

Rapid traverse rate is adjusted by setting the RAPID OVERRIDE switch at four steps, 100%, 50%, 25% and F0. When axial movement rapidly, in AUTO mode the program is executing G00. In HANDLE mode, this switch can control the velocity of rapid override scale simultaneously.

18

DRY RUN

ON: F code value during program is ignored and the feed is applied with select speed switch. (It must to be used for program check.)

OFF: The feed moved is according with the F code value during program.

19 ROGRAM RESTART

When program stop already. This switch has been selected ON, the program will be restart by next block of program.

20

SINGLE BLOCK

ON: The feed has stop after executing one block of program. When re-pushing the cycle start button, the feed stops after executing next block of program.

OFF: The feed moves

21

BLOCK BLOCK SKIP

ON: The block execute of program has ignored. When / mark in program.

OFF: The block of program include / has executed continuously, also.

22

OPTION STOP / M01

ON: When block of program include M01 code, the optional stop is executing completely and the machine stop.

OFF: M01 is ignored.


OPERATION MANUAL 17


23

Z-AXIS NEGLECT

When program is executing, this switch has been selected ON, Z axis neglect is valid.

24

MACHINE LOCK

When this switch has been selected ON, three axes lock is valid and M, S, T code revolution in normal until this button released.

25

PROGRAM PROTECT

Select the mode switch to EDIT. Set the program protect to 1, this switch is provided with the key. Edit the program by the MDI panel.

26

M.S.T LOCK

When this switch has been selected ON and program is executing, the machine revolution in normal M.S.T code ignored until this button released.

27

WORK LAMP

ON: The work lamp lights up. OFF: The work lamp doesnt work.

28

COOLANT 1

This key is selected to control the coolant pump on. It can cool work piece and tools.


OPERATION MANUAL 18


29

COOLANT 2

This key is selected to control the rear splash coolant pump on. It can flush all chips down to the chip tank.

30

CHIP CONVEYOR (OPTION)

When this key has been selected, these two keys can control chip conveyor turn CW or CCW and let chips transmit to chip tank.

31

MAGAZINE CW/CCW

CW: When push this button the magazine rotates one station in clockwise direction.

CCW: When push this button the magazine rotates one station in counter clockwise direction.

Note: In auto tool change the Z-axis must be turn to 2nd reference point.

32

AUTO POWER OFF

When this switch stay at power off, the cabinet door is opened, main power will be shut off. When this switch stay at by pass on, the indicating lamp on and the top of switch will light. When cabinet door is opened, main power will not be shut off. Program is executing M30 valid.

33

AIR BLOW

When this switch has been selected, and spindle revolution in vacuum situation, the air blow device of spindle front cover will action and blow out water attachment on spindle.


OPERATION MANUAL 19


34

ALARM LAMP

When machine announce alarm, this lamp will lights up till alarm status had released.

35

POWER LAMP

When the power lamp lights up, that means of the machine is ready.

Note: Some functions on operation panel are option, that accord to the orders of machine spec.

13.8.4 Emergency stop switch Please dont stop machine emergency while machine is operating,

unless it is necessary. When emergency stop switch has been used for urgently condition, programming of machine or movement of axes, spindle running and ATC will stop rapidly etc. Various things are like the above action will damage to machine, while machine is running and tooling is working on work piece.


OPERATION MANUAL 20

Turn on the main power supply switch of machine. (The switch place on the door of electrical

Release red EMG button. (Turn CW direction.)

13.9 FANUC I SERIES Operating Procedures

13.9.1 Steps of power on & Power off

(1) Power On

ON

OFF

Turn on the left button of CRT. (The power LED

goes on .)

Press key to display the position screen.

X 0.000 Y 0.000 Z 0.000 A 0.000

POS

The power on procedure finished.

CHIFAMACHINERY MAUFACTURER CO., LTD VP-1500

OPERATION MANUAL 21

Push EMG button.

Turn off the main power Switch of machine.

(2) Power Off

Turn on the right button of CRT. (The power LED

goes off .)

