Technical Product Documentation
Ultra Precision Lathe
PD with control Siemens 840D
Serial number:
Version:
Valid until:
Article number:
PD-2-01/03-840D
61503E
SPINNER WERKZEUGMASCHINENFABRIK GmbH
D-82054 Sauerlach, Rudolf-Diesel-Ring 24
Tel: 08104 / 803-0, Fax: 08104 / 803-19,
E-Mail: sales@spinnner-wzm.de; service@spinner-wzm.de
Technical Product Documentation
Keep this Technical Product Documentation always
at the machine!
It must always be available!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2
Technical Product Documentation
I. Table of contents
A USER INFORMATION
1 BASIC INFORMATION............................................................................................... 1-1
1.1 Basic information...................................................................................................................................1-2
2 BASIC SAFETY INFORMATION ................................................................................ 2-1
2.1 Warnings and symbols...........................................................................................................................2-2
2.2 Appropriate use .....................................................................................................................................2-2
2.3 Application limits ..................................................................................................................................2-3
2.4 When the machine can be used..............................................................................................................2-3
2.5 Working safely – Organizational measures ...........................................................................................2-3
2.6 Personnel selection and qualifications ...................................................................................................2-4
2.7 General hazards on the machine ............................................................................................................2-4
2.7.1 Mechanical hazards .........................................................................................................................2-4
2.7.2 Electrical hazards ............................................................................................................................2-4
2.7.3 Thermal hazards ..............................................................................................................................2-5
2.8 Special types of hazards.........................................................................................................................2-5
2.8.1 Electrical .........................................................................................................................................2-5
2.8.2 Pneumatic systems...........................................................................................................................2-5
2.8.3 Oil, grease and other chemical substances ......................................................................................2-5
2.9 Danger through vertical axes and tilted axes .........................................................................................2-6
2.10 Emergency OFF...................................................................................................................................2-6
2.11 Fire and explosion hazards/other hazards ............................................................................................2-7
3 PRODUCT DESCRIPTION ......................................................................................... 3-1
3.1 EC Declaration of conformity................................................................................................................3-2
3.2 Introduction ...........................................................................................................................................3-3
3.3 Areas of use ...........................................................................................................................................3-3
3.3.1 Areas of use.....................................................................................................................................3-3
3.4 Machine views of the PD series.............................................................................................................3-4
3.4.1 Overall view of the machine without housing .................................................................................3-4
3.4.2 Front view and right side of the machine ........................................................................................3-5
3.4.3 Left side of the machine ..................................................................................................................3-5
3.4.4 Rear view ........................................................................................................................................3-6
3.5 Mechanical design .................................................................................................................................3-6
3.5.1 Machine versions.............................................................................................................................3-6
3.6 Machine control system .........................................................................................................................3-7
3.7 Location of the ratings plate and CE symbol .........................................................................................3-8
3.8 Safety equipment ...................................................................................................................................3-8
3.9 Warning plates and safety information on the machine .......................................................................3-10
3.10 Technical data of the machine ...........................................................................................................3-11
3.10.1 Mechanical data ..........................................................................................................................3-11
3.10.2 Electrical data..............................................................................................................................3-12
3.10.3 Pneumatic system ........................................................................................................................3-12
3.10.4 Noise emission ............................................................................................................................3-12
3.10.5 Electromagnetic compatibility.....................................................................................................3-13
3.10.6 Continuous load/Intermittent duty...............................................................................................3-13
B ASSEMBLY/DISASSEMBLY
1 TRANSPORTATION AND STORAGE ........................................................................ 1-1
1.1 Introduction ...........................................................................................................................................1-2
1.2 Preparing for transportation...................................................................................................................1-2
1.3 Moving the base machine ......................................................................................................................1-3
1.3.1 Moving with a fork lift ....................................................................................................................1-3
1.3.2 Moving with a lifting truck..............................................................................................................1-4
1.3.3 Moving using a crane ......................................................................................................................1-5
1.4 Transportation over short distances .......................................................................................................1-7
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Technical Product Documentation
1.4.1 Packing the machine........................................................................................................................1-7
1.4.2 Unpacking the machine ...................................................................................................................1-8
1.5 Transportation overseas.........................................................................................................................1-8
1.5.1 Packing the machine........................................................................................................................1-8
1.5.2 Unpacking the machine .................................................................................................................1-10
1.6 Storage.................................................................................................................................................1-11
1.6.1 Introduction...................................................................................................................................1-11
1.6.2 Storage conditions for machines under a PE protective plastic sheet............................................1-11
1.6.3 Storage conditions for machines in a wooden crate.......................................................................1-11
1.6.4 Guarantee ......................................................................................................................................1-11
2 PUTTING INTO OPERATION..................................................................................... 2-1
2.1 Introduction ...........................................................................................................................................2-2
2.2 General requirements at the installation site ..........................................................................................2-2
2.2.1 Electrical connection .......................................................................................................................2-2
2.2.2 Pneumatic connection......................................................................................................................2-2
2.2.3 Other environmental conditions ......................................................................................................2-2
2.3 Installation diagrams/Foundation plan...................................................................................................2-3
2.4 Power supply types and connection information ...................................................................................2-6
2.4.1 Connecting to a TN power supply...................................................................................................2-7
2.4.2 Connecting to a TT power supply ...................................................................................................2-7
2.4.3 Connecting to a IT power supply ....................................................................................................2-8
2.5 Installation .............................................................................................................................................2-8
C OPERATION/MAINTENANCE
1 SWITCH ON/OFF ROUTINE ...................................................................................... 1-1
1.1 Switching on the machine ......................................................................................................................1-2
1.2 Reference the machine axes...................................................................................................................1-2
1.2.1 Introduction.....................................................................................................................................1-2
1.2.2 Manually moving the machine axes ................................................................................................1-3
1.2.3 Referencing the machine axes .........................................................................................................1-3
1.3 Switching off the machine .....................................................................................................................1-4
2 SETTING UP THE MACHINE ..................................................................................... 2-1
2.1 Setting up the clamping device ..............................................................................................................2-2
2.1.1 Mounting the clamping device ........................................................................................................2-2
2.2 Setting up the tools ................................................................................................................................2-2
2.2.1 Linear standard toolholder ..............................................................................................................2-3
2.2.2 Linear cartridge toolholder..............................................................................................................2-3
2.2.3 Turret toolholder .............................................................................................................................2-4
2.3 Tool measuring ......................................................................................................................................2-4
2.3.1 Adjusting the tools to the height of centres of the machine .............................................................2-4
2.3.2Tool measuring by touching the workpiece......................................................................................2-6
2.3.3 Optical tool measuring ....................................................................................................................2-6
3 MACHINE SPECIFIC OPTIONS OF THE CONTROL 840D ....................................... 3-1
3.1 Introduction ...........................................................................................................................................3-2
3.2 Operating elements of the Siemens control system 840.........................................................................3-4
3.2.1 Screen and keyboard .......................................................................................................................3-4
3.2.2 Machine control panel.....................................................................................................................3-5
3.2.3 Control panel on the left side of the machine front .........................................................................3-7
3.3 Permission mode....................................................................................................................................3-7
3.4 Manual operating device (option)..........................................................................................................3-9
3.5 Access levels........................................................................................................................................3-10
3.6 Main operating mode...........................................................................................................................3-10
3.6.1 Manual operating mode, JOG .......................................................................................................3-10
3.6.2 Semiautomatic operating mode, MDI............................................................................................3-11
3.6.3 Automatic operating mode, AUTO ...............................................................................................3-11
3.6.4 Reference point mode, REF-POINT .............................................................................................3-11
3.6.5 Increment mode.............................................................................................................................3-12
3.7 Setting the clamping pressures.............................................................................................................3-12
3.7.1 Value and function ranges .............................................................................................................3-12
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Technical Product Documentation
3.8 The tool correction memory ................................................................................................................3-13
3.8.1 Working planes and tool lengths ...................................................................................................3-14
3.8.2 Measuring up the tools ..................................................................................................................3-14
3.8.2.1 The X-axis for turning tools/dividing tools ...............................................................................................3-14
3.8.2.2 The Z-axis for turning tools/dividing tools ................................................................................................3-14
3.8.3 Entry of wear parameters...............................................................................................................3-15
3.8.3.1 The X-axis for turning tools/dividing tools ...............................................................................................3-15
3.9 Spindle synchronisation.......................................................................................................................3-15
3.9.1 Positional synchronised running Main spindle⇒sub-spindle without matching of the
clamping unit..........................................................................................................................................3-15
3.9.2 Positional synchronised running Main spindle⇒sub-spindle with matching of the
clamping unit..........................................................................................................................................3-16
3.10 Moving the sub-spindle to the dead stop (optional)...........................................................................3-17
3.11 Programming the C-Axis ...................................................................................................................3-19
3.11.1 Absolute programming of the C-axis...........................................................................................3-20
3.11.2 Relative programming of the C-axis............................................................................................3-20
3.11.3 Conversion of the feedrate mm/min in degrees/min ....................................................................3-20
3.11.4 Cylindrical interpolation..............................................................................................................3-20
3.11.5 Transmit ......................................................................................................................................3-22
3.12 The pick-off device unit.....................................................................................................................3-24
3.12.1 Gripping of a part out of the sub-spindle.....................................................................................3-24
3.12.2 Gripping of a part out of the main spindle...................................................................................3-25
3.12.3 Cycles in clear text ......................................................................................................................3-26
3.12.4 A list of the M-functions .............................................................................................................3-26
3.13 Measuring sensor ...............................................................................................................................3-27
3.13.1 Installation...................................................................................................................................3-27
3.13.2 Activation....................................................................................................................................3-27
3.13.3 Deactivation ................................................................................................................................3-27
3.13.4 Adjustment ..................................................................................................................................3-27
3.13.5 Feedrate for measuring................................................................................................................3-28
3.13.6 Error messages ............................................................................................................................3-29
3.13.7 State messages (display optional)................................................................................................3-29
3.13.8 PLC-Option bits ..........................................................................................................................3-30
3.14 UNIMAG-interface description.........................................................................................................3-31
3.14.1 Structure NC-parts program ........................................................................................................3-31
3.14.2 Signal description for the interface..............................................................................................3-32
3.14.3 Option bits...................................................................................................................................3-34
3.14.3.1 Setting the option bits:.............................................................................................................................3-35
3.14.4 A programming example .............................................................................................................3-36
3.14.4.1 Time diagram for the bar loading magazine.............................................................................................3-40
3.15 List of M-functions ............................................................................................................................3-41
3.16 Data transmission...............................................................................................................................3-44
3.16.1 Data transmission cable...............................................................................................................3-44
3.16.2 Installation of a data terminal ......................................................................................................3-44
3.17 Transmission of data into the control system respectively reading data from the control system
SINUMERIK 810D/840D .........................................................................................................................3-46
3.17.1 Interface base settings in the CNC ..............................................................................................3-46
3.17.2 Safeing parts programs from the control system .........................................................................3-47
3.17.3 Loading parts programs into the control system..........................................................................3-47
3.17.4 Edit and print parts programs ......................................................................................................3-48
3.17.5 Galvanic separation of V24-interfaces ........................................................................................3-49
4 ERROR DIAGNOSIS .................................................................................................. 4-1
4.1 Freeing the machine axes.......................................................................................................................4-2
4.2 Manual locking of the turret ..................................................................................................................4-2
4.3 Troubleshooting.....................................................................................................................................4-3
4.4 Alarm messages and operating messages...............................................................................................4-4
4.4.1 Basic information for error diagnosis..............................................................................................4-4
4.4.2 Alarm messages...............................................................................................................................4-5
4.4.3 Operation messages.........................................................................................................................4-9
5 MAINTENANCE.......................................................................................................... 5-1
5.1 Introduction ...........................................................................................................................................5-2
5.2 Warranty information ............................................................................................................................5-2
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Technical Product Documentation
5.3 General information on maintenance / care ...........................................................................................5-3
5.3.1 Machine...........................................................................................................................................5-3
5.3.2 Pneumatic system ............................................................................................................................5-3
5.3.3 Safety doors.....................................................................................................................................5-3
5.4 Lubrication ............................................................................................................................................5-3
5.4.1 Rollers of the V axis........................................................................................................................5-3
5.4.2 Rollers of the W axis.......................................................................................................................5-4
5.4.3 Rollers of the U axis........................................................................................................................5-4
5.4.4 Elevating screw ...............................................................................................................................5-5
5.4.5 Lubrication of the gripper drive ......................................................................................................5-5
5.5 Table of lubricants .................................................................................................................................5-6
5.5.1 Table of lubricant suppliers / manufacturers ...................................................................................5-8
5.6 Machine Control 840D - Battery/fan replacement.................................................................................5-8
5.7 Replacing the MMC battery ................................................................................................................5-11
5.8 Replacing the fine filter bag.................................................................................................................5-12
5.9 Table with control and maintenance measures ....................................................................................5-13
D ASSEMBLIES
1 ASSEMBLY PD-010-000 FOUNDATION PLATE/MACHINE BASE ........................... 1-1
1.1 Description ............................................................................................................................................1-2
1.2 Drawings and parts list ..........................................................................................................................1-2
1.2.1 Exploded view drawing...................................................................................................................1-2
1.2.2 Parts list...........................................................................................................................................1-4
2 ASSEMBLY PD-106-000 COOLANT SYSTEM .......................................................... 2-1
2.1 Description ............................................................................................................................................2-2
2.2 Maintenance and repair..........................................................................................................................2-2
2.3 Drawings and parts list ..........................................................................................................................2-2
2.3.1 Exploded view drawing...................................................................................................................2-2
2.3.2 Parts list...........................................................................................................................................2-4
3 ASSEMBLY PD-099-000 SPLASH GUARD ............................................................... 3-1
3.1 Description ............................................................................................................................................3-2
3.2 Drawings and parts list ..........................................................................................................................3-2
3.2.1 Exploded view drawing...................................................................................................................3-2
3.2.2 Parts list...........................................................................................................................................3-4
4 ASSEMBLY PD-020/021-000 SLIDING DOOR LEFT/RIGHT .................................... 4-1
4.1 Description ............................................................................................................................................4-2
4.2 Handling ................................................................................................................................................4-2
4.3 Maintenance and repair..........................................................................................................................4-2
4.4 Drawings and parts lists.........................................................................................................................4-2
4.4.1 Exploded drawing ...........................................................................................................................4-2
4.4.2 Parts list...........................................................................................................................................4-5
5 ASSEMBLY PD-030-000 WORKSPACE PANELING................................................. 5-1
5.1 Description ............................................................................................................................................5-2
5.2 Maintenance and repair..........................................................................................................................5-2
5.3 Drawings and parts list ..........................................................................................................................5-2
5.3.1 Exploded view drawing...................................................................................................................5-2
5.3.2 Parts list...........................................................................................................................................5-4
6 ASSEMBLY PD-015-000 CROSS-SLIDE ................................................................... 6-1
6.1 Description ............................................................................................................................................6-2
6.2 Maintenance and repair..........................................................................................................................6-2
6.3 Drawings and parts list ..........................................................................................................................6-2
6.3.1 Exploded view drawing...................................................................................................................6-2
6.3.2 Parts list...........................................................................................................................................6-4
7 ASSEMBLY PD-083-000 CENTRAL LUBRICATING UNIT ........................................ 7-1
7.1 Description ............................................................................................................................................7-2
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Technical Product Documentation
7.2 Handling ................................................................................................................................................7-2
7.3 Maintenance and repair..........................................................................................................................7-2
7.4 Drawings and parts list ..........................................................................................................................7-3
7.4.1 Detail assembly drawing .................................................................................................................7-3
7.4.2 Parts list...........................................................................................................................................7-5
8 ASSEMBLY PD-095-000 PNEUMATIC UNIT ............................................................. 8-1
8.1 Description ............................................................................................................................................8-2
8.2 Handling ................................................................................................................................................8-2
8.2.1 Filling and emptying the oil reservoir of the pneumatic unit...........................................................8-2
8.2.2 Setting the air oiler ..........................................................................................................................8-2
8.3 Maintenance and upkeep .......................................................................................................................8-3
8.4 Drawings and parts list ..........................................................................................................................8-3
8.4.1 Exploded view drawing...................................................................................................................8-3
8.4.2 Detail assembly - Pneumatic for options .........................................................................................8-5
8.4.3 Pneumatic diagram with subspindle option .....................................................................................8-6
8.4.4 Pneumatic diagram without subspindle option ................................................................................8-7
8.4.5 Parts list...........................................................................................................................................8-8
8.5 Control certificate of the pressure reservoir.........................................................................................8-10
9 ASSEMBLY PD-114-000 ELECTRIC CABINET (SIEMENS)...................................... 9-1
9.1 Description ............................................................................................................................................9-2
9.2 Maintenance and repair..........................................................................................................................9-2
9.3 Drawings and parts list ..........................................................................................................................9-2
9.3.1 Exploded view drawing...................................................................................................................9-2
9.3.2 Parts list...........................................................................................................................................9-4
10 ASSEMBLY PD-096/098-000 SAFETY BLOCK WITH/WITHOUT SUB
SPINDLE ..................................................................................................................... 10-1
10.1 Drawings and parts list ......................................................................................................................10-2
10.1.1 Exploded view drawing of safety block with sub-spindle ...........................................................10-2
10.1.2 Exploded view drawing of safety block without sub-spindle option ...........................................10-4
10.1.3 Parts list.......................................................................................................................................10-5
11 ASSEMBLY SB-NC-109-000 SPINDLE 5000/42.................................................... 11-1
11.1 Description ........................................................................................................................................11-2
11.2 Handling ............................................................................................................................................11-2
11.2.1 Setting the clamping stroke .........................................................................................................11-2
11.3 Drawings and parts list ......................................................................................................................11-3
11.3.1 Detail assembly ...........................................................................................................................11-3
11.3.2 Parts list.......................................................................................................................................11-5
12 ASSEMBLY SB-NC-135-000 SPINDLE 8000/32.................................................... 12-1
12.1 Description ........................................................................................................................................12-2
12.2 Handling ............................................................................................................................................12-2
12.2.1 Setting the clamping stroke .........................................................................................................12-2
12.3 Drawings and parts list ......................................................................................................................12-3
12.3.1 Detail assembly ...........................................................................................................................12-3
12.3.2 Parts list.......................................................................................................................................12-5
13 ASSEMBLY PD-09100 MAIN SPINDLE DRIVE 5000/42 (SIEMENS) .................... 13-1
13.1 Drawings and parts list ......................................................................................................................13-2
13.1.1 Detail assembly ...........................................................................................................................13-2
13.1.2 Parts list.......................................................................................................................................13-3
14 ASSEMBLY PD-092-000 MAIN SPINDLE DRIVE 8000/32 (SIEMENS) ................. 14-1
14.1 Drawings and parts list ......................................................................................................................14-2
14.1.1 Detail assembly ...........................................................................................................................14-2
14.1.2 Parts list.......................................................................................................................................14-3
15 ASSEMBLY SB-NC-166-000 ROD ......................................................................... 15-1
15.1 Drawings and parts list ......................................................................................................................15-2
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Technical Product Documentation
15.1.1 Detail assembly ...........................................................................................................................15-2
15.1.2 Parts list.......................................................................................................................................15-2
16 ASSEMBLY PD-088-000 FEEDSCREW X-AXIS.................................................... 16-1
16.1 Description ........................................................................................................................................16-2
16.2 Maintenance and repair......................................................................................................................16-2
16.2.1 Lubricating the X-axis.................................................................................................................16-2
16.3 Drawings and parts list ......................................................................................................................16-2
16.3.1 Exploded view drawing...............................................................................................................16-2
16.3.2 Parts list.......................................................................................................................................16-4
17 ASSEMBLY SB-NC-158-000 X-FEED DRIVE (SIEMENS)..................................... 17-1
17.1 Drawings and parts list ......................................................................................................................17-2
17.1.1 Exploded view drawing...............................................................................................................17-2
17.1.2 Parts list.......................................................................................................................................17-4
18 ASSEMBLY PD-089-000 FEEDSCREW Z-AXIS .................................................... 18-1
18.1 Description ........................................................................................................................................18-2
18.2 Maintenance and repair......................................................................................................................18-2
18.2.1 Lubricating the Z-axis .................................................................................................................18-2
18.3 Drawings and parts list ......................................................................................................................18-2
18.3.1 Exploded view drawing...............................................................................................................18-2
18.3.2 Parts list.......................................................................................................................................18-4
19 ASSEMBLY: SB-NC-159-000 Z-FEED DRIVE (SIEMENS).................................... 19-1
19.1 Drawings and parts list ......................................................................................................................19-2
19.1.1 Exploded view drawing...............................................................................................................19-2
19.1.2 Parts list.......................................................................................................................................19-4
20 ASSEMBLY PD-119-000 TAILSTOCK ................................................................... 20-1
20.1 Handling ............................................................................................................................................20-2
20.1.1 Adjusting the limit switches ........................................................................................................20-2
20.1.1.1 Monitoring characteristic.........................................................................................................................20-2
20.2 Maintenance and repair......................................................................................................................20-3
20.3 Drawings and parts lists.....................................................................................................................20-3
20.3.1 Detail assembly drawing and the ISO-view.................................................................................20-3
20.3.2 Parts list.......................................................................................................................................20-5
21 ASSEMBLY SB-NC-110-000 SPINDLE FLUSHING SYSTEM 5000/42 ................. 21-1
21.1 Description ........................................................................................................................................21-2
21.2 Handling ............................................................................................................................................21-2
21.2.1 Mounting .....................................................................................................................................21-2
21.3 Maintenance and repair......................................................................................................................21-3
21.4 Drawings and parts lists.....................................................................................................................21-3
21.4.1 Detail assembly drawing .............................................................................................................21-3
21.4.2 Parts list.......................................................................................................................................21-4
22 ASSEMBLY SB-NC-137-000 SPINDLE FLUSHING SYSTEM 8000/32 ................. 22-1
22.1 Description ........................................................................................................................................22-2
22.2 Handling ............................................................................................................................................22-2
22.2.1 Mounting .....................................................................................................................................22-2
22.3 Maintenance and repair......................................................................................................................22-3
22.4 Drawings and parts lists.....................................................................................................................22-3
22.4.1 Detail assembly drawing .............................................................................................................22-3
22.4.2 Parts list.......................................................................................................................................22-4
23 ASSEMBLY: PD-074-000 STROKE MONITORING DEVICE FOR THE MAIN
SPINDLE ..................................................................................................................... 23-1
23.1 Handling ............................................................................................................................................23-2
23.1.1 Adjustment of the clamping stroke monitoring device ................................................................23-2
23.2 Drawings and parts lists.....................................................................................................................23-3
23.2.1 An exploded view drawing..........................................................................................................23-3
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23.2.2 Parts list.......................................................................................................................................23-4
24 ASSEMBLY SB-NC-142-000 UNIVERSAL LIMIT STOP 5000/42 .......................... 24-1
24.1 Description ........................................................................................................................................24-2
24.2 Handling ............................................................................................................................................24-2
24.2.1 Mounting the universal limit stop................................................................................................24-2
24.3 Maintenance and repair......................................................................................................................24-3
24.4 Drawings and parts list ......................................................................................................................24-3
24.4.1 Detail assembly ...........................................................................................................................24-3
24.4.2 Parts list.......................................................................................................................................24-5
25 ASSEMBLY SB-NC-143-000 UNIVERSAL LIMIT STOP 8000/32 .......................... 25-1
25.1 Description ........................................................................................................................................25-2
25.2 Handling ............................................................................................................................................25-2
25.2.1 Mounting the universal limit stop................................................................................................25-2
25.3 Maintenance and repair......................................................................................................................25-3
25.4 Drawings and parts list ......................................................................................................................25-3
25.4.1 Detail assembly ...........................................................................................................................25-3
25.4.2 Parts list.......................................................................................................................................25-5
26 PULL-TYPE COLLET ASSEMBLY W25/5C........................................................... 26-1
26.1 Description ........................................................................................................................................26-2
26.2 Handling ............................................................................................................................................26-2
26.2.1 Mounting the pull-type collet ......................................................................................................26-2
26.3 Maintenance and repair......................................................................................................................26-4
26.4 Drawings and parts list ......................................................................................................................26-4
26.4.1 Exploded view drawing...............................................................................................................26-4
26.4.2 Parts list.......................................................................................................................................26-8
27 PUSH-TYPE COLLET ASSEMBLY F38/F48.......................................................... 27-1
27.1 Description ........................................................................................................................................27-2
27.2 Handling ............................................................................................................................................27-2
27.2.1 Mounting the push-type collet.....................................................................................................27-2
27.3 Maintenance and repair......................................................................................................................27-3
27.4 Drawings and parts list ......................................................................................................................27-3
27.4.1 Exploded view drawing...............................................................................................................27-3
27.4.2 Parts list.......................................................................................................................................27-6
28 POWER-CHUCK ASSEMBLY, 3 JAWS/4 JAWS................................................... 28-1
28.1 Description ........................................................................................................................................28-2
28.1.1 Mounting the power-chuck..........................................................................................................28-2
29 ASSEMBLY REDUCTION PIPE ............................................................................. 29-1
29.1 Description ........................................................................................................................................29-2
29.2 Handling ............................................................................................................................................29-2
29.2.1 Mounting the reduction pipe .......................................................................................................29-2
29.3 Maintenance and repair......................................................................................................................29-2
29.4 Drawings............................................................................................................................................29-3
29.4.1 Reduction pipes for pull-type collets...........................................................................................29-3
29.4.2 Reduction pipes for push-type collets and a chuck......................................................................29-5
30 ASSEMBLY PD-067-000 ROLLER BELT COVER................................................. 30-1
30.1 Description ........................................................................................................................................30-2
30.2 Maintenance and repair......................................................................................................................30-2
30.3 Drawings and the parts list.................................................................................................................30-2
30.3.1 Exploded view drawing...............................................................................................................30-2
30.3.2 Parts list.......................................................................................................................................30-4
31 ASSEMBLY: PD-078-000 Q-SLIDE/PD-082-000 REPLACEMENT-Q-SLIDE ........ 31-1
31.1 Drawings and parts list ......................................................................................................................31-2
31.1.1 Exploded view drawing...............................................................................................................31-2
31.1.2 Parts list.......................................................................................................................................31-5
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32 ASSEMBLY: PD-100-000 SUB-SPINDLE HEADSTOCK (SIEMENS).................... 32-1
32.1 Drawings and parts list ......................................................................................................................32-2
32.1.1 Exploding view drawing..............................................................................................................32-2
32.1.2 Parts list.......................................................................................................................................32-4
33 ASSEMBLY: PD-097-000 AIR DISTRIBUTOR....................................................... 33-1
33.1 Drawings and parts list ......................................................................................................................33-2
33.1.1 Assembly drawing .......................................................................................................................33-2
33.1.2 Parts list.......................................................................................................................................33-4
34 ASSEMBLY PD-069-000 SUB-SPINDLE 8000/32 (SIEMENS) .............................. 34-1
34.1 Handling ............................................................................................................................................34-2
34.1.1 Setting the clamping stroke .........................................................................................................34-2
34.2 Drawings and parts list ......................................................................................................................34-3
34.2.1 Detail assembly ...........................................................................................................................34-3
34.2.2 Parts list.......................................................................................................................................34-5
35 ASSEMBLY: PD-094-000 SUB-SPINDLE DRIVE 8000/32 (SIEMENS) ................. 35-1
35.1 Drawings and parts list ......................................................................................................................35-2
35.1.1 Detail assembly drawing and the ISO-view.................................................................................35-2
35.1.2 Parts list.......................................................................................................................................35-4
36 ASSEMBLY PD-090-000 FEED SPINDLE Q-AXIS ................................................ 36-1
36.1 Description ........................................................................................................................................36-2
36.2 Maintenance and repair......................................................................................................................36-2
36.2.1 Lubricating the Q axis (only with sub spindle option).................................................................36-2
36.3 Drawings and parts list ......................................................................................................................36-3
36.3.1 Detail exploded view drawing.....................................................................................................36-3
36.3.2 Parts list.......................................................................................................................................36-5
37 ASSEMBLY: PD-093-000 Q-FEED DRIVE (SIEMENS) ......................................... 37-1
37.1 Drawings and parts list ......................................................................................................................37-2
37.1.1 Exploded view drawing...............................................................................................................37-2
37.1.2 Parts list.......................................................................................................................................37-4
38 ASSEMBLY: PD-065-000 BAR GRIPPING DEVICE .............................................. 38-1
38.1 Handling ............................................................................................................................................38-2
38.1.1 Setting up the bar gripping device...............................................................................................38-2
38.1.2 Alignment of the bar gripping device..........................................................................................38-3
38.2 Maintenance and repair......................................................................................................................38-6
38.3 Drawings and parts list ......................................................................................................................38-6
38.3.1 Exploded view drawing...............................................................................................................38-6
38.3.2 Part list ........................................................................................................................................38-8
39 ASSEMBLY: PD-066-000 GRIPPER JAWS........................................................... 39-1
39.1 Description ........................................................................................................................................39-2
39.2 Handling ............................................................................................................................................39-2
39.2.1 Mounting of the gripper jaws ......................................................................................................39-2
39.2.2 Alignment of the gripper jaws .....................................................................................................39-3
39.3 Drawings and parts list ......................................................................................................................39-6
39.3.1 Exploded view drawing...............................................................................................................39-6
39.3.2 Parts list.......................................................................................................................................39-7
40 ASSEMBLY PD-075-000 STROKE MONITORING FOR THE SUB-SPINDLE ....... 40-1
40.1 Description ........................................................................................................................................40-2
40.2 Handling ............................................................................................................................................40-2
40.2.1 Adjustment of the clamping stroke monitoring device ................................................................40-2
40.3 Drawings and parts list ......................................................................................................................40-3
40.3.1 Detail exploded view drawing.....................................................................................................40-3
40.3.2 Parts list.......................................................................................................................................40-5
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41 ASSEMBLY PD-071-000 SPINDLES FLUSHING SYSTEM SUB SPINDLE
8000/32........................................................................................................................ 41-1
41.1 Description ........................................................................................................................................41-2
41.2 Handling ............................................................................................................................................41-2
41.2.1 Mounting .....................................................................................................................................41-2
41.3 Maintenance and repair......................................................................................................................41-3
41.4 Drawings and parts lists.....................................................................................................................41-3
41.4.1 Detail assembly drawing .............................................................................................................41-3
41.4.2 Parts list.......................................................................................................................................41-4
42 ASSEMBLY GANTRY LOADER PL 400 ................................................................ 42-1
42.1 Operation panel of the gantry loader .................................................................................................42-2
42.2 Overall view ......................................................................................................................................42-3
42.3 Program structure for gantry loader with 2 axes, with conveyor belt ................................................42-5
42.4 Program structure for gantry loader with 3 axes, with pallet, without stack ......................................42-6
42.5 Program structure for gantry loader with 3 axes, with pallet, with stack ...........................................42-7
42.6 Program structure for program of stacking ........................................................................................42-8
42.7 M functions PL - Channel 2..............................................................................................................42-9
42.8 Parameters (Global user data)..........................................................................................................42-11
42.9 Adjustable zero offsets ....................................................................................................................42-12
42.10 Main program in Channel 1 (example) ..........................................................................................42-13
42.11 Main program in Channel 2 (examples).........................................................................................42-14
42.12 Sub programs in channel 2.............................................................................................................42-24
42.13 Procedure of stacking ....................................................................................................................42-41
42.14 Program for basic position stack 1/2..............................................................................................42-42
42.15 Program structure for fetching / laying down the pallet.................................................................42-44
42.16 Error messages...............................................................................................................................42-46
42.16.1 Alarm messages.......................................................................................................................42-46
42.16.2 Operating messages.................................................................................................................42-47
42.17 Instructions to free the stacking system .........................................................................................42-50
42.18 Maintenance...................................................................................................................................42-51
42.19 Drawings and parts lists.................................................................................................................42-52
42.19.1 Bogie truck..............................................................................................................................42-52
42.19.2 Vertical axis ............................................................................................................................42-54
42.19.3 Drive rail .................................................................................................................................42-56
42.19.4 U axis ......................................................................................................................................42-58
42.19.5 Basic frame..............................................................................................................................42-60
42.20 Pneumatic diagram ........................................................................................................................42-62
42.20.1 Gantry loader...........................................................................................................................42-62
42.20.2 U axis ......................................................................................................................................42-63
43 ASSEMBLY TOOL MONITORING SYSTEM.......................................................... 43-1
43.1 Description ........................................................................................................................................43-2
44 ASSEMBLY: PD-WA-000 TAILSTOCK .................................................................. 44-1
44.1 Description ........................................................................................................................................44-2
44.2 Handling ............................................................................................................................................44-2
44.2.1 Monitoring characteristic ............................................................................................................44-2
44.3 Maintenance and repair......................................................................................................................44-2
44.4 Drawings and parts lists.....................................................................................................................44-2
44.4.1 Detail assembly drawing and the ISO-view.................................................................................44-2
44.4.2 Parts list.......................................................................................................................................44-4
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Technical Product Documentation
II. Index
The letter behind the index indicates the book where you can find something about the
index. The page also contains the chapter.
A
Absolute programming C....................................................................................................................................................... 3-20
Access levels C ...................................................................................................................................................................... 3-10
Adjust the pneumatic oiler D ...................................................................................................................................................8-2
Adjusting feet D.....................................................................................................................................................................38-3
Adjusting the tools to the height of centres C ..........................................................................................................................2-4
Adjustment microscope C ........................................................................................................................................................2-6
Adjustment of the clamping stroke monitoring D .................................................................................................................. 23-2
Adjustment of the clamping stroke monitoring of the sub spindle D..................................................................................... 40-2
Air distributor D ....................................................................................................................................................................33-2
Alarm messages C....................................................................................................................................................................4-4
Appropriate use A....................................................................................................................................................................2-2
B
Bar gripping device
Exchange D....................................................................................................................................................................... 38-3
Bar gripping device D............................................................................................................................................................ 38-2
Battery replacement C..............................................................................................................................................................5-8
Bearing block D .....................................................................................................................................................................38-4
Button
+/- C .................................................................................................................................................................................... 3-6
AUTO C.............................................................................................................................................................................. 3-6
Axis selection C .................................................................................................................................................................. 3-5
Clamp/release spindle C...................................................................................................................................................... 3-5
Cooling lubricant pump On/Off C ...................................................................................................................................... 3-6
Cycle start C........................................................................................................................................................................ 3-6
Cycle stop C........................................................................................................................................................................ 3-6
Drive On C.......................................................................................................................................................................... 3-6
Emergency OFF C............................................................................................................................................................... 3-5
Feed On/Off C..................................................................................................................................................................... 3-6
Increment selection C.......................................................................................................................................................... 3-5
JOG C ................................................................................................................................................................................. 3-5
key-operated switch C......................................................................................................................................................... 3-6
MCS/TCS C ........................................................................................................................................................................ 3-6
MDA C ............................................................................................................................................................................... 3-5
Ref C ................................................................................................................................................................................... 3-5
RESET C............................................................................................................................................................................. 3-5
SBL On/Off C ..................................................................................................................................................................... 3-6
Single/serial part C.............................................................................................................................................................. 3-5
Spindle On/Off C ................................................................................................................................................................ 3-6
C
Central lubricating unit D ........................................................................................................................................................7-2
CE-symbol A ........................................................................................................................................................................... 3-8
Clamping device C...................................................................................................................................................................2-2
Clamping stroke limitation C ...................................................................................................................................................2-2
Clamping stroke monitoring of the main spindle D ...............................................................................................................23-2
Cleaning the working area C.................................................................................................................................................... 5-3
Continuous load A ................................................................................................................................................................. 3-13
Control panel (left side of the machine front) C ......................................................................................................................3-7
Conversion of the feedrate C .................................................................................................................................................3-20
Coolant system D.....................................................................................................................................................................2-2
COUPON C ...........................................................................................................................................................................3-16
Cover belt D........................................................................................................................................................................... 30-2
Cross-slide D ...........................................................................................................................................................................6-2
Cylindrical interpolation C ....................................................................................................................................................3-20
D
Data transmission C ............................................................................................................................................................... 3-44
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Declaration of conformity A .................................................................................................................................................... 3-2
Delete alarm message C ........................................................................................................................................................... 1-2
Desiccant bags B......................................................................................................................................................................1-3
DIAMON/OF C .....................................................................................................................................................................3-19
Dimensions A ........................................................................................................................................................................3-11
Display base machine screen C................................................................................................................................................ 3-4
E
Edit key C .............................................................................................................................................................................. 3-15
Electric cabinet D.....................................................................................................................................................................9-2
Electromagnetic compatibility A............................................................................................................................................ 3-13
Emergency OFF A ............................................................................................................................................................ 2-6; 3-8
Enter key C ............................................................................................................................................................................ 3-15
Explosion hazard A..................................................................................................................................................................2-7
F
Fan replacement C ...................................................................................................................................................................5-8
Feed spindle Q-axis D............................................................................................................................................................36-2
Feedscrew X-axis D ...............................................................................................................................................................16-2
Feedscrew Z-axis D ...............................................................................................................................................................18-2
Filling/Emptying the pneumatic oiler D...................................................................................................................................8-2
Fine filter
Input B ................................................................................................................................................................................2-9
Output B..............................................................................................................................................................................2-9
Overflow B..........................................................................................................................................................................2-9
Fire hazard A ...........................................................................................................................................................................2-7
Foundation plan B ................................................................................................................................................................... 2-6
Foundation plate D ..................................................................................................................................................................1-2
Freeing the machine axes C ..................................................................................................................................................... 4-2
Frequenzy A............................................................................................................................................................................. 3-8
Function keys
Increment selection C.......................................................................................................................................................... 3-9
FXS... C .................................................................................................................................................................................3-17
G
Galvanic interface C............................................................................................................................................................... 3-49
Galvanic separation C ............................................................................................................................................................ 3-49
Gripper jaws D.......................................................................................................................................................................39-2
I
Increment mode C..................................................................................................................................................................3-12
Installation
electrical connection B........................................................................................................................................................ 2-2
Installation
Basic conditions B ..............................................................................................................................................................2-2
further environmental conditions B..................................................................................................................................... 2-2
pneumatic connection B...................................................................................................................................................... 2-2
Installation diagrams B ............................................................................................................................................................ 2-3
Installation instructions B ........................................................................................................................................................2-9
Interface parameters C ...........................................................................................................................................................3-44
Intermittent duty A................................................................................................................................................................. 3-13
K
Keyboard C .............................................................................................................................................................................. 3-4
Key-operated switch C............................................................................................................................................................. 3-5
L
Linear measurement system D .................................................................................................................................................6-2
Loading parts programs C......................................................................................................................................................3-47
Lock safety door C................................................................................................................................................................... 1-2
Locking the sliding door D ......................................................................................................................................................4-2
Lubricating the Q axis D........................................................................................................................................................ 36-2
Lubricating the X-axis D .......................................................................................................................................................16-2
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Technical Product Documentation
Lubricating the Z-axis D ........................................................................................................................................................18-2
Lubrication
Elevation screw C ............................................................................................................................................................... 5-5
Gripper drive C ...................................................................................................................................................................5-5
Rollers of the U axis C ........................................................................................................................................................5-4
Rollers of the V axis C........................................................................................................................................................5-4
Rollers of the W axis C .......................................................................................................................................................5-4
M
Machine base D .......................................................................................................................................................................1-2
Machine control panel C..........................................................................................................................................................3-5
Machine control system A ....................................................................................................................................................... 3-7
Machine no. A ......................................................................................................................................................................... 3-8
Machine panels A .................................................................................................................................................................... 3-9
Machine type A........................................................................................................................................................................ 3-8
Machine views A .....................................................................................................................................................................3-4
Main spindle drive 5000/42 D ...............................................................................................................................................13-2
Main spindle drive 8000/32 D ...............................................................................................................................................14-2
Manual locking of the turret C.................................................................................................................................................4-2
Manual operating device Siemens 840D C .............................................................................................................................. 3-9
Mechanical design A................................................................................................................................................................3-6
M-functions C........................................................................................................................................................................3-41
Micro-switch 5000/42 D........................................................................................................................................................ 11-2
Micro-switch main spindle D................................................................................................................................................. 12-2
Middle offset D......................................................................................................................................................................39-5
Mixing lubricants C ................................................................................................................................................................. 5-6
MMC battery C......................................................................................................................................................................5-11
Movement of the basic machine using a crane B .....................................................................................................................1-5
Movement of the basic machine using a fork lift B .................................................................................................................1-3
Movement of the basic machine using a lifting truck B...........................................................................................................1-4
N
Noise emission A ...................................................................................................................................................................3-12
Nominal current A ................................................................................................................................................................... 3-8
Nordmann Tool monitoring system D....................................................................................................................................43-2
O
Operating messages C ..............................................................................................................................................................4-4
Operating mode AUTO C ......................................................................................................................................................3-11
Operating mode JOG C..........................................................................................................................................................3-10
Operating mode MDI C .........................................................................................................................................................3-11
Operation panel
gantry loader D.................................................................................................................................................................. 42-2
Other hazards A .......................................................................................................................................................................2-7
Override for feed C .................................................................................................................................................................. 3-5
Override for spindle C ............................................................................................................................................................. 3-5
P
Parallelity measurement of the operating arm D ...................................................................................................................38-5
Permission button A................................................................................................................................................................. 3-9
Permission button C................................................................................................................................................................. 3-7
Permission mode C .................................................................................................................................................................. 3-7
Phoenix-Module C................................................................................................................................................................. 3-49
Pick-off device unit C ............................................................................................................................................................3-24
Pneumatic diagram Gantry loader D .....................................................................................................................................42-62
Pneumatic unit D .....................................................................................................................................................................8-2
Positional synchronised running C .............................................................................................................................. 3-15; 3-16
Power chuck D....................................................................................................................................................................... 28-2
Power supply
IT power supply B............................................................................................................................................................... 2-8
TN power supply B .............................................................................................................................................................2-7
TT power supply B..............................................................................................................................................................2-7
Preparations for transportation B .............................................................................................................................................1-2
Pressure monitors A................................................................................................................................................................. 3-9
Pull-type collet D ...................................................................................................................................................................26-2
Push-type collet D..................................................................................................................................................................27-2
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Technical Product Documentation
Q
Q-Feed drive D ......................................................................................................................................................................37-2
Q-slide D................................................................................................................................................................................31-2
R
Ratings plate A......................................................................................................................................................................... 3-8
Reduction pipe D ...................................................................................................................................................................29-2
Reference point mode REF-POINT C ................................................................................................................................... 3-11
Reference the machine axes C ................................................................................................................................................. 1-2
Relative programming C ........................................................................................................................................................3-20
Replacement Q-slide D ..........................................................................................................................................................31-2
ROD D ...................................................................................................................................................................................15-2
Roller belt cover D.................................................................................................................................................................30-2
S
Safeing parts programs C .......................................................................................................................................................3-47
Safety block D........................................................................................................................................................................10-2
Safety door A ........................................................................................................................................................................... 3-8
Safety equipment A.................................................................................................................................................................. 3-8
Safety glass A........................................................................................................................................................................... 3-9
Screen C................................................................................................................................................................................... 3-4
Setting the clamping pressures C ........................................................................................................................................... 3-12
Setting the clamping stroke (5000/42) D ............................................................................................................................... 11-2
Setting the clamping stroke (8000/32) D ............................................................................................................................... 12-2
Setting the gripper position D ................................................................................................................................................39-3
Sliding door left/right D...........................................................................................................................................................4-2
Spindle flushing 5000/42 D ...................................................................................................................................................21-2
Spindle flushing 8000/42 D ...................................................................................................................................................41-2
Spindle nut D ......................................................................................................................................................................... 36-2
Spindle sychronisation C .......................................................................................................................................................3-15
Spindle unit 5000/42 D.......................................................................................................................................................... 11-2
Spindle unit 8000/32 D.......................................................................................................................................................... 12-2
Splash guard D.........................................................................................................................................................................3-2
SPOS C ..................................................................................................................................................................................3-19
Stop ring 5000/42 D .............................................................................................................................................................. 11-2
Stop ring D............................................................................................................................................................................. 34-2
Stop ring main spindle 8000/32 D ......................................................................................................................................... 12-2
Storage B ............................................................................................................................................................................... 1-11
Stroke limiting ring 5000/42 D .............................................................................................................................................. 11-2
Stroke limiting ring D ............................................................................................................................................................ 34-2
Stroke limiting ring main spindle 8000/32 D......................................................................................................................... 12-2
Sub-spindle 8000/32 D ..........................................................................................................................................................34-2
Sub-spindle drive 8000/32 D .................................................................................................................................................35-2
Sub-spindle headstock D .......................................................................................................................................................32-2
Support bracket D ..................................................................................................................................................................39-2
Switch on C..............................................................................................................................................................................1-2
Switching off C ........................................................................................................................................................................ 1-4
SYNC_OFF C........................................................................................................................................................................3-15
SYNC_ON C .........................................................................................................................................................................3-15
T
Table of lubricant manufacturers C.......................................................................................................................................... 5-8
Table of lubricant suppliers C.................................................................................................................................................. 5-8
Table of lubricants C................................................................................................................................................................ 5-7
Tailstock D............................................................................................................................................................................. 20-2
Tailstock quill D .................................................................................................................................................................... 20-2
Technical data A ....................................................................................................................................................................3-11
Tension A................................................................................................................................................................................. 3-8
The tool correction memory C ............................................................................................................................................... 3-13
Threaded rod D ......................................................................................................................................................................25-2
Threaded rod D ......................................................................................................................................................................24-2
Throttle check valve
Gripper D .......................................................................................................................................................................... 38-2
Tie rod D................................................................................................................................................................................24-2
Time diagram C .....................................................................................................................................................................3-40
Tool drive A........................................................................................................................................................................... 3-13
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Technical Product Documentation
Tool lengths C........................................................................................................................................................................ 3-14
Tool measuring C.....................................................................................................................................................................2-4
Touching the workpiece C .......................................................................................................................................................2-6
TRACYL C............................................................................................................................................................................ 3-19
TRAFOOF C..........................................................................................................................................................................3-19
TRANSMIT C .............................................................................................................................................................. 3-19; 3-22
Transportation and storage B ................................................................................................................................................... 1-2
Transportation over short distances B......................................................................................................................................1-7
Transportation overseas B........................................................................................................................................................1-8
U
UNIMAG-interface
Option bits C.....................................................................................................................................................................3-34
Signal description C..........................................................................................................................................................3-32
Structure of the NC-parts program C ................................................................................................................................3-31
Universal limit stop 5000/42 D..............................................................................................................................................24-2
Universal limit stop 8000/32 D..............................................................................................................................................25-2
Unlock emergency off C .......................................................................................................................................................... 1-2
Unlocking the sliding door D...................................................................................................................................................4-2
Unpacking B ..........................................................................................................................................................................1-10
W
Warning plates A ................................................................................................................................................................... 3-10
Warnings and symbols A .........................................................................................................................................................2-2
Wear C ................................................................................................................................................................................... 3-15
Weight A................................................................................................................................................................................3-11
Wiper seals D...........................................................................................................................................................................5-2
Work precision B .....................................................................................................................................................................2-3
Working planes C .................................................................................................................................................................. 3-14
Workspace paneling D .............................................................................................................................................................5-2
X
X-feed drive D .......................................................................................................................................................................17-2
Z
Z-feed drive D........................................................................................................................................................................19-2
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Technical Product Documentation
III. List of figures
A User information
Figure 2-1: Picture of all Emergency OFF buttons on the machine PD (Control Siemens 840D .........................2-6
Figure 3-1: Overall view of the machine without its housing ...............................................................................3-4
Figure 3-2: Front view and right side of the PD series .........................................................................................3-5
Figure 3-3: Left side of the machine of the PD series; on the right with part catcher as option - on the
left without part catcher ...............................................................................................................................3-5
Figure 3-4: Rear view of the PD series .................................................................................................................3-6
Figure 3-5: The user interface for the machine’s control system ..........................................................................3-7
Figure 3-6: Ratings plate and CE symbol .............................................................................................................3-8
Figure 3-7: Warning plates and security information on the machine ................................................................3-10
B Assembly/Disassembly
Figure 1-1: Moving the PD machine using a fork lift ...........................................................................................1-4
Figure 1-2: Moving the PD machine using two lifting trucks ...............................................................................1-4
Figure 1-3: Moving the PD machine using a crane...............................................................................................1-5
Figure 1-4: Lifting device for PD-PL ...................................................................................................................1-6
Figure 1-5: Screwing the PD machine onto the transport planks ..........................................................................1-8
Figure 1-6: Assembly of the crate walls in preparation for transportation by sea.................................................1-9
Figure 1-7: Packaging for transportation by sea ...................................................................................................1-9
Figure 1-8: Dimensions of the transportation pallet............................................................................................1-10
Figure 2-1: Installation diagrams (front view) ......................................................................................................2-3
Figure 2-2: Installation diagram (top view) ..........................................................................................................2-4
Figure 2-3: Installation diagram (left and right side of the machine)....................................................................2-4
Figure 2-4: Installation diagram PD with gantry loader........................................................................................2-5
Figure 2-5: Foundation plan PD ...........................................................................................................................2-6
Figure 2-6: TN power supply................................................................................................................................2-7
Figure 2-7: TT-Netz..............................................................................................................................................2-7
Figure 2-8: IT power supply .................................................................................................................................2-8
Figure 2-9: Rubber pads for the installation .........................................................................................................2-9
Figure 2-10: Connecting a fine filter.....................................................................................................................2-9
C Operation/Maintenance
Figure 2-1: Spindle with clamping device and clamped workpiece......................................................................2-2
Figure 2-2: Linear standard toolholder .................................................................................................................2-3
Figure 2-3: Linear cartridge toolholder.................................................................................................................2-3
Figure 2-4: Turret toolholder ................................................................................................................................2-4
Figure 2-5: Adjusting the tools to the height of centres ........................................................................................2-5
Figure 2-6: Tool measuring by touching the workpiece .......................................................................................2-6
Figure 2-7: Optical tool measuring .......................................................................................................................2-7
Figure 3-1: Screen and keyboard of the Siemens control system 840D................................................................3-4
Figure 3-2: Connections and main switch underneath the control panel...............................................................3-5
Figure 3-3: Machine control panel........................................................................................................................3-5
Figure 3-4: Specifying the variable increment ......................................................................................................3-6
Figure 3-5: Control panel on the left side of the machine front ............................................................................3-7
Figure 3-6: Permission button...............................................................................................................................3-7
Figure 3-7: Manual operating device....................................................................................................................3-9
Figure 3-8: Menu for the clamping parameters...................................................................................................3-12
Figure 3-9: The tool correction memory.............................................................................................................3-13
Figure 3-10: Cylindrical interpolation ................................................................................................................3-21
Figure 3-11: Command TRANSMIT..................................................................................................................3-22
Figure 3-12: Command TRANSMIT..................................................................................................................3-23
Figure 3-13: Time diagram for the bar loading magazine...................................................................................3-40
Figure 3-14: HyperTerminal: Specifying a new name ........................................................................................3-45
Figure 3-15: HyperTerminal: Selection of an interface ......................................................................................3-45
Figure 3-16: HyperTerminal: Specifying the connection parameters .................................................................3-45
Figure 3-17: HyperTerminal: Specifying the settings .........................................................................................3-46
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Technical Product Documentation
Figure 3-18: HyperTerminal: Specifying the settings .........................................................................................3-46
Figure 3-19: HyperTerminal: Safeing parts programs ........................................................................................3-47
Figure 3-20: HyperText: Loading parts programs ..............................................................................................3-48
Figure 3-21: Modification of parts programs......................................................................................................3-48
Figure 3-22: Phoenix-Module PSM-ME-RS232/RS232-P .................................................................................3-49
Figure 5-1: Lubrication of the rollers of the V axis ..............................................................................................5-4
Figure 5-2: Lubrication of the rollers of the W axis .............................................................................................5-4
Figure 5-3: Lubrication of the rollers of the U axis ..............................................................................................5-5
Figure 5-4: Lubrication of the elevating screws of the pallet stack up device ......................................................5-5
Figure 5-5: Lubrication of the gripper drive .........................................................................................................5-6
Figure 5-6: Battery and van replacement ............................................................................................................5-10
Figure 5-7: Battery/van plug in unit....................................................................................................................5-10
Figure 5-8: Battery replacement .........................................................................................................................5-11
Figure 5-9: Open the fine filter tank ...................................................................................................................5-12
Figure 5-10: Fine filter - open the locking bolt..................................................................................................5-12
Figure 5-11: Fine filter bag.................................................................................................................................5-13
D Assemblies
Figure 1-1: Exploded view drawing of plate base.................................................................................................1-3
Figure 2-1: Exploded view drawing of coolant system.........................................................................................2-3
Figure 3-1: Exploded view drawing of splash guard ............................................................................................3-3
Figure 4-1: Exploded drawing left sliding door....................................................................................................4-3
Figure 4-2: Exploded drawing right sliding door..................................................................................................4-4
Figure 5-1: Exploded drawing of workspace paneling .........................................................................................5-3
Figure 6-1: Exploded view drawing of cross-slide ...............................................................................................6-3
Figure 7-1: Central lubricating unit ......................................................................................................................7-2
Figure 7-2: Layout of central lubricating unit.......................................................................................................7-4
Figure 8-1: Pneumatic unit....................................................................................................................................8-2
Figure 8-2: Exploded view drawing pneumatic - basic machine ..........................................................................8-4
Figure 8-3: Detail assembly - Pneumatic for options............................................................................................8-5
Figure 8-4: Pneumatic diagram with subspindle option........................................................................................8-6
Figure 8-5: Pneumatic diagram without subspindle option...................................................................................8-7
Figure 9-1: Exploded view drawing of electric cabinet Siemens 840D ................................................................9-3
Figure 10-1: Exploded view drawing of safety block with sub-spindle option...................................................10-3
Figure 10-2: Exploded view drawing of safety block without sub-spindle option..............................................10-4
Figure 11-1: Setting the clamping stroke ............................................................................................................11-2
Figure 11-2: Detail assembly spindle unit 5000/42 ............................................................................................11-4
Figure 12-1: Setting the clamping stroke ............................................................................................................12-2
Figure 12-2: Detail assembly spindle unit 8000/32 ............................................................................................12-4
Figure 13-1: Detail assembly of main spindle drive 5000/42 (Siemens 840D) ..................................................13-2
Figure 14-1: Detail assembly of main spindle drive 8000/32 (Siemens 840D) ..................................................14-2
Figure 15-1: Detail assembly of assembly ROD.................................................................................................15-2
Figure 16-1: Lubricating the X-axis....................................................................................................................16-2
Figure 16-2: Exploded view drawing of X-axis feedscrew.................................................................................16-3
Figure 17-1: Exploded view drawing of X-feed drive (Siemens 840D) .............................................................17-3
Figure 18-1: Lubricating the Z-axis ....................................................................................................................18-2
Figure 18-2: Exploded view drawing of Z-axis feedscrew .................................................................................18-3
Figure 19-1: Exploded view drawing of the Z-feed drive (Siemens 840D) ........................................................19-3
Figure 20-1: Limit switches of the tailstock........................................................................................................20-2
Figure 20-2: Detail assembly drawing and the ISO-view for the tailstock..........................................................20-4
Figure 21-1: Mounting of the spindle flushing system (for spindle speeds up to 5,000 r.p.m.)..........................21-2
Figure 21-2: Detail assembly drawing of the spindle flushing system 5000/42..................................................21-3
Figure 22-1: Mounting of the spindle flushing system (for spindle speeds up to 8,000 r.p.m.)..........................22-2
Figure 22-2: Detail assembly drawing of the spindle flushing system 8000/32..................................................22-3
Figure 23-1: Adjustment of the clamping stroke monitoring device...................................................................23-2
Figure 23-2: An exploded view drawing of the stroke monitoring for the main spindle.....................................23-3
Figure 24-1: Universal limit stop, stop part and mounting equipment................................................................24-2
Figure 24-2: Detail assembly of universal limit stop 5000/42 ............................................................................24-4
Figure 25-1: Universal limit stop, stop part and mounting equipment................................................................25-2
Figure 25-2: Detail assembly of universal limit stop 8000/32 ............................................................................25-4
Figure 26-1: Mounting the pull-type collet.........................................................................................................26-2
Figure 26-2: Pull-type collet W25 normal ..........................................................................................................26-5
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
18
Technical Product Documentation
Figure 26-3: Pull-type collet W25 long ..............................................................................................................26-6
Figure 26-4: Pull-type collet 5C .........................................................................................................................26-7
Figure 27-1: Mounting the push-type collet........................................................................................................27-2
Figure 27-2: Push-type collet F48.......................................................................................................................27-4
Figure 27-3: Push-type collet F38.......................................................................................................................27-5
Figure 28-1: Mounting of the power chuck ........................................................................................................28-2
Figure 29-1: Reduction pipes for pull-type collets - max. speed 5,000 r.p.m. ....................................................29-3
Figure 29-2: Reduction pipes for pull-type collets - max. speed 8,000 r.p.m. ....................................................29-4
Figure 29-3: Reduction pipes for push-type collets and a chuck - max. speed 5,000 r.p.m. ...............................29-5
Figure 29-4: Reduction pipes for push-type collets and a chuck - max. speed 8,000 r.p.m. ...............................29-6
Figure 30-1: Exploded view drawing of the roller belt cover .............................................................................30-3
Figure 31-1: Exploded view drawing of the Q-slide...........................................................................................31-3
Figure 31-2: Exploded view drawing of the replacement Q-slide.......................................................................31-4
Figure 32-1: Exploded view drawing of the sub-spindle headstock (Siemens 840D).........................................32-3
Figure 33-1: Detail assembly drawing for the air distributor ..............................................................................33-3
Figure 34-1: Setting the clamping stroke monitoring..........................................................................................34-2
Figure 34-2: Detail assembly sub-spindle 8000/32 (Siemens 840D)..................................................................34-4
Figure 35-1: Detail assembly drawing and the ISO view of the sub-spindle drive 8000/32 (Siemens) ..............35-3
Figure 36-1: Lubricating the Q axis....................................................................................................................36-2
Figure 36-2: Detail exploded view drawing of the drive spindle on the Q-axis..................................................36-4
Figure 37-1: Exploded view drawing of the Q-Feed drive (Siemens 840D).......................................................37-3
Figure 38-1: Throttle check valves for the bar gripping device ..........................................................................38-2
Figure 38-2: Covering panel in the working area ...............................................................................................38-3
Figure 38-3: Locking screws for the base plate PD-065-001..............................................................................38-3
Figure 38-4: Rough alignment of the front bearing block...................................................................................38-4
Figure 38-5: Air connection M84 .......................................................................................................................38-4
Figure 38-6: Parallelity measurement of the operating arm of the gripper device ..............................................38-5
Figure 38-7: Alignment of the operating arm of the gripper device ...................................................................38-6
Figure 38-8: An exploded view drawing of the bar gripping device...................................................................38-7
Figure 39-1: Mounting the tenon blocks.............................................................................................................39-2
Figure 39-2: Mounting of the gripper jaws .........................................................................................................39-2
Figure 39-3: Air connection M83 .......................................................................................................................39-3
Figure 39-4: Adjustment of the gripping position...............................................................................................39-4
Figure 39-5: Establishing the middle offset ........................................................................................................39-5
Figure 39-6: Measuring the middle offset...........................................................................................................39-5
Figure 39-7: Exploded view drawing of the gripper jaws...................................................................................39-7
Figure 40-1: Adjustment of the clamping stroke monitoring device...................................................................40-2
Figure 40-2: Detail exploded view drawing of the stroke monitoring on the sub-spindle ..................................40-4
Figure 41-1: Mounting of the spindle flushing system (for spindle speeds up to 8,000 r.p.m.)..........................41-2
Figure 41-2: Detail assembly drawing of the spindle flushing system 8000/32..................................................41-3
Figure 42-1: Operation panel of the gantry loader..............................................................................................42-2
Figure 42-1: Tool corrections of the gantry loader .............................................................................................42-3
Figure 42-2: Parts counter (gantry loader)..........................................................................................................42-4
Figure 42-3: Pallets counter (gantry loader) .......................................................................................................42-4
Figure 42-4: Program structure for gantry lader with 2 axes, with conveyor belt...............................................42-5
Figure 42-5: Program structure for gantry loader with 3 axes, with pallet, without stack...................................42-6
Figure 42-6: Structure of program for gantry loader with 3 axes, with pallet, with stack...................................42-7
Figure 42-7: Program structure for program of stacking ....................................................................................42-8
Figure 42-8: Procedure of stacking...................................................................................................................42-41
Figure 42-9: Program for basic position stack 1/2 ............................................................................................42-42
Figure 42-10: Program for basic position stack 1/2 ..........................................................................................42-43
Figure 42-11: Program structure for fetching / laying down the pallet .............................................................42-44
Figure 42-12: Program structure for fetching / laying down the pallet .............................................................42-45
Figure 42-13: Exploded drawing of the bogie truck .........................................................................................42-52
Figure 42-14: Assembly vertical axis ...............................................................................................................42-54
Figure 42-15: Exploded drawing of the drive rail.............................................................................................42-56
Figure 42-16: Exploded drawing of the U axis.................................................................................................42-58
Figure 42-17: Exploded drawing of the basic frame.........................................................................................42-60
Figure 42-18: Pneumatic diagram Gantry loader..............................................................................................42-62
Figure 42-19: Pneumatic diagram U axis..........................................................................................................42-63
Figure 44-1: Detail assembly drawing and the ISO-view for the tailstock..........................................................44-3
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
19
Technical Product Documentation
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
20
Technical Product Documentation
A User information
SPINNER WERKZEUGMASCHINENFABRIK GmbH
D-82054 Sauerlach, Rudolf-Diesel-Ring 24
Tel: 08104 / 803-0, Fax: 08104 / 803-19,
E-Mail: sales@spinnner-wzm.de; service@spinner-wzm.de
A User information
Basic information
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
1 Basic information
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-1
A User information
Basic information
1.1 Basic information
This technical product documentation should make it easier for you to familiarize yourself
with the machine and use the machine in accordance with its intended areas of
application.
The document contains important information on how to safely, correctly and
economically use the machine. Paying close attention will help you to avoid hazardous
situations, reduce repair costs and down-times and increase the reliability and life span of
the machine.
The technical product documentation includes instructions on how to prevent accidents
and help protect the environment in accordance with the existing national laws relating to
these subjects. The documentation must always be available at the location where the
machine is used.
The documentation is to be read and used by everyone who works on the machine, for
example, persons who are assigned to carry out the following tasks:
− Operation, including setup, correcting errors in the work procedure, care and disposal of
operational and additional materials
− Maintenance (maintenance, inspection, repair) and/or
− Transportation
The recognized technical regulations relating to the safe operation and appropriate usage
of the machine are to be observed in addition to the technical product documentation and
the applicable regulations relating to accident prevention in the country where the
machine is used.
The personnel assigned to carry out tasks on the machine must have read and
understood the technical product documentation, especially the chapter "Basic safety
instructions", before he or she begins working on the machine. It is too late to start
reading this material once you have started working. The basic safety instructions must
be observed.
The technical product documentation was created in accordance with the following
guidelines and norms:
− Machine guideline 89/392/EC of the commission dated June 14, 1989 to
standardize the legal guidelines of the member states for machines in draft
93/68/EC
− VDI 4500 Sheet 1: Technical documentation – Information for user (1995)
− DIN V 8418: User's information – References for the presentation (1988)
− DIN EN 292 Part 1 and 2: Safety of machinery – Basic terminology, methodology
(1991)
The Spinner company reserves the right to make changes at any time to the product
without prior notification. In addition, the information contained in this technical product
documentation can be changed without prior notification.
PD-2-01/03-840D
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1-2
A User information
Basic information
This technical product documentation contains copyright information protected by
copyrights. All rights reserved. It is not permitted to reprint, photocopy or store this
technical product documentation or any excerpt on an electronic storage medium without
the expressed consent of the Spinner company.
 Spinner Werkzeugmaschinenfabrik GmbH
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-3
A User information
Basic safety information
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
2 Basic safety information
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-1
A User information
Basic safety information
2.1 Warnings and symbols
The following designations and symbols are used for especially important information in
this technical product documentation:
DANGER
Information, regulations and prohibitions to prevent bodily harm
CAUTION
Special information, regulations and prohibitions to prevent
damage to equipment and materials
F
NOTE
Special statements/information regarding the (economic) use of
the machine
2.2 Appropriate use
The machine is built in accordance with the current state of the technology and
recognized safety regulations. However, the machine can be a source of danger when it
is not used by trained, or at least instructed, personnel, or when it is used incorrectly or
for something for which it is not intended. The following can occur in these cases:
•
•
•
•
Danger of bodily injury or death of the user or others
Damage to the machine and other material goods belonging to the user
Inefficient operation of the machine
Destruction of machine parts/tools due to collision.
Only use the machine when it is in technically perfect condition and for its intended
purpose, and be aware of the hazards and safety instructions stated in this technical
product documentation! In particular, correct (or have someone correct) any malfunctions
that affect the safety of the machine immediately!
The machine is only to be used for machining parts using the tools intended for this
purpose. Almost all materials that can be machined can be used such as metal, wood or
plastic. Materials such as ceramic may not be used. Both the use of this machine for any
other use and the overloading of the machine are considered inappropriate usage. The
manufacturer is not liable for any damage resulting from inappropriate use. The user
alone carries the responsibility in this case.
Appropriate use also includes the observance of the operation, maintenance and repair
guidelines as well as of the information in the technical product documentation.
You may not make any changes or structural modifications to the machine or add
equipment that may affect the safety of the machine without authorization from the
supplier. This also applies to the installation and setup of safety equipment.
PD-2-01/03-840D
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2-2
A User information
Basic safety information
2.3 Application limits
The application limits are determined by the maximum values of the machine, especially
those for:
• The feed ranges
• The dimensions relating to the spindle taper
• The speed of the spindle
• The diameter of the chuck
These values are listed in the technical data. Familiarize yourself with this data before
using the machine to avoid severely damaging the machine (see book
A User information, Chapter 3 Product Description).
2.4 When the machine can be used
• You are only to operate the machine when all safety equipment and safetyrelated equipment, e.g. removable safety equipment, emergency OFF equipment
or exhaust equipment, are available and function properly (see also Chapter 3
Product Description)!
2.5 Working safely – Organizational measures
• Do not carry out any work steps that negatively affect the safety of the machine!
• All safety information and information on hazards on the machine are to be
observed!
• All safety information and information on hazards on the machine are to be
maintained in a readable format together with all related documentation!
• Do not stand in the direct path of any objects that may fly off the spindle!
• The personnel should not have long exposed hair or wear loose clothing or
jewelry (including rings), otherwise there is a danger of bodily harm (e.g. when
clothing gets caught or the operator is pulled into the machine)! The operator
must conform to the personal safety measures in the national regulations related
to accident prevention (hair net, protective goggles, gloves, ear plugs or related
gear, protective steel-tipped shoes, etc.)!
• Check at regular intervals to ensure that the personnel are aware of the safety
measures and dangers in accordance with the technical product documentation!
• The responsibilities for the various tasks to be carried out in conjunction with the
operation of the machine must be clearly defined and maintained so that there
are no undefined areas of responsibility when it comes to safety! When making
changes to the machine that affect its safety or changing the way you operate
the machine, switch off the machine immediately and inform the office/person
responsible!
• Original parts and accessories are specially designed for this machine. We would
especially like to call your attention to the fact that original parts and accessories
not supplied by us have also not been tested and released by us! The installation
and/or the use of such products can therefore negatively affect the structural
properties of the machine! The manufacturer is not liable for any damage that
results from the use of parts and accessories that are not original parts and
accessories!
• Do not make any changes to the internal control software/machine software!
• Observe the fire prevention regulations when handling flammable materials!
• Switch off the machine immediately and lock it when a malfunction occurs! Have
the malfunction corrected as soon as possible!
• Before switching on or engaging the machine, make sure that no one will be
placed in a hazardous situation as a result of the machine startup!
PD-2-01/03-840D
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2-3
A User information
Basic safety information
• Observe and maintain the prescribed setup, maintenance, and inspection tasks
and schedules, including those specifications regarding the exchanging of
parts/components, in the technical product documentation! These tasks may only
be carried out by trained personnel!
• If the machine is switched off completely for maintenance and repair work, then it
must be protected against an unexpected startup (by switching the main switch
off and locking it with a padlock, and by removing all keys from the operating
panel)!
• When mounting equipment on the machine at head level or above, use an
appropriate and safe ladder and a working platform! Do not climb onto the
machine using parts of the machine as a ladder!
• Ensure that the operational and auxiliary materials, as well as old, exchanged
parts, are disposed of in a safe and environmentally sound manner!
• The operator must also make sure that no unauthorized persons work on the
machine!
• The operator is required to inspect the machine at least once per shift for
external damage and defects, and to inform the appropriate persons when a
change is discovered that affects the safety (and operation) of the machine!
• If the safety equipment needs to be removed when adding new equipment to the
machine or when carrying out maintenance or repair work, then the safety
equipment must be remounted and inspected immediately after the maintenance
and repair work is completed!
2.6 Personnel selection and qualifications
• Allow only trained or instructed personnel to work on the machine! Clearly define
which persons are responsible for the operation, equipping, maintenance and
repair of the machine!
• Make sure that the only persons that work on the machine are those assigned to
work on the machine!
• Personnel in training, receiving instructions or who are still in a general training
program are only to be allowed on the machine when under constant supervision
by experienced personnel!
• Work done on the electrical equipment of the machine may only be carried out
by an electrician or by trained personnel under the guidance and supervision of
an electrician in accordance with the regulations relating to electrical systems!
Work done on the hydraulic equipment of the machine may only be carried out
by personnel with special knowledge and experience in hydraulics! The
appropriate tools and equipment must be available!
2.7 General hazards on the machine
2.7.1 Mechanical hazards
• Danger of bodily injury in the form of bruises, cuts, bumps, stab wounds,
abrasions or any other injuries resulting from getting pulled into the machine,
etc.! These dangers are presented mainly by the moving machine parts, sharpedged workpieces/ sharp chips and filings, sharp tools, etc.! Do not reach into
moving machine parts!
2.7.2 Electrical hazards
• Danger of bodily injury due to contact with charged parts or current-carrying
parts in the electric cabinet! Allow only trained personnel to work on the electric
cabinet!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-4
A User information
Basic safety information
2.7.3 Thermal hazards
• Danger of bodily injury due to hot surfaces on the cooling system! Care is to be
taken when manually removing the machined workpieces! The workpieces can
still be very hot even though they are cooled while being machined!
2.8 Special types of hazards
2.8.1 Electrical
• Use only original circuit breakers with the prescribed current and voltage ratings.
Switch off the machine immediately when a malfunction in the electrical supply of
the machine is discovered!
• Work done on the electrical equipment or operating materials of the machine
may only be carried out by an electrician or by trained personnel under the
guidance and supervision of an electrician in accordance with the regulations
relating to electrical systems.
• Machine and equipment parts on which inspection, maintenance and repair work
must be done may not carry current or be under voltage when conducting such
work! Switch off the corresponding equipment!
• The electrical equipment of a machine is to be inspected regularly. Defects such
as loose connections must be repaired immediately!
2.8.2 Pneumatic systems
• Work on the pneumatic equipment may only be carried out by persons with
special knowledge and experience in pneumatics!
• All lines, hoses and threaded connections must be inspected regularly for leaks
and other recognizable external damage! Repair damage immediately!
• Depressurize any sections of the system and compressed air lines before
beginning the repair work!
• Do not confuse the hydraulic and compressed air lines!
2.8.3 Oil, grease and other chemical substances
• You must observe the applicable safety regulations for the product when
handling oil, grease and other chemical substances!
• Take care when handling hot operational and auxiliary materials! You may burn
or scald yourself!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-5
A User information
Basic safety information
2.9 Danger through vertical axes and tilted axes
THERE IS A HIGH RISK OF ACCIDENT AND INJURY FOR THE
USER IN CASE OF VERTICAL OR TILTED AXES BECAUSE THEY
CAN FALL DOWN OR START MOVING WHEN NOT EXPECTED!
IN SPITE OF SAFETY DEVICES (MOTOR BRAKES, FIXING
DEVICES ETC.) THE STAY BELOW THE VERTICAL AXIS OR AT
THE TILTED AXIS RESPECTIVELY MUST BE LIMITED AS FAR
AS POSSIBLE IN CASE OF MANUAL WORK AND FORBIDDEN
IN CASE OF SET UP WORK!
2.10 Emergency OFF
• To immediately stop the machine in case of an emergency press down the red
Emergency OFF button on the machine operator panel or the operator panel on
the left (see also book A User information, Chapter 3 Product Description)!
Figure 2-1: Picture of all Emergency OFF buttons on the machine PD (Control Siemens
840D
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-6
A User information
Basic safety information
2.11 Fire and explosion hazards/other hazards
Machine tools, e.g. for turning, milling, grinding, etc., that work with cutting oils, emulsions
(even water-based emulsions with a concentration >10%) can catch fire suddenly, even
when working dry. Explosive mixtures can also form in the closed working area when
using machine tools. When working dry, very fine metal particles may also be produced
that can lead to a dust explosion.
We would especially like to point out that the use of cutting oils of any kind as well as of
emulsions with concentrations >10% or dry work can only be done when the machine is
equipped with the corresponding fire and explosion prevention equipment. This
equipment can be purchased separately as an option. If the machine operator decides not
to use this equipment, then he or she must accept the fact that the machine's uses are
limited and that he or she assumes the risk of a fire or explosion when using cutting oils
or when working dry.
F
SPINNER DOES NOT ASSUME ANY RESPONSIBILITY WHEN
THE MACHINE OPERATOR IGNORES THESE FIRE AND
EXPLOSION HAZARDS OR USES THE MACHINE WITHOUT
THE SAFETY EQUIPMENT REQUIRED TO USE THE MACHINE!
There is still a small potential for danger that cannot be eliminated even if you have taken
all safety precautions. These dangers may only arise under certain circumstances or
cannot be recognized as hazardous. We would especially like to point out that you should
pay attention every time you use the machine. Inattention can lead to bodily injury and
damaged equipment.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-7
A User information
Product Description
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
3 Product Description
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-1
A User information
Product Description
3.1 EC Declaration of conformity
EC Declaration of conformity
as defined by the EC machine direction 98/37/EC
EC direction Electromagnetic compatibility 89/336/EEC
EC direction Low voltage 73/23/EEC
The machine
Description
Type
Serial number
Ultra precision lathe
PD
has been developed, designed and built according to the above mentioned EC directions in the own
risk of:
Company
SPINNER Werkzeugmaschinenfabrik GmbH
Rudolf-Diesel-Ring 24
D-82054 Sauerlach (near Munich)
Tel.: +49 8104/803-0; Fax: +49 8104/803-19
E-Mail: sales@spinner-wzm.de; service@spinner-wzm.de
If the machine has been modified or changed by the enduser, this certificate is not valid any more.
The following standards have been used to judge the electromagnetic compatibility:
EN 50081-2
EN 50082-2
The following harmonized standards have been used:
EN 294
EN 292 T1
EN 418
EN 563
EN 894-1/-2/-3
EN 954-1
EN 953
EN 349
EN 12415
EN 61000-4-2
EN 60204 T1 + T2
EN 1550
EN 55011
EN 61000-4-4
EN 1050
The following national standards, directions and specifications have been used
VDE 0100-T410
ENV 50141
DIN 45635 T16
ENV 50142
VDI 2854
ENV 50140
The following international standards, directions and specifications have been used:
IEC 801-2
Sauerlach 01/2003
PD-2-01/03-840D
.......................................................................
