精湛的技術‧傑出的產品
大立機器工業股份有限公司
DAH LIH MACHINERY INDUSTRY CO., LTD.
OPERATION AND MAINTENANCE MANUAL
誠信踏實
MCV-510
MCV-610
MCV-720
MCV-860
DMX-320
MCV-1200
MCV-1020BA
MCV-1250B
FANUC 31i/32i、0i
永續經營
031-T2-05-003
VERSION:2.2
APR/11/2011
TABLE OF CONTENTS
INTRODUCTION....……...….................................................. 2
WARNINGS................….................................................….. 3
FEATURES OF MCV-510……………………………………………… 4
FEATURES OF MCV-610、720、860 AND MCV-1020BA……….. 5
FEATURES OF MCV-1250B………………………………………….. 6
FEATURES OF MCV-1200………………………………………….
7
1. SAFETY PRECAUTIONS
1-1 GENERAL SAFETY PRECAUTIONS................................ 1-2
1-2 SAFETY PRECAUTIONS FOR OPERATING THE MACHINE.. 1-3
1-3 PRECAUTIONS FOR USING THE ELECTRICAL
COMPONENTS AND THE NC CONTROLLER...............….. 1-4
1-4 ILLUSTRATION OF THE DANGEROUS AREAS OF THE
MACHINE……………………………………………………….. 1-5
1-5 ILLUSTRATION OF THE LOCATIONS AND CONTENTS OF
WARNING SIGNS………………………………………………. 1-9
2. INTRODUCTION TO THE MACHINE
2-1 LAYOUT AND LIST OF COMPONENTS……………………… 2-2
2-2 DIMENSIONS....................................................…...... 2-8
2-3 WORKSPACE AND REFERENCE POINT……………………. 2-13
2-4 SPECIFICATIONS...............................................…..... 2-16
2-5 TOOL SPECIFICATIONS..…………………………………….. 2-21
2-5-1 RANGE OF USED TOOLS………………………………. 2-21
2-5-2 TOOLS……………………………………………………. 2-22
2-6 SPINDLE POWER AND TORQUE DIAGRAM..…................ 2-28
2-7 SOUND LEVEL.........…………………………………………. 2-42
3. PREPARATIONS FOR INSTALLATION
3-1 REQUIREMENTS OF THE ENVIRONMENT………………….. 3-2
3-2 REQUIREMENTS OF THE FOUNDATION AND THE
FOUNDATION DRAWINGS............................................ 3-3
3-2-1 METHOD FOR CONSTRUCTION THE FUNDATION….. 3-3
3-2-2 FOUNDATION DRAWINGS.............................…..... 3-5
3-3 REQUIREMENT OF POWER SOURCES……………………… 3-22
3-3-1 REQUIREMENT OF ELECTRICAL POWER……………. 3-22
3-3-2 PNEUMATIC REQUIREMENTS…………………………. 3-27
3-4 THE EQUIPMENT REQUIRED FOR TRANSPORTATION...... 3-29
3-5 OPERATION ENVIRONMENT FOR THE NC MACHINE......... 3-43
3-6 NOTES FOR TURNING ON THE MACHINE AFTER
INSTALLATION…………………………………………………. 3-45
3-6-1 BEFORE TURNING ON THE MACHINE………………… 3-45
3-6-2 AFTER TURNING ON THE MACHINE………………….. 3-46
4. TRANSPORTATION, INSTALLATION,
AND ADJUSTMENT
4-1 GUIDELINES FOR TRANSPORTATION............................ 4-2
4-2 GUIDELINES FOR INSTALLATION................................. 4-4
4-3 LEVEL ADJUSTMENT..............................................…. 4-6
5. OPERATIONS
5-1 CRT/MDI OPERATION AND DISPLAY..........................…. 5-3
5-1-1 EXPLANATION OF THE KEYBOARD……...............… 5-6
5-1-2 FUNCTION KEYS………………………………………… 5-8
5-1-3 FUNCTION KEYS AND SOFT KEYS…….....…........... 5-9
5-1-4 HELP FUNCTION………………………………………… 5-10
5-1-5 GRAPHICS DISPLAY (14” LCD)………...................... 5-11
5-2 OPERATION PANEL ................................................... 5-13
5-3 FUNCTION AND OPERATION OF THE OPERATION PANEL. 5-14
5-4 MACHINE OPERATION................................................ 5-23
5-4-1 EXAMINATION BEFORE TURNING ON THE MACHINE. 5-23
5-4-2 TURN ON THE MACHINE……………………………….. 5-24
5-4-3 TURN OFF THE MACHINE..................................... 5-25
5-5 HANDLE MODE………………………………………………… 5-26
5-6 AUTO MODE OPERATION.........……….......................... 5-28
5-6-1 MANUAL DATA INPUT(MDI)................................... 5-28
5-6-2 START AUTO OPERATION.................................... 5-29
5-6-3 STOP AUTO OPERATION................................…… 5-30
5-6-4 MANUAL INTERRUPTION (OPTIONAL FUNCTION) ….. 5-30
5-6-5 PROGRAM RESTART (OPTIOPNAL)…………………… 5-31
5-6-6 EDIT OPERATION FOR i SERIES……………….…..…. 5-34
5-6-7 SOFTWARE OPERTATOR`S PANEL…..….…………… 5-46
5-7 G FUNCTION……………………………………………………. 5-48
5-8 F FUNCTION...........................................................… 5-51
5-9 S FUNCTION...........................................................… 5-51
5-10 T FUNCTION………………………………………………….. 5-51
5-11 M FUNCTION..........................…............................… 5-52
6. AUTOMATIC TOOL CHANGE
6-1 DRUM TYPE……………............................................... 6-2
6-1-1 COMMANDS FOR ATC………………………………….. 6-2
6-1-2 PROCEDURE FOR ATC OPERATION.........…........… 6-3
6-1-3 ATC PROGRAMMING OPERATION…….................... 6-7
6-1-4 WRONG TOOL NUMBER...............…….….......……. 6-7
6-1-5 THE SETTING OF COUNTER………....….........…..... 6-8
6-1-6 TOOL NUMBER SETTING…………...............……….. 6-9
6-1-7 TOOL LOADING AND UNLOADING.................….….. 6-11
6-1-8 ADJUSTMENT OF THE TOOL EXCHANGING
POSITION IN THE Z-AXIS DIRECTION....................… 6-13
6-2 CAM TYPE……......……………………………………………. 6-14
6-2-1 COMMANDS FOR ATC……………........................... 6-14
6-2-2 PROCEDURE FOR ATC OPERATION.............…..….. 6-15
6-2-3 ATC PROGRAMMING OPERATION.………………..….. 6-19
6-2-4 WRONG TOOL NUMBER.......................…..……….. 6-19
6-2-5 THE SETTING OF COUNTER……...................…….. 6-20
6-2-6 TOOL NUMBER SETTING……..….............…………. 6-21
6-2-7 KEEP RELAY AND TIMER………………………………. 6-23
6-2-8 TOOL LOADING AND UNLOADING.................……... 6-25
6-2-9 ADJUSTMENT OF THE TOOL EXCHANGING
POSITION IN THE Z-AXIS DIRECTION....................… 6-27
7.
SETTING AND ADJUSTMENT
7-1 LEVEL ADJUSTMENT.................................................. 7-2
7-2 ADJUSTMENT AND SETTING OF THE PNEUMATIC AIR
PRESSURE...............................….......................….... 7-2
7-3 TIMER.......................................................….........… 7-3
7-3-1 SETTING OF DRUM TYPE............……………………. 7-3
7-3-2 SETTING OF CAM TYPE............………..……………. 7-5
7-3-3 FIX TIMER..................................…………….……. 7-7
7-4 KEEP RELAY.................................................…......… 7-9
7-5 DATA TABLE.................................................…......… 7-24
7-6 CHAIN APC (CAM ATC) TIMER……………………………….. 7-25
8. MAINTENANCE AND CARE
8-1 ROUTINE CHECKUPS.......................................…........ 8-2
8-2 LUBRICANT.........................................………………… 8-3
8-3 SPINDLE COOLING UNIT……………………………………… 8-4
8-4 CLEANING AND MAINTENANCE.................................... 8-5
8-5 THE POSITION OF SOLENOID, LIMIT SWITCH, AND
PROXIMATE SWITCH………………………………………….. 8-6
8-6 DOOR INTERLOCK RELEASE………………………………… 8-13
9. TROUBLESHOOTING
9-1 PARAMETER SETTINGS.............................................. 9-2
9-2 OVERTRAVEL………………………………………………….. 9-4
9-3 CHANGING BATTERIES.......................................…..... 9-5
9-4 TROUBLESHOOTING DURING THE PROCESS OF
AUTOMATIC TOOL CHANGING………………………………. 9-7
9-5 WARNING MESSAGES………………………………………… 9-9
9-5-1 DRUM TYPE……………………………………………… 9-9
9-5-2 CAM TYPE..............……………………………………. 9-13
10. AUTOMATIC PALLET CHANGER (APC
OPTIONAL)
10-1 OVERALL DRAWING AND THE NAME OF MAJOR PART.. 10-2
10-2 THE MAJOR SIZE OF THE MACHINE............................ 10-3
10-3 TRANSPORTATION AND INSTALLATION...................... 10-7
10-3-1 TRANSPORTATION(MCV-610＋APC)…….........…… 10-7
10-3-2 INSTRUCTION(MCV-1020BA＋APC)…………………. 10-9
10-4 COMMANDS OF APC OPERATION………………………… 10-16
10-4-1 MCV-610＋APC………………………………………… 10-16
10-4-2 MCV-1020BA＋APC……………………………………. 10-17
10-5 OPERATION PROCEDURES FOR APC.......................... 10-18
10-6 PROGRAMMING OF THE APC……………………………… 10-24
10-7 SETTING OF PART PROGRAM (APC).........……………… 10-32
10-8 MDI MODE MAINTENANCE OPERATION....................... 10-33
10-8-1 MCV-610＋APC………………………………………… 10-33
10-8-2 MCV-1020BA＋APC……………………………………. 10-36
10-9 HYDRAULIC DIAGRAM……………………………………… 10-37
APPENDIX
A1. AUTOMATIC TOOL LENGTH BREAKAGE DETECTION
(G36)……………………………………………………………. A-1
A2. AUTOMATIC TOOL LENGTH DETECTION (G37)…………… A-9
B. OPEN/CLOSE LINEAR SCALE………………………………. B-1
C. SETTING OF 4th & 5th AXIS…………………..………………. C-1
D1. CALL A/B PALLET PROGRAM (FOR CHAIN TYPE APC)…. D-1
D2. CALL A/B PALLET PROGRAM (FOR GEAR TYPE APC).…. D-2
E. Z AXIS RETURN WHEN AUTO TOOL CHANGE FOR
MACRO PROGRAM…………………………………………… E-1
INTRODUCTION.....................….................……..............….. 2
WARNINGS....................................................….............….. 3
FEATURES OF MCV-510.....................................…….....….... 4
FEATURES OF MCV-610、720、860、320 AND MCV-1020BA........ 5
FEATURES OF MCV-1250B.……………………………………..…… 6
FEATURES OF MCV-1200……………………………………..……… 7
2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
INTRODUCTION
This manual is written specifically for MCV-510, MCV-610, MCV-720, MCV860,DMX-320, MCV-1020BA, and MCV-1200, MCV-1250B. This manual provides
information about installations operations, basic maintenance and routine
checkups of these machines. This manual instructs you how to operate the
machine safely and correctly. Please read this manual carefully before
installation and operation.
Please be advised that this manual and warning signs on the machines
are important and must be fully understood. Programming references are given
in the manual of the FANUC controller.
Please obey the following rules when using the machine:
1. Do not operate this machine unless you are well-trained and completely
understand the functions and features of the machine.
2. Do not continue operating a machine if any faulty function is detected.
3. Do not use in the potential explosive environment.
PREFACE
3
WARNINGS
To prevent from serious injuries, the employers and owners must provide
necessary protections and equipments for installations and operations. The
employers and owners must also provide thorough training courses for the
operators. and they must carefully supervise all operations and obey the
following safety regulations:
1. This machine can be operated only by those who are well-trained and fully
understand the features and specifications of the machine as well as safety
rules for operating the machine.
2. Do not put any portion of your body on any moving component of the
machine. Do not enter the work space of the machine unless the power of
the machine is off.
3. Do not wear loose clothing or gloves since they may be tangled in the
machine. Tighten your clothes, especially the cuffs.
4. Wear safety glasses and safety shoes during operations.
5. Do not operate or maintain this machine unless properly trained and
supervised.
6. Make sure the spindle is stopped before changing or adjusting work pieces,
fixtures, and tools.
7. Do not use flammable or toxic coolant.
8. If the operator suspect the safety of operating the machine, he or she must
stop using this machine immediately and report to the manufacturer within
30 days.
4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
FEATURES OF MCV-510
This machine is a vertical machining center designed for metal cutting like
steel, iron, copper, aluminum and stainless the other material please don't cut
by this machine. It automatically changes tools for milling, drilling, boring, and
tapping. Please do not use this machine for other purposes. Special features
are as follows.
1. The tool unclamp button is located on the front end of headstock for the
purpose of easy operation.
2. The X, Y, Z motions are using φ 32-12P ball screws, which ensures high
rigidity.
3. Each ball screw is directly driven by a servomotor in order to reduce
backlashes and increase precision.
4. The Automatic Tool Change (ATC)：
(1) Drum type：it is set up vertically, and it operates without using a toolchanging arm. This design improves the reliability of tool changing.
(2) CAM type：rapid ATC construction for reduce worktime.
5. The X and Y axes are equipped with linear motion guides, which allow quick
motions, the Z axis utilizes the TURCITE design, which reduces vibrations
during operations.
6. The enclosed splash guard provides a safe and clean operation environment.
7. The control panel is attached to the splash guard to allow convenient
operations and to reduce space required for the machine.
8. The spindle is driven by the FANUC motor, which allow high-power output in
low speed.
9. Although some other materials such as plastic, carbon or wood have
considered that customers may cut it by this machine, and it may be able to
do depend on cutting condition, we insist that to think about health and
safety, do not such things unless they really know how to do it safely.
PREFACE
FEATURES OF MCV-610、
MCV-860、DMX-320、MCV720 AND MCV-1020BA
5
This machine is a vertical machining center designed for metal cutting like
steel, iron, copper, aluminum and stainless the other material please don't cut
by this machine. It automatically changes tools for milling, drilling, boring, and
tapping. Please do not use this machine for other purposes. Special features
are as follows.
1. The tool unclamp button is located on the front end of headstock for the
purpose of easy operation.
2. The X, Y, Z motions are using φ 40-12P ball screws, which ensures high
rigidity. Both ends of the screws are supported on preloaded bearings
specifically designed for ball screws. All the ball screws are also preloaded.
3. Each ball screw is directly driven by a servomotor in order to reduce
backlashes and increase precision.
4. The servomotors for the X, Y, and Z axes are installed on the outer-part of
the machine body in order to allow easy maintenance.
5. The Automatic Tool Change (ATC)：
(3) Drum type：it is set up vertically, and it operates without using a toolchanging arm. This design improves the reliability of tool changing.
(4) CAM type：rapid ATC construction for reduce worktime.
6. The X and Y axes are equipped with linear motion guides, which allow quick
motions, the Z axis utilizes the TURCITE design, which reduces vibrations
during operations.
7. The enclosed splash guard provides a safe and clean operation environment.
8. Although some other materials such as plastic, carbon or wood have
considered that customers may cut it by this machine, and it may be able to
do depend on cutting condition, we insist that to think about health and
safety, do not such things unless they really know how to do it safely.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6
FEATURES OF MCV-1200
1. slipping and provides perfect response and rigidity.
2.
All ballscrew are reduced in length to provide optimum performance and
minimal inertia
3. The new design by Dah Lin eliminates problem from the single key way
method, by adopting a twin key arrangement where the 2nd key is tapered
to provide perfect alignment, this prevent any outward movement of the
column to the base.
4. Single machine electrical cabinet equipped with heat exchanger as standard.
5. Short, strong machine spindle driven by Direct Mount Spindle motor
ensuring a perfect result in both rigidity and responsiveness of the spindle.
6. Strong compact machine ensures Dah Lih tradition for long life /
/ rigidity.
reliability
PREFACE
7
FEATURES OF MCV-1250B
1. The tool unclamp button is located on the front end of headstock for the
purpose of easy operate.
2. The X, Y, Z axes bearings are special bearings for ballscrew to make them
pretense.
3. Ballscrew and servo motor are connected by coupling to decrease backlash.
4. X, Y, Z servo motors are mounted on the outside of structure is easy to
maintenance.
5. The mountain-shaped arrangement of the ribs for the bed and saddle has the
shortest force line. It can prevent the ribs from deformations due to force
interactions.
6. Motion of CAM ATC can shortens the time of tool change and increase of
working efficiency.
7. The tool magazine is located at upper left side of the column. It has no
interruptions with the machine area. Tools are placed horizontally to reduce
chip pollution. Bi-directional tool change arm is available. It shortens the
time of tool change for the wanted tool to rotate the magazine and bring it to
the stand-by position.
8. The drawing bar is hold and driven by hydraulic mechanism while
unclamping tools. It results in the absorption of the force for the axial
direction and the prolongation of the life of the spindle bearing.
1-1 GENERAL SAFETY PRECAUTIONS................................ 1-2
1-2 SAFETY PRECAUTIONS FOR OPERATING THE MACHINE.. 1-3
1-3 PRECAUTIONS FOR USING THE ELECTRICAL
COMPONENTS AND THE NC CONTROLLER................…. 1-4
1-4 ILLUSTRATION OF THE DANGEROUS AREAS OF THE
MACHINE..............................................................…. 1-5
1-5 ILLUSTRATION OF THE LOCATIONS AND CONTENTS OF
WARNING SIGNS...............…...................................... 1-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1-2
1. SAFETY PRECAUTIONS
Safety concerns are very important in preventing accidents from
happening and in ensuring normal operations of the machine.
1-1 GENERAL SAFETY PRECAUTIONS
The following general safety precautions are helpful in preventing
accidents from happening. In other words, they help your company promote
productions.
1. Wear safety glasses.
2. Wear safety shoes.
3. Wear work clothes. Tighten the clothes, especially the cuffs.
4. Do not wear gloves when operating the machine
5. The environment of machine must bright and clean. Keep the places for
storing work pieces clean.
6. Do not blow metal chips and dusts around the high voltage controller and
the NC controller.
7. Make sure that the floor where the machine and the operator stand are
sturdy.
1. SAFETY PRECAUTIONS
1-3
1-2 SAFETY PRECAUTIONS FOR OPERATING
THE MACHINE
The operators must fully understand this manual and the following safety
precautions before operating the machine.
1. The operators or maintenance personnel must be aware of all the warning
labels on the machine. Do not remove or damage the warning labels.
2. To prevent any objects from entering the high voltage controller and the NC
controller, do not leave their covers open unless for the purpose of
adjustment or maintenance.
3. Do not alter the positions of limit switch to change travels.
4. Use designated tools to adjust, repair, and maintain the machine.
5. In case of any faulty function, stop operating the machine and press the
emergency button immediately.
6. Please note the following before starting the machine.
(1) Do not put your hands on any movable component of the machines, such
as SPINDLE, ATC, APC, and the work table.
(2) Do not use your hands to clean tools or chips on the work table. Cleaning
work can be performed only after the machine is stopped.
(3) Make sure that the machine is stopped before adjusting the orientation of
the coolant nozzle.
7. Standard shut-down procedures:
(1) Turn off the power switch.
(2) Clean the work table.
(3) Cover the slideways to prevent dusts from entering.
8. Do not load or unload tools until spindle is EXACT STOP.
9. During the maintenance, the machine must be in the status of complete stop.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1-4
1-3 PRECAUTIONS FOR USING THE ELECTRICAL
COMPONENTS AND THE NC CONTROLLER
Please note the following guidelines for routine maintenance and checkups.
1. Do not strike on the NC controller or heavily press on the control panel.
2. Use electrical cords specified in the manual. Do not use lengthy electrical
cords. Cover the electrical cords if they lie on the ground.
3. NC parameters can be altered by authorized technicians only.
4. Do not change the parameters of the high-voltage control panel or other
buttons.
5. Do not overload power sockets or electrical cords.
6. Turn off the NC controller, high-voltage control panel and the main power
before inspecting electrical components. Make sure that the switches are
locked in the "OFF" positions so that the switches cannot be accidentally
turned on.
7. Do not contact electrical components with wet tools.
8. Use designated and qualified fuses only. Do not use fuses with higher
capacities or use cooper cords to replace fuses.
9. Do not leave the door of the NC controller open since direct sunlight or
flashes will damage the controller.
10. Even the main switch in machine is shut off the electricity still
remains
in the wire from main source in customer's factory to the main switch in
machine
1. SAFETY PRECAUTIONS
1-4 ILLUSTRATION OF THE DANGEROUS
AREAS OF THE MACHINE
MCV-510
ELECTRIC CABINET
X、Y、Z MOVING AREA
ATC MOVINEG AREA
ENCLOSED GUARD
OPERATION AREA
1-5
1-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-610、MCV-720、MCV-860、MCV-1020BA
ELECTRIC CABINET
X、Y、Z MOVING AREA
ATC MOVINEG AREA
ENCLOSED GUARD
OPERATION AREA
1. SAFETY PRECAUTIONS
1-7
MCV-610＋APC
ELECTRIC CABINET
APC MOVE AREA
X、Y、Z MOVING AREA
ATC MOVINEG AREA
ENCLOSED GUARD
OPERATION AREA
1-8
MCV-1200
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1. SAFETY PRECAUTIONS
1-5 ILLUSTRATION OF THE LOCATIONS AND
CONTENTS OF WARNING SIGNS
FOR ALL THE SERIAL MACHINE
1-9
1-10
1
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1. SAFETY PRECAUTIONS
1-11
2
MCV-510
CAUTION
● The pocket facing the spindle must always kept
TOOL MAGAZINE
empty.
● Max. tool diameter：φ 90MM (3.6”)
Max. tool length：200MM (8”)
Max. tool weight：6kg (13.2lbs)
● When tool length is of 200MM, max. height of
workpiecs has to be less than 200MM.
MCV-610~1020BA
CAUTION
● The pocket facing the spindle must always kept
TOOL MAGAZINE
empty.
● Max. tool diameter：φ 90MM (3.6”)
Max. tool length：250MM (9.8”)
Max. tool weight：6kg (13.2lbs)
● When tool length is of 250MM, max. height of
workpiecs has to be less than 300MM.
1-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3
B
1. SAFETY PRECAUTIONS
4
X
Y
Z
1-13
1-14
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5
PLS TAKE PARTc d eOFF BEFORE OPERATION
AFTERWARD THE MACHINE CAN BE RUN
1. SAFETY PRECAUTIONS
6
CAUTION
THIS SOCKET PLUG(AC110V)IS
FOR INTERFACING THE TAPE
PUNCH MACHINE OR COMPUTER
ONLY , NOT FOR OTHER PURPOSE.
1-15
1-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7
WARNING
DO NOT TOUCH
KEEP HANDS AWAY
1. SAFETY PRECAUTIONS
8
1-17
1-18
9
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1. SAFETY PRECAUTIONS
10
● AUTOMATIC OIL TEMPERATURE REGULATOR.
AS ILLUSTRATED, THIS REGULATOR IS TO BE MOUNTED BEHIND THE
MACHINE.
● CONNECTION IN SEQUENCE
1. WIRE POWER SUPPLY TO COOLING PUMP
2. CONNECT COOLING HOSE "IN".
3. CONNECT COOLING HOSE "OUT".
4. USE MOBIL VELOVITE C AS COOLING OIL.
5. TURN THE MACHINE ON.
6. TURN THE REGULATOR ON.
REMEMBER TO TURN THE REGULATOR ON WHENEVER MACHINE IS
"ON".
● TEMPERATURE SETTING
SET THE TEMPERATURE AT 0 ℃ ON THE TEMPERATURE INDICATOR.