The power off procedure finished.

ON

OFF


OPERATION MANUAL 22

Select mode to REF.

Four steps rapid override is effective during rapid traverse. The axial is returned to the reference position as following: F0 to 100%.

Choice axial of zero return, keep push (+) button till the action finished and axial stop.(The 3 axes can do reference position return at the same time)

When machine finished the reference position return completion LED lamp goes on.

13.9.2 Manual reference position return

X

X


OPERATION MANUAL 23

The rapid override can be adjusted with the rapid override dial.

In the handle mode, pressing a feed axis on the operators panel continuously moves till the action finished and axial stop(The 3 axes can do rapid traverse at the same time)

13.9.3 Rapid override

Notices: 1. Table of Rapid override:

Rapid override Rapid feed rate (mm/sec) 10 % (F0) 1,500

25 % 3,750

50 % 7,500

100 % 15,000

2. When axial movement the rapid override can changed by manual

Change rotary switch to HANDLEmode


OPERATION MANUAL 24

The jog feed rate can be adjusted with the jog feed rate override dial.

In the JOG mode, pressing a feed axis and direction selection switch on the operators panel continuously moves till the action finished and axial stop. (The 3 axes can do rapid traverse at the same time.)

anytime.

13.9.4 JOG feed

Select mode to JOG

Notices

1. When axial movement the jog feed rate override can changed by manual anytime.


OPERATION MANUAL 25

Select mode to HANDLE.

Choice a feed axial X, Y, Z.

Select the distance to be moved for each step with the magnification dial.

Press the step switch by M.P.G, if an axis direction selection switch is pressed.

13.9.5 MPG feed

Notices: 1. M.P.G feed rate:

Magnification of rotary switch Actual feed dial amount of M.P.G X 1 0.001 mm (0.0001 in)

X 10 0.01 mm (0.001 in) X 100 0.1 mm (0.01 in)

- +


OPERATION MANUAL 26

Select mode to JOG, HANDLE, REF

Press Left hand hold tool holder carefully not drop on table, then put in / out tool holder to spindle.

7. Clamp / Unclamp by manual

Notices: 1. Keep the tool holder is cleaning before that tool holder put in spindle, avoid

chips to damaged spindle bore. 2. Press tool unclamp key let the collect of power drawbar loose, then spindle

can put in / out tool. 3. Release tool unclamp key, the tool holder in spindle is clamp.


OPERATION MANUAL 27

In MDI mode, input SXXXX MXX, press spindle on. S : spindle speed M03 : spindle C.W M04 : spindle C.C.W

The spindle speed can be adjusted with the spindle override magnification dial.

8. Manual operation spindle stop or spindle on

Change mode to HANDLE, JOG, REF. The spindle still revolution.

Press spindle on or stop key to execute.


OPERATION MANUAL 28

Select mode to HANDLE, JOG , REF.

Choice magazine rotate direction, push button of magazine C.W and

magazine C.C.W.

9. Manual operation magazine C.W or C.C.W

Notices: 1. The manual operation magazine followings:

Press one time the magazine rotate one station.


OPERATION MANUAL 29

Select mode to AUTO.

10. Auto operation

Search the program OXXX on CRT will display, then push CYCLE START to execute

Press CYCLE START key, the machine is programming.

a. Press FEED HOLD key, the programming goes dwell.

b. Press SINGLE BLOCK, the programming goes dwell.


OPERATION MANUAL 30

13.10. FANUC I Series M Code Function The M Function listed below are available in CHI-FA Machining Centers, those Functions not listed cant be used.