Nicolaus Spinner, Dipl. Ing (FH)
 SPINNER Werkzeugmaschinenfabrik GmbH
3-2
A User information
Product Description
3.2 Introduction
The machine in the PD series is a compact high precision lathe for meeting the highest
demands relating to geometry, surface quality and dimensional precision on small to
medium-sized rotary parts. The machine can be adapted to the production requirements
at various development levels, from the simple finishing lathe up to a fully automatic
turning cell, so that it is equally possible to have small series production or mass
production. The machine is fitted with the most recent CNC control systems for the
economic production runs from one piece upwards. This machine model is characterised
by generous machining potential from a machine which takes up a very small amount of
floor space.
3.3 Areas of use
There are many different areas in which machines in the PD series can be employed.
High precision parts for virtually all sectors of industry can be produced or finished.
The main areas of use lie in fine mechanics, optics, medical technology, computertechnology, for the manufacture of hydraulic and pneumatic components and parts for the
automobile and aircraft industries. The machines can also be used in entertainment
electronics manufacture, the ball-bearing Industry, for the manufacture of articles for daily
use and luxury articles such as watches or writing utensils, in toolmaking or also in
Research and Development and training.
3.3.1 Areas of use
Fine mechanics
Optics
Medical technology
Hydraulics/pneumatics
Electronics
Automobile/Aircraft Industry
Supply industries
Roller Bearing Industry
Tool making, mould making
PD-2-01/03-840D
: Measuring imstruments, small motors, axes, shafts, gears
: Microscopes, spectacle frames, housings, objectives
: Implants, medical apparatus, tools
: Valves, hydro-motors, hydro-pumps, slide valves for
pistons
: Plug connectors, disc drives, video
: Valves, nozzles for petrol injection and ABS, sensors
: Finishing of diecast, moulded and sintered parts
: Hard turning, the machining of ball cages
: Individual parts, electrodes, form cores
 SPINNER Werkzeugmaschinenfabrik GmbH
3-3
A User information
Product Description
3.4 Machine views of the PD series
3.4.1 Overall view of the machine without housing
7
6
5
4
8
3
2
1
9
Figure 3-1: Overall view of the machine without its housing
1)
2)
3)
4)
5)
6)
7)
8)
9)
Heavy machine base with coolant system
Rigid 40-degree cast iron bed in slanting position
Hardened and ground guide ways
Subspindle
Indexing turret or linear tools
Solid headstock housing
High precision spindle unit
Cross slide with linear measuring system
Coolant tank and chip box (chip conveyor as option)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-4
A User information
Product Description
3.4.2 Front view and right side of the machine
Machine
control panel
Safety doors
Electric cabinet
with cooling
system
Push buttons
Chip box
Main switch
Coolant tank
Socket for
permission button
Figure 3-2: Front view and right side of the PD series
3.4.3 Left side of the machine
Part catcher
Main spindle motor
Spindle covering unit
Socket for bar
feeder
Parts collector
Figure 3-3: Left side of the machine of the PD series; on the right with part catcher as
option - on the left without part catcher
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-5
A User information
Product Description
3.4.4 Rear view
Pneumatic unit
Electric cabinet
Central lubrication
reservoir
Figure 3-4: Rear view of the PD series
3.5 Mechanical design
The machines of the PD series are made of a thick walled sheet steel base which takes
the machinebed, the axes as well as the spindle unit. The solid machinebed, the cross
slide and the headstock housing are made of vibration damping cast iron material.
The cross slide unit has slide ways without backlash, preloaded ballscrews to move the
slides a linear measuring systems for a safe positioning in a range of 0.1 µm. All slide
ways are hardened and ground.
The working area is completely sealed and closed. A safety door with two sliding doors
and safety equipment guarantee a fast and not dangerous access to the working area to
change the workpiece or to set up the machine.
3.5.1 Machine versions
The machines of the PD series are built in different versions. The basic machine is
equipped with 2 linear axes (X and Z) which are controlled by CNC and a linear tool
holder. There are 2 types of spindles: one runs with 5000 rpm offering a bar capacity of
42mm, the other runs with 8000 rpm offering a bar capacity of 32mm. This basic machine
is already ready for service to machine precision parts.
The next higher version has an indexing turret for the tools and a tailstock for the
universal machining of wavy parts. The highest version is equipped with 3 axes controlled
by CNC (X, Z, C). In conjunction with driven tools there can be integrated complex milling
and drilling operations.
For a fully automatic handling all machine versions can be equipped with bar feeder
devices or with CNC controlled gantry loaders.
PD-2-01/03-840D
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3-6
A User information
Product Description
3.6 Machine control system
Machines of the PD series are fitted with the most recent control system SINUMERIK
840D from Siemens. Either the NCU 571.2 or the NCU572.2 is used as an NC CPU
depending on the complexity of the machine system and the number of axes.
Emergency Stop Button
Figure 3-5: The user interface for the machine’s control system
Two different kinds of user interface are available:
The simple variant MMC100.2 is fitted with a single-chip processor DOS interface with a
very high processing speed and reliability. It is possible to use this interface both for DINprogramming and also for graphics-aided contour programming. The MMC 100.2 also has
a line graphic function for off- and online-simulation.
The high-end user interface MMC103, with its Pentium processor and hard disk, runs
under the operating system WINDOWS 95 and, in addition to the options available with
the MMC100.2, also offers the WOP-package Autoturn for easy programming in the
workshop. An optional feature on the MMC103 is networking of the control system with
Ethernet for DNC-operation.
The drive modules for the axial and spindle drives are exclusively the digital drive module
SIMODRIVE 611D, which is capable of fulfilling the highest demands on dynamism, the
range of rotational speeds (which can be set), and concentricity. A high degree of
efficiency is obtained by returning the energy created when braking axes and spindles
over an energy feed and energy recovery module in the network. The electrical system in
the machine is designed in accordance with DIN EN 60204-1. The environment in the
switch cabinet is controlled using a cooling heat exchanger.
Please see Book C Operation/Maintenance, Chapter 3 Options for the control system
840D specific to each machine for description of the functions of the control system.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-7
A User information
Product Description
3.7 Location of the ratings plate and CE symbol
Figure 3-6: Ratings plate and CE symbol
The ratings plate and the CE symbol are located for the PD series on the rear of the
machine above the electric cabinet.
The ratings plate contains the following statements: Machine no., machine type, tension,
nominal current and frequency.
3.8 Safety equipment
The PD series machines come with a number of passive and active safety devices as
standard equipment. These devices guarantee maximum safety for the operating
personnel when using the machine. It is not permitted to remove this safety equipment or
make it inoperative as this significantly increases the risk of injury or accident.
YOU MAY NOT REMOVE SAFETY EQUIPMENT ON THE MACHINE
OR MAKE IT INOPERATIVE! THIS SIGNIFICANTLY INCREASES
THE RISK OF INJURY OR ACCIDENT!
1) Emergency OFF: The Emergency OFF buttons are located on the operator
panel of the machine control system (see Figure 3-5) and on the operator panel
next to the safety door (on the left). They are used to shut down the entire
machine system and are triggered by pressing the button or by a machine
malfunction. It is unlocked again by turning slightly in the counterclockwise
direction (see also the picture of the Emergency Off button in Book A User
information, Chapter 2 Basic safety information).
THE EMERGERNCY OFF BUTTON MAY ONLY BE UNLOCKED
AFTER THE REASON WHY THE EMERGENCY OFF WAS
TRIGGERED HAS BEEN CORRECTED! OTHERWISE THERE IS A
HIGH RISK OF INJURY OR ACCIDENT!
2) Safety door: The safety door prevents persons from reaching into the working
area while the machine is running. There is a locking switch to lock the door.
During first starting up the machine the door is unlocked. The closed door is
locked by a one-time opening and subsequent closing or by pressing the NC
start button. While doing this the key-operated switch must be turned to the left
position. The locked door is unlocked by turning the key-operated switch to the
right position or by pressing the NC-stop button.
PD-2-01/03-840D
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3-8
A User information
Product Description
THE SAFETY DOOR MUST ALWAYS REMAIN CLOSED! THE
KEY-OPERATED SWITCH ON THE SAFETY DOOR MAY NOT BE
DAMAGED, REMOVED OR MADE INOPERATIVE!
3) Safety glass: The safety door is equipped with a high-impact resistant plastic
screen. If a workpiece were to become loose and fly off the chucking tool, then
the safety glass will prevent the workpiece from breaking through. However, in
spite of this safety feature, the operator is still not allowed to stand directly in the
flight path of the spindle, and therefore of the workpiece.
THE SAFETY GLASS MUST BE REPLACED IMMEDIATELY
AFTER IT IS BROKEN OR WHEN IT IS CRACKED! IT SHOULD
ALSO BE REPLACED WHEN IT COMES INTO CONTACT WITH A
LOOSE WORKPIECE, EVEN IF NO EXTERNAL DAMAGE TO THE
SAFETY GLASS CAN BE FOUND! REPLACE THE SAFETY
GLASSES AFTER 2 YEARS AT THE LATEST FOR AGEING
REASONS!
4) Permission button: The permission button connected to the operator panel of
the machine allows the operator to set up the machine when the safety door is
open. The setup personnel must hold the button down in the middle position, and
an emergency OFF can be triggered in case of an emergency by pressing the
button down completely or by releasing it. Additional protective measures in
connection with this are the reduced feed speed (1.5 m/min) and the reduced
spindle speed (50 1/min).
ONLY TRAINED PERSONNEL ARE ALLOWED TO WORK IN THE
PERMISSION MODE!
5) Pressure monitors: The pressure monitor is located in the pneumatic unit. It
triggers an emergency OFF as soon as the pressure drops below a preset value.
THE DEFAULT SETTINGS OF THE PRESSURE MONITORS MAY NOT
BE CHANGED!
6) Machine housing: The machine housing protect the operator from rotating and
moving machine parts.
PD-2-01/03-840D
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3-9
A User information
Product Description
3.9 Warning plates and safety information on the machine
It is necessary not only to observe the basic safety instructions for the machine, but also
to observe the warnings and “safety information” plates (see the pictures below).
Warning plate on the right
side of the machine on
the left door of the electric
cabinet (left)
Warning plate on the
tailstock in the working
area (right) - exists only
when the machine is
equipped with a tailstock
Warning plate “Safety
door“ (left)
Warning plate “Running
spindle“ above the main
spindle in the working area
(right)
Warning plate „Cover“ on
the left side of the machine
(right)
Plate “Security notice“ on the left side of the
machine
Figure 3-7: Warning plates and security information on the machine
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-10
A User information
Product Description
3.10 Technical data of the machine
3.10.1 Mechanical data
Dimensions/
Weight
Axes
Main spindle
Subspindle
Tailstock
Indexing turret
Torque
PD-2-01/03-840D
L x W x H (without chip conveyor)
Floor space
Total weight
Total weight with gantry loader
Swing diameter above bed
Usual turning diameter
max. X stroke
max. Z stroke
max. speed X/Z
Speed (bar capacity 42 mm)
Speed (bar capacity 32 mm)
Ø Spindle nose (5000 1/min)
Ø Spindle nose (8000 1/min)
Ø Power chuck (5000 1/min)
Ø Power chuck (8000 1/min)
Max. force of clamping cylinder (5000
1/min)
Max. force of clamping cylinder (8000
1/min)
Speed
Ø Spindle nose
Ø Power chuck
Max. force of clamping cylinder
Diameter of quill
Stroke of quill
Stroke of tailstock
Force max.
Number of tool positions VDI20
Number of tool positions VDI16
Live tools VDI20
Live tools VDI16
Speed of live tools
Main spindle with 5000 1/min (30 min)
Main spindle with 8000 1/min (30 min)
Subspindle (30 min)
Live tool (30 min)
m
m²
kg
kg
mm
mm
mm
mm
m/min
1/min
1/min
mm
mm
mm
mm
dN
2,3x1,2x1,7
2,76
app. 2100-2300
app. 4500
300
120
400
400
12
5000
8000
110
100
140
125
600 (6 bar)
dN
500 (6 bar)
1/min
mm
mm
dN
mm
mm
mm
N
Piece
Piece
Piece
Piece
1/min
Nm
Nm
Nm
Nm
8000
100
125
500 (6 bar)
40
100
400 (NC)
3000 (6 bar)
12
16
6
8
6000
42
26
23
3,5
 SPINNER Werkzeugmaschinenfabrik GmbH
3-11
A User information
Product Description
3.10.2 Electrical data
Power
consumption
Control system
Electrical
system
Main spindle motor (40%)
Subspindle motor (40%)
Live tools
Coolant pump
Electric cabinet cooler
Chip conveyor
Siemens
Operating voltage
kW
kW
kW
kW
kW
kW
type
V
10,2
6,5
1,1
0,8
0,5
1,0
840D
400
Frequency
Control voltage
Power supply
Hz
V
kVA
Operation current IB
Nominal current of the safety
device IN
Connection
A
A
50/60
24 DC
20 (TN-power supply
network)
30
35
power supply
network
TN / TT / IT
(see book B Assembly/Disassembly,
chapter 2 Putting into operation)
3.10.3 Pneumatic system
Supply values
max. operating pressure
normal operating pressure
min. operating pressure
Compressed air flow rate (depends on
the clamping force)
Valves controlled by
Oil sprayer capacity
Quality
bar
bar
bar
Nl/min
10
6
3
~ 1000
V
litre
2
24 DC
0,05
According to
PNEUROP 6611
dB(A)
DIN
DIN
78-80
45635
45633
3.10.4 Noise emission
Noise
Max. volume, normal operation
Noise level measured according to:
Noise level measuring devices
according to:
Position of the measuring devices
1 m from the contour
1,6 m above the floor
Table 3-1: Technical data and noise emission
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-12
A User information
Product Description
Due to constant development of the equipment and accessories for our products as well
as due to technical requirements, we reserve the right to make technical changes that
serve to improve the operation, maintenance and safety of the machine.
3.10.5 Electromagnetic compatibility
The requirements for noise emissions for industrial areas in EN 55011 / EN 55022 Class
A are fulfilled. This product can cause radio interference when used at home. In this case,
the user must take the appropriate measurements and take suitable steps to eliminate
this interference, if necessary.
This device is only to be used in industrial environments and is not released for domestic,
business and commercial areas or small-scale operations.
The requirements in EN 50082_T2 (03/95) - Emission immunity in industrial areas as it
relates to ESD according to EN 61000-4-2, burst according to EN 61000-4-4 and surge
according to EN 61000-4-5, are maintained.
3.10.6 Continuous load/Intermittent duty
THE TOOL DRIVE IS NOT DESIGNED FOR CONTINUOUS LOAD!
WE RECOMMEND TO LIMIT THE INTERMITTENT DUTY TO
<50%!
PD-2-01/03-840D
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3-13
Technical Product Documentation
B Assembly/Disassembly
SPINNER WERKZEUGMASCHINENFABRIK GmbH
D-82054 Sauerlach, Rudolf-Diesel-Ring 24
Tel: 08104 / 803-0, Fax: 08104 / 803-19,
E-Mail: sales@spinnner-wzm.de; service@spinner-wzm.de
B Assembly/Disassembly
Transportation and storage
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
1 Transportation and storage
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-1
B Assembly/Disassembly
Transportation and storage
1.1 Introduction
The machine of the VC series is a precision tooling machine and is therefore to be
handled with the appropriate care during transportation and when moving the machine as
well as when placing in temporary storage. Please follow the instructions and observe the
guidelines stated in the following in order to prevent damaging the machine and reducing
the its precision.
Only devices and equipment that have been approved to move the machine and that can
handle the corresponding loads may be used. The applicable safety guidelines are to be
observed.
F
IF LIFTING AND TRANSPORTATION EQUIPMENT WAS SUPPLIED,
THEN ALL THIS EQUIPMENT MUST GENERALLY BE RETURNED
UNDAMAGED TO THE SPINNER COMPANY. PLEASE CHECK THE
CONTRACT AGREEMENTS IN THIS REGARD.
1.2 Preparing for transportation
1. Clean the machine (the working area, the outer surfaces of the machine), before
it is prepared for transportation. Empty the swarf containers and the cooling fluid
container or the chip conveyer (optional) (see Book a User information, Chapter
3 Product Description - Figure 3-2 to see the position of the swarf container and
the cooling fluid container).
WHEN HANDLING COOLING FLUIDS YOU SHOULD ABSOLUTELY
OBSERVE THE SAFETY INSTRUCTIONS ISSUED BY THE
MANUFACTURER! THERE CAN BE DANGER TO ONE’S HEALTH!
THE COOLING FLUID PUMP SHOULD NOT BE ALLOWED TO BE
SWITCHED ON AGAIN AFTER THE COOLING FLUID
CONTAINER HAS BEEN EMPTIED! THE PUMP CAN BE
DAMAGED THROUGH THE SUCKING IN OF AIR
2. Move the X-axis as far as it takes in the negative direction until the
corresponding guides on the X-axis are covered by the X-slide. Move the Z-axis
to the central position of its stroke and the Q-axis, if present, completely to the
left up to the limit switch.
3. Remove the fine filter (optional) by loosening the pipe clamps but unscrew the
hoses for the fine filter inlet, fine filter outlet and fine filter overflow before this
dis-assembly operation. The filter is located outside the machine on the rear
side; it should be emptied before transporting the machine. Keep the hoses safe.
F
IT IS ADVISABLE TO HAVE RAGS TO HAND WHEN REMOVING
THE HOSES, SINCE FLUID REMAINING IN THE SYSTEM CAN
RUN OUT.
4. Empty the central lubrication tank as required and also the pneumatics oiler.
5. Press the Emergency Stop Button and then turn the main switch for the machine
to 0 (see Book A User information, Chapter 3 Product Description to see the
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B Assembly/Disassembly
Transportation and storage
position of the main switch). Separate the machine from its pneumatic supply
lines and disconnect the mains cable.
ANY WORK ON ELECTRICAL MACHINERY OR FACTORY
EQUIPMENT MAY ONLY BE UNDERTAKEN BY A QUALIFIED
ELECTRICIAN OR BY TRAINED PERSONNEL UNDER THE
SUPERVISION OF A QUALIFIED ELECTRICIAN ACCORDING TO
AND IN ACCORDANCE WITH THE REGULATIONS RELATING TO
ELECTRICAL SYSTEMS!
.
6. Cover the blank machine parts with anti-corrosive oil, grease.
7. Lay/hang desiccant bags as required in the working area and in the electric
cabinet.
8. Secure the safety doors (working area doors). They should not be free to move
during transportation.
9. Pull out the permission button and all keys from the control console (see Book A
User information, Chapter 3 Product Description).
10.Stow away the parts bin (on the left hand side of the machine), if a gripper unit is
integrated into the machine. Ensure that the main spindle cover is firmly in place
and that there are no loose parts in the electric cabinet which could damage
components in the electric cabinet during transportation.
1.3 Moving the base machine
TO AVOID ANY POSSIBILITY OF DAMAGE TO THE MACHINE,
• ALL TRANSPORTATION EQUIPMENT MUST BE CHECKED
OPTICALLY TO ENSURE THAT IT IS IN A PERFECT AND
UNDAMAGED CONDITION!
• ONLY TRAINED PERSONNEL SHOULD BE CHARGED WITH
MOVEMENT/TRANSPORTATION!
• THE MACHINE SHOULD BE HANDLED AND SET DOWN WITH
EXTREME CARE (NO JOLTING)!
• CHECK THAT THE SUPPORT CAPABILITY OF THE FLOOR IS
SUFFICIENTLY HIGH DURING THE WHOLE STORAGE/
TRANSPORTATION OF THE MACHINE AT 2000 KG/M²
ACHTEN!
1.3.1 Moving with a fork lift
Machines in the PD production series can be lifted and moved using a fork lift with
sufficient lifting and carrying capacity (at least 3,000 kg - note that the machine weighs
2,300 kg!) (see Figure 1-1). One comes carefully under the machine from the left, as far
under as possible, and then lifts only as much as is necessary. The forks on the fork lift
must be at least 2.4 metres long.
PD-2-01/03-840D
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1-3
B Assembly/Disassembly
Transportation and storage
WHEN MOVING THE FORK LIFT UNDER THE MACHINE ONE
MUST ABSOLUTELY ENSURE THAT THE FORK LIFT DOES NOT
KNOCK AGAINST THE SPINDLE COVER, THE SPINDLE MOTOR
AND, IF INSTALLED, THE PARTS GRIPPER! ONLY LIFT THE
MACHINE UNDER THE MACHINE BASE! THE MACHINE MUST
NEVER BE LIFTED DIRECTLY UNDER THE ELECTRIC CABINET!
Figure 1-1: Moving the PD machine using a fork lift
1.3.2 Moving with a lifting truck
Machines in the PD production series can be lifted and moved using 2 short or one long
lifting truck with sufficient lifting and carrying capacity (note that the machine weighs
2,300 kg!) (see Figure 1-1). We recommend using two lifting trucks. The forks must be at
least 1.8 metres long in the case where only one lifting truck is used, while they must be
at least 1.2 metres long when two are used. One comes carefully under the machine from
the left (when using one lifting truck) or from both side (when using two lifting trucks), as
far under as possible, and then lifts only as much as is necessary.
WHEN MOVING THE LIFTING TRUCK UNDER THE MACHINE
ONE MUST ABSOLUTELY ENSURE THAT THE FORK LIFT DOES
NOT KNOCK AGAINST THE SPINDLE COVER, THE SPINDLE
MOTOR AND, IF INSTALLED, THE PARTS GRIPPER! ONLY LIFT
THE MACHINE UNDER THE MACHINE BASE! THE MACHINE
MUST NEVER BE LIFTED DIRECTLY UNDER THE ELECTRIC
CABINET!
Figure 1-2: Moving the PD machine using two lifting trucks
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-4
B Assembly/Disassembly
Transportation and storage
1.3.3 Moving using a crane
Machines in the PD production series can be lifted and moved using a crane with
sufficient lifting capability (at least 3,500 kg - note that the machine weighs 2,300 kg!).
The machine is lifted using two bars and a cable. The bars (Ø 40 mm, Length ca. 1.55 m,
material St 37) are inserted into the corresponding openings in the machine base. When
applying the cable make sure that it does not press against the machine guarding/safety
doors and thereby damage them. Secure the ends of the cable to the bars using sprung
pins and use a wooden board to act as a separator from other objects (see Figure 1-3).
Wooden
board
Sprung pin
Figure 1-3: Moving the PD machine using a crane
Machines in the PD-PL production series can be lifted and moved using a special lifting
device for a crane. The crane must have sufficient lifting and carrying capacity (10t). How
to mount and use the lifting device see following pages.
PD-2-01/03-840D
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1-5
B Assembly/Disassembly
Transportation and storage
Figure 1-4: Lifting device for PD-PL
All bolts are secured by means of locking rings according to DIN471 40-1.75.
The load hooks must be at least 2800 mm above the floor.
Use four chains. The breaking force must be >= 50000N.
Point of suspension must be above the centre of gravity of the machine.
Assemble the lifting device as shown in Figure 1-4. Note that the bolts VR-010-010
(1200mm) and VR-010-011 (930mm) are not directly assembled with the lifting device.
They are first inserted into the corresponding openings of the machine.
PROTECT THE MACHINE WITH A PE PLASTIC PROTECTIVE
COVER BEFORE INSERTING THE BOLTS VR-010-010 AND VR010-011.
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1-6
B Assembly/Disassembly
Transportation and storage
Intermediate plate to protect
the machine cover
NEVER WALK UNDER SUSPENDED LOADS!
ONE MUST AVOID HANGING THE MACHINE AT AN ANGLE
WHEN MOVING IT! THIS WILL NOT GUARANTEE SAFE MOVING
AND THE MACHINE CAN BE DAMAGED IN THE PROCESS!
CHECK THE LIFTING CAPACITY OF THE CABLE!
THE ENDS OF THE CABLE MUST ABSOLUTELY BE SECURED
USED SPRUNG PINS!
1.4 Transportation over short distances
1.4.1 Packing the machine
The machine must be prepared for transportation before it can be packed. The steps
required for this are described in this chapter under 1.1.
For transportation over short distances the machine from the PD production series stands
on two wooden planks and is screwed to them at the openings in the machine base using
4 screws M12x120 DIN931-8.8. One just uses PE plastic protective sheeting (fixed with a
waistband) sized 250x130x190 mm to cover the goods to be transported (see Figure 1-5).
It is therefore necessary to take great care when loading and handling the machine to
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1-7
B Assembly/Disassembly
Transportation and storage
avoid damaging the machine guard. We recommend the use of edge protection for the
spindle motor and, if installed, the parts gripper. One should avoid transportation on open
vehicles because of the possible negative effects of moisture.
Figure 1-5: Screwing the PD machine onto the transport planks
1.4.2 Unpacking the machine
1. Remove the waistband and the PE plastic protective sheeting. Check the delivery
for damage.
2. Remove the screws which hold the machine to the wooden planks.
3. Remove any edge protection for the spindle motor and the parts gripper which
may be on the machine (optional).
The machine can then be lifted off the planks using a fork lift (see 1.3.1).
1.5 Transportation overseas
1.5.1 Packing the machine
The machine must be prepared for transportation before it can be packed. The steps
required for this are described in this chapter under 1.1.
For the purposes of sea transport the machine from the PD production range should
stand on a pallet and is screwed to it at the openings in the machine base using 4 screws
M12x120 DIN931-8.8. Two pieces of PE plastic protective sheeting sized 250x130x190
mm are used to cover the goods. Here one of the pieces of sheeting is pulled up over the
machine from below before the machine is placed on the pallet. A wooden crate is made
for the machine which is different from the system used for transportation over short
distances. This packaging offers a much greater level of protection against damage and
environmental influences compared to open transportation (see Figure 1-7).
F
PD-2-01/03-840D
IT IS RECOMMENDED TO LIFT UP THE WALLS OF THE CRATE
WITH A LIFTING TRUCK OR FORK LIFT TO MAKE IT EASIER
TO SCREW THEM TOGETHER (SEE FIGURE 1-6).
 SPINNER Werkzeugmaschinenfabrik GmbH
1-8
B Assembly/Disassembly
Transportation and storage
Figure 1-6: Assembly of the crate walls in preparation for transportation by sea
The pallet has the internal dimensions of 1500 mm x 3100 mm. and is made according to
the drawing in Figure 1-8. The walls of the crate must produced in such a way that an
inner height of 1800 mm is achieved while the pallet base is 40 mm. thick. Where the
machine is fitted with a chip conveyer while being transported (optional) the 700 mm
which it juts out from the machine must be taken into account in the pallet width.
Figure 1-7: Packaging for transportation by sea
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 SPINNER Werkzeugmaschinenfabrik GmbH
1-9
B Assembly/Disassembly
Transportation and storage
Figure 1-8: Dimensions of the transportation pallet
1.5.2 Unpacking the machine
1. Remove the crate cover and the crate walls.
F
IT IS RECOMMENDED TO SUPPORT THE WALLS OF THE
CRATE WITH A LIFTING TRUCK OR FORK LIFT SO THAT
THEY CANNOT FALL DOWN WHEN THE SCREWS ARE
REMOVED (SEE FIGURE 1-6).
2. Remove the upper PE plastic protective sheeting and pull the second one
downwards. Check the delivery for damage.
3. Remove the screws which join the machine to the pallet.
4. Remove the edge protection for the spindle motor and the parts gripper
(optional).
The machine can then be lifted off the pallet using a fork lift (see 1.3.1).
PD-2-01/03-840D
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1-10
B Assembly/Disassembly
Transportation and storage
1.6 Storage
1.6.1 Introduction
The machine was packed professionally for shipping from the manufacturer to the
customer so as to adequately prevent any damage to the machine during transportation.
The type and quality of the packaging as well as the storage conditions are the deciding
factors in determining how long the machine can be placed in storage after transportation.
The packaging from the manufacturer should therefore not be damaged or changed in
any way.
DAMAGED OR ALTERED PACKAGING CAN SHORTEN THE
STORAGE TIME AFTER TRANSPORTATION! FOR THIS REASON,
DO NOT DAMAGE OR ALTER THE PACKAGING IN ANY WAY!
1.6.2 Storage conditions for machines under a PE protective plastic sheet
Storage:
Temperature:
Relative humidity:
Storage duration:
In closed rooms only
20 C° ± 10 C°
≤ 50%
Max. 1 month
1.6.3 Storage conditions for machines in a wooden crate
Storage:
Temperature:
Relative humidity:
Storage duration:
In closed rooms only
20 C° ± 10 C°
≤ 50%
Max. 4 month if additional bags of desiccant (silica gel)
are placed in the machine
1.6.4 Guarantee
If the storage conditions listed above cannot be fulfilled, then all guarantee claims for any
technical or optical defects resulting from this fact will be rejected. In particular, no
guarantee claims will be granted for damage due to corrosion. The machine may not be
stored in the open where it is exposed to the environment, regardless of the type of
packaging.
THE MACHINE MAY NOT BE PLACED IN STORAGE IN AN OPEN
AREA WHERE IT IS EXPOSED TO THE ENVIRONMENT!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-11
B Assembly/Disassembly
Putting into operation
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
2 Putting into operation
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-1
B Assembly/Disassembly
Putting into operation
2.1 Introduction
The machine should only be put into operation by trained service technicians from the
Spinner company or its representatives. You must be familiar with the operation and
handling of the machine, and you must study the technical product documentation and
the machine documentation.
2.2 General requirements at the installation site
2.2.1 Electrical connection
Short-circuit power of the net
(SK-net):
Connected load:
Nominal voltage:
Operation current IB:
Nominal current of the safety
device IN::
Power supply frequency:
Type of power supply, type
of connection:
≥3,6MVA (100xPnCharge/Re-charge-module in kW)
ca. 20 kVA
400 V ± 10%
30 A
35 A
50/60 Hz ± 2 Hz
see Chapter 2.4
2.2.2 Pneumatic connection
Hose:
10 mm inner diameter with mounting clamp
Max. supply pressure:
10 bar
Min. supply pressure:
3 bar
Flow rate (depends on the ~1000 Nl/min
clamping force):
Compressed air quality:
Quality class 2 according to PNEUROP 6611
F
THE MAINTENANCE UNIT FOR THE PNEUMATIC SYSTEM WITH WATER
SEPARATOR AND OIL MIST LUBRICATOR IS A SAFETY ELEMENT AND
PROTECTS THE MACHINE ASSEMBLIES CONNECTED AFTER THIS UNIT
FROM WEARING OUT. HOWEVER, THIS MAINTENANCE UNIT DOES NOT
REPLACE A CENTRAL COMPRESSED AIR SUPPLY WITH A CENTRAL
DRAIN AND DRYING SYSTEM TO BE PROVIDED BY THE USER.
2.2.3 Other environmental conditions
Temperature T:
Relative humidity:
Temperature variation:
Floor:
Load on floor:
Foundation:
Room height:
F
PD-2-01/03-840D
15°C < T < 35°C
≤ 70% at 20°C
< 5°C
Level concrete
At least 2000 kg/m²
Not required for a concrete floor with the properties listed
above; required for anchoring machine to the floor
At least 2,5 m (3 m is recommended)
NOTE THE INFORMATION ON THE FOLLOWING PAGE.
 SPINNER Werkzeugmaschinenfabrik GmbH
2-2
B Assembly/Disassembly
Putting into operation
THE GUARANTEED WORKING PRECISION AND RELIABILITY OF THE
MACHINE CAN ONLY BE OBTAINED WHEN EXTERNAL TEMPERATURE
INFLUENCES SUCH AS DIRECT HEAT OR SUNLIGHT, COLD AIR,
VIBRATIONS OR SHAKING FROM OTHER PRODUCTION UNITS IN THE
IMMEDIATE VICINITY ARE AVOIDED.
IF THE PRECISION REQUIREMENTS ARE INCREASED FOR THE
MACHINE, THEN IT MAY BE NECESSARY TO MAINTAIN A CONSTANT
ENVIRONMENTAL TEMPERATURE AND ISOLATE THE SURFACE ON
WHICH THE MACHINE IS INSTALLED FROM EXTERNAL INFLUENCES.
THE INSTALLATION SITE CAN SIGNIFICANTLY INFLUENCE THE NOISE
EMISSIONS COMING FROM THE MACHINE DURING NORMAL
OPERATION. TO PROTECT THE MACHINE OPERATOR, MAKE SURE
THAT THE MACHINE IS NOT INSTALLED AT A LOCATION WHERE
THERE ARE ADDITIONAL SOURCES OF NOISE OR THE NOISE LEVEL
IS AMPLIFIED!
2.3 Installation diagrams/Foundation plan
Figure 2-1: Installation diagrams (front view)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-3
B Assembly/Disassembly
Putting into operation
Figure 2-2: Installation diagram (top view)
Figure 2-3: Installation diagram (left and right side of the machine)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-4
B Assembly/Disassembly
Putting into operation
Figure 2-4: Installation diagram PD with gantry loader
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-5
B Assembly/Disassembly
Putting into operation
Figure 2-5: Foundation plan PD
2.4 Power supply types and connection information
MACHINES WITH THE SIEMENS CONTROL SYSTEM 840D MAY
NOT BE CONNECTED TO THREE-PHASE POWER SUPPLIES
WITH RESIDUAL CURRENT CIRCUIT BREAKERS!
According to DIN VDE 0160/05.88 Section 6.5 it is permitted to connect the machine to a
three-phase power supply without residual current circuit breakers!
It is not a problem to connect the machine to a TN power supply, and you must use an
isolating transformer in accordance with the instructions in SIMODRIVE 611 – Project
instructions Chapter 2.4.3 - Connecting to a TT power supply or IT power supply (see the
following circuit diagram).
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-6
B Assembly/Disassembly
Putting into operation
2.4.1 Connecting to a TN power supply
Power supply
Low consumption
transformer
1) If required, the neutral point of the low
consumption transformer can be connected
to TN power supply.
PE
NE module
Figure 2-6: TN power supply
2.4.2 Connecting to a TT power supply
Power supply
PE
N
Isolating transformer
PE
NE module
Figure 2-7: TT-Netz
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-7
B Assembly/Disassembly
Putting into operation
2.4.3 Connecting to a IT power supply
Power supply
PE
N
Isolating transformer
NE module
Figure 2-8: IT power supply
2.5 Installation
The machine should only be installed by trained service technicians from the Spinner
company or its representatives. You must be familiar with the operation and handling of
the machine, and you must study the technical product documentation and the machine
documentation.
It is recommended to transport the machine to its installation site while it is still in its
packaging as long as there is enough space there to unpack the machine (see Book B
Assembly/Disassembly, Chapter 1 Transportation and storage for information on how to
unpack the machine). Inspect the delivery after removing the transportation packaging to
make sure that the delivery is complete and undamaged (i.e. free of damage due to
transportation and storage).
The installation at the installation site is done on the delivered rubber pads (see Figure 29). Put them between the machine base and the floor. If bigger adjustment is necessary
we recommend to use wedge pads or other levelling elements.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-8
B Assembly/Disassembly
Putting into operation
Rubber pad
Figure 2-9: Rubber pads for the installation
If the machine is used without a barfeeder (option) there is no need to anchor the
machine on the floor otherwise the barfeeder and the machine must be attached to the
floor. This is necessary to keep the alignment between the barfeeder and the spindle of
the machine. For the attachment the machine base has recesses with the corresponding
drillings. We recommend foundation bolts with a length of about 80 - 120 mm.
You need to carry out the following steps to install the machine:
1. If used remove the transportation clamp that held the safety door during the
transportation.
2. Remove all bags of desiccant.
3. Clean all preserved machine parts with a clean cloth.
4. Check the pneumatic and central lubrication oil level. Refill the corresponding
reservoirs with oil if necessary. Use the oil indicated in book C
Operation/Maintenance, chapter 5 Maintenance.
5. Attach the fine filter (option) to the machine base (rear of the machine) using the
delivered clips. Connect correctly the hoses (fine filter input, fine filter output and
the fine filter overflow). Note the arrows on the housing of the fine filter (see
Figure 2-10).
Fine filter output
(designated by an
↓, pointing away
from the
connection)
Clips
Fine filter input
(designated by
an ↑, pointing to
the connection)
Fine filter overflow
Figure 2-10: Connecting a fine filter
6. Fill the coolant tank with coolant indicated in book C Operation/Maintenance,
chapter 5 Maintenance (for the location of the coolant tank see book A User
information, chapter 3 Product Description).
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-9
B Assembly/Disassembly
Putting into operation
THE MANUFACTURER'S SPECIFIED SAFETY MEASURES MUST
BE OBEYED WHEN HANDLING COOLANTS! THIS WORK
CONSTITUTES A HEALTH RISK!
7. Connect the machine to your compressed air system. Make the connection
between the machine and the power conduit first, then connect the power
conduit to the power supply.
WORK DONE ON THE ELECTRICAL EQUIPMENT OR
OPERATING MATERIALS OF THE MACHINE MAY ONLY BE
CARRIED OUT BY AN ELECTRICIAN OR BY TRAINED
PERSONNEL UNDER THE GUIDANCE AND SUPERVISION OF
AN ELECTRICIAN IN ACCORDANCE WITH THE REGULATIONS
RELATING TO ELECTRICAL SYSTEMS!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-10
Technical Product Documentation
C Operation/Maintenance
SPINNER WERKZEUGMASCHINENFABRIK GmbH
D-82054 Sauerlach, Rudolf-Diesel-Ring 24
Tel: 08104 / 803-0, Fax: 08104 / 803-19,
E-Mail: sales@spinnner-wzm.de; service@spinner-wzm.de
F
THE OPERATION AND PROGRAMMING OF THE MACHINE REQUIRES
SUFFICIENTLY TRAINED PERSONNEL WITH CORRESPONDING
EXPERT KNOWLEDGE. DESPITE INTENSIVE TRAINING IN CLASSES
OFFERED BY THE SPINNER COMPANY AND THEIR DISTRIBUTION
PARTNERS, OR SEMINARS AND CNC-PROGRAMMING CLASSES
OFFERED BY THE CONTROL MANUFACTURERS, A CERTAIN PERIOD
FOR FAMILIARIZATION MUST BE ASSUMED NECESSARY
SUBSEQUENT TO PUTTING THE MACHINE INTO OPERATION.
THE SAFETY REPRESENTATIVE OF THE COMPANY OPERATING THE
MACHINE MUST REPEATEDLY DRAW THE ATTENTION OF THE
OPERATING PERSONNEL TO THE DANGERS INHERENT TO
HANDLING THE INSTALLATION INDICATED IN THE BASIC
INFORMATION IN THE TECHNICAL PRODUCT DOCUMENTATION.
 SPINNER Werkzeugmaschinenfabrik GmbH
C Operation/Maintenance
Switch on/off routine
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
1 Switch on/off routine
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-1
C Operation/Maintenance
F
Switch on/off routine
THE NUMBERS IN THE FOLLOWING STATEMENTS REFER TO
BOOK C OPERATION/MAINTENANCE, CHAPTER 3 MACHINE
SPECIFIC OPTIONS OF THE CONTROL 840D, FIGURE 3-3.
FAMILIARIZE YOURSELF WITH THE MACHINE CONTROL
PANEL AND ITS BUTTONS SHOWN IN THE FIGURE BEFORE
YOU BEGIN WITH THE FOLLOWING INSTRUCTIONS.
1.1 Switching on the machine
You must carry out the following steps to switch the machine on. The machine is also
prepared for the referencing procedure at the same time:
1. Turn the main switch (on the control panel) clockwise to the ON position. Wait
until the control system is completely powered up. The base machine diagram
appears on the screen of the operating panel.
2. Close the safety door. Turn the key-operated switch (11) to a vertical position
(turn counter-clockwise) to lock the safety door, and press the green button cycle
start (15).
3. Unlock the emergency off switch, if necessary. Turn the switch in the direction of
the arrow to do this.
4. Open the tap of the compressed air supply (see assembly pneumatic unit).
5. Press the “Drive ON” button (17). The LED above the button lights up.
6. Press the “Spindle ON” (20) and the “Feed ON” (21) buttons. The LEDs above
the buttons lights up.
7. Delete the alarm message displayed on the screen. To do this, press the RESET
button (12).
1.2 Reference the machine axes
1.2.1 Introduction
After the machine has been switched on, the control system needs to determine the
current positions of the axes. The axes must be referenced. They can be referenced one
after the other from any position using the “+” or “-” keys (18).
BEFORE STARTING THE REFERENCE PROCEDURE THE
REFERENCE DIRECTION IS CHECKED AUTOMATICALLY BY THE
CONTROL SYSTEM! THE REFERENCE DIRECTION FOR THE XAXIS IS ALWAYS +X! THE DIRECTION FOR THE Z-AXIS DEPENDS
ON THE EQUIPMENT OF THE MACHINE! IF THERE IS A
TAILSTOCK THE REFERENCE DIRECTION IS -Z, WITHOUT
TAILSTOCK +Z!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-2
C Operation/Maintenance
Switch on/off routine
CAUTION, DANGER OF COLLISION!
THE AXES ARE MOVED INTO THE WORKING AREA WHEN
REFERENCING THESE AXES! MACHINE PARTS AND TOOLS CAN
COLLIDE WITH EACH OTHER AND BECOME DAMAGED!
IF NECESSARY, MOVE THE AXES MANUALLY BEFOREHAND TO
PREVENT COLLISIONS (SEE THE FOLLOWING STEPS)!
1.2.2 Manually moving the machine axes
CAUTION, DANGER OF COLLISION!
MAKE SURE THAT THE MACHINE PARTS AND TOOLS DO NOT
COLLIDE WITH EACH OTHER AND BECOME DAMAMGED WHEN
MANUALLY MOVING THE MACHINE AXES!
1. Press the JOG button (3). The machine is now in the JOG operating mode.
2. Set the feed override (10) to a low speed so that you have more time to react
when the danger of a collision arises.
3. Select the axis to be moved by pressing the corresponding axis button (8).
4. Move the corresponding axis(es) manually with the “+” or “-” buttons (18) until
there is no danger of a collision during referencing.
1.2.3 Referencing the machine axes
Not the warning given in chapter 1.2.1.
1. Switch on the machine (see 1.1).
2. Press the reference button (5). The “Move to reference point” mode is activated.
The LED of the button lights up.
3. Delete the alarm messages. Press the RESET button again to do this (12).
4. Set the feed override (10) to 100%.
5. Reference the X-axis by pressing the +X button, the Z-axis by pressing the +Z
respectively the -Z button (machine with tailstock).
F
PD-2-01/03-840D
THE AXES MAY REACH THE HARDWARE LIMIT SWITCH
WHEN REFERENCING OR MANUALLY MOVING THE MACHINE
AXES. THE AXES MUST THEN BE RELEASED AGAIN (SEE
BOOK C OPERATION/MAINTENANCE, CHAPTER 4 ERROR
DIAGNOSIS).
 SPINNER Werkzeugmaschinenfabrik GmbH
1-3
C Operation/Maintenance
Switch on/off routine
1.3 Switching off the machine
IN CASE OF MACHINES WITH MMC-SOFTWARE VERSION 5 AND
HIGHER THE MMC 103 MUST BE SHUT DOWN AS EVERY
COMPUTER WITH WINDOWS (SOFTKEY „EXIT“), BEFORE
SWITCHING OFF THE MACHINE BY MEANS OF THE MAIN SWITCH!
THEN PROCEED AS DESCRIBED BELOW!
To switch off the machine, first you need to press one of the Emergency OFF buttons.
Then turn the main switch to the 0 position (off). See book A User information, chapter 2
Basic safety information for the location of the emergency off buttons and chapter 3
Product Description for the location of the main switch.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-4
C Operation/Maintenance
Setting up the machine
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-04/00-840D
61503E
2 Setting up the machine
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-1
C Operation/Maintenance
Setting up the machine
2.1 Setting up the clamping device
2.1.1 Mounting the clamping device
Clamping devices are used to hold the workpieces to be machined and are mounted on
the spindle. There are various types of clamping devices, such as pull-type collets, pushtype collets and power-chucks, for example. When mounting, make sure that the
clamping devices have been trued radially to obtain an optimal repeating clamping
tension accuracy. The spindle headpieces of all collets and chucks are provided with
radial center screws for truing the clamping device using a dial gauge.
.
Spindle
Workpiece
Spindle headpiece
Figure 2-1: Spindle with clamping device and clamped workpiece
See the corresponding assemblies in book D Assemblies for mounting the clamping
devices.
YOU MUST ENSURE THAT YOU USE THE CORRECT SCREWS ,
APPLY THE CORRECT TIGHTENING TORQUE AND OBSERVE
THE MAX. OPERATING FORCE AND MAX. SPEED OF THE
CLAMPING DEVICE WHEN MOUNTING THE CLAMPING DEVICE!
The total stroke of the push/pull tube is not necessary when workpieces are clamped with
push-type collets or pull-type collets. The stroke is limited. In addition to this the stroke
limitation protects these clamping devices against damages. See book D Assemblies,
chapter 11 Assembly SB-NC-109-000 Spindle 5000/42 or chapter 12 Assembly SB-NC135-000 Spindle 8000/32 to adjust the stroke limitation.
2.2 Setting up the tools
There are different tool systems for the machines of the PD series: linear standard
toolholders, linear cartridge toolholders and turret toolholders.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-2
C Operation/Maintenance
Setting up the machine
2.2.1 Linear standard toolholder
Figure 2-2: Linear standard toolholder
2.2.2 Linear cartridge toolholder
Figure 2-3: Linear cartridge toolholder
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-3
C Operation/Maintenance
Setting up the machine
2.2.3 Turret toolholder
Figure 2-4: Turret toolholder
2.3 Tool measuring
The tools must be measured relative to the machine zero point before starting a CNC
programme otherwise the machine does not move the tool cutting edge to a certain
coordinate but its own physical zero point. The measuring can be done on the one hand
by touching the surface of the workpiece with the tool cutting edge in the two reference
planes X and Z, on the other hand without touching the workpiece by positioning the tool
cutting edge into the reticule of an adjustment microscope.
Before mounting the turning tools for the measuring they must be adjusted out of the
machine to the necessary height of centres of the machine.
F
THE HEIGHT OF CENTRES OF THE MACHINE IS INDICATED
ON THE LEFT OF THE CONTROL PANEL (SEE ADHESIVE
LABEL).
2.3.1 Adjusting the tools to the height of centres of the machine
The adjustment of the tools to the height of centres of the machine is done by an
adjustment microscope.(see Figure 2-5).
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-4
C Operation/Maintenance
Setting up the machine
3
4
2
5
1
Figure 2-5: Adjusting the tools to the height of centres
1)
2)
3)
4)
5)
Base plate
Microscope
Microscope support
Tool holder (e. g. cartridge, linearholder, turretholder)
Adapter for toolholder
Proceed as follows to adjust the height of centres:
1. Prepare the height of centres of the lathe (e. g. 77mm) with gauges.
F
NOTE THE THICKNESS OF THE INTERMEDIATE PLATE IN
CASE OF LINEARHOLDERS WHEN YOU ARE PREPARING THE
HEIGHT OF CENTRES. THIS THICKNESS (25MM) MUST BE
SUBTRACTED FROM THE HEIGHT OF CENTRES.
2. Position the block of gauges in case of cartridge and turret holders on the base
plate of the adjustment device, in case of linearholders on the adapter.
3. Adjust the microscope to the upper edge of the gauge block. Then remove the
block.
4. Insert the toolholder into the adapter. Adjust the height of the cutting edge in the
way that the cutting edge can be seen in the reticule of the microscope. With that
the height of centres is adjusted. The adjustment itself is done in case of:
cartridges
:by the setting screw
linearholders
:with the support plate or the excentric sleeve
turret holders
:by grinding off the turning tool or by compensating the
height difference with small plates.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-5
C Operation/Maintenance
Setting up the machine
2.3.2 Tool measuring by touching the workpiece
Spindle
Position e. g. X25, Z0
Toolholder
Workpiece
Figure 2-6: Tool measuring by touching the workpiece
F
THE TOOL MEASURING BY TOUCHING THE WORKPIECE
ASSUMES THAT THE TOOLS HAVE BEEN ADJUSTED
PREVIOUSLY TO THE HEIGHT OF CENTRES (SEE 2.3.1).
Proceed as follows to measure the tools by touching the workpiece:
1. Clamp the workpiece in the chuck of the spindle. Adjust the machining lenght of
the workpiece.
2. Clamp the toolholder on the cross slide in the way that there will not be any
collision.
3. Move the tool towards the workpiece using the handwheel.
4. Touch the surface area of the workpiece (diameter) with the cutting edge. Save
this value (e. g. position X25).
5. Touch the front end of the workpiece with the cutting edge. Save this value (e. g.
position Z0).
2.3.3 Optical tool measuring
The optical tool measuring is done by means of an adjustment microscope that is
mounted above the main spindle (see Figure 2-7).
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-6
C Operation/Maintenance
Setting up the machine
Guideway with clamp
Vertical movement
Longitudinal movement
Figure 2-7: Optical tool measuring
F
THE OPTICAL TOOL MEASURING ASSUMES THAT THE
TOOLS HAVE BEEN ADJUSTED PREVIOUSLY TO THE HEIGHT
OF CENTRES (SEE 2.3.1).
Proceed as follows to measure the tools by optical measuring
1. Clamp the workpiece in the chuck of the spindle. Adjust the machining length of
the workpiece.
2. Mount the toolholder (turret or linear) in the way that there will not be any
collision.
3. Insert the microscope into the dovetail guide situated above the spindle. Clamp
the support.
4. Adjust the microscope by a longitudinal movement to the front edge of the
workpiece. If necessary focus the microscope by a vertical movement.
5. Now the microscope has the position X0 (=axis of spindle) and Z0 (=front end of
the porkpiece). Then remove the workpiece.
6. Move the cutting edge of the tool to be measured into the reticule of the
microscope.
7. Save the diameter e. g. as position X0. Save the front end e. g. as position Z0.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-7
C Operation/Maintenance
Machine specific options of the control 840D
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
3 Machine specific options of the control 840D
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-1
C Operation/Maintenance
Machine specific options of the control 840D
3.1 Introduction
This chapter cannot present in detail all the capabilities of the Siemens control system
840D. The following descriptions refer for the most part to machine specific options.
Please refer to the Siemens manuals for more detailed information such as how to use Gfunctions for motions or M-functions, S-words, T-words and D-words (additional
functions). The manual contains precise instructions on DIN programming (DIN66025)
and complete lists of all G-functions.
Example:
Test MPF
N05 M3 S2000
N10 T0101
N15 G0 X100 Z20
N20 G1 X0 F0.2
N25 ....
N30 ....
N35 M5
N40 M30
(Main program test))
(Spindle speed 2000 rpm, clockwise rotation)
(Turn turret to position 1, tool correction D1)
(Moving X and Z in rapid feed)
(Feed 0.2mm/rotation)
(Spindle Stop)
(End of program)
Additional functions:
The additional functions, operating functions and auxiliary functions contain information
about the machining technology. A maximum of 5 M-functions, 1 S-function, 1 T-function
and 1 D-function can be programd in the same block.
T-functions:
The programmed tool number turns the turret to the necessary machining position (e. g.
T1 = turret station 1). When there is programmed a turret station which does not exist (e.
g. T13 when using a turret with 12 stations) the turret does not turn but the current tool
correction for T13D1 will be activated.
S-functions:
Generally the S-function contains the spindle speed. See Siemens programming manual
for special cases.
S2-functions:
Generally the S2-function contains the speed of the live tools (e. g. M2=3 S2=1500
means clockwise rotation 1500 1/min).
M-functions:
The M-functions are partially laid down in DIN 66025. A lot of M-functions are determined
by the manufacturer. See chapter 3.12.4.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-2
C Operation/Maintenance
Machine specific options of the control 840D
Examples:
N0025
T1D1
N0035
M3 S2000
N0040 M2=3 S2=2000
PD-2-01/03-840D
(Turret station 1, tool correction 1)
(Spindle speed=2000 1/min, clockwise rotation)
(Live tool=2000 1/min, clockwise rotation)
 SPINNER Werkzeugmaschinenfabrik GmbH
3-3
C Operation/Maintenance
Machine specific options of the control 840D
3.2 Operating elements of the Siemens control system 840
3.2.1 Screen and keyboard
2
3
1
4
8
5
7
6
Figure 3-1: Screen and keyboard of the Siemens control system 840D
1)
2)
3)
4)
5)
6)
7)
8)
Screen (displays data, options, functions, etc.)
Vertical soft-key bar (selection operating mode, functions, etc.)
Keyboard (input keyboard for numbers, letters, etc.)
Input field (delete input, move cursor, page up/down, etc.)
Panel opening (PCMCIA card option)
Other options in the horizontal soft-key bar
Return to base machine screen
Horizontal soft-key bar (selection functions, etc.)
F
PD-2-01/03-840D
THERE IS A V.24 AND AN MPI INTERFACE FOR
TRANSFERRING DATA AND A 230 V~ SOCKET UNDERNEATH
THE SCREEN. THE PERMISSION BUTTON AND THE
HANDWHEEL ARE ALSO CONNECTED UNDERNEATH THE
CONTROL PANEL(SEE FIGURE 3-2).
 SPINNER Werkzeugmaschinenfabrik GmbH
3-4
C Operation/Maintenance
Machine specific options of the control 840D
Main switch
4x4
V.24/MPI
Connection for
permission button
or hand wheel
Figure 3-2: Connections and main switch underneath the control panel
3.2.2 Machine control panel
1
2
11
12
3
13
4
5
14
6a
15
6b
16
7
17
18
8
19
9
20
21
10
22
Figure 3-3: Machine control panel
1) EMERGENCY OFF
2) MDA button
3) JOG button
4) Increment buttons (see note below)
5) Ref-button
6) Clamp/release spindles
7) Single/serial part
8) Select axes
9) Spindle override (potentiometer for spindle speed)
10) Feed override (potentiometer for stroke speed)
11) Key-operated switch to lock the safety door
12) RESET button
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-5
C Operation/Maintenance
Machine specific options of the control 840D
13) AUTO button
14) SBL (single block) ON/OFF
15) Cycle start/NC-Start (green), Cycle stop/NC-Stop (red)
16) Cooling lubricant pump On/Off
17) Drive On
18) +/- button
19) Switch between MCS/TCS
20) Spindle On (green), Spindle Off (red)
21) Feed On (green), Feed Off (red)
22) Key-operated switch for the various access levels
F
FOR INCREMENT LEVEL 1, THE STROKE OF THE AXES IS
0.001 MM FOR EACH AXIS, AND THE STROKE IS 0.01 MM FOR
EACH AXIS FOR INCREMENT LEVEL 10. THE STROKE OF THE
AXES IS 0.1 MM FOR EACH AXIS FOR INCREMENT LEVELS
100 OR HIGHER.
[.]
The button
calls up a previously defined increment. Press the INC option in the
vertical soft-key bar to specify this variable increment. It appears when you are in the
JOG operating mode. If the corresponding soft-key is pressed, then a screen opens in
which you can enter the increment. Confirm with OK (see Figure 3-4).
Increment input field
Confirm with OK
Figure 3-4: Specifying the variable increment
PD-2-01/03-840D
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3-6
C Operation/Maintenance
Machine specific options of the control 840D
3.2.3 Control panel on the left side of the machine front
1
2
3
4
Is activated by the
button
6
7
5
Figure 3-5: Control panel on the left side of the machine front
The control panel on the left side of the machine front has the following functions:
1)
2)
3)
4)
Button to clamp and release the clamping device of the main spindle
Potentiometer for feed
Axes selecting turn switch
Space for a button to clamp/release the clamping device of the subspindle (here
not in existence)
5) Cycle start button to start the program/the partial function
6) Handwheel
7) Emergency off button
3.3 Permission mode
In the permission mode the machine can be operated with limited functionality, and can
therefore be operated when the safety door is open. To enter the permission mode, the
key-operated switch for the safety door must be turned to the horizontal position (position
3) (see Chapter 3.2.2 for the location of the switch). The permission button, which is also
available as an option together with a handwheel (see Chapter 0), is to be held down in its
middle position.
Permission button
Figure 3-6: Permission button
PD-2-01/03-840D
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3-7
C Operation/Maintenance
Machine specific options of the control 840D
When the safety door is open, the following functionality is available in the permission
mode:
(The numbers in parentheses refer to the buttons in Figure 3-3)
• In the JOG operating mode (3)
By selecting the corresponding axis (8) and pressing the + or - button (18) the
axes and spindles can be moved. Incremental positioning (4) is also possible.
• In the MDA operating mode (2)
NC-blocks can be started. When there are several NC-blocks in a row, the
blocks are only processed in the single block (SBL = single block) mode.
Single block is set here automatically.
• In the AUTO operating mode (13)
Programs can be processed in the single block (SBL) mode. Single block is
set here automatically.
(See the Siemens manuals for an exact description of the operating modes)
THE MACHINE MAY ONLY BE OPERATED IN THE SETUP MODE BY
TRAINED PERSONNEL!
THE ROTATING SPINDLE AS WELL AS INCORRECTLY CLAMPED,
LOOSE WORKPIECES AND INCORRECTLY MOUNTED CHUCKS CAN
BE HAZARDOUS! FOR THIS REASON, DO NOT STAND IN THE
FLIGHT PATH OF THE SPINDLE AND DO NOT REACH IN TOWARDS
THE ROTATING SPINDLE, TOOLS, TURRET OR CHUCKS!
HANDLING SHARP TOOLS, HOT, LOOSE CHIPS, COMING IN
CONTACT WITH IRRITATING COOLANTS AND REMOVING SHARP
CHIPS CAN BE HAZARDOUS! MOVING MACHINE PARTS CAN CRUSH
YOUR HAND OR ARM! WEAR PROTECTIVE GLOVES AND GOGGLES,
ETC.! NOTE THE INFORMATION REGARDING THE HAZARDS
ASSOCIATED WITH COOLANTS ISSUED BY THE COOLANT
MANUFACTURERS!
F
IN PERMISSION MODE, THE FEEDS ARE LIMITIED TO A MAXIMUM
OF 1.5 M/MIN AND THE SPINDLE SPEED TO A MAXIMUM OF 50 RPM.
IF THE PERMISSION BUTTON IS RELEASED OR PRESSED ALL THE
WAY DOWN DURING THE MOVEMENT, THEN AN EMERGENCY OFF
IS TRIGGERED. THIS SAFETY DEVICE IS NECESSARY TO KEEP THE
DANGER OF AN ACCIDENT AT A MINIMUM.
In spite of all the safety equipment and safety measures, bodily injury cannot be ruled out
when operating the machine with the safety door open! For this reason, be especially
careful when operating the machine with the safety door open! If possible, keep the safety
door closed at all times! The machine operator is responsible for handing out the safety
door key only to trained employees qualified to carry out setup work and who have been
informed of the dangers.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-8
C Operation/Maintenance
Machine specific options of the control 840D
3.4 Manual operating device (option)
To make positioning the axes easier when setting up the machine, the axes and spindles
can be moved manually with the manual operating device. The programmer can stand
directly in front of the working area so that he or she can monitor the movements exactly.
The manual operating device can be used when the safety door is closed as well as when
it is open (permission mode). In the latter case, the permission button is to be pressed
and held in its ebd position.
Emergency Off
Handwheel
Rapid feed
+/- buttons
Increment buttons
Permission
button
Connection to
the control
console
Axes selector
Figure 3-7: Manual operating device
F
F
F
IN PERMISSION MODE, I.E. WITH THE SAFETY DOOR OPEN, INCREMENTAL
POSITIONING
IS
ONLY
POSSIBLE
USING
THE
+ AND - KEYS.
IN CASE OF THE PD SERIES WITH GANTRY LOADER, THE AXES CAN´T BE
MOVED BY MEANS OF THE MANUAL OPERATING DEVICE.
THE FUNCTION KEYS F1 UP TO F3 ARE USED FOR THE INCREMENTS AS
FOLLOWS:
F1 = INCREMENT 1
= 0,001 MM
F2 = INCREMENT 10 = 0,01 MM
F3 = INCREMENT 100 = 0,1 MM
When the axes selector is in position 0, the manual operating device is deactivated, the
keyboard at the control console activated.
The handwheel itself moves in small segmental subdivisions. The selected axis moves
correspondingly by the incremental setting for each segment turned. The handwheel is
selected as follows:
(The numbers in parentheses refers to the buttons in Figure 3-3)
1. Press the JOG button (3) after starting the control system.
2. Select an increment level pressing one of the function keys (see Figure 3-7). The
meaning of the function keys is described above.
3. To select an axis in case of the manual operating device turn the axis selector to
the corresponding axis (see Figure 3-7).
PD-2-01/03-840D
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3-9
C Operation/Maintenance
Machine specific options of the control 840D
3.5 Access levels
The following functions are allowed for the various key-operated switch settings (see
Chapter 3.2.2 for the location of the switch):
• Key-operated switch setting 0 for operators in training (all keys removed)
Read the tool correction
Read the parts program
Read the user variables
Read and write the global user data if not blocked in a definition
Operate the machine control panel
Operate the machine in the JOG operating mode
Start the selected program
• Key-operated switch setting 1 for trained operators who do not program the
machine (black key), additional functions for switch position 0
Write the Siemens tool corrections
• Key-operated switch setting 2 for programmer/setup personnel (green key),
additional functions for switch position 1
Write the tool geometry data
Write the tool setup corrections
Change the tool monitoring limit values
Write the adjustable zero offset
Change the D-No. of a tool edge
Select the program influence
Change wear-group magzine station/mag.
Change tool designation and Duplo
Change tool type
Select program influencing
Edit the parts program
Select the parts program
Delete the R-parameters
Write the R-parameters
With the option „Spindle monitoring for -no workpiece clamped-“: Program
execution without workpiece possible
Write global user data if not blocked in a definition
• Key-operated switch setting 3 (orange key), additional functions for switch
position 2
“Teach-In” operating mode
“Preset” operating mode
Set the parameters for the V24 interface
3.6 Main operating mode
3.6.1 Manual operating mode, JOG
The manual operating JOG mode is used for setting up the machine. The following
additional functions are available using the softkeys or the keyboard:
PD-2-01/03-840D
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3-10
C Operation/Maintenance
•
•
•
•
•
•
•
•
Machine specific options of the control 840D
Moving the axes with the arrow keys or the handwheel
Turning the turret with the keys of the machine control panel
Clamping/releasing the chuck with the button of the operating panel
Edit program memory
Edit tool memory
Automatic measurement of the tools
Zero offset
Autoturn (option)
3.6.2 Semiautomatic operating mode, MDI
The semiautomatic operating mode MDI is used for setting up the machine. Complete CN
blocks and instructions can be entered and executed. The following additional functions
are available using the softkeys or the keyboard:
•
•
•
•
•
•
•
•
Moving the axes by programming a G-function + X/Z-value
Operating the spindle by programming a M-function + S-word
Turning the turret by programming a T-function
Clamping/releasing the chuck with the button of the operating panel
Clamping/releasing the chuck by programming a M-function
Edit tool correction memory
Zero offset
Diagnostic menu
3.6.3 Automatic operating mode, AUTO
The automatic operating mode AUTO is used for the automatic running of parts programs
(production of workpieces). Complete parts programs are selected and executed. The
following additional functions are available using the softkeys or the keyboard:
•
•
•
•
•
•
•
Selecting and starting program
Clamping/releasing the chuck with the button of the operating panel
Program influencing
Edit program memory
Edit tool memory
Zero offset
Diagnostic menu
3.6.4 Reference point mode, REF-POINT
The reference point mode REF is used to move automatically to the reference points of
the machine. This mode is a submode of the JOG mode. The following additional
functions are available using the softkeys or the keyboard:
•
•
•
•
Edit program memory
Edit tool memory
Zero offset
Diagnostic menu
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-11
C Operation/Maintenance
Machine specific options of the control 840D
3.6.5 Increment mode
The increment mode INC (Increment) is used for setting up the machine. The axes can
be moved gradually with previously adjusted increments between 1µm and 100µm using
the arrow keys or continuously by means of the handwheel. The following additional
functions are available using the softkeys or the keyboard:
• Edit program memory:
• Edit tool memory
• Zero offset
• Diagnostic menu
3.7 Setting the clamping pressures
The nominal clamping pressures for the main spindle, sub-spindle and tailstock as well
the acceptable tolerance for each of these can be set directly on the CNC-control system
through entering the desired values. The menu can be reached using the softkey
sequence “Parameter” à “Clamping parameter” (see Figure 3-8).
F
CHANGES CAN ONLY BE MADE WHEN THE KEY SWITCH IS
AT POINT 2.
Figure 3-8: Menu for the clamping parameters
3.7.1 Value and function ranges
1. The main spindle and the sub-spindle
100 daN
< Nominal clamping force
75 daN
< Allowed tolerance
100 daN
< Actual clamping force
1000 mbar
< Actual clamping pressure
Clamping direction forwards = Entry 0
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
<
<
<
<
2000 daN
100 daN
2000 daN
10000 mbar
3-12
C Operation/Maintenance
Machine specific options of the control 840D
Clamping direction to the rear = Entry 1
2. The tailstock
10 daN
10 daN
10 daN
1000 mbar
<
<
<
<
Nominal clamping force
Allowed tolerance
Actual clamping force
Actual clamping pressure
<
<
<
<
400 daN
40 daN
400 daN
10000 mbar
3. Setting up the pneumatic system
Entry of the supply pressure and setting up of the pneumatic oiler already took place
when SPINNER undertook the first commissioning of the machine.
F
IT IS NOT NECESSARY FOR THE USER TO UNDERTAKE ANY OF THE
STEPS LISTED IN THE SECTION “PNEUMATICS-SETUP“
3.8 The tool correction memory
One accesses the tool correction memory over the softkey “Parameter” à “Tool
corrections” (see Figure 3-9).
Figure 3-9: The tool correction memory
PD-2-01/03-840D
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3-13
C Operation/Maintenance
Machine specific options of the control 840D
3.8.1 Working planes and tool lengths
Working planes
Selection Working plane
G17
X-Y
G18
X-Z
G19
Y-Z
Feed axis
Z
Y
X
Switch on state for Turning G18
:
Switch on state for Milling G17
:
Assignment of length
G17 L1=Z
G18
L1=X
L3=X
L2=Z
G17
G19
L1=X
L2=Z
Milling and turning the front face by cycle; the tool is set up as drill or milling
cutter (Tool type 110-250)
Normal machining by drilling; the tool is set up as drill (Tool type 500-540)
Machining the surface area; the tool is set up as shank end mill without rounding
off of the edge or as drill (tool type 110-250)
G18
G19
WHEN USING A DRILL IN THE G18 PLANE WITHOUT CYCLE
FOR A CENTRAL DRILLING THEN: L2=X AND L3=Z!
IN CASE OF AUTOTURN MIND THAT THE CORRECT WORKING
PLANE IS USED WHEN MACHINING WITH A DRILL (CENTRE OR
PARTIAL CIRCLE)! IF NECESSARY THE TOOL OR THE
PROGRAM MUST BE ADAPTED!
3.8.2 Measuring up the tools
3.8.2.1 The X-axis for turning tools/dividing tools
1.
2.
3.
4.
5.
6.
Touch the tool at the diameter (e. g. Ø 30 mm).
Position the cursor over the entry field “Length 1”.
Press the softkey “Determine correction”.
Select the X-axis.
Enter the current position as a radius (i.e. 15 mm for Ø 30 mm).
Press the softkey “Compensate”. The geometry data will be generated.
3.8.2.2 The Z-axis for turning tools/dividing tools
1.
2.
3.
4.
5.
6.
Touch the flat surface with the tip of the tool (e. g. Z-value=2; ≅ allowance 2mm).
Position the cursor over the entry field “Length 2”.
Press the softkey “Determine correction”.
Select the Z-axis.
Enter the current position.
Press the softkey “Compensate“” The geometry data will be generated.
PD-2-01/03-840D
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3-14
C Operation/Maintenance
Machine specific options of the control 840D
3.8.3 Entry of wear parameters
3.8.3.1 The X-axis for turning tools/dividing tools
1. Position the cursor over the entry field “Wear” of the length correction for “Length
1”.
2. Press the Edit key
. The cursor moves.
3. Enter the correction values with the prefix + or -.
4. Press the yellow Enter key
. The correction value will be added automatically
to the previously existing wear values.
ENTER THE CORRECTION VALUE AS A RADIUS!
3.9 Spindle synchronisation
The main and sub-spindles can be synchronised as described in the programming
manual for the 840D. The following macros were created for simplified selection and deselection of the synchronisation of the two spindles to each other with which the
synchronisation can be undertaken for standard applications:
SYNC_ON ⇒ Select synchronous running of the sub-spindle relative to the main spindle
SYNC_OFF ⇒ De-select synchronous running of the sub-spindle relative to the main
spindle
3.9.1 Positional synchronised running Main spindle⇒sub-spindle without
matching of the clamping unit
Synchronisation of the sub-spindle to the main spindle can be undertaken while they are
stationary or at any desired rotational speed of the main spindle, which is defined as the
lead spindle. The main spindle and the sub-spindle will, after selection, only have their
rotational speeds synchronised not their angular inclination. The main spindle is
automatically stopped when de-selection of the synchronisation is made while the subspindle will continue to run at the rotational speed which was selected for it at the last
synchronisation. The spindles remain coupled together after calling up SYNC_ON until
SYNC_OFF is called up.
F
THE SYNCHRONISATION ALSO REMAINS AFTER THE RESET
BUTTON HAS BEEN PUSHED!
An example:
N0010
NXXX
NXXX
N1010 M4 S3000
N1015 G4 F1
PD-2-01/03-840D
Machining on the main spindle
Spindle speed of the main spindle 3,000 r.p.m, anticlockwise
Dwell time until the spindle speed for the spindle has
been reached
 SPINNER Werkzeugmaschinenfabrik GmbH
3-15
C Operation/Maintenance
Machine specific options of the control 840D
N1015 SYNC_ON
N1020 M49
N1025 G1 G94 F2000 Q1=-300
N1030 M48
N1035
NXXX
NXXX
N1100 SYNC_OFF
N1105 G0 G95 Q1=0
N1110 M3=4 S3=4500
N1115
NXXX
NXXX
N1200 M3=5
N1205 M30
Selection of synchronisation; synchronous running of
the sub-spindle in relation to the main spindle
Open chuck on the sub-spindle
Sub-spindle moves to the workpiece
Close chuck on the sub-spindle
Cut-off workpiece
Stop the synchronisation, the main spindle stops, the
sub-spindle continues to turn
The sub-spindle moves back to the machining position
Change of spindle speed for the sub-spindle
Machining on the sub-spindle
The sub-spindle stops
End of program
3.9.2 Positional synchronised
matching of the clamping unit
running
Main
spindle⇒sub-spindle
with
THE ANGLE-OFFSET FOR THE COLLET FOR BOTH SPINDLES
MUST
BE
DETERMINED
BEFORE
A
POSITIONAL
SYNCHRONISED TRANSFER OF A MULTI-FACETED OR
MOULDED WORKPIECE IS UNDERTAKEN TO ALLOW
TRANSFER OF THE WORKPIECES FROM THE MAIN SPINDLE
TO THE SUB-SPINDLE!
An example:
The main spindle and the sub-spindle both have an hexagonal collet to accommodate an
hexagonal workpiece. Both spindles are standing at 0 degrees but there is an offset
between the hexagonal collets. The phase offset must be determined in this case so that
both collets run true. Proceed as follows:
1. Couple the main and the sub-spindle together while in operating mode MDI with
SYNC_ON.
2. Switch to operating mode JOG and select axis C3. Using key “+” align the collet
on the sub-spindle to the collet on the main spindle. The phase offset is the value
by which the collet on the sub-spindle must be turned in order to obtain correct
alignment to the collet on the main spindle.
3. An offset angle of 54.5 degrees is programmed with the command COUPON
(C3,C1,54.5).
An example:
N0010
NXXX
NXXX
N1010 M4 S3000
N1015 G4 F1
PD-2-01/03-840D
Machining on the main spindle
Spindle speed of the main spindle 3,000 r.p.m, anticlockwise
Dwell time until the spindle speed for the spindle has
 SPINNER Werkzeugmaschinenfabrik GmbH
3-16
C Operation/Maintenance
Machine specific options of the control 840D
N1015 SYNC_ON
N1018 COUPON (C3,C1,54.5)
N1020 M49
N1025 G1 G94 F2000 Q1=-300
N1030 M48
N1035
NXXX
NXXX
N1100 SYNC_OFF
N1105 G0 G95 Q1=0
N1110 M3=4 S3=4500
N1115
NXXX
NXXX
N1200 M3=5
N1205 M30
been reached
Selection of synchronisation; synchronous running of
the sub-spindle in relation to the main spindle
The sub-spindle is turned 54.5 degrees relative to the
main spindle
Open chuck on the sub-spindle
Sub-spindle moves to the workpiece
Close chuck on the sub-spindle
Cut-off workpiece
Stop the synchronisation, the main spindle stops, the
sub-spindle continues to turn
The sub-spindle moves back to the machining position
Change of spindle speed for the sub-spindle
Machining on the sub-spindle
The sub-spindle stops
End of program
IF THE MACROS SYNC_ON AND SYNC_OFF ARE NOT USED,
THEN BOTH SPINDLES MUST BE REFERENCED AFTER
STARTING UP THE MACHINE! THIS CAN BE ACCOMPLISHED,
FOR EXAMPLE, BY USING COMMAND M3 S3=100 FOR THE
MAIN SPINDLE AND BY USING COMMAND M3 S3=100 FOR THE
SUB-SPINDLE! ONE CAN ALSO USE THE COMMAND
SPCON(C1) G74 C1=0 FOR THE MAIN SPINDLE AND SPCON(C3)
G74 C3=0 FOR THE SUB-SPINDLE!
THE ANGLE MUST BE READJUSTED IN ALL CASES AFTER
EXCHANGING THE ROD ASSEMBLY, THE DRIVE BELT OR
CHUCKING TOOL FROM THE MAIN SPINDLE AND/OR SUBSPINDLE !
3.10 Moving the sub-spindle to the dead stop (optional)
The sub-spindle axis Q can be programmed with torque limitation. This is necessary when
the sub-spindle is used as a tailstock, for example, or when the sub-spindle with an
integrated dead stop moves hard towards a workpiece and this should sit well against the
dead stop. The program commands are as follows:
FXS[Q1]=1
FXS[Q1]=0
FXST[Q1]=0-100
FXSW[Q1]=2
PD-2-01/03-840D
Select “Move to the dead stop”
De-select “Move to the dead stop”
Select the clamping torque as a % of the motor torque
Select the width of the monitoring window as 2mm
 SPINNER Werkzeugmaschinenfabrik GmbH
3-17
C Operation/Maintenance
FXS[Q1]=0/1
Machine specific options of the control 840D
The command for the selection of the torque limiting must be in the
same program block, in which the axial movement for the dead stop is
programmed. A position must be programmed here which is at least 2
mm behind the actual stop. Once the dead stop has been de-selected
an axial movement of the Q-axis away from the stop must
programmed. There is inherent danger here of damaging the
machine.
FXST[Q1]=0-100 For programming in a program block with an FXS-command or in any
desired program block after selecting torque limiting. These will first
become active in the next program block in which an axial movement
is programmed. If this command is not programmed in then the stored
value of the setting record 43510 “FIXED_STOP_TORQUE” will be
used instead. No more than 40% of the motor torque should be
selected in order to avoid causing damage.
FXSW[Q1]=
As long as the Q-axis is sitting at the dead stop its position will be
monitored so that a break off of the stop can be observed, for
example. The window should be selected to be as small as possible. If
this value is not selected the program will take the value stored in the
setting record 43520 “FIXED STOPPED WINDOW”.