1-19
1-20
11
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1. SAFETY PRECAUTIONS
12
1-21
1-22
13
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
1. SAFETY PRECAUTIONS
14
1-23
2-1 LAYOUT AND LIST OF COMPONENTS............................ 2-2
2-2 DIMENSIONS....................................................…...... 2-8
2-3 WORKSPACE AND REFERENCE POINT......................... 2-13
2-4 SPECIFICATIONS...............................................…..... 2-16
2-5 TOOL SPECIFICATIONS.......................................…..... 2-21
2-5-1 RANGE OF USED TOOLS...................….......…...... 2-21
2-5-2 TOOLS....................................................…….... 2-22
2-6 SPINDLE POWER AND TORQUE DIAGRAM..................... 2-28
2-7 SOUND LEVEL.........…………………………………………. 2-42
2-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE
MACHINE
2-1 LAYOUT AND LIST OF COMPONENTS
MCV-510
1. Column
7. Work Table
2. Electrical Cabinet
8. Bed
3. Y-axis Servo Motor
9. Coolant Tank
4. Z-axis Servo Motor
10. Headstock
5. Tool Magazine
11. X-axis Servo Motor
6. Operation Panel
12. Level-Adjusting Bolt
2. INTRODUCTION TO THE MACHINE
MCV-610、MCV-720、MCV-1020BA
1. Column
7. Work Table
2. Electrical Cabinet
8. Bed
3. Y-axis Servo Motor
9. Coolant Tank
4. Z-axis Servo Motor
10. Headstock
5. Tool Magazine
11. X-axis Servo Motor
6. Operation Panel
12. Level-Adjusting Bolt
2-3
2-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-860、DMX-320
1. Column
7. Work Table
2. Electrical Cabinet
8. Bed
3. Y-axis Servo Motor
9. Coolant Tank
4. Z-axis Servo Motor
10. Headstock
5. Tool Magazine
11. X-axis Servo Motor
6. Operation Panel
12. Level-Adjusting Bolt
2. INTRODUCTION TO THE MACHINE
MCV-1200
1. Column
7. Work Table
2. Electrical Cabinet
8. Bed
3. Y-axis Servo Motor
9. Coolant Tank
4. Z-axis Servo Motor
10. Headstock
5. Tool Magazine
11. X-axis Servo Motor
6. Operation Panel
12. Level-Adjusting Bolt
2-5
2-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-1250B
1. Column
7. Work Table
2. Electrical Cabinet
8. Bed
3. Y-axis Servo Motor
9. Coolant Tank
4. Z-axis Servo Motor
10. Headstock
5. Tool Magazine
11. X-axis Servo Motor
6. Operation Panel
12. Level-Adjusting Bolt
2. INTRODUCTION TO THE MACHINE
MCV-1250B
1. Column
7. Work Table
2. Electrical Cabinet
8. Bed
3. Y-axis Servo Motor
9. Coolant Tank
4. Z-axis Servo Motor
10. Headstock
5. Tool Magazine
11. X-axis Servo Motor
6. Operation Panel
12. Level-Adjusting Bolt
2-7
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-8
2-2 DIMENSIONS
(MCV510)
TYPE
MCV-510
UNIT
mm
inch
A
2000
78.74
B
1890
74.41
C
580
22.83
D
800
31.5
E
100-510 3.94-20.08
F
864
34.02
G
1608
63.31
H
2464
97
I
2310
90.94
J
2100
82.68
K
210
8.27
L
220-580 8.66-22.83
M
400
15.75
N
1700
66.93
O
2076
81.73
P
480-840 18.9-33.07
Q
2400
94.49
R
1865
73.43
S
3170
124.8
T
1585
62.4
U
1585
62.4
V
3188
125.5
W
1455
57.28
X
855
33.66
Y
2600
102.36
2. INTRODUCTION TO THE MACHINE
2-9
MCV-610、MCV-720、MCV-860、MCV-1020BA
A
MCV-610
MCV-720
MCV-860
MCV-1020BA
B
C
D
E
F
G
H
I
250-710
560
2323
800
150-660
2675
950
2170
inch 18.9 9.84-27.9 22.04 91.46
31.5
5.9-26
105.3
37.4
85.43
mm 480
2323
800
150-660
2675
950
2170
Inch 18.9 9.84-27.9 22.04 91.46
31.5
5.9-26
105.3
37.4
85.43
mm 600
790
150-700
2503
950
2260
Inch 23.62 12.8-34.45 21.62 114.17 31.1 5.9-27.5 98.54
37.4
88.97
mm 600
1250
3100
mm 480
250-710
325-875
325-875
560
550
660
2900
2655
795
150-710
2715
inch 23.62 12.8-34.45 25.98 104.53 31.3 5.9-27.9 106.89 49.21 122.05
2-10
DMX-320
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE MACHINE
MCV-1200
2-11
2-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-1250B
2. INTRODUCTION TO THE MACHINE
2-3 WORKSPACE AND REFERENCE POINT
A
B
C
D
MCV-510
510
360
410
100
MCV-610
610
460
510
150
MCV-720
720
460
510
150
MCV-860
860
550
550
150
MCV-1200
1200
600
500
100
MCV-1020BA
1020
550
560
150
MCV-1250B
1250
650
700
200
Unit : mm
2-13
2-14
DMX-320
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
A
B
C
D
E
φ320
φ160
280
240
100KG
2. INTRODUCTION TO THE MACHINE
REFERENCE POINT
MCV-510
MCV-610
MCV-720
MCV-860
DMX-320
MCV-1200
MCV-1020BA
MCV-1250B
A
B
C
mm
180
410
255
inch
7.09
16.14
10.04
mm
230
510
305
inch
9
20
12
mm
230
510
360
inch
9
20
14.69
mm
275
550
430
inch
10.83
21.62
16.92
mm
300
500
600
inch
11.8
19.7
23.6
mm
275
560
510
inch
10.83
22.84
20.84
mm
325
700
625
inch
12.7
27.6
24.6
2-15
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-16
2-4 SPECIFICATIONS
MODEL
MCV-510
MCV-610
MCV-610+APC
MCV-720
MCV-860
DMX-320
WORKING
SURFACE
mm
700×410
950×560
630×420
950×560
950×550
φ320×280
in
27.6×16
37.4×22
24.8×16.5
37.4×22
37.4×21.7
12.6×11
T-SLOT
(SIZE×NUMBE
R)
mm
18×3
18×3
18×3
18×3
12×4
in
0.7×3
0.7×3
HOLE
0.7×3
0.7×3
0.47×4
MAX. TABLE
LOAD
Kg
300
500
500
500
800
100
lbs
660
1100
1100
1100
1763
220
mm
510
610
610
720
860
600
in
20.10
24.00
24.00
28.4
33.86
23.62
mm
360
460
460
460
550
550
in
14.20
18.00
18.00
18.00
21.65
21.65
HEADSTOCK
TRAVEL(Z)
mm
410
510
510
510
150-700
500
in
16.10
20.00
20.00
20.00
5.9-27.3
19.68
DISTANCE OF
SPINDLE END
TO TABLE TOP
mm
100-510
150-660
150-660
150~660
600
50-550
in
4-20.1
5.9-26
5.9-26
5.9-26
23.62
1.97-21.65
mm
410
480
480
480
600
600
in
16.10
18.90
18.90
18.9
23.62
23.62
N.T.40
N.T.40
N.T.40
N.T.40
N.T.40
LONGITUDINA
L
TRAVEL(X)
CROSS
TRAVEL(Y)
DISTANCE OF
SPINDLE
CENTER TO
COLUMN
SURGFACE
SPINDLE
NOSE
M16 SCREW
N.T.40
SPINDLE SPEED
rpm
100012000,1500
4000,6000,8000,10000,12000,15000,20000
10000
MIN. SPEED
rpm
1
1
1
1
1
1
CUTTING
FEED
mm/min
1-10000
1-10000
1-10000
1-10000
1-10000
1-10000
in/min
0.04-393
0.04-393
0.04-393
0.04-393
0.04-393
0.04-393
mm/min
18000
20000
20000
20000
40000
XY：40000
Z；30000
RAPID TRAVEL
XY：1574.8
in/min
709
787
787
787
1575
Z：1181.1
MIN. INPUT
INCREMENT
mm
0.001
0.001
0.001
0.001
0.001
0.001
in
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
2. INTRODUCTION TO THE MACHINE
MODEL
2-17
MCV-1200
MCV-1020BA
MCV-1020BA+APC
MCV-1250B
TABLE
WORKING
SURFACE
mm
1300×640
1250×660
1100×470
1400×820
in
51.8×25.19
49.2×26
43.3×18.5
55×32.5
T-SLOT
(SIZE×NUMBER)
mm
18×5
18×5
18×3
22×5
in
0.71×5
0.7×5
0.7×3
0.86×5
MAX. TABLE
LOAD
Kg
1000
1000
1000
1500
lbs
2200
2200
2200
3300
mm
1200
1020
1020
1250
in
47.24
40.00
40.00
49.2
mm
600
550
550
650
in
23.62
21.65
21.65
25.6
HEADSTOCK
TRAVEL(Z)
mm
500
560
560
700
in
19.68
22.00
22.00
27.6
DISTANCE OF
SPINDLE END TO
TABLE TOP
mm
100-600
150-710
150-710
200-900
in
3.93-23.62
5.9-28
5.9-28
7.8-35.5
DISTANCE OF
SPINDLE CENTER
TO COLUMN
SURGFACE
mm
805
600
600
710
in
31.69
23.62
23.62
28
N.T.40
N.T.40
N.T.40
N.T.40
TRAVEL
LONGITUDINAL
TRAVEL(X)
CROSS
TRAVEL(Y)
SPINDLE
SPINDLE NOSE
SPINDLE SPEED
rpm
100012000,1500
MIN. SPEED
rpm
1
1
1
1
mm/min
1-10000
1-10000
1-10000
1-5000
in/min
0.04-393
0.04-393
0.04-393
0.04-197
mm/min
X Y：30000
20000
20000
787
787
4000、6000、8000、10000、15000、20000
FEED
CUTTING FEED
Z：20000
RAPID TRAVEL
in/min
X Y：1181
Z：787
MIN. INPUT
INCREMENT
X Y：20000
Z：12000
X Y：787
Z：472
mm
0.001
0.001
0.001
0.001
in
0.0001
0.0001
0.0001
0.0001
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-18
MODEL
MCV-510
MCV-610
MCV-610+APC
MCV-720
MCV-860
DMX-320
BT40
BT40
BT40
BT40
BT40
BT40
TOOLS
16 (24)
16 (24)
16 (24)
16 (24)
φXmm
90×200
(77×300)
90×250
(77×300)
90×250
(77×300)
90×250
(77×300)
90×300
(77×300)
90×300
(77×300)
φxin
3.6×7.9
(3.0×11.8)
3.6×9.8
(3.0×11.8)
3.6×9.8
(3.0×11.8)
3.6×9.8
(3.0×11.8)
3.6×11.8
3.6×11.8
(3.0×11.8)
(3.0×11.8)
kg
6 (7)
6 (7)
6 (7)
6 (7)
6 (7)
6 (7)
lbs
13(15.2)
13(15.2)
13(15.2)
13(15.2)
13(15.2)
13(15.2)
ATC
TOOL HOLDER
STORAGE
MAX. TOOL
DIA×LENGTH
MAX. TOOL
WEIGHT
24(30.32.40) 24(30.32.40)
DRUM TYPE：BI-DIRECTIONAL
TOOL SELECT
CAM TYPE：RANDOM
MOTORS
SPINDLE MOTOR
(RATED OUTPUT
FOR 30)
KW
11
11
11
11
11
11
HP
14.7
14.7
14.7
14.7
14.7
14.7
X SERVO
MOTOR
KW
0.6
0.6
0.6
0.6
3
3
HP
0.8
0.8
0.8
0.8
4
4
Y SERVO
MOTOR
KW
0.6
0.6
0.6
0.6
3
3
HP
0.8
0.8
0.8
0.8
4
4
Z SERVO
MOTOR
KW
2.1
2.1
2.1
2.1
3
3
HP
2.8
2.8
2.8
2.8
4
4
HYDRAULIC
MOTOR
KW
×
×
1.5
×
×
×
HP
×
×
2
×
×
×
LUB. MOTOR
W
3.00
3.00
3.00
3.00
3.00
3.00
COOLANT
HP
1/2
1/2
1/2
1/2
3/4
3/4
MACHINE WEIGHT AND SPACE
FLOOR SPACE
NET WEIGHT
mm
2545x2610
3160x2585
3165x3055
3160x2585
3160x3000
3160x3000
in
75x90.9
124.4x101.8
123x121
124.4x101.8
124.4 x118.1
124.4
x118.1
kg
4200
4400
5420
4400
5400
5400
lbs
9240
9680
11900
9680
11900
11900
*X,Y AXES OF MCV-1020BA WITH APC ARE LINEAR WAY.
*(
)ARE CAM TYPE.
2. INTRODUCTION TO THE MACHINE
MODEL
MCV-1200
MCV-1020BA
MCV-1020BA+APC
MCV-1250B
BT40
BT40
BT40
BT40
24(30)(32)
16 (24)
16(24)
24
(76×300)
90×300
(77×300)
90×300
(77×300)
90×300
(77×300)
φxin
(2.9×11.8)
3.6×11.8
(3.0×11.8)
3.6×11.8
(3.0×11.8)
3.6×11.8
(3.0×11.8)
kg
(7)
6 (7)
6 (7)
6 (7)
lbs
(15.2)
13(15.2)
13(15.2)
13(15.2)
ATC
TOOL
HOLDER
STORAGE TOOLS
MAX. TOOL
DIA×LENGTH
MAX. TOOL
WEIGHT
2-19
φXmm
DRUM TYPE：BI-DIRECTIONAL
TOOL
SELECT
MOTORS
SPINDLE
MOTOR
(RATED
OUTPUT FOR
30)
CAM TYPE：
RANDOM
CAM TYPE：RANDOM
KW
7.5
11
11
15
HP
10
14.7
14.7
20
X SERVO
MOTOR
KW
3
1.0
1.0
3
HP
4
1.4
1.4
4
Y SERVO
MOTOR
KW
3
1.0
1.0
3
HP
4
1.4
1.4
4
Z SERVO
MOTOR
KW
3
2.1
2.1
3
HP
4
2.8
2.8
4
HYDRAULIC
MOTOR
KW
×
×
1.5
×
HP
×
×
2
×
LUB. MOTOR
W
3
3.00
3.00
80
COOLANT
HP
3/4
1/2
1/2
1.15
MACHINE WEIGHT AND SPACE
FLOOR
SPACE
NET WEIGHT
mm
3150x4060
4500x3640
5670x2975
4628x3270
in
124.02x159.84
177.2x143.3
224 x118
186X134
kg
7500
6000
7830
10300
lbs
16500
13200
17226
22660
2-20
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Locations and dimensions of bolt holes for the work table of MCV-610+APC
2. INTRODUCTION TO THE MACHINE
2-21
2-5 TOOL SPECIFICATIONS
2-5-1 RANGE OF USED TOOLS
■ DRUM TYPE ATC
MCV-510
MCV-610
φ90mm
φ90mm
φ90mm
φ90mm
φ90mm
φ135mm
φ135mm
φ135mm
φ135mm
φ135mm
MAX. LENGTH
200mm
250mm
250mm
300mm
300mm
MAX. LENGTH (*)
200mm
300mm
300mm
300mm
300mm
6kg
6kg
6kg
6kg
6kg
MCV-860
MCV-1200
MCV-1020BA
MCV-1250B
MAX. DIAMETER
MAX. WEIGHT
MCV-720 MCV-1020BA MCV-1250B
NOTE
1. Use quadrate guard.
2. No tools around.
■ CAM TYPE ATC
MCV-610
MCV-720
NOTE
DMX-320
MAX. DIAMETER
MAX. LENGTH (*)
MAX. WEIGHT
φ77mm
φ77mm
φ77mm
φ76mm
φ77mm
φ77mm
φ127mm
φ127mm
φ127mm
φ127mm
φ127mm
φ127mm
300mm
300mm
300mm
300mm
300mm
300mm
7kg
7kg
7kg
7kg
7kg
7kg
1. Use quadrate guard.
2. No tools around.
(*) If tools of maximum length and work pieces of maximum height are used, do
not change tools above the work piece since interferences may occur.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-22
2-5-2 TOOLS
Drawing of the BT tool shank.
Unit
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
BT40 mm 92.4 65.4 27 25 2 φ63 φ53 16.1 44.45 φ17 φ25.3 60° M16×2P 16.6 10 30°
BT50 mm 139.8 101.8 38 35 3 φ10 φ85 25.7 69.85 φ25 φ40.1 60° M24×3P 23.2 15 30°
2. INTRODUCTION TO THE MACHINE
2-23
Drawing of the BT pull stud
Unit A B C D E F
G
H
I
J
K
L M N O P
Q
R
S
BT40 mm 60 35 25 5
4
2
φ15
φ10
φ23
φ17
φ13 4 6 4 3 28 M16×2P 19 R1
BT50 mm 85 45 40 8
5
3
φ23
φ17
φ38
φ25
φ20 8 10 5 5 35 M24×3P 30 R1.5
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-24
Drawing of the CAT tool shank
Unit
CAT40
mm
A
C
D
E
F
G
H
I
J
87.30 68.25 19.05 3.2 15.87 25.01 22.60 30° 7.05 60°
K
L
M
N
O
P
Q
φ24.5 φ16.4 φ44.45 φ56.25 φ63.55
16.38
5/8"
.985
.890 30° .278 60°
φ.965 φ646 φ1.750 φ2.215 φ2.500
.645 11UNC
mm 120.65 10.6 19.05 3.2 15.88 37.7
35.3 30° 7.05 60°
φ40.22 φ26.19 φ69.85 φ91.3 φ98.43
25.9
4.000 .750 .125 .625 1.485 1.390 30° .278 60°
φ1.583 φ1.031 φ2.750 φ3.594 φ3.875
1.020 8UNC
inch 3.437
CAT50
B
inch
4.75
.678
.750 .125 .625
1"
2. INTRODUCTION TO THE MACHINE
2-25
Drawing of the CAT pull stud
CAT40
CAT50
單位
A
mm
38
B
C
D
E
16.25 5.5 11.17 1.5
F
.30
G
H
K
φ18.8 φ12.45 φ7.14
φ.740
.640
.12 .440 .060 .118
.750
mm
25.4
6.5 17.8 2.5
31.75 φ36.58
5.0
J
19.05 φ23.88
inch 1.49
59
I
inch 2.32 1.000 .25 .700 .100 .200 1.250
φ.940
φ1.44
φ29
φ.490
φ.281
φ20.83 φ11.68
φ1.140 φ.820
φ.460
L
5/8”11UNC
1”-8UNC
If the ATC mechanism is designed using the CAT tool shank, specific pull
studs, shown in the diagram, must be used.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-26
Drawing of DIN tool shank
Unit
A
B
C
D
E
F
G
H
I
J
DIN40 mm 68.5 φ63.55 φ56.25 11.1 19.1 60°
φ44.45 3.2 M16×2P φ17H7
DIN50 mm 101.7 φ97.5
φ69.85 3.2 M24×3P φ25H7
φ91.25 11.1 19.1 60°
2. INTRODUCTION TO THE MACHINE
2-27
Drawing of the DIN pull stud
單位 A
B
C
DIN40 mm 38 16.25 5.5
DIN50 mm 59
25.4
D
E
F
G
H
I
11 1.5 3.0 18 φ22 φ18.8
6.5 17.8 2.5 5.0 3.0 φ36
φ29
J
K
L
φ12.8
φ7.5
M16X2P
φ19.45 φ11.7
M25X3P
If the ATC mechanism is designed using the DIN tool shank, specific pull
studs, shown in the diagram, must be used.
2-28
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-6 SPINDLE POWER AND TORQUE DIAGRAM
2. INTRODUCTION TO THE MACHINE
2-29
2-30
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE MACHINE
2-31
2-32
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE MACHINE
2-33
2-34
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE MACHINE
2-35
2-36
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE MACHINE
2-37
2-38
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2. INTRODUCTION TO THE MACHINE
BUILD IN SPINDLE MOTOR (SY-170 / 20000RPM)
2-39
2-40
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
αL8/15000RPM
DIRECT COUPLING SPINDLE (DCS)
2. INTRODUCTION TO THE MACHINE
MCV-1200
2-41
2-42
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2-7 SOUND LEVEL
The sound pressure level at the operator's position according to Japanese
lndustrial Standard JIS B6004 :1980(Method of sound measurement for
machine tools ) is under 80 dbA.
3-1 REQUIREMENTS OF THE ENVIRONMENT....................... 3-2
3-2 REQUIREMENTS OF THE FOUNDATION AND THE
FOUNDATION DRAWINGS............................................ 3-3
3-2-1 METHOD FOR CONSTRUCTION THE FUNDATION...... 3-3
3-2-2 FOUNDATION DRAWINGS..................................... 3-5
3-3 REQUIREMENT OF POWER SOURCES...........…............. 3-22
3-3-1 REQUIREMENT OF ELECTRICAL POWER................ 3-22
3-3-2 PNEUMATIC REQUIREMENTS............................... 3-27
3-4 THE EQUIPMENT REQUIRED FOR TRANSPORTATION....... 3-29
3-5 OPERATION ENVIRONMENT FOR THE NC MACHINE......... 3-43
3-6 NOTES FOR TURNING ON THE MACHINE AFTER
INSTALLATION........................................................... 3-45
3-6-1 BEFORE TURNING ON THE MACHINE..................... 3-45
3-6-2 AFTER TURNING ON THE MACHINE........................ 3-46
3-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3. PREPARATIONS FOR
INSTALLATION
3-1 REQUIREMENTS OF THE ENVIRONMENT
In order to obtain the best designed performance of the machine,
conditions of the environment, such as room temperature, dusts, and
vibrations must be taken into account.
If the room temperature changes rapidly, the precision of the machine will
be significantly decreased.
Therefore, the machine must be installed in an environment which is free
of direct sunlight and far away from heat sources, such as heat exchangers.
The environment must also be well ventilated.
In the case in which the machine has to be installed in a humid or unclean
environment, the slideways and electrical components must be inspected
regularly to detect abrasions or rusts. The slideways and electrical
components can be easily damaged under bad environmental conditions. A
dusty and humid environment will also damage the NC controller. (See Section
3-5 for more information.)
Vibrations will decrease the precision of the machine. Thus the machine
must be installed in a place far away from objects that might cause vibrations.
3. PREPARATIONS FOR INSTALLATION
3-3
3-2 REQUIREMENTS OF THE FOUNDATION
AND THE FOUNDATION DRAWINGS
3-2-1 METHOD FOR CONSTRUCTING THE
FOUNDATION
1. Locations for installing the machine:
The machine must be installed in a location which is free from direct sunlight,
without rapid temperature changes, far away from heat sources or
vibrational objects, and well ventilated.
2. Notes for the Construction of the Foundation:
2.1. The foundation under the machine must be capable of supporting at least 5
ton/m2 of compressional pressure. If the soils are too soft and cannot
support the specified pressure, soil piles must be installed.
2.2. The construction of the foundation must be performed at least 4 weeks
before the installation of the machine.
2.3. Please refer to the foundation drawings for digging the foundation. The
digging depth must be 150-200 mm deeper than that shown in the drawings
since a layer of 150-200 mm stones will be placed on the ground.
2.4. The mixed ratio of the RC for the foundation is Concrete: Sand: Stone =
1:2:4. The tolerance of the foundation level must be within 15 mm.
2.5. Holes must be reserved for foundation bolts by inserting wooden patterns
before pouring RC into the foundation. The locations of the bolts are
shown in the foundation drawings. Please refer to the foundation drawings
for the size of the holes to be reserved. Draft of the patterns is 1/50-2/50.
The length of the pattern must be longer than that of the hole, so that the
patterns can be raised 25 mm above ground for the purpose of removing
the patterns.
2.6. The locations for burying foundation bolts are shown in the foundation
drawings. The bolts must be buried by the customers when installing the
machine.
3-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
2.7. During installation, the machine must be positioned so that the reserved
holes on the machine line up with the holes on the foundation. Each
foundation bolt is inserted through the level adjusting block as well as the
machine. As shown in Figure 1, the length of the bolt (above ground) is
a+b+c. Note that the reserved lengths (d) of all the bolts must be equal.
2.8. Insert a wedge around each level adjusting block under the machine. Then
place the level on the work table and perform coarse adjustment.
2.9. Pouring water into the foundation holes to keep the holes wet for 1-2 days
before pouring concrete. Before pouring concrete, the water must be
drained away and the holes must be cleaned . The mixed ratio of the RC is
Concrete: Sand: Stones=1:1.5:1.5.
The RC is poured until it reaches 1/3 of the level adjusting block. Keep the
RC wet for several days after pouring.
2.10. Do not adjust the level of the machine until at least 2 weeks after pouring
concrete. Remove the wedges after the adjustment.
figure 1
machine
lock nut
washer
adjusting bolt
level bolt
bolt
seat
snap ring
3. PREPARATIONS FOR INSTALLATION
3-2-2 FOUNDATION DRAWINGS
Space required for installing MCV-510
(Unit：mm)
3-5
3-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Space required for installing MCV-610、MCV-720
3. PREPARATIONS FOR INSTALLATION
Space required for installing MCV-860、DMX-320
3-7
3-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Space required for installing MCV-1020BA
3. PREPARATIONS FOR INSTALLATION
Space required for installing MCV-1200
3-9
3-10
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Space required for installing MCV-1250B
3. PREPARATIONS FOR INSTALLATION
FOUNDATION DRAWINGS
■ THE FOUNDATION BY BOLTING OF MCV-510、MCV-610、MCV-720
Unit ：mm
3-11
3-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ THE FOUNDATION BY CLAMPING OF MCV-510、MCV-610、MCV-720
Unit ：mm
3. PREPARATIONS FOR INSTALLATION
■ THE FOUNDATION BY BOLTING OF MCV-860、DMX-320
Unit ：mm
3-13
3-14
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ THE FOUNDATION BY CLAMPING OF MCV-860、DMX-320
Unit ：mm
3. PREPARATIONS FOR INSTALLATION
■ THE FOUNDATION BY BOLTING OF MCV-1020BA
Unit ：mm
3-15
3-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ THE FOUNDATION BY CLAMPING OF MCV-1020BA
Unit ：mm
3. PREPARATIONS FOR INSTALLATION
■ THE FOUNDATION BY CLAMPING OF MCV-1200
Unit ：mm
3-17
3-18
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ THE FOUNDATION BY BOLTING OF MCV-1250B
Unit ：mm
3. PREPARATIONS FOR INSTALLATION
■ THE FOUNDATION BY CLAMPING OF MCV-1250B
Unit ：mm
3-19
3-20
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ THE FOUNDATION BY BOLTING OF MCV-1020BA+APC
Unit ：mm
3. PREPARATIONS FOR INSTALLATION
■ THE FOUNDATION BY CLAMPING OF MCV-1020BA+APC
3-21
Unit ：mm
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3-22
3-3 REQUIREMENT OF POWER SOURCES
3-3-1 REQUIREMENT OF ELECTRICAL POWER
MODEL
SPINDLE MOTOR POWER SOURSE
POWER
CONSUMPTION(KW)
αP8
α8
αP8
αP12
αP15
α8
αP8
αP12
αP15
α8
16KVA
25KVA
20KVA
25KVA
25KVA
30KVA
20KVA
25KVA
25KVA
30KVA
12.956
19.281
14.456(12.956)
16.756(15.256)
18.481(16.981)
20.781(19.281)
12.956
15.256
16.981
19.281
MCV-1200、860、
DMX-320
α8
30KVA
21.481(19.281)
MCV-1020BA
αP12
αP15
α8
25KVA
25KVA
30KVA
17.456(15.256)
19.181(16.981)
21.481(19.281)
MCV-510
MCV-610
MCV-720
NOTE：(
) are APC
Note that the machine requires 200 V or 220±10% V of Voltage. A transformer
can be used if necessary.