M CODE LIST M-CODE DESCRIPTIONS ARMLESS TYPE ARM TYPE

M00 PROGRAM STOP O O M01 OPTIONAL PROGRAM STOP O O M02 PROGRAM END O O M03 SPINDLE C.W. O O M04 SPINDLE C.C.W. O O M05 SPINDLE STOP O O M06 TOOLING CHANGE O O M07 AIR BLOW ON O O M08 COOLANT ON O O M09 AIR BLOW & COOLANT OFF O O M10 ROTARY TABLE CLAMP * OPTION OPTION M11 ROTARY TABLE UNCLAMP * OPTION OPTION M19 SPINDLE ORIENTATION O O M23 CHIP CONVEYOR C.W # O O M24 CHIP CONVEYOR C.C.W # O O M25 CHIP CONVEYOR STOP # O O M26 SPINDLE AIR BLAST ON O O M27 AIR BLOW ON O O M29 RIGID TAPPING ON OPTION OPTION M30 PROGRAM END & RESET O O M50 TOOL COOLANT ON OPTION OPTION M52 X AXIS MIRROR IMAGE ON O O M53 YAXIS MIRROR IMAGE ON O O M54 MIRROR IMAGE OFF O O M80 TOOL UNCLAMP X O M81 TOOL CLAMP X O M86 POT DOWN (ARM TYPE) X O M87 POT UP (ARM TYPE) X O M90 MAGAZINE FORWARD (GENOVA) O X M91 MAGAZINE BACKWARD (GENOVA) O X M98 CALLING OF SUBPROGRAM O O M99 END OF SUBPROGRAM O O

* 4TH AXIS # CHIP CONVEYOR

O STANDARD X NO FUNCTION


OPERATION MANUAL 31

M CODE COMMAND REMARK

M00 PROGRAM STOP

(1) PROGRAM STOP. (2) SPINDLE STOP, 3 AXES STOP. (3) DOOR INTERLOCK INVALID. (DOOR LOCKED

WITH LIMIT SWITCHES CAN BE OPEENED) (4) RESTART AFTER PRESSCYCLE START

M 01 OPTIONAL STOP

CONDITION: OPTIONAL STOP SWITCH IS IN ON POSITION. (1) PROGRAM STOP. (2) SPINDLE STOP, 3 AXES STOP. (3) DOOR INTERLOCK INVALID. (DOOR LOCKED

WITH LIMIT SWITCHES CHANBE OPEENED) (4) WHILE PROGRAM IS EXECUTING IT'S STILL

VALID IF LAST SINGLE BLOCK HAS M19 (5) RESTART AFTER PRESS"CYCLE START"

M02 PROGRAM END

(1) PROGRAM STOP, ALARM LIGHT IS ON. (2) SPINDLE STOP, 3 AXES STOP. (3) DOOR INTERLOCK INVALID. (DOOR LOCKED

WITH LIMIT SWITCHES CAN BE OPEENED) (4) RESTART AFTER PRESS" CYCLE START"

M03 SPINDLE RUNS C.W.

DOOR INTERLOCK IS VALID.(THE DOOR LOCKED WITHLIMIT SWITCH MUST BE CLOSED). SPINDLE IS IN TOOL CLAMPING STATUS, CONFIRM LOW OR HIGH POSITION FOR GEAR TRANSMISSION, ATC READY. MANUAL TOOL UNCLAMPING IS UNV ALID. (1) UNDER "AUTO" & "MDI" MODE: EXECUTE

STINDLE RUNS C.W. (2) UNDER "HANDLE" MODE: EXECUTED SPINDLE

C.W, SPINDLE SPEED LIMIT WITHIN 100rpm WHILE DOOR IS OPEN MANUALLY

M04 SPINDLE RUNS C.C.W.

DOOR INTERLOCK IS VALID. (THE DOOR LOVKED WITH LIMIT SWITCH MUST BE CLOSED). SPINDLE IS IN TOOL CLAMPING STATUS, CONFIRM LOW OR HIGH POSITION FOR GEAR TRANSMISSION. MANUAL TOOL UNCLAMP9NG IS UNV ALID. (1) UNDER "AUTO"& "MDI" MODE: EXECUTE

SPINDLE RUNS C.C.W. (2) UNDER"HANDLE" MODE: EXECUTE SPINDLE

C.C.W, SPINDLE SPEED LIMIT WITHIN 100rpm WHILE DOOR IS OPEN MANUALLY.