USE OF THE FUNCTION „DEAD STOP“ REQUIRES A GOOD
DEAL OF CARE ON THE PART OF THE PROGRAMMER, SINCE
THE MAXIMUM SETTABLE TORQUE CANNOT BE LIMITED BY
THE MANUFACTURER! ONE SHOULD NEVER RUN AT 100% OF
THE POSSIBLE MOTOR TORQUE, SINCE THE FORCES
GENERATED COULD LEAD TO SELF-DESTRUCTION OF THE
FEED SPINDLE OR TO EXTENSIVE DAMAGE TO OTHER
MACHINE PARTS! THUS THE MAXIMUM ALLOWABLE TORQUE
SHOULD BE LIMITED TO 40%!
An example:
N0010
NXXX
NXXX
N1010 M4 S3000
Machining on the main spindle
Spindle speed of the main spindle 3,000 r.p.m, anticlockwise
N1015 G4 F1
Dwell time until the spindle speed for the spindle has
been reached
N1015 SYNC_ON
Selection of synchronisation; synchronous running of
the sub-spindle in relation to the main spindle
N1018 COUPON (C3,C1,54.1)
The sub-spindle is turned 54.5 degrees relative to the
main spindle
N1020 M49
Open chuck on the sub-spindle
N1025 G1 G94 F2000 Q1=-310 Sub-spindle moves to the workpiece
N1027 G1 F1000 Q1=-320 The sub-spindle moves hard up to the dead stop
FXS[Q1]=1
(Position of the dead stop Q1=-317)
N1028 FXST[Q1]=35
Clamping torque 35%, the rest of the path is deleted
PD-2-01/03-840D
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3-18
C Operation/Maintenance
N1029 FXSW[Q1]=1.5
N1030 M48
N1030 FXS[Q1]=0
N1035
NXXX
NXXX
N1100 SYNC_OFF
N1105 G0 G95 Q1=0
N1110 M3=4 S3=4500
N1115
NXXX
NXXX
N1200 M3=5
N1205 M30
F
Machine specific options of the control 840D
The window width for the monitoring is 1.5 mm
Close chuck on the sub-spindle
De-select the function “dead stop”
Cut-off workpiece
Stop the synchronisation, the main spindle stops, the
sub-spindle continues to turn
The sub-spindle moves back to the machining position
Change of spindle speed for the sub-spindle
Machining on the sub-spindle
The sub-spindle stops
End of program
THE FUNCTION „MOVE TO THE DEAD STOP“ IS AN OPTION
AND IS ONLY INTENDED FOR THE Q1-AXIS.
3.11 Programming the C-Axis
The programming runs according to DIN 66025. Additional information to the explanation
given below can be found in the SIEMENS-manual “Programming Instructions” - Chapter
on Cylindrical Interpolation and Transmit.
The following commands are used in the programming of the C-axis:
SPOS[1]=1
SPOS[3]=1
M3 ; M3=
C1=15
C3=15
TRAFOOF
DIAMON
DIAMOF
TRACYL
TRANSMIT
Select the main spindle on the C-axis with the reference point C=0
degrees
Select the sub-spindle on the C-axis with the reference point C=0
degrees
De-select the C-axis (main, sub-spindle)
The main spindle is positioned to 15 degrees
The sub-spindle is positioned to 15 degrees
De-select all co-ordinate transformations (Tracyl, Transmit)
Select diameter programming
De-select diameter programming
Select cylindrical interpolation (machining in the ZY=G19 plane)
Select TRANSMIT (diameter programming XY=G17 plane)
Conditions for calling up TRACYL and TRANSMIT:
TRACYL
TRAFOOF, SPOS=0
TRANSMIT
TRAFOOF, SPOS=0, G40, DIAMOF
Conditions after calling up TRACYL and TRANSMIT:
TRACYL
G19, DIAMON
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3-19
C Operation/Maintenance
TRANSMIT
Machine specific options of the control 840D
G17, G94
An example:
N030 SPOS=0
N035 G0 X20 Z2 T1 D1
N040 M2=3 S2=2000
N045 G1 G94 Z-10 F100
N050 C1=15 F800
Select the main spindle C-axis with the reference point C=0
degrees
Movement of the X-axis and Z-axis
Setting the rotational speed of the driven tool
Milling at feedrate mm/min
Milling at feedrate degrees/min
3.11.1 Absolute programming of the C-axis
Rapid traverse:
G0 G90 G94 C1=...
Feedrate:
G1 G90 G94 C1=...F...
C= angle in degrees, -360° ≤ C ≤ 360°
F= feedrate in degrees/minute, max. value = 10000
3.11.2 Relative programming of the C-axis
Rapid traverse:
G0 G91 G94 C1=...
Feedrate:
G1 G91 G94 C1=...F...
C= angle in degrees, -99999° ≤ C ≤ 99999°
F= feedrate in degrees/minute, max. value = 10000
3.11.3 Conversion of the feedrate mm/min in degrees/min
The conversion is only necessary when one must operate without the software option
“Cylindrical interpolation”:
Degrees/min = (F x 180) / (π x r)
r = Radius of the workpiece in mm; F = Feedrate for milling in mm/min
An example:
F = 100mm/min
r = 20mm
The desired miller feedrate
The radius of the workpiece which should be milled
Degrees/min = (100 x 180) / 3.14 x 20)
Degrees/min = 286.47
One must program a feedrate of 286 degrees/min in order for the miller, when moving
around the workpiece, to be travelling at a calculated feedrate of ca. 100 mm/min.
3.11.4 Cylindrical interpolation
Cylindrical interpolation allows simple programming of any desired contours on the
surface of the casing. One programs:
TRACYL (100,1)
PD-2-01/03-840D
for the partial diameter, 100mm, the machining spindle
 SPINNER Werkzeugmaschinenfabrik GmbH
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C Operation/Maintenance
TRACYL (150,2)
TRAFOOF
Machine specific options of the control 840D
for the partial diameter 150mm, the second spindle
De-select TRACYL
An example of a cylindrical interpolation
Ø workpiece:
20mm
Ø miller
2mm
Depth of the groove:
1mm
Command:
TRACYL (20,1)
Example MPF
N005 TRAFOOF
N010 STOPRE
N015 SPOS=0
N020 TRACYL (20,1)
N025 G19
N030 TRANS Z...
N035 T01 D06
N040 DIAMON
N045 G0 X18 Z5
N050 M2=3 S2=5000
N055 G1 G94 Z-20 F500
N060 G2 Z-25 Y-5 CR=5
N065 G1 Y-10
N070 G2 Z-20 Y-15 CR=5
N075 G1 Z-5
N080 X22
N085 M2=5
N090 G18
N095 TRAFOOF
N100 TRANS Z...
N105 G0 G95 X100 Z50
N115 M30
Figure 3-10: Cylindrical interpolation
Comments:
1) The processing of the casing surface will be allocated to the Y-axis.
2) One programs in the ZY-plane.
3) The external diameter of the workpiece is defined in the TRACYL-command.
4) The feed axis is the X-axis.
5) Miller radius correction is possible using G41/G42.
Tool definition:
1) The machining tool is defined as an end mill cutter type 120.
2) L1=X1; L2=Z1; L3=0
3) Enter the miller radius when using G41 or G42
PD-2-01/03-840D
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C Operation/Maintenance
Machine specific options of the control 840D
3.11.5 Transmit
The co-ordinate transformation TRANSMIT allows milling of the rear-side of rotary
workpieces on lathes. The desired program is programmed in the XY-plane. The machine
movement occurs according to the real machine co-ordinate system through interpolation
of the CNC-axes X, Z and C.
Select:
TRANSMIT (1) for the first machining spindle
Select:
TRANSMIT (2) for the second machining spindle
De-select:
TRAFOOF
Circular interpolation with CR=...
Example for the main spindle:
Example MPF
N005 TRAFOOF
N010 SPOS=0
N015 G40
N020 DIAMOF
N025 TRANSMIT(1)
N030 G17
N035 TRANS Z...
N040 T02 D01
N045 M2=3 S2=4000
N050 G0 X60 Z2 (P0)
N055 G1 G94 G42 X20 Y0 F400 (P1)
N060 G1 Z-2 (Plunging)
N065 Y10 (P2)
N070 G3 X10 Y20 CR=10 (P3)
N075 G1 X-20 (P4)
N080 Y-10 (P5)
N085 G3 X-10 Y-20 CR=10 (P6)
N090 G1 X20 (P7)
N095 Y0 (P1)
N100 G1 Z10 (Lifting out)
N105 G0 G95 G40 X60 (P0)
N110 G0 X300 Z150 D0 (Toolchange point)
N115 TRAFOOF
N120 TRANS Z...
N125 M30
Fräser
Figure 3-11: Command TRANSMIT
Comments:
1) One programs in the XZ-plane (G17).
2) The feed axis is the Z-axis.
3) Miller radius correction is possible using G41/G42.
PD-2-01/03-840D
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3-22
C Operation/Maintenance
Machine specific options of the control 840D
Tool definition:
1) The machining tool is defined as end mill cutter type 120.
2) L1=Z1; L2=0; L3=X1
3) Enter the miller radius when using G41 or G42
Example for the sub-spindle:
Example MPF
N005 TRAFOOF
N010 SPOS[3]=0
N015 G40
N020 DIAMOF
N025 TRANSMIT(2)
N030 G17
N035 TRANS Z...
N040 T02 D01 M2=3 S2=4000
N045 G0 X60 Z-2 (P0)
N050 G1 G94 X20 Y0 F400 (P1)
N055 G1 Z2 (Plunging)
N060 Y20 (P2)
N065 X-10 (P3)
N070 G3 X-20 Y10 CR=10 (P4)
N075 G1 Y-20 (P5)
N080 X10 (P6)
N085 G3 X20 Y-10 CR=10 (P7)
N090 G1 Y0 (P1)
N095 G1 Z-10 (Lifting out)
N100 G0 G95 G40 X60 (P0)
N105 G0 X300 Z150 D0 (Toolchange point)
N110 TRAFOOF
N115 TRANS Z...
M120 M30
Miller
Figure 3-12: Command TRANSMIT
Comments:
1) One programs in the XZ-plane (G17).
2) The feed axis is the Z-axis; here feed in +Z.
3) Miller radius correction is possible using G41/G42
Tool definition:
1) The machining tool is defined as an end mill cutter type 120.
2) L1=Z1; L2=0; L3=X1
3) Enter the miller radius when using G41 or G42
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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C Operation/Maintenance
Machine specific options of the control 840D
3.12 The pick-off device unit
The pick-off device unit is programmed in time during the main machining period in
parallel in the 2nd. channel (CHAN2) triggered.
3.12.1 Gripping of a part out of the sub-spindle
The following program must be selected in the 2nd channel for this purpose:
%_N_GRIPPER_MPF
N0010 GETD(AX5)
N0020 CATCH_PART
N0025 G4 F0.5
N0030 M49
N0040 G1 G94 Q1=20 F4000
N0050 PART_OUT
N0060 M48
M17
;Axis Q1 in Channel 2 is activated
;Cycle for gripping the finished part
;Dwell time for the pick-off device to open
;Opening the chuck on the sub-spindle
;Moving the sub-spindle back so that the part is free
;Cycle for placing down the part
;Chuck on the sub-spindle
This program can only be started with the command „START(2)“ from the first channel:
An example:
%_N_Rotary part_MPF
N0010 GETD(AX5)
N0020
:
:
N0030 M49
N0040 Q1=-300
N0050 M48
N0060
:
N0100 START(2)
N0110 T16
N0120 G0 Z100 X0
N0130 M69
N0140 G1 G94 F1500 Z150
N0150...
N0160 WAITE(2)
;Axis Q1 in Channel 2 is activated
;Machining the part on the main spindle
;Opening the chuck on the sub-spindle
;Collection of the part with the sub-spindle
;Clamping the sub-spindle
;Cut-off
;Start the pick-off device program in Channel 2
;Select stop
;Move stop into position
;Release main spindle
;Issue the bar
;Further machining as required
;Wait until the pick-off device program in Channel 2
has finished
N0170 M30
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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C Operation/Maintenance
Machine specific options of the control 840D
3.12.2 Gripping of a part out of the main spindle
The gripping of a part out of the main spindle is only possible using a special gripping
shell type pick-off device. The following program must be selected in the 2nd channel for
this purpose:
%_N_GRIPPER_MPF
N0010 CATCH_PART
N0020 G4 F0.5
N0030 WAITM(1,1,2)
N0050 PART_OUT
M17
;Cycle for gripping the finished part
;Dwell time for the pick-off device to open
;Synchronisation on the 1st marker in channels 1+2
;Cycle for placing down the part
This program can only be started with the command “START(2)” from the first channel:
An example:
%_N_ Rotary part _MPF
N0010
:
:
; Machining the part
Finishing the part machining
N0100 Start(2)
Start the pick-off device program in Channel 2
N0105 G4 F0.2
Dwell time since otherwise the WAITM is not effective
N0110 WAITM(1,1,2)
Wait at Marker 1 in channels 1+2
N0120 G96 S3000 X0
Cut-off
N0130 G97
Switch off constant cutting speed
N0140 WAIT(2)
Wait at the end of Channel 2
The following points should be observed concerning 2-channel-machining:
F
1) THE MAIN PROGRAM IS TO BE SELECTED IN CHANNEL 1 (CHAN1), THE
PICK-OFF DEVICE PROGRAM IN CHANNEL 2 (CHAN2).
2) THE CYCLES CATCH_PART AND PART_OUT MUST ONLY BE EXECUTED IN
ND
ST
THE 2
CHANNEL OR IN MDI IN 1 CHANNEL, SINCE THE FEEDBACK
SYSTEM IN CHANNEL 1 FOR THE PARTS PICK-OFF DEVICE IS NOT ACTIVE.
THERE IS THEREFORE SOME DANGER OF EXPERIENCING A CRASH!
ST
3) THE Q-AXIS MUST NOT BE USED IN 1
.CHANNEL BETWEEN THE
COMMANDS “START(2)” AND “WAIT(2)”.
ND
4) IF A CYCLE STOP OR RESET IS TRIGGERED FOR THE 2 CHANNEL DURING
ND
THE PROGRAM FLOW, THEN THE 2
CHANNEL CANNOT BE STARTED
AGAIN AFTERWARDS. THE GRABBER ARM MUST MOVED BACK INTO ITS
HOME POSITION IN MDI USING THE APPROPRIATE M-FUNCTIONS OR THE
CYCLE “PART_OUT“.
5) THE PROGRAM BLOCK TRAVERSE: ONLY EXECUTE THE PROGRAM BLOCK
TRAVERSE UP TO THE BLOCK IN WHICH “START(2)” IS PROGRAMMED,
ND
OTHERWISE THE 2 CHANNEL WILL NOT BE STARTED.
6) WAIT(2) SHOULD NOT BE PROGRAMMED IMMEDIATELY AFTER START(2),
SINCE THIS COMMAND WILL NOT BE ACTIVE OTHERWISE (SEE ALSO
“PROGRAMMING MANUAL” FROM SIEMENS). THERE MUST BE AT LEAST
PROGRAM BLOCK (E.G. G4 F0,2) IN BETWEEN.
PD-2-01/03-840D
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C Operation/Maintenance
Machine specific options of the control 840D
3.12.3 Cycles in clear text
%_N_CATCH_PART_SPF
N0010 M83 M84
N0015 M82
N0020 M93
M17
;Open pick-off device, move arm forwards
;Swing arm in
;Close pick-off device
%_N_PART_OUT_SPF
N0010 M92
N0015 M94
N0020 M81
N0025 M83
N0030 G4 F1
N0035 M91
N0040 M17
;Swing arm back
;Move arm in
;Move slide out
;Open pick-off device
;Dwell time
Move slide in
3.12.4 A list of the M-functions
M81/M91
M82/M92
M83/M93
M84/M94
PD-2-01/03-840D
Discharge rail forwards/backwards
Swing in/swing out pick-off device arm
Open/close pick-off device
Pick-off device arm forwards/backwards
 SPINNER Werkzeugmaschinenfabrik GmbH
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Machine specific options of the control 840D
3.13 Measuring sensor
In the following you will find a short description of the function of the "Mida"- measuring
sensor with infrared transmission as work piece measuring sensor
3.13.1 Installation
The measuring head is fixed on a tool holder so it can be mounted to the slide or any
turret station. This turret station corresponds to the tool number of the measuring sensor.
When programming this tool number the infrared LEDs at the measuring head point to
the receiver module which is fixed in the working area. The green LED in the receiver
indicates a correct adjustment of the receiver but also the radiation with a light or heat
source. The yellow one indicates its power supply.
3.13.2 Activation
The measuring sensor is activated in a parts program using M58. At the same time the
monitoring of the infrared transmission is started. During the initiation procedure (1.5 sec.)
the read access as well as the feed of all axes are blocked in channel 1. The message
„Wait for initiation of measuring head“ is displayed. After that the measuring head is
operational for 2:15min (message: Measuring head operational). If the measuring sensor
is moved within this period of time the period restarts. A new initiation with M58 is only
carried out when the standby period had been run out before, or the monitoring had been
deactivated otherwise (e. g. with M59).
Starting the measuring head for test reasons is also possible by pressing the Start/Resetbutton on the Interface-Unit E48. In this case no message will be displayed.
3.13.3 Deactivation
The measuring head deactivates itself automatically after 2:15min. It can also be
deactivated using M59, Reset or the next T-command. All corresponding messages of the
measuring-head will then disappear except “Battery low“.
Switching the probe longer than 2:15min will generate an error message.
3.13.4 Adjustment
After mounting the measuring sensor there must be set up a tool correction using the
number of the tool station where the sensor is mounted. For that move the axes in
succession to a known machine position using the command MEAS (see programming
sample). Then enter the difference between the known position and the measured
position (variable $AA_MM[axis]) into the tool correction of this axis. This has to be done
respectively for all considered axes if one of the following parameters has changed:
- Feed rate during measuring
- Length of touch-probe
- Used angle piece
- Mounting position of the crash-part
- Measuring direction
If necessary set up several cutting edges.
PD-2-01/03-840D
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3-27
C Operation/Maintenance
Machine specific options of the control 840D
Programming sample
N10 M58
N20 G94
N30 MEAS=1 G1 F100 Z0
N40 STOPRE
N50 IF $AC_MEA[1] GOTO F
WEITER
N60 SCHLEIFE
N70
MSG(“SENSOR
DID
NOT
SWITCH“)
M80 G4 F1
N90 STOPRE
N100 GOTOB SCHLEIFE
N110 WEITER
N120 R0=$AA_MM[Z1]
N120 R1=$AA_MW[Z1]
N70 G0 Z100
N80 M59
; Switching on the measuring head
; Switching to linear feeding
; Measuring sentence regarding Siemens
operators manual
; Stop reading before evaluation of the
measuring outcome
; Verification if the measuring sensor
switched
; Start of the infinite loop
; Message
; Waiting
; Stop reading
; Back to the infinite loop
; Continuation in this line when sensor
switched
; Entering measuring value into R0 (machine
coordinate system)
; Entering measuring value considering the
tool correction of the measuring sensor into
R1 (work piece coordinate system)
; Moving the measuring sensor away from
the work piece
; Switching off the monitoring of the
measuring sensor
3.13.5 Feedrate for measuring
1. With a feed rate up to 600mm/min there can be measured positions with a
accuracy in a range of 1 µm. If the turret is indexed between 2 measurements we
cannot warranty this accuracy.
2. The feed rate for measuring must be in a range within the axis can be stopped
after having measured, without being damaged. Maximum speed around
3000mm/min.
3. Measure always with the same feed rate you applied when setting up the tool
correction for the measuring sensor.
PROGRAMME ALWAYS M58 AT THE HEAD OF A MEASURING
PROCEDURE TO MAKE SURE THAT THE MEASURING HEAD IS STILL
ACTIVE AT THE MEASURING-POINT. WHEN THE STANDBY TIME RUNS
OUT DURING A MEASURING SENTENCE THIS WILL LEAD TO AN
INCORRECT MEASURING OUTCOME. IN THIS CASE THE MACHINE
STOPS, AN ALARM MESSAGE IS DISPLAYED AND THE MEASURING
MUST BE REPEATED.
IN SPITE OF THE CURRENT MESSAGE “MEASURING HEAD READY“
RESPECTIVELY “MEASURING HEAD SWITCHED“ A MOVEMENT OF THE
MEASURING HEAD WILL ONLY BE STOPPED BY A MEAS SENTENCE.
IN ALL OTHER CASES THE MEASURING SENSOR CAN BE
DESTROYED.
THE OPERATOR/PROGRAMMER HIMSELF MUST AVOID THE
COLLISION OF THE MEASURING SENSOR WITH THE WALLS OF THE
WORKING AREA, THE SPINDLE OR THE WORK PIECE.
PD-2-01/03-840D
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Machine specific options of the control 840D
3.13.6 Error messages
700500
Cause
Reaction
Solution
700532
Cause
Reaction
Solution
Note
Error with measurement device
The transmission between the measuring head and the receiver
could not be established or has been prematurely interrupted
(obstacle in the communication link, transmitter and receiver are not
correctly aligned, the battery is too low, the measuring head is not
installed, the standby time has run out during the current measuring
sentence).
Read lock and feed lock
RESET, remedy the cause, restart programme
Low battery measurement transmitter
Battery power too low, dirt on the transmitter or receiver respectively
both are not correctly aligned.
None
Replace the 9V battery of the measuring head or dismantle the head.
If the period between the measuring procedures is underneath 2min
15s, the measuring head remains constantly activated and the
lifespan of the battery is accordingly short.
3.13.7 State messages (display optional)
700533
Proceeding
Probe is touched
The machine control recognizes when the measuring head
monitoring is turned on that the work piece measuring sensor
switched.
700534
Proceeding
Measuring device ready and waiting
The measuring sensor monitoring is turned on and the infrared
transmission is active
700535
Proceeding
Wait, initialising measuring-device...
The infrared transmission is restarted with M58. During the initiation
(1.5s) the read access as well as the feed of all axes remain blocked
in channel 1.
700646
Proceeding
Measuring active
When the measuring sensor monitoring is turned on, a measuring
sentence is carried out with MEAS or MEAW.
PD-2-01/03-840D
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Machine specific options of the control 840D
3.13.8 PLC-Option bits
DB100.DBX58.0
DB100.DBX58.1
DB100.DBX58.2
DB100.DBX58.3
DB100.DBX58.4
PD-2-01/03-840D
=1 with measuring sensor (standard on machines with measuring
sensor)
=0 measuring head cannot be activated using M58, no messages are
displayed, there will not be any reaction to errors.
=0 (standard)
=1 the messages 700535 “Wait, initialising measuring-device...“,
700034 “Measuring device ready and waiting", 700646 “Measuring
active“ and 700 533 „Probe is touched“ will not be displayed on the
screen so that they will not cover any from the CN-programme possibly
generated messages.
=0 (standard) sensor from MARPOSS
=1 reserved for other manufacturers
=0 (standard)
=1 no feed lock in channel 2
=0 (standard) monitoring is turned off with a T-command
=1 monitoring does not switch off in the event of T-changing
 SPINNER Werkzeugmaschinenfabrik GmbH
3-30
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Machine specific options of the control 840D
3.14 UNIMAG-interface description
3.14.1 Structure NC-parts program
The UNIMAG-interface is a universal feed-interface over which feed units or magazines
from the majority of manufacturers can be driven. The following syntax must be observed
in order to obtain a smooth NC programming sequence:
%_N_UNIMAG_MPF
N0001 STOPRE
N0005 M68 (M54)
N0010 IF $A_OUT[8]= =FALSE GOTOF MARKE1
N0011 BAR START
MARKE1:
N0015 Begin machining program
N0020
:
:
N0190
N0200 Finish machining program
N0210 G0 X... Z...
N0220 G1 G94 F1000 Z...
N0230 M69
N0235 (M54)
N0240 G1 G94 F500 Z...
N0250 STOPRE
N0260 IF $A_OUT[8]= =FALSE GOTOF END
N0270 G0 G95 X... Z...
END:
N0280 M30
%_N_BAR BEGIN_SPF
N0005 Machining the raw bar
:
:
N0080 $A_OUT[8]=FALSE
N0090 M17
PD-2-01/03-840D
(Clamp, optional: M54 = move
permanently)
(Call-up the bar start program)
(Position the stop some distance
from the bar)
(Safety feature in case a part is
not cut-off)
(Release and move)
(optional
M54
as
an
acknowledgement function)
(Issue the bar)
(Pre-read stop)
(Detection of the end of the bar)
(Move stop away)
(End of program)
(e.g. face turning)
(Reset bar end-variable)
(Return back into the
program)
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main
3-31
C Operation/Maintenance
F
Machine specific options of the control 840D
$A_OUT[8]:
-$A_OUT[8] IS SET FROM THE FEED
-BAR END REACHED, $A_OUT[8]=TRUE
- BAR END NOT REACHED, $A_OUT[8] REMAINS ZERO
-$A_OUT[8] IS RESET IN THE NC-PROGRAM, $A_OUT[8]=FALSE
In the case of magazines which have an automatic bar change one should ensure that
the collet is opened at the end of the program when the end of the bar is reached.
The command M54 „move“ is only necessary for hydro-static feeders with non-gripping
moving heads (e.g. SAMECA-Monosam). The „normal“ moving command during the
period that the collet is open is issued automatically with the M-function M69 and
cancelled with M68. M54 can also, however, be used as pure move/acknowledgement
function by setting options bits, that is the move command will only be issued with M54
and the read release for the next NC-block will be locked out until the M-function from the
bar feed has been acknowledged.
When feeding out the bar the stop should first of all be positioned at a safe distance from
the bar and then moved axially in the direction of the bar, to ensure that the bar is pushed
back if the finished part was not cut off.
One should basically observe the program structure given above. Other programming
sequences do exist, however, (e.g. issue the bar at the beginning of the program) while
fulfilling the general conditions which apply (see programming example).
Single or series machining can be selected with the
key on the machine control
console. In the case of single part machining (LED OFF) the program stops after M30
while in the case of series part machining (LED ON) an NC start is executed automatically
after M30 and the program will run endlessly.
3.14.2 Signal description for the interface
• From the feed device to the lathe
No fault existing:
This signal is “high” for as long as there is no fault on the bar feed. If a fault is
reported (signal is “low”) then the lathe shifts over to the Emergency Stop
condition.
Material in place:
This signal is generally “high”. The signal will be “low” the end of the bar is
reached .
Feed-in position reached:
This signal is given out by magazines with automatic bar change. If a new bar
is pushed into the machine when a bar change occurs then the signal must be
“high” on reaching the feed-in position.
Feed is in motion:
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Machine specific options of the control 840D
This signal is “high”, when the slide is in motion. If the M-function M53 is
programmed in the lathe, the read release will be locked out while this signal
is “high”.
Max. slider position reached / optimisation of the remaining piece:
This signal is “high” as soon as the slider has reached its maximum position in
the lathe. An analysis of the optimisation of the remaining piece is not
available at this time.
Emergency-Stop:
The Emergency-Stop is executed on two channels at once. If the contacts are
opened, the Emergency-Stop on the lathe will be triggered and all drives are
stopped.
Identification of the dummy plug:
The dummy plug which is supplied with the machine must be inserted if the
lathe is going to be run without feed.
The last bar in the machining operation
This signal is “high” when the last bar in a magazine has been laid into the
feed-in channel.
Spindle release
This signal is “high” when the feed unit is ready and the lathe can begin the
machining operation.
The signals “No fault reported”, “Material in place”, “Emergency-Stop” and “Insertion
position reached” (only with magazines) must be supplied by the feed unit. All other
signal can be supplied by the feed unit but are not necessary for operation of the lathe.
• Signals going from the lathe to the feed unit:
Permission signal:
This signal is “high” when the safety door is locked.
Supply mode on:
This signal is “high” when there is no a Emergency-Stop condition existing on
the lathe.
Move axis:
This signal is “high” when the feed unit can move on its axis.
Start loading cycle:
This signal is “high” for ca. 2 seconds when a new bar should be loaded (only
in the case of magazines with automatic bar changing).
The collet is closed:
This signal is “high” when the collet is closed.
PD-2-01/03-840D
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Machine specific options of the control 840D
The machine also supplies 24V DC and 3-phase 400V AC. One is referred to
the electrical circuit diagram for the pin allocation.
Plug connector:
Supplier:
Harting Elektronik GmbH
Marienwerder Str. 3
32339 Espelkamp
On the lathe:
Base housing design h=56
Order-no.: 09300241270
Bush insert
Order-no.: 09330242701
On the feed unit:
Plug housing
Order-no.: 09300241520
Plug insert
Order-no.: 09330242601
3.14.3 Option bits
DBX100.0 = 1
DBX100.1 = 1
DBX100.2 = 1
DBX100.3 = 1
DBX100.4 = 1
DBX100.5 = 1
DBX100.6 = 1
DBX100.7 = 1
PD-2-01/03-840D
UNIMAG-interface active
This bit must be set to 1 for the PLC-block for the interface to be
processed.
Bar feed without automatic bar change
This bit must equal 1 for feed units while it must be 0 for magazines with
a bar change
Generally move when the spindle is running
The output will be move “high” if this bit is set to 1 as soon as the spindle
turns (should be 1, for example, for hydro-static bar feeds).
M54 release “Axial movement”
The output will be move “high” when M54 is programmed. M54 will only
be reset by an Emergency Stop, a fault on the feed unit, failing to be in
the operating mode AUTO, when the door is open and Reset. M54 will
also be suppressed for as long as the bar end is waiting.
Without shuttling of the magazines
This bit should be set to 1 if there be shuttling of the spindles when there
is automatic insertion of a new bar by the magazine.
Without a renewed program start after the end of the bar has been
reached (must always be 1 ). This bit it only for special purpose machines
and must be always be set to 1!
General movement in the operating mode “AUTOMATIC”
This bit should only be set in exceptional cases.
M54 “Move” also further when the bar end has been reached (reset by
M68)
This bit must be 1 when, for example, the bar is fed out at the beginning
of the program and the machining of the part must be completed when
the bar end appears. An appropriate length of remaining bar must be
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DBX101.0 = 1
DBX101.1 = 1
DBX101.2 = 1
DBX101.3 = 1:
DBX101.4 = 1:
DBX101.5 = 1
BDX101.6 = 1
Machine specific options of the control 840D
present for magazines.
With detection M53 Supply unit in motion
If M53 is programmed and the signal Supply unit in motion is“high”, then
the read in release is locked out until the supply movement has been
completed.
UNIMAG is valid for Spindle A
The bit is only relevant for machines from the product range TM.
UNIMAG is valid for Spindle B
The bit is only relevant for machines from the product range TM.
Automatic NC-Start also when the spindle is released.
A condition for an automatic NC-start during series part production is an
opened spindle at the end of the program (M30). If this bit is set to 1 then
this condition does not have to be met (e. g. for Autoturn programs).
Appropriate NC-programming must ensure that the collet is open for a
change of bar by a magazine.
Without Emergency-Stop for a fault UNIMAG
An Emergency-Stop is normally triggered if the bar feed reports a fault.
This is not the case when this bit = 1.
With a spindle lock-out from the feed unit
It is possible to get the feed unit to lock out or free up the spindle.
With M54 as an axial movement/acknowledgement function
The command “Move” is only given out with M54 and the read in release
for the NC-program block is locked out until the feed unit acknowledges
the M-function.
3.14.3.1 Setting the option bits:
1.
2.
3.
4.
5.
Press the softkey “Commissioning”.
Enter the keyword “SUNRISE”.
Press the softkey “PLC”.
Enter “DB100.DBB100” in the operand and “DB100.DBB101” one line below
Ensure that “B” shows under format (8 bits are shown on the right under the
operand)
6. Press the softkey “Change”.
7. Enter the appropriate values for your bar feedrate under DB100.DBB100 and
DB100.DBB101 (see following table). Finish the data inputting by pressing the
yellow Enter key.
8. Press the softkey “Accept”. Then switch the machine on and then off again.
Feed unit type
SAMECA - Monosam
SAMECA - Quicksam
LNS - Hydrobar
DBB100
00111111
00111111
00111111
DBB101
00001000
00001000
00001000
SAMECA - Multisam
FMB - Turbo
LNS - Sprint
10101001
10101001
10101001
00001000
00001000
00001000
PD-2-01/03-840D
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Machine specific options of the control 840D
3.14.4 A programming example
All programs shown here are examples. We do not give any guarantees for their
correctness or that they will run properly.
In the following programming example a bar is used with í 30 mm from which parts with a
length of 20 mm are cut off.
Measured tools: Parting tool, a right hand cutter T1 D1
left hand cutter T1 D2
Stop T2 D1
Example 1:
- for a magazine or feed unit with a remaining piece length of 0, that is no more parts will
be machined once the end of the bar has been reached
- issuing of the bar at the end of the program
- in the bar start program we are assuming that the new bar has been laid in the spindle
until its end is just behind the spindle nose. The new bar is let out and cut off to a
dimension of Z0.
The bar start program:
%_N_BAR START_SPF
N0005 G0 X200 Z200 D0
N0010 T2 D1
N0015 G0 X0 Z10
N0020 G1 G94 F1000 Z-20
N0025 M69
N0030 G1 G94 F500 Z1.0
N0035 M68
N0040 G0 X200 Z200 D0
N0045 T1 D2
N0050 G0 X32 Z0.0 M4 S3000
N0055 G1 G95 F0.05 X-0.4
N0060 G1 F1.0 X32
N0065 G0 X200 Z200 D0 M5
N0070 M17
Tool change position)
(Swing in stop)
(Position the stop at some distance from the bar)
(Pick up bar)
(Open and collet and move axially)
(Give out bar)
(Close collet)
(Tool change position)
(Parting tool, left cutter)
(Position parting tool)
(Cut off)
(Move upwards again)
(Tool change position)
Machining program:
%_N_UNIMAG_MPF
N0005 G54
N0010 M68
N0011 IF $A_OUT[8]= =FALSE
GOTOF MARKE1
N0015 BAR START
MARKE1:
N0020 G0 X200 Z200 D0
PD-2-01/03-840D
(Activate workpiece co-ordinate system)
(Close collet)
(Bar start program)
(Tool change position)
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Machine specific options of the control 840D
N0025 T1 D1
N0030 G0 X32 Z-20 M4 S3000
N0035 G1 G95 F0.05 X-0.4
N0040 G1 F1.0 X32
N0045 G0 X200 Z200 D0 M5
N0050 T2 D1
N0055 G0 X0 Z10
N0060 G1 G94 F1000 Z-20
N0065 M69
N0070 G1 G94 F500 Z0.3
N0075 STOPRE
N0080 IF $A_OUT[8]= =FALSE
GOTOF END
N0090 G0 X150 Z150 D0
END:
N0095 M30
(Parting tool, right cutter)
(Position parting tool)
(Cut off)
(Move parting tool up again)
(Tool change position)
(Stop)
(Position the stop some distance from the bar)
(Pick up bar)
(Open collet and move)
(Give out bar)
(Pre-read stop)
(Identification concerning end of bar)
(Move the stop away)
(End of the program)
Example 2:
- for a magazine or feed unit with a remaining piece length of 0, that is no more parts will
be machined once the end of the bar has been reached
- issuing of the bar at the end of the program
- in the bar start program we are assuming that the new bar has been laid in the spindle
until its end is just behind the spindle nose. The new bar is let out and cut off to a
dimension of Z-20.
The bar start program:
%_N_ BAR START _SPF
N0005 G0 X200 Z200 D0
N0010 T2 D1
N0015 G0 X0 Z10
N0020 G1 G94 F1000 Z-20
N0025 M69
N0030 G1 G94 F500 Z-19
N0035 M68
N0040 G0 X200 Z200 D0
N0045 T1 D2
N0050 G0 X32 Z-20 M4 S3000
N0055 G1 G95 F0.05 X-0.4
N0060 G1 F1.0 X32
N0065 G0 X200 Z200 D0 M5
N0070 M17
Machining program:
%_N_UNIMAG_MPF
N0005 G54
N0010 IF $A_OUT[8]= =FALSE
GOTOF MARKE1
N0011 STANGENANFANG
PD-2-01/03-840D
(Tool change position)
(Swing in stop)
(Position the stop at some distance from the bar)
(Pick up bar)
(Open and collet and move)
(Give out bar)
(Close collet)
(Tool change position)
(Parting tool, left cutter)
(Position parting tool)
(Position parting tool)
(Move upwards again)
(Tool change position)
(Activate workpiece co-ordinate system)
(Bar start program)
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Machine specific options of the control 840D
MARKE1:
N0015 G0 X200 Z200 D0
N0020 T2 D1
N0025 G0 X0 Z10
N0030 G1 G94 F1000 Z-20
N0035 M69
N0040 G1 G94 F500 Z0.3
N0045 STOPRE
N0046 IF $A_OU[8]= =FALSE
GOTOF MARKE2
N0050 G0 X150 Z150
N0055 M30
MARKE2:
N0060 M68
N0065 G0 X200 Z200 D0
N0070 T1 D1
N0075 G0 X32 Z-20 M4 S3000
N0080 G1 G95 F0.05 X-0.4
N0085 G1 F1.0 X32
N0090 G0 X200 Z200 D0 M5
N0095 M30
(Tool change position)
(Stop)
(Position the stop some distance from the bar)
(Pick up bar)
(Open and collet and move)
(Give out bar)
(Pre-read stop)
(Move the stop away)
(End of the program at the end of the bar)
(Close the collet)
(Tool change position)
(Parting tool, right cutter)
(Position parting tool)
(Cut off)
(Move parting tool up again)
(Tool change position)
(End of the program)
Example 3:
- for a magazine infeedable remaining bar ends which means that there still enough bar
material left to machine one more part.
- issuing of the bar at the end of the program
- no bar start program since the magazine moves in the new bar to an exact dimension
(Z-22) and the new bar head is sufficiently level.
Machining program:
%_N_UNIMAG_MPF
N0005 G54
N0010 G0 X200 Z200 D0
N0015 T2 D1
N0020 G0 X0 Z10
N0025 G1 G94 F1000 Z-20
N0030 M69 M54
N0035 G1 G94 F500 Z0.3
N0040 M68
N0045 G0 X200 Z200 D0
N0050 T1 D1
N0055 G0 X32 Z-20 M4 S3000
N0060 G1 G95 F0.05 X-0.4
N0065 G1 F1.0 X32
N0070 G0 X200 Z200 D0 M5
N0075 STPORE
PD-2-01/03-840D
(Activate workpiece co-ordinate system)
(Tool change position)
(Stop)
(Position the stop some distance from the bar)
(Pick up bar)
(Open collet and move)
(Give out bar)
(Close collet)
(Tool change position)
(Parting tool, right cutter)
(Position parting tool)
(Cut off)
(Move parting tool up again)
(Tool change position)
(Pre-read stop)
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Machine specific options of the control 840D
N0080 IF $A_OUT[8]= =FALSE
GOTOF END
N0081 M69
N0085 G4 X1.0
END:
N0090 M30
(Release for bar change)
(Dwell time)
(End of the program)
Comment:
The M54 programmed here lengthens the move command including going beyond the bar
end up to M68. The length of the remaining piece of bar must be adequate to allow the
last piece to be machined.
Example 4:
- for a magazine which positions the bar itself
- issuing of the bar at the end of the program
- no bar start program since the magazine moves in the new bar to an exact dimension
(Z0.3) and the new bar head is sufficiently level.
Machining program:
%_N_UNIMAG_MPF
N0001 M68
N0005 G54
N0010 G0 X200 Z200 D0
N0020 T1 D1
N0035 G0 X32 Z-20 M4 S3000
N0040 G1 G95 F0.05 X-0.4
N0055 G1 F1.0 X32
N0060 G0 X200 Z200 D0 M5
N0070 M69
N0075 G4 F0.2
N0080 M54
N0085 STPORE
N0090 IF $A_OUT[8]= =FALSE
GOTOF END
N0095 G4 X1.0
N0096 $A_OUT[8]=0
END:
N0100 M30
PD-2-01/03-840D
(Close collet)
(Activate workpiece co-ordinate system)
(Tool change position)
(Parting tool, right cutter)
(Position parting tool)
(Cut off)
(Move parting tool up again)
(Tool change position)
(Open collet)
(Move axially and wait for acknowledgement)
(Pre-read stop)
(Dwell time)
(End of the program)
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Machine specific options of the control 840D
3.14.4.1 Time diagram for the bar loading magazine
• Operational sequence in supply mode
Move axis onward
A0
1
0
A2
1
0
Move axially
max
200ms
Magazine deletes signal E4 if it stops
E4
1
0
E1
1
0
Axis in motion
optional
No malfunction
• With loading cycle
Move axis onward
A0
1
0
End of bar change
Move axially
A2
E4
1
0
max
200ms
1
0
optional
Axis in motion
E0
Bar end
1
0
ca. 2 sec
A3
1
0
Load cylcle start
A
E2
1
0
B
C
Feed-in position reached
ca. 50 ms
A: Depending on the parts program
B: Bar change Part 1: Exchange to place a new bar in the guide channel
C: Bar change Part 2: Move into the spindle
Total bar change sequence = B + C
Figure 3-13: Time diagram for the bar loading magazine
PD-2-01/03-840D
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Machine specific options of the control 840D
3.15 List of M-functions
M-function
Meaning
0
Programmed stop (unconditional), waiting for a new NC-start
1
Programmed stop (conditional), waiting for a new NC-start
2
End of program
3
Master spindle rotation clockwise, speed indication with S-word
4
Master spindle rotation counter clockwise, speed indication with Sword
Master spindle stop
5
6
7
Coolant 1 ON
8
Coolant 2 ON (option)
9
Coolant 3 ON (option)
10
Chip conveyor ON (option)
11
Chip conveyor OFF (option)
12
13
Turret rotation clockwise
14
Turret rotation counter clockwise
15
Tailstock sleeve forward
16
Tailstock sleeve back
17
And of subprogram
18
19
20
Clamping master spindle with status message
21
Releasing master spindle, after M20, without status message
22
Main coolant pump OFF
23
24
25
26
27
Coolant 1 OFF
28
Coolant 2 OFF
29
Coolant 3 OFF
30
End of program end back to the beginning of the program
31
32
33
34
35
36
37
PD-2-01/03-840D
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Machine specific options of the control 840D
38
39
40
41
42
43
44
45
46
47
Clamping subspindle with status message chuck EMPTY (option)
48
Clamping subspindle (also when spindle is running)
49
Releasing subspindle (also when the spindle is running)
50
Mechanical workpiece counter +1 (option)
51
Customer specific function
52
Customer specific function
53
Query: Feed being moved UNIMAG
54
Push command UNIMAG
55
Sliding door of the gantry loader OPEN
56
57
58
Workpiece measuring sensor ON (option)
59
Workpiece measuring sensor OFF(option)
60
61
Unselecting tool fracture monitor
62
Selecting tool fracture monitor
63
Tool fracture monitor ON (option)v
64
Tool fracture monitor OFF (option)
65
Sliding door of the gantry loader CLOSED
66
67
Clamping main spindle with status message chuck EMPTY (option)
68
Clamping main spindle (also when the spindle is running)
69
Releasing main spindle (also when the spindle is running))
70
Reserved - SIEMENS
71
72
Electric connection 2 ON (option)
73
Electric connection 2 AUS (option)
74
75
Electric connection 3 ON (option)
76
Electric connection 3 OFF (option)
77
Pneumatic connection 1 ON (option)
78
Pneumatic connection 2 ON (option)
PD-2-01/03-840D
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Machine specific options of the control 840D
79
Pneumatic connection 3 ON (Option)
80
Pneumatic connection 4 ON (Option)
81
Part gripper: Discharge rail forward
82
Part gripper: Gripper arm swing in
83
Part gripper: Gripper open
84
Part gripper: Gripper arm forward
85
Electric connection 1 ON
86
Electric connection 1 OFF
87
Pneumatic connection 1 OFF (Option)
88
Pneumatic connection 2 OFF (Option)
89
Pneumatic connection 3 OFF (Option)
90
Pneumatic connection 4 OFF (Option)
91
Part gripper: Discharge rail backward
92
Part gripper: Gripper arm swing out
93
Part gripper: Gripper close
94
Part gripper: Gripper arm backward
95
96
97
Machine is waiting for gantry loader
98
99=80
Customer specific auxiliary function (option)
99=81
Customer specific auxiliary function (option)
99=94
Customer specific auxiliary function (option)
99=95
Customer specific auxiliary function (option)
M2=3
Live tool rotation clockwise, speed indication with S2=...
M2=4
Live tool rotation counter clockwise, speed indication with S2=...
M2=5
Live tool stop
M3=3
Subspindle rotation clockwise, speed indication with S3=...
M3=4
Subspindle rotation counter clockwise, speed indication with S3=...
M3=5
Subspindle stop
PD-2-01/03-840D
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Machine specific options of the control 840D
3.16 Data transmission
The following chapter describes how to transfer parts programs between a PC and the
control system with Windows 95.
3.16.1 Data transmission cable
For the transmission of the data a standard 0-modem-cable can be used (for example 2x
9/25-pins double cable). Interface V.24 on Spinner machines.
Control system Siemens 840D:
• D-SUB 9 pins
• max. length of cable 30 m
• Reservation of the pins
Pin 1 DCD Carrier Detect
Pin 2 RxD Recieve Data
Pin 3 TxD Transmit Data
Pin 4 DTR Data Terminal Ready
Pin 5 1M Signal Ground
Pin 6 DSR Data Send Ready
Pin 7 RTS Request to Send
Pin 8 CTS Clear to Send
Pin 9 RI Ring Indicator
Examples for connections (7-lines-calbe):
Spinner-machine
9-DB-socket
2
3
4
5
6
7
8
9-DB-socket
3
2
6
5
4
8
7
PC
or.
Designation of signal
25-DB-socket
2
3
6
7
20
5
4
Data
Data
DTR - DSR
Signal mass
DSR - DTR
RTS - CTS
CTS - RTS
3.16.2 Installation of a data terminal
Before starting the data transmission, a data terminal has to be installed in which the
interface parameters are specified. This terminal is safed and can also be used for further
data transmission. The following describes how to specify the interface parameters:
1. Click with the left mouse button on „Start“ in your program „Windows“. Select
successively the options „Programs“, „Accessories“, „Hyperterminal“,
„HyperTerminal“.
2. Follow the instructions on the screen until you see the following window:
PD-2-01/03-840D
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Machine specific options of the control 840D
Figure 3-14: HyperTerminal: Specifying a new name
3. Enter a new name for a new connection (for example Siemens 840D). Select
also an Icon. Confirm with „OK“.
4. Select an interface in the opening window (for example COM1). Confirm with
„OK“.
Figure 3-15: HyperTerminal: Selection of an interface
5. Enter in the following window the connection parameters. Confirm with „OK“.
Baudrate:
Data bits:
Parity:
Stop bits:
Log:
19200
8
None
1
Hardware
Figure 3-16: HyperTerminal: Specifying the connection parameters
6. In the window „HyperTerminal“ select the option „Characteristics“ (in the menu
nd
„File“). Then select the register „Settings“ (the 2 card).
PD-2-01/03-840D
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Machine specific options of the control 840D
Figure 3-17: HyperTerminal: Specifying the settings
Enter the settings shown in Figure 3-17. Subsequently, click on „ASCIIconfiguration...“ and effect the following settings:
Figure 3-18: HyperTerminal: Specifying the settings
Shut the windows „ASCII-configuration“ and „Settings“ by clicking on „OK“.
7. Shut the window „HyperTerminal“.
This settings can always be changed in the corresponding terminal in the menu „File“
selecting the option „Characteristics“.
3.17 Transmission of data into the control system respectively
reading data from the control system SINUMERIK 810D/840D
3.17.1 Interface base settings in the CNC
Call up the control system´s base machine screen. Select in the horizontal soft-key bar
successively the options „Services“ and „Interface“.
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Machine specific options of the control 840D
Effect the following settings in the window which opens:
• Interface :
COM1
• Log:
RTS/CTS
• Baudrate:
19200
• Stop bits:
1
• Parity:
None
• Data bits:
8
• Arch.:
Punch tape with CR + LF
•
Confirm the settings with „OK“.
3.17.2 Safeing parts programs from the control system
To safe parts programs from the control system follow the instructions below:
1. Click with the left mouse button on „Start“ in your program „Windows“. Select
successively the options „Programs“, „Accessories“, „Hyperterminal“,
„HyperTerminal“.
2. Select the previously installed HyperTerminal (for example Siemens 840D) by a
double click. Introduce a floppy disk into the drive of your PC.
3. Select the option „Safeing Text“ in the menu „Transmission“ of your
HyperTerminal. Select the name of the drive where you introduced the disk and a
file name with the extension .txt (this extension enables you to edit the files with
the Windows-editor). Confirm with „Start“.
Figure 3-19: HyperTerminal: Safeing parts programs
4. Call up the control system´s base machine screen. Select in the horizontal softkey bar successively the options „Services“ and „Data out“. Position the cursor
with the arrow buttons on the directory „Parts programs“. Press the yellow
button
to display the entire directory structure. Position the cursor with the
arrow buttons on the parts program to safe.
5. Press the button V.24 to start the transmission. The transmission can be
observed on the screen of the PC.
6. End the safeing after the transmission. For this select the menu „Transmission“
of the HyperTerminal and the option „Safeing text“. Click on „End“. The program
HyperTerminal can also be closed.
3.17.3 Loading parts programs into the control system
To load parts programs into the control system follow the instructions below:
1. Click with the left mouse button on „Start“ in your program „Windows“. Select
successively the options „Programs“, „Accessories“, „Hyperterminal“,
„HyperTerminal“.
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Machine specific options of the control 840D
2. Select the previously installed HyperTerminal (for example Siemens 840D) by a
double click. Introduce the floppy disk which contains the parts program into the
drive of your PC.
3. Select the option „Transmit Text“ in the menu „Transmission“ of your
HyperTerminal. Open the Drop-Down-Window „Searching in:“. Select the drive
where you introduced the disk. Click on the parts program to load. Confirm with
„Open“.
Figure 3-20: HyperText: Loading parts programs
4. Call up the control system´s base machine screen. Select in the horizontal softkey bar successively the options „Services“ and „Data in“. Press the button V.24.
5. Select the option „Clipboard“ in the opening window. Confirm with „OK“.
6. Click with the left mouse button on „Open“ in the window „Transfer text file“(see
Figure 3-20) of the HyperTerminal (the window is still open).
7. Press the soft-key „stop“ of the current screen of the control system after the
transmission.
Now, you can copy the file out of the clipboard into the parts program memory.
3.17.4 Edit and print parts programs
To edit and print parts programs follow the instructions below:
1. Click with the left mouse button on „Start“ in your program „Windows“. Select
successively the options „Programs“, „Accessories“, „Editor“.
2. Select the option „Open“ in the menu „File“. Open the drop-down-window
„Searching in“. Select the drive where you introduced the floppy disk. Click on
the parts program which you want to edit then on „Open“. The parts program is
displayed on the screen and can be modified.
Figure 3-21: Modification of parts programs
3. To print the parts program select the option „Print“ in the menu „File“.
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Machine specific options of the control 840D
3.17.5 Galvanic separation of V24-interfaces
The above described transmission of data via V24 can damage the COM interface of the
MMC (concerning MMC 100-103) when using cables >15m. In this case we recommend
to use a galvanic interface for the protection. For this the module PSM-MERS232/RS232-P, article No. 13901 from Phoenix can be used. Note that the switch
„Device-Type“ in the module is on DCE (see Figure 3-22).
• Mount the Phoenix-Module quite close to the interface of the MMC.
• Connect the 24V power supply and the earth to the Phoenix-Module.
• Manufacture the cable according to the enclosed circuit diagram. Connect the
COM Port of the MMC with the module
• Connect the SUB-D Port B of the Phoenix-Module with the external PC using the
0-modem cable (see Figure 3-22).
DO NOT CONNECT THE MACHINE GROUNDING AND THE
GROUNDING OF THE EXTERNAL COMPUTER!
+24V
0V
8
9
5
4
7
3
6
2
1
SUB D
port B
DTE
with standard 0-modem cable to the PC
DCE
PHOENIX
PSM-ME-RS232/RS232-P
4
ge
br
8
9
5
we
gr
gn
gnge
GND RTS RxD TxD CTS
7
3
6
2
SUB-D port
1
To the COM Port MMC
Figure 3-22: Phoenix-Module PSM-ME-RS232/RS232-P
PD-2-01/03-840D
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Error diagnosis
Technical Product Documentation
Machine type:
Serial number:
Version:
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Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
4 Error diagnosis
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-1
C Operation/Maintenance
F
Error diagnosis
THE NUMBERS IN THE FOLLOWING INSTRUCTIONS REFER
TO BOOK C
OPERATION/MAINTENANCE, CHAPTER 3
MACHINE SPECIFIC OPTIONS OF THE CONTROL 840D.
FAMILIARIZE YOURSELF WITH THE MACHINE CONTROL
PANEL AND ITS BUTTONS SHOWN IN THE FIGURE BEFORE
YOU BEGIN WITH THE FOLLOWING INSTRUCTIONS.
4.1 Freeing the machine axes
No software limit switches may be active before referencing the linear machine axes X, Y
and Z. The software limit switches are set by the CNC-control system only after the axes
have reached the reference points. If the axes are moved manually or are moved too far
when referencing in this case, they will hit the hardware limit switch. In this case, all
machine functions are stopped and an alarm is sounded therefore damage to the
machine is avoided. The axes must be moved until they are free again. Carry out the
following steps to do this:
1. Press the green Start Cycle - NC-Start button (15) and hold it down during the
entire procedure.
2. Switch on the drives (17). The green LED above the button must light up.
3. Press the RESET button (12).
4. Press the JOG button (3) and select the axis (8) that is touching the hardware
limit switch.
5. Set the feed override (10) to 10%. Move the corresponding axis in the
appropriate direction to free it using the “+” or “-” buttons (18).
6. Release the green Start Cycle button (15).
7. Press the RESET button (12). The alarm messages are deleted.
Now the axes can be moved to their reference points.
4.2 Manual locking of the turret
When an emergency stop is triggered during the rotation of the turret the turret will remain
in an unlocked position so that the turret disc can be turned e. g. by hand. In this situation
the turret can no longer be set to its basic position by means of the normal switch on
routine of the CNC. It must be set again. Proceed as follows:
1.
2.
3.
4.
5.
Press the RESET (12) to delete all alarm messages.
Select the operating mode JOG (3).
Set the feed override (10) to 0%.
Index the turret again with the keys +T or -T.
All messages concerning the turret should disappear. If not switch off and on the
machine.
F
PD-2-01/03-840D
IF NECESSARY REPEAT THE STEPS. IN CASE OF ERRORS
CAUSED BY CRASH, THE TURRET MUST BE CHECKED BY A
SERVICE ENGENEER.
 SPINNER Werkzeugmaschinenfabrik GmbH
4-2
C Operation/Maintenance
Error diagnosis
4.3 Troubleshooting
When a failure arises first of all it is important to find out the reason of this failure.
Proceed as follows:
When?
While which operation?
Which failure?
Defining the failure
Remedy
Finding and getting rid of the
failure
1) When and how often? (frequency of failure)
2) While which operation?
3) Which failure arose?
1) When did the failure arise?
• Date and time?
• While running/while an operation? (How long did the running/operation last?)
• Did the failure arise while switching on the machine?
• Where there peaks in voltage, power failure or other failures in the power supply
main?
• How often did the failure arise:
- Once?
- Several times? (How often per hour/ per day / per month?)
2) While which operation did the failure arise?
• In which mode was the NC running when the failure arose? Typing-mode /
manual mode / automatic mode / referencing mode
• When in program running:
Where in the program?
Which number of program and line?
Which program?
While moving the axes?
While executing a M/S/T-code?
Failure specific to the program? Does a certain operation always trigger
the same failure? (Check if the failure happens again)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-3
C Operation/Maintenance
Error diagnosis
3) Which failure arose?
• Which alarm message has been displayed? (diagnosis screen)
- Number of alarm
- Text of alarm
• Which operation messages have been displayed? (diagnosis screen)
4) Other points to check
• Are there other sources of trouble near to the machine?
• Check mains voltage
• Are there damaged mechanical parts?
When you contact our after-sales service, please give us the following information:
Machine type
.......................................................................
Machine number
.......................................................................
Control type
.......................................................................
Description of failure as precise as possible (see above):
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
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..........................................................................................................................................
4.4 Alarm messages and operating messages
The numbers in parentheses refer to the machine control panal in book C
Operation/Maintenance, chapter 3 Machine specific options of the control 840D - Figure
3-3.
4.4.1 Basic information for error diagnosis
1) When an error message occurs, do not immediately press the RESET KEY. Note
whether an arrow is placed in front of the message. If an arrow is displayed, it
means that there are other messages.
For CNC-ISO first press the “Diagnose“ Softkey, then the “Messages“ or “Alarms
Softkey.
2) Note the complete alarm or message with number and text before looking in the
Spinner or Siemens manuals or before referring to the Spinner Service.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-4
C Operation/Maintenance
Error diagnosis
4.4.2 Alarm messages
700000
Process:
Solution:
Switch on the drive
The feed drives are not yet switched on and the pneumatic unit is not
under pressure.
Resolve all other existing errors. Press the button Drive ON (17) at the
machine control panel. As soon as the drives are on, the LED in the
drive button lights up to indicated this. Is the permission button
plugged in?
700001
Process:
Solution:
Emergency stop pressed
The Emergency stop button has been pressed.
Unlock the Emergency stop button(1) by rotating and pulling it, switch
on drives (17).
700002
Process:
Move command entered without permission
While the door was open, a move axis command was given manually
or from within the program without having pressed the permission
button first.
Switch on drives again (17) and press the permission button (see also
Book C Operation/Maintenance, Chapter 3 Machine specific options of
the control 840D - Figure 3-6 and Figure 3-7) or work with the door
closed.
Solution:
700003
Process:
Solution:
700004
Process:
Solution:
700005
Process:
Solution:
700006
Process:
Solution:
PD-2-01/03-840D
Compressed air is missing
The pneumatic pressure on the compressed air connection has fallen
below the required minimum pressure..
Check system pressure.
Circuit breaker triggered
A circuit breaker or a motor protection breaker has been triggered in
the electric cabinet.
Open the electric cabinet and reset the corresponding components
back to 1. If a circuit breaker or a motor protection breaker triggers
again, then consult an electrician.
Bar feeder emergency OFF
The bar feeder is in the emergency OFF state and has stopped the
machine.
See the Operating Manual of the bar feeder manufacturer..
Tailstock emergency limit switch
The Z axis has hit the hardware limit switch of the tailstock.
Move the Z axis away. To do this, press the Start cycle button (15) and
hold it down. Switch on the drive (see Message 700000). Then press
the RESET button and change to the JOG operating mode. The slide
can be released with the -Z button.
 SPINNER Werkzeugmaschinenfabrik GmbH
4-5
C Operation/Maintenance
700007
Process:
Solution:
700008
Process:
Solution:
700009
Process:
Solution:
700010
Process:
Solution:
Remark:
700010
Process:
Solution:
Remark:
700011
Process:
Solution:
700012
Process:
Solution:
PD-2-01/03-840D
Error diagnosis
Collision Z axis- Q axis! Release !
The Z axis and the Q axis have collided or the Z axis has hit the
hardware limit switch of the Q axis.
Release Z axis (see Solution for Alarm 700006).
The guideway lubricant pressure is not dropping
The oil in the lubricant pump is still under pressure after the end of the
pumping process.
Check the oil lines of the central lubrication system to see if they are
dirty
No pressure build-up for the slide bar lubrication
The required oil pressure was not reached in the lubrication system
while pumping.
Check to make sure that the oil lines do not leak. Start the pump
manually and check the motor or bleed the system.
Turret Parity / Over-temperature
1.
Over-temperature
or
temperature
sensor
defective
(DB80.DBX13.0=1).
2. Parity monitoring reacted (M97.1=1)
1. The Alarm and Emergency stop can be cleared with RESET (12),
once the cause is rectified. (Note: In functional condition:
DB80.DBX13.0=0).
2. Compare the current position with MB155 (in D-Format).
Only applicable with Sauter turret
Turret Parity / Over-temperature
1.
Over-temperature
or
temperature
sensor
defective
(DB80.DBX13.0=0).
2. Parity monitoring reacted (M96.4=1)
1. The Alarm and Emergency stop can be cleared with RESET (12),
once the cause is rectified. (Note: In functional condition
DB80.DBX13.0= 1).
2. Compare the current position with MB155 (in D-Format)..
Only applicable with Baruffaldi turret
Turret tool number too high
A tool station number has been entered that is greater than the
number of stations present on the turret.
Change the program.
Turret nominal position <> current position
After the turret is switched (MDA/AUTO mode), the programmed tool
and the indexed tool are not identical.
Use RESET (12) to clear the Emergency stop and Alarm. Switch the
turret to JOG mode (3) using T+ or T- to different stations. Check
MB155 (current position of the turret). MB155 (in D-Format) must
coincide with the selected station, otherwise the signal generator is
defective.
 SPINNER Werkzeugmaschinenfabrik GmbH
4-6
C Operation/Maintenance
Error diagnosis
700 013
Process:
Solution:
Bar feeder malfunction
There is a malfunction in the bar feeder unit.
See the Operating Manual of the bar feeder manufacturer.
700014
Process:
Main spindle clamping position monitor reacted
The clamping cylinder has moved during the turning operation and the
workpiece was crushed or thrown out of the chuck. Or: Option empty
stroke monitoring ⇒ The program was started without a workpiece and
the clamping cylinder has reached the Empty position.
Adjust the clamping pressure. Recalibrate the position switch. Turn the
key-operated switch to position 2, this deactivates the stroke
monitoring.
Solution:
700015
Process:
Solution:
Main spindle pressure monitoring reacted
The actual pressure in the clamping cylinder of the main spindle left
the permitted tolerance range while the spindle was running. The
spindle was stopped with the Emergency stop (1).
Check the adjustment of the pressure switch of the hydraulic system.
Correct it if necessary.
700016
Process:
Solution:
Sub-spindle clamping position monitor reacted
See Message700014
See Message700014
700017
Process:
Solution:
Sub-spindle pressure monitoring reacted
See Message700015
See Message700015
700018
Process:
Piece in main spindle not securely clamped
Solution:
Only in Option Empty monitoring ⇒ The program cannot be started
because the initiator Chuck empty has reacted.
Check whether the piece is correctly clamped. The initiator may need
to be recalibrated. To start the program without a piece, turn the keyoperated switch to position 2.
700019
Process:
Solution:
Piece in sub-spindle incorrectly clamped
See Message700018
See Message700018
700020
Process:
Solution:
Tailstock pressure monitoring reacted
See Message700015
See Message700015
700022
Process:
Solution:
Tool monitoring: Tool break!
Tool monitoring has detected a tool break.
Check the tool and replace if broken. Clear the Alarm with RESET
(12).
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-7
C Operation/Maintenance
700023
Process:
Solution:
700029
Process:
Solution:
700124
Process:
Solution:
PD-2-01/03-840D
Error diagnosis
Emergency stop from permission button
The permission button was pressed all the way down and triggered an
emergency stop.
Release the permission button. Clear the Alarm with RESET (12).
Check turret
Tool change could not be implemented within 10s due to an error (e.g.
Bit error from position sensor or no Strobe, Preindex or Lock signal,...)
Clear the Emergency stop with RESET (12). Switch the turret to JOG
mode (3) using T+ or T-. The Alarm can only be cleared once the turret
is locked. (Note: this Alarm may be caused by other messages which
must first be cleared.)
Pinole limit switch reached
The limit switch of the pinole has been reached. The safe clamping of
the workpiece can´t be ensured.
Position the tailstock in the way that by clamping the workpiece by
means of the pinole the limit switch can´t be reached. Check the
clamping of the tailstock and the workpiece. There must not be any
displacement by the pressure of the pinole.
 SPINNER Werkzeugmaschinenfabrik GmbH
4-8
C Operation/Maintenance
Error diagnosis
4.4.3 Operation messages
For error messages regarding referencing, refer to Book C Operation/Maintenance,
Chapter 1 Switch ON/OFF routine, where referencing is described in more detail.
700032
Process:
Move to reference point X
After the machine is switched on, the X axis must be referenced. To do
this, switch to the operating mode REF and use button +X to start
referencing. Avoid collisions! It may be necessary to move the axis to
another position beforehand using the JOG operating mode.
700033
Process:
Move to reference point Z
After the machine is switched on, the Z axis must be referenced. To do
this, switch to the operating mode REF and use button +Z to start
referencing. Avoid collisions! It may be necessary to move the axis to
another position beforehand using the JOG operating mode.
700034
Process:
Move to reference point Q
After the machine is switched on, the Q axis must be referenced. To
do this, switch to the operating mode REF and use button +Q to start
referencing.
700035
Process:
Close doors or press permission button
The safety door is not locked. The door must be locked either by
simply closing the door when the key-operated switch is in the vertical
position or by pressing the permission button when the key-operated
switch is in the horizontal position in order to be able to work with the
machine.
700036
Process:
Automatic only allowed in SBL
Automatic programs can only be processed in the single block when
the safety door is open.
700037
Process:
Door is open
The safety door is open.
700038
Process:
Top door is open
The top door in gantry loading machines is open.
700039
Process:
Left door is open
The left safety door is open.
700040
Process:
Right door is open
The right safety door is open.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-9
C Operation/Maintenance
Error diagnosis
700041
Process:
Switch on spindle
The spindle was switched off with the red Spindle Stop button (20).
Use the green Spindle Start button to switch the spindle back on again.
700044
Process:
Status message M20 is missing
The indexing lever of the main spindle has not engaged in the indexing
disc.
Remove covering hood above the spindle and check whether the
indexing lever is stiff or whether the lever is stuck on a tooth of the
index disc; if necessary, recalibrate the indexing lever.
Solution:
700045
Process:
Solution:
Status message M21 is missing
The main spindle indexing lever has not swung out of the indexing
disc.
Remove covering hood above the spindle and check whether the
indexing lever is stiff.
700048
Process:
Refill guideway oil
The oil level in the guideway oil reservoir is at a minimum
700050
Process:
Switch Feed on
The axis feed was stopped with the red Feed STOP button. Switch the
feed back on with the green Feed On button. The spindle must be
switched on beforehand (see Message 700041).
700058
Process:
Solution:
Status message M3=20 is missing
The sub-spindle indexing lever is not engaged.
Remove covering hood above the spindle and check whether the
indexing lever is stiff or whether the lever is stuck on a tooth of the
index disc; if necessary, recalibrate the indexing lever (see also
Message 700044).
700059
Process:
Solution:
Status message M3=21 is missing
The sub-spindle indexing lever has not swung out of the indexing disc.
Remove covering hood above the spindle and check whether the
indexing lever is stiff (see also Message 700045).
700060
Process:
Front main spindle clamping position not reached
The clamping cylinder was moved to the front clamping position in the
program with M68/M69 (dependent on rear clamping parameter), but
has not reached the corresponding position limit switch.
Check the clamping unit, recalibrate initiator if necessary.
Solution:
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-10
C Operation/Maintenance
700061
Process:
Solution:
Error diagnosis
Rear main spindle clamping position not reached
The clamping cylinder was moved to the rear clamping position in the
program with M68/M69 (dependent on rear clamping parameter S1),
but has not reached the corresponding position limit switch
Check the clamping unit, recalibrate initiator if necessary.
Solution:
Empty main spindle clamping position not reached
M67 was used to program an empty stroke of the clamping cylinder to
check that no workpiece is still present in the spindle.
Remove stuck workpiece or check initiator.
700063
Process:
Front main spindle clamping pressure not in nominal range
See Message 700060.
700132
Process:
Status message M81 is missing
The end position of the move programmed with M81 has not been
reached.
Put pneumatic cylinder in smooth operation mode, check the chokes
and silencers to see if they are plugged, check the hoses to see if they
are kinked. Check initiators (indicated with M81 in circuit diagram),
recalibrate if necessary. To do this, press the Emergency stop and
move the cylinder to both end positions in a depressurized state. The
initiator must light up at the end positions.
700062
Process:
Solution:
700133
Process:
Solution:
Status message M91 is missing
See Message 700132
See Message 700132
700134
Process:
Solution:
Status message M82 is missing
See Message 700132
See Message 700132
700135
Process:
Solution:
Status message M92 is missing
See Message 700132
See Message 700132
700136
Process:
Solution:
Status message M83 is missing
See Message 700132
See Message 700132
700137
Process:
Solution:
Status message M93 is missing
See Message 700132
See Message 700132
700138
Process:
Solution:
Status message M84 is missing
See Message 700132
See Message 700132
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-11
C Operation/Maintenance
Error diagnosis
700139
Process:
Solution:
Status message M94 is missing
See Message 700132
See Message 700132
700140
Process:
Solution:
Status message M15 is missing
See Message 700132
See Message 700132
700141
Process:
Solution:
Status message M16 is missing
See Message 700132
See Message 700132
700142
Process:
UNIMAG Load cycle step 1 active
The command Load cycle Start was given to the bar magazine at
program end by the lathe. The bar loader removes scrap parts and
places a new bar in the guide channel.
700143
Process:
UNIMAG Load cycle step 2 active
The bar loader has placed a new bar in the guide channel. After this
process, the input Material present is set to switch the spindle into
oscillation mode and the command Move is given.
700144
Process:
UNIMAG Load cycle step 3 active
The bar loader has positioned the bar in the spindle and the signal
Insert position reached is set. The machine should now start the
machining program automatically. If the start does not occur when
step 3 is active, check for errors in the lathe.
700145
Process:
The UNIMAG interface dummy plug is inserted
When a single part is selected, then you can work with the inserted
part.
700146
Process:
Load block: Feed is in motion (UNIMAG)
The message indicates that the bar feed is currently carrying out
insert or pulling movements or a bar change.
700147
Process:
End of bar
The Material present signal on the bar feed is at 0. A new bar must be
inserted.
700148
Process:
Last bar being machined
700150
Process:
UNIMAG: Insert position reached
Only with magazines: A new bar was inserted in the spindle and the
insert position has been reached.
PD-2-01/03-840D
Only with load magazine ⇒ the last bar is currently being machined.
Refill magazine.
 SPINNER Werkzeugmaschinenfabrik GmbH
4-12
C Operation/Maintenance
Error diagnosis
700232
Process:
Solution
Rear main spindle clamping pressure not in nominal range
See Message 700061
See Message 700061
700233
Process:
Clamp main spindle
The headstock spindle must be clamped before the program start.
Insert piece and clamp spindle.
700234
Process:
Front sub-spindle clamping position not reached
The clamping cylinder was moved to the rear clamping position in the
program with M48/M49 (dependent on rear clamping parameter S3),
but has not reached the corresponding position limit switch (Position
front = direction spindlenose).
Check clamping unit, recalibrate front initiators if necessary.
Solution:
700235
Process:
Solution:
Rear sub-spindle clamping position not reached
The clamping cylinder was moved to the rear clamping position in the
program with M48/M49 (dependent on rear clamping parameter S3),
but has not reached the corresponding position limit switch.
Check clamping unit, recalibrate front initiators if necessary
Solution:
Empty sub-spindle clamping position not reached
M47 was used to program an empty stroke of the clamping cylinder to
check that no workpiece is still present in the spindle
Remove stuck part or check initiator.
700237
Process:
Front sub-spindle clamping pressure not in nominal range
See Message 700234.
700238
Process:
Solution:
Rear sub-spindle clamping pressure not in nominal range
See Message 700235
See Message 700235
700239
Process:
Clamp sub-spindle
The headstock spindle must be clamped before program start. Insert
part and clamp spindle.
700240
Process:
Number of parts reached
The parts counter has reached the pre-selected number of parts. Enter
next number of parts.
700241
Check air initiators 1-4 (the error message only appears when the
corresponding equipment is available)
Both initiators that are assigned to an air connection have sent a high
signal to the control system at the same time triggering a load block.
This means that you can rule out that an initiator is defective or is
constantly being sprayed with swarf.
Check initiators, clean or replace if necessary.
700236
Process:
Process:
Solution:
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-13
C Operation/Maintenance
700242
Process:
700243
Process:
700244
Process:
700245
Process:
Error diagnosis
Check air initiators 5-8 (the error message only appears when the
corresponding equipment is available)
See Message 700241
Check tailstock initiators (the error message only appears when the
corresponding equipment is available)
See Message 700241
Check main spindle initiators (the error message only appears when
the corresponding equipment is available)
See Message 700241
Check sub-spindle initiators (the error message only appears when
the corresponding equipment is available)
See Message 700241
700248
Process:
Status message Automatic door open is missing
The automatic door moving pneumatic cylinder has not reached the
end position that should be reached when the door is open.
700249
Process:
Status message Automatic door closed is missing
The automatic door moving pneumatic cylinder has not reached the
end position that should be reached when the door is closed.
700250
Process:
Turret indexed
This message appears on the screen at the start of the indexing
process and disappears when the indexing bolt is reset.
(DB80.DBX14.0=1)
Open the door. Move the turret disk back and forth until the indexing
bolt is reset. If it is stuck, it must be released by mechanical
intervention.
Only applicable with Sauter turret
Solution:
Remark
700250
Process:
Solution:
Remark
700251
Process:
PD-2-01/03-840D
Turret indexed
This message appears on the screen at the start of the indexing
process and disappears when the indexing bolt is reset.
Press the Emergency stop button to release the feed and load block.
Move the turret disc back and forth until the indexing bolt is reset. If it
is stuck, it must be released by mechanical intervention.
Only applicable with Baruffaldi turret
Only switch turret with door closed
The tool turret may only be switched with the door closed or door open
with the permission button.
 SPINNER Werkzeugmaschinenfabrik GmbH
4-14
C Operation/Maintenance
700252
Process:
Solution:
Remark
700252
Process:
Solution:
Remark
Error diagnosis
Turret release is missing
1. This message appears as the only turret message immediately after
the machine is switched on and it disappears once the turret start-up
routine is terminated.
2. The message may be produced as a follow-up message.
1. Start drives (17) ⇒ Door closed , so that the turret implements the
start-up routine.
2. Clear other Alarms /Messages from the turret first.
Only applicable with Sauter turret
Turret release is missing
This message appears at the start of the tool change, it must
disappear when the tool change is complete and the turret locked.
Try to switch the turret in JOG mode using T+ or T-. Note: DB.80X13.3
goes to 1, when the tool change is correctly completed.
Only applicable with Baruffaldi turret
Remark
Turret dummy plug is inserted
The dummy plug is plugged in (DB80.DBX12.5=1).
After removing the dummy plug, the machine must be switched off and
back on again.
Only applicable with Sauter turret
700256
Process:
Status message M77 is missing
See Message 700132
700257
Process:
Status message M87 is missing
See Message 700132
700258
Process:
Status message M78 is missing
See Message 700132
700259
Process:
Status message M88 is missing
See Message 700132
700260
Process:
Status message M79 is missing
See Message 700132
700261
Process:
Status message M89 is missing
See Message 700132
700262
Process:
Status message M80 is missing
See Message 700132
700263
Process:
Status message M90 is missing
See Message 700132
700253
Process:
Solution:
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-15
C Operation/Maintenance
Error diagnosis
700339
Process:
Solution:
Tool monitoring : tool wear !
Tool break monitoring has detected tool wear.
Change tool. Is the tolerance window of the curve recorded by the
device correctly set?
700354
Process:
Solution:
Tool break monitoring: M63 programmed without M62
Tool break monitoring is not yet active.
In the NC program, program M62 before M63 (program active).