The customers must connect the electrical cord between the machine and
electrical socket themselves. Please refer to the following table for selecting
electrical cords with suitable cross section areas.
3. PREPARATIONS FOR INSTALLATION
MODEL
3-23
CROSS SECTION AREAS OF ELECTRICAL CORD
MCV-510
14 mm2
MCV-610
14 mm2
MCV-720
14 mm2
MCV-1020BA
14 mm2
MCV-1200、860、320
14 mm2
MCV-610＋APC
14 mm2
MCV-1020BA＋APC
14 mm2
The cross section areas listed above are calculated based on 220 V power
sources. If the power is not of 220 V, please follow your local standards to
select electrical cords.
Please refer to the following table for the cross section areas of ground cords.
ELECTRICAL CORD CROSS SECTION AREAS
S (mm2)
MINIMUM GROUND CORD CROSS SECTION AREAS
S (mm2)
S ≦ 16
S
16＜S ≦35
16
S ＞ 35
S/2
3-24
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
LOCATIONS OF POWER SOURCE AND TRANSFORMER
MCV-510
MCV-610~1020BA
3. PREPARATIONS FOR INSTALLATION
MCV-1200
3-25
3-26
MCV-1250B
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3. PREPARATIONS FOR INSTALLATION
3-27
3-3-2 PNEUMATIC REQUIREMENTS
The machine uses pneumatic to drive the automatic tool changer
(pneumatic ATC), to clean the spindle tapper, and to drive the oil mist unit. If
your machine is equipped with an APC, the work table tapper is also cleaned
by using air pressure. The customers must prepare air pumps themselves. The
requirements of air pressures and the air flowrates are listed as follows：
MODEL
AIR PRESSURE
FLOWRATE
MCV-510
6 kg/cm2
100 I/min
MCV-610
6 kg/cm2
100 I/min
MCV-720
6 kg/cm2
100 I/min
MCV-860、DMX-320
6 kg/cm2
100 I/min
MCV-1200
6 kg/cm2
100 I/min
MCV-1020BA
6 kg/cm2
100 I/min
MCV-610+APC
6 kg/cm2
100 I/min
MCV-1020BA+APC
6 kg/cm2
100 I/min
The machine is equipped with an air filter and an adjusting device, which
are used to filter dusts and collect vapors, respectively. If the temperature of
the supplied air is higher than that of the machine, the vapors will become
water. As a result, the spindle tapper, and the tool shank, thus the precision of
the machine will be decreased. Therefore, try to keep the temperature of the
supplied airs as low as possible.
Please refer to Section 7-2 for the location of the FRL unit of the air source
and for the adjustment of air pressure.
3-28
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
The following figure shows the junction for the inlet tube of the air
pressure source.
3. PREPARATIONS FOR INSTALLATION
3-29
3-4 THE EQUIPMENT REQUIRED FOR
TRANSPORTATION
The machine is packaged in wood cabinet for chipping and transportation.
The position of hanging and gravity show in the follow figure:
PLEASE FOLLOW THE LOCAL SAFETY PRECAUTIONS TO TRANSPORT
THE MACHINE.
TYPE
d(cm)
e(cm)
f(cm)
g(cm)
h(cm)
w(kg)
MCV-510
210
258
285
125
100
4800
MCV-610
220
265
305
130
110
5000
MCV-720
220
265
305
130
110
5000
MCV-860、320
220
297
300
145
110
6000
MCV-1200
220
337
244
160
110
7500
MCV-1020BA
242
297
300
145
110
7300
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3-30
After opened the wood cabinet. The machine can be moved by crane.
1. FORK LIFTER
110
B
efore moving the machine by fork lifter, please take off the guard from
machine to decrease the distance from gravity to fork lifter.
(2) Uses folk lifters that are capable of lifting at least 6 tons for MCV510,MCV-610 and MCV-720. Uses folk lifter that are capable of lifting at
least 7 tons for MCV-610+APC. Uses folk lifters that are capable of lifting
at least 9 tons for MCV-1020BA and MCV-1020BA+APC.
(3) Please follow the local safety precautions for operating a folk lifter.
(4) The gravity and dimention for moving machine by fork lifter are showing
as follow.
TYPE
W
L
A
MCV-510
4200 kg
210 cm
105 cm
MCV-610
4400 kg
220 cm
110 cm
MCV-720
4400 kg
220 cm
110 cm
MCV-860、320
54000 kg
220 cm
110 cm
MCV-1200
7500 kg
242 cm
121 cm
MCV-1020BA
6500 kg
242 cm
121 cm
3. PREPARATIONS FOR INSTALLATION
3-31
2. CRANE
A.
(1) Before move the machine by crane, please fix the hanger (NOTE)on the
top of machine column by M14 bolts (MCV-510,610,720)or M16 bolts
(MCV1020BA) or M20 bolts (MCV-1200) first and then can use the crane
capacity over than 10 tons to move the machine as follow.
(2) Please follow the local safety precautions to operate the crane.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3-32
NOTE：The dimension and material of the hanger are showing as follow the
customers must make the hanger by themselves before move the
machine.
MCV-510
MCV-610
MCV-720
(Unit：mm)
MATERIAL OF HANGER：SS41-JIS
40A-BS
ST44-2.DIN
3. PREPARATIONS FOR INSTALLATION
MCV-860、DMX-32、MCV-1020BA、MCV-1200
3-33
3-34
MCV-1250B
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3. PREPARATIONS FOR INSTALLATION
3-35
B.
(1) Use the crane which can load at least 10tons load and 5.7m height.
(2) Please take off the guard.
(3) Let the intersection point of the two wire ropes be the supporting point.
Keep the hook of the crane standing vertically. Move the supporting point to
the location above the center of gravity of the machine.
(4) Apply pads or wooden pieces to all sections where the wire ropes contact
with the machine. It will protect the machine from injury.
(5) Transportation should be with care according to the local regulations of the
crane operating.
3-36
MCV-510
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3. PREPARATIONS FOR INSTALLATION
MCV-610、MCV-720
3-37
3-38
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-860、DMX-320
3. PREPARATIONS FOR INSTALLATION
MCV-1200
3-39
3-40
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-1020BA
3. PREPARATIONS FOR INSTALLATION
3-41
3. MCV-1250B
(1) Use the crane capable of at least 15 tons load and 5.7m height (show as
fig.2).
(2) Y AXIS retractable cover and guard need be dismantle of machine.
(3) Let the intersection point of the two wire ropes as the supporting point.
Keep the hook of the crane parallel to the Y-direction.
Move the supporting
point to the location above the center of gravity of the machine.
(4) Apply pads or wooden pieces to all sections where the wire ropes contact
with the machine. It will protect the machine from injury.
(5) Transportation should be with care according to the local crane operating
regulations.
3-42
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-1250B (FIG.2)
3. PREPARATIONS FOR INSTALLATION
3-43
3-5 OPERATION ENVIRONMENT FOR THE NC
MACHINE
1. Temperature
0 ℃ ~ 45 ℃
Operation :
-20 ℃ ~ 60 ℃
Storage or transportation :
2. Temperature Change Rate
1.1 ℃/min
Maximum allowable temperature change rate :
3. Humidity
95 ﹪
Relative humidity
4. Vibrations
Operation
≦ 0.5 G
:
5. Electrical Power Capacity
(1) Power source for the NC controller
10 KVA
(2) Power source for the machine (including the NC controller)
MODEL
MCV-510
MCV-610
MCV-720
MCV-1020BA
MCV-1200
MCV-860
DMX-320
NOTE：(
SPINDLE
MOTOR
αP8
α8
αP8
αP12
αP15
α8
αP8
αP12
αP15
α8
αP12
αP15
POWER
SOURSE
16KVA
25KVA
20KVA
25KVA
25KVA
30KVA
20KVA
25KVA
25KVA
30KVA
25KVA
25KVA
α8
30KVA
) are APC
POWER
CONSUMPTION(KW)
12.956
19.281
14.456(12.956)
16.756(15.256)
18.481(16.981)
20.781(19.281)
12.956
15.256
16.981
19.281
17.456(15.256)
19.181(16.981)
21.481(19.281)
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3-44
(3) Current
The calculation of currents depends on local power sources, and the
formula is given as follows:
A =
1000 x KW
1 .7 3 x V x F A C T O R
F A C T O R = 0 .8
6. Voltage
200/220 V
± 10 ﹪
60/50 Hz
± 1 Hz
(1) If local power voltages are not of 200V/220V, a transformer is required.
(2) If local power voltages are not stable, a voltage stabilizer is required.
3. PREPARATIONS FOR INSTALLATION
3-45
3-6 NOTES FOR TURNING ON THE MACHINE
AFTER INSTALLATION
3-6-1 BEFORE TURNING ON THE MACHINE
1. Check the electrical power source entering the machine to ensure that it is 3phase, 60 Hz(or 50Hz), 200V (or 220V ) Ac power.
2. Check the electrical cord connecting to the machine to ensure that the cord
and phases are connected correctly.
3. Check if the external ground cord is well installed.
4. Check if the locking components (for transportation purposes) are removed.
5. Check if the foundation blots are tightened and make sure that the machine
is in good level condition.
6. Check if all the pipes are well connected.
7. Check if the enclosed guard and the door are function appropriately.
8. Check if there is enough oil in the slideways and pump oils several times
manually.
9.
Check the hydraulic oil pressure.
10. Check the spindle and tool shank to see if there is any loosing components.
11. Check the limit switches and blocks.
12. Check if there is any unnecessary object around the machine.
3-46
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3-6-2 AFTER TURNING ON THE MACHINE
1. Check if the direction of motion of the chip conveyer or not.
2. Check if the emergency stop function works or not .
3. Check if the power can be turned on and off normally or not .
4. Check if all the buttons and switches function or not.
5. Move the axes slowly to check if the lubricants are supplied normally.
6. Move the axes slowly to check if the limit switches function normally.
7. Check if the machine performs zero return normally or not .
8. Check if the spindle rotates normally or not.
9. Check if the interlock switch of the door function normally or not.
10. Check if the machine can be controlled by a program or not.
11. Check if there is any oil leak or not.
4-1 GUIDELINES FOR TRANSPORTATION............................ 4-2
4-2 GUIDELINES FOR INSTALLATION.................................. 4-4
4-3 LEVEL ADJUSTMENT..............................................…. 4-6
4-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
4. TRANSPORTATION,
INSTALLATION, AND
ADJUSTMENT
4-1 GUIDELINES FOR TRANSPORTATION
1. Fastening the counterbalance block
Headstock of the machine is balanced by using a counterbalance block. In
order to prevent the block from moving during transportation, the block is
fastened a steel rod and bolts, as shown in locations 1 and 2 in the figure.
2. Fixing the tool magazine
In order to prevent the tool magazine during transportation, the tool
magazine is fixed by using a block, as shown in location 3 in the figure.
3. Usually the machine is packed with a wooden box. Please use designated
areas for tighten wires for cranes before the box is opened.
4. TRANSPORTATION, INSTALLATION, AND ADJUSTMENT
4-3
4. Use fork lifters, as specified in Section 3-4, to move the machine to the
desired location.
5. Place the foundation leveling block at designated locations and install the
foundation leveling bolts in a way that 1/3-1/2 of each bolt is located above
the bed of the machine. Use fork lifter to carefully place the machine on the
leveling blocks, as shown in the figure.
ƒ
„

‚
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
4-4
4-2 GUIDELINES FOR INSTALLATION
1. Connect electrical power source.
(a) Follow the instruction in Section 3-3 to connect the electrical power
source with the machine.
(b) After connecting the electrical cord, the phases of the power source must
be checked, which can be done by observing the motion of the chip
conveyor. Normal function of the conveyor indicates that the phases are
connected correctly.
2. Install the Z axis servo motor.
For the sake of transportation, the Z-axis servo motor is usually
disconnected. The procedures for installing
the Z-axis servo motor are as
follows:
(a) Install the Z-axis motor along with the coupler. Since it is located at the
top of the machine, please watch out for safety.
(b) Turn on the main power and release the emergency switch so that the
machine is ready for operation.
(c) Use 8 mm wrench to tighten up the bolts on the coupler evenly
(d) Since the z axis motor is locked with a brake, the coupler cannot be
rotated manually. Please use the hand wheel to move the z axis upwards
in order to tighten the bolts appropriately.
(e) Remove the block for fixing the spindle. Keep the block for fixing the
spindle in case of transportation.
4. TRANSPORTATION, INSTALLATION, AND ADJUSTMENT
4-5
3. Release bolts on the counterbalance block.
(a) Loosen the bolts (location 1 shown in the figure) on the counterbalance
block behind the column.
(b) Turn the hand wheel to move the headstock downwards in order to move
the counter balance block upwards so that the steel rod for fixing the
block can be removed(location 2 shown in the figure). Keep the steel rod
for fixing the spindle in case of transportation.
4. Remove the block for fixing the tool magazine. (location 3 shown in the
figure)
5. Refer to Section 6-1-8(drum type) or 6-2-8(cam type) for calibrating the ATC
location.
4-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
4-3 LEVEL ADJUSTMENT
Levelness is a major factor that affects the precision of the machine. It will
also affect the life cycle of the machine.
To adjust the levelness of the machine, first, install the machine on a good
level surface. Use the level adjusting bolts on the bed of the machine to
roughly adjust the levelness. Second, place a level (about 200 mm long, 0.02
mm/m minimum measurement) on the work table. Adjust the level adjusting
bolts again so that the errors in the forward-backward and left-right directions
are within 0.04 mm/m, as shown in the figure. Finally, tighten the bolts carefully.
If vibrations occur due to the unbalance of the machine or discrete cutting
traces appear on the work piece after cutting, then the level adjusting bolts
must be adjusted again. Perform daily checkups of levelness in the first 2-3
days after the installation. Perform monthly checkups within the first 6 months.
After 6 months, the levelness must be checked once in three months.
4. TRANSPORTATION, INSTALLATION, AND ADJUSTMENT
THE ADJUSTMENT OF THE VERTICALNESS BETWEEN THE CENTRAL LINE
OF THE SPINDLE AND THE WORK TABLE CAN BE PERFORMED AS
FOLLOWS：
1. Vertical adjustments are in general adjusted by the manufacturer before
shipping. the verticalness is justified if levelness is adjusted. However,
verticalness may need to be adjusted regularly due to the rigidity of the
machine, which is true especially for large machines.
2. Measuring methods:
A. FRONT
C. RIGHT
B. REAR
D. LEFT
C
B
A
D
4-7
4-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3. The locations of the level adjusting bolts are shown in the figure.
ƒ
„
5
6
4
7
3
8
2
9
1
10

‚
4. Method of Adjustment:
4.1 Forward-backward direction:
If the reading of A is greater than that of B, the vertical column is tilted
forward. The following adjustment is required: reduce the levels of 5 and 6
equally. Then raise the levels of 4 and 7 equally, with the amount increased
as one half of that decreased in 5 and 6.
If the reading of B is greater than that of A, the vertical column is tilted
backward. The following adjustment is required: raise the levels of 5 and 6
equally. Then reduce the levels of 4 and 7 equally, with the amount
decreased as one half of that increased in 5 and 6.
4.2 Left-right direction:
If the reading of C is greater than that of D, the vertical column is tilted to
the left. Raise the levels of 4 and 5 equally or reduce the levels of 6 and 7
equally.
If the reading of D is greater than that of C, the vertical column is tilted to
the right. Reduce the levels of 4 and 5 equally or raise the levels of 6 and 7
equally.
5. Note：That what discussed above are general guidelines. Special situations
may be encountered in practical applications, and it takes experiences and
brain storming to deal with these situations.
5-1 CRT/MDI OPERATION AND DISPLAY.............................. 5-3
5-1-1 EXPLANATION OF THE KEYBOARD……...….........… 5-6
5-1-2 FUNCTION KEYS................................................ 5-8
5-1-3 FUNCTION KEYS AND SOFT KEYS……................... 5-9
5-1-4 HELP FUNCTION……………………........................ 5-10
5-1-5 GRAPHICS DISPLAY…………………...................…. 5-11
5-2 OPERATION PANEL ................................................... 5-13
5-3 FUNCTION AND OPERATION OF THE OPERATION PANEL. 5-14
5-4 MACHINE OPERATION................................................ 5-23
5-4-1 EXAMINATION BEFORE TURNING ON THE MACHINE. 5-23
5-4-2 TURN ON THE MACHINE...................................... 5-24
5-4-3 TURN OFF THE MACHINE..................................... 5-25
5-5 HANDLE MODE......................................................... 5-26
5-6 AUTO MODE OPERATION..…….................................… 5-28
5-6-1 MANUAL DATA INPUT(MDI)…………………………….. 5-28
5-6-2 START AUTO OPERATION.................................... 5-29
5-6-3 STOP AUTO OPERATION...................................... 5-30
5-6-4 MANUAL INTERRUPTION (OPTIONAL FUNCTION)..... 5-30
5-6-5 PROGRAM RESTART (OPTIOPNAL)………………...... 5-31
5-6-6 EDIT OPERATION FOR i SERIES…………………….… 5-34
5-6-7 SOFTWARE OPERTATOR`S PANEL...….……………... 5-46
5-7 G FUNCTION............................................................. 5-48
5-8 F FUNCTION............................................................. 5-51
5-9 S FUNCTION……………………………………………………. 5-51
5-10 T FUNCTION………………………………………………….. 5-51
5-11 M FUNCTION………………………………………………….. 5-52
5. OPERATIONS
5-3
5. OPERATIONS
5-1 LCD/MDI OPERATION AND DISPLAY
(16i/18i/21i series)
A.7.2”/8.4” LCD –mounted type cnc control nuit
B.9.5”/10.4” LCD-mounted type cnc control unit
5-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
C.9”/8.4”、CRT/LCD-WITH MDI UNIT(0i)
5. OPERATIONS
D.Stand-alone type standard MDI unit(16i/18i/21i)
5-5
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-6
5-1-1 EXPLANATION OF THE KEYBOARD
NO.
1
NAME
EXPLANATION
Power ON and OFF
buttons
OFF
Press theses buttons to turn CNC power ON and
OFF.
ON
RESET key
2
Press this key to reset the CNC, to cancel an
alarm, etc.
RESET
HELP key
3
4
Press this button to use the help function when
uncertain about the operation of an MDI key
(help function).
The soft keys have various functions, according
to the Applications. The soft key functions are
displayed at the bottom of the CRT screen.
HELP
Soft keys
Address and numeric keys
5
N
(
SHIFT key
6
SHIFT
INPUT key
7
INPUT
Cancel key
8
CAN
4
...
Press these keys to input alphabetic, numeric,
and other characters.
Some keys have two characters on their keytop.
Pressing the （SHIFT）key switches the
characters. Special character E is displayed on
the screen when a character indicated at the
bottom right corner on the key top can be
entered.
When an address or a numerical key is
pressed,the data is input to the buffer,and it is
displayed on the CRT screen. To copy the data
in the key input buffer to the offset
INPUT
key. This key is
register,etc.press the
equivalent to the [INPUT]key of the soft keys,
and either can be pressed to produce the same
result.
Pess this key to delete the last character or
symbol input buffer.When the key input buffer
displays.
＞N001X100Z_
CAN
and the cancel
key is pressed，Z is
canceled and
＞N001X100_is displayed.
5. OPERATIONS
NO.
NAME
5-7
EXPLANATION
Press these keys when editing the program.
ALTER
Program edit keys
9
ALTER
INSERT
DELETE
：Alteration.
INSERT
DELETE
Function keys
10
POS
PROG
...
：Insertion.
：Deletion.
Press theses keys to switch display screens
for each function.
There are four different cursor move keys.
：This key is used to move the cursor to
the right or in the forward direction.
The cursor is moved in short units in
the forward direction.
：This key is used to move the cursor to
the left or in the reverse direction. The
cursor is moved in short units in the
reverse direction.
Cursor move keys
11
：This key is used to move the cursor in
a downward or forward direction. The
cursor is moved in large units in the
forward direction.
：This key is used to move the cursor in
an upward or reverse direction.
The cursor is moved in large units in
the reverse direction.
Two kinds of page change keys are described
below.
Page change keys
12
PAGE
PAGE
PAGE
：This key is used to changeover the
page on the CRT screen in the forward
direction.
PAGE ：This key is used to changeover the
page on the CRT screen in the reverse
direction.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-8
5-1-2 FUNCTION KEYS
POS
：Press this key to display the position screen.
PROG
：Press this key to display the program screen.
OFFSET
SETTING
：Press this key to display the offset/setting screen.
SYSTEM
：Press this key to display the system screen.
MESSAGE
：Press this key to display the message screen.
GRAPH
：Press this key to display the graphics screen.
CUSTOM
：Press this key to display the custom screen
(conversational macro screen).
5. OPERATIONS
5-9
5-1-3 FUNCTION KEYS AND SOFT KEYS
POS
OFFSET
CUSTOM
SETTING
PROG
1. Press a function key on the MDI
panel. The chapter selection soft keys
SYSTEM
GRAPH
MESSAGE
that belong to the selected function
appear.
Function keys
2. Press one of the chapter selection soft
keys. The screen for the selected
chapter appears. If the soft key for a
(
(
(
(
(
(OPRT)
target chapter is not displayed, press
the continuous menu key(next-menu
key).
Chapter selection
soft keys
Operation
selection
keys
In some cases, additional chapters can
be selected within a chapter.
3. When the target chapter screen is
(
(
(
(
(
displayed, press the operation
selection key to display data to be
manipulated.
4. To redisplay the chapter selection soft
Return menu keys
Continuous menu keys
keys, press the return menu key.
The general screen display procedure is explained above. However, the actual
display procedure varies from one screen to another. For details, see the
description of individual operations.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-10
5-1-4 HELP FUNCTION
The help function displays on the screen detailed information about alarms
issued in the CNC and about CNC operations. The following information is
displayed.
1. Press the
HELP
key on the MDI panel. HELP (INITIAL MENU) screen is
displayed.
HELP (INITIAL MENU)
O1234
N00001
***** HELP *****
1. ALARM DETAIL
2. OPERATION METHOD
3. PARAMETER TABLEL
S 0 T0000
10:12:25
MEM **** *** ***
[ 1 ALM ] [ 2 OPR ] [ 3 PARA ] [
] [
]
2. Detailed information of alarms：
1
Press the soft key [1 ALAM].
2
Enter the alarm number.
3
Press soft key [SELECT]
3. OPERATION METHOD ：
1
Press the soft key [2 OPR].
2
Enter an item NO. from the keyboard.
3
Press soft key [SELECT]
4. PARAMETER TABLE ：
1
Press the soft key [3 PARA].
5. To exit from the help screen, press the
HELP
key or another function key.
5. OPERATIONS
5-1-5 GRAPHICS DISPLAY (10.4" LCD)
Procedure：
GRAPH
1. Press function key
.
2. Press soft key [PARAM].
3. Move the cursor with the cursor keys to a parameter to set.
INPUT
4. Enter data, then press the
GRAPHIC PARAMETER
key.
00000 N00000
AXES
P=
4
(XY=0,YZ=1,ZY=2,XZ=3,XYZ=4,ZXY=5)
RANGE
(MAX.)
X= 115000
Y= 150000
Z=
0
RANGE
(MIN.)
X=
0
Y=
0 Z=
0
SCALE
K=
70
GRAPHIC CENTER
X= 57500
Y= 75000
Z=
0
PROGRAM STOP N=
0
AUTO ERASE
A=
1
MDI
****
***
***
[ PARAM ] [ GRAPH ] [
14:23:54
] [
]
[
]
5. Repeat steps 2 and 3 until all required parameters are specified.
6. Press soft key [GRAPH].
7. Automatic operation is started and machine movement is drawn on the
screen.
5-11
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-12
GRAPHICS PARAMETER EXPLANATION ：
PARAMETER
EXPLANATION
AXES
：Specify the plane to use for drawing. The user can
choose from the following six coordinate systems.
RANGE(Max., Min.)
：Set the graphic range displayed on the screen by
specifying maximum and minimum values along each
axis.
：Set the graphic magnification
SCALE
The setting range is 0 to 10000(unit：0.01 time).
： X＝ _
Y＝_
GRAPHIC CENTER
Z＝_
Set the coordinate value on the workpiece coordinate
system at graphic center.
：N＝_
PROGRAM STOP
AUTO ERASE
Set the sequence No. of the end block when necessary
to partially display.
：When the AUTO operation is started under reset
condition, the program is executed after deleting the
previous drawing automatically (Automatic deleting＝
1). It is possible not to delete the previous drawing by
graphic parameter (Automatic deleting＝0).
5. OPERATIONS
5-2 OPERATION PANEL
For 18i/21i
For 0i
5-13
5-14
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-3 FUNCTION AND OPERATION OF THE
OPERATION PANEL
SINGLE BLOCK
(SBK)
：Only one block will be executed at a time in auto
mode.
DRY RUN (DRN)
：The feedrate specified in the program is disabled. The
real feedrate is determined by using the “JOG
FEEDRATE SWITCH” on the panel.
BLOCK DELETE
：Block started with (/) will be neglected in auto mode.
(BDT)
OP. STOP
：The program will stop when M01 is read in auto mode.
MST
：The M, S, and T commands are disabled.
PROGRAM RESTART ：After replacing broken tools or taking a break during
operation, this function allows the operator to specify
(RESTART)
the sequence number in a program where he or she
wants to restart the program.
Z LOCK
：The Z axis will be locked. (It must zero return, when
restart the program)
MC LOCK
：The X,Y and Z axes will be locked. (It must zero return,
when restart the program)
AUT OFF
：If the button is pressed , power will be cut off when
M00,M01,M02 0r M30 in the program is executed.