OPERATION MANUAL 32

M CODE COMMAND REMARK

M05 SPINDLE STOP RUNNING

(1) SPINDLE STOP RUNNING BUT OTHER FUNCTIONS ARE STILL VALID.

M06 AUTO TOOL CHANGE

ATC READY BULB IS LIT. SPINDLE IS IN STATUS OF ORIENTATION AND TOOL CLAMPING. LIGHT FOR ATC HOME POSITION IS LIT. ALARM LIGHT IS IN GOOD ORDER. Z AXIS IS LOCKED FOR V/M/C WITH FIXED COLUMN TYPE. Z & Y AXIS ARE LOCKED FOR V/M/C WITH TRAVELLING COLUMN TYPE. Z & Y AXISARE LOCKED FOR H/M/C. (1) TOOL IN SPINDLE EXCHANGED WITH TOOL IN

MAGAZINE.

M07 AUTO AIR BLAST

EXECUTE AUTO AIR BLAST, CLEAN COOLANT AND CHIPS.

M08 COOLANT IS ON

(1) COOLANT IS EJECTED.

M09 COOLANT IS OFF

"COOLANT" SWITCH IS "AUTO" MODE. (1) CHIP COOLANT IS OFF. DEEP HOLD DRILLING

IS OFF. AUTO AIR BLAST IS OFF.

M10 THE 4TH AXIS IS CLAMP

EITHER PNEUMATIC & HYDRAULIC SYSTEM IS NORMAL. (1) BRAKE OF THE 4TH AXIS IS CLAMP. STOP

RUNNING.

M11 THE 4TH AXIS IS UNCLAMP

EITHER PENUMATIC & HYDRAULIC SYSTEM IS NORMAL (1) BRAKE OF THE 4 TH AXIS IS UNCLAMP.

EXECUTE RUNNING.

M19 SPINDLE ORIENTATION

IN"AUTO" & "MDI"MODE: SPINDLE STOP. HIGH OR LOW GEAR SHIFT CONFIRMATION. "HANDLE" MODE: SPINDLE STOP. HIGHT OR LOW GEAR SHIFT CONFIRMATION. (1) EXECUTE SPINDLE ORIENTATION.

M CODE COMMAND REMARKM23 CHIP CONVEYOR CW

(1) EXECUTE CHIP CONVEYOR CW. CHIP CONVEYOR WILL RUNNING.

M24 CHIP CONVEYOR CCW

(1) EXECUTE CHIP CONVEYOR CCW. CHIP CONVEYOR WILL RUNNING FOR 3 SEC THEN STOP.

M23 CHIP CONVEYOR CW

(1) EXECUTE CHIP CONVEYOR STOP. CHIP CONVEYOR WILL STOP RIGHT AWAY.

M29 RIGID TAPPING. (ONLY

SPINDLE IN TOOL CLAMPING STATUS. HIGH OR LOW GEAR SHIFT CONFIRMATION. USE S


OPERATION MANUAL 33

FANUC SYSTEM) COMMAND WHILE IT CAN'T CHANGE SHIFT DIRECTLY UNDER GEAR TRANSMISSION TYPE.

M30 PROGRAM END

(5) PROGRAM STOP. (6) SPINDLE STOP, 3 AXES STOP. (7) DOOR INTERLOCK INVALID. (DOOR LOCKED

WITH LIMIT SWITCHES CAN BE OPEENED) (8) RESTART AFTER PRESS" CYCLE START"

M48 OVERRIDE CANCEL ON

THE OVERRIDE WILL DISABLE AND ALWAYS IN 100%.

M49 OVERRIDE CANCEL OFF

THE OVERRIDE WILL ENABLE

M50 COOLANT FOR DEEP HOLD DRILLING IS VALID

(1) COOLANT FOR DEEP HOLE DRILLING IS EXECUTED, M08 IS VALID.

M86 TOOL POT IS DOWN. (ONLY FOR ARM TYPE)

TOO MAGAZINE STOP ROTATING. (1) EXECUTE TOOL POT IS DOWN.