700500
Process:
Solution:
Error during measurement
Transmission between measuring head and receiver could not be
made or was interrupted (problem in the transmission route, sender
and receiver not aligned, empty battery, measuring head not attached,
standby time elapsed in active measurement set). The load and feed
blocks are triggered.
Press RESET (12), rectify the cause, restart the program.
700501
Process:
Solution:
Circuit breaker triggered in PL400 cabinet
See Message 700004
See Message 700004
700502
Process:
Solution:
Belt monitoring loading arm
The belt monitoring initiator has reacted.
Check belt.
700503
Process:
Paletting not ready
Stacking receives a movement command but the controller indicates it
is not ready.
Check the fuses 80F1 and 80F2 in the PL electric cabinet. Replace the
controller card.
Solution:
700504
Process:
Solution:
700505
Process:
Solution:
700506
Process:
Solution:
PD-2-01/03-840D
Stack 1 emergency limit switch up
Stack 1 in paletting has moved up too far and hit the emergency limit
switch.
Move the stack away using the 72S107.7 button in the PL electric
cabinet. Check the front trip cams of stack 1.
Stack 1 emergency limit switch down
Stack 1 in paletting has moved down too far and hit the emergency
limit switch.
Move the stack away using the 72S107.6 button in the PL electric
cabinet. Check the front trip cams of stack 1..
Stack 2 emergency limit switch up
See Message 700504 with reference to stack 2
See Message 700504 with reference to stack 2
 SPINNER Werkzeugmaschinenfabrik GmbH
4-16
C Operation/Maintenance
Error diagnosis
700507
Process:
Solution:
Stack 2 emergency limit switch down
See Message 700505 with reference to stack 2
See Message 700505 with reference to stack 2
700508
Process:
Solution:
Pneumatic compressed air in PL400 is missing
See Message 700003
See Message 700003
700510
Process:
Solution:
Initiator monitoring loader flap
Both initiators for the status message Loading flap OPEN/CLOSED
register high signals.
Replace the defective initiator.
700537
Process:
Solution:
Channel 2 waiting for status message Air 10 on
The status message from the initiators for Air 10 is missing.
Check why the initiator has not sent the status message.
700538
Process:
Solution:
Channel 2 waiting for status message Air 10 off
See Message 700537
See Message 700537
700539
Process:
Solution:
Channel 2 waiting for status message Air 11 on
See Message 700537
See Message 700537
700540
Process:
Solution:
Channel 2 waiting for status message Air 1 off
See Message 700537
See Message 700537
700541
Process:
Solution:
Channel 2 waiting for status message Air 12 on
See Message 700537
See Message 700537
700542
Process:
Solution:
Channel 2 waiting for status message Air 12 off
See Message 700537
See Message 700537
700543
Process:
Solution:
Channel 2 waiting for status message Air 9 on
See Message 700537
See Message 700537
700544
Process:
Solution:
Channel 2 waiting for status message Air 9 off
See Message 700537
See Message 700537
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-17
C Operation/Maintenance
Error diagnosis
700545
Process:
Solution:
Channel 2 waiting for status message M52 - Swivel grabber
See Message 700537
See Message 700537
700546
Process:
Solution:
Channel 2 waiting for status message M62 - Swivel grabber
See Message 700537
See Message 700537
700547
Process:
Solution:
Channel 2 waiting for status message M53 - Swivel grabber
See Message 700537
See Message 700537
700548
Process:
Solution:
Channel 2 waiting for status message M63 - Swivel grabber
See Message 700537
See Message 700537
700549
Process:
Finished part not removed from conveyor belt
The M12 query in Channel 2 indicates that the finished part placed on
the conveyor belt has not been removed.
Remove finished part from removal position. Check initiators 69S101.1
Finished part in removal position and 69S101.2 Finished part in clear
position for function and correct calibration.
Solution:
700550
Process:
Solution:
Loader waiting for unmachined part on the conveyor belt feeder
The M13 query in Channel 2 indicates that there is no unmachined part
located on the conveyor belt feeder.
Insert unmachined part. Check initiator 69S101.0 Unmachined part
present for function and correct calibration.
Solution:
Stack I pivot lever not in position
The status message is missing for the pivot lever in the programmed
position.
Check if the pivot lever is stuck. Check initiator 69S104.x.
700552
Process:
Solution:
Stack 2 pivot lever not in position
See Message 700551.
Check if the pivot lever is stuck. Check initiator 69S105.x.
700553
Process:
Solution:
Check air 9-12 initiators
See Message 700241
See Message 700241
700554
Process:
Release/clamp from Channel 2 on when Wait in Channel 1
The spindles can be released/clamped from Channel 2, if the NC
program has been paused in Channel .
See Programming instructions (Preparation for programming) Chapter
1.15
700551
Process:
Solution:
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-18
C Operation/Maintenance
Error diagnosis
700555
Process:
Solution:
Stack 1 or 2 not in initial position
To move the U axis, both stacks must be in the initial position.
Move the stack to the initial position with the 72S107.6 or 72S107.7
buttons in the PL electric cabinet.
700556
Process:
Solution:
Move to reference point V
See Message 700032
See Message 700032
700557
Process:
Solution:
Move to reference point W
See Message 700032
See Message 700032
700558
Process:
Solution:
Move to reference point U
See Message 700032
See Message 700032
700559
Process:
No unmachined parts palette present
The yellow signal light flashes to indicate that there is no unmachined
parts palette present.
Prepare unmachined parts palette.
Solution:
Solution:
Loader flap on the lathe status message is missing
The initiators for the status message Loader flap open/closed do not
register a high signal.
Check initiators.
700561
Process:
Solution:
Safety door on PL400 open
Either the door is open or the door locking relay is defective.
Close the door or check the door locking relay.
700661
Process:
Solution:
Remark
Turret start-up routine
The start-up routine could not be completed within 3s.
Press the RESET button (12). The message and the Emergency stop
are cleared, the turret returns to the start-up routine (attempt several
times). If the turret cannot complete the routine, check all turret signals
(Indexing signal DB80.DBX14.0, Strobe signal DB80.DBX14.1, Index
magnet, etc.).
Only applicable with Sauter turret
700737
Process:
Solution:
Spindle locked by bar feeder
Spindle release removed from bar feeder.
See Operating Manual for bar feeder
700560
Process:
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-19
C Operation/Maintenance
700761
Process:
Solution:
Remark
PD-2-01/03-840D
Error diagnosis
Turret-indexing phase too long
The status message Turret locked (DB80.DBX13.2) is missing.
Check the initiator Locked (see circuit diagram, page 18a). Try to
switch the turret in JOG mode (3) using the +T or -T buttons until it
locks. (Note: DB80.DBX13.2 goes to 1, when the turret is locked)
Only applicable with Baruffaldi turret
 SPINNER Werkzeugmaschinenfabrik GmbH
4-20
C Operation/Maintenance
Maintenance
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
5 Maintenance
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-1
C Operation/Maintenance
Maintenance
5.1 Introduction
The maintenance guidelines given in this document for SPINNER machines inform you on
how to carry out the required maintenance on the machines to retain the same precision,
availability and life span.
If the maintenance guidelines are not observed or if the specified maintenance intervals
are not maintained then this may lead to malfunctions when operating the machine and to
premature wear of the machine components. The operator of the machine must follow the
maintenance guidelines in order for a warranty claim to be granted by the SPINNER
company. Machine damage that is the result of a lack of care or maintenance or that is
due to non-adherence to the maintenance intervals are not covered by the warranty. We
therefore recommend that you keep a maintenance book in which all maintenance work
conducted is entered.
Inspection intervals can change depending on the intensity of use when machining, how
dirty the machining work is, the environmental conditions, any especially difficult operating
conditions, etc., and are to be changed accordingly by the operator, if necessary.
IF THE MAINTENANCE GUIDELINES ARE NOT OBSERVED OR IF
THE SPECIFIED MAINTENANCE INTERVALS ARE NOT
MAINTAINED, THEN THIS MAY LEAD TO MALFUNCTIONS WHEN
OPERATING THE MACHINE AND TO PREMATURE WEAR OF
THE MACHINE COMPONENTS!
5.2 Warranty information
SPINNER machines are manufactured with the greatest care and precision and are
subjected to numerous tests, functional and quality control checks before they are
delivered to the final customer. The geometry values and quality specifications
determined during these tests and checks are recorded in the machine log and serve as
base values and comparative values when inspecting the machine during a service call,
for example. There is a 1 year (= 2000 hours) replacement guarantee for
malfunctioning/defective machine components, mechanical assembly components or
assemblies as well as for electrical or electronic components belonging to the CNC
control system and the drive controller that malfunction or are defective due to premature
wear, poor materials or manufacturing defects. The following are not covered by the
warranty:
• Damage to the machine caused by operating errors such as machine collision or
crashes. In this case the machine tool must be completely inspected by a service
technician from the SPINNER company. In no case may the machine continue to
be operated. Additional machine components may become damaged or, when
parts relating to safety are damaged, the operating personnel may be injured.
SPINNER reserves the right to claim that damage to the machine may be the
result of a crash that occurred earlier even if the entire machine was inspected at
that time, and can reject a warranty claim for the free repair or exchange of the
assembly component.
• Damage to the machine caused by fire, the effects of water, other natural events
or natural disasters or by incorrect handling of the machine such as overloading
(e.g. belts that break due to overloading), results of impacts, crashes, gross
negligence, vandalism, etc.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-2
C Operation/Maintenance
Maintenance
• Damage to the machine caused by faulty repair work that was not done by a
SPINNER service technician or other authorized sales partners.
• The results of normal wear such as damage to the paint, scratches on the safety
glass of the safety door, wear to the wiper lips of the guideway cover, etc
5.3 General information on maintenance / care
5.3.1 Machine
You are to regularly remove chips left laying around in the working area. The cleaning
interval depends on the application and operating conditions. Never use compressed air
to do this. Instead, clean the working area using the emulsion from the cooling lubricant
system. Make sure that you do not point a concentrated stream directly at the labyrinth
packing of the spindle. This can allow water to penetrate and to cause premature wear.
Additionally, you should make sure that the machine is generally clean. It is
recommended to clean the machine regularly to prevent damage caused by too much
dirt. Also clean the machine when a technical engineer from Spinner (after-sales service)
is expected. You will help him to finish his work earlier.
ONLY CLEAN THE WORKING AREA WITH EMULSION FROM
THE COOLING LUBRICANT SYSTEM! DO NOT POINT A
CONCENTRATED STREAM DIRECTLY AT THE LABYRINTH
PACKING OF THE SPINDLE! THIS CAN ALLOW WATER TO
PENETRATE AND TO CAUSE PREMATURE WEAR!
5.3.2 Pneumatic system
Generally, you should make sure that the pneumatic system is in perfect operating
condition. Damaged hoses or couplings must be replaced immediately.
5.3.3 Safety doors
The safety door is equipped with a high-impact resistant Polycarbonate screen. If a
workpiece were to become loose and fly off the chucking tool, then the safety glass will
prevent the workpiece from breaking through. However, in spite of this safety feature, the
operator is still not allowed to stand directly in the flight path of the spindle, and therefore
of the workpiece.
THE SAFETY GLASS MUST BE REPLACED IMMEDIATELY
AFTER IT IS BROKEN OR WHEN IT IS CRACKED! IT SHOULD
ALSO BE REPLACED WHEN IT COMES INTO CONTACT WITH A
LOOSE WORKPIECE, EVEN IF NO EXTERNAL DAMAGE TO THE
SAFETY GLASS CAN BE FOUND! REPLACE THE SAFETY
GLASSES AFTER 2 YEARS AT THE LATEST FOR AGEING
REASONS!
5.4 Lubrication
5.4.1 Rollers of the V axis
The rollers of the V axis within the gantry loader system should be lubricated again every
2000 operating hours. Press the emergency off button for reasons of safety before
lubricating the rollers. Press about 1 cubic centimetre of grease through the lubricating
nipples of the 4 rollers (see Figure 5-1). Use e. g. FAG Arcanol L74.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-3
C Operation/Maintenance
Maintenance
Lubrication
nipple W axis
Lubrication
nipple W axis
Figure 5-1: Lubrication of the rollers of the V axis
5.4.2 Rollers of the W axis
The rollers of the W axis within the gantry loader system should be lubricated again every
2000 operating hours. Press the emergency off button for reasons of safety before
lubricating the rollers. Press about 1 cubic centimetre of grease through the lubricating
nipples of the 4 rollers (see Figure 5-2). Use e. g. FAG Arcanol L74.
Lubricating
nipple V axis
Lubricating
nipple V axis
Figure 5-2: Lubrication of the rollers of the W axis
5.4.3 Rollers of the U axis
The rollers of the U axis within the gantry loader system should be lubricated again every
2000 operating hours. Press the emergency off button for reasons of safety before
lubricating the rollers. Press about 1 cubic centimetre of grease through the lubricating
nipples of the 4 rollers (see Figure 5-3). Use e. g. FAG Arcanol L74.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-4
C Operation/Maintenance
Maintenance
Pivoted lever
Lubrication
nipple of the
elevation screw
Figure 5-3: Lubrication of the rollers of the U axis
5.4.4 Elevating screw
The bearings of the elevating screw within the gantry loader system should be lubricated
again every 1000 operating hours. Drive the U axis out of the stack area. Press the
emergency off button for reasons of safety before lubricating the bearings. Press about 2
cubic centimetres of grease into the lubrication nipples of the 8 elevating screws (see
Figure 5-4). Use e. g. FAG Arcanol L74.
Lubrication
nipple of the
rollers (4x)
Figure 5-4: Lubrication of the elevating screws of the pallet stack up device
5.4.5 Lubrication of the gripper drive
The chain drive and the operating cylinder for the gripper must be greased every 1000
operating hours to warranty a continuous operation. Apply the lubrication by means of
greasing spray and oil jug. Proceed as follows (see Figure 5-5):
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-5
C Operation/Maintenance
1.
2.
3.
4.
5.
Maintenance
Press the emergency off button for reasons of safety.
Remove the cover of the V axis.
Grease the piston rods with about 2 cubic centimetres of special grease.
Grease the chains with about 2 cubic centimetres of special grease.
Grease the gripper guides with about 2 cubic centimetres of oil.
Piston rods
Piston rods
Chains
Figure 5-5: Lubrication of the gripper drive
5.5 Table of lubricants
The lubricants recommended for SPINNER machines are listed in a table in the following.
They guarantee safe and proper operation (see Table 5-1).
You can use similar, exchangeable products from all name-brand mineral oil companies.
You can check to see if you can use similar mineral oils other than those listed in the
table by consulting the technical departments of the corresponding mineral oil companies.
It should be noted that only lubricants with the same viscosity and similar base oils can be
mixed without this having a negative influence on the lubrication. Mixing differently
structured lubricants can have a negative effect on the operating temperature and
lubricating characteristics, and therefore negatively affect the lubricating performance.
Disregarding the lubricant information or using lubricants other than those recommended
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-6
C Operation/Maintenance
Maintenance
in the table can lead to malfunctions when operating the machine and to premature wear
of machine components. Damage to the machine that is caused by the use of unsuitable
lubricants is not covered by the warranty.
MIXING DIFFERENTLY STRUCTURED LUBRICANTS CAN HAVE A
NEGATIVE EFFECT ON THE OPERATING TEMPERATURE, THE
LUBRICATING CHARACTERISTICS AND THEREFORE NEGATIVELY
AFFECT THE LUBRICATING PERFORMANCE!
Lubricant point
Central
lubrication
Pneumatic
unit
Cutting surface
(cooling)
Supplier/
manufacturer
ARAL
DEA
SHELL
AGIP
AVIA Bantleon
FINA
FINA
OPTIMOL
SHELL
AVIA Bantleon
AGIP
ARAL
FINA
Lubricant /
brand name
DEGANIT BW68
NOVAN CGLP68
TONNA S68
EXIDIA HG 68
AVIA GEAR RSU 68
HYDRAN G68
HYDRAN TS10
HYDO 10
MORLINA 10
AVIA FLUID RSL 10
ACER MV10
VITAM GF10
VULCITE MPD 32
AVIA Bantleon
AVIA Bantleon
AVILUB METACON 611
AVILUB METACON 9773
AVIA Bantleon
AVIA Bantleon
ARAL
AVILUB METACON 9804
AVILUB METACON 673
SULNIT US20
ARAL
SHELL
ACMOS
AVIA Bantleon
AGIP
AGIP
SULNIT HM-9
GARIA-TC
ACMOSIT 64-02
ACMOSIT 64-200
AVILUB METACOOL BEP
AVILUB METACOOL
RWL
AVILUB METACOOL ABX
ASTER TA/E
ASTER MP
AGIP
aquamet TOP EP
AVIA Bantleon
ARAL
AVIA Bantleon
KLÜBER
KLÜBER
ARAL
AVIA Bantleon
AVIA Bantleon
AGIP
SHELL
ARAL
METACON 609
ARALUB HLP 2
AVIALITH 2 EP
STABURAGS NBU 8EP
ISOFLEX NBU 15
ARALUB MKL2
OKS 422
AVIALITH 2 EP
Longtimegrease 2
ALVANIA EP (LF)2
ARALUB HLP2
AVIA Bantleon
AVIA Bantleon
Feed
screws
Bearings
Mainspindle
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Type of lubricant
Slide way oil
Light oil
(Hydraulic oil)
Metal cutting oil (General
use)
Metal cutting oil (General
use)
Metal cutting oil (General
use)
Metal cutting oil (Aluminium)
Metal cutting oil (Aluminium)
Emulsion (water) (general
use)
Emulsion (water) (general
use)
Metal cutting oil (Aluminium)
Metal cutting oil (General
use)
Emulsion (water) (general
use); concentrate - water
mixable
Metal cutting oil (Aluminium)
Bearing grease
Bearing grease
5-7
C Operation/Maintenance
Other
bearings
Maintenance
OPTIMOL
KLÜBER
AVIA Bantleon
AGIP
SHELL
ARAL
OLIT 2EP
CENTOPLEX 2
AVIALITH 2 EP
GR MU EP 2
ALVANIA RL2
ARALUB HLP 2
Universal grease
Table 5-1: Table of lubricants
5.5.1 Table of lubricant suppliers / manufacturers
ACMOS
ARAL
AVIA
Bantleon
DEA
FINA
KLUEBER
OPTIMOL
SHELL
AGIP
28199 Bremen, Germany, Tel: +49-421-511415, Fax: +49-421-511415
44776 Bochum, Germany, Tel: +49-234-3150, Fax: +49-234-3152254
89077 Ulm, Germany, Tel: +49-731-399020, Fax: +49-731-399010
80675 München, Germany, Tel: +49-89-589401,. Fax: +49-89-5894260
80539 München, Germany, Tel: +49-89-298518, Fax: +49-89-2283537
81379 München, Germany, Tel: +49-89-78760, Fax: +49-89-2283537
81671 München, Germany, Tel: +49-89-41830, Fax: +49-89-402453
44135 Dortmund, Germany, Tel: +49-231-92770, Fax: +49-231-9277377
97080 Würzburg, Germany, Tel: +49-0931-90098145, Fax: 093190098169
Table 5-2: Lubricant suppliers / manufacturers
5.6 Machine Control 840D - Battery/fan replacement
The NCU is equipped with SRAMs and time modules which are buffered by a battery. The
voltage of the buffer is monitored by the NCU. When this monitoring has reacted the
battery must be replaced within 6 weeks. The battery/van plug in unit in the NCU-box can
be replaced after switching off the machine control because the data are stored for 15
minutes.
Order number of the battery: 60519
F
PD-2-01/03-840D
THE BUFFER PERIOD OF THE APPLIED BATTERY IS 3
YEARS.
 SPINNER Werkzeugmaschinenfabrik GmbH
5-8
C Operation/Maintenance
Maintenance
WHEN USING ELECTRICAL EQUIPMENT IT IS INEVITABLE
THAT THERE ARE PARTS OF THIS EQUIPMENT WHICH ARE
DANGEROUSLY CHARGED! AN IMPROPER HANDLING OF THIS
EQUIPMENT WILL CAUSE DEATH, SERIOUS INJURIES OR
CONSIDERABLE DAMAGES TO THE MACHINE!
ONLY QUALIFIED PERSONS ARE ALLOWED TO REALIZE THE
MAINTENANCE OF THE EQUIPMENT! ONLY ADMITED
REPLACEMENT PARTS FROM THE MANUFACTURER MUST BE
USED!
ALL MODULES REMAIN DANGEROUSLY CHARGED FOR 5
MINUTES AFTER SWITCHING OFF THE MACHINE!
DO NOT RECHARGE USED BATTERIES BY HEAT OR OTHER
MEASURES! IT IS NOT ALLOWED TO RECHARGE USED
BATTERIES BECAUSE THIS WILL CAUSE A RUN OUT AND/OR
EXPLOSIONS!
The battery/van plug in unit is situated in the electric cabinet below the intermediate circuit
bars. The unit is replaced completely. To do this you need to carry out the following steps
(see also Figure 5-6):
DO NOT REMOVE THE COVER OF THE INTERMEDIATE
CIRCUIT BARS SITUATED ABOVE THE PLUG IN UNIT! THERE IS
A SERIOUS HAZARD OF INJURIES BECAUSE OF CHARGED
PARTS!
1.
2.
3.
4.
Switch off the machine.
Press the lever (underside) and pull out the plug in unit.
Put in the new plug unit within 15 minutes.
Switch on again the machine control. The battery alarm must disappear.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-9
C Operation/Maintenance
Maintenance
Covering of intermediate circuit
bars
Battery/van plug in unit
Figure 5-6: Battery and van replacement
Van
Lever
Battery
Figure 5-7: Battery/van plug in unit
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-10
C Operation/Maintenance
Maintenance
5.7 Replacing the MMC battery
Order number of the battery: 6FC5 247-0AA18-0AA0
ONLY REPLACE THE BATTERY WHEN THE MMC IS SWITCHED
ON! THERE IS DANGER OF LOOSING DATA!
ONLY QUALIFIED PERSONS ARE ALLOWED TO REALIZE THE
MAINTENANCE OF THE EQUIPMENT! ONLY ADMITED
REPLACEMENT PARTS FROM THE MANUFACTURER MUST BE
USED!
DO NOT RECHARGE USED BATTERIES BY HEAT OR OTHER
MEASURES! IT IS NOT ALLOWED TO RECHARGE USED
BATTERIES BECAUSE THIS WILL CAUSE A RUN OUT AND/OR
EXPLOSIONS!
The battery is situated on the back of the MMC. To change it you need to carry out the
following steps (see also Figure 5-8):
THE ASSEMBLIES CONTAIN ELECTRONIC PARTS WHICH CAN
BE DAMAGED BY ELECTROSTATIC CHARGE! TO AVOID THIS
THE BODY OF THE PERSON WHO TOUCHES SUCH AN
ELECTRONIC ASSEMBLY MUST DE DISCHARGED! TO DO THIS
IN THE SIMPLEST WAY A CONDUCTIVE AND GROUNDED
OBJECT MUST BE TOUCHED BEFORE (E. G. METAL PARTS OF
THE ELECTRIC CABINET WITHOUT PAINT, EARTHING
CONTACT OF SOCKETS)!
1. Disconnect the battery plug X11. Remove the battery from the fixture.
2. Press the new battery into the fixture.
3. Reconnect the battery plug X11. Pay attention to the polarity.
Fixture with battery
Battery plug
Figure 5-8: Battery replacement
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-11
C Operation/Maintenance
Maintenance
5.8 Replacing the fine filter bag
Proceed as follows to replace the fine filter bag:
1. Switch off the machine. The coolant pump is also switched off. The machine
must be without pressure. Make sure that nobody can switch on the machine.
2. Open the fine filter tank by turning the lever to the right side (see Figure 5-9)
Lever (Must be turned
clockwise)
Figure 5-9: Open the fine filter tank
THE FINE FILTER TANK MUST ONLY BE OPENED BY HAND! DO
NOT USE ANY LENGTHENING OR HAMMER! THE HOLDERS
FOR THE LOCKING BOLT COULD BE DAMAGED!
3. Turn the locking bolt about 90° (see Figure 5-10).
Locking bolt
Figure 5-10: Fine filter - open the locking bolt
4. Take off the cover of the fine filter tank. The fine filter is situated underneath (see
Figure 5-11).
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-12
C Operation/Maintenance
Maintenance
Figure 5-11: Fine filter bag
5. Check the fine filter bag. It must be replaced when 1 quarter of the bag is filled
with chips and dirt.
• Article-N°. Fine filter bag with fineness 250µ = 10098
• Article-N°. Fine filter bag with fineness 31µ = 10097
5.9 Table with control and maintenance measures
Control and maintenance measures
Cycle in
Maintenance point Maintenance/Control measure
hours
24
Maintenance unit for Empty water separator
the compressed air
Check level of the oil reservoir
40
Working area of the
machine, Machine
outside
40
Safety devices
40
Spindle
Clamping cylinder
Clamping device
40
Central lubrication
reservoir
Electric cabinet
100
PD-2-01/03-840D
Remove chips
General cleaning of the machine
Rust protection
Check guide ways if they are
damaged
Check door locking
Check safety glass if there are
damages
General visual check/function check
of all machine parts
Check function of pneumatic
clamping cylinder and if there are
cracks or damages
Check function of stroke limitation
rings and if there are cracks and
damages
Check function of chuck and
clamping collet, grease if necessary
Check the belts (wear and tension)
Check oil level
Check function of the cooling
system
Check seals of the electric cabinet
Clean the keyboard of the control
panel
 SPINNER Werkzeugmaschinenfabrik GmbH
Control period
Regularly,
minimum once a
day
Regularly,
according to use
and machining
conditions
Minimum once a
week
Irregularly,
according to use
and machining
conditions
Irregularly,
according to use
Regularly,
according to use
and machining
conditions
5-13
C Operation/Maintenance
Maintenance
100
Coolant device
100
Fine filter (option)
100
Part catcher (option)
200
Maintenance unit for
the compressed air
500
Coolant device
1000
Feed spindle
X/Z/Q
1000
Tailstock (option)
1000
Turret
2000
Part catcher (option)
Gantry loader
(option)
Main spindle motor
Sub spindle motor
Feed motor
5000
Clean the chip boc
Clean the coolant reservoir
Clean the sieves
Check level of the coolant
Clean / replace filter
Clean fine filter casing
Check level of the coolant
Clean part catcher and remove
chips
Check function
Check if the pneumatic hoses are
damaged
Clean air filter
Check adjustment (about 10
drops/min.)
Check pressure monitor
(Emergency OFF when P ≤ 3 bar
Check function of the coolant pump
and valves
Change coolant
Check reverse play
Grease spindles
Check tension of the belt
Check function electric/pneumatic
Check stroke of the tailstock quill
Check seals
Check function
Check oil level
Check wear
Check alignment and position
related to the spindle
Dismantling
Check wear of belt
Grease bearings
Check bearings, grease if
necessary
Check seals
Check electrical connections
Check function
Clean optic and guiding elements
Check electrical connections
Check functions
5000
Linear measuring
system
5000
Guide ways
Cross slide
X/Z/Q
Check play, if necessary re-adjust
Check wear
Check machine geometry
5000
Turret
5000
Feed spindle
X/Z/Q
5000
Spindle
Change oil according to the
instructions of the manufacturer
Dismantling and cleaning
Grease rolling bearings 1)
Replace seals
Check residual unbalance
(Recommended balance quality
according to DIN ISO 1940 T1,
class G2.5)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Irregularly,
according to
quantity of chips
Irregularly,
according to
contamination
Irregularly,
according to
contamination
Regularly
Irregularly,
according to chip
volume
Regularly
Irregularly,
according to use
and machine
conditions
Irregularly,
according to use
and machining
conditions
Irregularly,
according to
wear
Regularly
Irregularly,
according to use
and machining
conditions
Irregularly
according to use
and machining
conditions
Regularly
Regularly
Regularly
5-14
C Operation/Maintenance
Maintenance
Replace drive belt
Dismantling and cleaning
Replace set of seals
Check alignment to the spindle
5000
Tailstock
20000
Feed spindle
X/Z/Q
20000
Clamping cylinder
Spindle
Tailstock
20000
Cross slide
X/Z
Q-slide
25000
Bearing of the
spindle
50000
Bearing of the
spindle
Dismantling and cleaning
Replace bearings and spindles
Re-adjust pre-tension
Replace belt
Dismantling and cleaning
Replace set of seals
Check the permissible residual
unbalance
Dismantle and clean the X and Z
slide
Clean the lubrication hoses
Replace the wippers of the
guideways
Check the machine geometry
Check the spindle bearings, if
necessary grease them 2)
Check the play
Check concentricity of spindle nose
(outer diameter and surface)
Replace spindle bearings
Check the play
Check concentricity of spindle nose
(outer diameter and surface)
Check machine geometry
Irregularly
according to use
and machining
conditions
Regularly
Regularly
Regularly
Irregularly,
according to use
and machining
conditions
Irregularly,
according to use
and machining
conditions
1) Klüber, ISOFLEX NBU 15
2) Klüber, ISOFLEX LDS 18 Special A
F
THE SIMPLE MAINTENANCE WORK (UP TO 2000h) DESCRIBED IN THE
TABLE ABOVE CAN BE DONE BY QUALIFIED PERSONNEL OF THE
OPERATOR. ALL THE EXTENSIVE MAINTENANCE WORK (AFTER
2000h) SHOULD BE DONE BY A SERVICE ENGENEER FROM SPINNER.
IF YOU WANT, THE SPINNER COMPANY CAN GIVE A SPECIAL
TRAINING FOR THE OPERATOR´S MAINTENANCE STAFF SO THAT THE
EXTENSIVE MAINTENANCE WORK CAN BE DONE BY THE OPERATOR
HIMSELF. TO CONTROL IF ALL MAINTENANCE WORK HAS BEEN
DONE CORRECTLY WE RECOMMEND TO KEEP A MAINTENANCE
BOOK.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-15
Technical Product Documentation
D Assemblies
SPINNER WERKZEUGMASCHINENFABRIK GmbH
D-82054 Sauerlach, Rudolf-Diesel-Ring 24
Tel: 08104 / 803-0, Fax: 08104 / 803-19,
E-Mail: sales@spinnner-wzm.de; service@spinner-wzm.de
D Assemblies
Assembly PD-010-000 Foundation plate/Machine base
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00.840D
61503E
1 Assembly PD-010-000 Foundation
plate/Machine base
PD-1-04/00.840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-1
D Assemblies
Assembly PD-010-000 Foundation plate/Machine base
1.1 Description
The basis of the the PD machine is formed by a base welded out of thick sheet steel.
Fitted on this is a torsion resistant foundation plate made of cast iron with screwed-on
guide tracks. The hardened guide tracks are precision made, together with the foundatin
plate .
1.2 Drawings and parts list
1.2.1 Exploded view drawing
(see next page)
PD-1-04/00.840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-2
D Assemblies
Assembly PD-010-000 Foundation plate/Machine base
Figure 1-1: Exploded view drawing of plate base
PD-1-04/00.840D
 SPINNER Werkzeugmaschinenfabrik GmbH
1-3
D Assemblies
Assembly PD-010-000 Foundation plate/Machine base
1.2.2 Parts list
Assembly PD-010-000 Foundation plate/Machine base; Article No. 10585
Quant. Unit Description
4
Pcs PD-010-002 Guide track
1
Pcs PD-010-003 End cover plate
1
Pcs PD-010-008 Machine base
4
Pcs SB-NC-010-030/1 Adjustment screw
4
Pcs SB-NC-010-031 Lock nut
1
Pcs SB-NC-010-002 Headstock basic holder
1
Pcs PD-010-005 Cover, right
1
Pcs PD-010-006 Cover, left
1
Pcs PD-010-007 Lower cover
1
Pcs PD-010-010 Cover base
1
Pcs PD-010-011 Cable holder
1
Pcs PD-010-012 Plate for pneumatic connections
1
Pcs BK-012-081 Allen screw M8
1
Pcs BK-012-003 Rotary water connection
1
Pcs BK-012-006 Connecting head air/water
6
Pcs SB-NC-010-024 Washer
1
Pcs PD-011-037 Apron for machine base
6
Pcs SB-NC-085-019 Spacer roller valve battery
1
Pcs SB-NC-010-061 Cover panel for Z-motor
1
Pcs BK-012-032 Water hose connection
1
Pcs Angle piece Rectus G3/4
1
Pcs O-Ring 32x3
4
Pcs BK-002-005 Rubber plate
1
Pcs Ball valve BEE 3411-1/4
9
Pcs AVS1 Locking screw 261M-1/4
2
Pcs Seal 269N-1/4x1.5
1
Pcs Thiermann coolant hose
1
Pcs Plate M07
2
Pcs AVS2 Locking screw 261M-3/8
1
Pcs Menzel sepcial seal for coolant water distributor
36
Pcs SB-NC-010-017/1 Stopping plugs
4
Pcs Disk 13DIN6340
1
Pcs PD-010-001 Machine base
PD-1-04/00.840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
20893
20894
20899
21325
21326
21309
20896
20897
20898
20901
20902
21441
21320
20749
21318
21315
20872
21261
21345
21185
21317
30180
20540
21192
21319
21853
21333
20746
21338
21332
21312
21327
20892
1-4
D Assemblies
Assembly PD-106-000 Coolant system
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
2 Assembly PD-106-000 Coolant system
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-1
D Assemblies
Assembly PD-106-000 Coolant system
2.1 Description
The coolant system assembly consists of the swarf-catching container PD-018-001 and
the coolant tank PD-018-002 located below it. The coolant is fed to the relevant usage
points on the machine by means of a feed pump.
2.2 Maintenance and repair
The swarf-catching container must be emptied on a regular basis. The coolant must be
replaced as necessary according to the medium used. Losses causes by escaping
cooilant or evaporation of water from emulsions must be topped up by the operator.
2.3 Drawings and parts list
2.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-2
Assembly PD-106-000 Coolant system
D Assemblies
Figure 2-1: Exploded view drawing of coolant system
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
2-3
D Assemblies
Assembly PD-106-000 Coolant system
2.3.2 Parts list
Assembly PD-106-000 Coolant system
Quant. Unit Description
1
Pcs Brinkmann submersed pump TS13/110-61
8
Pcs BK-012-032 Water hose connection
3
Pcs Müller Coax-valve
2
Pcs Hose Ø 13x1500 PVC mesh and 2x straight connections
M22x1.5
Pcs Hose Ø 10x1000 PVC mesh and 2x straight connections
M16x1.5
1
Pcs SB-NC-100-009 Coolant distributor for turret
2
Pcs SB-NC-001-012 Distribution unit for spindle flushing
2
Pcs AVS Reducing nipple, conical 253M-3/4K-1/2
2
Pcs AVS Reducing nipple 253M-1/2-1/4
11
Pcs AVS Seal 269N-1/4x1.5
2
Pcs BEE Ball valve 3411-1/4
3
Pcs Ermeto Straight threaded joint XGE 10-PLR-ED
1
Pcs AVS Angle piece, conical 202M-1/4K-1/4
1
Pcs Ermeto Straight threaded joint XGAI 10-PLR
2
Pcs Ermeto Adjustable angle connection supports EVW10-PLR
5
Pcs Ermeto Straight threaded support with shaft EVGE 15-PLR-ED
5
Pcs AVS Straight threaded joint 151M-10/8-1/4
1
Pcs PD-018-001 Swarf container
1
Pcs PD-018-002 Coolant reservoir
1
Pcs PD-018-003 Support plate for coolant pump
2
Pcs PD-010-009 Connection block for swarf trough
1
Pcs AVS Locking screw 261M-1/4
1
Pcs AVS Locknut 256M-1/4
1
Pcs AVS Reducing nipple 252M-1/4-1/4
1
Pcs AVS T-joint 154-10/8
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22220
21185
30217
21186
21187
21335
21285
21188
21191
21853
21192
21213
21212
21193
21214
21334
21217
20879
20880
20881
20900
21319
21211
22036
22035
2-4
D Assemblies
Assembly PD-099-000 Splash guard
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
3 Assembly PD-099-000 Splash guard
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-1
D Assemblies
Assembly PD-099-000 Splash guard
3.1 Description
The machine paneling consists of an aluminium support frame with attached steel sheets.
The paneling complies with the relevant safety guidelines.
3.2 Drawings and parts list
3.2.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-2
D Assemblies
Assembly PD-099-000 Splash guard
Figure 3-1: Exploded view drawing of splash guard
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
3-3
D Assemblies
Assembly PD-099-000 Splash guard
3.2.2 Parts list
Assembly PD-099-000 Splash guard; Article No. 10781
Quant. Unit Description
4
Pcs PD-011-001 Mounting base
1
Pcs PD-011-002 Front right support
1
Pcs PD-011-003 Front left support
1
Pcs PD-011-004 Rear right support
1
Pcs PD-011-005 Rear left/new support
1
Pcs PD-011-006 Entry shaft
1
Pcs PD-011-008 Rear left inner holder
1
Pcs PD-011-009 Right inner holder
1
Pcs PD-011-011 Separator
1
Pcs PD-011-013 Crossbar
1
Pcs PD-011-014 Door track support
1
Pcs PD-011-015 Guide rail
2
Pcs PD-011-016 External door stop
1
Pcs PD-011-017 Central door stop
1
Pcs PD-011-019 Track for front plate
11
Pcs PD-011-020 Spacer roller
1
Pcs PD-011-022 Operating console
1
Pcs PD-011-023 Front right panel
1
Pcs PD-011-024 Front left panel
1
Pcs PD-011-025 Top right panel
1
Pcs PD-011-026 Top left panel
1
Pcs PD-011-028 Inner right panel
1
Pcs PD-011-030 Rear panel
1
Pcs PD-011-031 Inner left panel 1
1
Pcs PD-011-032 Inner left panel 2
1
Pcs PD-011-033 Inner left panel 3
1
Pcs PD-011-035 Outer left panel 2
1
Pcs PD-011-018 Front plate
1
Pcs PD-011-029 Inner right panel 2
1
Pcs PD-011-036 Outer left panel 3
1
Pcs PD-011-037 Apron for machine base
1
Pcs PD-011-041 Outer left plate 1 (without gantry loading)
1
Pcs PD-011-042 Cover panel
2
Pcs PD-011-044 Working light holder
2
Pcs SB-NC-030-052 Terminal
2
Pcs SB-NC-020-029 Terminal
2
Pcs PD-011-046 Support bracket for door locking
2
Pcs PD-011-047 Mounting plate 1
2
Pcs PD-011-048 Mounting plate 2
2
Pcs PD-011-049 Spacer block
1
Pcs PD-011-021 Enclosure for operating console
2
Pcs PD-011-045 Cable terminal for operating console
1
Pcs PD-011-027 Right side panel
1
Pcs PD-099-001 Holder 1 for energy chain
1
Pcs PD-099-002 Holder 2 for energy chain
1
Pcs PD-011-012 Cable duct
1
Pcs SB-NC-020-005 Cover for enclosure
1
Pcs SB-NC-165-001 Enclosure Version 2
1
Pcs PD-011-007 Rear left outer holder
1
Pcs PD-011-010 Right outer holder
1
Pcs PD-011-034 Left outer panel (with gantry loading)
2
Pcs Waldmann lamp
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
20836
20837
20838
20839
20840
20841
20843
20844
20846
20848
20849
20850
20851
20852
20854
20855
20857
20858
20859
20860
20861
20864
20865
20866
20867
20686
20870
20853
20863
20871
20872
20876
20877
21380
21222
21221
21992
21993
21994
21995
20856
21460
20862
22353
22354
20847
21220
22351
20842
20845
20869
30864
3-4
D Assemblies
4
2
1
2
1
1
1
1
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Assembly PD-099-000 Splash guard
Waldmann holder
Elan Safety door lock TZFW 24V DC/96
Holder for permission button Type ZSA ArtKlöckner Möller rubber sleeve KT 16
Pöppelmann plug GPN 910; 910/3222
Bosch bulkhead stuffing box 1823 391 227
AVS Locking screw 261M-1/4; 21319
AVS Seal 269N-1/4x1.5
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
30562
31174
30934
41220
21218
21319
21853
3-5
D Assemblies
Assembly PD-020/021-000 Sliding door left/right
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-04/00-840D
61503E
4 Assembly PD-020/021-000 Sliding door
left/right
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-1
D Assemblies
Assembly PD-020/021-000 Sliding door left/right
4.1 Description
According to the necessary safety regulations the machine is equipped with two sliding
doors. These are made of a profile frame of aluminium with integrated safety glasses.
The doors are guided at the top by means of rollers which can be eccentrically be
adjusted, at the bottom by a slideway.
4.2 Handling
During first starting up the machine the door is unlocked. The closed door is locked by a
one-time opening and subsequent closing or by pressing the NC start button. While doing
this the key-operated switch must be turned to the left position. The locked door is
unlocked by turning the key-operated switch to the right position or by pressing the NCstop button.
4.3 Maintenance and repair
The safety glasses of the sliding doors must always be in a perfect and undamaged state.
A damaged glass must be immediately replaced for reasons of safety. Only use original
replacement parts which are certified by a shelling test.
THE SAFETY GLASSES OF THE SLIDING DOORS MUST ALWAS
BE IN A PERFECT STATE! A DAMAGED GLASS MEANS A RISK
TO LIFE AND LIMB OF THE OPERATOR AND OF THIRD
PERSONS! THE GLASS MUST IMMEDIATELY BE REPLACED BY
AN ORIGINAL REPLACEMENT PART! REPLACE THE SAFETY
GLASSES AFTER 2 YEARS AT THE LATEST FOR AGEING
REASONS!
4.4 Drawings and parts lists
4.4.1 Exploded drawing
(See following page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-2
D Assemblies
Assembly PD-020/021-000 Sliding door left/right
* Included in assembly 10356
enthalten
Figure 4-1: Exploded drawing left sliding door
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-3
D Assemblies
Assembly PD-020/021-000 Sliding door left/right
Figure 4-2: Exploded drawing right sliding door
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-4
D Assemblies
Assembly PD-020/021-000 Sliding door left/right
4.4.2 Parts list
Assembly PD-020-000 Sliding door left; Article No. 10700
Quant. Unit Description
2
Pcs Rollon Roller journals E CPA28-2RS
2
Pcs Rollon Roller journals Z CPN28-2RS
1
Pcs PD-020-006 Top crossbeam
1
Pcs PD-020-005 Inner frame
1
Pcs PD-012-010 Door latch tongue
1
Pcs PD-012-009 Tongue holder V2
1
Pcs PD-012-005 Sliding pad
1
Pcs PD-020-008 Left apron
1
Pcs PD-020-007 Bottom crossbeam
1
Pcs PD-020-004 Outer frame
1
Pcs PD-020-003 Support plate
1
Pcs PD-020-001 Composite disc
1
Pcs PD-020-002 Intermediate plate
Article No.
26074
26073
22452
22453
21997
21996
20832
22454
22455
22456
22457
22459
22458
Assembly PD-021-000 Sliding door right; Article No. 10701
Quant. Unit Description
2
Pcs Rollon Roller journals E CPA28-2RS
2
Pcs Rollon Roller journals Z CPN28-2RS
1
Pcs PD-020-006 Top crossbeam
1
Pcs PD-020-002 Intermediate plate
1
Pcs PD-020-001 Composite disc
1
Pcs PD-020-003 Support plate
1
Pcs PD-021-001 Outer frame
1
Pcs PD-012-009 Tongue holder V2
1
Pcs PD-012-010 Door latch tongue
1
Pcs PD-012-005 Sliding pad
1
Pcs PD-021-003 Right apron
1
Pcs PD-020-007 Bottom crossbeam
1
Pcs PD-021-002 Inner frame
Article No.
26074
26073
22452
22458
22459
22457
22461
21996
21997
20832
22462
22455
22460
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
4-5
D Assemblies
Assembly PD-030-000 Workspace paneling
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
5 Assembly PD-030-000 Workspace paneling
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-1
D Assemblies
Assembly PD-030-000 Workspace paneling
5.1 Description
The entire working area of the machine is covered with stainless steel panels with the
corresponding wiper seals.
5.2 Maintenance and repair
Damaged seals must be replaced with appropriate new parts. If cooling lubricant
emulsions or oils are used that do not comply with the specifications in the operating
instructions, the seal lips will be destroyed.
5.3 Drawings and parts list
5.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-2
Assembly PD-030-000 Workspace paneling
D Assemblies
Figure 5-1: Exploded drawing of workspace paneling
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
5-3
D Assemblies
Assembly PD-030-000 Workspace paneling
5.3.2 Parts list
Assembly PD-030-000 Workspace paneling; Article No. 10591
Quant. Unit Description
1
Pcs PD-030-015 Cover panel 5
1
Pcs PD-030-016 Cover panel 6
1
Pcs PD-030-013 Connecting strips
1
Pcs PD-030-018 Wiper lip for cover panel 6
1
Pcs PD-030-019 Wiper lip for cover panel 4
1
Pcs PD-030-020 Wiper lip for cover panel 5
1
Pcs PD-030-017 Supports for cover panel 6
1
Pcs PD-030-001 Holding plate for Z-Q-limit switch
1
Pcs PD-030-003 Cover panel 1
1
Pcs PD-030-004 Cover panel 2
1
Pcs PD-030-005 Cover panel 3
1
Pcs PD-030-006 Botton slide rail
1
Pcs PD-030-007 Top slide rail
1
Pcs PD-030-008 Guide shoe
1
Pcs PD-030-010 Left holder
1
Pcs PD-030-011 Right holder
1
Pcs PD-030-021 Top left corner ledge
1
Pcs PD-030-022 Center corner ledge
1
Pcs PD-030-023 Top right corner ledge
1
Pcs PD-030-024 Right corner ledge
1
Pcs PD-030-025 Outer right corner ledge
1
Pcs PD-030-026 Left leveling piece
1
Pcs PD-030-027 Right leveling piece
1
Pcs Euchner Limit switch 3-row type
1
Pcs SB-NC-010-023 Holding angle for the limit switch
4
Pcs Cylindrical pin DIN 6325-5M6x20
2
Pcs Cylindrical pin DIN 6325-3M6x8
1
Pcs PD-030-009 Complete mounting frame
1
Pcs PD-030-014 Cover panel 4
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
20917
20918
20915
20920
20921
20922
20919
20903
20905
20906
20907
20908
20909
20910
20912
20913
21375
21376
21377
21378
21379
21641
21642
30354
21231
30794
30659
20911
20916
5-4
D Assemblies
Assembly PD-015-000 Cross-slide
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503D
6 Assembly PD-015-000 Cross-slide
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
6-1
D Assemblies
Assembly PD-015-000 Cross-slide
6.1 Description
The assembly PD-015-000 cross-slide unit forms the basis for the adjusting options of the
tool holder (turret or linear tool holder) mounted on the cross-slide rest PD-015-019. The
cross-slide rest moves on two guideway tracks, the front one of which is a V-guide. An
optical linear measurement system is located between the two guideway tracks. The Zslide located underneath is also moved on 2 sliding guideways. The upper of these
guideway tracks represents the small guideway for this system. Another optical linear
measurement system is located between these guideways.
6.2 Maintenance and repair
Ensure that the guideways are kept sufficiently lubricated. If necessary, the play of the
guideways can be adjusted by a SPINNER service technician to comply with the relevant
specifications.
6.3 Drawings and parts list
6.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
6-2
Assembly PD-015-000 Cross-slide
D Assemblies
Figure 6-1: Exploded view drawing of cross-slide
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
6-3
D Assemblies
Assembly PD-015-000 Cross-slide
6.3.2 Parts list
Assembly PD-015-000 Cross-slide, Article No. 10589
Quant. Unit Description
1
Pcs PD-015-001 Z-slide
1
Pcs SB-NC-010-057 Top sealing cover
1
Pcs SB-NC-010-058 Bottom sealing cover
1
Pcs SB-NC-014-001 Measuring head holder X
1
Pcs SB-NC-014-020 Measuring head holder Z-axis
1
Pcs SB-NC-014-021 Clamping plate for measuring head
1
Pcs Haidenhein Measurement system X-/Q-axis LS303/420
1
Pcs SB-NC-014-023 Support plate for measuring head Z-axis
1
Pcs PD-015-008 Glide shoe
1
Pcs PD-015-009 Guide strip Z-axis
2
Pcs PD-015-011 Bottom Z retainer gib
1
Pcs PD-015-012 Top Z retainer gib
1
Pcs PD-015-013 Top Z retainer gib
1
Pcs PD-015-014 Adjustment screw
1
Pcs PD-015-015 Holding cam
2
Pcs PD-015-016 Rotary lock
2
Pcs PD-015-018 Countersunk head bolt
1
Pcs PD-015-019 Slide X-axis
1
Pcs PD-015-022 Scale holder X-axis
1
Pcs PD-015-023 Scale holder X-axis
1
Pcs PD-015-024 Scale holder Z-axis
1
Pcs PD-015-025 Scale cover Z-axis
1
Pcs PD-015-026 Holding plate for X limit switch
1
Pcs PD-015-027 Cap for X limit switch
1
Pcs PD-015-028 Mount for X-axis drive
1
Pcs PD-015-029 Cover for motor holder X-axis
1
Pcs PD-015-033 Terminal block
2
Pcs PD-015-034 Cable terminal
1
Pcs Euchner Limit switch 3-row type
2
Pcs Pin DIN 6325 6M6x32
1
Pcs Pin DIN 6325 6M6x16
1
Pcs Euchner cam U8-25
4
Pcs Euchner cam U8-10
1
Pcs Euchner cam U8-200
1
Pcs Cylindrical pin DIN 6325 2M6x20
1
Pcs PD-015-030 Wiper lip
1
Pcs PD-015-031 Rear wiper lip
1
Pcs PD-015-032 Front wiper lip
10
Pcs BK-NC-010-035 Short adjusting screw
1
Pcs PD-015-020 Rear X-axis retainer gib
1
Pcs PD-015-021 Front X-axis retainer gib
1
Pcs PD-015-010 Base strip for the retainer gib
1
Pcs Haidenhein Measurement system Z-axis LS303/420
10
Pcs BK-NC-010-031 Long adjusting screw
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
20932
21275
21276
21280
21302
21303
21006
21304
20939
20940
20942
20943
20944
20945
20946
20947
20948
20949
20952
20953
20954
20955
20956
20957
20958
20959
21381
21382
30354
30857
30676
30397
30396
30711
30858
20960
20961
20962
20449
20950
20951
20941
21007
20412
6-4
D Assemblies
Assembly PD-083-000 Central lubricating unit
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-2-01/03-840D
61503E
7 Assembly PD-083-000 Central lubricating unit
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
7-1
D Assemblies
Assembly PD-083-000 Central lubricating unit
7.1 Description
The central lubricating unit automatically supplies the guideways of the cross-slide with
the necessary lubricating oil. The central lubricating unit is located on the rear of the
machine. If the oil level is too low, an alarm message is displayed on the CNC cotnrol
screen.
Button for manual
actuation of pump
(e.g. to bleed the oil
lines)
Filling inlet with
integrated sieve
and safety cap
Level indicator
Figure 7-1: Central lubricating unit
7.2 Handling
SWITCH OFF THE OPERATING VOLTAGE BEFORE OPENING
THE COVERING HOOD (FOR SERVICING)!
FOR TROUBLEFREE
LUBRICATING UNIT
OPERATION
OF
THE
CENTRAL
• ONLY USE CLEAN OIL OF A SUITABLE VISCOSITY
• THE FILLER NECKS MUST NOT BE REMOVED AND THE
INTEGRATED SIEVE MUST NOT BE DAMAGED
• THE SYSTEM MUST NOT BE OPENED DURING OPERATION
7.3 Maintenance and repair
Check the oil level in the central lubricating unit regularly. If the oil level is too low it must
be topped up. Only use oil specified in Book C Operation/Wartung, Chapter 5 Wartung.
When filling the central lubricating reservoir, ensure that everything is extremely clean.
Dirt particles in the oil circuit can cause malfunctions and negatively affect the machine’s
operation.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
7-2
D Assemblies
Assembly PD-083-000 Central lubricating unit
7.4 Drawings and parts list
7.4.1 Detail assembly drawing
(see next page)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
7-3
D Assemblies
Assembly PD-083-000 Central lubricating unit
View from rear
(main spindle side)
View from rear
(sub-spindle side)
Art. Nr. 31414
Art. Nr. 31413
Art. Nr. 31418
Art. Nr. 31412
Art. Nr. 31416
Art. Nr. 31407
Art. Nr. 31411
Art. Nr. 31406
Art. Nr. 31410
Art. Nr. 31403
Art. Nr. 31418
Art. Nr. 31408
Art. Nr. 31408
Art. Nr. 31401
Art. Nr. 31402
Figure 7-2: Layout of central lubricating unit
Order length for polyamide tubing PR 4.2,5 w - 3500 mm; Order No. 100120061
Order length for polyamide tubing PR 6.4 h - 2500 mm; Order No. 100120064
Lubricating pulses every 2 min/5 min
MAKE SURE THAT THE PUMP ELEMENTS ARE CORRECTLY
ALLOCATED TO THE LUBRICATING POINTS!
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
7-4
D Assemblies
Assembly PD-083-000 Central lubricating unit
7.4.2 Parts list
Assembly PD-083-000 Central lubricating unit; Article No.30873
Quant. Unit Description
1
Pcs Central lubricating package PD
1
Pcs PD-060-003 Dummy cap oil reservoir
1
Pcs SB-NC-145-005 Oil rating plate
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
30873
22075
30918
7-5
D Assemblies
Assembly PD-095-000 Pneumatic unit
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-2-01/03-840D
61503E
8 Assembly PD-095-000 Pneumatic unit
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-1
D Assemblies
Assembly PD-095-000 Pneumatic unit
8.1 Description
The pneumatic unit purifies the compressed air of the connected air supply from dust,
drains the compressed air and enriches it with oil to avoid a premature wear of all
following pneumatic components. The condensate is automatically emptied. The
pneumatic unit is situated on the rear of the machine.
Set screw of the air oiler
Push key to suck
in oil
Condensate separator
Pneumatic oiler
Pressure gauge for main
pressure
Oil suction hose
Main stop cock
Connection for
compressed air gun
Main connection for
compressed air supply
Figure 8-1: Pneumatic unit
8.2 Handling
8.2.1 Filling and emptying the oil reservoir of the pneumatic unit
The pneumatic system´s oil reservoir is filled by holding the oil suction hose (can be
pulled out) in a can filled with the correct grade of oil (for the type of oil, see book C
Operation/Maintenance, chapter 5 Maintenance). Press the key on the air oiler until the
reservoir is completely full. The level indicator will show the amount of oil in the reservoir.
The return valve on the bottom of the oil reservoir can be removed to drain-off the oil.
Note that the thread is left-handed! Obey the following instruction!
THE
PNEUMATIC
SYSTEM
MUST
BE
ABSOLUTELY
PRESSURELESS BEFORE THE OIL CAN BE DRAINED!
8.2.2 Setting the air oiler
The air in the pneumatic system has to be enriched with oil from the oil reservoir in order
to protect the pneumatic components from corrosion and wear. This is done by the air
oiler which must be set to dispense the proper amount of oil. Call up the machine base
screen by pressing the following key:
.
Then press successively the softkeys „Parameter“ and „Clamping parameters“. In the
window which opens set the variable “Oil adjustment“ to “1“. Press the yellow key
“Enter“
. Then observe the oiler. Set the air oiler so that an oil droplet forms every 10
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-2
D Assemblies
Assembly PD-095-000 Pneumatic unit
to 12 seconds. This is done by turning the screw on the air oiler. Reset the variable “Oil
adjustment“ to “0“. Press again the yellow key “Enter“.
8.3 Maintenance and upkeep
Check the oil level of the pneumatic unit periodically (depending on the status of the air).
If the oil level is too low refill the oil reservoir with the oil indicated in book C
Operation/Maintenance, chapter 5 Maintenance.
It is very important to be very clean when filling the pneumatic unit´s oil reservoir. Dirt
particles in the oil circuit can cause malfunctions and strongly affect the machine´s
operation.
Regularly empty the condensate separator by opening the drain plug. Regularly clean the
filter in the separator of the pneumatic unit. At the latest, change the filter when the
pneumatic unit is having problems.
8.4 Drawings and parts list
8.4.1 Exploded view drawing
(See following page)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-3
Assembly PD-095-000 Pneumatic unit
D Assemblies
Figure 8-2: Exploded view drawing pneumatic - basic machine
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-4
Assembly PD-095-000 Pneumatic unit
D Assemblies
8.4.2 Detail assembly - Pneumatic for options
Auxiliary assembly valve block • (Programmable air
connections)
Auxiliary assembly valve block ‚ (Indexing
device/Shutting slide for gantry loader/Door opener)
Auxiliary assembly valve block ƒ (Part catcher)
Figure 8-3: Detail assembly - Pneumatic for options
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-5
Assembly PD-095-000 Pneumatic unit
D Assemblies
8.4.3 Pneumatic diagram with subspindle option
Figure 8-4: Pneumatic diagram with subspindle option
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-6
Assembly PD-095-000 Pneumatic unit
D Assemblies
8.4.4 Pneumatic diagram without subspindle option
Figure 8-5: Pneumatic diagram without subspindle option
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-7
D Assemblies
Assembly PD-095-000 Pneumatic unit
8.4.5 Parts list
Assembly PD-095-000 Pneumatic unit - basic machine
Quant. Unit Designation
1
Pcs PD-095-001 Pneumatic feed-in
2
Pcs Techno-Chemie banjo bolt 2, G1/8; 380221483040
7
Pcs Techno-Chemie Sealing ring 2, DIN 7603; 391310800090
5
Pcs AVS Reducing nipple 1, 252M-1/8-1/8; 250653
2
Pcs Rexroth 5/2 path magnetic valve; 576 351 022 0
1
Pcs Rexroth Check valve 1, G1/8; 534 098 100 0
5
Pcs AVS Sealing ring 1, Aluminum; Typ 265A-1/8x1.5
3
Pcs Bosch Angle swivel screw fitting 1, G1/8 Tube D=8;
1823 391 122
1
Pcs Rexroth Check valve C4, lockable; 535 260 010 0
1
Pcs Rexroth Filter C4 5E-6M; 535 120 203 0
2
Pcs Rexroth Connecting flange 1; G1/4; 535 100 601 2
1
Pcs Rexroth Oiler C4, G1/8; 535 150 100 0
2
Pcs Rexroth 4x distributor C4, G1/4; 535 100 231 2
1
Pcs Rexroth Safety valve 10 bar; 134 607 011 0
3
Pcs AVS Sealing ring 3, Aluminum, Typ 265A-1/4x1.5
1
Pcs Rexroth Manometer 0-12 bar, G1/8; 353 019 010 0
1
Pcs SB-NC-160-002 Distributor block
6
Pcs Bosch Angled swivel screw fitting 2, G1/4, Tube D=8;
1823 391 123
1
Pcs Bosch Angled swivel distributor, G1/8; 1823 391 047
1
Pcs Bosch Distributor tube 2F, G1/8; 1823 391 405
2
Pcs Bosch Distributor ring 2F, G1/8; 1823 391 400
1
Pcs Riegler Socket with washer, inner diameter 9 (236F) with nut
3/8 (234B)
1
Pcs Riegler Double threaded nipple, G1/4-G3/8; 252.02
1
Pcs AVS Coupling connection NG5, G1/4, Typ 551M-1/4; 359010
3
Pcs Rexroth Locking screw 5, G1/4; 893 014 200 4
2
Pcs AVS Straight threaded joint 3, G1/8, 151M-8/6-1/8;
300020
1
Pcs Rexroth Sound absorber 2, G1/8; 532 401 110 0
1
Pcs AVS Banjo bolt 5, short, Typ 164M-11-1/4A
1
Pcs AVS Reducing nipple 2, 251M-1/8-1/4
1
Pcs Rexroth Left connection plate; 898 512 100 2
1
Pcs Rexroth Right connection plate; 898 512 101 2
4
Pcs Rexroth Locking screw 1, G3/8, 893 014 201 4
1
Pcs Rexroth Interlinking plate 2; 898 512 109 2
1
Pcs Rexroth Locking screw 2, G1/8; 893 014 190 4
1
Pcs Rexroth Sound absorber 1, G3/8; 532 401 112 0
1
Pcs Rexroth Steck-Fix, G3/8 outer diameter 8mm; 1823 391 159
1
Pcs Rexroth Pressure switch, G1/4; 341 058 020 0
1
Pcs Murrelektronik, 6x distributor MVC6-VC3.0; 27812
1
Pcs PD-095-005 Support plate for valve battery
1
Pcs Bosch Rotatable L-turn threaded union pipe, G1/4, Tube
D=8mm; 1823 391 205
2
Pcs PD-095-006 Spacer sleeve for terminal box
1
Pcs PD-095-007 Support bracket for tank
1
Pcs PD-095-002 Elbow 1
1
Pcs PD-095-003 Elbow 2
1
Pcs PD-095-004 Elbow 3
1
Pcs GESA Tank, article number D 80 S 137
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
22357
22321
22322
22317
31128
31114
22315
31130
26450
31111
31116
31119
31117
3113
22316
31112
22310
30206
31132
31133
31134
31138/
31137
31139
21339
31120
22319
31145
22320
22318
31123
31122
31126
31121
31129
31124
31154
31125
31142
22361
31231
22362
22352
22358
22359
22360
21854
8-8
D Assemblies
4
2
1
1
1
Pcs
Pcs
Pcs
Pcs
Pcs
Assembly PD-095-000 Pneumatic unit
Lapp Dummy screws
Rexroth Connecting flange; 535 100 607 2
Murelektronik MSUD valve plug; MSUD-CB1Z-G1.0
Murrelektronik Plug with cable; 00025043
Murrelektronik Connector M12 with valve plug; MSSL3-AWAO.6
Assembly PD-095-000 Pneumatics for options
Quant. Unit Designation
9
Pcs Rexroth 5-port solenoid valve with 2 outlets Magnet/Spring; 576
351 022 0
1
Pcs Rexroth 5-port solenoid valve with 2 outlets Magnet/Magnet;
576 352 022 0
1
Pcs Rexroth 5-port solenoid valve with 3 outlets Magnet/Magnet;
576 381 022 0
11
Pcs Rexroth Interlinking plate 1; 898 512 105 2
3
Pcs Rexroth Left connection plate; 898 512 100 2
3
Pcs Rexroth Right connection plate; 898 512 101 2
7
Pcs Rexroth Locking screw 1, G3/8; 893 014 201 4
6
Pcs Rexroth Sound absorber 1, G3/8; 532 401 112 0
1
Pcs Bosch Angle swivel screw fitting 4, G3/8, tube D=8; 1823 391
167
4
Pcs Bosch Steck-Fix, G3/8, tube outer diameter 8; 1823 391 159
2
Pcs Murrelektronik 4x distributor MVC4-VC3.0; 27802
1
Pcs Murrelektronik 6x distributor, MVC6-VC3.0; 27812
2
Pcs Rexroth Blanking plate; 898 512 149 2
1
Pcs PD-095-005 Support plate for valve battery
8
Pcs Bosch Steck-Fix G1/4, tube outer diameter 8; 1823 373 012
8
Pcs AVS Coupling connection type 551M-1/4
4
Pcs Bosch Straight connection reduced Ø4 Ø8
1
Pcs Bosch Pilot-controlled check valve
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42075
31118
31193
41103
31189
Article no.
31128
31158
31159
31153
31122
31122
31126
31124
31131
31154
31141
31142
31147
22361
31155
21339
31227
31266
8-9
D Assemblies
Assembly PD-095-000 Pneumatic unit
8.5 Control certificate of the pressure reservoir
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
8-10
D Assemblies
Assembly PD-114-000 Electric cabinet (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
9 Assembly PD-114-000 Electric cabinet
(Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
9-1
D Assemblies
Assembly PD-114-000 Electric cabinet (Siemens)
9.1 Description
The electric cabinet is used to contain all electrical components of the machine. Its design
complies with EMC requirements. The electric cabinet cooling system mounted on the
electric cabinet serves to keep the interior of the electric cabinet at a moderate
temperature. It consists of a cooling system with an air conditioning compressor. The use
of this device permits safe cooling of the electric cabinet without direct air exchange.
9.2 Maintenance and repair
The air supply and exhaust vents of the electric cabinet cooling system must always be
kept clear. If the cooling performace decreases, it may be necessary to clean the electric
cabinet cooling system in compliance with the manufacturer’s guidelines.
9.3 Drawings and parts list
9.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
9-2
D Assemblies
Assembly PD-114-000 Electric cabinet (Siemens)
Figure 9-1: Exploded view drawing of electric cabinet Siemens 840D
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
9-3
D Assemblies
Assembly PD-114-000 Electric cabinet (Siemens)
9.3.2 Parts list
Assembly PD-114-000 Electric cabinet Siemens
Quant. Unit Description
1
Pcs SB-NC-179-001 Electric cabinet SB-840 Version Rittal
2
Pcs PD-040-005 Support bracket
2
Pcs PD-040-002 Mounting bolts
2
Pcs PD-040-008 Special screws
8
Pcs SB-NC-050-013 Shim 2
1
Pcs PD-040-003 Front mounting strip
1
Pcs PD-040-004 Rear mounting strip
1
Pcs SB-NC-164-002 Panel
4
Pcs SB-NC-164-005 Mounting web 1 Type SB 80
12
Pcs Lütze Mounting clip MB 40/80
2
Pcs SB-NC-164-003 Support bar LSC-CP
6
Pcs SB-NC-164-004 Spacer 1
2
Pcs SB-NC-164-006 Mounting bar 2 Type M80
2
Pcs Elan Door switch, Order No. SEKB 33.103
2
Pcs SB-NC-164-007 Support plate for door switch
4
Pcs Tehalit Spacer M5159/2
1
Pcs Wiring duct TEH BA6 60040(1)
2
Pcs Elan Mounting clip MB 18/80
2
Pcs SB-NC-164-008 Spacer 2
1
Pcs SB-NC-164-009 Support plate for main switch
1
Pcs Lütze Cross-connection bar RG2000
1
Pcs Lütze Threaded track GS2000 (M4)
1
Pcs Rittal Cooling unit SK 3293.100; Des. 5A1 + Filter mats
1
Pcs 1F1 Automatic switch 2-Pole Type C2, Siemens
1
Pcs 1Q1 Load splitter Type NZM75-40, Klöckner-Möller
1
Pcs 1Q1.1 Auxiliary switch Type VHI-NZM7, Klöckner-Möller
1
Pcs 1Q2 Motor protection breaker Type PKZM0-4, Klöckner-Möller
1
Pcs 1T1 Transformer Type MTDN1500, Ismet
1
Pcs 2Q1 Motor protection breaker Type PKZM 1, Klöckner-Möller
2
Pcs 2S1/2S2 Auxiliary switch Type NHI11-PKZMO, Klöckner-Möller
1
Pcs 2Z1 Reset link Type 23004, Murr-Elektronik
1
Pcs 4F1 Automatic switch 1-Pole Type C6, Siemens
1
Pcs 4F3 Automatic switch 1-Pole Type C2, Siemens
3
Pcs 4S1/4S2/5S1 Auxiliary switch Type 5SX9100, Siemens
1
Pcs 4X4 Socket Type 51414, Murr-Elektronik
1
Pcs 5A1 Cooling unit Type KG4293, Rittal
1
Pcs 5F1 Automatic switch 1-Pole Type C6, Siemens
4
Pcs 6F2/6F3/6F4/6F7 Automatic 1-Pole Type C6, Siemens
1
Pcs 6GF Mains supply Type MDG20-400, Murr-Elektronik
1
Pcs 6Q1 Motor protection breaker Type PKZM0-1, Klöckner-Möller
1
Pcs 6S5 Auxiliary switch Type 5SX9100, Siemens
1
Pcs 6X1 Ground wire break terminal Type GTF76/48. Phoenix
1
Pcs 7A1 Distributor Type MVC6-VC3.0, Murr-Elektronik
1
Pcs 9A1 S7 Connection assembly Type IM36 IRM, Siemens
1
Pcs 9A2 S7 Analog assembly Type SM334-0CE00-0AA0, Siemens
6
Pcs 9A3/9A4/9A5/9A6/9A7/9A9 S7-Input assembly Type SM 321,
Siemens
1
Pcs 9A10 S7 Connection assembly Type IM361 IRM, Siemens
2
Pcs 9A13/9A14 S7 Output assembly Type SM322DO16*24V
1
Pcs 9A19 Operating panel Type 6FC52030AB100AA0, Siemens
1
Pcs 9A20 Machine control panel Type 6FC52030AB110AA2,
Siemens
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
20824
20821
21639
21182
20822
20823
31104
22343
21879
22341
22342
22344
22345
21880
22346
22347
31372
41318
60532
31166
41336
60504
41333
41341
41246
41245
41318
41086
31172
31372
41245
41245
31195
41333
41086
41066
31187
31022
31025
31020
31022
31021
31000
30966
9-4
D Assemblies
1
1
1
1
1
1
1
2
1
1
1
1
2
1
2
1
3
1
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
1
Pcs
1
1
1
1
1
Pcs
Pcs
Pcs
Pcs
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
Assembly PD-114-000 Electric cabinet (Siemens)
10P1 Running-hours counter Type BG70, Müller
11A1 Emergency stop switchgear Type PNOZ 10, Pilz
11S3 Emergency stop switch Type 3SB1400-0A, Siemens
11S4 Key-operated switch Type 1.10.108.852, Rafi
12A1 Emergency stop switchgear Type PZE-3V22, Pilz
13G1 Handwheel Type IHE100, Jakob
19F1 Automatic switch 1-Pole Type C2, Siemens
19S1/19S2 Auxiliary switch Type 5SX9100, Siemens
38K72.0 Relay Type 51120, Murr-Elektronik
38K72.1 Relay Type 51101, Murr-Elektronik
38K72.2 Control relay Type DIL R 22G, Klöckner-Möller
38K72.2 Control switch Type 04 DIL, Klöckner-Möller
38K72.3/38K72.4 Relay Type SR31/24V, Seebacher
38K72.5 Load relay Type DIL EM 01G, Klöckner-Möller
38K72.6/38K72.7 Relay Type 51120, Murr-Elektronik
40K76.6 Relay Type 51120, Murr-Elektronik
41K77.4/46K88.6/46K88.7 Relay Type 51120, Murr-Elektronik
52aA1 Feeder/negative feeder module 16/21kW Type
6SN11451BA000BA1, Siemens (1 spindle version)
52aA1 Feeder/negative feeder module 36/47 kW Type
6SN11451BA020CA1, Siemens (1 spindle version)
52aL1 Choke Type 6SN11110AA00CA0 36/47 kW, Siemens
52aZ1 Filter Type FN258-30-07, Schaffner
52bL1 Choke Type 6SN11110AA00BA0 16/21 kW
52bZ1 Filter Type FN258-30-07, Schaffner
53A1 X-Z axis/power unit Type 6SN11231AB000BA1, Siemens
(1 spindle version)
53A1 X-Z axis/power unit Type 6SN11231AB000AA0, Siemens
(2 spindle version)
53A1 X-Z axis/plug-in regulator Type 6SN11180DH220AA0,
Siemens (1 spindle version)
53A1 X-Z axis/plug-in regulator Type 6SN11180DH220AA0,
Siemens (2 spindle version)
53A2 Main spindle/power unit Type 6SN11231AA000DA1,
Siemens (1 spindle version)
53A2 Main spindle/power unit Type 6SN11231AA000DA0,
Siemens (2 spindle version)
53A2 Main spindle/plug-in regulator Type
6SN11180DG230AA0, Siemens (1 spindle version)
53A2 Main spindle/plug-in regulator Type
6SN11181DG230AA0, Siemens (2 spindle version)
54A1 Live tool Q axis/power unit Type 6SN11231AA000CA1,
Siemens (1 spindle version)
54A1 Live tool Q axis/power unit Type 6SN11231AB000AA0,
Siemens (2- spindle version)
54A1 Live tool Q axis/power unit Type 6SN11180DG210AA0,
Siemens (1 spindle version)
54A1 Live tool Q axis/power unit Type 6SN11180DH220AA0,
Siemens (2 spindle version)
55A1 Sub-spindle/plug-in regulator Type 6SN11181DG230AA0,
Siemens (2 spindle version)
55A1 Sub-spindle/power unit Type 6SN11231AA000CA0,
Siemens (2 spindle version)
56A2 NCU/plug-in regulator Type 6FC53570BA211AE1,
Siemens (1- spindle version)
56A2 NCU/Box Type 6FC52470AA000AA2, Siemens (1 spindle
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
41091
31160
31185
31162
31161
30625
41318
41086
41104
31171
41232
41212
41292
41006
41104
41104
41104
31052
31053
31069
60128
31068
60128
31055
31055
31074
31074
31059
31059
31070
31070
31054
31055
31073
31074
31070
31058
31373
60724
9-5
D Assemblies
1
Pcs
1
Pcs
1
Pcs
1
1
1
Pcs
Pcs
Pcs
2
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
1
Pcs
6
Pcs
5
Pcs
1
1
6
Pcs
Pcs
Pcs
1
Pcs
1
Pcs
1
Pcs
1
1
Pcs
Pcs
2
Pcs
Assembly PD-114-000 Electric cabinet (Siemens)
version)
56A2 NCU/plug-in regulator Type 6FC53570BB210AE0,
Siemens (2 spindle version)
56A2 NCU/Box Type 6FC53570AA200AA2, Siemens (2 spindle
version)
60F2 Automatic switch 1-Pole Type C6, Siemens (gantry
loading)
60S1 Auxiliary switch Type 5SX9100, Siemens (gantry loading)
61H1 Light Type DWDCE124, Waldmann (gantry loading)
61H2 Illuminated pushbutton unit Type 821100022, Elan
(gantry loading)
61K3/61K5 Load relay Type DIL EM 01G, Klöckner-Möller
(gantry loading)
61K5 Auxiliary switch Type 04 DIL, Klöckner-Möller (gantry
loading)
62A1 S7 Connection assembly Type IM361IRM, Siemens
(gantry loading)
62A2 S7 Input assembly Type 6ES73211BL000AA0, Siemens
(gantry loading)
62A5 S7 Output assembly Type 6ES73221BL000AA0, Siemens
(gantry loading)
62A6 S7 Output assembly Type SM322DO16*24V, Siemens
(gantry loading)
63S96.0/63S96.1/63S96.2/63S96.3/63S96.4/63S96.7
Pushbutton Type 1S.Z02, Elan (gantry loading)
64S97.0/64S97.1/64S97.2/64S97.3/64S97.7 Taster Type
1S.Z02, Elan (gantry loading)
65X1 Socket Type CDF 40, Amphenol (gantry loading)
65X1 Plug Type CDM40, Amphenol (gantry loading)
73K108.2 - 73K108.7 Relay Type 51120, Murr-Elektronik
(gantry loading)
80A1 AC power supply Type MDG20-24, Murr-Elektronik
(gantry loading)
80F1 Automatic switch 1-Pole Type C10, Siemens (gantry
loading)
80Q1 Motor protection breaker Type PKZM0-1, Klöckner-Möller
(gantry loading)
80S1 Auxiliary switch Type 5SX9100, Siemens (gantry loading)
80X1 Ground wire break terminal Type GTF76/48, Phoenix
(gantry loading)
81F1/81F2 Automatic switch 1-Pole Type C10, Siemens (gantry
loading)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
60894
60724
41245
41086
30864
60581
41006
41212
31022
31018
31019
31021
60588
60588
41294
41295
41104
31195
41087
41333
41086
41066
41087
9-6
D Assemblies
Assembly PD-096/098-000 Safety block with/without sub-spindle
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
10 Assembly PD-096/098-000 Safety block
with/without sub-spindle
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
10-1
D Assemblies
Assembly PD-096/098-000 Safety block with/without sub-spindle
10.1 Drawings and parts list
10.1.1 Exploded view drawing of safety block with sub-spindle
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
10-2
D Assemblies
Assembly PD-096/098-000 Safety block with/without sub-spindle
Figure 10-1: Exploded view drawing of safety block with sub-spindle option
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
10-3
D Assemblies
Assembly PD-096/098-000 Safety block with/without sub-spindle
10.1.2 Exploded view drawing of safety block without sub-spindle option
Figure 10-2: Exploded view drawing of safety block without sub-spindle option
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
10-4
D Assemblies
Assembly PD-096/098-000 Safety block with/without sub-spindle
10.1.3 Parts list
Assembly PD-096-000 Safety block with sub-spindle option; Article No. 10796
Quant. Unit Description
1
Pcs PD-096-001 Elbow 1
1
Pcs PD-096-002 Elbow 2
1
Pcs PD-096-003 Elbow 3
1
Pcs PD-096-004 Elbow 4
2
Pcs PD-097-000 Assembly air distributor
1
Pcs SB-NC-161-001 Valve base plate 1
1
Pcs SB-NC-161-002 Valve base plate 2
1
Pcs SB-NC-161-003 Distribution bank 1
1
Pcs SB-NC-161-004 Distribution bank 2
4
Pcs SB-NC-161-005 Adapter 1
8
Pcs SB-NC-161-006 Adapter 2
2
Pcs Techno Chemie Banjo bolt G1/8; 3802 2148 3040
4
Pcs Techno Chemie Conical nipple DIN 7603; 3913 1080 0090
3
Pcs Bosch Steck-Fix M5, pipe D=4 mm; 1823 373 009
16
Pcs AVS Banjo bolt Type 163M-11-1/8A; 304025
12
Pcs AVS Conical nipple Typ 265A-1/8x1.5; 252871
4
Pcs Rexroth Check valve G1/8; 534 098 100 0
1
Pcs Rexroth Silencer M5; 532 400 006 0
2
Pcs Ermeto Angle swivel joint G1/8, pipe D=6 mm; SWVE 6-PLR
2
Pcs Ermeto Straight threaded joint G1/8, pipe D=6 mm; GE 6-PLRED
1
Pcs Rexroth Silencer G1/8; 532 401 110 0
1
Pcs Bosch Angle joint G1/8, pipe D=8 mm; 1823 391 122
4
Pcs WIKA P/V converter (pressure/voltage converter) G1/8“;
891.14.540
2
Pcs Rexroth 5/2-port solenoid/solenoid valve; 576 365 022 0
4
Pcs Murrelektronik Valve plug; MSDU-CB1Z-G1.0
1
Pcs Ermeto Angle swivel joint G1/8, Rohr D=8 mm; SWVE 8-LLR
1
Pcs Rexroth 5/2 port solenoid/spring valve; 576 351 022 0
1
Pcs Murrelektronik Valve plug; MSUD-CB1Z-G1.0
2
Pcs Rexroth Electro/Pneumatic converter; 561 012 012 0
1
Pcs Bosch Locking screw M5; 1823 462 016
Article No.