DOOR.IT
：When auto tool change , axis move and spindle
rotate stop , then press this button that safety
door open for interlock switch release .
MANUAL GUIDE
(M.G)
：One single screen provides handy operation guidance
for programming through machine operation.
5. OPERATIONS
COOLANT
：Coolant will be ejected from the nozzles.
AIR BLOW
：Air blow will be ejected from the nozzle.
OIL MIST
：Oil mist will be ejected from the nozzles (option).
OIL HOLE
：Coolant will be ejected from the tool (option).
SHOWER
: Coolant will be ejected from the cover (option).
GUN
: Coolant will be ejected from the gun.
F4
：Addition function 4.
F5
：Addition function 5.
F6
：Addition function 6.
5-15
5-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
LIGHT
：To turn on/off the working light on the machine.
AUTO DR
：In the manual mode (HANDLE, JOG, RAPID, or ZERO
RETURN) to push it, the door will open or close
(option).
CLEAN
：The chip wash away from splash guard .
CHIP CW
：The chip conveyor will rotate to remove the chip from
the machine .
CHIP CCW
：The chip conveyor will rotate to remove the chip from
the machine .
O.T.REL
：If the axes do not return to the reference point before
operating the machine, the default travel limit will not
function, and the moving parts may overtravel or even
trigger limit switches. As a result, the machine will be
in the state of emergency stop (EMG). This situation
an be released by holding the this button on for
several seconds until the READY light on the control
panel is on. Then turn the hand wheels to move the
axes to their normal workspace.
5. OPERATIONS
5-17
TOOL MONITOR
：Display spindle tool number and prepare tool number.
CW
：Magazine rotate by CW button in manual mode.
CCW
：Magazine rotate by CCW button in manual mode.
5-18
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MODE SELECT
Turn this switch to select the following
operation modes：DNC, MEMORY, EDIT,
MDI, HANDLE, JOG, RAPID, and ZRN model.
PROGRAM PROTECT
The switch must be turned to the UNLOCK
position to edit the program or data.
Normally this switch is turn to LOCK
position, the mode can protect the data.
FEEDRATE
To adjust the feedrate in JOG mode or DRY
RUN (0~4000mm/min). This function is used
in auto mode associated with the command,
but it is disabled when executing G84 and
G74 (Tapping mode).
5. OPERATIONS
5-19
To select the axis to be moved in JOG and
RAPID modes.
To push axis direction button and “rapid”
button in RAPID mode, the feedrate is
RAPID.
To push axis direction button in RAPID
mode, the feedrate is JOG.
The program will be executed by push the
“CYCLE START” button.
The program can be stopped by pressing the
“FEED HOLD“ button. It can be restarted by
push the “CYCLE START” button.
SPINDLE CW/CCW STOP
When the S command is stored in
memory, the spindle can be started or
stopped by push these buttons in manual
mode. In addition, the spindle stop button is
pressed in ZERO RETURN mode, the
spindle can be oriented.
5-20
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
SPINDLE LOAD
Display the load of the spindle motor.
ZERO RETURN
Zero return for each axis will be performed
when the corresponding button is pressed
in ZERO RETURN mode.
EMERGENCY STOP
To stop the machine in case of emergency.
SPINDLE SPEED OVERRIDE
The spindle speed can be override by using
this switch.
Range：50-120﹪
5. OPERATIONS
◎ POWER
5-21
：The button lamp will lighting when the switch
on the electrical cabinet is turned ON.
◎ READY
：The button lamp will lighting after turning on
the machine.
◎ LUBRICATION ALARM
：The alarm will occur when the lubricant in the
tank is not enough, and the program will
stopped. Lubricant must be injected in order
to restart the program.
◎ TOOL NUMBER ALARM
：The alarm will occur when the T code is out of
range. For example, if the tool capacity is 32,
the command T35 will trigger this alarm
signal.
◎ SPINDEL ORIENT
：When the spindle orientation, it will lighting.
◎
：When spindle tool clamp, the lamp will light
TOOL CLAMP
5-22
◎
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
TOOL UNCLAMP
：When spindle tool unclamp , the lamp will
light.
◎
ARM REFERENCE
：This lamp mean the arm in the zero point.
◎
TOOL CATCH
：This lamp mean the arm clutch tool .
◎
REFERENCE POINT
：This lamp mean the Z axis in the tool change
range, which the arm can rotate.
5. OPERATIONS
5-23
5-4 MACHINE OPERATION
5-4-1 EXAMINATION BEFORE TURNING ON THE
MACHINE
(1) Get rid of the antirust oil on the moving components of the machine, such
as like on the slideways and the piston link of the tool magazine pneumatic
cylinder.
(2) Check if the air pressure is 7~ 8 kg/cm2.
(3) Check if the lubricant is enough. Check if the F.R.L. pneumatic unit function
normally.
(4) Check if there is enough space for each axis's movement.
5-24
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-4-2 TURN ON THE MACHINE
(1) Turn on the electrical power supply.
(2) Turn on the power switch on the electrical cabinet.
(3) Press the power on button (green) on the operation panel.
(4) Release the EMERGENCY STOP button on the operation panel.
(5) Press the START button on the lubricant tank to inject the lubricant to the
slideways. Then move each axis.
(6) Perform zero return for each axis so that travel limit in memory will be
effective.
(7) Select the desired mode and start operation.
5. OPERATIONS
5-25
5-4-3 TURN OFF THE MACHINE
(1) Let one block of a program be completed and then press the RESET key to
finish the work. Press the Z-AXIS ZERO RETURN button to move the spindle.
The unload the tool and put it back in the tool magazine manually or by
automatic operation.
(2) Clean the machine and then put antirust oil on the work table and spindle.
(3) Move each axis to the middle of its travel to keep the balance of the
machine.
(4) Press the EMERGENCY STOP button on the operation panel.
(5) Press the power off button (red) on the operation panel.
(6) Turn off the electrical power supply.
(7) Turn off the power switch on the electrical cabinet.
5-26
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-5 HANDLE MODE
a. MACHINE ZERO RETURN
(1) Turn the mode selector to the ZERO RETURN position.
(2) Press down the desired zero return button and the corresponding lamp
will light until the zero return is finished.
Note that normally zero return of each axis is performed immediately after
turning on the machine.
b. RAPID TRAVERSE
(1) Turn the mode selector to the RAPID position.
(2) Select the override rate (L, 25, 50, or 100 %)
(3) To select the desired axis to be moved.
5. OPERATIONS
c. JOG
(1) Turn the mode selector to the JOG position.
(2) Select the speed by adjusting the JOG FEEDRATE SWITCH.
(3) To select the desired axis to be moved.
d. HANDLE FEED: Slower feedrate can be obtained by using M.P.G.
(Manual Pulse Generator)
(1) Turn the mode selector to the HANDLE position.
(2) Select the axis. (The switch is on the M.P.G.)
(3) Rotate the wheel on the M.P.G. to start the motion of each axis.
C.W.:
+ direction.
C.C.W.: - direction.
(4) DISPLACEMENT SELECT
DISPLACEMENT FOR EACH WHEEL STEP
INPUT UNIT
X1
X 10
X 100
METRIC
0.001 mm
0.01 mm
0.1 mm
INCH
0.0001 inch
0.001 inch
0.01 inch
5-27
5-28
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-6 AUTO MODE OPERATION
5-6-1 MANUAL DATA INPUT (MDI):A single block of
commands can be executed from CRT/MDI
input.
(1) Turn the mode selector to the MDI mode.
(2) Press the
PROG
function key on the MDI panel to select the program
screen. The following screen appears：
PROGRAM (MDI)
0010
00002;
O0000;
G00 G90 G94 G40 G80 G50 G54 G69
G17 G22 G21 G49 G98 G67 G64 G15
B HM
T
D
F
S
MDI
****
***
***
20:40:05
[ PRGRM ] [ MDI ] [ CURRNT ] [ NEXT ] [ (OPRT) ]
(3) Input data.
(4) Press the
INSERT
key.
(5) Repeat (3) and (4) to enter more data.
(6) Press the cycle start key.
5. OPERATIONS
5-29
5-6-2 START AUTO OPERATION
a. MEMORY
(1) Turn the mode selector to the MEM mode.
(2) Select the program to be executed.
(3) Press the “CYCLE START” button, and then the program will be executed
The lamp above the “CYCLE START” button will light. When necessary,
press the “FEED HOLD” button to pause the execution. Press the “CYCLE
START” button again to continue executing the program.
b. DNC
(1) To utilize ATA reader or connect a personal computer to CNC controller
through an RS-232-C port for transmit program, then turn the mode
selector to the DNC mode.
(2) Press the “CYCLE START” button, and then the program will be executed.
The lamp above the “CYCLE START” button will light. When necessary,
press the “FEED HOLD” button to pause the execution. Press the “CYCLE
START” button again to continue executing the program.
5-30
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-6-3 STOP AUTO OPERATION
1. COMMANDS OF STOPPING AUTO OPERATION
(1) M00 (PROGRAM STOP): The program will stop at the block where M00 is
read and other statuses remain unchanged. The next block will be
executed if the “CYCLE START” button is pressed.
(2) M01 (OPTIONAL STOP): This command is the same as M00 except that it
will be effective only when the “OPT. STOP” button is pressed.
(3) M02,M30: Auto mode operation will be stopped when M02 (PROGRAM
FINISHED) or M30 is read. The only difference is that the cursor will return
to the beginning of the program when command M30 is read.
2. Auto operation can be stopped when the “FEED HOLD” button is pressed.
Press the "CYCLE START" button to continue executing the program.
5-6-4 MANUAL INTERRUPTION (OPTIONAL
FUNCTION)
Manual Pulse Generator (M.P.G.) will also be effective in auto operation
mode by using this optional function. To use this function, press the CALL
LIGHT button and keep it down to select an axis. Then use the other hand to
rotate M.P.G.
5. OPERATIONS
5-31
5-6-5 PROGRAM RESTART (OPTIONAL) :
Use this function to assign the sequence number that the program will
restart from after replacing a broken tool or taking a break.
BROKEN TOOL (P TYPE)
(1) Press "Feed Hold" to escape the tool, and replace it with a new one.
Modify the offset amount if it varies.
(2) Turn the program re-start switch on the machine operator's panel ON.
(3) Press "PRGRM" to display the present program.
(4) Find the program head. Press "RESET" During memory operation, select
"AUTO" mode, and press 0↑
(5) If the same sequence number appears more than once, the location of the
target block must be specified. Specify a frequency and a sequence number.
N
Frequency
Sequence number
N
Sequence number
(6) Press [P TYPE] key,and press [ RSTR] key.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-32
(7) After completion of block search, the CRT screen is changed to the program
re-start screen.
O0002
PROGRAM RESTART
M
DESTINATION
X 57.096
Y 56.877
Z 56.943
N01000
1
2
1
2
1
2
1
2
1
2
1* * * * * * * *
******** ********
DISTANCE TO GO
1 X 1.459
T ******** ********
2 Y 10.309
S *****
3 Z 7.320
S
0 T0000
MEM
****
***
[ RSTR ][
***
10:10:40
] [ FLSDL ] [
] [ (OPRT) ]
(DESTINATION) shows the position where the machining operation is restarted.
(DISTANCE TO GO)shows the distance between the current tool position
and the machining re-start position. The figure at the left side of the axis
name shows the order (parameter setting)described later when the tool
moves to the re-start position.
M.......... Shows M-code commanded recently 14 times in the past.
T........... Shows M -code commanded recently 2 times in the past.
S........... Shows s-code command in the last.
B........... Shows B-code command in the last.
Display the most previously commanded code in the head. Each code is
cleared with the program re-start command and the cycle start command in
reset conditions.
5. OPERATIONS
5-33
(8) Turn the program re-start switch OFF. At this time, the figure at the left side
of axis name (distance to go) flickers.
(9) Check the screen, and if M, S, T or B code should be output, select the MDI
mode, and output M, S, T or B code from MDI. Each code in this case is not
displayed on the program re-start screen.
(10) During memory operation, select "AUTO" mode, and check that the
distance of ( DISTANCE TO GO ) is correct, and that the tool does not hit
against the work and others. If it is about to collide with an obstacle, move
the tool manually to the location where it does not collide, then press
"Cycle Start" button. At this time, the tool moves to the machining re-start
position in the dry run mode by one axis in the order set to the parameters
( No. 0124 to 0127 ) , thus re-starting machining operation in succession.
5-34
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-6-6 EDIT OPERATION FOR i SERIES
1. PROGRAM REGISTRATION FROM RS-232C(PC→MT)
(1) Select EDIT mode.
(2) Turn the program protect to WRITE.
PROG
(3) Press function key
.
(4) Press right most soft key
.
(5) 1 Key in address 0.
2 Key in the program number.
(6) Key in 0~9999 for input all program.
(7) Press soft key [READ]
(8) Press soft key [EXEC]
2. PROGRAM REGISTRATION FROM CRT/MDI PANEL.
(1) Set the mode selector switch to EDIT.
(2) Turn the program protect key to WRITE.
(3) Press function key
PROG
. Make sure that the program text is displayed.
(4) Key in address O.
(5) Key in program number.
(6) Push the INSERT key.
With the above procedure, the program number is registered to the
memory. Thereafter, key in respective words of the program and press the
INSERT key to register them.
5. OPERATIONS
3. PROGRAM DELETION
Delete one program
(1) Set the mode selector switch to EDIT.
(2) Press function key
PROG
.
(3) Turn the program protect key to WRITE.
(4) Input address
0 .
(5) Key in the program number to be deleted.
(6) Press the
DELETE
key .The program with the entered program number
is deleted.
Delete all programs
(1) Set the mode selector switch to EDIT.
(2) Press
PROG
to display the program screen .
(3) Turn the program protect key to WRITE.
(4) Key in 0-9999
(5) Press edit key
DELETE
to delete all programs.
5-35
5-36
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
4. OUTPUTTING A PROGRAM
(1) Make sure the output device is ready for output.
For the two-path control, select the tool post for which a program to be
output is used with the tool post selection switch.
(2) To output to an NC program, specify the punch code system (ISO or EIA)
using a parameter.
(3) Press the EDIT switch on the machine operator's panel.
(4) Press function key
PROG
, then the program contents display screen or
program directory screen appears.
(5) Press soft key [(OPRT)].
(6) Press the rightmost soft key
(next-menu key).
(7) Enter address O.
(8) Enter a program number. If-9999 is entered, all programs stored in
memory are output .
To output multiple programs at one time, enter a range as follows：O△△
△△，O□□□□.
Programs No.△△△△ to No.□□□□ are output .
The program library screen displays program numbers in ascending order
when bit 4(SOR) of parameter No.3107 is set to 1.
(9) Press soft keys [PUNCH] and [EXEC]
The specified program or programs are output.
5. OPERATIONS
5-37
5. SEARCH
Scanning a program
(1) Press the cursor key
.
The cursor moves forward word by word on the screen; the cursor is
displayed at a selected word.
.
(2) Press the cursor key
The cursor moves backward word by word on the screen; the cursor is
displayed at a selected word.
(3) Holding down the cursor key
or
scans words continuously.
(4) The first word of the next block is searched for when the cursor key
is pressed.
(5) The first word of the previous block is searched for when the cursor key
is pressed.
(6) Holding down the cursor key
or
moves the cursor to the
head of a block continuously.
PAGE
displays the next page and searches for the
(7) Pressing the page key
first word of the page.
(8) Pressing the page key
PAGE
displays the previous page and searches for
the first word of the page.
PAGE
(9) Holding down the page key
another.
or
PAGE
displays one page after
5-38
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Searching a word
S
(1) Key in address
(2) Key in
1
2
.
.
＊ S12 cannot be searched for is only S1 is keyed in.
＊ S09 cannot be searched for by keying in only S9.
To search for S09, be sure to key in S09.
(3) Pressing the [SRH↓]key starts search operation.
Upon completion of search operation, the cursor is displayed at S12.
Pressing the [SRH↑] key rather than the
[SRH↓] key performs search
operation in the reverse direction.
Searching an address
(1) Key in address
M
.
(2) Press the [SRH↓] key.
Upon completion of search operation, the cursor is displayed at M03.
Pressing the [SRH↑] key rather than the [SRH↓] key performs search
operation in the reverse direction.
5. OPERATIONS
5-39
Heading a program
METHOD 1：
(1) Press
RESET
when the program screen is selected in EDIT mode.
When the cursor has returned to the start of the program , the contents of
the program are displayed from its start on the screen.
METHOD 2：
Search for the program number.
(1) Press address
, when a program screen is selected in the MEMORY or
EDIT mode.
(2) Input a program number.
(3) Press the soft key [O SRH].
METHOD 3：
(1) Select [MEMORY] or [EDIT] mode.
(2) Press
PROG
.
(3) Press the [(OPRT)] key.
(4) Press the [REWIND] key.
METHOD 4：
(1) Select [MEMORY] or [EDIT] mode.
(2) Press
PROG
.
(3)Press address
CURSOR
(4) Press
key.
5-40
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6. INSERTING A WARD
(1) Search for or scan the word immediately before a word to be inserted.
(2) Key in an address to be inserted.
(3) Key in data.
(4) Press the
INSERT
key.
Altering a word
(1) Search for or scan the word to be altered.
(2) Key in an address to be inserted.
(3) Key in data.
(4) Press the
ALTER
key.
5. OPERATIONS
5-41
7. DELETING A WORD
(1) Search for or scan a word to be deleted.
(2) Press the
DELETE
key.
Deleting a block
(1) Search for or scan address N for a block to be deleted.
(2) Key in
EOB
(3) Press the
DELETE
.
Deleting multiple blocks
(1) Search for or scan a word in the first block of a portion to be deleted.
(2) Key in address
N
.
(3) Key in the sequence number for the last block of the portion to be deleted.
(4) Press the
DELETE
key.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-42
8. PROGRAM NUMBER SEARCH
METHOD 1：
(1) Select EDIT or MEMORY mode.
(2) Press
PROG
(3) Key in address
to display the program screen.
.
(4) Key in a program number to be searched for.
(5) Press the [O SRH] key.
(6) Upon completion of search operation, the program number searched for
is displayed in the upper-right corner of the CRT screen If the program is
not found, P/S alarm No.71 occurs.
METHOD 2：
(1) Select EDIT or MEMORY mode.
(2) Press
PROG
to display the program screen.
(3) Press the [O SRH] key.
In this case, the next program in the directory is searched for.
5. OPERATIONS
5-43
9. SEQUENCE NUMBER SEARCH
(1) Select MEMORY mode.
(2) Press
PROG
.
(3) If the program contains a sequence number to be searched for , perform
the operations 4 to 7 below.
(4) Key in address
N
.
(5) Key in a sequence number to be searched for.
(6) Press the [N SRH] key.
(7) Upon completion of search operation, the sequence number searched for
is displayed in the upper-right corner of the CRT screen.
If the specified sequence number is not found in the program currently
selected, P/S alarm No.060 occurs.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-44
10. AUTOMATIC INSERT SEQUENCE NO.
1. Sequence No. setting 1. Procedure as follows：
(1) Select the MDI mode.
(2) Press function key
OFFSET
SETTING
.
(3) Press soft key [SETING] to display the setting data screen.
This screen consists of several pages.
PAGE
PAGE
(4) Press page key
displayed.
or
until the desired screen is
An example of the setting data screen is shown below.
SETTING (HANDY)
O0001 N00000
PARAMETER WRITE
TV CHECK
PUNCH CODE
INPUT UNIT
I/O CHANNEL
SEQUENCE NO.
TAPE FORMAT
SEQUENCE STOP
SEQUENCE STOP
=
=
=
=
=
=
=
=
=
1
0
1
0
0
0
0
(0:DISABLE 1:ENABLE)
(0:OFF 1:ON)
(0:EIA 1:ISO)
(0:MM 1:INCH)
(0-3:CHANNEL NO.)
(0:OFF 1:ON)
(0:NO CNV 1:F15)
0(PROGRAM NO.)
0(SEQUENCE NO.)
MDI **** *** ***
[ OFFSET ] [ SETING ] [ WORK ] [
]
[ (OPRT) ]
(5) Move the cursor to the sequence No., then press[1：ON]
2. Select the edit mode.
3. Press function key
4. Key in address
5. Press
INSERT
N
PROG
.
,and key in start value, ex：N10.
key.
6. Edit a signal block.
7. Press
8. Press
EOB
key.
INSERT
key, then perform automatic sequence number insertion.
5. OPERATIONS
5-45
11. BACKGROUND EDITING
(1) Enter EDIT or MEMORY mode.
(2) Press function key
PROG
.
(3) Press soft key [(OPRT)],then press soft key [BG-EDT].
The background editing screen is displayed [PROGRAM(BG-EDT) is
displayed at the top left of the screen].
(4) Edit a program on the background editing screen in the same way as for
ordinary program editing.
(5) After editing is completed, press soft key [(OPRT)], then press soft key
[BG-EDT]. The edited program is registered in foreground program
memory.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-46
5-6-7 SOFTWARE OPERATOR'S PANEL
OFFSET
SETTING
1. Press function key
.
, then press chapter selection soft key
2. Press the continuous menu key
[OPR].
3. The screen consists of several pages.
PAGE
Press page key
PAGE
or
until the desired screen is displayed.
OPERATOR`S PANEL
O0000 N00000
ABS
AFL
ZLK
ON
ON
ON
ON
ON
ON
ON
ON
CUT
:
:
:
:
:
:
:
:
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ACTUAL POSITION (ABSOLUTE)
Y
0.000
X
0.000
Z
0.000
S
0 T0000
MDI **** *** *** 16:05:59
[ MACRO ] [
] [ OPR ] [ TOOLLF ] [ (OPRT) ]
5. Move the cursor to the desired switch by pressing cursor key
or
.
6. Push the cursor move key
or
to match the mark ■ to an
arbitrary position and set the desired condition.
5. OPERATIONS
ABS：When the function is on，manual absolute is valid.
AFL：When the function is on，M、S、T command are disable.
ZLK：When the function is on ，it unnecessary zero return at restart the
program.
CUT：When the function is on ，spindle cutting protect will cancel.
5-47
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-48
5-7 G FUNCTION
The G code are divided into the following types
One-shot G code：The G code is effective only in the block in which it is
specified.
Model G code：The G code is effective until another G code of the same group
is specified.
G code Group
▲
G00
G01
Positioning
01
Circular interpolation CW
G03
Circular interpolation CCW
G04
Dwell
G09
00
G10
▲
Linear interpolation
G02
G07
▲
Meaning
G15
Hypothetical axis interpolation
Exact stop
Data setting
17
Polar coordinates command cancel
G16
Polar coordinates command
G17
XY plane selection
G18
02
G19
G20
▲
G21
▲
G22
ZX plane selection
YZ plane selection
06
04
Inch input
Metric input
Stored stroke limit ON
G23
Stored stroke limit OFF
G27
Reference point return check
G28
Reference point return
G29
00
Return from reference point
G30
Return to 2nd ,3rd,4th reference
G31
Skip function
5. OPERATIONS
G code Group
▲
G40
G41
Cutter radius compensation cancel
07
G42
G43
G44
G47
08
G49
▲
G50
00
G50.1
08
11
G53
▲
Tool length compensation cancel
Scaling cancel
18
Programmable mirror image cancel
Programmable mirror image
00
Local coordinate system setting
Machine coordinate system selection
Work coordinate system 1 selection
G55
Work coordinate system 2 selection
14
Work coordinate system 3 selection
G57
Work coordinate system 4 selection
G58
Work coordinate system 5 selection
G59
Work coordinate system 6 selection
G60
G65
G66
G67
G68
▲
Tool offset double increase
G54
G56
▲
Tool offset decrease
Scaling
G51.1
G52
Tool length compensation -
Tool offset double decrease
G51
▲
Tool length compensation +
Tool offset increase
G48
▲
Cutter radius compensation left
Cutter radius compensation right
G45
G46
Meaning
G69
00
12
16
Single direction positioning
Macro call
Macro modal call A
Macro model cancel
Coordinate system rotation
Coordinate system rotation cancel
5-49
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-50
G code Group
▲
G73
Peck drilling cycle
G74
Counter tapping cycle
G76
Fine boring cycle
G80
Canned cycle cancel
G81
Drilling cycle
G82
Drilling cycle
G83
Peck drilling cycle
Tapping cycle
G85
Boring cycle
G86
boring cycle
G87
Back boring cycle
G88
Boring cycle
G89
Boring cycle
G91
G92
▲
09
G84
G90
▲
Meaning
G98
03
00
10
G99
Absolute command
Incremental command
Work coordinate change
Canned cycle initial point return
Canned cycle R point return
NOTE :
1. G code marked ▲ are set when the power is turned on.
2. The G code of group 00 are not model and are effective only in block where
they are specified.
3. When two or more G codes of the same group are specified in the same
block, the one specified last is effective.
4. The G code of group 01 is specified when the canned cycle is executed, the
canned cycle is cancelled automatically to the state of G80.
5. OPERATIONS
5-51
5-8 F FUNCTION
The feedrate of linear interpolation (G01), circular interpolation (G02,G03),
and canned cycles is determined by the value following the F code.
Range: 1-10000 mm/min.
5-9 S FUNCTION
The speed of spindle is determined by the value following the S code.
M03(M04) and the S command must be in the same block.
Range:
30~20000rpm (Built - In)
1~15000rpm(direct coupling spindle)
5-10 T FUNCTION
The tool number is selected by using the T command. Normally T code is
used associated with M06. Please refer to CHAPTER 6 (ATC) for details.