M52 X AXIS MIRROR IS ON

(1) X AXIS MIRROR FUNCTION OUTPUT.

M53 Y AXIS MIRROR IS ON

(1) Y AXIS MIRROR FUNCTION OUTPUT.

M CODE COMMAND REMARKM54 MIRROR FOR X.Y. 4TH AXIS IS OFF

(1) MIRROR FUNCTION FOR X.Y. 4TH AXIS IS CLOSED.

M80 TOOL UNCLAMP.

IN "AUTO" & "MDI" MODE: TOOL CLAMP. ARM ROTATES TO 60 DEGREE OR HOME POSITION. IN "HANDLE" MODE: SPINDLE STOP. PNEUMATIC SYSTEM ARE NORMA (1) EXECUTE TOOL UNCLAMP.

M81 SPINDLE TOOL CLAMP.

IN "AUTO" & "MDI" MODE: TOOL UNCLAMP. ARM ROTATES TO 180 DEGREE OR HOME POSITION. IN "HANDLE" MODE: SPINDLE STOP. PNEUMATIC SYSTEM IS NORMAL. (1) EXECUTE TOO CLAMP.

M86 TOOL POT IS DOWN. (ONLY FOR ARM TYPE)

ARM ROTATES TO HOME POSITION AND IN TOOL CLAMP STATUS. (1) EXECUTE TOOL POT DOWN.

M87 TOOL POT IS UP.(ONLY

ARM ROTATES TO HOME POSITION AND IN TOOL CLAMP STATUS.


OPERATION MANUAL 34

FOR ARM TYPE) (1) EXECUTE TOOL POT UP. TOOL WILL BACK TO MAGAZINE.

M90 ATC FORWARD (ONLY FOR GENEVA WHEEL TYPE)

SPINDLE HAS TO BE ASSURED IN FOLLOWING STATUS. AFTER ORIENTATION & TOOL CLAMP STATUS. ATC HOME POSITION BACKWARD IS LIT. ATC READY STATUS. EITHER PNEUMATIC SYSTEM IS NORMAL. (1) EXECUTE ATC FORWARD POSITION FOR TOOL CLAMP.

M91 ATC BACKWARD (ONLY FOR GENEVA WHEEL TYPE)

SPINDLE HAS TO BE ASSURED IN FOLLOWING STATUS. AFTER ORIENTATION & TOOL CLAMP STATUS. ATC HOME POSITION FORWARD IS LIT. ATC READY STATUS. EITHER PNEUMATIC SYSTEM IS NORMAL. (1) EXECUTE ATC FORWARD POSITION FOR TOOL CLAMP.

M CODE COMMAND REMARKM98 CALL SUB PROGRAM

TO CALL SUB PROGRAM

M99 SUB PROGRAM STOP

TO MAKE SUB PROGRAM STOP, WHILE EXECUTING M99, IT WILL BACKS TO MAIN PROGRAM AGAIN.


OPERATION MANUAL 35

13.11 Alarm Message & Release 13.11.1 Descriptions of Alarm message Unit: FANUC / OM series

Alarm No.

Display (Armless type) Display (Arm type) Address for PMC

Message & Release

1000 E-stop E-stop X21.4 Emergency stop is active. Check e-stop button or over travel.

1001 Air pressure low Air pressure low X21.7 Air pressure low. (6kg/cm2)

1002 Coolant 1 overload Coolant 1 overload X22.0 Coolant 1 pump motor overload Reset the overload relay FR1

1003 Coolant 2 overload Coolant 2 overload X22.1 Chip flush nozzle pump motor overload. Reset the overload relay FR5 or FR6.

1004 Coolant 3 overload Coolant 3 overload X22.2 Water curtain, coolant through tool holder or coolant through spindle pump motor overload. Reset the overload relay FR7.