22370
22371
22372
22373
22364
22323
22324
22325
22326
22327
22328
22321
22322
30601
22337
22315
31114
31146
22335
22363
31145
31130
31152
31144
31193
22336
31128
31193
31143
31233
Assembly PD-098-000 Safety block without sub-spindle option; Article No. 10790
Quant. Unit Description
Article No.
1
Pcs SB-NC-161-001 Valve base plate 1
22323
1
Pcs SB-NC-161-002 Valve base plate 2
22324
1
Pcs SB-NC-161-003 Distribution bank 1
22325
1
Pcs SB-NC-161-004 Distribution bank 2
22326
2
Pcs SB-NC-161-005 Adapter 1
22327
4
Pcs SB-NC-161-006 Adapter 2
22328
2
Pcs SB-NC-162-001 Lock
22331
12
Pcs AVS Banjo bolt Type 163M-11-1/8A; 304025
22337
6
Pcs AVS Conical nipple Typ 265A-1/8x1.5; 252871
22315
2
Pcs Rexroth Check valve G1/8; 534 098 100 0
31114
1
Pcs Rexroth Silencer M5; 532 400 006 0
31146
1
Pcs Rexroth Blind plate; 898 512 149 2
31147
2
Pcs Ermeto Straight threaded joint G1/8, pipe D=6 mm; GE 6-PLR- 22363
ED
1
Pcs Rexroth Silencer G1/8; 532 401 110 0
31145
1
Pcs Bosch Angle joint G1/8, pipe D=8 mm; 1823 391 122
31130
2
Pcs WIKA P/V converter (pressure/voltage converter) G1/8“;
31152
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
10-5
D Assemblies
1
2
2
1
1
1
1
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Assembly PD-096/098-000 Safety block with/without sub-spindle
891.14.540
Rexroth 5/2 port solenoid/solenoid valve; 576 365 022 0
Murrelektronik Valve plug; MSDU-CB1Z-G1.0
Ermeto Angle swivel joint G1/8, pipe D=6 mm; SWVE 6-PLR
Ermeto Angle swivel joint G1/8, pipe D=8 mm; SWVE 8-LLR
Rexroth 5/2 port solenoid/spring valve; 576 351 022 0
Murrelektronik Valve plug; MSUD-CB1Z-G1.0
Rexroth Electro/Pneumatic converter; 561 012 012 0
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
31144
31193
22335
22336
31128
31193
31143
10-6
D Assemblies
Assembly SB-NC-109-000 Spindle 5000/42
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
11 Assembly SB-NC-109-000 Spindle 5000/42
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
11-1
D Assemblies
Assembly SB-NC-109-000 Spindle 5000/42
11.1 Description
The spindle unit has a classic moveable/fixed bearing arrangement using precision
angular contact ball bearings. The bearing package built into the front in a tandem-O
arrangment forms the fixed bearing point. Located between the two bearing points is the
air supply integrated in the spindle for the clamping cylinder used at the spindle end. This
clamping cylinder is set up as a tandem cylinder to increase strength. The stroke limiting
rings located on the end permit adjustment of the push/pull tube clamping stroke in both
directions.
11.2 Handling
11.2.1 Setting the clamping stroke
Stroke limiting rings
Micro-switch
Stop ring
Figure 11-1: Setting the clamping stroke
Proceed as follows to set the clamping stroke:
1. Loosen the 2 attachment screws on the stroke limiting rings.
2. Rotate the stroke limiting rings away from the stop ring until the full path of the
clamping cylinder can be traversed.
3. Mount the chucking tool and clamp a workpiece in.
4. Rotate the stroke limiting ring that limits the stroke in this clamping direction until
it touches the stop ring. Rotate the stroke limiting ring about 1 turn back and then
as far as required until the spacing slits in the stroke limiting ring are not lying
over the cavities in the headstock spindle. If this is not done, the ring rotation
trueness and therefore also the spindle trueness will not be ensured. Tighten the
stroke limiting ring with the attachment screws.
5. Leave the workpiece in place. Rotate the second stroke limiting ring up to the
stop ring until the stroke of the stop ring is still sufficient to open the chucking
tool and remove the workpiece. Note however that the stroke must be sufficiently
great that the micro-switches cannot be overlapped in any circumstance. The
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
11-2
D Assemblies
Assembly SB-NC-109-000 Spindle 5000/42
spacing slits in the stroke limiting ring must not lie over the cavities in the
headstock spindle. Otherwise, the ring rotation trueness and therefore also the
spindle trueness will not be ensured. Tighten the stroke limiting ring with the
attachment screws.
6. Check the chucking tool function.
THE SPINDLE MUST NOT BE OPERATED IF THE STROKE
LIMITING RINGS ARE NOT TIGHTENED! SPINDLE ELEMENTS
MAY BE DAMAGED!
11.3 Drawings and parts list
11.3.1 Detail assembly
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
11-3
D Assemblies
Assembly SB-NC-109-000 Spindle 5000/42
Figure 11-2: Detail assembly spindle unit 5000/42
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
11-4
D Assemblies
Assembly SB-NC-109-000 Spindle 5000/42
11.3.2 Parts list
Assembly SB-NC-109-000 Spindle unit 5000/42; Article No. 10470
Quant. Unit Description
5
Pcs Spindle bearing B71916E.TPA.P4.UL
1
Pcs SB-NC-109-001 Spindle housing
1
Pcs SB-NC-109-002 Rear cover
2
Pcs Parker O-Ring 2-016, 15.6x1.78
1
Pcs SB-NC-109-003 Front cover
1
Pcs SB-NC-109-004 Front cover
1
Pcs Parker O-Ring 2-161, 139.37x2.62
1
Pcs SB-NC-109-005 Bearing ring
2
Pcs SB-NC-109-006 Balancing element
1
Pcs SB-NC-109-007 External spacer ring
2
Pcs SB-NC-109-009 Sealing disc
1
Pcs SB-NC-109-010 Inner ring air supply
1
Pcs SB-NC-109-011 Cover disc
1
Pcs SB-NC-109-012 Belt wheel Rod T.2.5 Z=128 DT=101.85
DK=101.35
1
Pcs SB-NC-109-013 Flanged wheel
1
Pcs SB-NC-109-015 Indexed wheel
1
Pcs SB-NC-109-016 Pre-loaded nut
1
Pcs SB-NC-109-017 Locking nut
14
Pcs Parker O-Ring 2-010, 6.07x1.78
1
Pcs SB-NC-109-019 Clamping cylinder 2
1
Pcs SB-NC-109-020 Separating piston
3
Pcs Parker O-Ring 2-048, 120.37x1.78
1
Pcs SB-NC-109-021 Sealing plate
2
Pcs SB-NC-109-022 Piston
2
Pcs SB-NC-109-023 Reducer disc
4
Pcs Shaft locking ring DIN471-55x2
2
Pcs Parker O-Ring 2-034, 53.7x1.78
2
Pcs Merkel Airzet PK 125, L2529-059.161
4
Pcs Helmbrecht PDF Rod seal C1 5040 N3571
1
Pcs SB-NC-109-027 Rod belt pulley T.2.5 Z=128 DT=101.85
DK=101.35
1
Pcs SB-NC-109-028 Carrier Rod belt pulley
1
Pcs Toothbelt Synchroflex T2.5/650/4
2
Pcs Feather key 6885 A10/8x45
3
Pcs Parker O-Ring 2-041, 75.92x1.78
1
Pcs SB-NC-109-034 Flanged pulley without indexing
1
Pcs SB-NC-109-035 Headstock spindle
1
Pcs SB-NC-109-018 Clamping cylinder 1
1
Pcs SB-NC-109-036 Push/pull tube
1
Pcs SB-NC-109-008 Inner spacer ring
1
Pcs SB-NC-109-024 Stopper
1
Pcs SB-NC-109-026 Support ring
2
Pcs SB-NC-109-025 Adjusting nut
1
Pcs SB-NC-109-042 Main belt wheel HTD 8m Z=42 centre piece
2
Pcs SB-NC-109-044 Intermediate flanged wheel
2
Pcs SB-NC-109-043 Main belt wheel HTD 8m Z=42 edge piece
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
21718
21719
21720
30611
21721
21722
30801
21723
21724
21725
21727
21728
21729
21730
21731
21733
21734
21735
30803
21737
21738
30605
21739
21740
21741
30807
30802
30056
30806
100426
21746
30811
30805
30804
21752
21753
21736
21755
21726
21742
21744
21743
22405
22404
22403
11-5
D Assemblies
Assembly SB-NC-135-000 Spindle 8000/32
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
12 Assembly SB-NC-135-000 Spindle 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
12-1
D Assemblies
Assembly SB-NC-135-000 Spindle 8000/32
12.1 Description
The spindle unit has a classic moveable/fixed bearing arrangement using precision
angular contact ball bearings. The bearing package built into the front in a tandem-O
arrangment forms the fixed bearing point. Located between the two bearing points is the
air supply integrated in the spindle for the clamping cylinder used at the spindle end. This
clamping cylinder is set up as a tandem cylinder to increase strength. The stroke limiting
rings located on the end permit adjustment of the push/pull tube clamping stroke in both
directions.
12.2 Handling
12.2.1 Setting the clamping stroke
Stroke limiting rings
Micro-switch
Stop ring
Figure 12-1: Setting the clamping stroke
Proceed as follows to set the clamping stroke:
1. Loosen the 2 attachment screws on the stroke limiting rings.
2. Rotate the stroke limiting rings away from the stop ring until the full path of the
clamping cylinder can be traversed.
3. Mount the chucking tool and clamp a workpiece in.
4. Rotate the stroke limiting ring that limits the stroke in this direction until it touches
the stop ring. Rotate the stroke limiting ring about 1 turn back and then as far as
required until the spacing slits in the stroke limiting ring are not lying over the
cavities in the headstock spindle. If this is not done, the ring rotation trueness
and therefore also the spindle trueness will not be ensured. Tighten the stroke
limiting ring with the attachment screws.
5. Leave the workpiece in place. Rotate the second stroke limiting ring up to the
stop ring until the stroke of the stop ring is still sufficient to open the chucking
tool and remove the workpiece. Note however that the stroke must be sufficiently
great that the micro-switches cannot be overlapped in any circumstance. The
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
12-2
D Assemblies
Assembly SB-NC-135-000 Spindle 8000/32
spacing slits in the stroke limiting ring must not lie over the cavities in the
headstock spindle. Otherwise, the ring rotation trueness and therefore also the
spindle trueness will not be ensured. Tighten the stroke limiting ring with the
attachment screws.
6. Check the chucking tool function.
THE SPINDLE MUST NOT BE OPERATED IF THE STROKE
LIMITING RINGS ARE NOT TIGHTENED! SPINDLE ELEMENTS
MAY BE DAMAGED!
12.3 Drawings and parts list
12.3.1 Detail assembly
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
12-3
D Assemblies
Assembly SB-NC-135-000 Spindle 8000/32
Figure 12-2: Detail assembly spindle unit 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
12-4
D Assemblies
Assembly SB-NC-135-000 Spindle 8000/32
12.3.2 Parts list
Assembly SB-NC-135-000 Spindle unit 8000/32; Article No. 10538
Quant. Unit Description
5
Pcs Spindle bearing HS71914C.T.P4.UL
1
Pcs SB-NC-135-001 Spindle housing
1
Pcs SB-NC-135-002 Rear cover
2
Pcs Parker O-Ring 2-016, 15.6x1.78
1
Pcs SB-NC-135-003 Front cover
1
Pcs SB-NC-135-004 Front cover
1
Pcs Parker O-Ring 2-159, 126.67x2.62
1
Pcs SB-NC-135-005 Bearing ring
2
Pcs SB-NC-109-006 Balancing element
1
Pcs SB-NC-135-007 External spacer ring
2
Pcs SB-NC-135-009 Sealing disc
1
Pcs SB-NC-135-010 Inner ring air supply
1
Pcs SB-NC-135-011 Cover disc
1
Pcs SB-NC-135-012 Belt wheel Rod T.2.5 Z=108 DT=85.94
DK=85.94
1
Pcs SB-NC-135-013 Flanged wheel
1
Pcs SB-NC-135-015 Indexed wheel
1
Pcs SB-NC-135-016 Pre-loaded nut
1
Pcs SB-NC-135-017 Locking nut
14
Pcs Parker O-Ring 2-010, 6.07x1.78
1
Pcs SB-NC-135-019 Clamping cylinder 2
1
Pcs SB-NC-135-020 Separating piston
1
Pcs Parker O-Ring 2-043, 88.62x1.78
1
Pcs SB-NC-135-021 Sealing plate
2
Pcs SB-NC-135-022 Piston
2
Pcs SB-NC-135-023 Reducer disc
4
Pcs Shaft locking ring DIN471-45x1.75
2
Pcs Parker O-Ring 2-031, 44.17x1.78
2
Pcs Parker Piston seal set profile OA, OA 0110 00811
4
Pcs Helmbrecht PDF Rod seal C1 4035 N3571
1
Pcs BK-NC-020-071 Toothed wheel/encoder T2.5 Z=108 DK=85.45
DT=85.94
1
Pcs BK-NC-020-070 Path holder
1
Stl Toothbelt Synchroflex T2.5/600/4
2
Pcs Feather key 6885 A6/6x45
3
Pcs Parker O-Ring 2-038, 66.40x1.78
1
Pcs SB-NC-135-025 Flanged pulley without indexing
1
Pcs SB-NC-135-026 Headstock spindle
1
Pcs SB-NC-135-018 Clamping cylinder 1
1
Pcs SB-NC-135-008 Inner spacer ring
2
Pcs Parker O-Ring 2-046, 107.67x1.78
1
Pcs SB-NC-135-024 Stopper
1
Pcs SB-NC-109-026 Support ring
1
Pcs SB-NC-135-006 Push/pull tube
2
Pcs SB-NC-109-025 Adjusting nut
1
Pcs SB-NC-135-031 Main belt wheel HTD 8m Z=36 centre piece
2
Pcs SB-NC-135-032 Main belt wheel HTD 8m Z=36 edge piece
2
Pcs SB-NC-135-033 Intermediate flanged wheel
4
Pcs SB-NC-020-007 Slide-on sleeve adjusting key
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
21901
21902
21903
30611
21904
21905
30834
21906
21907
21908
21910
21911
21912
21913
21914
21916
21917
21918
30803
21920
21921
30837
21922
21923
21924
30841
30835
30839
30838
20208
20207
30152
30840
30836
21926
21927
21919
21909
30607
21925
21744
21724
21743
22407
22406
22408
20376
12-5
D Assemblies
Assembly PD-09100 Main spindle drive 5000/42 (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
13 Assembly PD-09100 Main spindle drive
5000/42 (Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
13-1
D Assemblies
Assembly PD-09100 Main spindle drive 5000/42 (Siemens)
13.1 Drawings and parts list
13.1.1 Detail assembly
Figure 13-1: Detail assembly of main spindle drive 5000/42 (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
13-2
D Assemblies
Assembly PD-09100 Main spindle drive 5000/42 (Siemens)
13.1.2 Parts list
Assembly PD-091-000 Main spindle drive Article No. 10802
Quant. Unit Description
1
Pcs Siemens Servo-motor 1FT6084-8AK71-1AG3
2
Pcs SB-NC-156-005 Thrust plate
1
Pcs SB-NC-156-001 Belt pulley 5000 Z=35 DK=87.76 DT=89.13
1
Pcs SB-NC-156-002 Clamping ring
1
Pcs Ring clamp cone-clamping element TLK300 32x36
4203.032.001
1
Pcs PD-091-001 Base plate for main spindle motor 1FT6084
1
Pcs SB-NC-156-003 Adjustable plate for main spindle motor
1FT6084
3
Pcs Toothed belt HTD 1040-8M-8
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22194
22190
22191
31063
22375
22192
31284
13-3
D Assemblies
Assembly PD-092-000 Main spindle drive 8000/32 (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
14 Assembly PD-092-000 Main spindle drive
8000/32 (Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
14-1
D Assemblies
Assembly PD-092-000 Main spindle drive 8000/32 (Siemens)
14.1 Drawings and parts list
14.1.1 Detail assembly
Figure 14-1: Detail assembly of main spindle drive 8000/32 (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
14-2
D Assemblies
Assembly PD-092-000 Main spindle drive 8000/32 (Siemens)
14.1.2 Parts list
Assembly PD-092-000 Main spindle drive 8000/32; Article No.10801
Quant. Unit Description
1
Pcs Siemens Servo-motor 1FT6084-8AK71-1AG3
2
Pcs SB-NC-156-005 Thrust plate
1
Pcs SB-NC-157-001 Belt pulley 8000 Z=35 DK=87.76 DT=89.13
1
Pcs SB-NC-156-002 Clamping ring
1
Pcs Ring clamp cone-clamping element TLK300 32x36
4203.032.001
1
Pcs PD-091-001 Base plate for main spindle motor 1FT6084
1
Pcs SB-NC-156-003 Adjustment plate for main spindle motor
1FT6084
3
Pcs Toothed belt HTD 1080-8M-8
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22194
100065
22191
31063
22375
22192
31285
14-3
D Assemblies
Assembly SB-NC-166-000 ROD
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
15 Assembly SB-NC-166-000 ROD
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
15-1
D Assemblies
Assembly SB-NC-166-000 ROD
15.1 Drawings and parts list
15.1.1 Detail assembly
Figure 15-1: Detail assembly of assembly ROD
15.1.2 Parts list
Assembly SB-NC-166-000 ROD
Quant. Unit Description
2
Pcs FAG Bearing 608.2RSR
1
Pcs Shaft locking ring DIN 471-8x0.8
1
Pcs Heidenhain ROD 486.0003-1024
1
Pcs SIEMENS Flat spring coupling V23422-A0008
1
Pcs BK-NC-20-069 Synchro system holder
1
Pcs BK-NC-20-072 Spacer
1
Pcs BK-NC-20-073 Synchro system axis
4
Pcs BK-NC-20-077 Clamp I
4
Pcs BK-NC-20-078 Clamp II
3
Pcs BK-NC-20-079 Clamp
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Artikel no.
30083
30081
31066
30082
20239
20209
20210
20206
20205
20238
15-2
D Assemblies
Assembly PD-088-000 Feedscrew X-axis
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
16 Assembly PD-088-000 Feedscrew X-axis
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
16-1
D Assemblies
Assembly PD-088-000 Feedscrew X-axis
16.1 Description
The feedscrew of the X-axis is a planetary roller spindle with rotary nut. The preloaded
feedscrew nut, without clearance, is driven by a toothed belt drive.
16.2 Maintenance and repair
The feedscrew of the X-axis has a central bore and is equipped with a grease nipple (see
Figure 16-1). This grease nipple is used to force the high performance grease into the
bearing and spindle nut. Lubrication can only be implemented at a certain slide position. If
lubrication is carried out at another slide position, the grease cannot reach the necessary
areas and the process has to be repeated.
16.2.1 Lubricating the X-axis
Grease nipple
Figure 16-1: Lubricating the X-axis
Proceed as follows to lubricate the X-axis:
1. Select the JOG mode.
2. Move the X slide to the measurement A = 40 mm.
3. Press the Emergency stop button.
4. Use the grease press to force 3-5 cm³ high performance grease, as specified in
the table of lubricants, into the spindle.
5. Unlock the Emergency stop button.
6. Move the X slide slowly across the entire movement range.
16.3 Drawings and parts list
16.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
16-2
D Assemblies
Assembly PD-088-000 Feedscrew X-axis
Figure 16-2: Exploded view drawing of X-axis feedscrew
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
16-3
D Assemblies
Assembly PD-088-000 Feedscrew X-axis
16.3.2 Parts list
Assembly PD-088-000 Feedscrew X-axis; Article No. 10782
Quant. Unit Description
1
Pcs SB-NC-113-001 Bearing housing X-axis
2
Pcs SB-NC-113-002 Adjusting strip
1
Pcs PD-088-001 Feedscrew X-axis gradient 6mm
2
Pcs INA Axial-Radial bearing NKX35Z/P5
3
Pcs Larco Grease nipple 291 M6
4
Pcs SB-NC-011-018 Nut for feedscrew
1
Pcs SB-NC-113-003 Drive shaft X-feedscrew
1
Pcs SB-NC-113-004 Support sleeve
1
Pcs SB-NC-113-005 Pressure disc
1
Pcs SB-NC-113-006 Pre-loaded nut
12
Pcs Cylindrical pin DIN 6325-5M6x14
24
Pcs Spring washer DIN 2093 10x5.2x0.4
1
Pcs SB-NC-113-007 Lock washer
1
Pcs SB-NC-113-008 Adjusting nut
1
Pcs SB-NC-113-009 Locknut
1
Pcs Dowel pin 4x12 DIN 1481
1
Pcs SB-NC-113-012 Holder for stripper
1
Pcs Synchroflex toothed belt ZR-T5/630/16
1
Pcs SB-NC-154-002 Stripper 1
1
Pcs SB-NC-154-003 Stripper 2
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
21793
21794
22305
30189
30312
21160
21795
21796
21797
21798
30778
30821
21799
21800
21801
30820
21790
30210
22187
22188
16-4
D Assemblies
Assembly SB-NC-158-000 X-feed drive (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
17 Assembly SB-NC-158-000 X-feed drive
(Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
17-1
D Assemblies
Assembly SB-NC-158-000 X-feed drive (Siemens)
17.1 Drawings and parts list
17.1.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
17-2
D Assemblies
Assembly SB-NC-158-000 X-feed drive (Siemens)
Figure 17-1: Exploded view drawing of X-feed drive (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
17-3
D Assemblies
Assembly SB-NC-158-000 X-feed drive (Siemens)
17.1.2 Parts list
Assembly SB-NC-158-000 X-feed drive Siemens 840D; Article No. 10706
Quant. Unit Description
1
Pcs SB-NC-158-002 Motor holding plate
1
Pcs SB-NC-158-004 Supports
1
Pcs SB-NC-158-001 Belt pulley
1
Pcs SB-NC-158-003 Clamping sleeve
1
Pcs Siemens Servo-motor 1FT6061-1AF71-1AH0
2
Pcs SB-NC-020-012
1
Pcs Ring clamp clamping element TLK300, 24x28, 4203.024.001
1
Pcs O-Ring 107.62x2.62
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22196
22198
22195
22197
21164
31064
31065
17-4
D Assemblies
Assembly PD-089-000 Feedscrew Z-axis
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
18 Assembly PD-089-000 Feedscrew Z-axis
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
18-1
D Assemblies
Assembly PD-089-000 Feedscrew Z-axis
18.1 Description
The feedscrew of the Z-axis is a planetary roller spindle with rotary nut. The rotating
feedscrew is supported by a compact axial inclined ball bearing on the foundation plate.
The free spindle end is held in a guide sleeve. The feedscrew is driven by a toothed belt
drive.
18.2 Maintenance and repair
The feedscrew of the Z-axis has a central bore and is equipped with a grease nipple (see
Figure 18-1). This grease nipple is used to force the high performance grease into the
bearing and spindle nut. Lubrication can only be implemented at a certain slide position. If
lubrication is carried out at another slide position, the grease cannot reach the necessary
areas and the process has to be repeated.
18.2.1 Lubricating the Z-axis
Z slide
Grease nipple
Drive Z slide
Adjustment of
slide position
Figure 18-1: Lubricating the Z-axis
Proceed as follows to lubricate the Z-axis:
1.
2.
3.
4.
Select the JOG mode.
Move the Z slide to the measurement A = 13 mm.
Press the Emergency stop button.
Use the grease press to force 3-5 cm³ high performance grease, as specified in
the table of lubricants, into the spindle.
5. Unlock the Emergency stop button.
6. Move the Z slide slowly across the entire movement range.
18.3 Drawings and parts list
18.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
18-2
D Assemblies
Assembly PD-089-000 Feedscrew Z-axis
Figure 18-2: Exploded view drawing of Z-axis feedscrew
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
18-3
D Assemblies
Assembly PD-089-000 Feedscrew Z-axis
18.3.2 Parts list
Assembly PD-089-000 Feedscrew Z-axis; Article No. 10783
Quant. Unit Description
1
Pcs PD-089-001 Feedscrew Z-axis gradient 6mm
1
Pcs SB-NC-114-002 Housing Z-feed nut
1
Pcs SB-NC-113-008 Adjusting nut
1
Pcs SB-NC-113-009 Locknut
1
Pcs SB-NC-114-003 Link Z-axis
2
Pcs SB-NC-114-004 Sleeve
2
Pcs SB-NC-114-005 Sleeve for cross-slide
1
Pcs SB-NC-011-040 Support bearing for Z-axis
1
Pcs SB-NC-011-034 Feather key
1
Pcs INA Axial inclined ball bearing ZKLF25752RS
1
Pcs SB-NC-114-007 Locknut Z-axis bearing
1
Pcs SB-NC-114-008 Locknut
1
Pcs Larco Grease nipple 291 M6
1
Pcs SB-NC-114-001 Fixing nut Z-feedscrew
1
Pcs SB-NC-114-009 Locknut Z-feedscrew
1
Pcs Synchroflex drive belt ZR-T5/725/16
2
Pcs SB-NC-154-003 Stripper 2
2
Pcs SB-NC-114-006 Shearing pin
1
Pcs SB-NC-011-020 Drive disc
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22306
21803
21800
21801
21804
21805
21806
21313
21149
30190
21808
21809
30312
21791
21810
30185
22188
21807
21148
18-4
Assembly: SB-NC-159-000 Z-feed drive (Siemens)
D Assemblies
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
19 Assembly: SB-NC-159-000 Z-feed drive
(Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
19-1
Assembly: SB-NC-159-000 Z-feed drive (Siemens)
D Assemblies
19.1 Drawings and parts list
19.1.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
19-2
D Assemblies
Assembly: SB-NC-159-000 Z-feed drive (Siemens)
Figure 19-1: Exploded view drawing of the Z-feed drive (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
19-3
D Assemblies
Assembly: SB-NC-159-000 Z-feed drive (Siemens)
19.1.2 Parts list
Assembly SB-NC-159-000 Z-feed drive; Article no. 10707
Quant. Unit Designation
1
Pcs Siemens Servo-motor 1FT6061-1AF71-3AG0
1
Pcs SB-NC-020-018 Clamp for the adjusting plate
1
Pcs SB-NC-159-002 Motor holding plate
1
Pcs SB-NC-020-017 Clamp for the adjusting plate
1
Pcs SB-NC-159-001 Pulley wheel
1
Pcs SB-NC-159-003 Clamping ring
1
Pcs Ringspann cone-clamping element TLK300, 24x28,
4203.024.001
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21169
22200
21170
22199
22201
31064
19-4
D Assemblies
Assembly PD-119-000 Tailstock
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-11/02-840D
61503D
20 Assembly PD-119-000 Tailstock
PD-1-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
20-1
D Assemblies
Assembly PD-119-000 Tailstock
20.1 Handling
20.1.1 Adjusting the limit switches
Limit switch for status
message M15
(quill at the front)
Limit switch for status
message M16
(quill at the back)
Limit switch for
monitoring the end
position of the quill
Figure 20-1: Limit switches of the tailstock
When the tailstock is in the working position, adjust the limit switches for the quill as
follows (see signs of the switches to find them and their function in the circuit diagram):
• The limit switch for “Quill at the back“ must light up when the quill has been
moved to the back. The workpiece is not clamped by the quill (feedback
message M16).
• The limit switch for “Quill at the front“ must light up when the quill has been
moved to the front. The workpiece is clamped by the quill (feedback message
M15).
• The limit switch for “Quill in end position“ must light up when the quill is at the
front without workpiece in the chuck.
20.1.1.1 Monitoring characteristic
When during the machining of a workpiece the limit switch “M15“ is left or the limit switch
“Qill in end position“ is reached the machine is stopped with an emergency-off error
message.
PD-1-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
20-2
D Assemblies
Assembly PD-119-000 Tailstock
20.2 Maintenance and repair
Lubrication of the quill is achieved automatically over the pressurised lubrication system.
F
THEORETICAL PRESSING FORCE 636N/BAR
MAX. PRESSURE 5 BAR
RIGIDITY IN MACHINE X-AXIS, QUILL COMPLETELY MOVED
OUT, MEASUREMENT AT THE OUTERMOST END OF THE
QUILL (NOT AT THE POINT) AGAINST Q SLIDE C=40N/µm
20.3 Drawings and parts lists
20.3.1 Detail assembly drawing and the ISO-view
(See following page)
PD-1-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
20-3
Assembly PD-119-000 Tailstock
D Assemblies
Figure 20-2: Detail assembly drawing and the ISO-view for the tailstock
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
20-4
D Assemblies
Assembly PD-119-000 Tailstock
20.3.2 Parts list
Assembly PD-119-000 Tailstock
Quant. Unit Description
1
Piece Tailstock case
Parts number/Spezification
PD-119-001
1
Piece Base plate
PD-119-002
2
1
1
1
1
1
1
1
1
1
1
1
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
PD-119-003
PD-119-004
PD-119-005
PD-119-006
PD-119-007
PD-119-034
PD-119-009
PD-119-010
PD-119-011
PD-119-012
PD-119-013
PD-119-014
1
1
1
1
1
1
1
1
1
1
1
4
1
3
3
1
4
4
1
2
2
2
1
4
2
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
1
3
3
1
Piece
Piece
Piece
Piece
Aligning strip
Cover
Holder for cabel tow
Protection cover
Quill
Seal support
Centering point
Pressure disk
Inner distance bushing
Outer distance sleeve
Aligning ring
Auxiliary centering
bushing
Anti-rotation device
Pressure rod
Aligning ring
Distance bushing
Axial bearing support
Pressure disk
Seal plate part 1
Seal plate part 2
Piston
Cylinder flange 1
Cylinder flange 2
Tension rod
Cylinder tube
Pressure bolt
Clamp for sensor
Casted end case
Upper washer
Lower washer
2-fold distributor
Screw joint 1/8-M8
Valve NG4 G1/8
Plug R1/8
Sperical roller bearing
Spindle bearing
Needle roller bearing
without internal ring
Seal ring G24x32x4
Sensor magnet., cylind.
Cable box
O-ring 53,7x1,78
PD-1-11/02-840D
PD-119-015
PD-119-016
PD-119-017
PD-119-018
PD-119-019
PD-119-020
PD-119-021
PD-119-022
PD-119-023
PD-119-025
PD-119-026
PD-119-027
PD-119-028
PD-119-029
PD-119-030
PD-119-031
PD-050-043
PD-050-044
-
ID-Number
ID: 100002
Cast: 100003
ID: 100004
Cast: 100005
ID: 100006
ID: 100007
ID: 100008
ID: 100009
ID: 100010
ID: 101410
ID: 100012
ID: 100013
ID: 100014
ID: 100015
ID: 100016
ID: 100017
-
ID: 100018
ID: 100019
ID: 100020
ID: 100021
ID: 100022
ID: 100023
ID: 100024
ID: 100025
ID: 100026
ID: 100028
ID: 100029
ID: 100030
ID: 100031
ID: 100032
ID: 100033
ID: 100034
ID: 21003
ID: 21004
ID: 100566
ID: 100035
ID: 100036
ID: 26132
ID: 100037
ID: 26030
ID: 100040
-
ID. 100041
ID: 100042
ID: 100043
ID: 100044
 SPINNER Werkzeugmaschinenfabrik GmbH
20-5
D Assemblies
1
1
1
3
1
1
Piece
Piece
Piece
Piece
Piece
Piece
Assembly PD-119-000 Tailstock
O-ring 63.22x1.78
O-ring 82.22x2.62
Stripper A5 55x63x7/5,5
Rof seal E5
Rod seal C1
Piston seal
PD-1-11/02-840D
-
 SPINNER Werkzeugmaschinenfabrik GmbH
ID: 100045
ID: 100046
ID: 100047
ID: 100048
ID: 100049
ID: 100050
20-6
D Assemblies
Assembly SB-NC-110-000 Spindle flushing system 5000/42
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
21 Assembly SB-NC-110-000 Spindle flushing
system 5000/42
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
21-1
D Assemblies
Assembly SB-NC-110-000 Spindle flushing system 5000/42
21.1 Description
In the spindle flushing system the cooling fluid flows through the spindle to the clamped
workpiece. It can even serve as a cooling system for the interface for appropriate
workpieces and the chucking tools can also be rinsed free of chips. In the case of very
small workpieces which cannot be removed from the machine using a gripper, these can
be rinsed out of the chucking tools by the spindle flushing system and caught in a
container.
21.2 Handling
21.2.1 Mounting
3
2
4
5
1
6
8
7
Figure 21-1: Mounting of the spindle flushing system (for spindle speeds up to 5,000
r.p.m.)
You can assemble the spindle flushing system as follows:
1. Remove the adjusting nut 3 and the stop ring 4. Insert the sealing package 6
(Merkel B0153-131.175 - O-ring 41x1.78) according to Figure 21-1. Use screw 5
to fix the stop ring in place.
Screw 5: 12 pcs. DIN 912 M3x25-12.9; Mmax=1,5Nm
2. Assemble flange 1 onto the end of the spindle. Use screw 2.
Screw 2: 6 pcs. DIN 912 M3x6-12.9; Mmax=1,2Nm
3. Mount radial shaft seal ring 8 with a little grease. Connect the rotation guide 1
with the mounting bracket 7. Ensure exact alignment of the rotation guide.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
21-2
D Assemblies
Assembly SB-NC-110-000 Spindle flushing system 5000/42
21.3 Maintenance and repair
Check all of the O-rings on the carriage and all other seals regularly before mounting and
using the spindle flushing system. This also includes the radial shaft seal ring. These
should be replaced immediately if signs of wear or cracks are found
Regularly check the cooling fluid connection to make sure that the line does not leak.
DRY RUNNING OF THE SPINDLE FLUSHING SYSTEM WILL
LEAD TO DESTRUCTION OF THE RADIAL SHAFT SEALING
RING!
WATCH OUT FOR THIS DURING WORK OPERATIONS WHERE
THE SPINDLE OPERATES FOR A SHORT PERIOD WITHOUT
ACTIVATED SPINDLE FLUSHING!
21.4 Drawings and parts lists
21.4.1 Detail assembly drawing
Figure 21-2: Detail assembly drawing of the spindle flushing system 5000/42
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
21-3
D Assemblies
Assembly SB-NC-110-000 Spindle flushing system 5000/42
21.4.2 Parts list
Sub-assembly SB-NC-110-000 Spindle flushing unit 5000/42; Article no. 10474
Quant. Unit Designation
1
Pcs SB-NC-110-001 Longitudinal seal holder
1
Pcs SB-NC-110-002 Sealing runner
1
Pcs Merkel radial shaft seal ring 14x28x7; 0145-129.678
1
Pcs Securing ring DIN472-28x1.2
1
Pcs Merkel rod seal 32x39.3x3.2 OMS-MR B0153-131.175
1
Pcs Parker O-ring 2-030, 41x1.78
1
Pcs BK-NC-020-103 Torque support
1
Pcs BK-NC-020-109 Base holder
1
Pcs BK-NC-020-105 Support bracke
1
Pcs T-tenon block DIN 508-6 (Thread M5)
1
Pcs BK-NC-020-107 Clamping plate
1
Pcs SB-NC-137-003 Connector
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21710
21711
30799
30800
30798
30797
21531
21534
21529
30791
21533
21933
21-4
D Assemblies
Assembly SB-NC-137-000 Spindle flushing system 8000/32
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
22 Assembly SB-NC-137-000 Spindle flushing
system 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
22-1
D Assemblies
Assembly SB-NC-137-000 Spindle flushing system 8000/32
22.1 Description
In the spindle flushing system the cooling fluid flows through the spindle to the clamped
workpiece. It can even serve as a cooling system for the interface for appropriate
workpieces and the chucking tools can also be rinsed free of chips. In the case of very
small workpieces which cannot be removed from the machine using a gripper, these can
be rinsed out of the chucking tools by the spindle flushing system and caught in a
container.
22.2 Handling
22.2.1 Mounting
4
3
2
5
1
6
7
9
8
Figure 22-1: Mounting of the spindle flushing system (for spindle speeds up to 8,000
r.p.m.)
You can assemble the spindle flushing system as follows:
1. Attach seal holder with integrated sealing package 7 (Merkel B0153-131.171 - Oring 29.87x1.78) to the stop ring 4 and the push/pull tube 6. Use screw 5 to fix
the seal support.
Screw 5: 12 pcs. DIN 912 M3x25-12.9; Mmax=1,5Nm
2. Assemble flange 2 onto the end of the spindle. Use screw 3.
Screw 2: 6 pcs. DIN 912 M3x6-12.9; Mmax=1,2Nm
3. Mount radial shaft seal ring 9 with a little grease. Connect the rotation guide 1
with the mounting bracket 8. Ensure exact alignment of the rotation guide.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
22-2
D Assemblies
Assembly SB-NC-137-000 Spindle flushing system 8000/32
22.3 Maintenance and repair
Check all of the O-rings on the carriage and all other seals regularly before mounting and
using the spindle flushing system. This also includes the radial shaft seal ring. These
should be replaced immediately if signs of wear or cracks are found
Regularly check the cooling fluid connection to make sure that the line does not leak.
DRY RUNNING OF THE SPINDLE FLUSHING SYSTEM WILL
LEAD TO DESTRUCTION OF THE RADIAL SHAFT SEALING
RING!
WATCH OUT FOR THIS DURING WORK OPERATIONS WHERE
THE SPINDLE OPERATES FOR A SHORT PERIOD WITHOUT
ACTIVATED SPINDLE FLUSHING!
22.4 Drawings and parts lists
22.4.1 Detail assembly drawing
Figure 22-2: Detail assembly drawing of the spindle flushing system 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
22-3
D Assemblies
Assembly SB-NC-137-000 Spindle flushing system 8000/32
22.4.2 Parts list
Assembly SB-NC-137-000 Spindle flushing unit 8000/32; Article no. 10540
Quant. Unit Designation
1
Pcs Merkel radial shaft seal ring 14x28x7; 0145-129.678
1
Pcs Securing ring DIN472-28x1.2
1
Pcs Merkel bar seal DIN 472-28x1.2
1
Pcs Merkel O-ring 2-025, 29.87x1.78
1
Pcs BK-NC-020-103 Torque support
1
Pcs BK-NC-020-109 Base holder
1
Pcs BK-NC-020-105 Support bracke
1
Pcs T-tenon block DIN 508-6 (Thread M5)
1
Pcs BK-NC-020-107 Clamping plate
1
Pcs SB-NC-137-001 Longitudinal seal holder
1
Pcs SB-NC-137-002 Sealing runner
1
Pcs SB-NC-137-003 Connector
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
30799
30800
30843
30842
21531
21534
21529
30791
21533
21931
21932
21933
22-4
D Assemblies
Assembly: PD-074-000 Stroke monitoring device for the main spindle
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-2-11/02-840D
61503E
23 Assembly: PD-074-000 Stroke monitoring
device for the main spindle
PD-2-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
23-1
D Assemblies
Assembly: PD-074-000 Stroke monitoring device for the main spindle
23.1 Handling
23.1.1 Adjustment of the clamping stroke monitoring device
Clampimg ring
B
A
D
C
Figure 23-1: Adjustment of the clamping stroke monitoring device
1) Micro switch for clamping ring at the back (Siemens: 24S44.5; Fanuc: 23S02.3)
2) Micro switch for clamping ring at the front (Siemens: 24S44.4; Fanuc: 23S02.2)
3) Micro switch for clamping ring in position „clamped without workpiece“ (Siemens:
24S44.6; Fanuc: 23S02.4)
4) Locking screw for micro switch
Adjust the clamping stroke monitoring device as follows:
1. Adjust the clamping stroke limitation (see Book D Assemblies, Chapter 11
Assembly SB-NC-109-000 Spindle 5000/42).
2. Clamp a workpiece.
3. When the clamping ring moves to the back then adjust the micro switch A in the
way that its LED lights up. When the clamping ring moves to the front then adjust
the micro switch B in the way that its LED lights on.
4. Release the workpiece.
5. When the clamping ring moves to the back then adjust the micro switch A in the
way that its LED lights up. When the clamping ring moves to the front then adjust
the micro switch B in the way that its LED lights on.
6. Clamp without workpiece. Adjust the micro switch C in the way that its LED lights
on.
PD-2-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
23-2
D Assemblies
F
Assembly: PD-074-000 Stroke monitoring device for the main spindle
IN CASE OF OVERLAPPING OF THE MICRO SWITCHES THE
STROKE MUST BE LENGTHENED. MOUNT MICRO SWITCH C
UNDERNEATH MICRO SWITCH A IF THE CLAMPING IS DONE
BY MEANS OF THE OPPOSITE CLAMPING DIRECTION (THE
PUSH/PULL TUBE MOVES FORWARD TO THE SPINDLE
NOSE).
THE SPINDLE MUST NEVER BE OPERATED WHEN THE
STROKE LIMITING RINGS ARE NOT CLAMPED! THE SPINDLE
ELEMENTS CAN BE DAMAGED!
23.2 Drawings and parts lists
23.2.1 An exploded view drawing
Figure 23-2: An exploded view drawing of the stroke monitoring for the main spindle
PD-2-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
23-3
D Assemblies
Assembly: PD-074-000 Stroke monitoring device for the main spindle
23.2.2 Parts list
Assembly PD-074-000 Stroke monitoring for the main spindle; Article no. 22002
Quant. Unit Designation
Article
no.
1
Pcs SB-NC-109-024 Stop
21742
3
Pcs Bosch Initiator; 0830 100 525
30853
3
Pcs Bosch coupling housing; 1834 484 089
30854
3
Pcs PD-074-001 Connection adapter
22003
2
Pcs PD-074-002 Clamping holder
22004
1
Pcs PD-074-003 Base holder on the right
22005
3
Pcs PD-074-004 Clamp
22006
1
Pcs PD-074-005 Base holder on the left
22007
PD-2-11/02-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
23-4
D Assemblies
Assembly SB-NC-142-000 Universal limit stop 5000/42
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
24 Assembly SB-NC-142-000 Universal limit
stop 5000/42
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
24-1
D Assemblies
Assembly SB-NC-142-000 Universal limit stop 5000/42
24.1 Description
The universal limit stop assembly SB-NC-142-000 serves to support workpieces against
the spindle unit in an axial position, regardless of whether the chucking tool (pull-type
collet) is moved along the axis. The adjustable threaded rod SB-NC-143-002 is used to
set the axial position of the universal limit stop SB-NC-143-001 within the spindle. The
universal limit stop can be modified to adapt to the conditions and requirements of the
current clamping situation. The spindle moves in the axial direction by turning the
threaded rod SB-NC-143-002 with respect to the guide tube 1 SB-NC-143-004. The guide
screw SB-NC-143-005 glued into the guide tube 2 SB-NC-143-006 can be clamped by
clamping the tie rod SB-NC-143-007 against the threaded rod SB-NC-143-007, thereby
fixing the threaded rod in place.
24.2 Handling
24.2.1 Mounting the universal limit stop
2
1
3
5
4
Figure 24-1: Universal limit stop, stop part and mounting equipment
1)
2)
3)
4)
5)
Socket spanner
Allen key SW5 for length adjustment
Guide sleeve
Stop part
Universal limit stop
Proceed as follows to mount the universal limit stop:
1. Screw the guide sleeve using the supplied socket key into the push/pull tube
from the front.
2. Push the universal limit stop from the back through the push/pull tube and
through the attached guide sleeve. Fix the universal limit stop at the rear to the
spindle with 6 screws DIN 912-M3x6, Mmax=1.5 Nm.
3. Screw the stop part onto the front of the universal limit stop.
4. Loosen the tie rod using an SW6 Allen key. Rotate the threaded rod using the
Allen key towards/away from the spindlenose until the required clamping depth of
the workpiece to be processed is set.
5. Reclamp the tie rod.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
24-2
D Assemblies
Assembly SB-NC-142-000 Universal limit stop 5000/42
24.3 Maintenance and repair
The system must be protected against corrosion after use and must be suitably cleaned.
24.4 Drawings and parts list
24.4.1 Detail assembly
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
24-3
D Assemblies
Assembly SB-NC-142-000 Universal limit stop 5000/42
Figure 24-2: Detail assembly of universal limit stop 5000/42
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
24-4
D Assemblies
Assembly SB-NC-142-000 Universal limit stop 5000/42
24.4.2 Parts list
Assembly SB-NC-142-000 Universal limit stop 5000/42; Article No. 10614
Quant. Unit Description
1
Pcs SB-NC-143-001 Universal limit stop
1
Pcs SB-NC-143-002 Threaded rod
1
Pcs SB-NC-143-004 Guide tube 1
1
Pcs SB-NC-143-005 Guide screw
1
Pcs SB-NC-143-006 Guide tube 2
1
Pcs SB-NC-143-007 Tie rod
1
Pcs SB-NC-143-008 Seal runner
1
Pcs Merkel Rod seal 22x29.3x3.2 OMS-MR B0153-131.171
1
Pcs O-Ring 23.52x1.78
1
Pcs SB-NC-142-001 Guide sleeve
1
Pcs Retaining ring DIN6799-9
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22026
22027
22029
22030
22031
22032
22033
30843
30875
22025
30885
24-5
D Assemblies
Assembly SB-NC-143-000 Universal limit stop 8000/32
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
25 Assembly SB-NC-143-000 Universal limit
stop 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
25-1
D Assemblies
Assembly SB-NC-143-000 Universal limit stop 8000/32
25.1 Description
The universal limit stop assembly SB-NC-143-000 serves to support workpieces against
the spindle unit in an axial position, regardless of whether the chucking tool (pull-type
collet) is moved along the axis. The adjustable threaded rod SB-NC-143-002 is used to
set the axial position of the universal limit stop SB-NC-143-001 within the spindle. The
universal limit stop can be modified to adapt to the conditions and requirements of the
current clamping situation. The spindle moves in the axial direction by turning the
threaded rod SB-NC-143-002 with respect to the guide tube 1 SB-NC-143-004. The guide
screw SB-NC-143-005 glued into the guide tube 2 SB-NC-143-006 can be clamped by
clamping the tie rod SB-NC-143-007 against the threaded rod SB-NC-143-007, thereby
fixing the threaded rod in place.
25.2 Handling
25.2.1 Mounting the universal limit stop
2
1
3
5
4
Figure 25-1: Universal limit stop, stop part and mounting equipment
1)
2)
3)
4)
5)
Socket spanner
Allen key SW5 for length adjustment
Guide sleeve
Stop part
Universal limit stop
Proceed as follows to mount the universal limit stop:
1. Screw the guide sleeve using the supplied socket key into the push/pull tube
from the front.
2. Push the universal limit stop from the back through the push/pull tube and
through the attached guide sleeve. Fix the universal limit stop at the rear to the
spindle with 6 screws DIN 912-M3x6, Mmax=1.5 Nm.
3. Screw the stop part onto the front of the universal limit stop.
4. Loosen the tie rod using an SW6 Allen key. Rotate the threaded rod using the
Allen key towards/away from the spindlenose until the required clamping depth of
the workpiece to be processed is set.
5. Reclamp the tie rod.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
25-2
D Assemblies
Assembly SB-NC-143-000 Universal limit stop 8000/32
25.3 Maintenance and repair
The system must be protected against corrosion after use and must be suitably cleaned.
25.4 Drawings and parts list
25.4.1 Detail assembly
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
25-3
D Assemblies
Assembly SB-NC-143-000 Universal limit stop 8000/32
Figure 25-2: Detail assembly of universal limit stop 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
25-4
D Assemblies
Assembly SB-NC-143-000 Universal limit stop 8000/32
25.4.2 Parts list
Assembly SB-NC-143-000 Universal limit stop 8000/32; Article No. 10613
Quant. Unit Description
1
Pcs SB-NC-143-001 Universal limit stop
1
Pcs SB-NC-143-002 Threaded rod
1
Pcs SB-NC-143-003 Guide sleeve
1
Pcs SB-NC-143-004 Guide tube 1
1
Pcs SB-NC-143-005 Guide screw
1
Pcs SB-NC-143-006 Guide tube 2
1
Pcs SB-NC-143-007 Tie rod
1
Pcs SB-NC-143-008 Seal runner
1
Pcs Merkel Rod seal 22x29.3x3.2 OMS-MR B0153-131.171
1
Pcs O-Ring 23.52x1.78
1
Pcs Retaining ring DIN6799-9
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
22026
22027
22028
22029
22030
22031
22032
22033
30843
30875
30885
25-5
D Assemblies
Pull-type collet assembly W25/5C
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-04/00-840D
61503E
26 Pull-type collet assembly W25/5C
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-1
D Assemblies
Pull-type collet assembly W25/5C
CHUCKING TOOLS MAY ONLY BE MOUNTED, CHANGED AND
SET UP BY TRAINED PERSONNEL!
LOOSE, INCORRECTLY CLAMPED PARTS ARE HAZARDOUS
AND MAY CAUSE INJURY!
THE MOVING CLAMPING CYLINDER AND THE PUSH/PULL
TUBE ARE HAZARDOUS AND MAY CAUSE INJURY!
26.1 Description
The pull-type collet assembly is used to securely clamp the workpiece to be machined.
The pull-type collet, which is connected to the push/pull tube through an adapter, clamps
the workpiece when the tube is moved back.
26.2 Handling
26.2.1 Mounting the pull-type collet
Spindle nose
1
2
3
4
5
6
2
1
7
4
6
8
5
Figure 26-1: Mounting the pull-type collet
1)
2)
3)
4)
5)
Adapter for the push/pull tube
Spindle headpiece
Collet seat
Pull-type collet
4 set screws for radial adjustment
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-2
D Assemblies
Pull-type collet assembly W25/5C
6) 1 special screw to ensure that the collet does not turn
7) 4 axial mounting bolts (M8x20, strength grade 8.8 DIN 912)
8) Spindle nose
1. Move the push/pull tube as far as possible in the direction of the spindle nose.
2. Screw the adapter (1) into the push/pull tube of the spindle using a suitable
wrench.
3. Move the push/pull tube back again until the adapter is not extended out any
more and the spindle headpiece can be mounted.
4. Unscrew the set screws (5) in the spindle headpiece (2). Then place the spindle
headpiece on the spindle nose (8). Loosely tighten the axial mounting bolts (7).
5. Check to see if the centering seat (3) runs true using a dial gauge. Adjust the
centering seat using the set screws (5). Tighten the screws moderately.
F
IF NECESSARY, UNSCREW THE BOLT ON THE OPPOSITE
SIDE WHEN ALIGNING. THIS WILL ALLOW MORE FREEDOM
OF MOVEMENT FOR THE ASSEMBLY IN THE DESIRED
DIRECTION.
6. Tighten the axial mounting bolts (7) step by step up to a torque of 30 Nm. Check
to see if the centering seat runs true after each bolt is tightened.
7. Move the push/pull tube back in the direction of the spindle nose until it touches
the spindle headpiece.
8. Then check to see if the centering seat runs true again.
9. Then screw the collet on until all threads have made contact. Then unscrew the
collet until you can see the beginning of the groove. The torsional locking screw
(6) can then be screwed in.
10.Set the clamping forces.
11.Set the stroke limit of the clamping cylinder.
12.Adjust the clamping position monitor.
Carry out steps 10-12 according to the machine model/spindle type.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-3
D Assemblies
Pull-type collet assembly W25/5C
26.3 Maintenance and repair
The push-type collet assembly is to be regularly removed, cleaned, greased and checked
for wear. The cleaning/inspection period depends on how dirty it is and how long the
machine has been running. Defective parts are to be replaced immediately.
DEFECTIVE PARTS MAY ONLY BE REPLACED WITH MATCHING
REPLACEMENT PARTS THAT FULFILL THE REQUIREMENTS!
26.4 Drawings and parts list
26.4.1 Exploded view drawing
(See following page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-4
D Assemblies
Pull-type collet assembly W25/5C
Figure 26-2: Pull-type collet W25 normal
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-5
D Assemblies
Pull-type collet assembly W25/5C
Figure 26-3: Pull-type collet W25 long
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-6
D Assemblies
Pull-type collet assembly W25/5C
Figure 26-4: Pull-type collet 5C
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-7
D Assemblies
Pull-type collet assembly W25/5C
26.4.2 Parts list
Assembly SB-NC-151-000 Pull-type collet W25 normal
Number Unit
Designation
desig.
1
Piece
SB-NC-151-001 Spindle headpiece W25
1
Piece
SB-NC-151-002 Adapter for W25
4
Piece
4x srews M1x1x8 DIN 914-45H
1
Piece
Collet 364E
Article
Number
22142
22143
20177
10010
Assembly PD-076-000 Pull-type collet W25 long
Number Unit
Designation
desig.
1
Piece
PD-076-001 Spindle headpiece W25
1
Piece
PD-076-002 Adapter for W25
4
Piece
4x screws M1x1x8 DIN 914-45H
1
Piece
Collet 364E
Article
Number
21976
21977
20177
10010
Assembly SB-NC-146-000 Pull-type collet 5C
Number Unit
Designation
desig.
1
Piece
SB-NC-146-001 Spindle headpiece 5C
1
Piece
SB-NC-146-002 Adapter for 5C
4
Piece
4x screws M1x1x8 DIN 914-45H
Article
Number
22070
22071
20177
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
26-8
D Assemblies
Push-type collet assembly F38/F48
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-04/00-840D
61503E
27 Push-type collet assembly F38/F48
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
27-1
D Assemblies
Push-type collet assembly F38/F48
CHUCKING TOOLS MAY ONLY BE MOUNTED, CHANGED AND
SET UP BY TRAINED PERSONNEL!
LOOSE, INCORRECTLY CLAMPED PARTS ARE HAZARDOUS
AND MAY CAUSE INJURY!
THE MOVING CLAMPING CYLINDER AND THE PUSH/PULL
TUBE ARE HAZARDOUS AND MAY CAUSE INJURY!
27.1 Description
The push-type collet assembly is used to securely clamp the workpiece to be machined. If
the push/pull tube moves towards the spindle nose, then a pressure collet moves over the
slotted push-type collet. The push-type collet is thereby pressed together and clamps the
workpiece.
27.2 Handling
27.2.1 Mounting the push-type collet
Spindle nose
10
1
2
3
4
5
7
6
1
8
3
5
6
9
7
10
Figure 27-1: Mounting the push-type collet
1)
2)
3)
4)
Spindle headpiece for push-type collets
Centering seat
Pressure collet
Compression spring
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
27-2
D Assemblies
Push-type collet assembly F38/F48
5) Push-type collet
6) Lock nut
7) 4 set screws for radial adjustment
8) 4 axial mounting bolts (M8x20, strength grade 8.8 DIN 912)
9) Spindle nose
10) Pulling chock (already mounted in the spindle headpiece)
1. Unscrew the set screws (7) in the spindle headpiece (1). Then place the spindle
headpiece on the spindle nose (9). Loosely tighten the axial mounting bolts (8).
2. Check to see if the centering seat (2) runs true using a dial gauge. Adjust the
centering seat using the set screws (7). Tighten the screws moderately.
F
IF NECESSARY, UNSCREW THE BOLT ON THE OPPOSITE
SIDE WHEN ALIGNING. THIS WILL ALLOW MORE FREEDOM
OF MOVEMENT FOR THE ASSEMBLY IN THE DESIRED
DIRECTION.
3. Tighten the axial mounting bolts (8) step by step up to a torque of 30 Nm. Check
to see if the centering seat runs true after each bolt.
4. Then check to see if the centering seat runs true again.
5. Move the push/pull tube as far away from the spindle nose as possible.
6. Insert the pressure collet (3), compression spring (4) and the collet (5). The
pulling chock (10) must sit in the groove in the pressure collet when inserting the
collet. You can then screw on the lock nut (6) and tighten it.
7. Set the clamping forces.
8. Set the stroke limit.
9. Adjust the clamping position monitor.
Carry out steps 7-9 according to the machine model/spindle type.
27.3 Maintenance and repair
The push-type collet assembly is to be regularly removed, cleaned, greased and checked
for wear. The cleaning/inspection period depends on how dirty it is and how long the
machine has been running. Defective parts are to be replaced immediately.
DEFECTIVE PARTS MAY ONLY BE REPLACED WITH MATCHING
REPLACEMENT PARTS THAT FULFILL THE REQUIREMENTS!
27.4 Drawings and parts list
27.4.1 Exploded view drawing
(See the following page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
27-3
D Assemblies
Push-type collet assembly F38/F48
Figure 27-2: Push-type collet F48
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
27-4
D Assemblies
Push-type collet assembly F38/F48
Max. Bar capacity: Ø32mm
Max. Clamping diam.: 32mm
Figure 27-3: Push-type collet F38
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
27-5
D Assemblies
Push-type collet assembly F38/F48
27.4.2 Parts list
Assembly SB-NC-111-000 Push-type collet F48
Number Unit
Designation
desig.
1
Stk
SB-NC-111-001 Pressure collet
1
Stk
SB-NC-111-002 Lock nut
1
Stk
SB-NC-111-003 Spindle headpiece F48
2
Stk
SB-NC-111-004 Pulling chock
1
Stk
Compression spring D 475-681
1
Stk
Collet 173E
Article
Number
21713
21714
21715
21716
21717
10541
Assemby SB-NC-147-000 Push-type collet F38
Number Unit
Designation
desig.
1
Stk
SB-NC-147-001 Pressure collet
1
Stk
SB-NC-147-002 Lock nut
1
Stk
SB-NC-147-003 Spindle headpiece F38
2
Stk
SB-NC-111-004 Pulling chock
1
Stk
Compression spring D 475-681
1
Stk
Collet 164E
Article
Number
22062
22063
22064
21716
20172
10151
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
27-6
D Assemblies
Power-chuck assembly, 3 jaws/4 jaws
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-04/00-840D
61503E
28 Power-chuck assembly, 3 jaws/4 jaws
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
28-1
D Assemblies
Power-chuck assembly, 3 jaws/4 jaws
THE MOUNTING, CHANGING AND SETTING UP OF CHUCKING
TOOLS MAY ONLY BE CARRIED OUT BY PERSONNEL WITH
THE APPROPRIATE TRAINING!
THERE IS A DANGER OF AN ACCIDENT OCCURRING IF
INCORRECTLY CLAMPED PARTS BECOME FREE!
THERE IS A DANGER OF AN ACCIDENT OCCURRING DUE TO
THE MOVING CLAMPING CYLINDER AND THE PUSH/PULL
RODS!
28.1 Description
The power-chuck assembly is used to safely clamp the workpiece to be machined and is
connected directly to the push/pull rod. When it is moved in the direction of the spindle
nose, the jaws are pressed outwards, and when it is moved away from the spindle nose,
the jaws are pressed inwards. This provides you with two methods of clamping
workpieces.
28.1.1 Mounting the power-chuck
Spindle nose
2
1
3
4
5
6
7
Figure 28-1: Mounting of the power chuck
1)
2)
3)
4)
5)
Connecting threads
Power-chuck
Jaw base
Tenon block
Head jaw
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
28-2
D Assemblies
Power-chuck assembly, 3 jaws/4 jaws
6) 4 adjustment screws for radial alignment
7) 3 or 4 axial mounting bolts (M8x20, strength grade 8.8 DIN 912)
1. Move the push/pull rod as far as possible in the direction of the spindle nose.
2. Release the adjustment screws (6) in the power-chuck (2). Screw the chuck
completely into the push/pull rod using the connecting threads (5). The bores for
the mounting bolts (7) and the corresponding bores in the spindle nose must line
up.
3. Move the push/pull rod carefully back again until the chuck touches the spindle
nose. Screw the mounting bolts (7) on loosely.
4. Check the solid chuck body (2) with a dial gauge to make sure it is true when
rotating. Align the chuck using the adjustment screws (7). Do not screw the bolts
in too tight, only moderately.
F
IF NECESSARY, UNSCREW THE BOLT ON THE OPPOSITE
SIDE WHEN ALIGNING. THIS WILL ALLOW MORE FREEDOM
OF MOVEMENT FOR THE ASSEMBLY IN THE DESIRED
DIRECTION.
5. Tighten the axial mounting bolts (7) step by step up to a torque of 30 Nm. Check
to make sure that the chuck is true when rotating.
6. Check to make sure that the chuck is true when rotating one more time.
7. Set the clamping forces.
8. Set the stroke limit.
9. Adjust the clamping position monitor.
Carry out steps 7-9 according to the machine series/type of spindle.
F
PD-1-04/00-840D
TECHNICAL DATA AS WELL AS INFORMATION ABOUT THE
FUNCTION AND MAINTENANCE OF THE POWER CHUCK CAN
BE FOUND IN THE TECHINCAL DOCUMENTATION OF THE
MANUFACTURER.
 SPINNER Werkzeugmaschinenfabrik GmbH
28-3
D Assemblies
Assembly Reduction pipe
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
29 Assembly Reduction pipe
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
29-1
D Assemblies
Assembly Reduction pipe
29.1 Description
Reduction pipes are used to reduce the size of the spindle bore in the rotating spindle.
This becomes necessary when operating with bar feed units in order to guide the material
optimally and to avoid vibrations and drifting of the material from its central axis
particularly at high spindle revolutions .
There are various inner diameter pipes available which are matched to the gradation of
the bar feed unit. The pipe inner diameter A should have the same diameter as the guide
pipe for the bar feed. The maximum workpiece diameter is always 1 mm smaller than the
inner diameter of the reduction pipe.
The length of the reduction pipe depends on the type of clamping system being used.
Shorter pipes are used when using pull-type collets while longer pipes are used when
using push-type collets or power clamping chucks.
29.2 Handling
29.2.1 Mounting the reduction pipe
You can mount the reduction pipe as follows:
1. Switch off the machine by pressing the Emergency Stop Button. The machine
must not be switched on again by other persons while the mounting is taking
place.
2. Remove the support ring at the end of the spindle SB-NC-109-026 (see Book
Sub-assemblies, Chapter 11 Assembly SB-NC-109-000 Spindle 5000/42 or.
Chapter 12 Assembly SB-NC-135-000 Spindle unit 8000/32).
F
THE STOP RING SB-NC-109-025 MUST BE TURNED TOWARDS
THE REAR BEFORE REMOVING THE SUPPORT RING WHERE
NECESSARY
3. Lead the reduction pipe from the end of the spindle into the main spindle.
4. Fix the end of the reduction pipe onto the clamping cylinder 2 (SB-NC-135-019).
Use the three screws M6X12.
5. Check the function of the clamping cylinder.
THE MACHINE MUST ONLY BE OPERATED WHEN THE
REDUCTION PIPE HAS BEEN PROPERLY MOUNTED AND FIXED
IN PLACE! IT IS NECESSARY TO CHECK THE FUNCTION OF
THE CLAMPING UNIT ONCE THE MOUNTING OPERATION IS
SUCCESSFUL! DAMAGED REDUCTION PIPES SHOULD NO
LONGER BE USED!
29.3 Maintenance and repair
Used sufficient anti-corrosion agent when storing the reduction pipes in storage.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
29-2
D Assemblies
Assembly Reduction pipe
29.4 Drawings
29.4.1 Reduction pipes for pull-type collets
Section A-A
Article No.
1068509.0
1068513.0
1068517.0
1068520.0
1068550
ØA
9
13
17
20
Special
ØB
11
15
19
22
Special
Figure 29-1: Reduction pipes for pull-type collets - max. speed 5,000 r.p.m.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
29-3
D Assemblies
Assembly Reduction pipe
Section A-A
Article No.
1059809.0
1059813.0
1059817.0
1059820.0
1059850
ØA
9
13
17
20
Special
ØB
11
15
19
22
Special
Figure 29-2: Reduction pipes for pull-type collets - max. speed 8,000 r.p.m.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
29-4
D Assemblies
Assembly Reduction pipe
29.4.2 Reduction pipes for push-type collets and a chuck
Section A-A
Article No.
1059609.0
1059613.0
1059617.0
1059620.0
1059624.0
1059627.0
1059631.0
1059635.0
1059638.0
1059650
ØA
9
13
17
20
24
27
31
35
38
Special
ØB
11
15
19
22
26
29
33
37
40
Special
Figure 29-3: Reduction pipes for push-type collets and a chuck - max. speed 5,000 r.p.m.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
29-5
D Assemblies
Assembly Reduction pipe
Section A-A
Article No.
1059709.0
1059713.0
1059717.0
1059720.0
1059724.0
1059727.0
1059750
ØA
9
13
17
20
24
27
Special
ØB
11
15
19
22
26
29
Special
Figure 29-4: Reduction pipes for push-type collets and a chuck - max. speed 8,000 r.p.m.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
29-6
D Assemblies
Assembly PD-067-000 Roller belt cover
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
30 Assembly PD-067-000 Roller belt cover
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
30-1
D Assemblies
Assembly PD-067-000 Roller belt cover
30.1 Description
The equipment serves to fully cover the machining work area of the machine PD. The
cover belt PD-067-017 is passed through a bending spring PD-067-018.
30.2 Maintenance and repair
One must take care concerning the free moving smoothness of the whole system.
Excessive dirt can lead to jamming of the belt and possible damage to the equipment. If
one establishes during operation that the cover belt PD-067-017 is no longer being drawn
in cleanly, then the equipment should be cleaned in the area of the wipers PD-067-012
and PD-067-013. The forces and lengths shown in the drawing should be observed when
replacing belt PD-067-017.
30.3 Drawings and the parts list
30.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
30-2
D Assemblies
Assembly PD-067-000 Roller belt cover
The pre-loading of the spring (PD-067-018) should be adjusted in
such a way that on extracting the belt (dimension B) to a length of
550mm the block position of the spring is reached. The belt entry
force Fz is ca. 25N
Figure 30-1: Exploded view drawing of the roller belt cover
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
30-3
D Assemblies
Assembly PD-067-000 Roller belt cover
30.3.2 Parts list
Assembly PD-067-000 Roller belt cover; Article no. 10559
Quant. Unit Designation
1
Pcs PD-067-001 Shaft guide pulley
2
Pcs FAG Radial ball bearing 608 RSR (in the guide pulley)
1
Pcs PD-067-002 Guide pulley
1
Pcs PD-067-003 Ring (in the guide pulley)
1
Pcs Securing ring DIN 472-22x1
1
Pcs PD-067-004 V-ring-support (guide pulley)
1
Pcs Forsheda V-ring V-18A (B 3992-058.603)
1
Pcs Hexagonal nut DIN 934-M8
1
Pcs PD-067-006 Shaft spring housing
2
Pcs SFK Radial ball bearing 20/37/9 RS1
1
Pcs PD-067-007 Internal spacer ring
1
Pcs PD-067-008 External spacer ring
1
Pcs PD-067-009 Bearing cap
1
Pcs PD-067-010 Cap below
1
Pcs PD-067-012 Wiper 1
1
Pcs PD-067-013 Wiper 2
1
Pcs PD-067-014 Belt holder
1
Pcs PD-067-015 Housing cover 1
1
Pcs PD-067-016 Housing cover 2
1
Pcs PD-067-017 Niro-belt
1
Pcs PD-067-018 Spring-belt
1
Pcs PD-067-011 Support shaft for the extendable belt
1
Pcs PD-067-005 Housing
1
Pcs PD-067-019 Washer
1
Pcs PD-067-017 Guideway wiper
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21937
30083
21938
21939
30845
21940
30847
21942
30846
21943
21944
21945
21946
21948
21949
21950
21951
21952
21953
21954
21947
21941
21981
20811
30-4
D Assemblies
Assembly: PD-078-000 Q-slide/PD-082-000 Replacement-Q-slide
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
31 Assembly: PD-078-000 Q-slide/PD-082000 Replacement-Q-slide
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
31-1
D Assemblies
Assembly: PD-078-000 Q-slide/PD-082-000 Replacement-Q-slide
31.1 Drawings and parts list
31.1.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
31-2
D Assemblies
Assembly: PD-078-000 Q-slide/PD-082-000 Replacement-Q-slide
Figure 31-1: Exploded view drawing of the Q-slide
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
31-3
D Assemblies
Assembly: PD-078-000 Q-slide/PD-082-000 Replacement-Q-slide
Figure 31-2: Exploded view drawing of the replacement Q-slide
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
31-4
D Assemblies
Assembly: PD-078-000 Q-slide/PD-082-000 Replacement-Q-slide
31.1.2 Parts list
Assembly PD-078-000 Q-slide; Article no. 10578
Quant. Unit Designation
1
Pcs PD-050-001 Guide plate for the sub-spindle
1
Pcs PD-050-009 Locating rail
2
Pcs PD-050-010 Bolts for the locating rail
2
Pcs PD-050-011 Setting block
2
Pcs PD-050-012 Setting wedge
1
Pcs PD-050-013 Guideway wiper
1
Pcs PD-050-014 Guideway wiper
1
Pcs PD-050-015 Base strip for the retainer gib
2
Pcs PD-050-016 Retainer gib below
2
Pcs PD-050-017 Holder for the measuring scale
2
Pcs PD-050-018 Clamp for the measuring scale
1
Pcs PD-050-046 Guideway wiper
1
Pcs PD-050-045 Holder for the safety switch
2
Pcs SB-NC-010-015 Retainer gib strip on the Z-axis
1
Pcs Euchner cam U8-25
2
Pcs Euchner cam U8-10
1
Pcs Heidenhain Measuring System X/Q-axis LS303/420
4
Pcs Cylindrical pin DIN 6325-4M6x20
2
Pcs Cylindrical pin DIN 6325-4M6x30
2
Pcs Bär pressure spring D10-13
1
Pcs Euchner limit switch single row type
1
Pcs Busak und Luyken wiper ASA-60x70x7/10-N
1
Pcs PD-030-001 Holding plate for Z/Q-limit switch
1
Pcs Euchner limit switch 3-row type
1
Pcs SB-NC-010-023 Holding angle for the limit switch
1
Pcs PD-050-019 Holder for the measuring head
Article no.
20987
30963
20965
20973
20974
20812
20813
20975
20976
20977
20978
20814
21005
21291
30397
30396
21006
30861
30862
30623
30355
30622
20903
30354
21231
20979
Assembly PD-082-000 Replacement-Q-slide; Article no. 10599
Quant. Unit Designation
1
Pcs PD-050-013 Guideway wiper
2
Pcs PD-050-016 Retainer gib below
2
Pcs SB-NC-010-015 Retainer gib for Z-axis
1
Pcs PD-082-001 Q-slide-replacement plate
Article no.
20812
20976
21291
22017
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
31-5
D Assemblies
Assembly: PD-100-000 Sub-spindle headstock (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
32 Assembly: PD-100-000 Sub-spindle
headstock (Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
32-1
D Assemblies
Assembly: PD-100-000 Sub-spindle headstock (Siemens)
32.1 Drawings and parts list
32.1.1 Exploding view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
32-2
D Assemblies
Assembly: PD-100-000 Sub-spindle headstock (Siemens)
One additionally needs:
Energy line pipe R58-35 links; Order number 58.05.075.0
complete with connecting elements 581.12
Article number 31236
Figure 32-1: Exploded view drawing of the sub-spindle headstock (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
32-3
D Assemblies
Assembly: PD-100-000 Sub-spindle headstock (Siemens)
32.1.2 Parts list
Assembly PD-100-000 Sub-spindle headstock; Article no. 10800
Quant. Unit Designation
1
Pcs PD-068-001 Housing for the sub-spindle
1
Pcs PD-068-006 Holder for the ROD-housing
2
Pcs PD-068-007 Clamping segment 1
2
Pcs PD-068-008 Clamping segment 2
1
Pcs PD-050-025 Flap cover
1
Pcs PD-050-028 Spring support
1
Pcs PD-068-005 Holding bracket for the air spring
1
Pcs PD-068-004 Holding bolts
1
Pcs PD-068-003 Cable holder
2
Pcs PD-050-026 Hinge for the flap cover
2
Pcs PD-050-027 Hinge
1
Pcs PD-068-002 Cover plate
1
Pcs PD-050-030 Axial bolts for the air spring
2
Pcs Pin DIN 6325 10M6x32
2
Pcs Pin DIN 6325 10M6x36
1
Pcs Bansbach Gas spring A1A1-40-060-205/050N 9202
2
Pcs Pin DIN 6325 6M6x16
4
Pcs PD-050-043 Washer above
4
Pcs PD-050-044 Washer below
1
Pcs PD-068-009 T-grooved plate
1
Pcs PD-068-012 Pressure cap
1
Pcs PD-100-001 Holder for the cable support unit
1
Pcs PD-068-011 Cover plate
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21955
21960
21961
21962
20985
20988
21959
21958
21957
20986
20964
21956
20990
30848
30849
30212
30676
21003
21004
21963
22024
22374
21965
32-4
D Assemblies
Assembly: PD-097-000 Air distributor
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
33 Assembly: PD-097-000 Air distributor
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
33-1
D Assemblies
Assembly: PD-097-000 Air distributor
33.1 Drawings and parts list
33.1.1 Assembly drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
33-2
D Assemblies
Assembly: PD-097-000 Air distributor
Figure 33-1: Detail assembly drawing for the air distributor
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
33-3
D Assemblies
Assembly: PD-097-000 Air distributor
33.1.2 Parts list
Assembly PD-097-000 Air distributor; Article no. 22364
Quant. Unit Designation
2
Pcs PD-097-001 Connection piece
2
Pcs PD-097-002 Hose connector 1
2
Pcs PD-097-003 Hose connector 2
2
Pcs PD-097-005 Clamping ring 2
1
Pcs Ermeto Straight screw-in-swivel joint G1/8“, pipe D=6 mm; GE
6PLR-ED
2
Pcs Ötiker 2-ear-clamp made out of pipe (13.0-15.0 mm); 1315
2
Pcs O-ring 5.70x1.90
2
Pcs O-ring 20.35x1.78
2
Pcs Bosch locking screw M5; 1823 462 016
1
Pcs Ermeto angled- swivel joint G1/8“, Pipe D=6 mm; SWVE 6-PLR
1
Pcs Bosch PU-plastic hose D=8x1, L=3244
1
Pcs Bosch PU- plastic hose D=14x1.5, L=3280
1
Pcs Rubber sleeve holder KT16 (holed: D=12 mm) - contained in the
spray protection sub-assembly PD-099-000 Article no. 10781
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
22365
22366
22367
22369
22363
31234
31235
31233
22335
41220
33-4
D Assemblies
Assembly PD-069-000 Sub-spindle 8000/32 (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
34 Assembly PD-069-000 Sub-spindle 8000/32
(Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
34-1
D Assemblies
Assembly PD-069-000 Sub-spindle 8000/32 (Siemens)
34.1 Handling
34.1.1 Setting the clamping stroke
Stroke limiting ring
Stop ring
Micro-switch
Figure 34-1: Setting the clamping stroke monitoring
Proceed as follows to set the clamping stroke:
1. Loosen the 2 attachment screws on the stroke limiting rings.
2. Rotate the stroke limiting rings away from the stop ring until the full path of the
clamping cylinder can be traversed.