5-52
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
5-11 M FUNCTION
M CODE
MEANING
M00
Program stop
M01
Option stop
M02
End of program
M03
Spindle forward rotation
M04
Spindle reverse rotation
M05
Spindle stop
M06
Auto tool change
NOTE
M07
M08
Coolant on
M09
Coolant off
M10
Z-axis interlock cancel on
M11
Z-axis interlock cancel off
M12
4TH axis clamp
OPTION
M13
4TH axis unclamp
OPTION
M14
5TH axis clamp
OPTION
M15
5TH axis unclamp
OPTION
M16
Coolant on for oil hole(spindle must rotary)
OPTION
M17
Coolant off for oil hole
OPTION
M18
M19
Spindle orientation
M20
Shower coolant on
OPTION
M21
Shower coolant off
OPTION
M22
OIL MIST ON
OPTION
M23
OIL MIST OFF
OPTION
M24
INDEX TABLE 1 START
OPTION
M25
5. OPERATIONS
M CODE
MEANING
NOTE
M26
M27
M28
M29
M30
End of program
M31
Spindle tool judge cancel
M32
Programming air blowing on
M33
Programming air blowing off
M34
Chip clean on
OPTION
M35
Chip clean off
OPTION
M36
M37
M38
Spindle air blow on
M39
Spindle air blow off
M40
M40 ON
OPTION
M41
M40 OFF
OPTION
M42
M42 ON
OPTION
M43
M42 OFF
OPTION
M44
M44 ON
OPTION
M45
M44 OFF
OPTION
M46
M46 ON
OPTION
M47
M46 OFF
OPTION
M48
M48 ON
(TOOL MEASURE AIR BLOW ON)
OPTION
M49
M48 OFF
(TOOL MEASURE AIR BLOW OFF)
OPTION
M50
OPTION
M51
OPTION
M52
M53
M54
M55
5-53
5-54
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
M CODE
MEANING
NOTE
M56
APC door up
OPTION
M57
APC door down
OPTION
M58
APC pallet up
OPTION
M59
APC pallet down
OPTION
M60
Automatic pallet change
OPTION
M61
Pallet and door up, pallet move to right
OPTION
M62
Pallet move to left, pallet and door down
OPTION
M66
Pallet move to left
OPTION
M67
Pallet move to right
OPTION
M68
Chip conveyor on
M69
Chip conveyor off
M70
Mirror image cancel
M71
X-axis mirror image
M72
Y-axis mirror image
M63
M64
M65
M73
M74
4 axis mirror image
OPTION
M75
M76
M77
M78
M79
M80
M81
Magazine forward
(Tool pot down)
M82
Magazine down
(Arm catch tool)
M83
Magazine up
M84
Magazine backward
M85
(Tool change)
(Arm retract)
(Tool pot up)
5. OPERATIONS
M CODE
MEANING
M86
M87
M88
M89
M90
M91
M92
M93
M94
Cutting protect cancel
M95
Cutting protect on
M96
M97
M98
Call sub-program
M99
End of sub-program
M601
Pallet A move to working area
M602
Pallet B move to working area
Note: ( ) mean the CAM type ATC.
NOTE
5-55
5-56
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
M00 (PROGRAM STOP) :
The program will stop at the block where M00 is read and other statuses
remain unchanged. The next block will be executed if the CYCLE START button
is pressed.
M01 (OPTION STOP) :
This command is the same as M00 except that it will be effective only when the
OPT. STOP button is pressed.
M03，M04，M05 :
M03(M04) and the S command must be in the same block to start the spindle.
To change the speed of the spindle when the spindle is rotating, simply use the
S command. The spindle desires to be stopped with command M05.
M06：
Automatic tool change. refer to CHAPTER 6.
M08，M09：
When the machine is machining, it can use by M08; and stop the coolant by M09.
1. Spindle must be rotating before M08 can be executed.
2. Coolant can be hold by M00, and M01.
3. Coolant also can be hold by M06.
M10，M11：
Z axis shall be move by manual when it interlock. At fist, enter command M10
at MDI mode to release interlock, and then move Z axis by HANDLE mode.
Cancel M10 by M11.
5. OPERATIONS
M12，M13：
M12 and M13 will be effective when rotary table is equipped.
M16，M17：
This function is use like M08 and M09. (spindle must rotary)
M32，M33：
This function is blowing air from the nozzle to clean chip from the tool is
machining.
M40~M49：
There are optional addition M functions.
5-57
5-58
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
M56~M59 :
That commands are for APC (Automatic pallet changer)only, refer to chapter 10.
M70，M71，M72 :
1. These commands must be used along in a block. They cannot be used with
any other command in a block.
2. The reference point of mirror image function is the current point (not the
origine). You may need to move to origin before using these commands.
M81，M82，M83，M84，M85 :
These commands are not effective in the MEM mode. Please refer Chapter 6 for
further explanations.
M94，M95:
When cutting protect on , the spindle must rotary in the cut mode(ex.G01,G02) .
If the spindle not rotary in cutting mode , SPINDLE SPEED =0, MODIFY
PROGRAM alarm display. It can cancel by M94 command .
When M94 command is on , cutting protect will cancel , until as follow :
1.M95 command is on.
2.The MDI key "Reset" is pushed.
3.M30 command is on .
If the software operator's panel "cut" is on , this function is cancel.
If it off , this function is on.
6-1 DRUM TYPE……………............................................... 6-2
6-1-1 COMMANDS FOR ATC.......................................... 6-2
6-1-2 PROCEDURE FOR ATC OPERATION....................… 6-3
6-1-3 ATC PROGRAMMING OPERATION…....................... 6-7
6-1-4 WRONG TOOL NUMBER...............…....….......……. 6-7
6-1-5 THE SETTING OF COUNTER………................…..... 6-8
6-1-6 TOOL NUMBER SETTING…………...............……….. 6-9
6-1-7 TOOL LOADING AND UNLOADING...............……….. 6-11
6-1-8 ADJUSTMENT OF THE TOOL EXCHANGING
POSITION IN THE Z-AXIS DIRECTION.................…… 6-13
6-2 CAM TYPE……......………………..………………………….. 6-14
6-2-1 COMMANDS FOR ATC……………........................... 6-14
6-2-2 PROCEDURE FOR ATC OPERATION..............…..…. 6-15
6-2-3 ATC PROGRAMMING OPERATION…………………….. 6-19
6-2-4 WRONG TOOL NUMBER.......................…..……….. 6-19
6-2-5 THE SETTING OF COUNTER……...............………… 6-20
6-2-6 TOOL NUMBER SETTING……..…..............…………. 6-21
6-2-7 KEEP RELAY AND TIMER………………………………. 6-23
6-2-8 TOOL LOADING AND UNLOADING...............……….. 6-25
6-2-9 ADJUSTMENT OF THE TOOL EXCHANGING
POSITION IN THE Z-AXIS DIRECTION..….....……….… 6-27
6-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6. AUTOMATIC TOOL CHANGE
6-1 DRUM TYPE
6-1-1 COMMANDS FOR ATC
M19 : Spindle orientation.
M81 : Magazine forward.
M82 : Magazine down.
M83 : Magazine up.
M84 : Magazine backward.
M6 : Automatic tool changing.
NOTE：
1. M06 cannot be executed if it is not used associated with T code in the same
block.
2. M81-M84 are used for correcting ATC positions in the MDI mode.
3. Z axis zero return when read “M6” command, please refer to appendix E.
6. AUTOMATIC TOOL CHANGE
6-1-2 PROCEDURE FOR ATC OPERATION
Zero point return on z axis
Execute M06T△△
Compare T code with
the number of tool in the
spindle
T＝D0
T△△M6 FINISH
T＝D0
Compare tool
number of spindle with tool
number of preparatory
position
D0＝C2
Magazine don’t stop rotating until the
magazine tool number is the same as the
number of tool in the spindle.
Spindle orientation (M19)
Magazine forward (M81)
Magazine down (M82)
Magazine rotates to search
for the tool number
Magazine upward (M83)
Magazine backward (M84)
M6 T△△FINISH
D0＝C2
6-3
6-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
The diagrams of Act’s behaviors
Step one：
a：The z axis shifts towards the tool
change point.
(G28 G91 Z0)
Step two：
a：Spindle orientation. (M19)
b：The magazine shifts towards the tool
change point. (M81)
6. AUTOMATIC TOOL CHANGE
Step three：
a：The magazine comes to the tool
change point.
b：The magazine buckles the tool.
c：The spindle releases the tool.(M82)
d：The magazine pulls the tool down.
(M82)
Step four：
a：To select a tool .
b：The magazine ascent. (M83)
c：The spindle clamps the tool.(M83)
6-5
6-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Step five：
a：The magazine withdraws from the tool
change point. (M84)
Step six：
a：All action finish for ATC.
b：The Z axis can move.
6. AUTOMATIC TOOL CHANGE
6-7
6-1-3 ATC PROGRAMMING OPERATION
Due to the construction and design of the ATC, T△△ and M06 commands
must be specified at same block to perform automatic tool changing. M06 will
not function without T command. If only T command is specified in MDI mode,
the tool magazine will rotate until the corresponding tool come to the stand-by
position. If "T△△M06" is specified, the corresponding tool will be inserted to
the spindle. If the specified tool is already on the spindle, "T△△M06" will be
skipped and continue executing next block of program.
6-1-4 WRONG TOOL NUMBER
If the command of tool number out of range (refer to Section 6-1-5 for
settings), the tool magazine will keep rotating and TOOL NUMBER ALARM will
appear.
6-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6-1-5 THE SETTING OF COUNTER
(1) Press function key
SYSTEM
.
(2) Press the softkey of [PMC]
[PMCPRM]
[COUNTER] , then the
screen displays as follows：
PMC PARAMETER (COUNTER) #001
NO
01
02
.
.
.
.
ADDRESS
C00
C04
.
.
.
.
MONIT
RUN
PRESET
CURRENT
△△(NOTE1) △△(NOTE2)
0
0
.
.
.
.
.
.
.
.
NOTE 1：The capacity of tool magazine is a fixed number.
MCV-510、MCV-610、MCV-720：16
MCV-1020BA：16
MCV-1020BA＋24TOOL：24
MCV-1250B＋24TOOL：24
NOTE 2：This is the number of tool at the stand-by position of tool magazine, If
this value is not identical to that of the tool number at the stand-by
position, errors will occur. In this case, the value must be changed so
that it is identical to that of the tool number at the stand-by position.
6. AUTOMATIC TOOL CHANGE
6-9
6-1-6 TOOL NUMBER SETTING
(1) Open the program protect key and turn to MDI mode.
(2) Press [PMC]
[PMCPRM]
[ DATA] key,then the screen display
as follows：
PMC DATA TBL CONTROL #001
TABLE COUNTS＝3
GROUP
MONIT RUN
NO
001
002
003
NO.OF DATA
(NOTE 4)
10
4 (NOTE 5)
ADDRESS
D0000
D0050
D0080
PARAMETER TYPE
00000001
0
00000001
1
00000001
1
(NOTE 3)
NOTE 3：
PARAMETER
#7
#6
#5
#4
#3
#2
#1
#0
0:Binary format
1:BCD format
0:without protection for input
1:with protection for input
NOTE 4：Total of DATA TABLE (Tool magazine total＋1)
MCV-510、MCV-610、MCV-720：17
MCV-1020BA：17
MCV-1020BA＋24TOOL：25
MCV-1250B＋24TOOL：25
NOTE5 : Don't change it .
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6-10
(3) Press [G.DATA]key, the screen displays as follows：
PMC PRM (DATA) 001/001
NO
000
001
002
..
..
.
008
009
ADDRESS
D0000
D0001
D0002
..
..
.
MONIT RUN
DATA
(SPINDLE TOOL NO.)
1
2
..
(NOTE 7)
..
.
(NOTE 6)
NOTE6：Valid number of address.
MCV-510、MCV-610、MCV-720：D1~D16
MCV-1020BA：D1~D16
MCV-1020BA＋24TOOL：D1~D24
MCV-1250B＋24TOOL：D1~24
NOTE7：Valid number of DATA TABLE.
MCV-510、MCV-610、MCV-720、MCV-1020BA：1~16
MCV-1020BA＋24TOOL：1~24
MCV-1250B＋24TOOL：1~24
6. AUTOMATIC TOOL CHANGE
6-11
6-1-7 TOOL LOADING AND UNLOADING
■ MANUAL OPERATION
1. UNLOADING
(1) Turn the mode selector to manual mode (HANDLE, JOG, RAPID, or ZERO
RETURN).
(2) Move the spindle to appropriate position.
(3) Hold the tool tightly with left hand and press down the TOOL
CLAMP/UNCLAMP button for about 0.5 second, until the tool is released
from the spindle.
2. LOADING
(1) Turn the mode selector to manual mode (HANDLE, JOG, RAPID, or ZERO
RETURN).
(2) Move the spindle to appropriate position.
(3) Clean the tapper of the spindle and the tool shank.
(4) Press down the TOOL CLAMP/UNCLAMP button for about 0.5 second
with your right hand. At the same time, insert the tool into the spindle with
your left hand. Note that the tool may need to be wrapped to protect your
hand. Make sure that the tool has been correctly clamped before releasing
the button.
6-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ ATC (Automatic Tool Changing)
1. Perform Z-axis zero return before automatic tool changing.
2. Make sure that the numbers of the tools in tool magazine match those
specified in the program.
3. Automatic tool changing can be done in MDI mode. For example, if the
command M06 T05; is given in MDI mode, the 5th tool in tool magazine will
be inserted into the spindle.
6. AUTOMATIC TOOL CHANGE
6-13
6-1-8 ADJUSTMENT OF THE TOOL EXCHANGING
POSITION IN THE Z-AXIS DIRECTION
(1) Perform Z-axis zero return with no tool in the spindle. Then visually check
the heights of the headstock and tool magazine to see if they may interfere
with each other. If interferences may occur, change the value of the
parameter 18M: 1850. Higher (lower) value of the parameter will increase
(decrease) the height of the spindle. The unit of the value is mm (millimeter).
(2) Turn off the machine and then turn on the machine again. Move the spindle
down and then perform zero return. Then visually check the heights of the
headstock and tool magazine to see if they may interfere with each other. If
interference may occur, change the value of the parameter. Repeat the
above procedures until no interference may occur.
(3) Perform Z-axis zero return and then insert a tool into the spindle. Enter M19
→ EOB → INSERT → CYCLE START.
(4) Enter M81 → EOB → INSERT → CYCLE START and the tool magazine will
move towards the spindle. Check if the relative position between the spindle
and the tool magazine is appropriate. If not, correct it as follows:
(a) Cancel the Z axis relative coordinate in RELATIVE screen.
(b) Input M10 in MDI mode to release the Z-axis interlock.
(c) Turn the mode selector to the HANDLE position and then use hand wheel
to adjust the Z axis.
(d) Enter M84 → EOB →
INSERT → CYCLE START and the tool
magazine will move away from the spindle.
(e) The Z component of the relative coordinates shown on the screen is the
amount to be changed. Add this value to that of the parameter 18M: 1850.
(f) Turn off the machine and then turn on the machine.
(5) Repeat (3) and (4) until the tool changing position in the Z-axis direction is
correct.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6-14
6-2 CAM TYPE
6-2-1 COMMANDS FOR ATC
M19：SPINDLE ORIENTATION
M81：TOOL POT DOWN
M82：ARM CATCH TOOL
M83：TOOL CHANGE (ARM ROTARY)
M84：ARM RETRACT
M85：TOOL POT UP
M6：AUTO TOOL CHANGE
NOTE：
1. In MDI mode, the M81~M85, are used for releasing the ATC trouble.
2. When M06 was interrupted, can change to MDI mode, then after execute
M19、M88, push buttons of
ATC
ARM
and “CALL LIGHT” together on the
panel that execute the ATC cycle step by step.
3. Z axis zero return when read “M6” command, please refer to appendix E.
6. AUTOMATIC TOOL CHANGE
6-15
6-2-2 PROCEDURE FOR ATC OPERATION
(A) The simultaneous operation sequence of T and M6 code.
Z axis reference point return
Execute M06T△△
Execute M6
Compare T code and
spindle tool number
T＝D0
T△△M6 FINISH
T＝D0
Compare T code and
reserved tool number
T＝C2
Magazine rotate to reserved tool
number same as T code
Spindle orientation (M19)
Tool pot down (M81)
Arm catch tool (M82)
Tool change (M83)
Arm back home position (M84)
Tool pot up (M85)
M6 T△△tool change finish
T＝C2
6-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
(B) Sequence of ATC single block operation
Z axis reference point return
M19 (spindle orientation)
Spindle orientation finish
M81 (tool pot down)
Tool pot down finish
M82 (arm catch tool )
Arm catch tool finish
M85
M83 (tool change)
M82
Tool change finish
M84 (arm retract)
Arm retract finish
M85 (tool pot up)
Tool up finish
M84
6. AUTOMATIC TOOL CHANGE
6-17
The diagrams of CAM TYPE ATC`s behaviors
STEP 1：
a. Magazine rotation for the standby tool no.
b. Z-axis returns to the tool-changing
position (G91 G28 Z0)
c. The spindle orientation (M19).
STEP 2：
a. Tool pot down (M81).
STEP 3：
a. Arm catch tool (M82).
6-18
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
STEP 4：
a. Tool change (arm rotary) (M83)
(1) Tool unclamp for spindle.
(2) Arm down.
(3) 180° rotation.
(4) Arm up.
(5) Tool clamp for spindle.
STEP 5：
a. Arm retract (M84)
STEP 6：
a. Tool pot up (M85)
b. ATC complete.
c. Magazine can rotates.
6. AUTOMATIC TOOL CHANGE
6-19
6-2-3 ATC PROGRAMMING OPERATION
ATC system is single direct in design, T△△ and M6 can either work
or together in a single block.
If only T△△input, magazine rotate to T△△ reserved tool position for
waiting.
If only M06 input, Arm exchange the tool of spindle and reserved tool pot.
While M06 and T△△ input together, magazine select the T△△ to reserved
position then execute M06 to exchange the tools of spindle and reserved tool.
6-2-4 WRONG TOOL NUMBER
If the T code is same as the spindle tool, there will be the "T CODE＝
SPINDLE ALARM" display.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6-20
6-2-5 THE SETTING OF COUNTER
(1) Press the function key of
SYSTEM
(2) Press the softkey of [PMC]
.
[PMCPRM]
[COUNTER]then the screen
displays as follows：
PMC PARAMETER (COUNTER) #001
NO
01
ADDRESS
C00
MONIT
RUN
PRESET
CURRENT
△△(NOTE1) △△(NOTE2)
NOTE1：The capacity of tool magazine is a fixed number.
24 tools (standard)：24
30 tools (option)：30
32 tools (option)：32
40 tools (option)：40
NOTE2：This is the number of tool at the stand-by position of tool Magazine, If
this value is not identical to that of the tool number at the stand-by
position, errors will occur. In this case, the value must be changed so
that it is identical to that of the tool number at the stand-by position.
6. AUTOMATIC TOOL CHANGE
6-2-6 TOOL NUMBER SETTING
(1) Open the program protect key and turn to MDI mode.
[PMCPRM]
(2) Press[PMC]
[DATA]softkey, then the screen display as
follows：
PMC DATA TBL CONTROL #001
TABLE COUNTS＝3
GROUP
MONIT RUN
NO
001
002
003
NO.OF DATA
(NOTE 4)
10
4 (NOTE 5)
ADDRESS
D0000
D0050
D0080
PARAMETER TYPE
00000001
0
00000001
1
00000001
1
(NOTE 3)
NOTE 3：
PARAMETER
#7
#6
#5
#4
#3
#2
#1
#0
0:Binary format
1:BCD format
0:without protection for input
1:with protection for input
NOTE 4：Total of DATA TABLE (Tool pot total＋1)
24 tools (standard)：25
30 tools (option)：31
32 tools (option)：33
40 tools (option)：41
NOTE5：Don't change it.
6-21
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6-22
(3) Press[G.DATA]key, screen display as follows：
PMC PRM (DATA) 001/001
NO
000
001
002
..
..
.
008
009
ADDRESS
D0000
D0001
D0002
..
..
.
MONIT RUN
DATA
(SPINDLE TOOL NO.)
1
2
..
(NOTE 7)
..
.
(NOTE 6)
NOTE6：Valid number of ADDRESS
24 tools (standard)：D1~D24
30 tools (option)：D1~D30
32 tools (option)：D1~D32
40 tools (option)：D1~D40
NOTE7：The number will be changed according to tool change.
6. AUTOMATIC TOOL CHANGE
6-23
6-2-7 KEEP RELAY AND TIMER
KEEP RELAY
K12
＃7
CAM
T24/30
＃6
＃5
＃4
＃3
＃2
＃1
＃0
M6.C5
M6.C4
M6.C3
M6.C2
M6.C1
M6.C0
＃0
M6.C0：Magazine ready.
0：NO
1：YES
＃1
M6.C1：Spindle orientation finish ,ready to execute the tool pot down
movement(M81)
0：NO
1：YES
＃2
M6.C2：Tool pot down finish, ready to execute arm catch tool (M82)or
tool pot up (M85) movement.
0：NO
1：YES
＃3
M6.C3：Arm catch tool finish ready to execute tool change (M83)or arm
retract (M84)movement.
0：NO
1：YES
＃4
M6.C4：Tool change finish, ready to execute arm retract (M84)
movement.
0：NO
1：YES
＃5
M6.C5：Arm retract finish ready to execute tool pot up (M85)movement.
0：NO
1：YES
＃7
T24/30：Tool capacity
0：24 tools (standard)
1：30 tools (option)
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
6-24
TIMER
TMR NO DATA
ATC
NOTE
6
20000
CAM MAGAZINE ROTATION ALARM DELAY TIMER
7
700
CAM COUNTER ALARM DELAY TIMER 1
8
700
CAM COUNTER ALARM DELAY TIMER 2
9
1000
CAM COUNTER DELAY TIMER
10
1000
ALL
11
2000
CAM ARM CATCH TOOL ALARM TIMER
12
500
CAM TOOL UNCLAMP FINISH TIMER
14
500
CAM POT HORIZONTAL FINISH TIMER
15
500
CAM POT VERTICAL FINISH TIMER
16
1500
CAM TOOL CLAMP TIMER
23
5000
CAM POT ALARM DELAY TIMER
32
60000
CAM MAGAZINE ROTATION LIMIT TIMER
SPINDLE ORIENTATION DELAY TIMER
6. AUTOMATIC TOOL CHANGE
6-25
6-2-8 TOOL LOADING AND UNLOADING
■ MANUAL OPERATION
1. UNLOADING
(1) Turn the mode selector to manual mode (HANDLE, JOG, RAPID, or ZERO
RETURN).
(2) Move the spindle to appropriate position.
(3) Hold the tool tightly with left hand and press down the TOOL
CLAMP/UNCLAMP button for about 0.5 second until the tool is released
from the spindle.
2. LOADING
(1) Turn the mode selector to manual mode (HANDLE, JOG, RAPID, or ZERO
RETURN).
(2) Move the spindle to appropriate position.
(3) Clean the tapper of the spindle and the tool shank.
(4) Press down the TOOL CLAMP/UNCLAMP button for about 0.5 second
with your right hand. At the same time, insert the tool into the spindle with
your left hand. Note that the tool may need to be wrapped to protect your
hand. Make sure that the tool has been correctly clamped before releasing
the button.
6-26
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
■ ATC (Automatic Tool Changing)
(1) Perform Z-axis zero return before automatic tool changing.
(2) Make sure that the numbers of the tools in tool magazine match those
specified in the program.
(3) Automatic tool changing can be done in MDI mode. For example, if the
command M06 T05; is given in MDI mode, the 5th tool in tool magazine will
be inserted into the spindle.
6. AUTOMATIC TOOL CHANGE
6-27
6-2-9 ADJUSTMENT OF THE TOOL EXCHANGING
POSITION IN THE Z-AXIS DIRECTION
(1) Perform Z-axis zero return with no tool in the spindle. Then visually check
the heights of the headstock and tool magazine to see if they may interfere
with each other. If interferences may occur, change the value of the
parameter 18M: 1850. Higher (lower) value of the parameter will increase
(decrease) the height of the spindle. The unit of the value is mm (millimeter).
(2) Turn off the machine and then turn on the machine again. Move the spindle
down and then perform zero return. Then visually check the heights of the
headstock and tool magazine to see if they may interfere with each other. If
interference may occur, change the value of the parameter. Repeat the
above procedures until no interference may occur.
(3) Perform Z-axis zero return and then insert a tool into the spindle. Enter M19
→ EOB → INSERT→ CYCLE START.
(4) Enter M81 → EOB → INSERT → CYCLE START and the tool magazine will
move down.
(5) Enter M82 → EOB → INSERT → CYCLE START and the tool magazine will
move towards the spindle. Check if the relative position between the spindle
and the tool magazine is appropriate. If not, correct it as follows:
(a) Cancel the Z axis relative coordinate in RELATIVE screen.
(b) Input M10 in MDI mode to release the Z-axis interlock.
(c) Turn the mode selector to the HANDLE position and then use hand wheel
to adjust the Z axis.
(d) Enter M84 → EOB → INSERT → CYCLE START and the tool magazine
will move away from the spindle.
(e) Enter M85 → EOB → INSERT → CYCLE START and the tool pot will
move up.
(f) The Z component of the relative coordinates shown on the screen is the
amount to be changed. Add this value to that of the parameter 18M：1850.
(g) Turn off the machine and then turn on the machine.
(6) Repeat (3) and (4) and (5) until the tool changing position in the Z-axis
direction is correct.
7-1 LEVEL ADJUSTMENT.................................................. 7-2
7-2 ADJUSTMENT AND SETTING OF THE PNEUMATIC AIR
PRESSURE.............................….........................….... 7-2
7-3 TIMER.....................................…...............….........… 7-3
7-3-1 SETTING OF DRUM TYPE............……………………. 7-3
7-3-2 SETTING OF CAM TYPE.........………………..………. 7-5
7-3-3 FIX TIMER.....................................………….……. 7-7
7-4 KEEP RELAY.................................................…......… 7-9
7-5 DATA TABLE.........................................…......…...... 7-24
7-6 CHAIN APC (CAM ATC) TIMER……………………………….. 7-25
7-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7. SETTING AND ADJUSTMENT
7-1 LEVEL ADJUSTMENT
Please refer to Section 4-3 for level adjustment.