1005 Chip conveyor overload Chip conveyor overload X22.3 Chip conveyor motor overload. Reset the overload relay FR2.

1006 Arm motor overload X22.4 ATC arm motor overload. Reset the overload relay FR3.

1007 Tool Magazine motor overload

X22.5 Tool magazine motor overload. Reset the overload relay FR4.

1008 Tool clamp limit switch alarm

Tool clamp limit switch alarm

X17.2 Tool clamp limit switch fault.SQ1 1

1009 Tool unclamp limit switch alarm

Tool unclamp limit switch alarm

X17.3 Tool unclamp limit switch fault. SQ2 0

1010 Tool magazine forward limit switch alarm

Tool pot down limit switch alarm

X20.1 Tool magazine forward or tool pot down limit switch fault. SQ3 0

1011 Tool magazine backward limit switch alarm

Tool pot up limit switch alarm

X20.2 Tool magazine backward or tool pot up limit switch fault.SQ4 1

1012 Tool magazine counter sensor alarm

Tool magazine counter sensor alarm

X20.0 Tool magazine counter, index sensor fault. (Cable no.280)


OPERATION MANUAL 36

1013 Spindle cooler alarm Spindle cooler alarm X21.5 Spindle oil cooler alarm. 1014 R688.6

1015 R688.7

1016 Tool in spindle R691.0 The T No. will be called is in spindle.

1017 Tool can't be found Tool can't be found R691.1 T code is fault. 1018 No tool in spindle R691.2 Spindle tool No. is 0. Setting

DGN No. D440=Spindle tool No.

1019 HYD OL HYD OL X22.6 Hydraulic motor overload.

1020 Spindle motor fan overload Spindle motor fan overload X22.7 Spindle motor fan overload. KM0

1021

2001 Lubrication level low Lubrication level low X21.6

13.11.2 Descriptions of Alarm message Unit: FANUC / Oi-M series Alarm

No. Display (Armless type) Display (Arm type) Address for

PMC Message & Release

1000 E-stop E-stop X8.4 Emergency stop is active. Check e-stop button or over travel.

1001 Air pressure low Air pressure low X6.0 Air pressure low. (6kg/cm2)

1002 Coolant 1 overload Coolant 1 overload X7.5 Coolant 1 pump motor overload Reset the overload relay FR1

1003 Coolant 2 overload Coolant 2 overload X8.1 Chip flush nozzle pump motor overload. Reset the overload relay FR5 or FR6.

1004 Coolant 3 overload Coolant 3 overload X8.2 Water curtain, coolant through tool holder or coolant through spindle pump motor overload. Reset the overload relay FR7.

1005 Chip conveyor overload Chip conveyor overload X7.6 Chip conveyor motor overload. Reset the overload relay FR2.

1006 Arm motor overload X7.7 ATC arm motor overload. Reset the overload relay FR3.

1007 Tool Magazine motor overload

X8.0 Tool magazine motor overload. Reset the overload relay FR4.


OPERATION MANUAL 37

1008 Tool clamp limit switch alarm

Tool clamp limit switch alarm

X4.1 Tool clamp limit switch fault.SQ1 1

1009 Tool unclamp limit switch alarm

Tool unclamp limit switch alarm

X4.2 Tool unclamp limit switch fault. SQ2 0

1010 Tool magazine forward limit switch alarm

Tool pot down limit switch alarm

X5.1 Tool magazine forward or tool pot down limit switch fault. SQ3 0

1011 Tool magazine backward limit switch alarm

Tool pot up limit switch alarm

X5.2 Tool magazine backward or tool pot up limit switch fault.SQ4 1

1012 Tool magazine counter sensor alarm

Tool magazine counter sensor alarm

X5.0 Tool magazine counter, index sensor fault. (Cable no.280)

1013 Spindle cooler alarm Spindle cooler alarm X6.2 Spindle oil cooler alarm. 1014 R688.6

1015 R688.7

1016 Tool in spindle R565.0 The T No. will be called is in spindle.

1017 Tool can't be found Tool can't be found R565.1 T code is fault. 1018 No tool in spindle R565.2 Spindle tool No. is 0. Setting

DGN No. D440=Spindle tool No.