3. Mount the chucking tool and clamp a workpiece in.
4. Rotate the stroke limiting ring that limits the stroke in this direction until it touches
the stop ring. Rotate the stroke limiting ring about 1 turn back and then as far as
required until the spacing slits in the stroke limiting ring are not lying over the
cavities in the headstock spindle. If this is not done, the ring rotation trueness
and therefore also the spindle trueness will not be ensured. Tighten the stroke
limiting ring with the attachment screws.
5. Leave the workpiece in place. Rotate the second stroke limiting ring up to the
stop ring until the stroke of the stop ring is still sufficient to open the chucking
tool and remove the workpiece. Note however that the stroke must be sufficiently
great that the micro-switches cannot be overlapped in any circumstance. The
spacing slits in the stroke limiting ring must not lie over the cavities in the
headstock spindle. Otherwise, the ring rotation trueness and therefore also the
spindle trueness will not be ensured. Tighten the stroke limiting ring with the
attachment screws.
6. Check the chucking tool function.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
34-2
D Assemblies
Assembly PD-069-000 Sub-spindle 8000/32 (Siemens)
THE SPINDLE MUST NOT BE OPERATED IF THE STROKE
LIMITING RINGS ARE NOT TIGHTENED! SPINDLE ELEMENTS
MAY BE DAMAGED!
34.2 Drawings and parts list
34.2.1 Detail assembly
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
34-3
D Assemblies
Assembly PD-069-000 Sub-spindle 8000/32 (Siemens)
Figure 34-2: Detail assembly sub-spindle 8000/32 (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
34-4
D Assemblies
Assembly PD-069-000 Sub-spindle 8000/32 (Siemens)
34.2.2 Parts list
Assembly PD-069-000 Sub-spindle 8000/32 (Siemens)
Quant. Unit Description
5
Pcs Spindle bearing HS71914C.T.P4.UL
2
Pcs Parker O-Ring 2-016, 15.6x1.78
1
Pcs SB-NC-135-003 Front cover
1
Pcs Parker O-Ring 2-159, 126.67x2.62
1
Pcs SB-NC-135-005 Bearing ring
2
Pcs SB-NC-109-006 Balancing element
1
Pcs SB-NC-135-007 External spacer ring außen
2
Pcs SB-NC-135-009 Sealing disc
1
Pcs SB-NC-135-010 Inner ring air supply
1
Pcs SB-NC-135-011 Cover disc
1
Pcs SB-NC-135-012 Belt wheel ROD, T2.5 Z=108 DT=85.94
DK=85.45
1
Pcs SB-NC-135-013 Flanged wheel
1
Pcs SB-NC-135-015 Indexed wheel
1
Pcs SB-NC-135-016 Pre-loaded nut
1
Pcs SB-NC-135-017 Locking nut
14
Pcs Parker O-Ring 2-010, 6.07x1.78
1
Pcs SB-NC-135-019 Clamping cylinder 2
1
Pcs SB-NC-135-020 Separating piston
1
Pcs Parker 2-043, 88.62x1.78
1
Pcs SB-NC-135-021 Sealing plate
2
Pcs SB-NC-135-022 Piston
2
Pcs SB-NC-135-023 Reducer disc
4
Pcs Shaft locking ring DIN 471-45x1.75
2
Pcs Parker O-Ring 2-031, 44.17x1.78
2
Pcs Parker Piston seal set profile OA; 0110 00811
4
Pcs Helmbrecht PDF Rod seal C1 4035 N3571
2
Pcs Feather key DIN 6885-A6/6x45
3
Pcs Parker O-Ring 2-038, 66.40x1.78
1
Pcs SB-NC-135-025 Flange pulley without indexing
1
Pcs SB-NC-135-026 Headstock spindle
1
Pcs SB-NC-135-018 Clamping cylinder 1
1
Pcs SB-NC-135-008 Inner spacer ring
2
Pcs Parker O-Ring 2-046, 107.67x1.78
1
Pcs BK-NC-020-071 Toothed wheel ROD T2.5 Z=108 DK=85.45
DT=85.94
1
Pcs BK-NC-020-070 Rod toothed wheel holder
1
Pcs Toothbelt Synchroflex T2.5/600/4
4
Pcs PD-069-001 Plain washer
2
Pcs Pin DIN 6325 10M6x20
1
Pcs PD-069-002 Spindle housing
1
Pcs PD-069-003 Rear cover
1
Pcs SB-NC-135-004 Front cover
1
Pcs SB-NC-135-024 Stopper
1
Pcs SB-NC-109-026 Support ring
1
Pcs SB-NC-135-006 Push/pull tube
2
Pcs SB-NC-109-025 Adjusting nut
1
Pcs SB-NC-135-031 Main belt wheel centre piece HTD-8M Z=36
2
Pcs SB-NC-135-032 Main belt wheel edge piece HTD-8M Z=36
2
Pcs SB-NC-135-033 Intermediate flanged wheel
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article No.
21901
30611
21904
30834
21906
21724
21908
21910
21911
21912
21913
21914
21916
21917
21918
30803
21920
21921
30837
21922
21923
21924
30841
30835
30839
30838
30840
30836
21926
21927
21919
21909
30607
100427
20207
30152
21966
30850
21967
21968
21905
21925
21744
21907
21743
22407
22406
22408
34-5
D Assemblies
Assembly: PD-094-000 Sub-spindle drive 8000/32 (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
35 Assembly: PD-094-000 Sub-spindle drive
8000/32 (Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
35-1
D Assemblies
Assembly: PD-094-000 Sub-spindle drive 8000/32 (Siemens)
35.1 Drawings and parts list
35.1.1 Detail assembly drawing and the ISO-view
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
35-2
D Assemblies
Assembly: PD-094-000 Sub-spindle drive 8000/32 (Siemens)
Figure 35-1: Detail assembly drawing and the ISO view of the sub-spindle drive 8000/32
(Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
35-3
D Assemblies
Assembly: PD-094-000 Sub-spindle drive 8000/32 (Siemens)
35.1.2 Parts list
Assembly PD-094-000 Sub-spindle drive 8000/32 (Siemens); Article no. 10785
Quant. Unit Designation
1
Pcs PD-070-002 Motor holder
1
Pcs PD-070-001 Clamping plate
1
Pcs PD-070-004 Cover strip
2
Pcs Pin 8M6x16 DIN6325
1
Pcs Siemens Servo-motor 1FT6082-8AK71-1AG3 Sub-spindle drive
1
Pcs SB-NC-156-002 Clamping ring
1
Pcs Ringspann cone-clamping element TLK300 32x36 4203.032.001
1
Pcs SB-NC-157-001 Pulley wheel 8000 Z=48 DK=120.86 DT=122.23
1
Pcs PD-070-003 Motor carrier
3
Pcs Belt 1, HTD 720-8M/8
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21970
21969
21972
30852
22191
31063
100065
21971
31310
35-4
D Assemblies
Assembly PD-090-000 Feed spindle Q-axis
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
36 Assembly PD-090-000 Feed spindle Q-axis
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
36-1
D Assemblies
Assembly PD-090-000 Feed spindle Q-axis
36.1 Description
The feed spindle on the Q-axis is a planetary roller threaded spindle of the highest
precision and rigidity. It is supported on one side by an axial angular contact ball bearing
set and is driven over toothed belts and toothed belt pulleys from a feed motor.
36.2 Maintenance and repair
The feedscrew of the Q-axis has a central bore and is equipped with a grease nipple (see
Figure 36-1). This grease nipple is used to force the high performance grease into the
bearing and spindle nut. Lubrication can only be implemented at a certain slide position. If
lubrication is carried out at another slide position, the grease cannot reach the necessary
areas and the process has to be repeated.
36.2.1 Lubricating the Q axis (only with sub spindle option)
Spindle
Grease nipple
Q slide
Cover
Figure 36-1: Lubricating the Q axis
To lubricate the Q axis proceed as follows:
1.
2.
3.
4.
5.
6.
Select the REF mode.
Move the Q slide to its reference position.
Select the JOG mode.
Move the Q slide to the position Q1=20 using the arrow keys (see screen).
Press the emergency off button. Remove the cover of the grease nipple.
Use the grease press to force 3-5 cm³ high performance grease, as specified in
the table of lubricants, into the spindle.
7. Unlock the Emergency off button.
8. Move the Q slide slowly across the entire movement range.
9. Put the cover onto the nipple.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
36-2
D Assemblies
Assembly PD-090-000 Feed spindle Q-axis
36.3 Drawings and parts list
36.3.1 Detail exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
36-3
D Assemblies
Assembly PD-090-000 Feed spindle Q-axis
Figure 36-2: Detail exploded view drawing of the drive spindle on the Q-axis
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
36-4
D Assemblies
Assembly PD-090-000 Feed spindle Q-axis
36.3.2 Parts list
Assembly PD-090-000 Feed spindle Q-axis; Article no. 10784
Quant. Unit Designation
1
Pcs PD-055-001 Bearing flange
1
Pcs PD-055-002 Protective pipe
1
Pcs PD-055-003 Nut housing
1
Pcs PD-055-004 Securing ring
1
Pcs PD-055-005 Securing nut
1
Pcs PD-055-006 Clamping nut
1
Pcs PD-090-001 Feed spindle Q-axis lead 6 mm
1
Pcs PD-055-008 Cap
1
Pcs PD-055-009 End flange
1
Pcs PD-055-010 Connecting pipe
1
Pcs SB-NC-011-034 Parallel key
1
Pcs SB-NC-011-020 Drive disc for the Z-axis
1
Pcs INA Axial-angular contact ball bearing ZKLF25752RS
1
Pcs SB-NC-114-007 Securing nut for Z-axis bearing
1
Pcs SB-NC-114-008 Securing nut
1
Pcs Larco lubricating nipple No. 291 M6
1
Pcs SB-NC-114-001 Fixing nut for the Z-feed spindle
1
Pcs SB-NC-114-009 Securing nut for the Z-feed spindle
1
Pcs O-ring 31.47x1.78
4
Pcs Cylindrical pin DIN6325-5M6x8
1
Pcs Synchroflex toothed pulley belt T5/815/16 ZB=163
(A=282.055mm)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
20923
20924
20925
20926
20927
20928
22304
20929
20930
20931
21149
21148
30190
21808
21809
30312
21791
21810
30621
30144
30195
36-5
D Assemblies
Assembly: PD-093-000 Q-Feed drive (Siemens)
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
37 Assembly: PD-093-000 Q-Feed drive
(Siemens)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
37-1
D Assemblies
Assembly: PD-093-000 Q-Feed drive (Siemens)
37.1 Drawings and parts list
37.1.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
37-2
D Assemblies
Assembly: PD-093-000 Q-Feed drive (Siemens)
Figure 37-1: Exploded view drawing of the Q-Feed drive (Siemens 840D)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
37-3
D Assemblies
Assembly: PD-093-000 Q-Feed drive (Siemens)
37.1.2 Parts list
Assembly PD-093-000 Q-Feed drive Siemens 840D; Article no. 10707
Quant. Unit Designation
1
Pcs Siemens servo-motor 1FT6061-1AF71-3AG0
1
Pcs Ringspann cone-clamping element TLK300 24x28 4203.024.001
1
Pcs SB-NC-159-002 Motor holding plate for the Z-feed motor
1
Pcs SB-NC-020-017 Clamping plate
1
Pcs SB-NC-020-018 Clamping plate
1
Pcs SB-NC-159-001 Pulley wheel Z=40 DK=62.85 DT=63.66 T=5
1
Pcs SB-NC-159-003 Clamping ring
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
31064
22200
21170
21169
22199
22201
37-4
D Assemblies
Assembly: PD-065-000 Bar gripping device
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
38 Assembly: PD-065-000 Bar gripping device
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-1
D Assemblies
Assembly: PD-065-000 Bar gripping device
38.1 Handling
38.1.1 Setting up the bar gripping device
The speed at which the bar gripping device moves out or in, swings in or out as well as
the speed at which the gripper opens and closes can be set using the appropriate throttle
check valves (see Figure 38-1).
On the upper side of the machine; for
setting: Swinging in/swinging out
Behind the left side machine
cover; for setting: Movement
in/movement out
In the working area on the grabber arm;
for setting: grabber open and close
Figure 38-1: Throttle check valves for the bar gripping device
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-2
D Assemblies
Assembly: PD-065-000 Bar gripping device
38.1.2 Alignment of the bar gripping device
The bar gripping device should be set up and aligned at the works in such a way that it
grips the machined workpiece axially and radially in an optimum manner. It is possible
that the bar gripping device will need exchanging or re-aligning after a collision with other
machine elements in the working area or after wear has occurred on a shock absorber.
Proceed as follows to exchange the equipment:
1. Switch off the machine and remove left-hand side panelling, the panel above the
bar gripping device (roof) and the panel PD-065-045 in the working area (can be
moved over the gripper arm), though which the operating arm is passed (see
Figure 38-2).
Covering panel PD-065-045 in the
working area
Figure 38-2: Covering panel in the working area
2. Mark all of the electrical and pneumatic connections and then disconnect them.
The arm can be swung in manually.
3. Remove the screws which are shown in Figure 38-3 M8x80 (4 pcs.). Ensure that
the adjusting feet PD-065-009 do not turn. Pull the swinging arm into the working
area and lift the bar gripping device out of the machine using at least two people.
DO NOT PUT YOUR HANDS INTO THE SIDE SLIT ON THE
SUPPORT PIPE PD-065-019 WHEN LIFTING OUT THE
GRABBING DEVICE! THERE IS THE DANGER OF BEING
INJURED THROUGH SQUASHING! THE GRABBING DEVICE
MUST BE LIFTED EVENLY (PARALLEL), SINCE OTHERWISE
THE OPERATING ARM WILL SLIP INTO THE GUIDE PIPE!
THERE IS DANGER IN THIS CASE OF SUFFERING INJURY
THROUGH SQUASHING AT THE CLAMPING CUP!
Adjusting feet
M8x80 (4x)
Figure 38-3: Locking screws for the base plate PD-065-001
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-3
D Assemblies
Assembly: PD-065-000 Bar gripping device
4. Fix the clamping strips PD-065-002 (from the old bar gripping device) over the
oblong slots in the base plate PD-065-001 of the new bar gripping device using a
little thick grease. Place the new device in the shaft and put screws M8x80 back
in again to fix the base plate. Tighten them up manually so that they are still
loose enough to allow the base plate to be moved over the adjusting feet (see
also Figure 38-3).
5. Restore all of the pneumatic and electrical connections. The machine and the air
supply should not be switched on just yet. Move the swinging arm into its starting
position.
Aligning the gripper device:
1. Align the front bearing block PD-065-003 roughly using a calliper gauge after
mounting the gripper device, so that the distances to the shaft walls on both
sides are the same (see Figure 38-4). Then tighten the four fixing screws M8x80
up to hand tight to fix the base plate PD-065-001 in position (see Figure 38-3).
Front bearing block
Figure 38-4: Rough alignment of the front bearing block
2. Disconnect the air connection M84 (gripper arm at the front - see Figure 38-5)
and close this off with a suitable blind plug. Switch on the machine and the air
supply. The operating arm can now be moved manually forwards and backwards.
Air connection M84
Figure 38-5: Air connection M84
3. In order to align the operating arm its horizontal and vertical parallelity over the
required operating length (which depends on the machining program) and in the
swung-in position of the gripper arm must be measured and corrected for any
deviation above 0.02mm. Place the dial gauge on it as shown in Figure 38-6. Fix
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-4
D Assemblies
Assembly: PD-065-000 Bar gripping device
the foot on the X-slide in order to be able to bring the gauge past the operating
arm in the Z-direction.
WHEN MOVING THE OPERATING ARM DOWNWARDS
WITH THE DIAL GAUGE, ONE MUST ABSOLUTELY MAKE
SURE THAT THIS DOES NOT COLLIDE WITH MACHINE
ELEMENTS
IN
THE
WORKING
AREA!
ALSO ENSURE THAT NO COLLISION OCCURS WITH
MACHINE
ELEMENTS
IN
THE
WORKING
AREA WHEN SWINGING IN THE SWINGING ARM.
Vertical alignment
Horizontal alignment
Figure 38-6: Parallelity measurement of the operating arm of the gripper device
Start by measuring the horizontal parallelity and the vertical parallelity. The
horizontal parallelity is corrected by moving the front bearing block PD-065-003
or the base plate PD-065-001 to the left or right, while the vertical parallelity is
corrected by turning the adjusting feet PD-065-009 to move upwards or
downwards (see Figure 38-7).
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-5
D Assemblies
Assembly: PD-065-000 Bar gripping device
Turning of the adjusting feet is
undertaken on the left side of the
machine (see above).
Figure 38-7: Alignment of the operating arm of the gripper device
Measure and correct the parallelity until the point is reached where the horizontal
and vertical deviations are smaller than 0.02mm. Then tighten up the four screws
M8x80, which go through the adjusting feet until the base plate PD-065-001 can
no longer be moved to the side, but the height of the plate must still alterable,
however, since this is important for aligning the gripper jaws. Allow the swinging
arm to swing out again and push it back into its starting position. We refer the
reader to Book D Assemblies, Chapter 39 Assembly PD-066-000 Gripper jaws
for instructions on how to set up the gripper jaws
4. Once the gripper jaws have been set up the four screws M8x80 are tightened up
to the point where the base plate PD-065-001 cannot be moved either to the side
or in its height. Assemble on the panels which were removed and move the
swinging arm into its starting position.
38.2 Maintenance and repair
There is no maintenance and repair work to be undertaken on this assembly.
38.3 Drawings and parts list
38.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-6
D Assemblies
Assembly: PD-065-000 Bar gripping device
Figure 38-8: An exploded view drawing of the bar gripping device
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
38-7
D Assemblies
Assembly: PD-065-000 Bar gripping device
38.3.2 Part list
Assembly PD-065-000 Bar gripping device; Article no. 10343
Quant. Unit Designation
1
Pcs Bosch cylinder, double action D=25 Hub=500, 0822 034 212
1
Pcs PD-065-021 Guide tube
4
Pcs Nadella Roller (concentric), FRN32
2
1
4
2
Pcs
Pcs
Pcs
Pcs
1
2
1
1
1
2
1
2
1
1
1
4
2
1
4
4
1
1
2
1
2
1
2
1
1
1
1
2
1
1
1
4
2
1
2
1
4
4
1
1
2
1
2
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
FAG Radial ball bearing 61824-2RS1
Festo Rotary cylinder DSR 25
ACE Shock absorber FA1010K2-B
Sensor 1 (inductive) OMNI-RAY: M8x1; DW-AD-603-M8-295
PNP-Closer-5m
PD-065-006 Roller carrier
ACE Shock absorber MC150MH2
PD-065-004 Bearing block at the rear
PD-065-003 Bearing block at the front
PD-065-005 Bridge
PD-065-008 Stop screw
PD-065-013 Holder for the rotary cylinder
PD-065-014 Support
PD-065-011 Pulley wheel
PD-065-012 Pressure disc
Toothbelt ZR-T5/560/16
PD-065-020 Clamping cup
PD-065-047 Stop screw
PD-065-019 Support piper
PD-065-016 Supply line pipe
PD-065-017 Entry point
PD-065-022 Holder for hose
Bosch cylinder, double action D=25 Hub=25; 0822 034 202
PD-065-036 Gripper jaws
PD-065-035 Guide plate at the front
PD-065-029 Crank web
PD-065-032 Axis
PD-065-033 Tensioning strut
PD-065-031 Starter disc
PD-065-030 Bearing bolts
PD-065-027 Holding bolts for the cylinder
PD-065-028 Connecting head
Cylindrical pin DIN 6325-5M6x14
PD-065-023 Link cylinder
PD-065-024 Clamping cover
PD-065-026 Cover for the swinging arm
Tenon block DIN 508-5-M4-8
Cylindrical pin DIN 6325-5M6x8
PD-065-001 Base plate
PD-065-002 Clamping strip
PD-065-046 Inward movement shaft
PD-065-009 Adjusting foot
PD-065-010 Spacer disc
PD-065-045 Covering plate
Cylindrical pin DIN 6325-8M6x40
PD-065-048 Guide rod
PD-065-034 Guide plate at the rear
PD-065-007 Stop segment
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
30772
21600
30656/
30657
30774
30501
30777
30359
21585
30776
21583
21582
21584
21587
21592
21593
21590
21591
30775
21599
21627
21598
21595
21596
21601
30773
21615
21614
21608
21611
21612
21610
21609
21606
21607
30778
21602
21603
21605
30779
30144
21580
21581
21624
21588
21589
21626
30769
21625
21613
21586
38-8
D Assemblies
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
4
8
Assembly: PD-065-000 Bar gripping device
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
Pcs
PD-065-018 End plate
PD-065-015 Connecting flange
PD-065-043 Panel at the inside left 2
PD-065-044 Panel at the outside left 1
Bosch cylinder, double action D=20 Hub=200, 0822 333 508
PD-065-039 Console
PD-065-037 Collection cup
PD-065-040 Sliding block
PD-065-038 Collection channel
PD-065-042 Panel at the outside left 3
PD-065-041 Cup1
PD-065-025 Swinging arm
Murrelektronik 6-way-distributor MVC6-VC3.0
PD-065-049 Holder for initiators
IPF sensor (inductive) 2, IB 090170 10-30VDC/200MA/SN1.5
Angled 3-pin plug, connection arrangement turned through 180°;
VK990938
Pcs SB-NC-085-019 Spacer roller for PD/SB
Pcs O-ring 4.9x1.9
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
21597
21594
21622
21623
30620
21618
21616
21619
21617
21621
21620
21604
31142
41402
41400
41403
21261
30780
38-9
D Assemblies
Assembly: PD-066-000 Gripper jaws
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-1-04/00-840D
61503E
39 Assembly: PD-066-000 Gripper jaws
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
39-1
D Assemblies
Assembly: PD-066-000 Gripper jaws
39.1 Description
Various standardised sets of gripper jaws are available for the gripping device PD-065000. These can be mounted onto the bar gripping device according to the attached
exploded view drawing using the support bracket PD-066-005. Alignment of the gripper
jaws centrically to the workpiece which is to be removed is achieved due to the special
design of the gripper element as well as the support bracket when mounting the gripper.
39.2 Handling
39.2.1 Mounting of the gripper jaws
The required gripper jaws are mounted on the gripping arm using the support bracket PD066-005 and tenon blocks (see also Figure 39-7). Loosening the angle allows the
clamping range of the gripper jaws to be adjusted. The mounting is undertaken as
follows:
1. Move the tenon blocks in the longitudinal slots to the lower end of the swinging
arm (see Figure 39-1).
Tenon block
Figure 39-1: Mounting the tenon blocks
2. Mount the support bracket into place and then the gripper jaws onto that.
Support
bracket
Grabber jaws
Figure 39-2: Mounting of the gripper jaws
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
39-2
D Assemblies
Assembly: PD-066-000 Gripper jaws
39.2.2 Alignment of the gripper jaws
Alignment of the gripper jaws requires the operating arm to be already set up and aligned
horizontally and vertically. If that has not been done yet then first follow the steps
described in Book D Assemblies, Chapter 38 Assembly PD-065-000 Bar gripping device
to align the operating arms and then continue according to the instructions on this page.
1. Switch off the machine and air supply. Disconnect the air connection M83
(Gripper open) and close this off with a suitable blind plug. The jaws can now be
opened and close manually in the following procedures. Switch the machine and
the air supply back on again.
Air connection M83
Figure 39-3: Air connection M83
2. The gripper position in the radial direction to the spindle axis may have to be
adjusted manually before the jaws can be aligned. Clamp a workpiece in the
chuck or the collet. Pull the swinging arm into the working area and allow this to
swing with opened jaws without colliding with any other part. Move the arm in an
axial direction back to the gripping position. Remove the cover from the swinging
arm as well as the screws shown on the right in Figure 39-4 and the arm can
now be adjusted in the radial direction (see Figure 39-4 on the left as an
example)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
39-3
D Assemblies
Assembly: PD-066-000 Gripper jaws
Cylindrical bolts
Support bracket
Grabber jaw
Direction of adjustment
3rd. Screw under the
cylinder connection
Figure 39-4: Adjustment of the gripping position
rd
The 3 screw can only be removed if the holding bolts for the cylinder have been
taken out. You should, however, replace them once the screw has been
removed!
3. Align the swinging arm in such a way that the jaws totally surround the
workpiece. Fix this gripper setting by tightening up the screws shown on the right
in Figure 39-4 again (up to those which are below the cylinder connection).
The last step served to achieve provisional adjustment of the gripper position in the radial
direction to the spindle axis. A swing-in command would cause the swinging arm to reach
the workpiece with the jaws. Nevertheless, since the height of the whole gripper device
has not been set exactly yet a middle offset of the workpiece axis will exist as shown in
Figure 39-5. If one were to clamp in a large workpiece in this situation then one will not be
able to shift the lower support bracket far enough down to make an adjustment since its
available adjusting distance is already virtually exhausted.
4. Close the jaws manually. We are assuming in the example given here that the
lower jaw is resting against the workpiece after the closing operation and the
upper one does not reach it (see Figure 39-5 on the left). Loosen the screws of
the Support bracket which stands off from the workpiece. Move the angle
towards the workpiece until the jaw mounted on it rests against the workpiece
(see Figure 39-5 on the right). Tighten the screws up again to fix the angle in
place.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
39-4
D Assemblies
Assembly: PD-066-000 Gripper jaws
Figure 39-5: Establishing the middle offset
5. In this example we should recognise that the middle axis of the workpiece is
located too far down since the gripping device is sitting too high. The axis should
be corrected by adjusting it upwards. The position of the unclamped workpiece is
governed by the chuck, however, so it is not just a matter of simply loosening the
support bracket and adjusting its height. The workpiece cannot move with it. The
support bracket and the jaws as well as the workpiece are seen as fixed. The
correction in this case is not achieved by shifting the angle upwards but by
lowering the whole gripping device. One must first of all determine the correction
required. To do this open the jaws manually and move the swinging arm of the
device away from the workpiece. Switch the machine and the air supply off and
attach the air connection M83 on again. Switch the machine and the air supply
on again. Clamp in a 5 mm gauge block as shown in Figure 39-6.
WHEN CLOSING THE JAWS THERE IS THE DANGER OF
SQUASHING ONE’S FINGERS, SINCE THE GUAGE BLOCK
MUST BE HELD IN PLACE AT FIRST! BE CAREFUL!
Guage block
e. g. 1mm
e. g. 3mm
Figure 39-6: Measuring the middle offset
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
39-5
D Assemblies
Assembly: PD-066-000 Gripper jaws
Measure the distances from the jaws to the edge of the gauge block using a
calliper gauge. In our example the gripper device must be lowered by 1 mm to
cause both distances to be the same.
6. Mount the dial gauge on again as was done for aligning the operating arm (see
Book D Assemblies, Chapter 38 Assembly PD-065-000 Bar gripping device).
Lower the gripper device with the help of the dial gauge through turning each of
the four adjusting feet by the same amount, namely 1 mm. Check the vertical
and horizontal parallelity of the operating arm again. Make corrections as
required (see Book D Assemblies, Chapter 38 Assembly PD-065-000 Bar
gripping device).
7. Check afterwards whether the middle offset still exists by proceeding in the same
way as for the first measurement. Please note that after every height adjustment
of the gripping unit the parallelity of the operating arm must be checked and
corrected where necessary. Continue such measurements until there is no
further middle offset to correct.
8. Once the correct alignment of the jaws has been achieved tighten up the three
screws on the gripper arm again. The screws under the cylinder connection can
only be inserted when the cylinder bolts are removed for a short time. These
should, nevertheless, be put back immediately after tightening the screws up
firmly (see Figure 39-4). Tighten up the fixing screws for the support bracket
again. Ensure that all of the pneumatic connections are re-established after
switching off the machine and that the air supply is switched on again.
39.3 Drawings and parts list
39.3.1 Exploded view drawing
(see next page)
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
39-6
D Assemblies
Assembly: PD-066-000 Gripper jaws
ID-No.
Gripper jaw
PD-066-001
Ø-area
Ø32- Ø24
Ø24- Ø18
Ø18- Ø12
Required mounting space a for a fully
opened gripper
34mm
26mm
20mm
PD-066-002
Ø12- Ø4.5
14mm
PD-066-003
Ø4.5- Ø2.25
7mm
PD-066-004
Ø2.25- Ø1.4
4mm
Figure 39-7: Exploded view drawing of the gripper jaws
39.3.2 Parts list
Assembly PD-066-000 Gripper jaws; Article no. 10466
Quant. Unit Designation
2
Pcs PD-066-005 Jaw base
2
Pcs PD-066-001 Gripper jaw D32 - D12
4
Pcs Tenon block DIN508-5M4-8
2
Pcs PD-066-002 Gripper jaw D12 - D4.5
2
Pcs PD-066-003 Gripper jaw D4.5 - D2.25
2
Pcs PD-066-004 Gripper jaw D2.25 - D1.4
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21647
21643
21644
21645
21646
39-7
D Assemblies
Assembly PD-075-000 Stroke monitoring for the sub-spindle
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-2-01/03-840D
61503E
40 Assembly PD-075-000 Stroke monitoring for
the sub-spindle
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
40-1
D Assemblies
Assembly PD-075-000 Stroke monitoring for the sub-spindle
40.1 Description
The stroke monitoring of the sub-spindle serves to monitor the position of the clamping
cylinders in the sub-spindle. A micro-switch tracks the position of the stop ring on the
actuating piston of the clamping device which tracks the position of the piston and
therefore the clamping device.
40.2 Handling
40.2.1 Adjustment of the clamping stroke monitoring device
Clamping ring
A
Stroke limiting ring
B
C
Figure 40-1: Adjustment of the clamping stroke monitoring device
A) Micro switch for clamping ring at the back (34S64.4)
B) Micro switch for clamping ring at the front (34S64.5)
C) Micro switch for clamping ring in position „clamped without workpiece“ (34S64.6)
D) Locking screw for micro switch
Adjust the clamping stroke monitoring device as follows:
1. Adjust the clamping stroke limitation (see Book D Assemblies, Chapter 11
Assembly SB-NC-109-000 Spindle 5000/42).
2. Clamp a workpiece.
3. When the clamping ring moves to the back then adjust the micro switch A in the
way that its LED lights up. When the clamping ring moves to the front then adjust
the micro switch B in the way that its LED lights on.
4. Release the workpiece.
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
40-2
D Assemblies
Assembly PD-075-000 Stroke monitoring for the sub-spindle
5. When the clamping ring moves to the back then adjust the micro switch A in the
way that its LED lights up. When the clamping ring moves to the front then adjust
the micro switch B in the way that its LED lights on.
6. Clamp without workpiece. Adjust the micro switch C in the way that its LED lights
on.
F
IN CASE OF OVERLAPPING OF THE MICRO SWITCHES THE
STROKE MUST BE LENGTHENED. MOUNT MICRO SWITCH C
IN THE WAY THAT ITS PLUG IS ON THE RIGHT SIDE IF THE
CLAMPING IS DONE BY MEANS OF THE OPPOSITE
CLAMPING DIRECTION (THE PUSH/PULL TUBE MOVES
FORWARD TO THE SPINDLE NOSE).
THE SPINDLE MUST NEVER BE OPERATED WHEN THE
STROKE LIMITING RINGS ARE NOT CLAMPED! THE SPINDLE
ELEMENTS CAN BE DAMAGED!
40.3 Drawings and parts list
40.3.1 Detail exploded view drawing
(see next page)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
40-3
D Assemblies
Assembly PD-075-000 Stroke monitoring for the sub-spindle
Figure 40-2: Detail exploded view drawing of the stroke monitoring on the sub-spindle
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
40-4
D Assemblies
Assembly PD-075-000 Stroke monitoring for the sub-spindle
40.3.2 Parts list
Assembly PD-075-000 Stroke monitoring of the sub-spindle; Article no. 22008
Quant. Unit Designation
1
Pcs SB-NC-135-024 Stop
3
Pcs Bosch Initiator; 0830 100 525
3
Pcs Bosch couplings housing; 1834 484 089
1
Pcs PD-075-001 Base holder
3
Pcs PD-074-001 Connection adapter
2
Pcs PD-074-002 Clamp holder
3
Pcs PD-074-004 Clamp
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21925
30853
30855
22009
22003
22004
22006
40-5
D Assemblies
Assembly PD-071-000 Spindles flushing system sub spindle 8000/32
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-04/00-840D
61503E
41 Assembly PD-071-000 Spindles flushing
system sub spindle 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
41-1
D Assemblies
Assembly PD-071-000 Spindles flushing system sub spindle 8000/32
41.1 Description
In the spindle flushing system the cooling fluid flows through the spindle to the clamped
workpiece. It can even serve as a cooling system for the interface for appropriate
workpieces and the chucking tools can also be rinsed free of chips. In the case of very
small workpieces which cannot be removed from the machine using a gripper, these can
be rinsed out of the chucking tools by the spindle flushing system and caught in a
container.
41.2 Handling
41.2.1 Mounting
4
3
2
5
1
6
7
9
8
Figure 41-1: Mounting of the spindle flushing system (for spindle speeds up to 8,000
r.p.m.)
You can assemble the spindle flushing system as follows:
1. Attach seal holder with integrated sealing package 7 (Merkel B0153-131.171 - Oring 29.87x1.78) to the stop ring 4 and the push/pull tube 6. Use screw 5 to fix
the seal support.
Screw 5: 12 pcs. DIN 912 M3x25-12.9; Mmax=1,5Nm
2. Assemble flange 2 onto the end of the spindle. Use screw 3.
Screw 2: 6 pcs. DIN 912 M3x6-12.9; Mmax=1,2Nm
3. Mount radial shaft seal ring 9 with a little grease. Connect the rotation guide 1
with the mounting bracket 8. Ensure exact alignment of the rotation guide.
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
41-2
D Assemblies
Assembly PD-071-000 Spindles flushing system sub spindle 8000/32
41.3 Maintenance and repair
Check all of the O-rings on the carriage and all other seals regularly before mounting and
using the spindle flushing system. This also includes the radial shaft seal ring. These
should be replaced immediately if signs of wear or cracks are found
Regularly check the cooling fluid connection to make sure that the line does not leak.
DRY RUNNING OF THE SPINDLE FLUSHING SYSTEM WILL
LEAD TO DESTRUCTION OF THE RADIAL SHAFT SEALING
RING!
WATCH OUT FOR THIS DURING WORK OPERATIONS WHERE
THE SPINDLE OPERATES FOR A SHORT PERIOD WITHOUT
ACTIVATED SPINDLE FLUSHING!
41.4 Drawings and parts lists
41.4.1 Detail assembly drawing
Figure 41-2: Detail assembly drawing of the spindle flushing system 8000/32
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
41-3
D Assemblies
Assembly PD-071-000 Spindles flushing system sub spindle 8000/32
41.4.2 Parts list
Assembly SB-NC-137-000 Spindle flushing unit 8000/32; Article no. 10540
Quant. Unit Designation
1
Pcs Merkel radial shaft seal ring 14x28x7; 0145-129.678
1
Pcs Securing ring DIN472-28x1.2
1
Pcs Merkel bar seal DIN 472-28x1.2
1
Pcs Merkel O-ring 2-025, 29.87x1.78
1
Pcs BK-NC-020-103 Torque support
1
Pcs BK-NC-020-107 Clamping plate
1
Pcs SB-NC-137-001 Longitudinal seal holder
1
Pcs PD-071-001 Support bracke
1
Pcs SB-NC-137-003 Connector
1
Pcs SB-NC-137-002 Sealing runner
PD-1-04/00-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
30799
30800
30843
30842
21531
21533
21931
21973
21933
21932
41-4
D Assemblies
Assembly Gantry loader PL 400
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-01/03-840D
61503D
42 Assembly Gantry loader PL 400
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-1
D Assemblies
Assembly Gantry loader PL 400
42.1 Operation panel of the gantry loader
1
2
7
3
8
4
9
5
6
10
Figure 42-1: Operation panel of the gantry loader
1) Turning 0°/180°
2) Turning 90°/270°
3) Open/close blank gripper
4) Open/close gripper for machined part
5) Conveyor ON/OFF
6) Test part out
7) NC Stop
8) NC Start
9) Single block
10) NC start locking
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-2
D Assemblies
Assembly Gantry loader PL 400
42.2 Overall view
Tool corrections for gantry loader: T1 in channel 2
D5(V0, W0)
Locking part out
First part
on pallet
D1(V0, W0)
D2(V0, W0)
Turning station
Waiting position
D6(V0, W0) Raw part
D0(V125, W850)
D7 (V0, W0) Finished part
GRIP1_DIST_D1 (Raw part gripper)
GRIP2_DIST_D2 (Finished part gripper)
Workpiece change in turning machine
PALLET_V_DIST_IN_U
(Pallet offset vertical)
D3(V0, W0)
Insert raw part
D4(V0, W0)
Take out finished part
PALLET_V_DIST_IN_W
GRIP2_DIST_D4
GRIP1_DIST_D3
Description of the pallet geometry
Number of parts in W direction - PARTS_W
Number of parts in
U direction - PARTS_U
Zero offset U axis in channel 2
Figure 42-1: Tool corrections of the gantry loader
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-3
D Assemblies
Assembly Gantry loader PL 400
Parts counter
Number of parts in W direction = PARTS_W
Current position = W_COUNTER
+
U
-
Number of parts in
U direction = PARTS_U
Current position = W_COUNTER
First part
-W+
Figure 42-2: Parts counter (gantry loader)
Pallets counter
Pallets supply (stack 1)
Parts pallet on bogie
truck
Number of parts
pallets
(Status)=$A_OUT[5]
=PALLET_ON_U_AXIS
(still to be machined)
=PALLET_COUNTER
Figure 42-3: Pallets counter (gantry loader)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-4
D Assemblies
Assembly Gantry loader PL 400
42.3 Program structure for gantry loader with 2 axes, with conveyor
belt
NC-Start
Basic position
axes L109
Basic position
gripper L106
Picking up raw
part
Deposit finished
part
No
Raw part in
light barrier
Yes
Go to waiting
position
WAITM(2,1,2)
from gantry loader
No
Both
WAITM(2,1,2)
signals?
WAITM(2,1,2)
from turning
machine
Yes
Workpiece change
in turning machine
e.g. L104/L107
WAITM(1,1,2)=
Start at turning
machine
No
Serial part
Yes
Deposit part and
basic position e.g.
L110
Back to the
beginning of the
program
End of program
Figure 42-4: Program structure for gantry lader with 2 axes, with conveyor belt
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-5
D Assemblies
Assembly Gantry loader PL 400
42.4 Program structure for gantry loader with 3 axes, with pallet,
without stack
NC-Start
Basic position
axes
L101
Basic position
gripper
L100
No error
ERROR=0
WHILE
U_COUNTER </=
PARTS_U do
WHILE
W_COUNTER</=
PARTS_W do
Calculation of
position L103
Yes
Check to see
weather there are
input errors e.g.
L102
Error?
else
Set
U_COUNTER=1
Set
W_COUNTER=2
else
Calculation of
position L103
Picking up raw part
Deposit finished part
Raw part
present?
Deposit
finished part
in 1/2
No
Go to waiting
position
Go to waiting
position
WAITM(2,1,2)
from gantry loader
WAITM(2,1,2)
from gantry loader
2x WAITM ?
WAITM(2,1,2) from
turning machine
WAITM(2,1,2) from
turning machine
Workpiece change in
turning machine e.g. L104
2xWAITM?
Workpiece change
in turning machine
WAITM(1,1,2)=Start
at turning machine
Locking out?
ERROR=1
Set
W_COUNTER=1
No
Locking out part
L105/L108
Calculation of
position L103
Deposit finished
part in 1/1
Increase W
W_COUNTER +1
Serial part?
End WHILE for
W-Number
End WHILE for
U-Number
No
Basic position axes
U/V/W e.g. L111
Set
W_COUNTER = 1
Increase U
U-COUNTER+1
End of program
Figure 42-5: Program structure for gantry loader with 3 axes, with pallet, without stack
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-6
D Assemblies
Assembly Gantry loader PL 400
42.5 Program structure for gantry loader with 3 axes, with pallet,
with stack
Basic position
Stack 1
NC-Start
Error?
ERROR=1
No Error
ERROR=0
Basic position
stack 2
ERROR=1
Errorr?
No error
ERROR=0
WHILE
PALLET_COUNTER >/= 0
do
Pallet on U axis
$A_OUT[5]=1
N
Y
Else
Pallet on U axis
$A_OUT[5]=1
N
Pallet on U axis
$A_OUT[5]=1
IF W_COUNTER=1
N
IF U_COUNTER=1
Y
N
N
IF W_COUNTER<>1
IF U_COUNTER<>1
Y
Y
IF no pallet on U axis
Y
Y
N
N
N
IF U_COUNTER=1
Y
Y
N
N
IF W_COUNTER=1
Y
Y
N
PALLET_COUNTER>0
Programm of
stacking
L116/L117/L118
Y
Picking up pallet from
stack 1
No error
ERROR=0
Error?
Y
ERROR=1
Y
Decrease number of
pallets
Increase number of
pallets
N
Serial part
End WHILE for
PALLET_COUNTER
End of program
Figure 42-6: Structure of program for gantry loader with 3 axes, with pallet, with stack
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-7
D Assemblies
Assembly Gantry loader PL 400
42.6 Program structure for program of stacking
NC-Start
Basic position
axes
L101
Basic position
gripper
L100
No error
ERROR=0
WHILE
U_COUNTER </=
PARTS_U do
WHILE
W_COUNTER</=
PARTS_W do
Calculation of
position L103
Yes
Check to see
weather there are
input errors e.g.
L102
Error?
ERROR=1
else
Set
W_COUNTER=1
Set
U_COUNTER=1
else
Picking up raw part
Deposit finished part
Raw part
present?
No
Go to waiting
position
WAITM(2,1,2)
from gantry loader
2x WAITM ?
WAITM(2,1,2) from
turning machine
Workpiece change in
turning machine e.g. L104
WAITM(1,1,2)=Start
at turning machine
Locking out?
No
Locking out part
L105/L108
Increase W
W_COUNTER +1
Serial part?
End WHILE for
W-Number
End WHILE for
U-Number
No
Basic position axes
U/V/W e.g. L111
Set
W_COUNTER = 1
Increase U
U-COUNTER+1
End of program
Figure 42-7: Program structure for program of stacking
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-8
D Assemblies
Assembly Gantry loader PL 400
42.7 M functions PL - Channel 2
M50
M60
M51
M61
M52
M62
M53
M63
Gripper 1 open
Gripper 1 close
Gripper 2 open
Gripper 2 close
Gripper turn through U/W
Gripper turn back through U/W (home position)
Gripper turn through V
Gripper turn back through V (home position)
M10
M11
M20
M21
M12
M13
Feed conveyer belt on
Feed conveyer belt off
Finished parts conveyer belt on
Finished parts conveyer belt off
Detection whether finished part removed ? (optional)
Detection whether unmachined part present? (optional)
M15
M16
M68
M69
M48
M49
M47
M67
Tailstock move forward
Tailstock move back
Clamp main spindle
Release main spindle
Clamp sub-spindle
Release sub-spindle
Release sub-spindle with status message empty (optional)
Release main spindle with status message empty (optional)
M31
M32
M33
M34
M25
M26
M27
M28
M29
M41
M42
M43
M44
M95
M96
M97
M98
M99
Set rapid traverse Stack 1
Reset rapid traverse Stack 1
Direction of movement upwards Stack 1
Direction of movement downwards Stack 1
Start motor for Stack 1 until Code 7 is reached
Start motor for Stack 1 until Code 2 is reached
Start motor for Stack 1 until Code 3 is reached
Start motor for Stack 1 until Code 4 is reached
Start motor for Stack 1 until Code 5 is reached
Set rapid traverse Stack 2
Reset rapid traverse Stack 2
Direction of movement upwards Stack 2
Direction of movement downwards Stack 2
Start motor for Stack 2 until Code 7 is reached
Start motor for Stack 2 until Code 2 is reached
Start motor for Stack 2 until Code 3 is reached
Start motor for Stack 2 until Code 4 is reached
Start motor for Stack 2 until Code 5 is reached
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-9
D Assemblies
M77
M78
M79
Assembly Gantry loader PL 400
M90
Air 9 ON or unlock Stack 1
Air 10 ON or unlock Stack 2
Air 11 ON or swing the rotating gripper into the vertical position
(part horizontal)
Air 12 ON or close rotating gripper
Air 9 OFF or lock Stack 1
Air 10 OFF or lock Stack 2
Air 11 OFF or swing the rotating gripper back into the horizontal
position (part vertical)
Air 12 OFF or open rotating gripper
M71
M72
M73
M74
Air 1 in PD ON
Air 1 in PD OFF
Air 2 in PD ON
Air 2 in PD OFF
M80
M87
M88
M89
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-10
D Assemblies
Assembly Gantry loader PL 400
42.8 Parameters (Global user data)
GUD2: It is possible to make entries with the black key
PALLET_COUNTER
Pallet counter count downward (+ value)
CHECK
Pushing out automatically after here determined number
(0=without)
NEXT_CHECK
Remaining number of parts till the next pushing out
(+value)
W_COUNTER
Position counter on W-axis counting upwards (+ value)
U_COUNTER
Position counter on U-axis counting downwards (+
value)
BLANK_IN_GRIPPER
BLANK_TURNED
FINISHED_IN_GRIPPER
FINISHED_TURNED
PALLET_ON_U_AXIS
Indicator that a blank is in the gripper
Indicator that a blank has been turned
Indicator that a finished part is in the gripper
Indicator that a finished part has been turned
Indicator for pallet on U-axis
GUD3: It is possible to make entries with the green key
GRIP1_DIST_D1
pallet (+ value)
GRIP2_DIST_D2
pallet (+ value)
GRIP1_DIST_D3
value)
GRIP2_DIST_D4
the spindle (+ value)
GRIP1_DIST_D6
turned (+ value)
GRIP2_DIST_D7
value)
Start up movement for Gripper 1 to pick up a blank from the
Start up movement for Gripper 2 to lay a finished part on the
Start up movement for Gripper 1 to lay a blank in the spindle (+
Start up movement for Gripper 2 to take a finished part out of
Safety distance for Gripper 1 when part to be machined is
Safety distance for Gripper 2 when finished part is turned (+
PARTS_W
PARTS_U
W_GRID
U_GRID
Number of parts in the W-direction (+/- value)
Number of parts in the U-direction (+/- value)
Pallet indexing in the W-direction (+ value)
Pallet indexing in the U-direction (+ value)
PALLET_DIST_W
PALLET_DIST_U
PALLET_DIST_V_IN_W
PALLET_DIST_V_IN_U
Pallet offset in the W-direction [mm] (± value)
Pallet offset in U-direction [mm] (± value)
Pallet offset in V along W [mm] (± value)
Pallet offset in V along U [mm] (± value)
VPOS
WPOS
UPOS
Calculated V-co-ordinate (± value)
Calculated W-co-ordinate (± value)
Calculated U-co-ordinate (± value)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-11
D Assemblies
POS_CODE_1
POS_CODE_2
JUMP_POS
ERROR
PLSTOP
PDSTOP
Assembly Gantry loader PL 400
Status code for turning of a blank (+ value)
Status code for turning of a finished part (+ value)
Program jump destination for entry into the program
(+ value)
Indicator for error detection
Indicator that the loading program has finished
Indicator that the main program has finished
42.9 Adjustable zero offsets
G54 Offset for U=0 in gripper position D1 (grip first blank)
G55 Offset for U=0 in gripper position D2 (drop off first finished part)
G56 Offset for U=0 in stack position STACK 1 (pallets with unmachined parts)
G57 Offset for U=0 in stack position STACK 2 (pallets with machined parts)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-12
D Assemblies
Assembly Gantry loader PL 400
42.10 Main program in Channel 1 (example)
%_N_LOADERCALL_MPF
;$PATH=/_N_MPF_DIR
:0010 ; Example for main program in channel 1
:0020 INIT(2,"/_N_WKS_DIR/_N_LOADER_WPD/_N_MPF0001_MPF") ; to be selected
corresponding to the gantry loader program
:0080 G0 Z350 D0
:0090 X460
:0100 START(2)
; Start gantry loader
:0110 G4 F0.1
; Gantry loader fetches first part
:0120 NEXTPART:
:0125 M55
; Open flap
:0126 PDSTOP=0
:0130 WAITM(2,1,2)
; Machine is ready and starts change
:0140 MSG "Change of workpiece")
:0150 G4F1
:0160 STOPRE
:0170 IF (ERROR<>0) GOTOF END
:0180 WAITM(1,1,2)
; Gantry loader is ready and starts the machine
:0190 M65
; Close flap
:0200 STOPRE
:0210 MSG("Bearbeitung") ; Here calling up machining program
:0220 G4F10
; In the meantime the gantry loader fetches automatically the next
part
:0230 STOPRE
:0300 IF $A_OUT[2] AND NOT PLSTOP GOTOB NEXTPART ; Machining finished
:0310 WAITM(2,1,2)
END:
:0330 PDSTOP=1
:0340 G4 F0.5
:0350 WAITE(2)
:0360 M30
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-13
D Assemblies
Assembly Gantry loader PL 400
42.11 Main program in Channel 2 (examples)
%_N_MPF0001_MPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0010 ;(Gantry loader program)
N0020 ;( 2-axes , conveyor belts)
N0030 ;(Loading in sub spindle, unloading in main spindle)
N0040 DEF REAL LSV=36 ; Light barrier in V
N0050 DEF REAL LSW=357 ; Light barrier in W
N0070 PLSTOP=0
N0090 L109 ;(Basic position axes)
N0100 L106 ;(Basic position gripper)
LABELBACK_N120:
N0120 STOPRE
N0130 IF BLANK_IN_GRIPPER==1 GOTOF LABEL_N240
N0140 G01 W0 T1 D1 F20000
N0150 V=GRIP1_DIST_D1
N0160 M50 M52 ; Turn gripper 1 to +
N0170 G01 V0 F3000
N0180 M11 ;(Conveyor belt off)
N0190 M60 ; Close gripper 1
N0200 G04 F1 ; Fetching unmachined part
N0210 STOPRE
N0220 BLANK_IN_GRIPPER=1
N0230 G01 V=GRIP1_DIST_D1 F3000
LABEL_N240:
N0240 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N420
N0250 W0 D2 M10 F20000 ; Supply belt on
N0260 M62 ; Pivot back
N0270 M12 ;(Query belt = empty ? )
N0280 M21 ; Removal belt off
N0290 G01 V0 F3000
N0300 M51 ; Laying down machined part
N0380 G04 F1
N0390 G0 V=GRIP2_DIST_D2
N0400 STOPRE
N0410 FINISHED_IN_GRIPPER=0
LABEL_N420:
N0420 D0 V=LSV W=LSW ; Moving to the light barrier
N0430 STOPRE
N0440 IF $A_OUT[3]
N0450 BLANK_IN_GRIPPER=0
N0460 ENDIF
N0470 IF $A_OUT[3] GOTOB LABELBACK_N120 ; Next when no unmachined part is
existent
N0480 G01 V125 D0 F20000
N0490 W850 M20
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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D Assemblies
Assembly Gantry loader PL 400
N0500 WAITM(2,1,2)
N0510 G4 F0.5
N0520 STOPRE
N0530 IF PDSTOP==1 GOTOF END
N0540 L107 ;(Workpiece change)
N0550 WAITM(1,1,2)
N0560 IF $A_OUT[2] GOTOB LABELBACK_N20 ;(Back to line 20 in case of serial part)
END:
N0580 PLSTOP=1
N0590 L110 ;(Laying down part. + base position)
N0600 M30
%_N_MPF0002_MPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0010 ;( Gantry loader program )
N0020 ;( 3-axes with pallet , without stack )
N0030 ;( Loading in main spindle, unloading in sub spindle )
N0040 DEF REAL VPOS_COARSE
N0050 DEF REAL LSV=36 ; Light barrier in V
N0060 DEF REAL LSW=357 ; Light barrier in W
N0080 PLSTOP=0
N0090 L101 ;(Basic position axes)
N0100 IF BLANK_IN_GRIPPER GOTOF GO_ON
N0110 L100 ;(Basic position gripper)
GO_ON:
N0120 L102 ;(Checking weather there are input errors)
N0130 IF (ERROR<>0 )
N0140 WAITM(2,1,2)
N0150 GOTOF LABELFORW_N1180
N0160 ENDIF
LABELBACK_N180:
N0180 IF (U_COUNTER>PARTS_U) GOTOF LABELFORW_N870
LABELBACK_N190:
N0190 IF (W_COUNTER>PARTS_W) GOTOF LABELFORW_N830
N0200 STOPRE
; N0230 IF FINISHED_TURNED==0
; N0240 TURN_FINISHED
; N0250 ENDIF
N0260 G54
N0270 L103 ;(Position calculation)
N0280 G01 W=WPOS U=UPOS F84000 T1 D1
N0290 IF BLANK_IN_GRIPPER==1 GOTOF LABEL_N400
N0300 VPOS_COARSE=VPOS+GRIP1_DIST_D1
N0310 M50 M52
N0320 V=VPOS_COARSE
N0330 V=VPOS F6000
N0340 M60
N0350 G04 F1 ; Fetching unmachined part
PD-1-01/03-840D
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D Assemblies
Assembly Gantry loader PL 400
N0360 STOPRE
N0370 BLANK_IN_GRIPPER=1
; N0380 BLANK_TURNED=0
LABEL_N400:
N0390 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N470
N0400 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0410 G55 V=VPOS_COARSE D2 F20000
N0420 U=UPOS W=WPOS M62
N0430 V=VPOS F6000
N0440 M51
N0450 G04 F0.5 ; Laying down machine part
N0455 V=VPOS_COARSE F48000
N0460 STOPRE
N0465 FINISHED_IN_GRIPPER=0
LABEL_N470:
N0470 D0 V=LSV W=LSW M52 ; Moving to the light barrier
N0480 STOPRE
N0490 IF $A_OUT[3]==1
N0500 BLANK_IN_GRIPPER=0
N0510 ENDIF
N0520 IF $A_OUT[3]==1 GOTOF _N750 ; Next when there is no unmachined part
; N0530 IF BLANK_TURNED==1 GOTOF _N550
; N0540 TURN_BLANK
; _N550:
N0560 G01 V125 D0 F60000
N0570 W850
N0580 CALCULATE_CHECK
N0590 WAITM(2,1,2)
N0600 G4 F0.5
N0610 STOPRE
N0620 IF PDSTOP==1 GOTOF END
N0630 L104 ;(workpiece change)
N0640 WAITM(1,1,2)
N0650 STOPRE
N0660 IF $A_OUT[4]
N0670 L105 ;(Pushing out)
N0680 STOPRE
; N0690 FINISHED_TURNED=1
N0700 $A_OUT[4]=0
; N0710 ELSE
; N0720 TURN_FINISHED
N0730 ENDIF
_N750:
N0750 W_COUNTER=W_COUNTER+1
N0760 STOPRE
N0770 IF $A_OUT[2]==0
N0780 ERROR=1
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D Assemblies
Assembly Gantry loader PL 400
N0790 GOTOF _N1130 ; Single part
N0800 ENDIF
N0810 GOTOB LABELBACK_N190
LABELFORW_N830:
N0830 W_COUNTER=1
N0840 U_COUNTER=U_COUNTER+1
N0850 GOTOB LABELBACK_N180
LABELFORW_N870:
N0870 U_COUNTER=1 W_COUNTER=2
N0875 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N970
N0880 L103 ;(Position calculation)
N0890 G55 G00 U=UPOS D2
N0900 G01 W=WPOS F20000
N0910 M62 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0920 V=VPOS_COARSE
N0930 V=VPOS F3000
N0940 M51 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0950 G04 F0.5
N0955 V=VPOS_COARSE F20000
N0960 STOPRE
N0965 FINISHED_IN_GRIPPER=0
LABEL_N970:
N0970 V125 D0
N0980 W850
N0990 WAITM(2,1,2)
N1000 L104 ;(Workpiece change)
N1010 W_COUNTER=1
N1020 L103 ;(Position calculation)
N1030 G55 G00 U=UPOS D2
N1040 G01 W=WPOS F20000
N1050 M62 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N1060 V=VPOS_COARSE
N1070 V=VPOS F3000
N1080 M51 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N1090 G04 F0.5
N1095 V=VPOS_COARSE F20000
N1100 STOPRE
N1105 FINISHED_IN_GRIPPER=0
N1110 GOTOF END
_N1130:
N1130 WAITM(2,1,2)
END:
N1150 G4 F0.5
N1160 L101 ;(Basic position axes)
LABELFORW_N1180:
N1180 PLSTOP=1
N1200 M30
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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D Assemblies
Assembly Gantry loader PL 400
%_N_MPF0003_MPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0010 ;( Gantry loader program )
N0020 ;( 3-axes with pallet , without stack )
N0030 ;( Loading in sub spindle, unloading from main spindle)
N0050 DEF REAL VPOS_COARSE
N0060 DEF REAL LSV=36 ; Light barrier in V
N0070 DEF REAL LSW=357 ; Light barrier in W
N0080 PLSTOP=0
N0090 L101 ;(Basic position axes)
N0100 IF BLANK_IN_GRIPPER GOTOF GO_ON
N0110 L106 ;(Basic position gripper)
GO_ON:
N0120 L102 ;(Checking weather there are input errors)
N0130 IF (ERROR<>0 )
N0140 WAITM(2,1,2)
N0150 GOTOF LABELFORW_N2050
N0160 ENDIF
LABELBACK_N180:
N0180 IF (U_COUNTER>PARTS_U) GOTOF LABELFORW_N860
LABELBACK_N200:
N0200 IF (W_COUNTER>PARTS_W) GOTOF LABELFORW_N820
N0210 STOPRE
; N0220 IF FINISHED_TURNED==0
; N0230 TURN_FINISHED
; N0240 ENDIF
N0250 G55
N0260 L103 ;(Position calculation)
N0270 G01 W=WPOS U=UPOS F84000 T1 D1
N0280 IF BLANK_IN_GRIPPER==1 GOTOF LABEL_N380
N0290 VPOS_COARSE=VPOS+GRIP1_DIST_D1
N0300 M50 M52
N0310 V=VPOS_COARSE
N0320 V=VPOS F6000
N0330 M60
N0340 G04 F1 ; Fetching unmachined part
N0350 STOPRE
N0360 BLANK_IN_GRIPPER=1
N0370 BLANK_TURNED=0
LABEL_N380:
N0380 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N460
N0390 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0400 G55 V=VPOS_COARSE D2 F20000
N0410 U=UPOS W=WPOS M62
N0420 V=VPOS F6000
N0430 M51
PD-1-01/03-840D
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D Assemblies
Assembly Gantry loader PL 400
N0440 G04 F0.5 ; Laying down machined part
N0445 V=VPOS_COARSE F48000
N0450 STOPRE
N0455 FINISHED_IN_GRIPPER=0
LABEL_N460:
; N0460 D0 V=LSV W=LSW M52 ; Moving to the light barrier
; N0470 STOPRE
; N0480 IF $A_OUT[3]==1
; N0490 BLANK_IN_GRIPPER=0
; N0500 ENDIF
; N0510 IF $A_OUT[3]==1 GOTOF _N740 ; Next part when there is no unmachined part
;from here pivoting gripper
; N0520 IF BLANK_TURNED==1 GOTOF _N540
; N0530 TURN_BLANK
; _N540:
N0550 G01 V125 D0 F60000
N0560 W850
N0570 CALCULATE_CHECK
N0580 WAITM(2,1,2)
N0590 G4 F0.5
N0600 STOPRE
N0610 IF PDSTOP==1 GOTOF END
N0620 L107 ;(workpiece change)
N0630 WAITM(1,1,2)
N0640 STOPRE
N0650 IF $A_OUT[4]
N0660 L108 ;(Pushing out)
N0670 STOPRE
N0690 $A_OUT[4]=0
; N0700 ELSE
; N0710 TURN_FINISHED
N0720 ENDIF
_N740:
N0740 W_COUNTER=W_COUNTER+1
N0750 STOPRE
N0760 IF $A_OUT[2]==0
N0770 ERROR=1
N0780 GOTOF _N2000 ; Single part
N0790 ENDIF
N0800 GOTOB LABELBACK_N200
LABELFORW_N820:
N0820 W_COUNTER=1
N0830 U_COUNTER=U_COUNTER+1
N0840 GOTOB LABELBACK_N180
LABELFORW_N860:
N0860 U_COUNTER=1 W_COUNTER=2
N0870 L103 ;(Position calculation)
PD-1-01/03-840D
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D Assemblies
Assembly Gantry loader PL 400
N0875 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N970
N0880 G54 G00 U=UPOS D2
N0890 G01 W=WPOS F20000
N0900 M52 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0910 V=VPOS_COARSE
N0920 V=VPOS F3000
N0930 M51
N0940 G04 F0.5
N0950 V=VPOS_COARSE F20000
N0960 STOPRE
N0965 FINISHED_IN_GRIPPER=0
LABEL_N970:
N0970 V125 D0
N0975 W850
N0980 WAITM(2,1,2)
N0990 L107 ;(Workpiece change)
N1000 W_COUNTER=1
N1010 L103 ;(Position calculation)
N1020 G54 G00 U=UPOS D2
N1030 G01 W=WPOS F20000
N1040 M52 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N1050 V=VPOS_COARSE
N1060 V=VPOS F3000
N1070 M51
N1080 G04 F0.5
N1085 V=VPOS_COARSE F20000
N1090 STOPRE
N1095 FINISHED_IN_GRIPPER=0
_N2000:
N2010 WAITM(2,1,2)
END:
N2030 G4 F0.5
N2040 L101 ;(Basic position axes)
LABELFORW_N2050:
N2050 PLSTOP=1
N2060 M30
%_N_MPF0004_MPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Gantry loader program )
N0010 ;( 3-axes with pallet , with stack )
N0015 ;( Loading into main spindle, unloading from sub spindle )
N0017 PLSTOP=0
N0020 L112 ;(Basic position stack 1)
N0025 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
N0030 L113 ;(Basic position stack 2)
N0035 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
PD-1-01/03-840D
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D Assemblies
Assembly Gantry loader PL 400
LABELBACK_N40:
N0040 IF (PALLET_COUNTER<0 ) GOTOF LABELFORW_N145 ;(While-loop)
N0045 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N65 ;(If-Gate)
N0050 IF (W_COUNTER<>1 ) GOTOF LABELFORW_N65 ;(If-Gate)
N0055 IF (U_COUNTER<>1 ) GOTOF LABELFORW_N65 ;(If-Gate)
N0060 GOTOF LABELFORW_N135 ;(Sprung)
LABELFORW_N65:
N0065 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N80 ;(If-Gate)
N0070 IF (U_COUNTER==1 ) GOTOF LABELFORW_N80 ;(If-Gate)
N0075 GOTOF LABELFORW_N125 ;(Sprung)
LABELFORW_N80:
N0080 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N95 ;(If-Gate)
N0085 IF (W_COUNTER==1 ) GOTOF LABELFORW_N95 ;(If-Gate)
N0090 GOTOF LABELFORW_N125 ;(Sprung)
LABELFORW_N95:
N0095 IF ($A_OUT[5]<>0 ) GOTOF LABELFORW_N140 ;(If-Gate)
N0100 IF (U_COUNTER<>1 ) GOTOF LABELFORW_N140 ;(If-Gate)
N0105 IF (W_COUNTER<>1 ) GOTOF LABELFORW_N140 ;(If-Gate)
N0110 IF (PALLET_COUNTER<=0 ) GOTOF LABELFORW_N145 ;(If-Gate)
N0115 L114 ;(Fetch pellet of stack 1)
N0120 PALLET_COUNTER=PALLET_COUNTER-1 ;(Counter decrease.)
LABELFORW_N125:
N0125 L116 ;( Stacking)
N0130 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
N0132 IF NOT $A_OUT[2] GOTOF LABELFORW_N145 ; Single part
N0133 IF PDSTOP==1 GOTOF LABELFORW_N145 ; Stop of channel 1
LABELFORW_N135:
N0135 L115 ;(Laying down pallet stack 2)
LABELFORW_N140:
N0140 GOTOB LABELBACK_N40 ;(Jumping back to While)
LABELFORW_N145:
N0145 PLSTOP=1
N0160 M30
%_N_MPF0005_MPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Gantry loader program )
N0010 ;( 3-axes with pallet , with stack )
N0015 ;( Loading into sub spindle, unloading from main spindle)
N0017 PLSTOP=0
N0020 L112 ;(Basic position stack 1)
N0025 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
N0030 L113 ;(Basic position stack 2)
N0035 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
LABELBACK_N40:
N0040 IF (PALLET_COUNTER<0 ) GOTOF LABELFORW_N145 ;(While-loop)
N0045 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N65 ;(If-Gate)
PD-1-01/03-840D
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D Assemblies
Assembly Gantry loader PL 400
N0050 IF (W_COUNTER<>1 ) GOTOF LABELFORW_N65 ;(If-Gate)
N0055 IF (U_COUNTER<>1 ) GOTOF LABELFORW_N65 ;(If-Gate)
N0060 GOTOF LABELFORW_N135 ;(Jump)
LABELFORW_N65:
N0065 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N80 ;(If-Gate)
N0070 IF (U_COUNTER==1 ) GOTOF LABELFORW_N80 ;(If-Gate)
N0075 GOTOF LABELFORW_N125 ;(Sprung)
LABELFORW_N80:
N0080 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N95 ;(If-Gate)
N0085 IF (W_COUNTER==1 ) GOTOF LABELFORW_N95 ;(If-Gate)
N0090 GOTOF LABELFORW_N125 ;(Jump)
LABELFORW_N95:
N0095 IF ($A_OUT[5]<>0 ) GOTOF LABELFORW_N140 ;(If-Gate)
N0100 IF (U_COUNTER<>1 ) GOTOF LABELFORW_N140 ;(If-Gate)
N0105 IF (W_COUNTER<>1 ) GOTOF LABELFORW_N140 ;(If-Gate)
N0110 IF (PALLET_COUNTER<=0 ) GOTOF LABELFORW_N145 ;(If-Gate)
N0115 L114 ;(Fetching pellet stack 1)
N0120 PALLET_COUNTER=PALLET_COUNTER-1 ;(Counter decrease)
LABELFORW_N125:
N0125 L117 ;( stacking)
N0130 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
N0132 IF NOT $A_OUT[2] GOTOF LABELFORW_N145 ; Single part
N0133 IF PDSTOP==1 GOTOF LABELFORW_N145 ; Stop of channel 1
LABELFORW_N135:
N0135 L115 ;(Laying down pallet stack )
LABELFORW_N140:
N0140 GOTOB LABELBACK_N40 ;(Back to While)
LABELFORW_N145:
N0145 PLSTOP=1
N0150 WAITM(2,1,2)
N0155 WAITM(1,1,2)
N0160 M30
%_N_MPF0006_MPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Gantry loader program )
N0010 ;( 3-axes with pallet , with stack )
N0015 ;( Loading into main spindle, unloading from sub spindle)
N0017 PLSTOP=0
N0020 L112 ;( Basic position stack 1 )
N0025 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
N0030 L113 ;( Basic position stack 2 )
N0035 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
LABELBACK_N40:
N0040 IF (PALLET_COUNTER<0 ) GOTOF LABELFORW_N145 ;( While-loop)
N0045 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N65 ;( If-Gate )
N0050 IF (W_COUNTER<>1 ) GOTOF LABELFORW_N65 ;( If-Gate )
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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D Assemblies
Assembly Gantry loader PL 400
N0055 IF (U_COUNTER<>1 ) GOTOF LABELFORW_N65 ;( If-Gate )
N0060 GOTOF LABELFORW_N135 ;( Jump )
LABELFORW_N65:
N0065 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N80 ;( If-Gate )
N0070 IF (U_COUNTER==1 ) GOTOF LABELFORW_N80 ;( If-Gate )
N0075 GOTOF LABELFORW_N125 ;( Jump )
LABELFORW_N80:
N0080 IF ($A_OUT[5]<>1 ) GOTOF LABELFORW_N95 ;( If-Gate )
N0085 IF (W_COUNTER==1 ) GOTOF LABELFORW_N95 ;( If-Gate )
N0090 GOTOF LABELFORW_N125 ;( Sprung )
LABELFORW_N95:
N0095 IF ($A_OUT[5]<>0 ) GOTOF LABELFORW_N140 ;( If-Gate )
N0100 IF (U_COUNTER<>1 ) GOTOF LABELFORW_N140 ;( If-Gate )
N0105 IF (W_COUNTER<>1 ) GOTOF LABELFORW_N140 ;( If-Gate )
N0110 IF (PALLET_COUNTER<=0 ) GOTOF LABELFORW_N145 ;( If-Gate )
N0115 L114 ;( Fetching pallet stack 1)
N0120 PALLET_COUNTER=PALLET_COUNTER-1 ;( Counter decrease)
LABELFORW_N125:
N0125 L118 ;( Stacking )
N0130 IF (ERROR<>0 ) GOTOF LABELFORW_N145 ;(Query of error)
N0132 IF NOT $A_OUT[2] GOTOF LABELFORW_N145 ; Serial part
N0133 IF PDSTOP==1 GOTOF LABELFORW_N145 ; Stop of channel 1
LABELFORW_N135:
N0135 L115 ;( Laying down pallet stack 2)
LABELFORW_N140:
N0140 GOTOB LABELBACK_N40 ;( Back to While )
LABELFORW_N145:
N0145 PLSTOP=1
N0150 WAITM(2,1,2)
N0155 WAITM(1,1,2)
N0160 M30
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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D Assemblies
Assembly Gantry loader PL 400
42.12 Sub programs in channel 2
%_N_L100_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Basic position gripper )
N0002 ;( Picken, HS-GS )
N0005 M50 ; Unmachined part open gripper
N0010 M61 ; Machined part close gripper
N0015 M62
N0020 M53
N0025 M17
%_N_L101_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Basic position axes )
N0002 ;( with pallet , without stacking )
N0005 G01 V125 D0 F20000
N0010 W0
N0015 G00 V-250 U860
N0020 M17
%_N_L102_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Checking weather there are input errors )
N0005 ERROR=0
N0010 IF (U_COUNTER>=1 ) GOTOF LABELFORW_N20
N0012 MSG("U_COUNTER >=1 !!!")
N0015 ERROR=1
LABELFORW_N20:
N0020 IF (W_COUNTER>=1 ) GOTOF LABELFORW_N30
N0022 MSG("W_COUNTER >=1 !!!")