7-2 ADJUSTMENT AND SETTING OF THE
PNEUMATIC AIR PRESSURE
The F.R.L pneumatic unit is located as shown in the figure. The required air
pressure is about 5-7 kg/cm2. To adjust the air pressure of the F. R. L. unit, pull
and rotate the adjusting bolt, as shown in the figure.
AIR BLOW
SPINDLE
AIR
F.R.L
7. SETTING AND ADJUSTMENT
7-3
7-3 TIMER
7-3-1 SETTING OF DRUM TYPE
TMR NO. DATA
1
NOTE
600000 LUB. OIL OFF TIMER
2
6000
AIR PRESSURE CHECK DELAY TMR WHEN PALLET DOWN
3
60000 CHIP CONVEYOR ON
4
60000 CHIP CLEAN 1 ON
5
60000 CHIP CLEAN 2 ON
6
1000
SPINDLE ORIENTATION FINISH TIMER
7
500
MAGAZINE FORWARD
8
60000 MAGAZINE ROTATION LIMIT TIME
9
3000
SPINDLE AIR BLOW TIMER
10
500
TOOL UNCLAMP TIMER
11
M40/M41 DELAY TIMER
12
M42/M43 DELAY TIMER
13
M44/M45 DELAY TIMER
14
M46/M47 DELAY TIMER
15
M48/M49 DELAY TIMER
16
1500
PALLET LEFT ARRIVAL DELAY TIMER
17
1500
PALLET RIGHT ARRIVAL DELAY TIMER
18
3000
H/L WIRE ALARM DELAY TIMER
19
3000
PALLET UP ARRIVAL DELAY TIMER
20
3000
PALLET DOWN ARRIVAL DELAY TIMER
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-4
TMR NO. DATA
21
NOTE
1000
CALL LIGHT DELAY TIMER(AUTO POWER OFF)
24
7000
AUTO LUBRICATION HYDRAULIC DETECT DELAY TIMER
25
200
4TH AXIS CLAMP DELAY TIMER
26
200
4TH AXIS UNCLAMP DELAY TIMER
5000
AIR PRESSURE CHECK TIMER
22
23
27
28
29
30
31
32
33
34
35
36
37
38
39
40
NOTE：(
)FOR MCV-1020BA.
7. SETTING AND ADJUSTMENT
7-5
7-3-2 SETTING OF CAM TYPE
TMR NO. DATA
1
NOTE
600000 LUB. OIL OFF TIMER
2
6000
AIR PRESSURE CHECK DELAY TMR WHEN PALLET DOWN
3
60000 CHIP CONVEYOR ON
4
60000 CHIP CLEAN 1 ON
5
60000 CHIP CLEAN 2 ON
6
20000 MAGAZINE ROTATION ALARM DELAY TIMER
7
700
COUNTER ALARM DELAY TIMER 1
8
700
COUNTER ALARM DELAY TIMER 2
9
1000
COUNTER DELAY TIMER
10
1000
ORIENTATION FINISH TIMER
11
2000
ARM CATCH TOOL ALARM TIMER
12
500
TOOL UNCLAMP FINISH TIMER
13
1500
PALLET LEFT ARRIVAL DELAY TIMER
14
500
POT HORIZONTAL FINISH TIMER
15
500
POT VERTICAL FINISH TIMER
16
500
TOOL CLAMP TIMER
17
1500
PALLET RIGHT ARRIVAL DELAY TIMER
18
3000
H/L WIRE ALARM DELAY TIMER
19
3000
PALLET UP ARRIVAL DELAY TIMER
20
3000
PALLET DOWN ARRIVAL DELAY TIMER
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-6
TMR NO. DATA
NOTE
21
1000
CALL LIGHT DELAY TIMER(AUTO POWER OFF)
22
60000 MAGAZINE ROTATION LIMIT TIME
23
5000
POT ALARM DELAY TIMER
24
7000
AUTO LUBRICATION HYDRAULIC DETECT DELAY TIMER
25
200
4TH AXIS CLAMP DELAY TIMER
26
200
4TH AXIS UNCLAMP DELAY TIMER
27
M40/M41 DELAY TIMER
28
M42/M43 DELAY TIMER
29
M44/M45 DELAY TIMER
30
M46/M47 DELAY TIMER
31
M48/M49 DELAY TIMER
32
33
34
35
36
37
38
39
40
5000
AIR PRESSURE CHECK TIMER
7. SETTING AND ADJUSTMENT
7-7
7-3-3 FIX TIMER
DRUM TYPE
TMR NO.
DATA
NOTE
01
500
LED FLASH ON
02
500
LED FLASH OFF
03
3000
SPINDEL RESET TIMER
04
7000
HYD PRESSURE CHECK DELAY TIMER
05
500
SPINDLE STOP DELAY TMR WHEN SAFETY DOOR OPEN
07
1000
EXTERNAL DATA INPUT DELAY TIMER
08
1000
AUTO START DELAY TIMER
09
60000
CHIP CONVEYOR OFF
10
10000
4TH AXIS CLAMP/UNCLAMP ALARM DELAY TIMER
11
30000
AUTO LUBRICATION ON TIMER
14
7000
ALARM DELAY TIMER
15
500
CUTTING MODE CHECK IN M CODE DELAY TIMER
16
500
CUTTING MODE CHECK IN T CODE DELAY TIMER
17
500
CUTTING MODE CHECK IN S CODE DELAY TIMER
06
12
13
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-8
CAM TYPE
TMR NO.
DATA
NOTE
01
500
LED FLASH ON
02
500
LED FLASH OFF
03
200
COUNTER ALARM DELAY TIMER
04
7000
HYD PRESSURE CHECK DELAY TIMER
05
500
SPINDLE STOP DELAY TMR WHEN SAFETY DOOR OPEN
06
1000
MESSAGE TIMER
07
1000
EXTERNAL DATA INPUT DELAY TIMER
08
1000
AUTO START DELAY TIMER
09
60000
CHIP CONVEYOR OFF
10
10000
4TH AXIS CLAMP/UNCLAMP ALARM DELAY TIMER
11
30000
AUTO LUBRICATION ON TIMER
12
50
ARM CW TIMER
13
50
ARM CCW TIMER
14
7000
ALARM DELAY TIMER
15
500
T CODE DELAY TIMER
16
3000
SPINDEL RESET TIMER
17
500
CUTTING MODE CHECK IN M CODE DELAY TIMER
18
500
CUTTING MODE CHECK IN T CODE DELAY TIMER
19
500
CUTTING MODE CHECK IN S CODE DELAY TIMER
7. SETTING AND ADJUSTMENT
7-4 KEEP RELAY
＃7
K0
＃6
DRUM
CAM
ARM.K TUC.K
＃5
＃4
＃3
＃2
＃1
＃0
TAP.A P.TOOL SP.CYC M.SP
AL.SP
AIR.K
TAP.A P.TOOL SP.CYC M.SP
AL.SP
AIR.K
＃0
AIR.K：When tool unclamp in manual mode, spindle air blow
0：unvalid
1：valid
＃1
AL.SP：When alarm, spindle stop
0：valid
1：unvalid
＃2
M.SP：When M00、M01
0：spindle stop
1：spindle not stop
＃3
SP.CYC：When M00、M01, spindle is stop (K0.2=0)
0：push cycle start, spindle start again
1：push cycle start, spindle not start
＃4
P.TOOL：Tool number display
0：display prepare tool number
1：display prepare tool pot
＃5
TAP.A：AIR blow in rigid tap
0：unvalid
1：valid
＃6
TUC.K：Tool clamp/unclamp
0：clamp
1：unclamp
＃7
ARM.K：ARM position
0：not in catch position
1：in catch position
7-9
7-10
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
K1
＃7
＃6
＃5
＃4
＃3
＃2
＃1
＃0
DRUM
OIL
M6.ORI
M.COL SP.COL M6.COL
COL
CAM
OIL
M6.ORI
M.COL SP.COL M6.COL
COL
＃0
COL：Under the K1.1, K1.2, K1.3 condition, the coolant will be
0：valid
1：unvalid
＃1
M6.COL：When M6, the coolant will be (K1.0=0)
0：OFF
1：ON
＃2
SP.COL：When spindle stop, the coolant will be (K1.0=0)
0：OFF
1：ON
＃3
M.COL：Under M00、M01, the coolant will be (K1.0=0)
0：OFF
1：ON
＃6
M6.ORI：After M6, spindle orientation release
0：valid
1：unvalid
＃7
OIL：Auto lubrication system
0：oil out by timer
1：oil out when axis move
7. SETTING AND ADJUSTMENT
＃7
K2
＃6
＃5
＃4
＃3
＃2
＃1
＃0
DRUM
ISB/ISC ZER.K RT.K
PWR.OF
AL.L
ST.L
CAL.L
CAM
ISB/ISC ZER.K RT.K
PWR.OF
AL.L
ST.L
CAL.L
＃0
CAL.L：CALL LIGHT
0：valid
1：unvalid
＃1
ST.L：Green call light (working) (OPTIONAL)
0：unvalid
1：valid
＃2
AL.L：Red call light (alarm) (OPTIONAL)
0：unvalid
1：valid
＃3
PWR.OF：When alarm, the auto power off
0：unvalid
1：valid
＃5
RT.K：To confirm rapid feed that use push button
0：valid
1：unvalid
＃6
ZER.K：Zero return remembrance
0：valid
1：unvalid
＃7
ISB/ISC：Manual handle feed rate select
0：ISB (decimal 3 digits)
1：ISC (decimal 4 digits)
7-11
7-12
K3
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
＃7
DRUM ZRP.H
CAM
ZRP.H
＃6
＃5
＃4
＃3
＃2
＃1
＃0
YRP.H
XRP.H B.MEM A.MEM
45MEM ZRN.X
ZR.H
YRP.H
XRP.H B.MEM A.MEM
45MEM ZRN.X
ZR.H
＃0
ZR.H：After power on, cycle start and rapid 100% valid
0：must be zero return of three axes
1：must be not zero return of three axes
＃1
ZRN.X：X axis zero return direction
0：negative direction
1：positive direction
＃2
45MEM：A、B axis zero return remembrance
0：valid
1：unvalid
＃3
A.MEM：A axis zero position
0：don’t memory
1：memory
＃4
B.MEM：B axis zero position
0：don’t memory
1：memory
＃5
XRP.H：X axis zero position
0：don’t memory
1：memory
＃6
YRP.H：Y axis zero position
0：don’t memory
1：memory
＃7
ZRP.H：Z axis zero position
0：don’t memory
1：memory
7. SETTING AND ADJUSTMENT
K4
＃7
DRUM HYDP.K
CAM
HYDP.K
＃6
＃5
＃4
＃3
＃2
＃1
＃0
HL.K
5.K
DB.C
HL.K
5.K
DB.C
＃0
DB.C：Draw bar oil level check signal (X2.0)
0：valid
1：unvalid
＃4
5.K：5TH use
0：unvalid
1：valid
＃6
HL.K：SPINDLE WITH H/L WIRE
0：unvalid
1：valid
＃7
HYDP.K：HYD pressure check (X9.6)
0：unvalid
1：valid
7-13
7-14
K5
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
＃7
＃6
＃5
＃4
＃3
＃2
＃1
＃0
DRUM APCDIT APCRDM APCRDH DUP.H TBUP.H XY.INT APC.B APC.A
CAM APCDIT APCRDM APCRDH DUP.H TBUP.H XY.INT APC.B APC.A
＃0
APC.A：Pallet A at the APC side
0：no pallet
1：pallet
＃1
APC.B：Pallet B at the APC side
0：no pallet
1：pallet
＃2
XY.INT：X、Y axes interlock when APC pallet up
(if with APC, it should be set 1)
0：unvalid
1：valid
＃3
TBUP.H：APC pallet
0：down
1：up
＃4
DUP.H：APC DOOR
0：down
1：up
＃5
APCRDH：APC READY signal
0：OFF
1：ON
＃6
APCRDM：APC READY
0：be controlled by the APC operation panel push button
1：always ready
＃7
APCDIT：APC side door interlock signal
0：unvalid
1：valid
7. SETTING AND ADJUSTMENT
K6
＃7
＃6
＃5
＃4
＃3
＃2
＃1
7-15
＃0
DRUM APC.PC
AIR.PC M30.STC M30.ST M30.CL
CAM APC.PC
AIR.PC M30.STC M30.ST M30.CL
＃0
M30.CL：The machine will call another pallet program after M30 command
0：unvalid
1：valid
＃1
M30.ST：After M30, auto cycle start (with APC)
0：unvalid
1：valid
＃2
M30.STC：Auto cycle start (K6.1=1)
0：cycle start once
1：cycle start continually
＃3
AIR.PC：Air blow(chain type APC)
0：when pallet down
1：when pallet up
＃7
APC.PC：When pallet down, air pressure detect signal
0：unvalid
1：valid
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-16
K7
＃7
＃6
＃5
＃4
＃3
＃2
DRUM
BPR.A
APR.A
BPL.A
APL.A
4UCL
4CL
4UCL.M 4CL.M
CAM
BPR.A
APR.A
BPL.A
APL.A
4UCL
4CL
4UCL.M 4CL.M
＃0
4CL.M：4TH axis clamp signal (X3.6)
0：unused
1：is used
＃1
4UCL.M：4TH axis unclamp signal (X3.7)
0：unused
1：is used
＃2
4CL：When the clamp signal is used for 4TH axis
0：NO (normal open)
1：NC (normal close)
＃3
4UCL：When the unclamp signal is used for 4TH axis
0：NO (normal open)
1：NC (normal close)
＃4
APL.A：A pallet left arrival
0：finish
1：not finish
＃5
BPL.A：B pallet left arrival
0：finish
1：not finish
＃6
APR.A：A pallet right arrival
0：finish
1：not finish
＃7
BPR.A：B pallet right arrival
0：finish
1：not finish
＃1
＃0
7. SETTING AND ADJUSTMENT
K8
＃7
＃6
＃5
＃4
DRUM
NI.AL
CIP.TC JOG.H
CAM
NI.AL
CIP.TC JOG.H
＃3
＃2
7-17
＃1
＃0
INTRP
T.JOG
T.HAN
INTRP
T.JOG
T.HAN
＃0
T.HAN：Playback(TEACH IN HANDLE)(OPTIONAL)
0：unvalid
1：valid
＃1
T.JOG：Playback(TEACH IN JOG)(OPTIONAL)
0：unvalid
1：valid
＃3
INTRP：Manual handle interruption
0：unvalid
1：valid
＃4
JOG.H：Press positive or negative direction signal button at the jog mode
0：no remain
1：remain
＃5
CIP.TC：Chip conveyor start
0：manual (push button)
1：auto (when M6, M01, M00, M02, and M30)
＃7
NI.AL：Nitrogen balance pressure alarm
0：unvalid
1：valid
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-18
＃7
K9
DRUM
CAM
＃6
＃5
＃4
＃3
SLUB.K
＃2
＃1
＃0
MP.DINT SDINT
DINT
SLUB.K ATCM84 ATCM83 ATCM82 MP.DINT SDINT
DINT
＃0
DINT：Door interlock signal (X2.4)
0：NO (normal open)
1：NC (normal close)
＃1
SDINT：When door interlock is on, spindle speed
0：50 RPM below
1：control by S command
＃2
MP.DINT：When door interlock is on, MPG feed
0：X1、X10 valid
1：X1、X10、X100 valid
＃3
ATCM82：ATC troubleshooting
0：not in M82
1：in M82
＃4
ATCM83：ATC troubleshooting
0：not in M83
1：in M83
＃5
ATCM84：ATC troubleshooting
0：not in M84
1：in M84
＃6
SLUB.K：Air pressure alarm select
0：generally spindle
1：oil lub spindle
7. SETTING AND ADJUSTMENT
K10
＃7
＃6
DRUM SP.LUB TL.AL
CAM SP.LUB TL.AL
＃5
＃4
LUB.K
＃3
＃2
＃1
＃0
AIR.AL S.COL
OIL.AL
LUB.K DB.CK AIR.AL S.COL
OIL.AL
＃0
OIL.AL：Lubrication alarm display
0：valid
1：unvalid
＃2
S.COL：Spindle cooling alarm display
0：valid
1：unvalid
＃3
AIR.AL：Air pressure isn’t enough alarm display
0：valid
1：unvalid
＃4
DB.CK：Draw bar oil level isn’t enough alarm display
0：valid
1：unvalid
＃5
LUB.K：Lubrication control
0：valid
1：unvalid
＃6
TL.AL：T code = spindle tool alarm display
0：valid
1：unvalid
＃7
SP.LUB：Spindle oil-air lubrication alarm display
0：unvalid
1：valid
7-19
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-20
＃7
K11
＃6
＃5
＃4
＃3
＃2
＃1
＃0
DRUM
CAM
POT.K M6.RST
＃0
M6.RST：M6 reset
0：normal
1：reset
＃1
POT.K：Pot to advance vertical
0：unuse
1：use
7. SETTING AND ADJUSTMENT
K12
＃7
DRUM
T16/24
CAM
T24/30
＃6
7-21
＃5
＃4
＃3
＃2
＃1
＃0
M6.C5
M6.C4
M6.C3
M6.C2
M6.C1
M6.C0
＃0
M6.C0：Magazine ready
0：NO
1：YES
＃1
M6.C1：Spindle orientation finish, ready to execute the tool pot down
movement (M81)
0：NO
1：YES
＃2
M6.C2：Tool pot down finish, ready to execute arm catch tool (M82) or
tool pot up (M85) movement
0：NO
1：YES
＃3
M6.C3：Arm catch tool finish ready to execute tool change (M83) or arm
retract (M84) movement
0：NO
1：YES
＃4
M6.C4：Tool change finish, ready to execute arm retract(M84)
movement
0：NO
1：YES
＃5
M6.C5：Arm retract finish ready to execute tool pot up (M85) movement
0：NO
1：YES
＃7
(DRUM) T16/24：The capacity of tool magazine
0：16 tools
1：24 tools
＃7
(CAM) T24/30：The capacity of tool magazine
0：24 tools
1：30 tools
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-22
＃7
＃6
＃5
DRUM
MIT.2
MIT.1
M48M.K M46M.K M44M.K M42M.K M40M.K
CAM
MIT.2
MIT.1
M48M.K M46M.K M44M.K M42M.K M40M.K
K13
＃0
M40M.K：M40 finish detect
0：unused
1：used
＃1
M42M.K：M42 finish detect
0：unused
1：used
＃2
M44M.K：M44 finish detect
0：unused
1：used
＃3
M46M.K：M46 finish detect
0：unused
1：used
＃4
M48M.K：M48 finish detect
0：unused
1：used
＃5
MIT.1：M40、M42 interlock
0：unused
1：used
＃6
MIT.2：M44、M46 interlock
0：unused
1：used
＃4
＃3
＃2
＃1
＃0
7. SETTING AND ADJUSTMENT
＃7
K14
＃6
＃5
＃4
＃3
＃2
＃1
7-23
＃0
DRUM
M48H.K M46H.K M44H.K M42H.K M40H.K
CAM
M48H.K M46H.K M44H.K M42H.K M40H.K
＃0
M40H.K：M40 output hold
0：hold
1：not hold
＃1
M42H.K：M42 output hold
0：hold
1：not hold
＃2
M44H.K：M44 output hold
0：hold
1：not hold
＃3
M46H.K：M46 output hold
0：hold
1：not hold
＃4
M48H.K：M48 output hold
0：hold
1：not hold
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-24
7-5 DATA TABLE
DATA TABLE FOR APC PROGRAM NUMBER：
GN.NO.
DATA
D50
PROGRAM NUMBER OF PALLET A
D52
PROGRAM NUMBER OF PALLET B
SPINDLE USE TIME：
GN.NO.
DATA
D80
SEC OF SPINDLE USE TIME
D82
MINUTE OF SPINDLE USE TIME
D84
HOUR OF SPINDLE USE TIME
D86
DAY OF SPINDLE USE TIME
7. SETTING AND ADJUSTMENT
7-25
7-6 CHAIN APC (CAM ATC) TIMER
TMR NO. DATA
1
NOTE
600000 LUB. OIL OFF TIMER
2
6000
AIR PRESSURE CHECK DELAY TMR WHEN PALLET DOWN
3
60000 CHIP CONVEYOR ON
4
60000 CHIP CLEAN 1 ON
5
60000 CHIP CLEAN 2 ON
6
20000 MAGAZINE ROTATION ALARM DELAY TIMER
7
700
COUNTER ALARM DELAY TIMER 1
8
700
COUNTER ALARM DELAY TIMER 2
9
1000
COUNTER DELAY TIMER
10
1000
ORIENTATION FINISH TIMER
11
2000
ARM CATCH TOOL ALARM TIMER
12
500
TOOL UNCLAMP FINISH TIMER
13
700
A PALLET LEFT ARRIVAL DELAY TIMER
14
500
POT HORIZONTAL FINISH TIMER
15
500
POT VERTICAL FINISH TIMER
16
500
TOOL CLAMP TIMER
17
6000
A PALLET LEFT ALARM DELAY TIMER
18
3000
H/L WIRE ALARM DELAY TIMER
19
2000
PALLET UP ARRIVAL DELAY TIMER
20
3000
PALLET DOWN ARRIVAL DELAY TIMER
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7-26
TMR NO. DATA
NOTE
21
1000
CALL LIGHT DELAY TIMER(AUTO POWER OFF)
22
60000 MAGAZINE ROTATION LIMIT TIME
23
5000
POT ALARM DELAY TIMER
24
7000
AUTO LUBRICATION HYDRAULIC DETECT DELAY TIMER
25
200
4TH AXIS CLAMP DELAY TIMER
26
200
4TH AXIS UNCLAMP DELAY TIMER
27
M40/M41 DELAY TIMER
28
M42/M43 DELAY TIMER
29
M44/M45 DELAY TIMER
30
M46/M47 DELAY TIMER
31
M48/M49 DELAY TIMER
32
700
B PALLET LEFT ARRIVAL DELAY TIMER
33
600
B PALLET LEFT ALARM DELAY TIMER
34
1000
A PALLET RIGHT ARRIVAL DELAY TIMER
35
1000
B PALLET RIGHT ARRIVAL DELAY TIMER
5000
AIR PRESSURE CHECK TIMER
36
37
38
39
40
8-1 ROUTINE CHECKUPS.......................................…........ 8-2
8-2 LUBRICANT.....................................................…...... 8-3
8-3 SPINDLE COOLING UNIT............................................. 8-4
8-4 CLEANING AND MAINTENANCE.................................... 8-5
8-5 THE POSITION OF SOLENOID, LIMIT SWITCH, AND
PROXIMATE SWITCH...............................................…. 8-6
8-6 DOOR INTERLOCK RELEASE....................................... 8-13
8-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
8. MAINTENANCE AND CARE
8-1 ROUTINE CHECKUPS
1. Daily checkup
(1) Check if the lubricant is sufficient.
(2) Remove chips on the sideways.
(3) Clean the tapper of the spindle.
(4) Check the pneumatic air pressure. (5kg/cm2-7kg/cm2)
(5) Check whether the emergency stop and door interlock function works or not.
(6) Check whether the all the buttons and switches function works or not.
2. Weekly checkup
Please refer to Section 8-4.
3. Seasonally checkup
Check the levelness and backlashes.
8. MAINTENANCE AND CARE
8-2 LUBRICANT
8-3
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
8-4
8-3 SPINDLE COOLING UNIT
1. The cooler is on the back side of the machine.
2. Procedures for connecting the cooler:
(1) Plug the power cord of the cooler into the designated socket shown in the
figure.
(2) Connect the inlet and outlet cooling oil tubes to designated locations, as
shown in the figure.
(3) Use Mobil Velocite C or similar oil for the cooler.
(4) Turn on the machine.
(5) Turn on the cooler.
3. TEMPERATURE SETTING OF THE COOLER
Turn the regulator at 0°C so that the motor of the cooler will start running when
the temperature of the cooling oil is 0°C above room temperature.
8. MAINTENANCE AND CARE
8-4 CLEANING AND MAINTENANCE
8-5
8-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
8-5 THE POSITION OF SOLENOID, LIMIT SWITCH
AND PROXIMATE SWITCH
LIMIT SWITCH AND PROXIMATE SWITCH
8. MAINTENANCE AND CARE
NO.
LS1
LS6
LS10
LS2
LS7
LS11
LS3
POSITION
BRAND
MODEL
X LIMIT AND ZERO POINT
OMROM
VB-3121
DECELEARAYION
BALLUFF
LR50067
Y LIMIT AND ZERO POINT
OMROM
VB-3121
DECELEARAYION
BALLUFF
LR50067
LS8
Z LIMIT AND ZERO POINT
DECELEARAYION
OMROM
VB-2121
LS9
A DECELEARATION
LS12
TOOL CLAMP
OMRON
ZC-Q2155
LS13
TOOL UNCLAMP
OMRON
ZC-Q2155
LS18
TOOL MAGAZINE FORWARD OMRON
ZC-Q2155
LS17
TOOL MAGAZINE
BACKWARD
OMRON
ZC-Q2155
LS19
TOOL MAGAZINE UP
OMRON
ZC-Q2155
LS20
TOOL MAGAZINE DOWN
OMRON
ZC-Q2155
LS30
APC DOOR SWITCH
OMRON
WLCA2
LS16
TOOL COUNTER
BALLUFF
BES516-325E3R
LS33
APC
BALLUFF
BES516-325E3R
NOTE
DEPEND ON
4TH
APC
PNP/NO，
2MM
8-7
8-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
SOLENOID VALVE
8. MAINTENANCE AND CARE
NO.