1019 HYD OL HYD OL X7.7 Hydraulic motor overload.

1020 Spindle motor fan overload Spindle motor fan overload X7.4 Spindle motor fan overload. KM0

1021 Arm position fault

2001 Lubrication level low Lubrication level low X6.1

13.12. Trouble of Magazine Alarm & Release

13.12.1 OM-D/OM-C Armless type of GENEVA magazine 1. Ensure the spindle yes or no M80 UNCLAMP IN HANDLE M81 CLAMP 2. If clamp for sure let magazine backward. M90 Magazine Forward M91 Magazine Backward 3. Ensure the Spindle No. equal to Magazine No.

CLAMP


OPERATION MANUAL 38

4. To search SPINDLE No.

MAGAZINE No.

5.Please attention the if data setting error, that will to make tools confused and appearance of

disorder. 13.13 SIEMENS 810D

1. :

SUNRISE ( +

)

()

2.

()

()

3.

() ()

Actual access level Manufacturer

Reset 100%

NCK reset

MENU select CNC ISO

CNC ISO

MENU select Startup

DGNOS D440 2 D432 2 CORRECT

D440 2 D432 1 ERROR


OPERATION MANUAL 39

() ()

()

2. :

MD33050 LUBRICATION_DIST

MD34090 REFP_MOVE_DIST_CORR [0]:

MD36100 POS_LIMIT_MINUS

MD36110 POS_LIMIT_PLUS

MD36920 SAFE_ENC_GEAR_PITCH

MD34090 REFP_MOVE_DIST_CORR [0]

Z

MD30600 FIX_POINT_POS[0]

MD30600 FIX_POINT_POS[1]

3. M CODE

MDA :

Machine data Axis-specific

Axis +

Axis -


OPERATION MANUAL 40

M74

M2

Z

13.14 SIEMENS 810DE/840DE Alarm message & Release 510008 "Feed not enabled?" Descriptions Feed not enable.

Reaction

Alarm display. 3 axes + 1 Spindle cant running.

Remedial measures

Push FEED START key on the operation panel, and the LED lights up.

510009 Waiting for spindle speed Descriptions Waiting for spindle speed.

The three phase of main power not balance. Reaction

Alarm display. Spindle is stalling speed, and the speed gradually to go down. NC stop. NC on stand-by cancel. Mode group on stand-by cancel.

Remedial measures

To inspect the 3 phase of main power whether to differ 10% or not.

510010 "Magazine jog active" Descriptions To start magazine rotate by handle mode. 510010 "Magazine jog active" Descriptions To start magazine rotate by handle mode. (16 Tools20 Tools24 Tools32 Tools)

510011 "Pot up/down jog active" Descriptions To start pot up/down by handle mode. (24 Tools32 Tools) 510012 "Arm jog active" Descriptions Arm rotating by handle mode. (24 Tools32 Tools)

Geneva magazine in-position and out-position by handle mode. (16 Tools20 Tools)


OPERATION MANUAL 41

510100 "Arm rotation timeout" Descriptions Arm rotating by handle mode, the timing stop.(24 Tools, 32 Tools)

Geneva magazine in-position and out-position by handle mode, the timing stop. (16Tools20 Tools) One approach switch of arm rotating 0,60,90 to break down. (24 Tools, 32 Tools) Limit switch of Geneva magazine in-position and out-position to breakdown. (16 Tools, 20 Tools)

Reaction

Alarm display. NC on stand-by cancel. Mode group on stand-by cancel.

Remedial measures

One of the approach switch to lose efficacy for arm to rotate 06090. Then check out the position of arm to rotate, the switch end lights goes on or not. Whether PLC I/O to have input a signal or not. (I35.6I35.7I36.0) One of the approach switch to lose efficacy for magazine in-position or magazine out-position, Whether PLC I/O to have input a signal or not. (I35.1I35.2)

510101 "Tool clamp timeout" Descriptions The timeout of spindle clamping. (16Tools20 Tools24 Tools32 Tools)

The limit switch of spindle clamping to lose efficacy. Reaction

Alarm display. Mode group on stand-by cancel.