N0025 ERROR=1
LABELFORW_N30:
N0030 GRIP1_DIST_D1=ABS(GRIP1_DIST_D1)
N0035 GRIP2_DIST_D2=ABS(GRIP2_DIST_D2)
N0040 GRIP1_DIST_D3=ABS(GRIP1_DIST_D3)
N0045 GRIP2_DIST_D4=ABS(GRIP2_DIST_D4)
N0050 GRIP1_DIST_D6=ABS(GRIP1_DIST_D6)
N0055 GRIP2_DIST_D7=ABS(GRIP2_DIST_D7)
N0060 U_GRID=ABS(U_GRID)
N0065 W_GRID=ABS(W_GRID)
N0070 M17
PD-1-01/03-840D
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D Assemblies
Assembly Gantry loader PL 400
%_N_L103_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Position calculation )
N0002 ;( U/V/W-axis )
N0003 DEF REAL NOM
N0004 DEF REAL DENOM
N0005 DEF REAL DISTORSION
N0008 NOM=(W_COUNTER-1)*PALLET_DIST_U
N0010 DENOM=PARTS_W-1
N0015 DISTORSION=NOM/DENOM
N0020 UPOS=((1-U_COUNTER)*U_GRID)-DISTORSION
N0025 NOM=(W_COUNTER-1)*PALLET_DIST_V_IN_W
N0030 DISTORSION=NOM/DENOM
N0040
VPOS=(((U_COUNTER-1)*PALLET_DIST_V_IN_U)/(PARTS_U1))+DISTORSION
N0045 NOM=(U_COUNTER-1)*PALLET_DIST_W
N0050 DENOM=PARTS_U-1
N0055 DISTORSION=NOM/DENOM
N0060 WPOS=((1-W_COUNTER)*W_GRID)+DISTORSION
N0065 M17
%_N_L104_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Loading into main spindle )
N0003 ;( Unloading from sub spindle )
N0006 DEF REAL V_WAITPOS=125
N0007 DEF REAL W_WAITPOS=850
N0009 G01 G94 V=V_WAITPOS D0 M62 M63 F84000
N0010 W=W_WAITPOS M69 ;(or M68 for opening main spindle)
N0060 G03 W=GRIP1_DIST_D3 V0 CR=500 T1 D3
N0065 G01 G09 V0 F40000 ; Exact stop
N0070 G09 W0 F20000 ; Insert unmachined part
N0075 M68 ;(or M69 for closing main spindle)
N0085 M50 ; Unmachined part open gripper
N0090 G04 F0.5
N0091 STOPRE
N0092 BLANK_IN_GRIPPER=0
N0093 BLANK_TURNED=0
N0095 G01 V0 W=-GRIP2_DIST_D4 D4 F40000
N0100 M52 ; Pivot
N0105 G09 W0 F6000
N0110 M61 ; Machined part closing gripper
N0115 G04 F0.5
N0116 STOPRE
N0117 FINISHED_TURNED=0
N0118 FINISHED_IN_GRIPPER=1
N0120 M48 ;(or M49 for opening sub spindle)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-25
D Assemblies
Assembly Gantry loader PL 400
N0130 G01 W=-GRIP2_DIST_D4 F6000
N0135 M49 ;(or M48 for closing sub spindle)
N0180 G02 V=V_WAITPOS W=W_WAITPOS CR=800 D0 F84000
N0186 STOPRE
N0190 M17
%_N_L105_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( pushing out )
N0002 ;( machined part into sun spindle )
N0004 G0 D0 V125
N0005 G01 W0 D5 F20000
N0010 M62
N0015 V0
N0020 M51
N0025 G04 F1
N0050 STOPRE
N0060 FINISHED_TURNED=1
N0070 FINISHED_IN_GRIPPER=0
N0080 V125 D0
N0090 M61 M52
N0100 M17
%_N_L106_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Basic position gripper )
N0002 ;( Picken, GS-HS )
N0005 M50
N0010 M51
N0015 M62
N0020 M63
N0025 M17
%_N_L107_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Loading into sub spindle )
N0003 ;( Unloading from main spindle )
N0006 DEF REAL V_WAITPOS=125
N0007 DEF REAL W_WAITPOS=850
N0009 G01 G94 V=V_WAITPOS D0 M62 M53 F60000 ; Turning and pivot
N0010 W=W_WAITPOS M49 ;(or M48 for opening sub spindle)
N0060 G03 W=-GRIP1_DIST_D3 V0 CR=800 T1 D3
N0065 G01 G09 V0 F6000 ; Exact stop
N0070 G09 W0 F10000 ; Insert unmachined part
N0085 M48 ;(or M49 for closing sub spindle)
N0075 M50 ; Open unmachined part gripper
N0080 G04 F0.5
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-26
D Assemblies
Assembly Gantry loader PL 400
N0081 STOPRE
N0082 BLANK_IN_GRIPPER=0
N0083 BLANK_TURNED=0
N0090 G01 W=-GRIP1_DIST_D3 F10000
N0095 G01 V0 W=GRIP2_DIST_D4 D4 F84000
N0100 M52 ; Pivot
N0105 G09 W0 F6000
N0110 M61 ; Close machined part gripper
N0115 G04 F0.5
N0124 STOPRE
N0125 FINISHED_TURNED=0
N0126 FINISHED_IN_GRIPPER=1
N0120 M69 ; (or M68 for opening main spindle)
N0130 G01 W=GRIP2_DIST_D4 F6000
N0135 M68 ; (or M69 for closing main spindle)
N0180 G02 V=V_WAITPOS W=W_WAITPOS CR=500 D0 F84000
N0186 STOPRE
N0190 M17
%_N_L108_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Pushing out )
N0002 ;( Machined part in main spindle )
N0004 G0 D0 V125
N0005 G01 W0 D5 F20000
N0015 V0
N0020 M51 ; Close machined part gripper
N0025 G04 F1
N0050 STOPRE
N0060 FINISHED_TURNED=1
N0070 FINISHED_IN_GRIPPER=0
N0080 V125 D0
N0100 M17
%_N_L109_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Basic position axes )
N0002 ;( with conveyor belts )
N0005 G01 V125 D0 F20000
N0010 W0
N0015 M17
%_N_L110_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Laying down machined part )
N0002 ;( on conveyor belt to SKIP )
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-27
D Assemblies
Assembly Gantry loader PL 400
N0005 G01 W0 D2 F20000
N0010 V=GRIP2_DIST_D2
N0015 M52 M21
N0020 G01 V0 F3000
N0025 M51
N0030 G04 F1
N0035 G01 V=GRIP2_DIST_D2 F3000
N0050 STOPRE
N0070 FINISHED_IN_GRIPPER=0
N0040 V125 D0 F20000
N0045 W100 M20
N0050 M17
%_N_L111_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Basic position axes )
N0002 ;( With pallet, with stacking )
N0005 G01 V125 D0 F20000
N0010 W0
N0015 M17
%_N_L112_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Basic position stack 1 )
N0010 ERROR=0 ;( Delete error )
N0015 CASE (POS_CODE_1) OF 101 GOTOF LABELFORW_N75 112 GOTOF
LABELFORW_N95 102 GOTOF _N115 123 GOTOF _N115 103 GOTOF _N135 134
GOTOF _N135 104 GOTOF _N155 145 GOTOF _N155 105 GOTOF _N175 151 GOTOF
_N175 DEFAULT GOTOF _N65
_N65: ; -->Please check: POS_CODE_1
N0065 ERROR=1 ;( Set error )
N0070 ;( 1st .jump )
LABELFORW_N75:
N0075 JUMP_POS=20
N0080
N0085 GOTOF LABELFORW_N195
N0090 ;( 2nd jump )
LABELFORW_N95:
N0095 JUMP_POS=30
N0100 L114
N0105 GOTOF LABELFORW_N195
N0110 _N115: ;( 3rd jump )
N0115 JUMP_POS=60
N0120 L114
N0125 GOTOF LABELFORW_N195
N0130 _N135: ;( 4th jump )
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-28
D Assemblies
Assembly Gantry loader PL 400
N0135 JUMP_POS=90
N0140 L114
N0145 GOTOF LABELFORW_N195
N0150 _N155: ;( 5th jump )
N0155 JUMP_POS=125
N0160 L114
N0165 GOTOF LABELFORW_N195
N0170 _N175: ;( 6th jump )
N0175 JUMP_POS=160
N0180 L114
N0185 GOTOF LABELFORW_N195
N0190
LABELFORW_N195:
N0195 M17
%_N_L113_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Basic position stack 2 )
N0010 ERROR=0 ;( Delete error )
N0015 CASE (POS_CODE_2) OF 201 GOTOF LABELFORW_N75 215 GOTOF
LABELFORW_N95 205 GOTOF _N115 253 GOTOF _N115 203 GOTOF _N135 234
GOTOF _N135 204 GOTOF _N155 242 GOTOF _N155 202 GOTOF _N175 221 GOTOF
_N175 DEFAULT GOTOF _N65
_N65: ; -->Please check: POS_CODE_2
N0065 ERROR=1 ;( Set error )
N0070 ;( 1st jump )
LABELFORW_N75:
N0075 JUMP_POS=20
N0080
N0085 GOTOF LABELFORW_N195
N0090 ;( 2nd jump )
LABELFORW_N95:
N0095 JUMP_POS=30
N0100 L115
N0105 GOTOF LABELFORW_N195
rd
N0110 _N115: ;( 3 jump )
N0115 JUMP_POS=60
N0120 L115
N0125 GOTOF LABELFORW_N195
N0130 _N135: ;( 4th jump )
N0135 JUMP_POS=90
N0140 L115
N0145 GOTOF LABELFORW_N195
th
N0150 _N155: ;( 5 jump )
N0155 JUMP_POS=125
N0160 L115
N0165 GOTOF LABELFORW_N195
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-29
D Assemblies
Assembly Gantry loader PL 400
N0170 _N175: ;( 6th jump )
N0175 JUMP_POS=160
N0180 L115
N0185 GOTOF LABELFORW_N195
N0190
LABELFORW_N195:
N0195 M17
%_N_L114_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Fetching pallet )
N0010 ;( stack 1 )
N0015 CASE (JUMP_POS) OF 20 GOTOF LABELFORW_N20 30 GOTOF
LABELFORW_N30 60 GOTOF _N60 90 GOTOF _N90 125 GOTOF _N125 160 GOTOF
_N160 DEFAULT GOTOF _N215
; -->Please check: JUMP_POS
LABELFORW_N20:
N0020 G56 ;( Zero offset stack 1 )
N0025 G00 G94 U0
LABELFORW_N30:
N0030
N0035 STOPRE
N0040 POS_CODE_1=112
N0045 M31 M33 M26
N0050 STOPRE
N0055 POS_CODE_1=102
N0060 _N60:
N0065 STOPRE
N0070 POS_CODE_1=123
N0075 M32 M33 M27
N0080 STOPRE
N0085 POS_CODE_1=103
N0090 _N90:
N0095 STOPRE
N0100 M77 ;( Open pawl 1 )
N0105 POS_CODE_1=134
N0110 M31 M34 M28
N0115 STOPRE
N0120 POS_CODE_1=104
N0125 _N125:
N0130 STOPRE
N0135 M87 ;( Close pawl 1 )
N0140 POS_CODE_1=145
N0145 M32 M34 M29
N0150 STOPRE
N0155 POS_CODE_1=105
N0160 _N160:
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-30
D Assemblies
Assembly Gantry loader PL 400
N0165 STOPRE
N0170 POS_CODE_1=151
N0175 M31 M34 M25
N0180 STOPRE
N0185 POS_CODE_1=101
N0190
N0195 STOPRE
N0200 JUMP_POS=20
N0205 $A_OUT[5]=1
N0210 GOTOF LABELFORW_N220
_N215:
N0215 ERROR=1 ;(Set error)
LABELFORW_N220:
N0220 M17
%_N_L115_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0005 ;( Laying down pallet )
N0010 ;( Stack 2 )
N0015 CASE (JUMP_POS) OF 20 GOTOF LABELFORW_N20 30 GOTOF
LABELFORW_N30 60 GOTOF _N60 90 GOTOF _N90 125 GOTOF _N125 160 GOTOF
_N160 DEFAULT GOTOF _N215
; -->Please check: JUMP_POS
LABELFORW_N20:
N0020 G57 ;( Zero offset stack 2 )
N0025 G01 G94 F14000 U0
LABELFORW_N30:
N0030
N0035 STOPRE
N0040 POS_CODE_2=215
N0045 M41 M43 M99
N0050 STOPRE
N0055 POS_CODE_2=205
N0060 _N60:
N0065 STOPRE
N0070 POS_CODE_2=253
N0075 M42 M43 M97
N0080 STOPRE
N0085 POS_CODE_2=203
N0090 _N90:
N0095 STOPRE
N0100 M78 ;( Open pawl 2 )
N0105 POS_CODE_2=234
N0110 M41 M43 M98
N0115 STOPRE
N0120 POS_CODE_2=204
N0125 _N125:
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-31
D Assemblies
Assembly Gantry loader PL 400
N0130 STOPRE
N0135 M88 ;( Close pawl 2)
N0140 POS_CODE_2=242
N0145 M42 M44 M96
N0150 STOPRE
N0155 POS_CODE_2=202
N0160 _N160:
N0165 STOPRE
N0170 POS_CODE_2=221
N0175 M41 M44 M95
N0180 STOPRE
N0185 POS_CODE_2=201
N0190
N0195 STOPRE
N0200 JUMP_POS=20
N0205 $A_OUT[5]=0
N0210 GOTOF LABELFORW_N220
_N215:
N0215 ERROR=1 ;(Set error)
LABELFORW_N220:
N0220 M17
%_N_L116_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Stacking program )
N0002 ;( 3-axes with stacking )
N0003 ;( with workpiece change main spindle-sub spindle = L104 )
N0005 DEF REAL VPOS_COARSE
N0006 DEF REAL LSV=36 ; Light barrier in V
N0007 DEF REAL LSW=357 ; Light barrier in W
N0100 L111 ;(Basic position axes)
N0105 IF BLANK_IN_GRIPPER==1 GOTOF GO_ON
N0110 L100 ;(Basic position gripper)
GO_ON:
N0020 L102 ;(Checking weather there are errors)
N0025 IF (ERROR<>0 ) GOTOF LABELFORW_N170
LABELBACK_N30:
N0030 IF (U_COUNTER>PARTS_U) GOTOF LABELFORW_N160
LABELBACK_N35:
N0035 IF (W_COUNTER>PARTS_W) GOTOF LABELFORW_N145
N0241 STOPRE
; N0242 IF FINISHED_TURNED==0
; N0244 TURN_FINISHED
; N0246 ENDIF
N0036 G54
N0040 L103 ;(Position calculation)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-32
D Assemblies
Assembly Gantry loader PL 400
N0045 G01 W=WPOS U=UPOS F84000 T1 D1
N0265 IF BLANK_IN_GRIPPER==1 GOTOF LABEL_N73
N0050 VPOS_COARSE=VPOS+GRIP1_DIST_D1
N0053 M50 M52
N0055 V=VPOS_COARSE
N0060 V=VPOS F6000
N0065 M60
N0070 G04 F1 ; Fetching unmachined part
N0324 STOPRE
N0325 BLANK_IN_GRIPPER=1
N0326 BLANK_TURNED=0
LABEL_N73:
N0073 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N100
N0074 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0075 G55 V=VPOS_COARSE D2 F20000
N0080 U=UPOS W=WPOS M62
N0085 V=VPOS F6000
N0090 M51
N0092 G04 F0.5 ; Laying down machined part
N0094 V=VPOS_COARSE F84000
N0096 STOPRE
N0098 FINISHED_IN_GRIPPER=0
LABEL_N100:
; N0101 D0 V=LSV W=LSW M52 ; Moving to the light barrier
; N0103 STOPRE
; N0430 IF$A_OUT[3]==1
; N0431 BLANK_IN_GRIPPER=0
; N0432 ENDIF
; N0104 IF $A_OUT[3] GOTOF _N135 ; Next when there is no unmachined part
;from here pivoting gripper
; N0105 IF BLANK_TURNED==0
; N0106 TURN_BLANK
; N0107 ENDIF
N0108 G01 V125 D0 F60000
N0110 W850
N0112 CALCULATE_CHECK
N0115 WAITM(2,1,2)
N0116 G4 F0.5
N0117 STOPRE
N0118 IF PDSTOP==1 GOTOF END
N0120 L104 ;(Workpiece change)
N0125 WAITM(1,1,2)
N0127 STOPRE
N0128 IF $A_OUT[4]
N0130 L105 ;(Pushing out)
N0634 STOPRE
N0131 $A_OUT[4]=0
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-33
D Assemblies
Assembly Gantry loader PL 400
; N0132 ELSE
; N0133 TURN_FINISHED
N0134 ENDIF
_N135:
N0135 W_COUNTER=W_COUNTER+1
N0138 STOPRE
N0140 IF $A_OUT[2] GOTOB LABELBACK_N35 ; Serial part
N0142 GOTOF _N165
LABELFORW_N145:
N0145 W_COUNTER=1
N0150 U_COUNTER=U_COUNTER+1
N0155 GOTOB LABELBACK_N30
LABELFORW_N160:
N0160 U_COUNTER=1 W_COUNTER=1
_N165:
N0165 WAITM(2,1,2)
END:
N0167 G4 F0.5
N0168 L111 ;(Basic position axes)
LABELFORW_N170:
N0170 M17
%_N_L117_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Stacking program )
N0002 ;( 3-axes with stacking )
N0003 ;( with workpiece change sub spindle-main spindle = L107 )
N0005 DEF REAL VPOS_COARSE
N0006 DEF REAL LSV=36 ; Light barrier in V
N0007 DEF REAL LSW=357 ; Light barrier in W
N0015 L111 ;(Basic position axes)
N0105 IF BLANK_IN_GRIPPER==1 GOTOF GO_ON
N0110 L100 ;(Basic position gripper)
GO_ON:
N0020 L102 ;(Checking weather there are errors)
N0025 IF (ERROR<>0 ) GOTOF LABELFORW_N170
LABELBACK_N30:
N0030 IF (U_COUNTER>PARTS_U) GOTOF LABELFORW_N160
LABELBACK_N35:
N0035 IF (W_COUNTER>PARTS_W) GOTOF LABELFORW_N145
N0241 STOPRE
; N0242 IF FINISHED_TURNED==0
; N0244 TURN_FINISHED
; N0246 ENDIF
N0036 G54
N0040 L103 ;(Position calculation)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-34
D Assemblies
Assembly Gantry loader PL 400
N0045 G01 W=WPOS U=UPOS F84000 T1 D1
N0265 IF BLANK_IN_GRIPPER==1 GOTOF LABEL_N73
N0050 VPOS_COARSE=VPOS+GRIP1_DIST_D1
N0053 M50 M52
N0055 V=VPOS_COARSE
N0060 V=VPOS F6000
N0065 M60
N0070 G04 F1 ; Fetching unmachined part
N0324 STOPRE
N0325 BLANK_IN_GRIPPER=1
N0326 BLANK_TURNED=0
LABEL_N73:
N0073 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N100
N0074 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0075 G55 V=VPOS_COARSE D2 F20000
N0080 U=UPOS W=WPOS M62
N0085 V=VPOS F6000
N0090 M51
N0092 G04 F0.5 ; Laying down machined part
N0094 V=VPOS_COARSE F84000
N0096 STOPRE
N0098 FINISHED_IN_GRIPPER=0
LABEL_N100:
; N0101 D0 V=LSV W=LSW M52 ; Moving to light barrier
; N0103 STOPRE
; N0430 IF $A_OUT[3]==1
; N0431 BLANK_IN_GRIPPER=0
; N0432 ENDIF
; N0104 IF $A_OUT[3] GOTOF _N135 ; Next when there is no unmachined part
;from here pivoting gripper
; N0105 IF BLANK_TURNED==0
; N0106 TURN_BLANK
; N0107 ENDIF
N0108 G01 V125 D0 F60000
N0110 W850
N0112 CALCULATE_CHECK
N0115 WAITM(2,1,2)
N0116 G4 F0.5
N0117 STOPRE
N0118 IF PDSTOP==1 GOTOF END
N0120 L107 ;(Workpiece change)
N0125 WAITM(1,1,2)
N0127 STOPRE
N0128 IF $A_OUT[4]
N0130 L108 ;(Pushing out)
N0634 STOPRE
N0131 $A_OUT[4]=0
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-35
D Assemblies
Assembly Gantry loader PL 400
; N0132 ELSE
; N0133 TURN_FINISHED
N0134 ENDIF
_N135:
N0135 W_COUNTER=W_COUNTER+1
N0138 STOPRE
N0140 IF $A_OUT[2] GOTOB LABELBACK_N35 ; Serial part
N0142 GOTOF _N165
LABELFORW_N145:
N0145 W_COUNTER=1
N0150 U_COUNTER=U_COUNTER+1
N0155 GOTOB LABELBACK_N30
LABELFORW_N160:
N0160 U_COUNTER=1 W_COUNTER=1
_N165:
N0165 WAITM(2,1,2)
END:
N0167 G4 F0.5
N0165 L111 ;(Basic position axes)
LABELFORW_N170:
N0170 M17
%_N_L118_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0001 ;( Stacking program )
N0002 ;( 3-axes with stacking )
N0003 ;( with workpiece change main spindle-main spindle = L119 )
N0006 DEF REAL LSV=36 ; Light barrier in V
N0007 DEF REAL LSW=357 ; Light barrier in W
N0015 L111 ;( Basic position axes )
N0105 IF BLANK_IN_GRIPPER==1 GOTOF GO_ON
N0110 L100 ;(Basic position gripper)
GO_ON:
N0020 L102 ;(Checking weather there are errors)
N0025 IF (ERROR<>0 ) GOTOF LABELFORW_N170
LABELBACK_N30:
N0030 IF (U_COUNTER>PARTS_U) GOTOF LABELFORW_N160
LABELBACK_N35:
N0035 IF (W_COUNTER>PARTS_W) GOTOF LABELFORW_N145
N0241 STOPRE
; N0242 IF FINISHED_TURNED==0
; N0244 TURN_FINISHED
; N0246 ENDIF
N0036 G54
N0040 L103 ;(Position calculation)
N0045 G01 W=WPOS U=UPOS F84000 T1 D1
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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D Assemblies
Assembly Gantry loader PL 400
N0265 IF BLANK_IN_GRIPPER==1 GOTOF LABEL_N73
N0050 VPOS_COARSE=VPOS+GRIP1_DIST_D1
N0053 M50 M52
N0055 V=VPOS_COARSE
N0060 V=VPOS F6000
N0065 M60
N0070 G04 F1 ; Fetching unmachined part
N0324 STOPRE
N0325 BLANK_IN_GRIPPER=1
N0326 BLANK_TURNED=0
LABEL_N73:
N0073 IF FINISHED_IN_GRIPPER==0 GOTOF LABEL_N100
N0073 VPOS_COARSE=VPOS+GRIP2_DIST_D2
N0075 G55 V=VPOS_COARSE D2 F20000
N0080 U=UPOS W=WPOS M
53 M62
N0085 V=VPOS F6000
N0090 M51
N0092 G04 F0.5 ; Laying down machined part
N0094 V=VPOS_COARSE F84000
N0096 STOPRE
N0098 FINISHED_IN_GRIPPER=0
LABEL_N100:
; N0101 D0 V=LSV W=LSW M52 ; Moving to the light barrier
; N0103 STOPRE
; N0430 IF$A_OUT[3]==1
; N0431 BLANK_IN_GRIPPER=0
; N0432 ENDIF
; N0104 IF $A_OUT[3] GOTOF _N135 ; Next when there is no unmachined part
;from here pivoting gripper
; N0105 IF BLANK_TURNED
; N0106 TURN_BLANK
; N0107 ENDIF
N0108 G01 V125 D0 F60000 M52
N0110 W850
N0112 CALCULATE_CHECK
N0115 WAITM(2,1,2)
N0116 G4 F0.5
N0117 STOPRE
N0118 IF PDSTOP==1 GOTOF END
N0120 L119 ;(Workpiece change)
N0125 WAITM(1,1,2)
N0127 STOPRE
N0128 IF $A_OUT[4]
N0130 L105 ;(Pushing out)
N0634 STOPRE
N0131 $A_OUT[4]=0
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-37
D Assemblies
Assembly Gantry loader PL 400
; N0132 ELSE
; N0133 TURN_FINISHED
N0134 ENDIF
_N135:
N0135 W_COUNTER=W_COUNTER+1
N0138 STOPRE
N0140 IF $A_OUT[2] GOTOB LABELBACK_N35 ; Serial part
N0142 GOTOF _N165
LABELFORW_N145:
N0145 W_COUNTER=1
N0150 U_COUNTER=U_COUNTER+1
N0155 GOTOB LABELBACK_N30
LABELFORW_N160:
N0160 U_COUNTER=1 W_COUNTER=1
_N165:
N0165 WAITM(2,1,2)
END:
N0167 G4 F0.5
N0165 L111 ;( Basic position axes )
LABELFORW_N170:
N0170 M17
%_N_L119_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N0010 ;( Unloading from main spindle )
N0020 ;( Loading into main spindle )
N0030 DEF REAL V_WAITPOS=125
N0040 DEF REAL W_WAITPOS=850
N0050 G01 G94 V=V_WAITPOS D0 M52 M53 F84000 ; Pivoting
N0060 W=W_WAITPOS M51 ; Open machined part gripper
N0070 STOPRE
N0080 G03 W=GRIP2_DIST_D4 V0 CR=500 T1 D4 ; Moving in
N0090 G01 G09 V0 F40000 ; Exact stop
N0100 G09 W0 F20000
N0110 M61 ; Machined part gripper
N0120 G04 F0.3
N0124 STOPRE
N0125 FINISHED_TURNED=0
N0126 FINISHED_IN_GRIPPER=1
N0130 M69 ; Open main spindle
N0140 G01 V0 W=GRIP2_DIST_D4 D4 F20000
N0150 M62 M63 ; Pivoting
N0160 G01 V0 W=GRIP1_DIST_D3 D3 F84000
N0170 G01 W0 F6000 ; Insert unmachined part
N0180 M68 ; Close main spindle
N0110 M50 ; Open unmachined part gripper
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-38
D Assemblies
Assembly Gantry loader PL 400
N0120 G04 F0.3
N0224 STOPRE
N0225 BLANK_IN_GRIPPER=0
N0226 BLANK_TURNED=0
N0130 G01 W=GRIP1_DIST_D3 F40000
N0140 G02 V=V_WAITPOS W=W_WAITPOS CR=500 D0 F84000 ; Move out
N0180 STOPRE
N0190 M17
%_N_CALCULATE_CHECK_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N010 STOPRE
N020 IF CHECK==0 GOTOF END
N040 IF REST_BIS_CHECK<=0
N050 $A_OUT[4]=1 ; Pushing out
N060 REST_BIS_CHECK=CHECK
N070 ENDIF
N080 REST_BIS_CHECK=REST_BIS_CHECK-1
N090 END:
N100 M17
%_N_TURN_FINISHED_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N010 ; (Insert and fetching position =D7)
N020 DEF REAL V_BEFOR=0 ; Insert position
N030 DEF REAL W_BEFOR=0 ; Insert position
N040 DEF REAL V_AFTER=0 ; Fetching position
N050 DEF REAL W_AFTER=0 ; Fetching position
N070 M62 ; Machined part gripper down
N110 M89 ; Turning pivoting gripper
N120 M80 ; Open pivoting gripper
N130 D7 G0 V=GRIP2_DIST_D7
N140 W=W_BEFOR
N150 G01 V=V_BEFOR F20000
N160 M90 ; Close pivoting gripper
N170 M51 ; Open gripper 2 (machined part)
N175 G4 F0.3
N180 G0 V=GRIP2_DIST_D7
N190 M79 ; Turn back pivoting gripper
N200
N210 W=W_AFTER
N220 G1 F20000 V=V_AFTER
N230 M61 ; Close Gripper 2 (machine part)
N235 G4 F0.5
N240 M80 ; Open pivoting gripper
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-39
D Assemblies
Assembly Gantry loader PL 400
N250 G0 V=GRIP2_DIST_D7
N260 STOPRE
N270 FINISHED_TURNED=1
N280 M17
%_N_TURN_BLANK_SPF
;$PATH=/_N_WKS_DIR/_N_LOADER_WPD
N010 ; (Insert and fetching position=D6)
N020 DEF REAL V_BEFOR=0 ; Insert position
N030 DEF REAL W_BEFOR=0 ; Insert position
N040 DEF REAL V_AFTER=0 ; Fetching position
N050 DEF REAL W_AFTER=0 ; Fetching position
N070 M52 ; Unmachined part gripper down
N110 M79 ; Turning pivoting gripper
N120 M80 ; Open pivoting gripper
N130 D6 G0 V=GRIP1_DIST_D6
N140 W=W_BEFOR
N150 G1 F20000 V=V_BEFOR
N160 M90 ; Close pivoting gripper
N170 M50 ; Gripper 1 (unmachined part) open
N175 G4 F0.3
N180 G0 V=GRIP1_DIST_D6
N190 M89 ; Turn back pivoting gripper
N200
N210 W=W_AFTER
N220 G1 F20000 V=V_AFTER
N230 M60 ; Close gripper 1 (unmachined part)
N235 G4F0.3
N240 M80 ; Open pivoting gripper
N250 G0 V=GRIP1_DIST_D6
N260 STOPRE
N270 BLANK_TURNED=1
N280 M17
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-40
D Assemblies
Assembly Gantry loader PL 400
42.13 Procedure of stacking
Stack 1
Stack 2
Switching cam
Switching cam
Adjustment of the cam (switching
point!)
Adjustment of the cam (switching
point!)
Vmax = 23mm/s, adjustment with potentiometer
X=position: unlock stack 1 / 2
Y=position: lock stack 1 / 2
Position code stack 1 (unmachined parts)
POS_CODE_1 Position of the stacker unit
101
at position 7
112
between position 7 and 2
102
at position 2
123
between position 2 and 3
103
at position 3
134
between position 3 and 4
104
at position 4
145
between position 4 and 5
105
at position 5
151
between position 5 and 7
Position code stack 2 (machined parts)
POS_CODE_2 Position of the stacker unit
201
at position 7
215
between position 1 and 5
205
at position 5
253
between position 5 and 3
203
at position 3
234
between position 3 and 4
204
at position 4
242
between position 4 and 2
202
at position 2
221
between position 2 and 7
Figure 42-8: Procedure of stacking
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-41
D Assemblies
Assembly Gantry loader PL 400
42.14 Program for basic position stack 1/2
NC-Start
Reset
ERROR=0
Y
IF
POS_CODE_1
=101
N
IF
POS_CODE_1
=112
Y
JUMP_POS=30
N
IF
POS_CODE_1
=123
Y
N
JUMP_POS=60
IF
POS_CODE_1
=103
Y
N
IF
POS_CODE_1
=134
Y
JUMP_POS=90
N
IF
POS_CODE_1
=104
Fetching pallet
Stack 1, L114
Y
N
IF
POS_CODE_1
=145
Y
JUMP_POS=125
N
IF
POS_CODE_1
=101
Y
N
IF
POS_CODE_1
=105
Y
N
JUMP_POS=160
IF
POS_CODE_1
=151
Set
JUMP_POS=20
Set
ERROR=1
Y
N
End of program
Figure 42-9: Program for basic position stack 1/2
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-42
D Assemblies
NC-Start
Assembly Gantry loader PL 400
Reset
ERROR=0
Y
IF
POS_CODE_2
=201
N
IF
POS_CODE_2
=215
Y
JUMP_POS=30
N
IF
POS_CODE_2
=205
Y
N
JUMP_POS=60
IF
POS_CODE_2
=253
Y
N
IF
POS_CODE_2
=203
Y
JUMP_POS=90
N
IF
POS_CODE_2
=234
Fetching pallet
Stack 1, L114
Y
N
IF
POS_CODE_2
=204
Y
JUMP_POS=125
N
IF
POS_CODE_2
=242
Y
N
IF
POS_CODE_2
=202
Y
N
JUMP_POS=160
IF
POS_CODE_2
=221
Set
JUMP_POS=20
Set
ERROR=1
Y
N
End of program
Figure 42-10: Program for basic position stack 1/2
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-43
D Assemblies
Assembly Gantry loader PL 400
42.15 Program structure for fetching / laying down the pallet
NC-Start
Move U axis to position
stack 1
IF JUMP_POS
=20
N
Y
IF JUMP_POS
=30
Set 7/2,
POS_CODE_1=112
Move stack to position 2
Set 2,
POS_CODE_1=112
Set 2/3,
POS_CODE_1=123
Move stack to position 3
Set 3,
POS_CODE_1=103
Move stack to position 4
Set 4,
POS_CODE_1=104
N
IF JUMP_POS
=60
Y
N
OPEN Pawl 1 M77
IF JUMP_POS
=90
Y
Set 3/4,
POS_CODE_1=134
N
CLOSE pawl 1 M87
IF JUMP_POS
=125
Y
Set 4/5,
POS_CODE_1=145
Move stack to position 5
Set 5,
POS_CODE_1=105
Y
Set 5/7,
POS_CODE_1=151
Move stack to position 7
Set 7,
POS_CODE_1=101
N
IF JUMP_POS
=160
N
Set jump
JUMP_POS=20
Pallet on
U axis
$A_OUT[5]=1
Set
ERROR=1
End of program
Figure 42-11: Program structure for fetching / laying down the pallet
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-44
D Assemblies
Assembly Gantry loader PL 400
NC-Start
Move U axis to position
stack 2
IF JUMP_POS
=20
N
Y
IF JUMP_POS
=30
Set 7/5,
POS_CODE_1=112
Move stack to position 5
Set 5,
POS_CODE_1=112
Set 5/3,
POS_CODE_1=253
Move stack to position 3
Set 3,
POS_CODE_2=203
Move stack to position 4
Set 4,
POS_CODE_2=204
N
IF JUMP_POS
=60
Y
N
OPEN Pawl 2 M78
IF JUMP_POS
=90
Y
Set 3/4,
POS_CODE_2=234
N
CLOSE pawl 2 M88
IF JUMP_POS
=125
Y
Set 4/2,
POS_CODE_2=242
Move stack to position 2
Set 2,
POS_CODE_1=105
Y
Set 2/7,
POS_CODE_2=221
Move stack to position 7
Set 7,
POS_CODE_2=201
N
IF JUMP_POS
=160
N
Set jump
JUMP_POS=20
Pallet on
U axis
$A_OUT[5]=1
Set
ERROR=1
End of program
Figure 42-12: Program structure for fetching / laying down the pallet
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-45
D Assemblies
Assembly Gantry loader PL 400
42.16 Error messages
42.16.1 Alarm messages
700501
Process:
Solution:
Circuit breaker triggered in PL400 cabinet
A circuit breaker or a motor protection breaker has been triggered in
the electric cabinet of the gantry loader.
Open the electric cabinet of the gantry loader and reset the
corresponding components back to 1. If a circuit breaker or a motor
protection breaker triggers again, then consult an electrician.
700502
Process:
Solution:
Belt monitoring loading arm
The belt of the V axis is tore.
Please contact the Spinner after sales service.
700503
Process:
Stacking not ready
At least one of the regulator circuit boards to control the motors for
stack 1 or stack 2 indicates „Not ready“.
Check if both stacks can be moved. By means of an electrician check
the power supply respectively the regulator circuit boards.
Solution:
700504
Process:
Solution:
700505
Process:
Solution:
Stack 1 emergency limit switch up
Stack 1 in stacking has moved up too far and hit the emergency limit
switch.
Move the stack away using the 72S107.7 button in the PL electric
cabinet. (see instructions)
Stack 1 emergency limit switch down
Stack 1 in stacking has moved down too far and hit the emergency
limit switch.
Move the stack away using the 72S107.6 button in the PL electric
cabinet. (see instructions)
700506
Process:
Solution:
Stack 2 emergency limit switch up
See Message 700504 with reference to stack 2
See Message 700504 with reference to stack 2
700507
Process:
Solution:
Stack 2 emergency limit switch down
See Message 700505 with reference to stack 2
See Message 700505 with reference to stack 2
700508
Process:
Pneumatic compressed air in PL400 is missing
The pneumatic pressure on the compressed air connection has fallen
below the required minimum pressure of 6 bar.
Open main valve of the pneumatic system and check the system
pressure.
Solution:
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-46
D Assemblies
Assembly Gantry loader PL 400
42.16.2 Operating messages
700537
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 10 is on
The end position of the programmed movement was not reached.
Check the pneumatic cylinder for freedom of movement, check the
chokes and silencers to see if they are plugged, check the hoses to
see if they are kinked. Check the initiators and re-adjust them as
necessary. To do this press the Emergency Stop Button and move the
cylinder in a depressurised state to both end positions; the initiator
should light up at each of the end positions.
700538
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 10 is off
See Message 700537
See Message 700537
700539
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 11 is on
See Message 700537
See Message 700537
700540
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 11 is on
See Message 700537
See Message 700537
700541
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 12 is on
See Message 700537
See Message 700537
700542
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 12 is on
See Message 700537
See Message 700537
700543
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 9 is on
See Message 700537
See Message 700537
700544
Occurrence:
Solution:
Channel 2 is waiting for feedback that Air 9 is off
See Message 700537
See Message 700537
700545
Occurrence:
Solution:
Channel 2 is waiting for the feedback: turn M52 - Gripper
The end position of the programmed movement was not reached.
Check the pneumatic cylinder for freedom of movement, check the
chokes and silencers to see if they are plugged, check the hoses to
see if they are kinked. Check the initiators and re-adjust them as
necessary. To do this press the Emergency Stop Button and move the
cylinder in a depressurised state to both end positions; the initiator
should light up at each of the end positions.
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-47
D Assemblies
Assembly Gantry loader PL 400
700546
Occurrence:
Solution:
Channel 2 is waiting for the feedback: turn M62 - Gripper
The end position of the programmed movement was not reached.
Check the pneumatic cylinder for freedom of movement, check the
chokes and silencers to see if they are plugged, check the hoses to
see if they are kinked. Check the initiators and re-adjust them as
necessary. To do this press the Emergency Stop Button and move the
cylinder in a depressurised state to both end positions; the initiator
should light up at each of the end positions
700547
Occurrence:
Solution:
Channel 2 is waiting for the feedback: turn M53 - Gripper
The end position of the programmed movement was not reached.
Check the pneumatic cylinder for freedom of movement, check the
chokes and silencers to see if they are plugged, check the hoses to
see if they are kinked. Check the initiators and re-adjust them as
necessary. To do this press the Emergency Stop Button and move the
cylinder in a depressurised state to both end positions; the initiator
should light up at each of the end positions.
700548
Occurrence:
Solution:
Channel 2 is waiting for the feedback: turn M63 - Gripper
The end position of the programmed movement was not reached.
Check the pneumatic cylinder for freedom of movement, check the
chokes and silencers to see if they are plugged, check the hoses to
see if they are kinked. Check the initiators and re-adjust them as
necessary. To do this press the Emergency Stop Button and move the
cylinder in a depressurised state to both end positions; the initiator
should light up at each of the end positions.
700549
Process:
Solution:
Finished part not removed from conveyor belt
The finished part was not removed from the conveyor belt.
Check if the conveyor belt runs. Check the initiator „Finished part in
laying down position“ and „Finished part in confirming position“.
700550
Process:
Solution:
Loader waiting for unmachined part on the conveyor belt feeder
There is no unmachined part located on the conveyor belt feeder.
Insert unmachined part. Check initiator „Unmachined part present“.
700551
Process:
Stack 1 pivot lever not in position
The end position of the pivot lever for the pallet locking of stack 1 has
not been reached.
Check the pivot lever and pneumatic cylinder for freedom of
movement, check the hoses to see if they are kinked. Check the
initiators and re-adjust them as necessary. Move the cylinder in a
depressurised state to both end positions; the initiator should light up
at each of the end positions.
Solution:
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-48
D Assemblies
700552
Process:
Solution:
700553
Occurrence:
Solution:
Assembly Gantry loader PL 400
Stack 2 pivot lever not in position
The end position of the pivot lever for the pallet locking of stack 1 has
not been reached.
Check the pivot lever and pneumatic cylinder for freedom of
movement, check the hoses to see if they are kinked. Check the
initiators and re-adjust them as necessary. Move the cylinder in a
depressurised state to both end positions; the initiator should light up
at each of the end positions.
Checking the initiators for Air 9-12
Both initiators which are allocated to an air connection have reported a
High-Signal to the control system at the same time and triggered a
read in block. One can deduce from this that an initiator is always
reporting high and it is either defect or is being continuously dampened
by chips or similar materials.
Check the initiator and clean it or replace it as necessary.
Solution:
Release/clamp initiated from Channel 2 only during Wait in Channel 1
A release/clamp from Channel 2 is programmed although a program is
running in Channel 1 and is not in a waiting condition.
Change the parts program.
700555
Process:
Solution:
Stack 1 or 2 not in initial position
To move the U axis, both stacks must be in the initial position.
Move the stack to the initial position (see instructions).
700556
Occurrence:
Moving axis to reference point V
Once the machine is switched on the V-axis must be referenced. To do
this change the operating mode to REF, select Axis V and move to the
reference point using the + key. Watch out for freedom from collision!
700557
Occurrence:
Moving axis to reference point W
Once the machine is switched on the W-axis must be referenced. To
do this change the operating mode to REF, select Axis W and move to
the reference point using the + key. Watch out for freedom from
collision!
700558
Occurrence:
Moving axis to reference point U
Once the machine is switched on the U-axis must be referenced. To
do this change the operating mode to REF, select Axis U and move to
the reference point using the + key. Watch out for freedom from
collision!
700554
Occurrence:
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-49
D Assemblies
Assembly Gantry loader PL 400
700560
Occurrence:
Solution:
Feedback from the loader flap on the lathe is missing
The end position for the loading flap was not reached.
Check the pneumatic cylinder for freedom of movement, check the
chokes and silencers to see if they are plugged, check the hoses to
see if they are kinked. Check the initiators and re-adjust them as
necessary. To do this press the Emergency Stop Button and move the
cylinder in a depressurised state to both end positions; the initiator
should light up at each of the end positions.
700561
Occurrence:
The safety door on the PL400 is open
The safety door on the PL400 is open. It must be closed for a parts
program to be started.
10701
or
10703
Occurrence:
The Channel 2 Protected Area 1 specific to that channel has been
violated
Solution:
Protected Area 1 is preventing movement of the loader arm into the
area of the headstock.
See Siemens-Diagnosis Manual or program the movement of the
loader arm in another way.
42.17 Instructions to free the stacking system
When the machine was turned of and the stacks were not in the base position the
referencing procedure can not be done afterwards because the U-axis is locked. The
stacks must be moved to the base position using the two yellow keys (see left bottom in
the electric cabinet).
Upper key: 72S107.6 = Move up stack
Lower key: 72S107.7 = Move down stack
When one of the stacks is already in its base position the keys only take effect on the
stack which is not in its base position.
When one of the stacks reached the end limit switch use also these keys for the freeing
procedure. In addition to that the same freeing routine as used for freeing an axis from
the limit switch must be done to suppress the emergency off message (2 persons are
necessary).
First person:
1. Select the JOG mode
2. Close and lock the safety doors
3. Press and hold down the cycle start key
4. Switch on drives
5. Delete alarm message by means of the RESET key
6. Check: Drives must stay kept on
Second person:
1. Open the electric cabinet of the gantry loader
2. Free the stack by means of the yellow keys (see above)
First person:
1. Release the cycle start button
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-50
D Assemblies
Assembly Gantry loader PL 400
42.18 Maintenance
See chapter maintenance in book C.
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-51
D Assemblies
Assembly Gantry loader PL 400
42.19 Drawings and parts lists
42.19.1 Bogie truck
Figure 42-13: Exploded drawing of the bogie truck
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-52
D Assemblies
Assembly Gantry loader PL 400
Assembly PL-024-000 Bogie truck
Quant. Unit Designation
2
Piece PL-003-014 Clamp for motor carrier
4
Piece PL-003-003 Vertical wiper
4
Piece PL-003-002 Horizontal wiper
2
Piece PL-003-021 Pulley wheel
4
Piece PL-003-023 Intermediate disc
4
Piece PL-003-022 Washer
2
Piece NADELLA Roller concentric FRN32
1
Piece NADELLA Roller concentric FRN40
1
Piece EUCHNER Limit switch triple SN03R08-552
4
Piece FAG Deep groove ball bearing WL6004-2RSR
2
Piece PL-003-020 Axis for the guide roller
1
Piece PL-003-013 Coupling 2
1
Piece PL-003-012 Coupling 1
1
Piece SIEMENS Motor 1FK6042-6AF71-1AH0 +
ALPHA Gear unit SPG 075-M01
1
Piece PL-003-016 Complete pulley wheel (BRECO At5, Z=28)
1
Piece PL-024-001 Motor holding plate
1
Piece PL-024-002 Holder 1
1
Piece PL-024-003 Holder 2
1
Piece PL-003-017 Holding disc
1
Piece PL-003-004 Terminal box
1
Piece PL-003-001 Bogie truck
1
Piece PL-003-009 Covering
1
Piece PL-003-008 Holder for limit switch
1
Piece PL-003-007 Connection for the cable tow
1
Piece PL-003-005 Cover for terminal box
1
Piece PL-003-006 Holder for terminal rail
1
Piece PL-003-019 Valve plate
2
Piece NADELLA Roller eccentric RRNR32
3
Piece NADELLA Roller eccentric FRNR40
1
Piece EUCHNER Cam for limit switch U8-25
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21083
21072
21071
21090
21092
21091
30656
30654
30354
30671
21089
21082
21081
21085
21086
21073
21070
21078
21077
21076
21074
21075
21088
30657
30655
30396
42-53
D Assemblies
Assembly Gantry loader PL 400
42.19.2 Vertical axis
Figure 42-14: Assembly vertical axis
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-54
D Assemblies
Assembly Gantry loader PL 400
Assembly PL-012-000 vertical axis
Quant. Unit Designation
1
Piece PL-002-025 Front housing
1
Piece PL-002-024 Rear housing
1
Piece PL-002-018 Holder for turning cylinder
1
Piece Toothed belt ZR-T5
2
Piece PL-002-026 Round guiding rail
1
Piece PL-002-022 Belt coupling
1
Piece Inductiv sensor
2
Piece EUCHNER Limit switch cam U8-25
1
Piece EUCHNER Limit switch cam U8-40
2
Piece PL-002-023 Clamp for belt
1
Piece PL-002-021 Cover plate
1
Piece PL-002-020 Switching piece
1
Piece PL-002-016 End cover
1
Piece Compression spring
2
Piece PL-002-017 Terminal for cable
1
Piece PL-002-019 Holder for energy chain
1
Piece Energy chain
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
Article no.
21067
21066
21060
30669
21068
21064
30664
30397
30398
21065
21063
21062
21058
30668
21059
21061
30670
42-55
Assembly Gantry loader PL 400
D Assemblies
42.19.3 Drive rail
Figure 42-15: Exploded drawing of the drive rail
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-56
D Assemblies
Assembly Gantry loader PL 400
Assembly PL-025-000 Drive rail
Quant. Unit Designation
4
Piece Guide rail for gantry loader
2
Piece PL-004-006 Clamp for the motor carrier
3
Piece PL-004-007 Limit switch plate
2
Piece PL-004-008 Support for the cable drag
1
Piece PL-004-001 Main carrier
1
Piece PL-004-015 Complete guide pulley
1
Piece Motor 3000 rpm + Gear unit
1
Piece PL-004-005 Motor carrier plate
1
Piece PL-004-002 End piece on the left
1
Piece PL-004-003 End piece on the right
1
Piece PL-004-014 Cover of the support housing
1
Piece PL-004-016 End disc
2
Piece Deep groove ball bearing
1
Piece PL-025-001 Cover
3
Piece Individual limit switch
1
Piece Toothed belt
1
Piece Energy chain of gantry loader, horizontal
1
Piece PL-004-011 Complete pulley
1
Piece PL-004-012 Holding disc
1
Piece PL-004-004 Cap
1
Piece PL-004-009 Clamp for pulley belt
1
Piece PL-004-010 Connection piece for the bogie truck
1
Piece DIN471 Retaining ring 20x1.2
PD-1-01/03-840D
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Assembly Gantry loader PL 400
D Assemblies
42.19.4 U axis
Figure 42-16: Exploded drawing of the U axis
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-58
D Assemblies
Assembly Gantry loader PL 400
Assembly PL-026-000 U axis
Quant. Unit Designation
2
Piece NADELLA Guide rail FSH 40 L=1050+960
8
Piece FAG Deep groove ball bearing 6004-2RSR
3
Piece EUCHNER Individual limit switch NB01K-556
2
Piece EUCHNER End limit switch cam U8-100
1
Piece BRECO-M Toothed belt AT5 L=4065mm / W=50mm
2
Piece NADELLA Roller concentric FRN40
2
Piece NADELLA Roller excentric FRNR40
2
Piece PL-014-026 Axis for the guide roller
4
Piece PL-003-023 Intermediate disc
1
Piece PL-026-001 Motor carrier
1
Piece PL-003-017 Holding disc
2
Piece PL-004-006 Clamp for the motor suport
4
Piece PL-003-022 Washer
4
Piece SB-NC-010-030/1 Setting screw
4
Piece SB-NC-010-031 Lock nut
4
Piece PL-003-002 Horizontal wiper
1
Piece SIEMENS Motor 1FK6042-6AF71-1AH0 - Zv03
+ ALPHA gear unit SPG 075-M01
1
Piece PL-014-001 Main carrier
1
Piece PL-014-002 Base for the U axis
2
Piece PL-014-003 Cap for the base
4
Piece PL-014-004 End piece
2
Piece PL-014-005 Side panel
1
Piece PL-014-006 End panel
8
Piece PL-014-007 Assembly bracket
4
Piece PL-014-008 Mounting foot
1
Piece PL-014-009 Slide for U axis
1
Piece PL-014-010 Cover plate 1
1
Piece PL-014-011 Cover plate 2
1
Piece PL-014-012 Cover plate 3
1
Piece PL-014-013 Cover plate 4
2
Piece PL-014-014 Cover plate 5
2
Piece PL-014-015 Cover plate 6
2
Piece PL-014-016 Mounting strip
3
Piece PL-014-017 Pallet support
4
Piece PL-014-018 Intermediate disc
4
Piece PL-014-019 Bearing block
2
Piece PL-014-020 Complete guide pulley wheel (BRECO AT5,
Z=28)
4
Piece DIN471-20x1.2 Retaining ring 1
4
Piece DIN472-42x1.75 Retaining ring 2
2
Piece PL-014-021 Holder for the limit switch
1
Piece PL-014-022 Clamping plate
1
Piece PL-014-023 Clamp for pulley belt
2
Piece PL-014-024 Side panel
2
Piece PL-014-025 Guide roller
1
Piece PL-014-027 Complete pulley (BRECO AT5, Z=28)
2
Piece PL-014-028 Spacer sleeve
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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Assembly Gantry loader PL 400
D Assemblies
42.19.5 Basic frame
Figure 42-17: Exploded drawing of the basic frame
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-60
D Assemblies
Assembly Gantry loader PL 400
Assembly PL-028-000 Basic frame
Quant. Unit Designation
2
4
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
4
4
1
1
1
1
1
2
1
4
1
1
1
1
1
2
9
1
1
1
1
5
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
Piece
PL-006-020 Plate
PL-006-021 Clamp
PL-006-003 Cap for base
PL-006-019 Support
PL-006-009 Filling plate
PL-006-018 Mounting plate
PL-006-001 Base for gantry loader
PL-006-004 Side panel on the left
PL-006-006 Suppport
PD-012-009 Holder for tongue
PL-006-005 Side panel on the right
PL-006-014 Holder for plug-in window
PL-006-015 Plug-in window
PL-006-008 Strip for front apron
PL-006-011 Insertion on the left side
PL-006-016 Metal cover
PL-006-017 Rear apron
PL-006-013 Guiding rail
PL-006-012 Suppport for guiding rail
PL-009-001 Insertion for pneumatic unit
PD-011-016 Outer door stop
PD-011-020 Distance roll
SB-NC-010-030/1 Setting screw
SB-NC-010-31 Lock nut
ELAN Safety door locking TZFW 24V DC/96
PD-011-046 Support bracket for door locking
PD-011-047 Fixing plate 1
PD-011-048 Fixing plate 2
PL-006-023 Spacer
WALDMANN Holder
PL-006-010 Insertion on the right side
BK-012-205 Sign
PL-006-002 Rack for gantry loader
WALDMANN Lamp
PL-006-007 Front apron
PL-028-001 Operation panel for PL-840
PD-011-021 Housing for operation panel
PL-028-004 Cable clamp for operation panel
ELAN Light button D16-Z
ELAN Push button D16-Z
ELAN Key button D16-Z
PL-028-002 Sign 1
PL-028-003 Sign 2
ELAN Dummy plug form ZB No. 009 3998
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
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D Assemblies
Assembly Gantry loader PL 400
42.20 Pneumatic diagram
42.20.1 Gantry loader
Figure 42-18: Pneumatic diagram Gantry loader
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-62
D Assemblies
Assembly Gantry loader PL 400
42.20.2 U axis
Figure 42-19: Pneumatic diagram U axis
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
42-63
D Assemblies
Assembly Tool monitoring system
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Ultra Precision Lathe PD
PD-1-01/03-840D
61503E
43 Assembly Tool monitoring system
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
43-1
D Assemblies
Assembly Tool monitoring system
43.1 Description
(See manual of the manufacturer in the following)
PD-1-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
43-2
TOOL Monitor SEM-MODUL
Operating manual
System for the monitoring and control of machine tools
Version from 23. October 2002
as of software version 1.50
1
General _____________________________________________ 2
1.1
About these operating instructions ______________________________2
1.2
Operating elements of the SEM-Modul ____________________________2
1.3
First steps ___________________________________________________4
1.4
Measuring points and measured variables ________________________4
1.5
Original curve, smoothed curve and trend of the mean height ________6
1.5.1
1.5.2
1.5.3
1.5.4
Original curve ___________________________________________________
Smoothed curve _________________________________________________
Mean height ____________________________________________________
Trend of the mean height __________________________________________
6
6
6
6
1.6
Types of limits and their monitoring strategies _____________________7
1.7
Cuts and Programs____________________________________________7
1.7.1
1.7.2
1.8
Control signals _______________________________________________8
1.8.1
1.8.2
1.8.3
1.8.4
1.8.5
1.8.6
1.9
Cut ___________________________________________________________ 7
Program _______________________________________________________ 7
The inputs “Program active” P.a. and “Cut active” S.a. ___________________
The input “Limit active” G.a. ________________________________________
The input “Reserve” Res. __________________________________________
The input “Data valid” D.g. _________________________________________
The input “Alarm reset” A.r. ________________________________________
Inputs for the scrap gate and program numbers ________________________
8
8
8
8
8
8
Relay and opto-coupler outputs to control the machine _____________9
2
How do I create a first monitoring program? _____________ 10
3
The menu structure __________________________________ 10
3.1
The main menu “Program” ____________________________________11
3.1.1
3.1.2
3.1.2.1
Submenu “Re-learn everything” ________________________________________12
3.1.2.2
Submenu “Re-learn part” _____________________________________________13
3.1.2.3
Submenu “Adjust limits to curve” _______________________________________13
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.2
Menu “Monitoring”_______________________________________________ 11
Menu “Learn” __________________________________________________ 12
Menu “Add” ____________________________________________________
Menu “Select” __________________________________________________
Menu “Delete” __________________________________________________
Menu “Check” __________________________________________________
Menu “Trial run” ________________________________________________
Menu “Communication with the PC” _________________________________
Menu “Log in” __________________________________________________
13
15
15
15
16
16
16
The main menu “Edit” ________________________________________17
3.2.1
Menu “Measuring point” __________________________________________ 17
3.2.1.1
Submenu “Change” _________________________________________________18
3.2.1.2
Submenu “Add”_____________________________________________________20
3.2.1.3
Submenu “Remove” _________________________________________________20
3.2.2
Menu “Cut” ____________________________________________________ 21
3.2.2.1
Submenu “Change” _________________________________________________21
3.2.2.2
Submenu “Add”_____________________________________________________22
3.2.2.3
Submenu “Remove” _________________________________________________22
3.2.3
Menu “Limit” ___________________________________________________ 23
3.2.3.1
Graphically editing limits ______________________________________________24
3.2.3.2
Submenu “Change” _________________________________________________26
3.2.3.3
Submenu “Add”_____________________________________________________28
3.2.3.4
Submenu “Remove” _________________________________________________28
3.2.3.5
Submenu “Learning parameters” _______________________________________28
3.2.3.6
Submenu “Learn” ___________________________________________________28
3.2.4
Menu “Modules” ________________________________________________ 29
3.2.4.1
Module “Negation” __________________________________________________30
3.2.4.2
Module “Scrap gate” _________________________________________________30
3.2.4.3
Module “Recording operating data” _____________________________________31
3.2.4.4
Module “Missing piece register (Type 1)” _________________________________33
3.2.4.5
Module “Missing piece register (Type 2)” _________________________________35
3.2.4.6
Module “Missing piece register (Type 3)” _________________________________35
3.2.4.7
Module “Counter (down)” _____________________________________________36
3.2.4.8
Module “Counter (up)” _______________________________________________37
3.2.4.9
Module “Information” ________________________________________________37
3.2.5
Menu “Extras” __________________________________________________ 38
3.2.5.1
Submenu “Zero point subtraction” ______________________________________39
3.2.5.2
Submenu “Mean height” ______________________________________________40
3.2.5.2.1 Graphically editing the mean height ___________________________________40
3.2.5.2.2 “Change” ________________________________________________________41
3.2.5.2.3 “Remove” _______________________________________________________41
3.2.5.2.4 “Add” ___________________________________________________________42
3.2.5.2.5 “Reset trend” _____________________________________________________42
3.2.5.3
Submenu “Program” _________________________________________________42
3.2.5.4
Submenu “Alarm texts”_______________________________________________42
3.2.5.5
Submenu “Inputs” ___________________________________________________44
3.2.5.6
Submenu “Outputs” _________________________________________________44
3.2.5.7
Submenu “External program selection” __________________________________45
3.2.5.8
Submenu “Status line” _______________________________________________47
3.2.5.9
bus)
Submenu “Settings” (display contrast, clock, calibrate touch-screen, language, CAN
47
3.2.5.10 Submenu “Operator administration” _____________________________________48
3.2.5.10.1 “Group” ________________________________________________________49
3.2.5.10.2 “Operator” ______________________________________________________49
3.3
The main menu “Display” _____________________________________50
3.3.1
3.3.2
Menu “Program info”_____________________________________________ 50
Menu “Measuring point” __________________________________________ 50
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.4
50
51
52
52
52
The main menu “Help” ________________________________________53
3.4.1
3.4.2
3.4.3
3.4.4
4
Menu “Alarms” _________________________________________________
Menu “Signal test” ______________________________________________
Menu “Trend” __________________________________________________
Menu “TP signal test” ____________________________________________
Menu “CAN bus” ________________________________________________
Menu “Index”___________________________________________________
Menu “Help tour”________________________________________________
Menu “Information” ______________________________________________
Menu “System info” _____________________________________________
53
53
53
54
Data backup and remote operation of the SEM-Modul______ 54
4.1
Terminal software SEM-Term __________________________________54
4.2
Sin-Term terminal software for remote operation from the 840D / 810D 55
4.3
Backup on a PC with the aid of a memory card____________________56
5
Rear connection of the SEM-Modul_____________________ 57
5.1
SEM-Modul without dynamic evaluation (standard) ________________57
5.2
SEM-Modul with dynamic evaluation (option) _____________________57
5.3
Control signal periods and reaction times of the module ___________58
5.4
Usable control signals from the machine tools ___________________58
5.4.1
P.a. options (signal for “new work piece”) ____________________________ 58
5.4.1.1
P.a. for lathes ______________________________________________________58
5.4.1.2
P.a. for machining centers (without external program selection) _______________58
5.4.2
S.a. options (signal for “next cut”) __________________________________ 59
5.4.2.1
S.a. for lathes ______________________________________________________59
5.4.2.2
S.a. for machining centers ____________________________________________59
5.4.2.3
S.a. for rotary cycle machines and multi-spindle lathes ______________________59
5.4.3 G.a. options (signal to report missing work pieces) for rotary cycle machines and
multi-spindle lathes ____________________________________________________ 59
5.4.4 Feed-stop options_______________________________________________ 59
6
Instructions for changing the EPROM ___________________ 60
7
Technical specifications SEM-Modul ____________________ 62
8
Index ______________________________________________ 63
-2-
1
General
1.1 About these operating instructions
These operating instructions first explain the operating elements and the basic operating steps as a
brief overview (Chap. 1.2 to 1.4). Before the operation is explained in detail, chapters 1.5 to 1.8 include
an explanation of the curves formed and the monitoring strategies as well as the control signals
necessary for synchronization with the work piece processing. In Chapter 2 there is an explanation on
which menus are required to create a monitoring program.
In the extensive Chapter 3 all available menus of the Tool Monitor are described “from left to right” and
from “top to bottom” within the main menu. This makes it easy to find the submenu in the operating
manual which you have a question about. The index (last chapter) can also be used for this purpose.
A brief explanation of the expressions “main menu” and “submenu”: these expressions are used strictly
according to the hierarchy of the menu structure so that the level in the menu structure can be easily
recognized. Sometimes a submenu is further divided into additional submenus, which are also referred
to as “submenus” (and not sub-submenu). Branches in the menu structure to a lower level are marked
in the text with the character >>. The menus themselves are printed in this operating manual in bold
italics and are placed in quotation marks (e.g. menu “Monitoring”). When text from the input field of
the menus is mentioned, then it is printed in bold and placed in quotation marks (e.g. “Alarm text”).
Since a Tool Monitor only functions well when it is operated correctly, the author has made every effort
to write an operating manual that is easy to understand. Please let us know if you find any mistakes,
unclear formulations, or missing entries in the index. On a final note, it is not easy as the author of an
operating manual to put himself in the position of a machine operator who is using such a Tool Monitor
for the first time.
Dr.-Ing. Klaus Nordmann
1.2 Operating elements of the SEM-Modul
The SEM-Modul can be operated in four different ways:
1. Operation using the keypad next to the display
The basic functions of the keys on the SEM-Modul are:
Canceling an operation without changing a value and exiting menus by moving
up the menu structure.
Confirmation of settings and executing operating steps, opening submenus.
Opening a main menu and a submenu.
Cursor movement in the menu fields and graphic movement of limits.
Changing a numeric value or a text and selecting graphically displayed limits so
that they may be moved with the cursor.
-32. Operation using the touch-screen
The SEM-Modul can also be operated completely on the display by pressing the menu texts and key
symbols. All functions for program handling and configuration can thus be executed very easily.
Depending on your preferences, input can be either via the keypad or via the touch-screen.
3. Control using an attached computer with the SEM-Term software
Using the SEM-Term software the SEM-Modul can, for example, be controlled from a PC-based
master computer or a work station. All functions that the SEM-Modul contains can be set using the
SEM-Term software. In addition, it is possible to save the data from programs and settings in the SEMModul. The menus are clicked with the mouse on the PC monitor, the keys on the SEM-Modul are
equivalent to the same ones on the PC.
4. Remote operation using the operating panel of the controls Sinumerik 840D or 810D
using the SIN-Term software
The SEM-Modul can be called up using the so-called Area Shift Key of the Siemens control. The
measurement curves are then visualized on the screen of the 840D or 810D.
SIN-Term software
(840D/810D)
The softkeys, which are arranged horizontally and vertically, and the NC keypad of the Sinumerik can
be used to control the tool monitoring system in the same way as the keypad on an SEM-Modul unit.
For more information on installation, see Chap. 4.2.
-4-
1.3 First steps
After switching on the power, information on the software date, serial number, and telephone number
or e-mail and Internet address of Nordmann GmbH & Co.KG appears.
Start menu
This display is acknowledged with
on the operating panel or the touch-screen. Next a sample
program appears which consists of eight measuring points and a cut. Play with the buttons a little bit
first off to get an idea of how the SEM-Modul works. However, avoid changing numeric values for the
moment. This program should be deleted as soon as your first self-configured monitoring program has
been learned.
Sample program
If you wish to learn the operation of the Tool Monitor yourself without the benefit of a training course,
then you should read through the entire operating manual. We do not feel that a “brief introduction” is
adequate since it might cut out details essential to your application. Judge for yourself which functions
you do not need.
1.4 Measuring points and measured variables
The acoustic emissions, the force of a tool, the effective power of a drive, the reflective intensity of a
laser beam, or the dynamic portion of the measured values (requires the inclusion of the “Dynamic
option”) are used as measurement variables for monitoring (see the brochure “Tool Monitoring for the
Protection and Unsupervised Operation of Machine Tools”). With the exception of current and
dynamic, all measured variables are displayed as measurement curves in dB units using a logarithmic
scale across the time axis. A change in the measured values of +6dB means that the measured value
doubled. An increase of +20dB is equivalent to an increase in the measured value by a factor of 10.
Increases of.. % or of .. dB, which are calculated according to the following formulas, are listed in the
-5following table:
− Increase in measured value [dB ] = 20 × lg
- Increase in measured value [%] = 100 ×10
[
Increase in measured value [% ]+100
100
 Increase in measured value[dB ]


20


]
− 100
Since changes in the measured value by a factor of 100 or more cannot easily be displayed on a
measurement curve using a linear scale, the measurement and visualization uses a logarithmic scale.
The advantage of this, possibly unusual scale in [dB] lies in the improved display of very weak values
and the avoidance of over-control for very high values. The SEM-Modul has eight inputs, each of which
can be fitted with a sensor for one of the measured values mentioned above. These inputs are called
measuring points and are numbered from 1 to 8.
Increase in measured
value of
... dB
is equivalent to an
increase of... %
0.5 dB
1 dB
1.5 dB
2 dB
2.5 dB
3 dB
3.5 dB
4 dB
5 dB
6 dB
8 dB
10 dB
12 dB
15 dB
20 dB
40 dB
60 dB
106%
112%
119%
126%
133%
141%
150%
158%
178%
200%
251%
316%
400%
565%
1000% (= x10)
10,000% (= x100)
100,000% (= x1,000)
(initial value 100%)
The names of the measuring points can also be changed (edited) later to allow a more effective
assignment to the stations (layers) of a machine being monitored. The editing of the measuring point
name is done on the SEM-Modul in the main menu “Edit” >> “Measuring point” >> “Change”, but
may also be accomplished on a PC with the aid of the SEM-Term software (see Chapter 4.1).
-6-
1.5 Original curve, smoothed curve and trend of the mean height
1.5.1 Original curve
The data supplied by the sensors connected is saved as a curve and displayed over time. Generally,
all direct voltages between 0V and 10V can be visualized on the SEM-Modul as measurement curves.
1.5.2 Smoothed curve
In addition, it is also possible to form a “smoothed curve” in which the curve value is caculated as a
floating mean of the measured values for the last 2 to 1000 milliseconds (which can be set in the main
menu “Edit” >> “Measuring point” >> “Change”). This smoothes out any peaks in measured value
which may occur (e.g. for acoustic emission) so that the machine is not stopped by accidental peaks in
the measured values.
1.5.3 Mean height
Further, the “Mean height” can be determined. It is calculated as the mean of a measurement curve
or of the section of a measurement curve and may also be determined as a mean over several work
pieces if desired (see also Chap. 3.2.5.2). It is usually used for wear detection since it is independent
of brief variations in the height of the measurement curve.
The time period for the calculation of the “Mean height” is represented by a horizontal bar along the
upper edge of the measurement curve. It can be limited by shifting this time marker to the interesting
section of the curve. Areas without measured values (aircutting) or curve areas with greatly varying
measured values (e.g. cutting blank pieces) can thus be specially excluded from the calculation of the
“Mean height”. The beginning and the end of the time period should be in relatively horizontal areas
of the curves or just before and after a measurement curve so that time shifts in the curve have no
influence on the mean height calculated.
The “Mean height” calculated appears as a vertical column on the right side of the display and can be
monitored with separate limits (see also Chapter 3.2.5.2).
1.5.4 Trend of the mean height
In order to better be able to follow the behavior of the “Mean height” over a larger number of work
pieces, it may also be displayed as a “Trend” over the number of work pieces machined (see also
Chapter 3.3.5). This makes it easier to judge whether a tool causes an even increase in the measured
values across the number of work pieces produced or whether a mean of the mean height across
several work pieces needs to be added.
-7-
1.6 Types of limits and their monitoring strategies
The measurement curves, described in Chapter 1.5, and the mean heights can now be monitored
using different limits which stop the machine or its feed or switch to another speed when violations
occur, i.e. when impermissible values arise. Please read Chapter 3.2.3, or Chap. 1.2 and 1.3 of the
brochure “Tool Monitoring for the Protection...” or “Strategies and Sensor Techniques for Tool
Monitoring with Nordmann Tool Monitors”. There you will find additional important information on use of
the sensors, measurement curves, monitoring strategies or types of limits.
1.7 Cuts and Programs
1.7.1 Cut
In order to be able to monitor tools for breakage or wear, it is necessary to record limit values. Different
tools also require different limits. The data associated with a special process is referred to as a “Cut”.
In CNC machines with automatic tool changers at least one cut is assigned to each tool. The sequence
of cuts required for monitoring the machining of a work piece is saved in the SEM-Modul in a
“Program” (see Chapter 3.2.2).
1.7.2 Program
A program is composed of the sensors which are connected (measuring points) and their associated
measurement curves. The curves per measuring point can extend over several cuts, especially in
machine tools with tool changers (CNC lathes or machining centers). The measured variables and the
associated limits (height, beginning and end points) are stored with their freely programmable outputs
(relays or opto-couplers) in each active measuring point. Furthermore, there is the option to store
special information for each existing cut. The curves measured from the last time the part was
machined (original curve, mean height, trend of the man height) are saved for each activated
measuring point.
Programs can be stored either under a numeric sequence or under a name (max. 20 characters). An
alphanumeric keyboard which is operated by touch-screen can be called up on the screen to do this.
Alternatively, programs can be called up directly using the NC control (in BCD or binary code). In
addition, it is possible to externally select a 4 digit program number using 16 control lines. With binary
coding of the 16 control lines, it is also possible to externally select a 5 digit number (max. 65536).
(See Chapter 3.2.5.7)
-8-
1.8 Control signals
1.8.1 The inputs “Program active” P.a. and “Cut active” S.a.
Depending on the case in question, the device requires one or two 24V control signals supplied by the
machine tool in order to be able to synchronize with the machining. In CNC machines these signals are
typically implemented with M or H functions. For non-CNC controlled machines freely programmable
cam switches or existing control signals from the machine can be used (see Chapter 5.4).
The two most important signals are Program active P.a. and Cut active S.a. Tool monitoring is usually
activated with the P.a. signal before the machining of the work piece begins. It remains set for the entire time
the piece is machined and is only deleted at the end of the machining. The S.a. signal is set for the duration of
the work on a work piece, i.e. for the duration of a cut.
Since a program, e.g. in machining centers or CNC lathes, usually contains several cuts, S.a. can be set and
deleted again several times while a P.a. signal is present. The first S.a. is always assigned to cut 1, the
second S.a. to the second cut, etc., in other words, the cut number is incremented by 1 for each additional
S.a.
The control signals S.a. and P.a. can be generated directly on the SEM-Modul by simultaneously
and
buttons in order to, for example, make it possible to record measurement
pressing the
values without connecting the unit to the machine control (see Chapter 3.2.1.1).
1.8.2 The input “Limit active” G.a.
“Limit active” G.a. is used in rotary cycle machines, automatic multi-spindle lathes, or transfer lines to
display missing work pieces so that individual measuring points can be specially switched off when
their tools are moving out into “empty space” due to missing wor pieces (see Chapters 3.2.4.4 to
3.2.4.6 for more information).
1.8.3 The input “Reserve” Res.
If a control signal is switched to the input “Reserve”, then the SEM-Modul interrupts the measurement
and monitoring until the signal has been withdrawn.
1.8.4 The input “Data valid” D.g.
“Data valid” D.g. (= strobe) informs the SEM-Modul whether valid values are present on the 16 program number inputs, e. g the number of a monitoring program selected automatically by the machine
or by the master computer (see also: “Tool Monitoring for the Protection and Unsupervised Operation of
Machine Tools” and Chapters 3.2.5.7 and 5.3.)
1.8.5 The input “Alarm reset” A.r.
“Alarm reset” A.r. allows the external acknowledgement of an alarm, that is without any manual
operation of the unit. This is done by switching a 24V pulse to A.r. after the alarm.
The monitoring is then continued with a new work piece.
1.8.6 Inputs for the scrap gate and program numbers
If a “Scrap gate” is to be controlled with the aid of the SEM-Modul (see Chapter 3.2.4.2), up to 16
inputs (terminals X3 A0 to A15) can be used to signal that scrap was produced.
If a “Program number” is to be implemented with the aid of the SEM-Modul (see Chapter 3.2.5.7),
-9then up to 16 inputs can also be used (terminals X3 A0 to A15) to create a program number.
The implementation of a “Scrap gate and program number” would be a special case. In this case
the 16 inputs on the SEM-Modul must be accordingly distributed.
1.9 Relay and opto-coupler outputs to control the machine
The violation of a limit during the machining is reported to the machine by switching a potential-free
changeover contact or opto-coupler. The spindle or feed drives can be stopped or, for example,
switched from a rapid to a work speed with the aid of these outputs.
The SEM-Modul has 12 programmable opto-couplers (+24V / 150mA) to report the violation of limit
values. In addition, two defined opto-coupler outputs with the function “Feed release” and “Receive
data” are available. Furthermore, 4 programmable potential-free changeover contacts can also be
used as outputs.
You need to differentiate between relays/opto-couplers with and without alarm displays. Relays/optocouplers with alarm displays must be acknowledged either manually with a keypad input from the front
panel, or using a 24V high signal on the input “Alarm reset” (see also Chapter 3.2.5.6).
All relays or opto-couplers can be programmed for their switching behavior. Several different behaviors
are possible: 1. immediate switching upon limit violation, 2. switching at the end of the cut, that is, after
drop off of the S.a. signal, and 3. switching at the end of the program, i.e. after drop off of the P.a.
signal (see Chapter 3.2.3.2). When no alarm text has been set, then the switching takes place without
being shown on the display, and the monitoring continues. The relays are reset according to the way
they were set up (see Chapter 3.2.5.6). The outputs are reset upon a rising edge of a defined input or
after a preset time between 10ms and 10sec. These relays can thus be used, for example, to control a
parts counter or to report the contract between the grinding wheel and the work piece or dresser when
grinding.
The opto-coupler output on X1 terminal 28 (“Feed release”) makes “self-monitoring” of the unit
possible. This output can be used, for example, to prevent the machine from producing when the
monitoring has not been activated. This output only releases the feed in the following cases:
•
•
•
•
When the monitoring is running with a program already learned
During a learning process over at least two work pieces (available at the end of 2000)
During a test run (available at the end of 2000)
During a signal test (available at the end of 2000)
The correct reception of data (D.e.) can be acknowledged with the opto-coupler X3 terminal 34 for
external program number switching (see also Chapters 3.2.5.7 and 5.3).
- 10 -
2 How do I create a first monitoring program?
The chapter sequence of the following operating instructions is oriented on the structure of the menus,
beginning with the main menu “Program” and continuing on to the main menu “Help”. You should
read all chapters in order to become familiar with all functions of the system. For impatient people, I
would, however, like to explain in advance the sequence in which one should proceed to create a first
monitoring program with the associated limit values:
First you need to “Add” (see Chap. 3.1.3) a program. A copy of the program “DEMO”, which is
installed in each new unit at the factory, is available regarding the number of measuring points and preselected limit types. Here you must give the new program an individual name (see Chap. 3.1.3). The
new program uses the pre-sets of the demo program, but not the measurement curves or limit value
heights.
In order to adjust the measuring point configuration of the demo program to the machine tool which is
to be monitored now, you must select the main menu “Edit”, then the menu “Measuring point” and
then the submenu “Remove” (Chap. 3.2.1.3) to delete measuring points that are not required. Any
additional measuring points which may be required are then created under the submenu “Add” (Chap.
3.2.1.2) and set for use with this machine under the submenu “Change” (Chap. 3.2.1.1).
The program “DEMO” should now be deleted as it is no longer necessary.
Then the suitable limit types need to be selected for each measuring point of the new program. This is
done using the menu “Limit” (see Chap. 1.6 and 3.2.3), whereby first the unnecessary limits are
removed (Chap. 3.2.3.4). Any additional limits which may be necessary are added (Chap. 3.2.3.3) and
then their settings are checked and, if necessary, adjusted using the submenu “Change” (Chap.
3.2.3.2).
When the control signals P.a. and S.a. and, if necessary, the external program number (see Chap. 0,
5.3 and 5.4) are not yet present, then these must now be prepared.
Then in the main menu “Program”, the menu “Learn” and then the submenu “Re-learn everything”
(Chap. 3.1.2.1) can be selected to record the measurement curves. As soon as the number of work
pieces pre-selected for learning has been machined, the SEM-Modul places the limit values above
and, if necessary, below the measurement curves. These limits are to be understood as mere
suggestions since the distances of the limits before learning were not specified. They must therefore
be checked and possibly graphically corrected by moving and shortening them (Chap. 3.2.3.1).
When this has also taken place, then the monitoring can be started in the menu “Monitoring” in the
main menu “Program”.
3 The menu structure
The operating interface contains 4 main menus and is modeled on Windows:
“Program”
“Edit”
“Display”
“Help”
key the menu bar “Program” is highlighted in blue. A selection of the other main
By pressing the
and
menus “Edit”, “Display” and “Help” can now be done using the
keys. A pull-down menu is
or
opened with the
keys. A selection of the individual menu items within a pull-down menu is
done using the
or
keys. A menu item that has been selected is then highlighted in blue and when
key is pressed a dialog box is opened in which the appropriate settings can be made, or
the
or
another branch into a submenu from this menu item is offered.
- 11 -
3.1 The main menu “Program”
key again.
The main menu “Program” is opened first by pressing the
key or by pressing the
Settings which affect entire monitoring programs are possible here, e.g. creation of a new program
using the menu item “Add”.