POSITION
BRAND
MODEL
SOL1 Spindle air blow
CHELIC
SV-6102
SOL2 Tool clamp
CHELIC
SV-6102
SOL3
Tool magazine up and
down
CHELIC
SV-6202
SOL4
Tool magazine forward and
backward
CHELIC
SV-6202
SOL5 Air blow by instruction
SMC
VX2120
SOL6 Coolant
SMC
VX2120
SOL7 Oil hole
SMC
VX2120
SOL8 APC air blow
SMC
VX2120
NORTHMAN
SWH-G2-D2
VICKERS
DG4V-3-2N
NORTHMAN
DPR-02B-OK-20
SOL9 APC Door up and down
VICKERS
SOL10
SOL11
APC Hydraulic motor
SOL12 Table up and down
8-9
NOTE
OPTION
Directional
valve
Reduce
1DGMX1-3-D13-13W-2 valve
NORTHMAN
WSH-G2-C2-D2
VICKERS
DG4V-3-2C
Directional
valve
Flow
restrictor
VICKERS DGMF-3-X-A2W-B2W-2 valve
ONRTHMAN
SWH-G2-D2
Directional
valve
VICKERS
DG4V-3-2N
Flow
NORTHMAN
MT-OW-K-20
restrictor
VICKERS DGMF-3-X-A2W-B2W-2 valve
NORTHMAN
MT-OW-20
8-10
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
PNEUMATIC SCHEME
8. MAINTENANCE AND CARE
Hydraulic diagram of MCV-610 A.P.C system
8-11
8-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Hydraulic diagram of MCV-1020BA A.P.C system
8. MAINTENANCE AND CARE
8-13
8-6 DOOR INTERLOCK RELEASE
Install two "safety interlock switches with guard locking" on the front door of the
guard.
The safety switch can’t relieve the pin from the interlock state until all stop
conditions of moveable parts, as follows, yield.
1. Spindle stops completely.
2. Three axes stop completely.
3. Magazine stops completely.
8-14
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
The manual unlocking ports are provided as shown below. Either of the covering
security screws can be removed by the special screwdriver bit supplied allowing a
thin screwdriver blade to be inserted and pushed to unlock the guard locking
mechanism.
IT IS IMPORTANT THAT THE SECURITY SCREW IS REPLACED AND FULLY
TIGHTENED TO MAINTAIN THE IP67 PROTECTION RATING.
9-1 PARAMETER SETTINGS.............................................. 9-2
9-2 OVERTRAVEL.....................................................….... 9-4
9-3 CHANGING BATTERIES..…..................................…..... 9-5
9-4 TROUBLE SHOOTING DURING THE PROCESS OF
AUTOMATIC TOOL CHANGING...................................... 9-7
9-5 WARNING MESSAGES.........................................….... 9-9
9-5-1 DRUM TYPE.......................…………………………. 9-9
9-5-2 CAM TYPE.......................……………………………. 9-13
9-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
9. TROUBLESHOOTING
9-1 PARAMETER SETTINGS
Parameters of the machine are set by the manufacturer. Only backlashes
may need to be changed by the user. If the user wants to change the settings of
certain parameters, he must fully understand the meanings of the parameters
because incorrect settings may cause malfunctions. Please refer to operation
manual by FANUC for the meaning of each parameter.
The procedures for parameter settings are as follows:
(1) Turn the mode selector to the MDI position.
OFFSET
(2) Press the function key SETTING .
(3) Press soft key [SETING].
(4) Move the cursor to "PARAMETER NUMBER", then press [1:ON] to enable
parameter writing, at this time, the CNC displays the P/S alarm state (No.100).
(5) Press the function key
SYSTEM
, press soft key [PARAM].
(6) Enter the parameter number for the parameter value to be set.
(7) Press soft key [NO.SRH].
(8) Enter the new value and then press the
INPUT
.
(9) Repeat (6) and (7) and (8) to change the settings of other parameters.
(10) After setting parameters, return the setting screen,Move the cursor to
PARAMETER WRITE and press soft key [(OPRT)], then press [0:OFF].
(11) Press the
RESET
key to release the alarm message.
9. TROUBLESHOOTING
9-3
BACKLASH COMPENSATION
Parameter No. 1851 shows the values of backlash compensations for all
axes.
ADJUSTMENT POSITION FOR AUTOMATIC TOOL CHANGE
If the servo motor of the Z axis is disassembled, its location will change
when it is reassembled. Parameter No. 1850 is used to perform proper
adjustment.
I/O DEVICE
Parameters of No. 20 and No.100 ~ No.242 are related to the settings of I/O
devices.
9-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
9-2 OVERTRAVEL
1. When the travel of an axis reaches its limit, the warning message of overtravel
will be displayed on the screen. The procedures for releasing the message are
as follows:
(1) To move passage distance that go to the opposite direction of overtravel.
(2) Press the RESET key to cancel alarm.
2. If the axes do not return to the reference point before operating the machine,
the travel limit will unvalid, and the moving parts may overtravel or even
trigger limit switches. As a result, the machine will be in the state of
emergency stop (EMG). The procedures for releasing the emergency stop are
as follows:
(1) Press the “OT RELEASE” button on for several seconds until the READY
lamp lights on the operation panel.
(2) Turn the hand wheels to move the axes to their normal work area. Carefully
watch the directions when moving the axes.
9. TROUBLESHOOTING
9-5
9-3 CHANGING BATTERIES
When the power of the batteries are exhausted, the sign BAT will be
displayed on the screen. The procedures for changing batteries are as follows:
(1) Turn on the machine.
(Note：if the power is not on while changing batteries, all the data stored in
the memory will be erased.)
(2) Remove the cover of the battery case.
(3) Take out batteries.
(4) Change batteries.
(5) Put the cover back.
(6) Turn off the machine.
16i/18i/21I
NC UNIT
9-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
0i NC UNIT
9. TROUBLESHOOTING
9-7
9-4 TROUBLESHOOTING DURING THE PROCESS
OF AUTOMATIC TOOL CHANGING
If errors occurs during the process of automatic tool changing or the
process is paused by pressing the EMG button, the magazine must be returned
to its original position. ex：The magazine is stopped when going downwards for
drum type.
(1) Check if the pneumatic air pressure reaches 6 kgf/cm2.
(2) Select the MDI mode.
(3) Enter M83 (tool magazine pointing upwards.)
(4) Press the
EOB
→
INSERT
button.
(5) Press the CYCLE START button. The tool magazine will turn upwards and
insert the tool into the spindle.
(6) Enter M84 (tool magazine pointing to the left.)
(7) Press the EOB
→
INSERT
button.
(8) Press the CYCLE START button. The magazine will point to the left, which is
its original position.
9-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Checking if normal for the tool changing mechanisms as follows：
ex：DRUM TYPE
(1) Move the Z axis downwards and then return to its reference point.
(2) Select the MDI mode.
(3) Enter M19 →
EOB
→
INSERT
→ CYCLE START.
(4) Enter M81 →
EOB
→
INSERT
→ CYCLE START.
(5) Enter M82 →
EOB
→
INSERT
→ CYCLE START.
(6) Enter M83 →
EOB
→
INSERT
→ CYCLE START.
(7) Enter M84 →
EOB
→
INSERT
→ CYCLE START.
The above test if smooth, then we can check the continuous tool changing
process as follows：
(1) Let the Z axis zero return.
(2) Enter T□□M06 →
EOB
→ INSERT
→ CYCLE START.
9. TROUBLESHOOTING
9-9
9-5 WARNING MESSAGES
If warning messages that appear on the screen, please depend on way to
remove as follows：
9-5-1 DRUM TYPE
1010： SPINDLE ALARM
The alarm number will be displayed on the spindle controller (in the left
electrical box). Please refer to the FANUC manual for details of spindle
alarms.
1020： SPINDLE COOLING ALARM
The spindle cooling doesn’t work.
(1) Pressure is too low.
(2) The compressor is off.
1030： AIR PRESSURE TOO LOW
Air pressure isn’t enough, and please adjust pressure of F.R.L. unit that
reach 6~7 kgf/cm2. (If it cancel the alarm awhile, set keep relay K10#3 to 1)
1040： LUBRICATION LEVEL TOOLOW
The lubrication alarm lamp on the control panel will light. Please check
the oil level in the tank of the lubricator and top up to the upper level
mark if necessary. (If it cancel the alarm awhile, set keep relay K10#0 to 1)
1050： X、Y、Z AXES NOT ZERO RETURN
It is necessary to perform X、Y、Z axis zero return while turn on the
power. (If it cancel the alarm awhile, set keep relay K3#0 to 1)
1060： A AXIS NOT ZERO RETURN
It is necessary to perform A axis zero return before enacting the MEM
mode while turning the power on.
1070： SPINDLE OIL-AIR LUBRICATION ALARM
9-10
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
(1) Execute program will pause.
(2) Please check oil-air lubricator above the left electrical box and air
dryer device.
1080： SPINDLE OIL-AIR LUBRICATION SYSTEM NOT READY
(1) Execute program will pause.
(2) Please check oil-air lubricator above the left electrical box and air
dryer device.
1090： PALLET DOWN NOT OK (MCV-1020BA＋APC)
This alarm means that the air pressure doesn’t reach after pallet down in
a machine with APC option.
1100： M6 WHITOUT T CODE ALARM
The m6 command need T code in DRUM type ATC.
1110： MG ROT LONG TIME AL
Check counter X8.0.
1120： HYDRAULIC PRESSURE ALARM
(1) This alarm means that the hydraulic pressure is below 30 kgf/cm2 in a
machine with APC option. The hydraulic pressure must be adjusted.
(2) This alarm means that the hydraulic pressure is low in other option
device.
1130： TOOL LIFE FINISH
Cause：The life of the last tool of group ends.
Solution：(1) [OFFSET/SETTING] → [►] → [TOOLLF] → [OPRT] →
[CLEAR] → [EXEC]
(2) Please reset and replace tool of specify.
1140： SPINDLE SPEED = 0，MODIFY PROGRAM
In cutting travel, it can not zero in the spindle speed, modify the program.
(1) The M94 command is provisional off this function (M95 on).
(2) To cancel it that in the soft operation panel seven.
9. TROUBLESHOOTING
1150 :
9-11
H/L WIRE CHANGE ALARM
H/L wire change error, check X4.3 and Y3.1 in LOW wire, check
X4.4 and Y3.0 in HIGH wire.
1160： SPINDLE COOLING BREAK OFF
To check the break K1M.
1170 :
LUBRICATION BREAK OFF
Check the break K4M.
2001： DRAW BAR OIL LEVEL TOO LOW
Draw bar oil level isn’t enough, so be added.
2002： TOOL NUMBER AL
Tool number is incorrect.
2003： AIR DRY POWER- OFF AL
The air dryer is not power on.
2004： AIR PRESSURE AL
Air pressure isn’t enough, and please adjust pressure of F.R.L. unit that
reach 6~7 kgf/cm2. (If it cancel the alarm awhile, set keep relay K10#3 to 1)
2005： NITROGIN PRESSURE TOO LOW
Please re-assembly the nitrogen cylinder. Reference chapter 4-2.
2010： OIL PRESSURE BREAK OFF
To check the break K0M.
2011： COOLANT BREAK OFF
To check the break K2M.
2012： CHIP CONVEYOR BREAK OFF
To check the break K3M.
2013： HEAT EXCHANGER BREAK OFF
To check the break K5M.
2014： CHIP CLEANER BREAK OFF
9-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
To check the break K10M.
2015： SHOW COOLANT BREAK OFF
To check the break K16M.
2016： MAGAZINE BREAK OFF
To check the break K6M.
2017： ATC ARM BREAK OFF
To check the break K8M.
2018： CHIP CONV 2 BREAK OFF
To check the break K3AM.
2019： OIL COOLER BREAK OFF
To check the break K19M.
2020： AIR DRYER BREAK OFF
To check the break K20M.
2021： COOLANT BREAK OFF
To check the break K7M.
2061： PRESS “FEED HOLD” BUTTON IN HANDLE MODE
Cause：A or B pallet move to left/right side, and not arrival.
Solution：Turn to “HANDLE” mode, and press “feed hold” button, then
pallet move to the correct position.
2062： TOOL CLAMP ABNORMAL
Cause：Tool clamp signal of spindle is abnormal.
Solution：(1) Check tube if install error.
(2) Check tool clamp / unclamp signal if install error. (clamp：
X3.1；unclamp：X3.0)
(3) If it adjust invalid, then replace it.
The alarms which are not included above-mentioned number, then please look
up FANUC maintenance manual.
9. TROUBLESHOOTING
9-13
9-5-2 CAM TYPE
1010： SPINDLE ALARM
The alarm number will be displayed on the spindle controller (in the left
electrical box). Please refer to the FANUC manual for details of spindle
alarms.
1020： SPINDLE OIL COOLING ALARM
The spindle cooling doesn’t work (If it cancel the alarm awhile, set keep
relay K10#2 to 1)
(1) Pressure is too low.
(2) The compressor is off.
1030： AIR PRESSURE TOO LOW
Air pressure isn’t enough, and please adjust pressure of F.R.L. unit that
reach 6~7 kgf/cm2. (If it cancel the alarm awhile, set keep relay K10#3 to 1)
1040： LUBRICATION LEVEL TOO LOW
The lubrication alarm lamp on the control panel will light. Please check
the oil level in the tank of the lubricator and top up to the upper level
mark if necessary. (If it cancel the alarm awhile, set keep relay K10#0 to 1)
1050： X、Y、Z AXIS NOT ZERO RETURN
It is necessary to perform X、Y、Z axis zero return while turn on the
power. (If it cancel the alarm awhile, set keep relay K3#0 to 1)
1060： A AXIS NOT ZERO RETURN
It is necessary to perform A axis zero return before enacting the MEM
mode while turning the power on.
1070： SPINDLE OIL-AIR LUBRICATION ALARM
(1) Execute program will pause.
(2) Please check oil-air lubricator above the left electrical box and air
dryer device. (If it cancel the alarm awhile, set keep relay K10#7 to 1)
1080： SPINDLE OIL-AIR LUBRICATION SYSTEM NOT READY
9-14
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
(1) Execute program will pause.
(2) Please check oil-air lubricator above the left electrical box and air
dryer device. (If it cancel the alarm awhile, set keep relay K10#7 to 1)
1090： PALLET DOWN NOT OK
This alarm means that the air pressure doesn’t reach after pallet down in
a machine with APC option.
1100： SPINDLE SPEED = 0，MODIFY PROGRAM
In cutting travel, it can not zero in the spindle speed, modify the program.
(1) The M94 command is provisional off this function (M95 on).
(2) To cancel it that in the soft operation panel seven.
1110： COUNTER ERROR ALARM1
(1) Check the counter signal (X8.0) if normal.
(2) Check the DATA TABLE SETTING.
1120： MAGAZINE STOP ALARM
Check the counter signal (X8.0) if normal.
1130： MAGAZINE ROT MORE 20S
Check the DATA TABLE SETTING.
SYSTEM → PMCPRM → DATA → G.DATA
1140： COUNTER ALARM 2
(1) Check the counter signal (X8.0) if normal.
(2) Check magazine position.
1150： MAGAZINE NOT READY
(1) Check pot (X3.4 is 0 when pot up, X3.5 is 1 when pot down).
(2) Check X2.1，X2.2，X2.3：
X2.1 → 0
X2.2 → 0
X2.3 → 1
9. TROUBLESHOOTING
9-15
1160： ARM CATCH TOOL ALARM
Check X2.1，X2.2，X2.3：
X2.1 → 0
X2.2 → 1
X2.3 → 0
1170： SPINDLE COOLING BREAK OFF
To check the break K1M.
1180： LUBRICATION BREAK OFF
To check the break K4M.
1190： MG ROT LONG TIME AL
Check counter X8.0.
1200： H/L WIRE CHANGE ALARM
H/L wire change error, check X4.3 and Y3.1 in LOW wire, check X4.4 and
Y3.0 in HIGH wire.
1210： HYDRAULIC PRESSURE ALARM
(1) This alarm means that the hydraulic pressure is below 30 kgf/cm2 in a
machine with APC option. The hydraulic pressure must be adjusted.
(2) This alarm means that the hydraulic pressure is low in other option
device.
1220： TOOL LIFE FINISH
Cause：The life of the last tool of group ends.
Solution：(1) [OFFSET/SETTING] → [►] → [TOOLLF] → [OPRT] →
[CLEAR] → [EXEC]
(2) Please reset and replace tool of specify.
1230： HIGH PRESSURE FILTER ALARM
Cause：High pressure filter is jam for coolant through spindle.
Solution：To dismount filter and clear it.
1240： PALLET MOVE ALARM
9-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
Cause：A or B pallet not move to the correct position.
Solution：(1) If pallet move to left side and not arrival, then check signal
X2.7(MC.Q)、X4.5(HOK.A)、X4.6(HOK.B).
(2) If pallet move to right side and not arrival, then check
signal X2.7(MC.Q)、X1.3(APC.SR)、X1.5(TA.LS)、X1.6
(TB.LS).
2001： DRAW BAR OIL LEVEL TOO LOW
Draw bar oil level isn’t enough, so be added.
2002： TOOL NUMBER ALARM
The T code is error.
2003： T CODE=SPINDLE ALARM
The T code equal spindle tool.
2004： AIR PRESSURE AL
Air pressure isn’t enough, and please adjust pressure of F.R.L. unit that
reach 6~7 kgf/cm2. (If it cancel the alarm awhile, set keep relay K10#3 to 1)
2005： AIR DRY POWER- OFF AL
The air dryer is not power on.
2006： NITROGIN PRESSURE TOO LOW
Please re-assembly the nitrogen cylinder. Reference chapter 4-2.
2010： OIL PRESSURE BREAK OFF
To check the break K0M.
2011： COOLANT BREAK OFF
To check the break K2M.
2012： CHIP CONVEYOR BREAK OFF
To check the break K3M.
2013： HEAT EXCHANGER BREAK OFF
To check the break K5M.
2014： CHIP CLEANER BREAK OFF
9. TROUBLESHOOTING
9-17
To check the break K10M.
2015： SHOW COOLANT BREAK OFF
To check the break K16M.
2016： MAGAZINE BREAK OFF
To check the break K6M.
2017： ATC ARM BREAK OFF
To check the break K8M.
2018： CHIP CONV 2 BREAK OFF
To check the break K3AM.
2019： OIL COOLER BREAK OFF
To check the break K19M.
2020： AIR DRYER BREAK OFF
To check the break K20M.
2021： COOLANT BREAK OFF
To check the break K7M.
2061： PRESS “FEED HOLD” BUTTON IN HANDLE MODE
Cause：A or B pallet move to left/right side, and not arrival.
Solution：Turn to “HANDLE” mode, and press “feed hold” button, then
pallet move to the correct position.
2062： TOOL CLAMP ABNORMAL
Cause：Tool clamp signal of spindle is abnormal.
Solution：(1) Check tube if install error.
(2) Check tool clamp / unclamp signal if install error. (clamp：
X3.1；unclamp：X3.0)
(3) If it adjust invalid, then replace it.
The alarms which are not included above-mentioned number, then please look
up FANUC maintenance manual.
10-1 OVERALL DRAWING AND THE NAME OF MAJOR PART.
10-2
10-2 THE MAJOR SIZE OF THE MACHINE............................. 10-3
10-3 TRANSPORTATION AND INSTALLATION........................ 10-7
10-3-1 TRANSPORTATION(MCV-610＋APC)……..…........... 10-7
10-3-2 INSTRUCTION(MCV-1020BA＋APC) ...................... 10-9
10-4 COMMANDS OF APC OPERATION................................ 10-16
10-4-1 MCV-610＋APC........................…...................… 10-16
10-4-2 MCV-1020BA＋APC............................................ 10-17
10-5 OPERATION PROCEDURES FOR APC........................... 10-18
10-6 PROGRAMMING OF THE A.P.C.................................... 10-24
10-7 SETTING OF PART PROGRAM (APC).....………………….. 10-32
10-8 MDI MODE MAINTENANCE OPERATION........................ 10-33
10-8-1 MCV-610＋APC..............................................… 10-33
10-8-2 MCV-1020BA＋APC............................................ 10-36
10-9 HYDRAULIC DIAGRAM……..……..………………………… 10-37
10-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10. AUTOMATIC PALLET
CHANGER(APC OPTIONAL)
10-1 OVERALL DRAWING AND THE NAME OF
MAJOR PART
1. Z AXIS MOTOR
7. APC DOOR
2. MAGAZINE
8. HEADSTOCK
3. GUARD
9. OPERATING PANEL
4. TABLE
10. APC
5. BED
11. LEVEL BOLT
6.COOLANT TANK
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-2 THE MAJOR SIZE OF THE MACHINE
MCV-610+APC
NOTE：(
)MCV-1020BA＋APC SIZE
10-3
10-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-610＋APC
NOTE：(
)MCV-1020BA＋APC SIZE
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
PALLET SIZE
MCV-610＋APC
10-5
10-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-1020BA＋APC
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-7
10-3 TRANSPORTATION AND INSTALLATION
10-3-1 TRANSPORTATION (MCV-610＋APC)
The transportation of machine please refer SECTION 3-4 of this manual, the
transportation of APC unit as follows figure:
10-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
INSTRUCTION OF INSTALLATION
INSTALLATION (MCV-610＋APC)
1. Adjust the machine's levelness as described in Section 4-3.
2. Install the pallet changer as follows:
(1) Connect the machine and pallet changer by using the two designated
bolts. Do not screw the two bolts too tightly because the pallet changer
needs to be adjusted later
(2) Connect the hydraulic pipes and electrical cords. Do not turn on the
machine before connecting the pipes, otherwise leaking will occur.
3. Adjust the levelness of the pallet changer by using the level adjusting bolts
so that the table can move smoothly.
4. Tighten the two connecting bolts mentioned in the procedure 2.(1).
back
P
O
A.P.C
Y
left
right
X
S
R
fore
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-3-2 TRANSPORTATION (MCV-1020BA＋APC)
The transportation of machine please refer section 3-4 of this manual , the
transportation of APC unit as follows figure：
10-9
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-10
INSTALLATION (MCV-1020BA＋APC)
A. Tools for use
1. Jack
2. Level gauge
3. Steel ruler
4. Wrench
B. Procedure of installation
1. Connecting the machine with pallets.
(1) Lock for the two connector attached for connecting with automatic
pallet changers.(shown as fig 1)
(2) After connecting the two part, it is no necessary to screw them tightly
because the bed still needs checking.
Machine bed
The bed of APC side
FIG.1
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-11
2. CONNECTING FOR HYDRAULIC PIPES
(1) Six hydraulic pipes relative to APC should be connected.
a. Holes of P and T on
b. Hydraulic cylinder on the automatic door.
c. Pallet positioning.
(2) The six pipes are all marked for connections. If the signs are vague,
please connect pipes according to the circuit diagram.
C. LEVELING FOR PALLETS
1. Height
(1) Make sure that pallet A is on the side of the machine and pallet B is on
the side of APC. Positions of both pallet A and B are shown as figure 1.
(2) Return pallets to the 1st reference point by means of manual zero
return.
(3) Input M56 to ascend he automatic door under MDI mode. Due to no
loading of the automatic door, connect points, such as 24V & 371,
should be short.
(4) Input M58 to elevate table under MDI mode.
(5) Move the table along the negative direction of the Y axis with the
manual pulse generator. Due to the ascended states of tables, it should
be noticed that pallet A should not to hit the rack of pallet B. It comes
to a stop when pallet A gets close to pallet B.
(6) Put a steel rule on pallet A,B to level them as shown in fig 2.
10-12
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
(7) There are seven level screws on the of automatic pallet changers.
Adjust these screws until pallet A and pallet B are of the same height,
meanwhile, put a level gauge on the iron board for leveling (illustrated
as fig 3).
(8) The adjustment does not accomplished until both pallets are of the
same height.
2. Alignment for both left and right sides of pallets
(1) Input M59 to descend pallets in the MDI mode after leveling both pallets
to the same height.
(2) Input G91 G30 P3 Y0 to return the Y axis to the 3rd reference point.
(3) Use a long steel rule to check if both the left and right sides of pallets
are of alignment.(illustrated as fig 4)
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
(4) There are eight screws for adjusting the parallelism of pallets, on the
bottom of the pallet. The screw H. in fig.5,has to be released before
adjusting these eight screws.
FIG 5
(5) The adjustment has not been accomplished until the parallelisms of
both pallet A and B are the same.
3. Dynamic adjustment
(1) Disassemble the gear on the side of the table.
Rack
Gear
FIG6
10-13
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-14
(2) Return both X to 2nd reference point and Y to 2nd reference point.
(3) Input M58 to ascend pallet under MDI mode.
(4) Push pallet A to move right by hand at this moment. Observe if
interferences occur while pallet enter the A position of pallet change. It
should be noticed not to hit the limit switch on pallets while pushing the
pallet.
(5) In case of interferences, please repeat step (2) until interferences
disappear.
(6) Retain pallet A on pallet changer A (no pushing towards the
machine).Return Y axis to the 3rd reference point. Push pallet B staying
on pallet changer B left towards the machine (making sure in advance
that the pallet is ascendant). Interferences may occur due to a little error
for setting the 3rd reference point of Y axis .Thus, the parameters can be
adjusted to －550000(16i/18 is - 5500000) for MCV1020BA.The No. of
parameters needed to be adjusted above are No.1241
(7) Repeat step (5) till no interferences may occur while pushing pallets.
4. Correcting the pitch of rack & gear
(1) Both A and B pallets are retained on the positions of A,B pallet changers.
(2) Mount the gears once more.
(3) Input M57 to position pallets and descend the automatic door under MDI
mode.
(4) Move Y axis to the center X axis is returned to 2nd reference point.
(5) Input M58 to ascend the pallet under the MDI mode.
(6) Move Y axis towards pallet A (positive direction) with the manual pulse
generator. Check if the pitch of the gear matches that of the rack of pallet
A. Knock on the gear lightly until both pitches are in agreement.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-15
5. Change the pallet in MDI mode step by step.
(1) Make sure first that all adjustments above are of no questions.