Remedial measures

One of the clamping limit switch to lose efficacy. Whether PLC I/O to have input a signal or not. (I33.5)

510102 "Tool Unclamp timeout" Descriptions The timeout of spindle unclamping.(16Tools20 Tools24 Tools32 Tools)

The limit switch of spindle unclamping to lose efficacy. Reaction


Remedial measures

One of the unclamping limit switch to lose efficacy. Whether PLC I/O to have input a signal or not. (I33.6)

510103 "Master coolant motor overloaded " Descriptions Coolant pump overload.

Reaction


Remedial measures

To check NC cable plate F8 Thermal overload relay point 95 to have DC 24V output or no, point 96 to have output DC24V or no. Whether PLC I/O to have input a signal or not. (I37.1) If point 96 to have output DC24V, to measurement KM1 contactors 3 phase power are AC 380V.


OPERATION MANUAL 42

510104 "Rotary axis clamp/release error (I39.1/I39.2)" Descriptions 4TH rotary axial reference point error.

Reaction


Remedial measures

This is a procedure to guard the hardware to decide PIN IN / OUT for which mode before. Then modify PLC. When install the 4TH rotary axis first time, the hardware scanning will not to make a mistake.

510116 "Waiting for tool released /Unclamp(I33.6)" Descriptions Waiting for spindle unclamp.

Reaction


510117 "Waiting for tool clamped " Descriptions Waiting for spindle clamped

Reaction


510118 "Waiting for rotary axis clamped " Descriptions Waiting for 4TH rotary axis PIN OUT

Reaction

Alarm display. Mode group on stand-by cancel. Execute M10

510118 "Waiting for rotary axis Unclamped " Descriptions Waiting for 4TH rotary axis PIN IN

Reaction


510118 " Waiting for tool change " Descriptions Waiting for tool change

Reaction


510308 " Safety door not locked, spindle speed limited " Descriptions Interlock to open, the minimum spindle speed 100RPM

Reaction


Remedial measures

This is a protect procedure. When front door to open, the 3 axes feed rate goes to the lowest and the program to execute will be change to single block.


OPERATION MANUAL 43

510309 " Manual tool release active " Descriptions S13 manual tool release active to start

Reaction


510310 " Spindle rotation direction changed-->NC start will change back " Descriptions S13 manual tool release active to start

Reaction


600308 " Arm not at original, Z axis locked " Descriptions Arm not at original, Z axis locked. (24 Tools32 Tools)

Reaction

Alarm display NC on stand-by cancel Mode group on stand-by cancel. 4 Axis to limit action.

Remedial measures

This is a protect procedure, when tool (I36.0) no signal to input. One of the (I35.6/I35.7) point has signal input, then check ATC arm at original position or no.

600309 " Magazine not at basic position, Z axis locked " Descriptions Magazine not at basic position, Z axis locked. (16 Tools20 Tools)

Reaction

Alarm display. Mode group on stand-by cancel. 4 Axis to limit action.

Remedial measures

This is a protect procedure, when tool (I35.1) no signal to input. And the (I35.2) has signal input or no, that mean the magazine not at basic position.

600408 Rotary axis is clamped (I39.1/I39.2) Descriptions 4TH Rotary axis is clamped

Reaction


600500 " Spindle fan overloaded (I37.0)" Descriptions Spindle fan overloaded

Reaction


Remedial measures

Check NC wiring plate Q2 motor start point (1.61) has DC 24V, and later (1.62) point has DC24V input/output or no. The PLC I/O has signal input or no.(I37.0) If (1.62) point has DC24V output, measurement Q2 start motor 3 phase power is AC 380V or not.


OPERATION MANUAL 44

600501 "Spindle oil chiller fault" Descriptions Spindle oil chiller fault

Reaction


Remedial measure

To refer to oil coolers operation manual for alarm release.

600509 " Tool not clamped, Spindle locked

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