Menu “Program”
3.1.1 Menu “Monitoring”
If the system is switched to the Monitoring mode, the stored data (limits) is compared with the current
measured values. The system is then active and, for example, switches the machine off or the feed
drive from rapid to working speed when a limit violation occurs. The red bar under the menu bar and in
the lower status line where it says “Monitoring” shows that monitoring operation is switched on. The
measuring points may only be observed in this mode; a change in the limit heights is not possible.
Monitoring
key,
To end the monitoring or to change the settings, you must select the point “Program” with the
then the menu item “End monitoring” appears which is acknowledged with . The unit is then in the
set mode again.
- 12 -
End monitoring
3.1.2 Menu “Learn”
By calling up the menu item “Learn”, you have the option of creating or optimizing a program in three
different ways. The following selections are possible: “Re-learn everything”, “Re-learn part”, and
“Adjust limits to curve”.
Learn
3.1.2.1 Submenu “Re-learn everything”
If a new program for a monitoring task is to be created which has never been learned in the past, for
example after re-equipping for a new type of work piece which has not yet been monitored, then the
key. A window is opened in which the
menu item “Re-learn everything” is activated with the
number of work pieces which are to be used for learning can be set using the
key. An increase in
the number of work pieces means that the scatter of the individual machining is taken into account
when the limits are calculated automatically and that the manual finishing of the limits is performed
more quickly.
or by pressing the blue highlighted line “ReThe unit is set into the learn mode by confirming with
learn everything”. The production machine is started. As soon as the signals for measurement start
(P.a./S.a.) are present, then a machining curve is recorded. If learning is to take place over more than
one work piece, then all measurement curves are displayed on the monitor. The region between the
highest and the lowest measurement curves is filled with the color of the measurement curve. As soon
as the preset number of work pieces have been machined, the SEM-Modul automatically adjusts the
limits (red) selected for the measuring points in question to the measurement curve (yellow). You
should now check the position of the limits in all measurement curves recorded once more and edit
them graphically if necessary (see Chap. 3.2.3.1).
- 13 selects the point
If the learning process is to be ended before it is complete, then opening with
“Program”. There the menu item “End learning” appears which you then confirm with . The unit is
then in the set mode again.
3.1.2.2 Submenu “Re-learn part”
If a monitoring program with the appropriate settings already exists and it turns out that the limits in a
measuring point are not optimal for the curve, then it is possible to re-learn one or more measuring
points. The limit values in the measuring points which are not re-learned are then maintained.
Re-learn part
The first setting in the dialog box which opens is the number of work pieces over which learning is to
or
keys. With the
key you select the measuring point which
take place. This is preset using the
is to be re-learned. By pressing the
key the entry at that measuring point is changed from “Do not
change” to “Re-learn”. The box is closed with , and the system is in the learning process. When
learning is to take place over more than one work piece, then an envelope curve with all measurement
curves to be re-learned in a measuring point is formed as with the menu item “Re-learn everything”.
After the preset number of work pieces has been recorded, the limits in the measuring point in
question are adjusted to the newly recorded measurement curve and may then be manually optimized
selects
if necessary. If the learning process is to be ended before it is complete, then opening with
the point “Program”. There the menu item “End learning” appears which you then confirm with .
The unit is then in the set mode again.
3.1.2.3 Submenu “Adjust limits to curve”
This function can be used to adjust limits to the curve last recorded. When the menu item “Adjust
limits to curve” is confirmed with , a query about adjusting all limits in all cuts appears. If you
or by pressing “Yes” on the touch-screen, then the limits are immediately readjusted to
confirm with
key in the dialog
the existing measurement curve. You may cancel by changing to “no” with the
field and then confirming with .
3.1.3 Menu “Add”
In order to create a new program for a new monitoring task, a program name must first be assigned.
The learned measurement curves, cuts, and limits are then stored under this name in the SEM-Modul
and can remain the memory of the system after the machine has been re-equipped so that they may
be called up again should the program ever be needed. The memory in the system is large enough
(without a memory extension) for about 20 programs with 5 measuring points with 1 cut each (or e.g. 1
measuring point with 5 cuts). The memory requirements for a program vary with the number of cuts
and the limits used. Should the memory no longer be large enough to create a program, then it is
possible to save the data with the program SEM-Term, as described in Chapter 4.1.
- 14 -
Enter program name
key, a dialog box to enter the program name appears. This
When you open the menu “Add” with the
name can be the designation of the work piece to be machined (e.g. “HOUSING LID”) or its number.
This makes it possible to clearly assign the tool monitoring program to the work piece produced. If only
and
a program number is to be entered, then you may select the appropriate digits using the
keys. You may move to the next position using the
key.
button in this box and then
The simplest way to enter a name or a number is, however, to press the
confirm with . A keyboard field appears which makes it possible to easily select letters on the touchscreen.
Keyboard field on the display
- 15 -
3.1.4 Menu “Select”
If more than one program is stored in the SEM-Modul, then the menu item “Select” appears. With
you can confirm “Select” and a field is opened in which all programs saved in the SEM-Modul are
or
keys and confirmed with . The program can
listed. The desired program is selected with the
now be edited, or the system is activated by switching to “Monitoring” (see Chap. 3.1.1).
Select
3.1.5 Menu “Delete”
In order to remove a program which is no longer required, the pull-down menu “Program” is opened
and the item “Delete” is selected. A submenu with all saved programs appears. The program to be
or
keys and confirmed with the
key. A confirmation query is then
deleted is selected with the
carried out.
3.1.6 Menu “Check”
The activated program is checked for completeness of all its program components (modules) when
you select the menu “Check”. If a module has been deleted and an entry in the program still refers to
this module, the system reports the error. Then a message appears indicating which measuring point
or limit refers to the non-existent module.
Result of the program check
If all settings are correct, then the system reports: “No errors in the program”.
- 16 3.1.7 Menu “Trial run”
The menu “Trial run” is used to test the limit value setting without running the risk of a false alarm
when a limit is violated. As soon as this menu is selected, the measurement curves can be recorded
over any number of work pieces. The measurement curves are all graphically displayed whereby the
area between the highest and lowest curve is filled out in the color of the curve. The trial run is ended
by selecting the point “Program” with the
key. Then the menu item “End trial run” appears, to be
confirmed with . The unit is then in the set mode again.
3.1.8 Menu “Communication with the PC”
The menu item “Communication with the PC” only appears on the screen of a PC if the SEM-Modul
was connected to an external computer with the RS 232 cable supplied beforehand. A requirement for
this is the installation and use of the SEM-Term communications software on the PC. The SEM-Modul
can then be operated completely from the PC, which, for example, makes remote control using an
open windows-based control possible.
Display on the PC monitor
It is possible to read out programs and to save them on the hard disk of the PC by clicking “Save program on the PC” with the mouse on the PC monitor. A window is opened in the currently opened
the data
program in which the program name is displayed. As soon as you confirm this field with
transfer begins. The programs are placed in the directory of the program SEM-Term.exe.
A transfer of the programs from the PC back to the SEM-Modul is triggered by clicking “Load
program from the PC”. In this case, the program to be loaded must be in the same directory as the
program SEM-Term.
It is also possible to save data related to the entire monitoring system on the PC or to load it from the
PC. This data is called “global modules” (see Chapter 3.2.4.4 for more information).
3.1.9 Menu “Log in”
Depending on the operator group, different settings are possible. Passwords can be assigned which let
operators release different menus. When an operator “logs in” his personal user interface is switched
on. Depending on the application, areas can be blocked and thus protected from accidental change or
deletion. The configuration of the interface is explained in Chapter 3.2.5.10 (main menu “Edit” >>
menu “Extras” >> submenu “Operator administration”).
- 17 -
3.2 The main menu “Edit”
All system configurations for measuring points, cuts, limits, modules and other system settings which
are found under “Extras” are undertaken in this menu. You may set your own alarm texts.
Menu Edit
3.2.1 Menu “Measuring point”
If changes are to be made to measuring points, then you must first choose between “Change”,
“Add”, or “Remove”.
Menu Measuring point
- 18 -
3.2.1.1 Submenu “Change”
If “Change” is selected, a list of the existing measuring points for the current program is displayed.
Selecting measuring points
After selecting the measuring point which is to be changed, a menu window for this measuring point
appears. In the field “Name” you may now enter a name for the measuring point e.g. “Rough turn”,
“Drill 2.5mm” or “Station 3”, etc.
Edit measuring point, part 1
or
keys or using the keyboard field on the touch-screen which is
Entry is done either using the
opened by pressing either the name of the measuring point currently displayed (here: effective power)
key and then Keyboard. After ending entry it is completed with .
or the
It is possible to deactivate a measuring point in the input field “Active” using the
or
keys. If you
switch from “Active” “yes” to “Active” “no” then there is no recording of the curves from this
measuring point. You use this function to switch off measuring points that are only occasionally used
while machining specific work pieces and switch them back on for other work pieces.
Deleting the measuring point (Chap. 3.2.1.3) and later adding the measuring point means that the
position of the measuring point is not maintained and cannot even be changed manually. If, for
example, Measuring point 2 is deleted from a system with four sensors, then measuring points 1, 3 and
4 become measuring points 1, 2 and 3. If the “old” measuring point 2 is added back now, it is added
at the end of the list and becomes number 4.
The “channel” of a measuring point is the input of the value measured by the sensor on the rear of the
unit. The measuring channel to be displayed for this measuring point can be selected in the line
“Channel”. By default, the channel which is set is the same as the measuring point number. In special
cases the channel can be switched to obtain a different sequence of measuring points.
- 19 For certain monitoring tasks it may make sense to give a measured value a “smoothing time”,
or
especially for an acoustic measured value. A time value in [milliseconds] can be given using the
keys. The higher the time set is, the calmer the curve will be. Disturbances from acoustic peaks will
be suppressed. Very long smoothing times, however, lead to reaction times for limit value overshoots
that are too large, and the system will react too slowly. Thus, for example, the measured value for
acoustic emission for a spiral drill which is monitored with an upper limit should not be smoothed.
Otherwise the acoustic event of breakage which only lasts 0.5ms could be smoothed away.
The SEM-Modul offers the option of using its own external 24V control signal to start the
measurement. The signal is called “Cut active” (S.a.). For four axis lathes or NC controlled automatic
circular table machines different S.a. signals can be assigned to monitor the individual tools. The input
designated S.a. (terminal X2 34) is preset for all measuring points. Another input can be selected
or
keys. Logically, one first assigns input A15 and then A14,
under “S.a.- signal input” using the
etc. so that the inputs A0, A1, A2 ... are not assigned when a program change takes place at the same
time.
The signal “S.a.+ hand start” is a special case. When you select this signal it is possible to do a socalled hand measurement without an external S.a.- signal. In the operation mode “Monitoring”, “Learn”
or “Trial run”, the keys OK and ESC must be pressed simultaneously to do this.
Edit measuring point, part 2
If a machine has the option to detect missing work pieces (=”missing pieces”) on the loading unit, then
this can be used to activate a so-called missing piece process on the SEM-Modul. This function
prevents the generation of false alarms during warm up (without work pieces) or when the machine is
idling (with monitoring switched on). The output of a missing piece register is selected in the line
or
keys. This register must be programmed in advance
“Missing piece signal input” with the
as a module, which is described in Chap. 3.2.4.4 Module “Missing piece register (Type 1)”.
For example, when you select the signal “FREG.1”, the current measuring point is not displayed in the
cut following the missing piece.
The number after “FREG.” indicates after how many cycles the measuring point is to be hidden. If
layer 1 is monitored by measuring point 1 and layer 4 is monitored by measuring point 2 on a six axis
lathe, then “FREG.1” is entered in “measuring point 1” and “FREG.4” in “measuring point 2”.
“Reset signal for the cut counter”: In special cases a “Reset signal for the cut counter” can be
set. If any input is programmed in this field, then a reset from the current cut to the first cut, whose
measurement starts after the next S.a. signal, is carried out when a 24V pulse is put on this input.
Seven preset measured variables, whose scale value and display range are adjusted to our sensors,
and a user-defined measured variable can be found under the setting “Measured variable”.
Only in the setting “User defined” is it possible to change the values in the 5 input lines below it for
the unit, for the scale and for the display range.
The unit of the measured variable can be selected by choosing the desired letter in the field “Unit”
or
keys. It is also possible to enter the value using the keyboard field on the touchusing the
screen by pressing the
key while the field “Unit” is selected and confirming with .
- 20 It is possible to adjust the scale and the display range (zoom) in the four following input fields. With the
aid of the display range you can zoom the measured values. Please remember here that limits or parts
of envelope curves which are above or below the display range after such a zoom are no longer
effective.
Edit measuring point, part 3
3.2.1.2 Submenu “Add”
If a measuring point is to be added because an additional sensor has been attached, then the
submenu “Add” is confirmed with . The measuring point inserted is automatically assigned the next
available measuring point number. The further steps are analogous to those in Chapter 3.2.1.1.
3.2.1.3 Submenu “Remove”
If the submenu “Remove” is selected under the menu “Measuring point”, the window “Delete
keys
or
measuring point” is opened. The measuring point to be removed is marked with the
and confirmed with . A confirmation query follows.
If measuring points are only to be switched off for a specific period of time, then it is advantageous not
to delete them and to add them back later, but only to deactivate them as is described in Chapter
3.2.1.1.
- 21 -
3.2.2 Menu “Cut”
If changes are to be made in the so-called “cuts” using the menu “Cut”, then you must first choose
between “Change”, “Add”, and “Remove”.
Edit cut
3.2.2.1 Submenu “Change”
Cuts which have already been learned can be changed regarding their duration and the number of
measured values. When you select “Change” a list of the steps learned is displayed. The cut is
selected and then confirmed with .
Cut
The top input line of the following menu is titled “Name of the cut”. A name for the cut can be entered
here which designates the monitored cutting process. The entry is done in the same way as it is for
program names as described in Chap. 3.1.3.
In the second line of the menu the maximum duration of the cut that can be displayed can be set in
or
keys, the cursor is
either seconds or milliseconds. Setting the digits is accomplished with the
moved to the next digit with the
key.
You can move to the unit field using the
to seconds or vice versa using the
or
key. Here you may change the time unit from milliseconds
key.
In the following field you may set the “Number of measured values displayed during learning” with
or
keys. The value should be as small as possible to save memory capacity. A value below
the
128, however, is not recommended since there are then too few measuring points would be learned
and the curve would look “jagged”.
- 22 The settings for the cut selected are implemented by confirming with , the menu is closed
automatically and the next cut may be edited. If no other cuts need to be edited, then the open window
key.
is closed with the
When viewing the changed cut as a diagram of measurement curves, one can see that the cut
duration actually implemented is usually a bit higher than the pre-selected values. This is done for
safety reasons so that a reduction of the feed speed for a tool does not lead to an overshoot of the
right limit of the display.
3.2.2.2 Submenu “Add”
If a cut is to be added manually, then the submenu “Add” is selected. The next higher cut is then
automatically added after the last cut. The steps to make the further settings are analogous to the ones
described in Chapter 3.2.2.1.
3.2.2.3 Submenu “Remove”
If a cut is to be removed from an existing program, then a window is opened under “Remove” with a
or
keys and
list of all cuts stored in the program. The cut to be deleted is selected using the
confirmed with . An additional query whether the cut should really be deleted then follows.
If a cut which lies within a series of cuts is deleted, then the following cuts each move up one number.
- 23 -
3.2.3 Menu “Limit”
There are a number of limit types available. Generally, we differentiate between “straight limits”, “upper
and lower envelope curves”, “minimum limits”, “time limits”, and the “mean height”.
Limit types 1
Limit types 2
1) “Minimum limit”: Must be crossed at least once, otherwise the output assigned to it switches.
2) “Time limit”: Switches the output assigned to it as soon as it has been reached.
3) “Straight limits”, “Envelope curves”, and “Mean height”: Switch the assigned outputs as soon as they
are overshot (limits with “over”) or undershot (limits with “under”).
- 24 -
3.2.3.1 Graphically editing limits
If existing or newly learned programs are to be optimized with limit corrections, then the desired
measuring point and, if more than one cut was learned, the appropriate cut are to be selected. You can
and
or
or
keys to the right of the display.
use either the touch-screen or the
After selecting the appropriate curve, the limits or the associated set values are selected by repeatedly
key. When the mean height is activated (see Chapter 3.2.5.2), then two vertical lines
pressing the
appear after you press
once which represent the time period for the calculation of the “mean height”
(see Chap. 3.2.5.2.1 for setting the time period). Each additional press of the
key makes the
consecutive selection of all activated limits possible. The beginning of the limit is always selected first,
followed by the end and then the height. When the limit is selected the color changes (from red to
yellow), in addition, the area selected is marked with a flashing arrow. The limit type is shown at the top
left of the display.
Beginning of the limit
or
key. After the beginning of the limit has
The beginning of the limit may be shifted using the
been correctly set, the end of the limit can be jumped to by pressing the
key once. The end of the
limit may then be edited in the same manner, again using the
or
keys.
End of the limit
key, using the
The height of a limit can be adjusted after another press on the
the beginning and the end points of the limit are marked with a flashing arrow.
or
keys. Then
- 25 -
Setting the height of the limit
key again sets a flashing arrow in the left third of the envelope curve when you are
Pressing the
dealing with envelope curve limits. This arrow can now be moved with the four arrow keys to shape
the envelope curve, for example, to adjust it to a changed shape of the measurement curve.
The editing of all other limits is done in the same manner by repeatedly pressing the
key. The same
key. The limit value corrections are
process can be performed in the opposite direction using the
saved and exited using the
or
keys.
Shaping a limit
If all limits in all measuring points and cuts have been checked and, if necessary, optimized after
automatic learning, then the monitoring can be activated (see also Chapter 3.1.1).
- 26 -
3.2.3.2 Submenu “Change”
Settings associated with the limits can be established with the submenu “Change”.
Edit limit
After selecting “Change” a list of all limits activated in this program appears:
Select limit
keys. After confirmation with , a
or
The appropriate limit is selected for editing using the
submenu is opened in which the desired “Output” is assigned to the limit selected with the
or
keys (relays 1-4 or opto-couplers 1-12). If the Tool Monitor has a second internal expansion module
which has an additional 8 measuring channels, then these switch outputs with the names IO2.relay 1 to
IO2.opto-coupler 12 can be selected.
Previously programmed modules can also be linked with a limit so that when a limit is violated the
corresponding module is switched instead of immediately using a switch output. Whether an output
switches and which one is set in the module in question (Chap. 3.2.4) (e.g. Module “Scrap gate”, see
Chap. 3.2.4.2).
With reference to the module “Scrap gate” there are outputs Scrap.1 to Scrap.16 or, in general,
Name of scrap gate.1 to Name of scrap gate.16. (The scrap gates can be assigned individual names,
see Chap. 3.2.4.2.) The number behind the dot indicates how many cycles of the machine are to take
place after the limit violation before the scrap gate module, and therefore the scrap gate, is switched.
- 27 -
Edit limit part 1
The next field makes the selection of an alarm text possible. Standard texts like “Tool dull”, “Tool
broken”, “Contact to work piece” and “No message” are preset. If you created your own alarm
texts (Chap. 3.2.5.4), then these appear in the list too. A selection of the alarm texts takes place with
the
or
keys, the alarm text is accepted with .
With the fields “Beginning” and “End” the beginning and the end of the limit in time can also be
numerically set exactly to the millisecond with the keys
,
and
(as an alternative to graphic
setting). Normally, however, the limit is set graphically as described in Chap. 3.2.3.1.
Edit limit part 2
If an alarm is not to be triggered immediately when a limit is exceeded, then a limit violation time can
be set. Only when the measured value has violated the limit for longer than the so-called “violation
period” does this limit’s output switch. It is unimportant here whether the limit was not exceeded for
some of the time since the durations of multiple violations of the limit value are added together. This
gives this setting a very different quality from that of smoothing a curve (see Chap. 1.5.2 and 3.2.1.1).
The measurement of the violation period begins again with each new cut.
The setting is done in the field “Limit violation takes place after a violation period of” using the
key.
The reaction time of the output to an alarm can be determined individually for each limit in the separate
measuring points and cuts. Under “Output switches after limit violation” the preset is
or
“immediately”. If a different reaction of the output is now necessary, then this can be set with the
keys. If, for example, a thread cutting process is being monitored, then an immediate stop of the
machine is usually not desired since the tool cannot be retracted from the thread after a stop. In such a
case the appropriate measuring point in a cut is changed from “immediately” to “at end of cut”. The
machine is then only stopped when the process has ended and the machine has been released.
It is also possible to allow the machine to work until the end of a work piece in the case of wear
detection by the system. In this case the setting “at program end” is selected.
- 28 Due to these different switching options from a relay or opto-coupler, only one input on the machine
control is required in many cases, which, however, has different effects on the stop of the production
machine. This is an advantage since it simplifies the interface in the case of an existing machine which
is to be retrofitted with a tool monitoring system.
3.2.3.3 Submenu “Add”
If the submenu “Add” is selected, then a list of all limits which can be activated in the system is
keys and then confirmed with . After
or
displayed. The limit to be added is selected with the
the limit has been added to one measuring point and one cut in the current
confirmation with
program. The set values of this limit are then displayed automatically and can be corrected as required
(as described in Chap. 3.2.3.2).
3.2.3.4 Submenu “Remove”
If a limit from an existing program is to be removed in a measuring point, then it is possible to do this
using the submenu “Remove” in the menu “Limit”. After selecting this menu item the limit to be
keys and confirmed with . A confirmation query follows.
or
removed is selected with the
3.2.3.5 Submenu “Learning parameters”
The distance that a limit takes from a measured curve after learning is set for each type of limit in the
menu “Learning parameters”. You have the option to create individual learning distances for the
different types of limits. This is done with the addition of so-called learning parameters. The individually
added learning parameters receive a new name which can be used to assign the learning parameter to
the limits. For this purpose, a limit type is selected from the main menu “Edit” >> “Limit” >>
key, and
is pressed. Afterwards a menu titled
“Learning parameters” >> “Add” with the
“Learning parameters” appears in which the height differentials of the limit from the measurement
curve and the time distances of the limits relative to the beginning and the end of the curve to be
learned can be set.
3.2.3.6 Submenu “Learn”
If a limit from an existing program is to be re-learned in a measuring point, then it is possible to do this
in the menu “Limit” with the submenu “Learn”. After selecting this menu a selection of all limits
keys and
or
activated in a measuring point takes place. A limit is selected for learning with the
confirmed with . A confirmation query then takes place.
Select
- 29 -
3.2.4 Menu “Modules”
A module can be viewed as a specific software component in which several customer desires were
implemented which are a sensible expansion of the functionality of the SEM-Modul.
There are two methods to add modules to the device using the submenu “Add”.
1. Global:
Modules added globally are hierarchically above the programs. For example, a counter module
which continues to count the number of work pieces produced even after switching to another
program.
2. Local:
Modules added locally only affect the current program. After switching to a different program
they are no longer active. If the other program also had, for example, a local counter module,
then the counting of the work pieces produced would begin again at zero there.
Menu “Modules”
The submenu “Change” is only offered if a module has already been activated. It only shows those
modules which have already been activated, whereas on selecting the submenu “Add” (Global or
Local), the complete list of available modules appears:
Select module
- 30 -
3.2.4.1 Module “Negation”
The Negation module is capable of negating any signal input and making it available as a new signal
input.
When you select the line “Negation” and press , a field is opened in which initially only the name for
the module must be entered. The preset is “not_”. The name should be chosen so that it contains the
name of the signal input which is to be negated.
Assign module name
key. Afterwards a dialog opens in which a signal input can be
The name is accepted with the
assigned to the module “Negation”.
Edit module “Negation”
key. Afterwards the signal input to be negated is selected
The field signal input is selected with the
(using the keypad or touch-screen).
with the keys
or
This setting is accepted with the
key.
3.2.4.2 Module “Scrap gate”
When a limit value is violated and this switches the module “Scrap gate” as an output (see Chap.
3.2.3.2), then the output programmed in the module “Scrap gate” can switch a scrap gate which
directs the faulty work piece into a scrap container or faulty part container. Here is a description of how
the module “Scrap gate” is set:
When the line “Scrap gate” is selected and you press , a field opens in which a name for the
module must be entered. The preset is “Scrap”. The name can either be accepted with the
key or
and
keys or using the keyboard on the touch-screen. Careful: this name is
changed using the
referenced by the output of the limit which is supposed to switch this module when it is violated.
- 31 -
Scrap gate 1
The “Cycle input” is the signal at whose time point the scrap gate is switched. Normally the Cut active
(S.a.) signal is used. Depending on the position of the sensor which switches the scrap gate after a
limit value violation, the scrap gate can be switched with the positive or negative edge of “cycle
input”. In the field “Output (Scrap gate)” you choose the relay which controls the scrap gate.
Scrap gate 2
If every work piece is scrap due to a machine error or tool breakage, then the machine can be stopped
after an adjustable number of work pieces in the line “Alarm when 5 scrap pieces are produced in
or . The “Alarm output” used for the
sequence”. The standard value 5 can be changed with
stop should be selected as a relay (1, 2, 3 or 4) or as an opto-coupler (1 to 12).
All standard texts and alarm texts which have previously been individually entered can be selected in
the line “Alarm text” (see Chap. 2.2.5.4).
Normally the scrap gate switches back to the container with good pieces as soon as no more scrap is
produced. If a reset of the scrap gate via an external signal is still necessary, then an input is selected
under “Input to delete pieces” on which a 24V control voltage to reset the scrap gate can be placed.
3.2.4.3 Module “Recording operating data”
The module “Recording operating data” makes it possible to log run times and reasons for stops for
the machine tool monitored by the SEM-Modul. It can be used only in combination with software, which
must be ordered separately, for a central PC which is connected to the Tool Monitors using a CAN bus.
This PC can be operated as a second server in addition to the company server so that operating data
from various PC's in the company can be viewed.
To preset recording of operating data, the line “Recording operating data” in the window “New
module” is selected, confirmed with , and given a name in the following input line. After entering the
name an input mask appears:
- 32 -
Operating data 1
Usually either P.a. or S.a. is set in the input line “Signal input”. It is used to detect whether the
machine is running or is stopped. However, any other input to which another suitable signal from the
machine tool is switched can also be used.
The first “Delay time for detection “Machine running”” is used to avoid registration of brief
stoppages, each of which would cause an annoying query on the reason for the stop which the
operator would have to answer.
In the same way, brief re-starts of a machine can be hidden with “Delay time for detection “Machine
running””.
Operating data 2
Sometimes we also want to record brief stops, but do not require a stop reason query. Then the stop
reason query can be delayed until the stop has lasted at least a minimum period of time using the input
line “Stop reason query when machine is stopped for.... seconds”.
The preset number of 100 in the input line “Maximum number of storable operating states” means
that 100 run/stop changes can be stored in the Tool Monitor until the next query by a central PC which
is connected to the Tool Monitors in a machine hall using the CAN bus. This memory is cleared again
after the operating data has been queried by the central PC. It is possible to raise this number, but that
uses additional memory.
As soon as the SEM-Modul is switched into the monitoring mode and the machine stops, then the stop
reason is queried with the following display after the delay times set above have expired:
- 33 -
Stop reasons 1
Stop reasons 2
key and confirmed with . The stop reasons
A suitable reason for the stop is selected with the
stored this way can now be called up by the central PC if it is connected to the SEM-Modul using the
CAN bus and has the BDE/MDE software.
3.2.4.4 Module “Missing piece register (Type 1)”
During the re-start or idle running of, for example, an automatic rotary cycle machine, a transfer line, or
a multi-spindle machine, the SEM-Modul would trigger false alarms if the measurements at the
individual stations were started and then the lower limits were violated because of a lack of machining
work. The so-called missing piece register is now used to avoid these false alarms by having the
machine send a suitable 24V signal to the SEM-Modul to indicate the missing work pieces. Three
different situations can arise here which take different types of machines into account.
The missing piece register Type 1 can only be used as depending on one fixed station (e.g. loading
station). It is possible to record a missing piece with this register which was detected by an appropriate
sensor on the loading station. From the main menu “Edit” >> “Extras” >> “Modules” >> “Add”, you
select “Missing piece register (Type 1)” with . A window opens in which a name for a new module
can be entered. “FREG” is preset. By pressing the
key twice, a keyboard appears with the help of
the new (or preset) name of the missing
which any name may be entered on the touch-screen. With
piece register is accepted.
- 34 -
Missing piece register (Type1) part 1
Standard for “Cycle” and “Missing piece input” are the preset signals Cut active (S.a.) and Limit
active (G.a.). If no part is on the first layer of an automatic multi-spindle lathe or on the first station of
an automatic rotary cycle machine, then a 24V signal must be placed on this missing piece input
(G.a.). An internal floating register is then incremented by one with each additional cycle of the
machine (S.a.).
Missing piece register (Type1) part 2
With the setting “No” for the query “Missing piece input as RS flip-flop” the Limit active signal (G.a.)
must be sent before the Cut active signal (S.a.) and have dropped off again during the Cut active
signal. With the setting “Yes” the RS block makes it possible to temporarily store the signal sent, i.e.
the signal does not have to be sent before the Cut active signal, but can already be registered and
stored during the last cut as a brief pulse (duration >10 ms).
The following two menu items “Input to delete pieces” and “Input to set pieces” are programmed
when the missing piece register memory is to be completely cleared or set. Any digital input (A0 to A15
on terminal X3) can be programmed here.
The number of machining stations on the machine is set under “Output number”. Sixteen stations
are preset, the maximum value that may be set is 32 stations. Horizontal and vertical machining units
that work on the same work piece are viewed together as one station. The value of the output number
is found in the largest number after the dot in the names of the “Missing piece signal inputs” in the
menu “Measuring point”, e.g. Freg.16 (see Chap. 3.2.1.1).
So that a measuring point is switched off at the right time after detection of missing work pieces, the
number of machine cycles the measuring point is located after the station where the missing work
pieces were detected and reported to the “Missing piece input” (Chapter 3.2.1.1) must be entered
under “Missing piece signal input” using the main menu “Edit” >> “Measuring point” >>
“Change”. After “Change” has been selected there and confirmed with , then an overview of all
activated measuring points appears. The desired measuring point is selected with . Scrolling to the
line “Missing piece signal input” is done with the
key, then the desired position in the missing
key. The number after “FREG” indicates after how many cycles
piece register is selected with the
the measuring point is to be hidden after the missing piece has been recognized on the loading station.
- 35 As an example, the position information is explained based on a six axis automatic lathe in which
layers 1 and 4 are being monitored: In “Measuring point 1” the entry must be “FREG.1”, and in
“Measuring point 2”, “FREG.4” must be entered. The layers monitored are not evaluated when the
signal sequence is appropriate, and a false alarm is avoided.
3.2.4.5 Module “Missing piece register (Type 2)”
When work pieces are removed from a transfer machine, for example for measurement tasks or after
tool breakage, then this would necessarily lead to false alarms in the following stations which are
monitored since the lower limits would be undershot. This can be avoided by activating the missing
piece register Type 2.
It is possible to record a missing piece which is not necessarily dependent on a fixed station, as was
the case with the Type 1 missing piece register, with missing piece register Type 2. This means that
this missing piece register is used when work pieces can be removed from the machine at any station.
However, the removal of this work piece must then be detected, e.g. using a proximity switch, and this
information must be sent to the Tool Monitor by the machine PLC.
This 24V control signal can be set to the correct position and processed using the floating register on
the SEM-Modul. “Missing piece register (Type 2)” is selected from the main menu “Edit” >>
“Extras” >> “Modules” >> “Add” with . A window is opened in which a name for a new module can
be entered. “FREG”, possibly with an attached number if another missing piece register has already
the
been activated, is preset. The name may also be changed in the usual manner. After pressing
new (or preset) name of the missing piece register is accepted. The following menu then appears:
Missing piece register (Type 2)
Standard for the “Cycle input” is Cut active (S.a.). Under “Missing piece input station 1-32” an
key. If there is no part on the layer (=station)
appropriate digital input (A0 to A15) is selected with the
of a multi-spindle automatic lathe or the station of a rotary cycle machine that is to be monitored, then
there must be a 24V control signal on this missing piece input (A0 or A1 ... to A15). This register is
incremented by one with each additional cycle of the machine (S.a.). The number of layers (stations) is
keys (maximum 32). For a 6 or 8 spindle lathe,
or
selected in the line “Output number” with the
use the number 6 or 8. All settings of the register are accepted with .
The position information of each measuring point in this floating register must be entered in the main
menu “Edit” >> “Measuring point” >> “Change” under “Missing piece signal input” (see Chapter
3.2.1.1).
3.2.4.6 Module “Missing piece register (Type 3)”
The “Missing piece register (Type 3)” is a consistent further development of the missing piece
register Type 2 for the situation that several measuring points are working on a work piece
simultaneously (e.g. horizontal and vertical machining units). Very good experience has been made
using this register with micron rotary cycle machines of type Multistar and Dico. Our technicians
undertake an individual adjustment to the machine. Please consult us in advance for the exact
configuration of this missing piece register.
- 36 -
3.2.4.7 Module “Counter (down)”
With the “Counter” programmable in the module it is possible to stop the machine or output a warning
message after a specific number of work pieces.
The line “Counter (down)” in the menu “Module”, submenu “Add” is selected with . Now an input
line for assigning a name to this module appears. Preset is “Count”. The name of the downward
counter is accepted with .
Counter down 1
First you must enter the current “Counter reading” from which the countdown is to take place. If the
counter is to be reset to a specific initial value (starting value), then this can be done using an external
input and/or automatically when the counter has reached 0.
The “Initial value” is set to the desired number of work pieces that are to be produced. If the counter
is to jump back to the “Initial value” automatically when it reaches zero, then the field “If counter
reading = 0” needs to be set from “do not change” to “re-initialize”.
The “Cycle input” is to be set to the desired input with which a countdown is to take place, e.g. Cut
active (S.a.).
In addition, the counter can be reset to the initial value using an external 24V control signal before the
counter reading has reached 0. An appropriate input must be set under “Initialization input” to do
this.
Counter down 2
The programming for the machine stop is done in the field “Output on zero operation”. This is where
a relay or opto-coupler for the desired reaction by the system is selected. Finally, an alarm message
which is to be displayed on the SEM-Modul when the counter reaches 0 can be selected in the field
“Alarm text on zero operation”.
- 37 -
You can enter this alarm text yourself, e.g. “Number produced reached” as described in Chapter
3.2.5.4. After the alarm text has been edited as described in Chap. 3.2.5.4, it appears in the window
“Alarm text” of the counter menu so it can be selected.
3.2.4.8 Module “Counter (up)”
This counter works in the opposite direction from the downward counter, i.e. it counts up to the desired
number of pieces, at which an alarm text can then be generated, starting with the first piece.
Counter up 1
Counter up 2
3.2.4.9 Module “Information”
This module makes the free entry of additional texts possible. Thus the text “Work piece XY from
material 0815”, if created as a “local” module, can be added to various programs which are all used to
monitor the production of this piece. In contrast, the information that can be stored in the menu
“Program info” (see Chap. 3.2.5.3 and 3.3.1) cannot be transferred to other programs.
- 38 -
These texts can then be displayed during monitoring operation from the main menu “Display” >>
“Module”:
Displayed information called “Info”
3.2.5 Menu “Extras”
Configurations which refer to the current program are grouped in the menu “Extras” under the main
menu “Edit”. These settings are normally only made once and then remain in the memory of the
system. When you “Add” new programs, all settings of the menu “Expand” are accepted into the new
programs. When you “Learn” new programs these values are also accepted into the newly learned
programs, however, without any manually changed beginning and end points or heights of limit values.
Instead, the limit value distances set in the so-called “Learning parameters” (see Chap. 3.2.3.5) are
taken into account.
Edit Extras
- 39 3.2.5.1 Submenu “Zero point subtraction”
The zero point subtraction from a measured value means that the area of the measurement curve
before the work piece makes contact with the tool is stored and subtracted from the following curve.
This means that a new zero point is calculated. After this so-called “Zero point subtraction” only that
portion of the measurement curve which is due to machining the work piece is displayed. For sensors
that measure force and effective power this function is also present in the ADDM or WLM, but it is not
as flexible. The zero point subtraction on the display has the advantage that a zero point can be made
after the beginning of the measurement. This gives you the capability of checking whether the
measurement curve at the time of the zero point subtraction is horizontal, i.e. no longer distorted by
power or force components due to the the acceleration or deceleration of the tool.
The submenu “Zero point subtraction” is selected under the main menu “Edit”, menu “Extras”.
Zero point subtraction 1
As long as the zero point subtraction is switched to “passive”, no subtraction is undertaken by the
software. Only when the subtraction is switched to “active” does it take effect, and a vertical line
appears in a cut in the measuring point in question, which, like a time limit, can be moved on the
screen (Chapter 3.2.3.1). An “Offset” can be entered which is normally set to zero. When you change
the “Offset” to a specific value, e.g. to 10dB, then the measured value on the vertical line is not tared
to zero, but to 10dB.
It is also possible to use numeric input in addition to the graphic input in the menu “Zero point
subtraction”. The “Beginning” and the “End” can be entered in the number field.
Zero point subtraction 2
Starting with the marker “Beginning”, the mean of the measured value is calculated until the marker
“End” after which the actual zero point subtraction takes place.
- 40 -
Graphic zero point subtraction
3.2.5.2 Submenu “Mean height”
It is possible to perform wear measurements using the mean height since this value is not influenced
by brief variations in the height of the curve (please read Chap. 1.5.3 and 1.5.4).
The possible settings in the menu “Mean height” do not refer to the limits “Above mean height” and
“Below mean height”, but to the basis for the calculation of the mean height (time period and number of
work pieces to be used for the mean).
3.2.5.2.1 Graphically editing the mean height
If the “Mean height” is to be adjusted to a machining curve, then proceed as follows. The two vertical
key. These give the time period in which the
position bars are shown on the display with the
calculation is to be carried out. This value may be enlarged or made smaller using the
or
keys. It
is possible to position the time period for the mean on the display with the
or
keys. Please
remember when adjusting the measurement range of the “Mean height” that the time markers are not
placed on steep rises or falls in the curves, but on horizontal sections of the curve since otherwise
small time shifts of the measurement curves may make the values of the “Mean height” (= column on
the right edge of the display) vary greatly.
Graphic mean height
- 41 -
3.2.5.2.2 “Change”
By selecting the menu line “Change” the values for the calculation of the mean height can also be
entered numerically.
Mean height
The % entry refers to the time axis of the display of the measurement curve (right edge of the display
= 100%).
The “Beginning” and the “End” of the mean formation can be entered in the numeric field. The
length of the bar on the upper edge of the display changes accordingly when the values are accepted
with . When setting the section of the curve to be used for the calculation, you must remember that
the time markers must not be placed on steep increases or decreases in the curve, but on horizontal
sections of the curve since otherwise small time shifts of the measurement curves may make the value
of the “Mean height” (column on the right edge of the display) vary greatly.
Menu Mean height
When you see in the trend view that the mean height varies in spite of an optimally selected time
period, then there is the possibility to use a floating mean. This is done by increasing the value in the
line “Number of work pieces over which the mean is to be formed” from the preset value 1 with
key. However, the value should not exceed 10% of the work pieces produced by the tool until
the
the stop time end since the mean height is otherwise too slow to react to suddenly increasing wear.
3.2.5.2.3 “Remove”
If the “Mean height” is not to be calculated, then under “Edit” >> “Extras” >> “Mean height” the
item “Remove” can be selected. After a confirmation query the “Mean height” is deleted.
- 42 -
3.2.5.2.4 “Add”
If the “Mean height” is not present at a measuring point in a cut because it was deleted previously,
then “Add” can be used to activate the calculation of the “Mean height”, and you come to the menu
that is described in Chapter 3.2.5.2.2.
3.2.5.2.5 “Reset trend”
If the “Trend of the mean height” is to be reset for a measuring point, then this is done using the
submenu “Reset trend” after a confirmation query. To reset additional trend views you must change
to the appropriate measuring point or the appropriate cut.
3.2.5.3 Submenu “Program”
The first thing that is seen in the submenu “Program” is a memo field. Brief notes for a program can
key and then confirm with . A
be placed here. To create a text in this field you must first press the
keyboard field appears which makes it possible to select the letters on the touch-screen. The desired
text can now be entered.
and the text appears in the field
After you have entered your text, the keyboard field is closed with
“Comment”. With an additional press on the
key the field “Program” is closed and the text has
been saved. The text just created can then be called up under the menu “Program info” in the main
menu “Display” without the ability to change the text there.
Edit Program
The reaction times of the limits or modules are adjustable in order to ensure the ability to monitor in
time critical monitoring situations. The query interval for the limits that is preset is 10ms, i.e. the system
needs at most 10ms reaction time until it switches an alarm output. It is possible to reduce this reaction
time to e.g. 5ms, but this may result in a cycle overflow. After a preset number (factory setting: 5
cycles) a “Warning on cycle overflow” appears as a text message on the display and a “Cancel on
cycle overflow” of the monitoring program takes place in order to avoid malfunctions due to scan
intervals that are too short.
With the setting “Wait for P.a.” (at the beginning of the measurement) the positive edge of the
Program active signal is evaluated when the field is set to “yes”. If you switch to “No” then only the
Cut active signals are evaluated.
3.2.5.4 Submenu “Alarm texts”
In addition to the fixed preset alarm texts “Tool dull”, “Tool broken”, and “Work piece contact”,
which may be assigned to a limit or a module, it is possible to write your own alarm texts in this menu.
If no alarm text has been created yet, then only the menu “Add” appears after opening the menu
- 43 “Alarm texts”. If alarm texts which you have created are already present, then the items “Change”
and “Remove” also appear.
Create alarm texts
After selection of the menu “Add”, the following input line appears:
Enter alarm text
keys or by pressing the
Now a text can be entered here either with the aid of the , , and
and using the keyboard available on the touch-screen (see Chap. 3.1.3).
key
The alarm text you have created is now available in this program as a selection text for limits and
modules, as described in Chapters 3.2.3.2 and 3.2.4.
If an existing alarm text is to be changed, then proceed in the same manner as for “Add”. Select the
item “Change” in the selection menu, and then a list of all alarm texts previously created appears.
Select alarm text
The desired alarm text is selected and can be edited as described above under “Add”.
- 44 -
The texts do not need to be entered again for additional programs that are added later. They are
automatically taken over into the newly added program from the current program.
Alarm texts that are no longer required are deleted using the menu “Remove”.
3.2.5.5 Submenu “Inputs”
Under “Inputs” in the main menu “Edit” >> submenu “Extras”, it is possible to set a bounce time.
This is necessary as soon as the SEM-Modul is controlled by mechanical contacts (relays) since these
may generate edge changes in quick succession over a period of several milliseconds, the so-called
bounce. The preset bounce time is 0ms and can be set individually for each input in increments of
1ms. When the menu item is selected a scrollable list of all inputs appears.
Select inputs
The input whose bounce time is to be set needs to be selected. A window opens in which the bounce
or
keys. After pressing
the time set is then accepted.
time can be set with the
Setting the bounce time
3.2.5.6 Submenu “Outputs”
In the submenu “Outputs” of the main menu “Edit” >> menu “Extras” the reset behavior of the
relays or opto-couplers is set. First a scrollable list of all existing outputs appears:
- 45 -
Select outputs
After an output has been selected the following settings are possible.
Set outputs
A time in milliseconds can be set under “Automatic reset after”. If 0 is entered here then the output is
permanently switched until it is reset by an acknowledgement on the SEM-Modul or by an external
signal. The external signal is usually alarm reset (A.r.). However, it is also possible to use an individual
“Reset signal” for each output.
3.2.5.7 Submenu “External program selection”
When your Tool Monitor is equipped with the option “External program selection”, then you can
select the required monitoring programs from the machine control using data lines. The basic settings
necessary for this are set in the main menu “Edit” >> menu “Extras” >> submenu “External
program selection” (Tool Monitors which are not equipped with “external program selection” do not
display this submenu).
The exchange of control signals takes place using the handshake procedure. The Tool Monitor must
be in the state “Learn”, “Monitoring”, or “Trial run” to do this. See Chapter 5.3 for the signal sequence
diagram with the necessary signal periods and reaction times.
The machine control sends a program number to the maximum 16 digital signal inputs of the X3 plug
(rear view: see Chapter 5.1). The number of program numbers depends on the setting of the program
number query in BCD or binary format. For external selection in BCD format, program numbers 1 to
9999 (or 65536 for transfer in binary format) are available. All data lines which are sent to the SEMModul for the program number in question must be stable when D.g. (“Data valid”) is sent from the
machine. As soon as the program number has been read in and processed on the SEM-Modul, a D.e.
signal (“Data received”) is sent back. When the machine control has received this D.e. signal, the D.g.
signal must drop off. The Tool Monitor reacts to this with the withdrawal of the D.e. signal and waits for
P.a. (“Program active”).
The menu “External program selection” offers the following settings:
- 46 -
External program selection 1
The required digital inputs of the X3 input block (max. A0 to A15) are set under “Inputs used”.
You may choose between binary and BCD format under “Coding”.
External program selection 2
The maximum number of programs to be selected is set under “Number of programs”.
Under “Create programs before learning” you can select either “yes” or “no” to decide whether
programs are to be manually added beforehand.
Under “Double prog. no.” you decide whether two 4-digit program numbers are sent twice to use, for
example, the left 4 digits (sent first) for a work piece number and the right 4 digits for a tool number.
The Tool Monitor sends the Data received (D.e.) signal only after the second 4-digit number.
The entry for “Time out” is only set when using the double program number. It indicates within which
time the second D.g. must be sent after the first D.g. (see Chapters 1.8.4 and 5.3).
Under “D.e. duration” you determine how long the SEM-Modul should send the D.e. signal (see also
Chapter 5.3).
- 47 -
3.2.5.8 Submenu “Status line”
The contents of the modules “Counter up”, “Counter down” as well as the module “Missing
piece register”
can be displayed on the status line with the aid of this menu item. Only those modules which have
already been added to the unit are offered here.
3.2.5.9 Submenu “Settings” (display contrast, clock, calibrate touch-screen, language, CAN
bus)
The settings for the system time, the touch-screen (only visible on the SEM-Modul), the language, and
the options (only visible on a PC with maintenance software from Nordmann GmbH & Co.KG) are
grouped in the menu “Settings”.
Settings (update image)
Setting the clock is done under the menu item “Clock”.
System time
key. The digit is then set with the
or
keys.
The cursor is moved to the digit of the date with the
key is used to move to the clock setting. After finishing the setting the field is exited
Afterwards the
with .
If the menu “Language” is opened, then the display texts can be switched to various languages. The
languages German, French, English, Italian, Spanish and Polish are available in the SEM-Modul. The
or
keys and confirmed with .
desired language is selected with the
- 48 -
Language
When you select the menu item “Calibrate touch-panel”, a dark screen with a yellow cross appears.
You must touch the cross exactly in the middle with a pen. Another cross then appears. A total of four
points are asked for. With this, the touch-panel is calibrated relative to the underlying keyboard
symbols of the graphic display.
CAN bus
When you select the menu item “CAN bus”, a window where the ID number of the device is to be
entered appears. Further, the transfer speed (baud rate) can be set and a name for the device can be
assigned.
3.2.5.10 Submenu “Operator administration”
The submenu “Operator administration” of the SEM-Modul makes it possible to identify operators
for the recording of operating data if the operating data recorded by the SEM-Modul (usually run-time
diagrams of the machine and the reasons for stops) is also centrally stored. Second, an operatorspecific release or block of any menu functions on the SEM-Modul is made possible. This is so
because for certain applications some menus are not necessary. In addition, complicated functions
(e.g. module missing piece register 2 and 3) can be blocked for certain groups of operators or for
individual operators. The menu items that are blocked then no longer appear in the menu. Log in on
the SEM-Modul as “SUPERUSER” is necessary to set up the operator administration:
Select “Log in” under the main menu “Program”. A list in which the name “SUPERUSER” must be
selected appears. When you select “SUPERUSER” with , a dialog box appears in which a password
must be entered. This password can be requested under the telephone number ++49/(0)2233/968834.
When log in has been successful, the name of the operator who is logged in appears at the top right of
the display. In this case it is SUPERUSER (he remains logged in as long as the device is provided with
power or until another operator logs in). Only this SUPERUSER is now able to select the submenu
“Operator administration” under the main menu “Edit” >> menu “Extras” (without prior log in as a
- 49 super user, this menu item is not visible). Here it is possible to “Add”, “Edit” or, if necessary,
“Remove” operators or operator groups.
3.2.5.10.1 “Group”
“Group” means a group of operators of the machine tools and Tool Monitors. The division of operators
into groups makes it possible to block specific menus for operators who should not be distracted by the
numerous menus which are of no importance to them. In addition, accidental improper operation or
incorrect setting of the unit can be avoided. The operators are assigned to these groups using the
submenu “Operator” (see next Chapter 3.2.5.10.2). However, before this can be done, the group itself
must be created in the submenu “Operator administration”, submenu “Group”:
Such a group must first be created using the submenu “Add”. Then an input field with the title
“Operator group” appears. At the top a name for this group is to be entered (e.g. “Maintenance”,
“Machine operators” or similar). In the lines below the name all menus of the Tool Monitor can be
or
keys.
switched to either “free” or “locked” using the
After switching the power to the Tool Monitor off and then on again, you must log in again. As long as
no operator is logged in, the group “No operator logged in” is automatically active. The superuser
can also assign rights to this group which should be oriented on the menus for the operator who
normally works with the unit first in the mornings after the power to the Tool Monitor has been switched
on.
3.2.5.10.2 “Operator”
In the main menu “Edit” >> menu “Extras” >> submenu “Operator administration” >> “Operator”
>> “Add” you may create operators. The “Name”, “Password” and “Group” of the operator can be
entered in the submenu “Operator”. A password can be assigned, but this is not necessary.
The operator can be assigned to any group in the field “Group”.
With the exception of the superuser, all persons can be assigned to a group.
- 50 -
3.3 The main menu “Display”
3.3.1 Menu “Program info”
The program name (see also Chapter 3.1.3) and comments on the program (see also Chapter 3.2.5.3)
are displayed under the menu “Program info”. This text is tied to this program.
Program info
If program-related texts are to be entered which may also be called up in other programs without
having to type them in again, then this should take place as a local module (see Chap. 3.2.4.9).
3.3.2 Menu “Measuring point”
If more than one “Measuring point” is evaluated, then the individual measuring points may be
selected here. Another possibility to select measuring points is offered by the keyboard on the SEMor
keys you can switch the measuring points faster and more easily. This is
Modul. Using the
equally possible on the touch-screen using the up and down arrow keys.
Measuring point
3.3.3 Menu “Alarms”
In the menu “Alarms” the last 50 alarms which occurred can be displayed with their exact times.
and
keys, it is possible to page through the alarm curves. For each case, crosshairs
Using the
mark the location where the limit was violated.
- 51 -
Alarm
3.3.4 Menu “Signal test”
The control signals on the rear connection terminals (Chapter 0), measured values, and the state of
the switch outputs are visualized under “Signal test”. This function can especially be used to select
or and
keys so that they can
and
the desired outputs (relays and opto-couplers) using the
then be switched on or off using the
and
keys. A 1 or 0 is displayed for each signal that is present
or drops off.
If the SEM-Modul is equipped with an internal expansion module, then one of the two cards is selected
key. The internal expansion module (=IO card 2) allows expansion by 1, 2 or 8 measuring
using the
points to a total of up to 16 measuring points including the first IO card.
Signal test
- 52 -
3.3.5 Menu “Trend”
Using the “Trend view” (see Chapter 1.5.4 for explanations on the trend) you can check whether the
tool can be monitored for wear. Large variations in the trend can be filtered out by forming an additional
mean over several work pieces (see Chap. 3.2.5.2.2).
Trend
3.3.6 Menu “TP signal test”
When you select “TP signal test”, a black display is shown. This function is used to test the keypad
and the touch-screen of the SEM-Modul or any external keyboard that may be attached. When you
touch the touch-screen, a small window becomes visible in which the coordinates of the point touched
can be seen. When you press one of the keys on the module another window is opened with the name
of the key.
3.3.7 Menu “CAN bus”
The menu item “CAN bus” is only displayed if the corresponding module has been implemented in the
SEM-Modul. Up to 32 modules can be linked to each other and displayed on a central computer using
the CAN bus.
Diagnostic view of the CAN bus
- 53 -
3.4 The main menu “Help”
3.4.1 Menu “Index”
Information on the Help tour, introduction, operation, and on the menus is found under the menu item
keys and then opened using the
and
“Index”. The various items can be selected using the
key.
Index
3.4.2 Menu “Help tour”
This menu item offers a bit of help so you can get to know the basic settings of the SEM-Modul better.
Help tour
3.4.3 Menu “Information”
The telephone numbers of Nordmann GmbH & Co. KG, the Internet address, the software version, and
the serial number of the unit are found under “Information”. (See also Chapter 1.3)
- 54 -
3.4.4 Menu “System info”
Information on the assignment of the memory banks is displayed under “System info”.
System info
4
Data backup and remote operation of the SEM-Modul
4.1 Terminal software SEM-Term
A connection between the SEM-Modul and a PC is possible using the SEM-Term software program
which must be ordered separately. The following are the main functions it supports:
•
•
Backup of programs on the hard disk of a PC.
Editing programs on the PC (correction of limit values).
Since the same images and menus are displayed on the PC monitor as on the SEM-Modul display, the
operation is also identical. The menus on the PC can be reached and clicked on using the mouse.
Remote operation of the SEM-Modul using the control panel of an open CNC control is also performed
using this software. The following keys are used during operation:
Keys on the SEM-Modul
ESC
OK
Cursor keys
Menu
-+
Keys on the PC keyboard
ESC
Return or Enter
Cursor keys
5 on the numeric keypad
-+
When texts e.g. for program names or for names of measuring points are to be entered, which is
usually done on the SEM-Module using the keyboard displayed on the touch-screen, it can also be
done on the PC using a keyboard displayed on the monitor. Instead of pressing the “ ” key of the
SEM-Modul, on the PC, you need to press the 5 key on the numeric keypad of the PC keyboard. You
may also double-click with the mouse arrow in the input line where text is to appear. The characters of
the keyboard displayed on the monitor can be selected using either the mouse or the cursor keys.
They are confirmed by pressing Return or Enter.
On open machine controls which have a touch-screen, the operation of the SEM-Modul can also take
place on the touch-screen of the CNC control.
Note on the possibly unattractive display of the texts: If the background of the texts displayed on the
PC screen appears to be “blurry” at the bottom of the screen, then you need to change the size of the
window. This effect only occurs with certain window sizes.
- 55 -
4.2 Sin-Term terminal software for remote operation from the 840D / 810D
The program SEM-Term is used in a special version called SIN-Term for remote control of the SEMModul using the operating computer MMC 103 as of software version 5.0 of the Sinumerik 840D or
810D. The operation is identical to that of the program SEM-Term. In addition softkey symbols are
displayed at the right and bottom edge of the screen so that the tool monitoring can be operated
completely using the softkeys. The PC keyboard to the right of the monitor of the MMC 103 (operating
panel OP 031) can also be used according to the following key assignment.
Keys on the SEM-Modul
Keys on the Sinumerik 840D/810D
Softkey (ESC)
Input key or Softkey (OK)
Cursor keys or appropriate softkeys
Selection key or softkey (menu)
Softkeys (+ and -)
If you wish to install the Sin-Term software yourself, then please proceed as follows:
1. Prepare the control
• After start-up of the control, press the key “M” (bottom left).
• Afterwards the task bar can be reached with the key “Screen”
(bottom right).
• Check which key is free (blue keys at the bottom 0-7 = HSoftKey (HSK) 0-7).
• If no key is free, then scroll further with the > key until a free key can be seen.
• Normally HSK 7 is free.
⇒ Make a note of the free key. Caution! : Counting from the left starts with “0” and not with “1”!
2. Prepare laptop for data transfer
• Connect the laptop to the control using the serial port (rear comport 1 or 2 ).
⇒ Important: The SEM-Modul will later be connected to the same port – therefore please
make a note of the port as well.
• Exit Windows and move to the DOS level.
• Insert Diskette 3.
• Change from directory C:> to directory A:> by entering: a: >enter< .
• Change to the folder A:\Transfer> by entering: cd Transfer >enter<,
• Now we start the data transfer program Interserver by entering: intersvr >enter< .
⇒ A window opens on the laptop; on the left side a list of the existing drives on the laptop is
displayed.
3. Connect the control to the laptop
• Reset the control (press the micro-switch on the rear – it is to the right of the battery, the
lower of the two micro-switches).
• Press key 6 when the control starts up, exactly when Microsoft is started (or F8 using an
external keyboard).
• Select point 4 “Start Windows (Service Mode)” in the boot menu.
• Enter the password (usually: SUNRISE).
• Select point 2 “Windows for MMC2”.
⇒ The connection between the laptop and the control is running when the drive assignments
for the control are displayed on the right portion of the window on the laptop; i.e. drive A:>
from the laptop would thus be drive E:> (removable disk E) on the control.
- 56 4. Begin automatic installation
⇒ As of now no more entries are made on the laptop, only the diskette drive is required.
• Open the folder “My Computer”.
• Open the folder C:\840d-system (or C:\810d-system for the Sinumerik 810D).
• Open the OEM folder and check that the folder is empty.
⇒ If the folder is filled with files, then please contact Mr. Wenzel or Mr. Lucas (both from
Nordmann) and obey their instructions, if necessary cancel the installation, i.e. continue with
point 6.
• If the OEM folder is empty, then close the folder with Alt+F4.
• Also close the folder C:\840d-system (or 810d-system).
• Insert Diskette 1.
• Open drive E:> and start setup.exe.
• After Setup has been initialized, the directory must be changed to C:\OEM (selection with:
Alt+V). After all, the data should be installed at the correct destination.
• Insert Diskette 2 when prompted (remove Diskette 1 beforehand).
⇒ After the installation has been completed, some data must be changed manually (manual
installation).
5. Manual installation (you need your notes)
• Insert Diskette 3.
• Copy the folder E:\Pictures into the folder C:\OEM (replace existing files).
• Copy the files E:\SinTerm.dll into the folder C:\OEM and E:\IniFiles\SinTerm.ini into the
folder C:\OEM\IniFiles.
• Adjust the task to the key in the directory C:\OEM\Regie.ini
(e.g. Task 7 is equivalent to key 7 → see notes) and save.
• Open C:\OEM\language\Re_gr.ini and adjust HSK to the task (see notes) and save.
⇒ Do the same with the foreign languages!!! (if required).
• Update the comport assignment in the SinTerm.ini in the folder C:\OEM\IniFiles (see notes
again).
⇒ Installation is complete.
6. Final steps
• Close all windows (with Alt+F4).
• Now press ALT + F4 on the laptop (the laptop is now disconnected from the control).
• Exit the control (ALT + F4) and select item “Shut down the Computer?”.
• After shutting down the control in the menu, select point 9 “Return To Main Menu”.
• In the following menu enter selection 6 “Reboot System (warm boot)”.
• As soon as the Siemens interface has started again, switch the serial interface to inactive.
⇒ Do not forget to test the function.
4.3 Backup on a PC with the aid of a memory card
This function is currently in preparation. Then the monitoring programs in the SEM-Modul can be
stored on a “Smart Media” card and can be saved on a PC, viewed, and printed out as measurement
curves if desired after the card has been removed form the unit.
- 57 -
5 Rear connection of the SEM-Modul
5.1 SEM-Modul without dynamic evaluation (standard)
5.2 SEM-Modul with dynamic evaluation (option)
The so-called “Dynamic evaluation” makes the measurement and monitoring of the amplitude
modulation of measured values possible, to recognize for example the chatter during grinding based
on the acoustic emission measured values or missing teeth in milling using the dynamic portion of the
effective power. The rear connection and the setting for the dynamic option are described in the
brochure NORDMANN Sensor Technology (Chap. 5).
- 58 -
5.3 Control signal periods and reaction times of the module
Program number
A0-A15
from machine
t > 2ms !
t > 2ms !
D.G.
10 ms - 30 ms (Reaction time of the SEM-Modul)
from machine
t1
t > 2ms !
D.E.
from SEM-Modul
t > 2ms !
P.A.
from machine
t > 100ms !
S.A.
from machine
st
2
1 cut
t > 2ms !
nd
cut
nth cut
t2
G.A.
from machine
Reaction times t1 of the SEM-Modul
t1 = 10-75 ms
In monitoring operation
t1 = 25-1000 ms
In learning mode
t > 1ms !
Required cut pause times t2
t2 = 2-30 ms !
In monitoring operation
t2 = 2-500 ms !
In learning mode
5.4 Usable control signals from the machine tools
5.4.1 P.a. options (signal for “new work piece”)
5.4.1.1 P.a. for lathes
•
•
•
•
Chuck close / closed
Coolant on during the entire machining process
Close load gate (for automatic)
Door closed (manual)
5.4.1.2 P.a. for machining centers (without external program selection)
•
•
•
Table in position
Parallel switching of the table number
Pallet clamped / jammed
- 59 5.4.2 S.a. options (signal for “next cut”)
5.4.2.1 S.a. for lathes
•
•
•
Revolver in position
Coolant on / off
Spindle revolves
5.4.2.2 S.a. for machining centers
•
•
•
Tool clamped / jammed
Pallet clamped / jammed
Coolant on / off
5.4.2.3 S.a. for rotary cycle machines and multi-spindle lathes
•
•
•
•
•
Machining operation
Inverted quick traverse
Chuck closed
Unit forwards
Cam (mechanical, Balluff, PLC)
5.4.3 G.a. options (signal to report missing work pieces) for rotary cycle machines and multispindle lathes
•
•
•
Inductive switch on loading magazine or station affected
Manual switch on the station from which the piece was taken
Rod end signal or re-load signal
5.4.4 Feed-stop options
•
•
•
•
•
•
•
Feed hold, feed stop (breakage)
Stop in zero position, cycle end (breakage, wear)
Hydraulic pressure too low (wear)
Door open (breakage)
Switch cabinet temperature too high (wear)
Main drive off (breakage)
Remove controller release (breakage, collision)
- 60 -
6 Instructions for changing the EPROM
The software of the SEM-Modul Tool Monitor is stored in 2 EPROM's. The following steps must be
carried out to replace these memory chips with EPROM's containing a later program version. Please
pay careful attention to the sequence:
1. Save all monitoring programs which are still required on a PC using the SEM-Term software.
Otherwise all monitoring programs which have already been learned and all pre-sets will be lost
when the EPROM's are changed.
2. Pull the power plug or disconnect or switch off the power supply.
3. Unscrew the front plate and remove it from the unit. The circuit board is attached to the back of the
front plate. The plugs must be pulled.
4. Carefully pry both EPROM's (the chips with the silver stickers) from their sockets, inserting a
screwdriver from the front.
5. If EPROM's as of version 1.22 were on the board, then you may skip step 6.
6. If EPROM's up to and including version 1.21 were on the board, then the solder jumper is to be
changed as shown in the picture.
7. Carefully place the new EPROM's into the sockets as shown in the picture. Make sure that the
notch is correctly oriented and that none of the pins is bent.
8. We recommend also removing one of the two S-RAM chips (SEC KM68400) from their sockets in
the same way as the EPROM's and then re-insert them to ensure that the data memory is really
cleared.
9. Finally plug all the plugs back into the sockets of the Tool Monitor and make sure they fit tightly.
10. Screw the front plate back on.
11. Restore the power.
12. Transfer the monitoring programs which were saved earlier on the PC using the program SEMTerm back into the Tool Monitor.
Should you have any questions, please contact Mr. Lucas (-15) or Mr. Gutsche (-16)
Please send the old EPROM's back to the address given below.
Thank you.
Nordmann GmbH & Co.KG
Abteilung Service
Kalscheurener Str. 8
50354 Hürth
++49/(0)2233/9688-0 or –15 or -16
EPROM 2
EPROM 1
S-RAM
S-RAM
- 61 -
This is what the soldered jumper for EPROM's
looks like up to Version 1.21.
The EPROM's have the type designation
M27C2001 (256 KByte per EPROM).
This is what the soldered jumper for EPROM's
looks like as of Version 1.22.
The EPROM's have the type designation
M27C4001 (512 KByte per EPROM).
Only required for board version PRO 1.0.
Scratched off
Soldered
- 62 -
7 Technical specifications SEM-Modul
Monitoring strategies
Monitoring of acoustic emission, effective power, force, torque, hydraulic pressure,
path and/or laser light with static limits and sample curves (tolerance range) with
respect to course (un-smoothed, smoothed, and dynamic portion) and mean. Division
of the machining into cuts.
Measuring points (sensors)
max. connectable: 16 (individual unit), expandable to max. 480 (using CAN)
Memory
Number of cuts storable
Standard 1Mb
with memory expansion 2Mb
approx. 500/n
approx. 1000/n
depends on the types of limit selected, n = number of active measuring points
1 to 9999 with the setting on external selection in BCD format
1 to 65536 with the setting on external selection in binary format
1 to 99999999 with the setting on double prog. no. in binary and BCD format
Number of program numbers
Limits per measuring point and cut
unlimited:
Straight limit over (under) curve, limit over (under) mean height, upper (lower)
envelope curve, minimum limit, time limit
Display of measurement curve
LCD color graphic display with background lighting
Operation
Touch-screen, keypad, open control with Windows 95, 98, 2000, NT or using an
external master computer with Windows interface or e.g. a DLOG terminal.
CAN bus (up to 30 units)
12 Bit, 1 ms scan time per measuring point regardless of the number of measuring
points
max. 10ms with 16 sensors with 8 limits each
0.97ms until opto-coupler switches with 4 sensors with 4 limits each
1.1ms+0.97ms until relay switches with 4 sensors with 4 limits each
Network connection
Resolution of the A/D converter
Standard reaction time
min. reaction time opto-coupler
min. reaction time relays
Opto-coupler outputs
max. opto-coupler current
Relay outputs
max. relay current
12 closures for wear and breakage reporting,
feed release, data reception (handshake)
150mA at 24V
4 potential-free changeover contacts for wear and breakage reporting,
1A at 24V
Control inputs
Program no.
Number
16
Data valid (D.g.)
1
Program active (P.a.)
1
(max. 1 program active per system)
Cut active (S.a.)
1
(but up to 16 Cut active inputs per system definable)
Limit active (G.a.)
1
(but up to 16 Limit active inputs per system definable)
Alarm reset
1
Code and meaning
max. 8 digits (see above under “Number of program
numbers”)
Strobe for Prog. no.
Display of the beginning of work piece machining
Activation of the monitoring for a process
Suppression of false alarms for missing pieces
Reset of the alarm relays using an external signal
Control voltage inputs
Duration of a “Cut active” signal
Minimum pause between 2 “Cut active” signals
17 - 38V DC (5mA)
see Chapter 0 and 5.3
see Chapter 0 and 5.3
Operating voltage for the SEM-Modul
Power consumption of the SEM-Modul
24V DC + - 10%
max. 50VA (when 8 sensors are connected)
Protection type tabletop unit, control panel unit and flat display
Protection type special housing for the SEM-Modul
IP 54
depending on version, up to IP 65
Max. permiss. environmental temperature for tabletop unit
40°C
Max. permiss. environmental temperature for control panel unit 45°C
Dimensions W * H * D [mm]
Tabletop unit:
Control panel unit
Cutout dimensions and installation depth:
(depth plus approx. 20 mm for cables)
Front plate dimensions of the control
panel unit:
Top hat rail module:
Flat display:
External dimensions of flat display with
retaining clip:
254 * 142 * 260
236 * 138 * 215
269 * 160
120 * 133 * 215
250 * 150 * 44
265 * 150 * 68
- 63 -
8 Index
Adjust limits to curve.................................... 13
Alarm ........................................................... 50
Alarm output ................................................ 31
Alarm reset\ A.r.............................................. 8
Alarm text on zero operation........................ 36
Alarm texts....................................... 31, 37, 42
Tool broken .....................................................42
Tool dull...........................................................42
Work piece contact..........................................42
Automatic reset after ................................... 45
Beginning of the limit ................................... 24
Bounce time................................................. 44
Calibrate touch-panel................................... 48
CAN bus ................................................ 48, 52
Cancel on cycle overflow ............................. 42
Check........................................................... 15
Clock............................................................ 47
Comment ..................................................... 42
Communication with the PC ........................ 16
Contact to work piece .................................. 27
Control signal periods .................................. 58
Control signals ............................................... 8
Counter (down) ............................................ 36
Counter (up)................................................. 37
Counter reading ........................................... 36
Create alarm texts ....................................... 43
Create programs before learning................. 46
Cut ........................................................... 7, 21
Add ..................................................................22
Change............................................................21
Remove ...........................................................22
Select ..............................................................21
Cut active\ S.a. .............................................. 8
Cycle input ....................................... 31, 35, 36
D.e. duration ................................................ 46
Data backup................................................. 54
Data valid\ D.g. .............................................. 8
Double prog. no. .......................................... 46
Edit............................................................... 17
Edit limit ....................................................... 26
End monitoring............................................. 11
End of the limit ............................................. 24
Envelope curves .......................................... 23
EPROM change........................................... 60
External program selection
BCD format......................................................45
Binary format ...................................................45
Feed-stop options ........................................ 59
FREG........................................................... 19
G.a. options ................................................. 59
Global Module.............................................. 29
Group........................................................... 49
Help ............................................................. 53
Help tour ...................................................... 53
Index ............................................................ 53
Information............................................. 37, 53
Initial value ................................................... 36
Input to delete pieces............................. 31, 34
Input to set pieces........................................ 34
Inputs used .................................................. 46
Keyboard field on the display....................... 14
Language
English ............................................................47
French .............................................................47
Italian...............................................................47
Polish ..............................................................47
Spanish ...........................................................47
Learn ......................................................12, 28
Learning .......................................................28
29
Limit .............................................................23
Add ..................................................................28
Change............................................................26
Remove ...........................................................28
Select ..............................................................26
Shaping ...........................................................25
Limit active\ G.a. ............................................8
Limit types ....................................................23
Load program from the PC ..........................16
Local Module................................................29
Log in .....................................................16, 48
Mean height ...........................................23, 40
Change ..........................................................41
Graphically editing...........................................40
Measured variables........................................4
Measuring point......................4, 10, 12, 17, 50
Add ..................................................................20
Change............................................................18
Remove ...........................................................20
Minimum limit ...............................................23
Missing piece input.......................................34
Missing piece register (Type 1) ....................33
Missing piece register (Type 2) ....................35
Missing piece register (Type 3) ....................35
Missing piece signal input ......................19, 34
Module .........................................................29
Modules
Add ..................................................................29
Change............................................................29
Monitoring ....................................................11
Negation.......................................................30
New Module .................................................31
No message.................................................27
Number of programs....................................46
Number of work pieces over which the mean is
to be formed .............................................41
Number produced reached ..........................37
Operating elements........................................2
Operator .......................................................49
Operator administration .........................16, 48
Original curve .................................................6
Output (Scrap gate) .....................................31
Output number .............................................35
Output on zero operation .............................36
Output switches after limit violation..............27
Outputs
Opto-coupler......................................................9
Relay .................................................................9
P.a. options ..................................................58
Program .............................................7, 11, 42
Add ..................................................................13
Delete ..............................................................15
Select ..............................................................15
-2Program active\ P.a. ...................................... 8
Program info ................................................ 50
Program numbers.......................................... 8
Rear connection........................................... 57
Recording operating data ............................ 31
re-initialize.................................................... 36
Re-learn everything................................ 12, 13
Re-learn part................................................ 13
Remote operation of the SEM-Modul .......... 54
Reserve\ Res. ................................................ 8
Reset signal ................................................. 45
Reset signal for the cut counter ................... 19
Reset trend .................................................. 42
S.a. options.................................................. 59
S.a.- signal input .......................................... 19
S.a.+ hand start ........................................... 19
Save Program on the PC............................. 16
Scrap gate ......................................... 8, 26, 30
Select outputs .............................................. 45
SEM-Term ................................................... 54
Sensors........................................................ 20
Measured value inputs ....................................57
Setting the height of the limit ....................... 25
Signal test .................................................... 51
Sin-Term .................................................. 3, 55
Smoothed curve.............................................6
Smoothing time ............................................19
Start menu .....................................................4
Straight limits ...............................................23
SUPERUSER...............................................48
System info ..................................................54
System time .................................................47
Technical specifications ...............................62
Time limit......................................................23
Time out .......................................................46
Tool broken ..................................................27
Tool dull........................................................27
TP signal test ...............................................52
Trend............................................................52
Trend of the mean height...............................6
Trial run........................................................16
Types of limits ................................................7
Usable control signals ..................................58
User defined.................................................19
Wait for P.a. .................................................42
Warning on cycle overflow ...........................42
Zero point subtraction ..................................39
Zoom ............................................................20
\\SERVER1\Dokumentation\Geräte\SEM-MODUL\Bedienungsanleitung\Bed-AnlSEM-Modul12.01.01.doc
D Assemblies
Assembly: PD-WA-000 Tailstock
Technical Product Documentation
Machine type:
Serial number:
Version:
Valid until:
Article number:
Precision lathe PD
PD-2-01/03-840D
61503E
44 Assembly: PD-WA-000 Tailstock
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
44-1
D Assemblies
Assembly: PD-WA-000 Tailstock
44.1 Description
The tailstock consists of a guide housing PD-WA-002 as well as the quill PD-WA-003
inside which is secured against rotating. This quill is actuated by means of pneumatic
cylinder and is fitted at the front end with a carrier for a centring live centre.
44.2 Handling
When the tailstock is in the working position, adjust the limit switches for the quill as
follows (see signs of the switches to find them and their function in the circuit diagram):
• The limit switch for “Quill at the back“ must light up when the quill has been
moved to the back. The workpiece is not clamped by the quill (feedback
message M16).
• The limit switch for “Quill at the front“ must light up when the quill has been
moved to the front. The workpiece is clamped by the quill (feedback message
M15).
• The limit switch for “Quill in end position“ must light up when the quill is at the
front without workpiece in the chuck.
44.2.1 Monitoring characteristic
When during the machining of a workpiece the limit switch “M15“ is left or the limit switch
“Qill in end position“ is reached the machine is stopped with an emergency-off error
message.
44.3 Maintenance and repair
Lubrication of the quill is achieved automatically over the pressurised lubrication system.
44.4 Drawings and parts lists
44.4.1 Detail assembly drawing and the ISO-view
(see next page)
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
44-2
D Assemblies
Assembly: PD-WA-000 Tailstock
Figure 44-1: Detail assembly drawing and the ISO-view for the tailstock
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
44-3
D Assemblies
Assembly: PD-WA-000 Tailstock
44.4.2 Parts list
Assembly PD-WA-000 Tailstock
Quant. Unit Designation
4
Pcs PD-050-043 Washer above
2
Pcs Threaded pin DIN 913-M8x1x16
1
Pcs PD-WA-003 Quill
2
Pcs Merkel dirt wiper seal P6-40; L2511-004.816
1
Pcs PD-WA-005 Cylinder flange
1
Pcs PD-WA-004 Intermediate flange
1
Pcs PD-WA-002 Tailstock housing
1
Pcs PD-WA-006 Anti-rotation device made from DIN 912 M10x16
1
Pcs PD-WA-007 Upper strip
2
Pcs PD-WA-008 Aligning strip
1
Pcs PD-WA-010 Cover
1
Pcs PD-WA-011 Adapter for the tow chain holder
3
Pcs PD-WA-012 Outer spacer washer
2
Pcs Cylinder switch, electrical 3m PUR
2
Pcs Clamp holder for the electrical cylinder switch
PD-2-01/03-840D
 SPINNER Werkzeugmaschinenfabrik GmbH
44-4