(2) Lock up the diagnostic numbers. K5. Both parameters should be set to
01100111.Modify them so long as.
(3) The functions of M codes of APC are as follows：
a. M56：The automatic door ascends.
b. M57：The automatic door descends.
c. M58：The pallet ascends.
d. M59：The pallet descends.
e. M66：The pallet moves left.
f. M67：The pallet moves right.
(The M code mentioned above can be executed only in the MDI mode.)
(4) Input M code in accordance with the practical conditions of the machine,
to execute pallet changing.
(5) After all behaviors being sure of no questions, it’s able to input a program
to test the continuous changing.
6. Automatic pallet changing by program
(1) Make a test program as follows.
0 1234;
G00 G91 X200.;
M60;
M99;
(2) M60 is the mode of automatic pallet changing. It’s executing program is
as section 10-6.
D. Accomplishment
After all behaviors being sure of no questions, tighten the untighten screws
of the connector.
10-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-4 COMMANDS OF APC OPERATION
10-4-1 MCV-610＋APC
M56
：APC Door up
M57
：APC Door down
M58
：APC Table up
M59
：APC Table down
M60
：Automatic pallet change
M61
：Table and door up , pallet A move to right
M62
：pallet B move to left , table and door down
M63
：Table and door up , pallet B move to right
M64
：Pallet A move to left, table and door down
M66
：Pallet A move to left
M67
：Pallet A move to right
M68
：Pallet B move to left
M69
：Pallet B move to right
M601 ：Pallet A move to working area
M602 ：Pallet B move to working area
NOTE：M56 ~ M59 and M66~M69 are used for maintenance, only effect in MDI
mode, for detail please refer section 10-8-1 of this manual.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-4-2 MCV-1020BA＋APC
M56 ：APC Door up
M57 ：APC Door down
M58 ：APC pallet up
M59 ：APC pallet down
M60 ：Automatic pallet change
M61 ：pallet and door up , pallet move to right
M62 ：pallet move to left , pallet and door down
M66 ：pallet move to left
M67 ：pallet move to right
M601 ：Pallet A move to left，pallet B move to right
M602 ：Pallet B move to left，pallet A move to rught
NOTE：M56 ~ M59 and M66~M67 are used for maintenance, only effect in MDI
mode, for detail please refer section 10-8-2 of this manual.
10-17
10-18
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-5 OPERATION PROCEDURES FOR APC.
Execute command M60
(2nd refer point return on X axis
1ST refer point return on X axis for MCV-1020BA)
Pallet B is on APC side
1st refer point return
on Y axis
judge
(2nd for 1020BA)
Pallet A is on APC side
2nd refer point return
on Y axis
Pallet and automatic
door up
Pallet and automatic
door up
Pallet A moves right
Pallet B moves right
2nd refer point return
on Y axis
1st refer point return
on Y axis
(3rd for 1020BA)
Pallet B moves left
Pallet A moves left
Pallet and automatic
door down
Pallet and automatic
door down
APC Finish
(3rd for
1020BA)
(2nd for
1020BA)
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-19
NOTE：
1. The exchange position for Table A at the 1st reference points on X axis (2nd
reference points on X axis for MCV-1020BA) and 1st reference point on Y
axis(2nd for 1020BA).
2. The exchange position for Table B is at the 1st reference point of X axis( 2nd
reference point on X axis for MCV-1020BA) and the 2nd reference point of Y
axis(3rd for 1020BA).
3. The lamp of ZERO RETURN button will light when each axis's zero return is
performed and both axes move back to their 1st reference points. The lamp
of ZERO RETURN button will blink when each axis's G30 command is
performed and the axes move back to the 2nd, 3rd, ... reference points.
4. The table will move up only at the following four positions:
(1) (X,Y)：1st reference point, 1st reference point.(MCV-610＋APC)
(2) (X,Y)：1st reference point,2nd reference point.(MCV-610＋APC)
(3) (X,Y)：2nd reference point, 2nd reference point.(MCV-1020BA＋APC)
(4) (X,Y)：2nd reference point,3rd reference point.(MCV-1020BA＋APC)
5. When the table is up(K5.2＝1), X and Y axes will be interlocked (cannot move
in both directions) except both tables are on the APC side.
10-20
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
THE DIAGRAMS OF MCV-610＋APC`S BEHAVIORS.
D-ROD
E-BLOCK
Procedure 1：
i) A pallet move to X, Y 1st reference point.
ii) pallet and door up.
iii) A pallet move to right.
Procedure 2：Y axis move to 2nd reference point.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
Procedure 3：B pallet move into machine.
Procedure 4：
i) Pallet and door down
ii)APC change finish.
10-21
10-22
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
THE DIAGRAMS OF MCV-1020BA＋APC`S BEHAVIORS.
Step：1
a：Pallet B moves to X 2nd、Y 3rd reference point.
Step：2
a：Pallet and door up.
b：Hydraulic motor drives the rack.
c：Pallet B is moved into the APC.
Step：3
a：Saddle moves to 2ndreference point on Y axis.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
Step ：4
a：Hydraulic motor drives the rack .
b：Pallet A is moved into the saddle.
Step：5
a：Pallet and door down.
b：Complete the automatic pallet change.
10-23
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-24
10-6 PROGRAMMING OF THE A.P.C.
The command for operating the automatic pallet exchange is M60, and the
program for M60 is as following:
The macro program of MCV-610＋APC：
0 9002；
#100＝#4003；
G91 G28 X0；
IF[#1013 EQ 1] GOTO 1；
IF[#1014 EQ 1] GOTO 2；
G#100；
#3000＝1(APC SIDE NO PALLET)
N1 G28 Y0；
M61；
G30 Y0；
M62；
G#100；
M99；
N2 G30 Y0；
M63；
G28 Y0；
M64；
G#100；
M99；
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-25
Note:
1. If alarm message "3001 APC SIDE NO PALLET" is displayed on the screen,
there is no pallet on the pallet changer.
2. There is a APC READY button on the pallet changer and auto pallet
exchanging (or M60) command can be executed only when this button lights.
3.
M63
M62
B
M64
M61
A
M61:
Table A and auto door move up, and then Table A moves to the right into the
pallet changer.
Conditions:
(1) Signal for APC READY is ON. (The button lights.)
(2) X axis is at the 1st reference point.
(3) Y axis is at the 1st reference point.
(4) There is no table on the A position of the pallet changer.
(5) Auto door up is done.
(6) Table up is done.
10-26
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
M62:
Table B moves to the left into the machine, and then table and auto door move
down.
Conditions:
(1) X axis is at the 1st reference point.
(2) Y axis is at the 2nd reference point.
(3) There is a table on the B position of the pallet changer.
(4) Auto door up is done.
(5) Table up is done.
M63:
Table and auto door move up, and then Table B moves to the right into the
pallet changer.
Conditions:
(1) Signal for APC READY is ON. (The button lights.)
(2) X axis is at the 1st reference point.
(3) Y axis is at the 2nd reference point.
(4) There is no table on the B position of the pallet changer.
(5) Auto door up is done.
(6) Table up is done.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
M64 :
Table A moves to the left into the machine, and then table and auto
move down.
Conditions:
(1) X axis is at the 1st reference point.
(2) Y axis is at the 1st reference point.
(3) There is a table on the A position of the pallet changer.
(5) Auto door up is done.
(6) Table up is done.
door
10-27
10-28
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
THE MACRO PROGRAM OF MCV-1020BA＋APC：
O9002；
#100＝#4003；
IF [#1013 EQ 1] GOTO 1；
IF [#1014 EQ 1] GOTO 2；
G#100；
#3000＝1(PALLET A,B BOTH OUTSIDE)；
N1G30G91P2Y0；
G10L50；
N1321P1R-85000；
N6950R-88000；
G11；
G91G30X0；
M61；
G30P3Y0；
M62；
G53G90X0Y0；
G10L50；
N1321P1R-3000；
N6950R-6000；
G11；
G#100；
M99；
N2G30G91P3Y0;
G10L50；
N1321P1R-85000；
N6950R-88000；
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
G11；
G30X0；
M61；
G30P2Y0；
M62；
G#100；
G53G90X0Y0；
G10L50；
N1321P1R-3000；
N6950R-6000；
G11；
M99；
﹪
10-29
10-30
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
NOTE：
1. If alarm message"3001 PALLET A,B BOTH OUTSIDE " is displayed on the
screen, there is no pallet on the pallet changer.
2. There is a APC READY button on the pallet changer and auto pallet
exchanging(or M60) command can be executed only when this button lights.
3.
M61
B
M62
M61
A
M62
M61：
Table and auto door move up, and then Table moves to the right into the pallet
changer.
Conditions：
(1) Signal for APC READY is ON.(The button lights.)
(2) X axis is at the 2nd reference point.
(3) When Y axis is at the 2nd reference point, there is no pallet on the A
position of the pallet changer.
When Y axis is at the 3rd reference point, there is no pallet on the B position
of the pallet changer.
(4) Auto door up is done.
(5) Table up is done.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
M62：
Table move to the left into the machine, and then table and auto door move
down.
Conditions：
(1) X axis is at the 2nd reference point.
(2) When Y axis is at the 2nd reference point, there is a pallet on the A position
of the pallet changer.
When Y axis is at the 3rd reference point, there is a pallet on the B position
of the pallet changer.
(3) Auto door up is done.
(4) Table up is done.
4.
(1) M60 command only in MEM mode.
It must be set 60 in No. 6072 of parameter.
(2) It must be set 1 in No.3202.4 of parameter for edit O9000~O9999.
10-31
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-32
10-7 SETTING OF PART PROGRAM (APC)
PROCEDURE：
1. Press the function key SYSTEM
2. Press the soft key [PMC]→[PMCPRM]→[DATA]→[G.DATA].
3. Input part program number to address as follows：
ADDRESS：
D50
：Part program number for pallet A
D52
：Part program number for pallet B
Note：
1. When it wants automatic call program, K6.0 must be set 1.
2. If A、B pallet program number are the same, K6.0 set 0 or D50 and D52 set
same part program number.
3. If it wants automatic cycle once after command M30, K6.1 set 1 and K6.2
set 0, then press the “CYCLE START” button.
4. If it wants automatic cycle continually after command M30, K6.1 and K6.2
set 1.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-8 MDI MODE MAINTENANCE OPERATION
10-8-1 MCV-610＋APC
The following M commands are valid at MDI mode for maintenance under
certain conditions:
M56 : Auto door up.
M57 : Auto door down.
M58 : Table up.
M59 : Table down.
M66 : Table A moves to the left.
Conditions.
(1) Auto door up.
(2) Table up.
(3) X axis is at the 1st reference point.
(4) Y axis is at the 1st reference point.
(5) There is a table on the A position of the pallet changer.
M67 : Table B moves to the right.
Conditions:
(1) Auto door up.
(2) Table up.
(3) X axis is at the 1st reference point.
(4) Y axis is at the 1st reference point.
(5) There is no table on the A position of the pallet changer.
10-33
10-34
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
M68 : Table B moves to the left.
Conditions:
(1) Auto door up.
(2) Table up.
(3) X axis is at the 1st reference point.
(4) Y axis is at the 2nd reference point.
(5) There is a table on the B position of the pallet changer.
M69 : Table B moves to the right.
Conditions:
(1) Auto door up.
(2) Table up.
(3) X axis is at the 1st reference point.
(4) Y axis is at the 2nd reference point.
(5) There is no table on the B position of the pallet changer.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-35
If the above M commands are ineffective with all the conditions satisfied, do
the following:
(1) Check if the hydraulic pressure is enough (35 kg/cm2±10%). Note that the
pressure cannot exceed (35+10%) kg/cm2 ), otherwise the table will be
deformed by the hydraulic clamp force.
(2) Check if the solenoid is dirty. If so, clean it.
SOLENOID VALVE
HYDRAULIC UNIT
PRESSURE
ADJUSTEMENT
APC DOOR UP、DOWN
A PALLET LEFT、RIGHT
B PALLET LEFT、RIGHT
PALLET UP、DOWN
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
10-36
10-8-2 MCV-1020BA＋APC
Use MDI mode while maintenance. The following M codes can start
solenoid valve under the satisfactions of both operation program and
conditions.
M56：Auto door up.
M57：Auto door down.
M58：Table up.
M59：Table down.
M66：Table moves to the left.
Conditions.
(1) Auto door up.
(2) Table up.
(3) X axis is at the 2nd reference point.
(4) a. Y axis is at the 2ndt reference point, there is a table on the pallet
changer A.
b. Y axis is at the 3rd reference point, there is a table on the pallet
changer B.
M67：Table moves to the right.
Conditions：
(1) Auto door up.
(2) Table up.
(3) X axis is at the 2nd reference point.
(4) a. Y axis is at the 2ndreference point, there is no table on the pallet
changer A.
b. Y axis is at the 3rd reference point, there is no table on the pallet
changer B.
10. AUTOMATIC PALLET CHANGER (APC OPTIONAL)
10-9 HYDRAULIC DIAGRAM
MCV-610 APC HYDRAULIC DIAGRAM
10-37
10-38
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
MCV-1020BA＋APC
A1. AUTOMATIC TOOL LENGTH BREAKAGE DETECTION
(G36)………............................................................... A-2
A2. AUTOMATIC TOOL LENGTH B DETECTION (G37)……….... A-9
B. OPEN/CLOSE LINEAR SCALE...................................... B-1
C. SETTING OF 4th & 5th AXIS.......................………........... C-1
D1. CALL A/B PALLET PROGRAM (FOR CHAIN TYPE APC)…
D-1
D2. CALL A/B PALLET PROGRAM (FOR GEAR TYPE APC)…… D-2
E.
Z AXIS RETURN WHEN AUTO TOOL CHANGE FOR
MACRO PROGRAM…………………………………………… E-1
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
A-2
A1.AUTOMATIC TOOL LENGTH
BREAKAGE DETECTION(G36)
1. O9011 this G36 macro for FANUC 18M, 0iMB, 18iMB and 21iMB.
2. Definition：By using G36 command to detect automatically if tool
is broken.
3. General wiring diagrams.
I/O interface PCB
105A
24V
Sensor
MCV I/O interface PCB
terminal
DL-VM001 TB1:105 & 24V
DL-VM002 TB2:325 & 24V
DL-VM004 TB1:325 & 24V
DL-VM005 TB5:325 & 24V
MCH I/O interface PCB
4. Set machine type.
Type
MCH-500 MCH-800
#504
1
other
2
3
5. Set tool compensation type.
#500：Tool compensation number.(preset value=2)
Not greater Greater than
than 200
200
Type A
Type B
Type C
1
2
3
4
5
6
6. Set machine coordinate (X,Y,Z) of Sensor：
Refer to the Automatic Tool Length Detect(G37).
7. Application：
Command：
G36
H__( X__Y__ )
A. TOOL DETECTION
G36 ：Command of auto. tool length breakage detection
H：OFFSET NO. of tool length in program
X,Y：X,Y axes bias of tool edge to center of face cutter
NOTE：(
) can be forgotten when they are not used.
A-3
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
A-4
8. Flow chart of auto. Tool length detection：
START
Is there output of signal
from sensor?
YES
ALARM(3003 SKIP SIGNAL IS BREAK)
NO
H=NULL
YES
ALARM(3001 FORMAT ERROR)
NO
H No. over range?
YES
ALARM(3004 TOOL COMPENSATION NO. OVER)
NO
Z axis zero return;
Move X,Y to sensor.
inch or metric
system
inch
metric
#107=0.03937
#107=1
#504 setting error
YES
ALARM(3005 MACHINE TYPE DATA ERROR)
NO
Bring down Z axis to the
position about 30mm(1.18inch)
to sensor
Touch sensor
Is there output of signal
from sensor?
NO
YES
Compare the
measurement data with
tool length offset
>1mm
(0.03937inch)
<1mm
(0.03937inch)
Write tool wear to offset
value
END
ALARM(3002 TOOL BROKEN)
A. TOOL DETECTION
%
O9011(TOOL BROKEN DETECTION)
(FORMATOG36H--,G36)(G36-MCV-V1.1,20080125)
G500
M45
M94
IF[#1015EQ1]GOTO902
IF[#11NE#0]GOTO1
#11=#149
N1
(OFFSET TYPE)
IF[#500EQ#0]GOTO10
IF[#500EQ0]GOTO10
IF[#500GT6]GOTO10
#109=#500
GOTO20
N10
#109=2
N20
IF[#11EQ0]GOTO903
IF[#109LT4]GOTO30
IF[#109EQ4]GOTO40
IF[#11GT400]GOTO903
GOTO50
N30
IF[#11GT200]GOTO903
GOTO50
N40
IF[#11GT999]GOTO903
N50
#104=#3005AND4
IF[#104EQ0]GOTO60
IF[#4006EQ21]GOTO60
GOTO70
N60
#106=0(MM)
GOTO80
N70
A-5
A-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
#106=1(INCH)
N80
#30=0
#21=0
#28=0
#120=0
#101=#4001
#102=#4003
#103=#4014
IF[#103EQ54.1]GOTO90
#29=#[5223+[[#103-54]*20]]+#5203
GOTO100
N90
#108=#4130
#29=#[7003+[[#108-1]*20]]+#5203
N100
IF[#504EQ#0]GOTO904
IF[#504EQ0]GOTO904
IF[#504GT3]GOTO904
IF[#109GT3]GOTO160
IF[#109GT1]GOTO150
#105=#[#11+2000]
IF[#[#11+2000]EQ0]GOTO905
GOTO180
N150
#105=[#[#11+2200]]+[#[#11+2000]]
IF[#[#11+2200]EQ0]GOTO905
GOTO180
N160
IF[#109GT4]GOTO170
#105=#[#11+10000]
IF[#[#11+10000]EQ0]GOTO905
GOTO180
N170
#105=[#[#11+11000]]+[#[#11+10000]]
IF[#[#11+11000]EQ0]GOTO905
N180
G91G28Z0
A. TOOL DETECTION
G49G90G40G80
IF[#504EQ3]GOTO500
M26
IF[#504EQ1]GOTO500
G10L50
N1321P2R-50000
G11
N500
M19
IF[#106EQ0]GOTO190
#107=0.03937(INCH)
GOTO200
N190
#107=1(MM)
N200
G00G90G53X[#501*#107+#24]Y[#502*#107+#25]
G00G90G53Z[#503*#107+#105+[50.*#107]]
N202
#31=2*#107
#32=3*#107
G4X1.
G91G31Z[-[100.*#107]]F[1000*#107]
G04
IF[#1015NE1]GOTO901
G91G01G09Z#31F[400*#107]
#3004=2
G31Z-#32F[50*#107]
G04
#21=#5063
G91G01G09Z#31F[400*#107]
G91G31Z-#31F[50*#107]
M95
G04
#27=[#21+#5063]/2
#30=800/60000
#33=[#503*#107]
#28=[#29+#27]-#33+#30
#110=#28-#105
A-7
A-8
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
IF[#109GT3]GOTO220
IF[#109GT1]GOTO210
#[#11+2000]=#28
GOTO240
N210
#[#11+2000]=#[#11+2000]+#110
GOTO240
N220
IF[#109GT4]GOTO230
#[#11+10000]=#28
GOTO220
N230
#[#11+10000]=#[#11+10000]+#110
N240
#3004=0
IF[[ABS[#110]]GT1]GOTO250
GOTO260
N250
#120=1
N260
G91G28Z0
IF[#504EQ3]GOTO510
G28Y0
M27
IF[#504EQ1]GOTO510
G10L50
N1321P2R50000
G11
N510
G#101G#102
IF[#103EQ54.1]GOTO270
G90G#103
GOTO300
N270
G90G54.1P[#108]
N300
IF[#120EQ1]GOTO901
M95
A. TOOL DETECTION
M99
N900
#3000=1(FORMAT ERROR)
N901
#3000=2(TOOL BROKEN)
N902
#3000=3(SKIP SIGNAL IS BREAK)
N903
#3000=4(TOOL COMPENSATION NO. OVER)
N904
#3000=5(MACHINE TYPE DATA ERROR)
N905
#3000=6(TOOL LENGTH DATA ERROR)
%
NOTE 1：
#500：Tool compensation number.(preset value=2)
Not greater Greater than
than 200
200
Type A
Type B
Type C
1
2
3
4
5
6
#501：X axis machine coordinate of center of Sensor.
#502：Y axis machine coordinate of center of Sensor
#503：Z axis machine coordinate of center of Sensor
#504：Set machine type.
Type
#504
NOTE 2：
It must be set
MCH-500 MCH-800
1
2
other
3
A-9
A-10
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
(1)
36 in NO.6051 of parameter (18M, 0i/18i/21iMB)
(2)
1 in NO.6200.1(SK0)
(3)
1 in NO.3201.5(N99)
A2.AUTOMATIC TOOL LENGTH
DETECTION(G37)
1.O9010 this G37 macro for FANUC 18M,0iMB,18iMB,21iMB.
2.Definition：By using G37 command to detect automatically tool
Length.
3.General wiring diagrams.
MCV I/O interface PCB
terminal
DL-VM001 TB1:105 & 24V
DL-VM002 TB2:325 & 24V
DL-VM004 TB1:325 & 24V
DL-VM005 TB5:325 & 24V
I/O interface PCB
105A
24V
Sensor
Type
MCH I/O interface PCB
terminal
MCH-500 MCH-800 other
#504
1
4.Set machine type.
2
3
5.Set tool compensation type.
#500：Tool compensation number.(preset value=2)
Not greater Greater than
than 200
200
Type A
Type B
Type C
1
2
3
4
5
6
6.Set machine coordinate (X,Y,Z) of Sensor：
A. Machine coordinate of Sensor：
A. TOOL DETECTION A-11
#501：X axis machine coordinate of center of Sensor.
#502：Y axis machine coordinate of center of Sensor
#503：Z axis machine coordinate of center of Sensor
Put a tool which length is already know
#503
B. Method of setting #503：
on the spindle.
If machine type is MCH input M26
SENSOR
command of auto. tool length detection
ON, If machine type=MCH-800 define the coordinate values of
stored stroke checks in the negative directions for Y axis in
machine coordinate system(parameter 1321=-50000 and M26 ).
Manually move Z axis to Sensor. Detecting Sensor signal by
DGN(18M：X1004.7,0i/18i/21iMB：X4.7) While tool approaches
Sensor, move Z axis slowly until tool touches Sensor.
(18M：X1004.7,0i/18i/21iMB：X4.7) is ON when Sensor is
touched.
Ex. 0iMB：
X4
□1111111
1
Write down Z axis machine coordinate of this point.
#503：Z axis machine coordinate – tool length
Ex：Z axis coordinate：– 324.158
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
A-12
Tool length
： 230.45
Then #503= – 324.158 – 230.45= – 554.608
Note：(1) It’s not necessary to set #501,#502 and #503 every time,
Unless they are modified or cleared.
(2) #503 is a negative value.
(3) If machine type is MCH, When #501~#503 setting
complete, Input M27 command of auto. tool length
detection OFF, If machine type=MCH-800 define the
coordinate values of stored stroke checks in the
negative directions for Y axis in machine coordinate
system(parameter 1321=50000 and M27 ).
7.Application：
Command：
G37
H__Z__( T__X__Y__ )
G37 ：Command of auto. tool length detection
H：OFFSET NO. of tool length in program
Z：about tool length(Max . ±50mm)
T：tool number (It can be forgotten when tool number is spindle
tool)
X,Y：X,Y axes bias of tool edge to center of face cutter
NOTE：(
) can be forgotten when they are not used.
A. TOOL DETECTION A-13
8. Flow chart of auto. Tool length detection：
START
Is there output of signal
from sensor?
H=NULL
or
Z=NULL
YES
ALARM(3003 SKIP SIGNAL IS BREAK)
YES
ALARM(3001 FORMAT ERROR)
NO
H No. over range?
YES
ALARM(3004 TOOL COMPENSATION NO. OVER)
YES
ALARM(3005 MACHINE TYPE DATA ERROR)
NO
#504 setting error
NO
Z axis zero return
Is there data in T?
NO
YES
Automatic tool change
X,Y axis move to the
position of sensor
inch or metric system
metric
inch
#107=0.03937
#107=1
Bring down Z axis to the position
about 50mm(1.97inch) to sensor
Touch sensor
Is there output of signal
from sensor?
NO
YES
Write tool length to
offset value
END
ALARM(3002 TOOL NOT FOUND)
A-14
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
%
O9010(TOOL LENGTH MEASUREMENT)
(FORMATOG37T--H--Z--,G37H--Z--,G37)(G37-MCV-V1.1 20080125)
G500
M45
M94
IF[#1015EQ1]GOTO902
(OFFSET TYPE)
IF[#500EQ#0]GOTO10
IF[#500EQ0]GOTO10
IF[#500GT6]GOTO10
#109=#500
GOTO20
N10
#109=2
N20
IF[#109LT4]GOTO30
IF[#109EQ4]GOTO40
IF[#11GT400]GOTO903
GOTO50
N30
IF[#11GT200]GOTO903
GOTO50
N40
IF[#11GT999]GOTO903
N50
#104=#3005AND4
IF[#104EQ0]GOTO60
IF[#4006EQ21]GOTO60
GOTO70
N60
#106=0(MM)
GOTO80
N70
#106=1(INCH)
N80
#30=0
#21=0
#28=0
#101=#4001
#102=#4003
A. TOOL DETECTION A-15
#103=#4014
IF[#103EQ54.1]GOTO90
#29=#[5223+[[#103-54]*20]]+#5203
GOTO100
N90
#108=#4130
#29=#[7003+[[#108-1]*20]]+#5203
N100
IF[#504EQ#0]GOTO904
IF[#504EQ0]GOTO904
IF[#504GT3]GOTO904
G00G91G28Z0
G49
IF[#20EQ#0]GOTO130
IF[#20EQ#4120]GOTO130
IF[#504NE1]GOTO500
G91G30Y0Z0
N500
G91G28Z0
M6T#20
N130
M19
IF[#504EQ3]GOTO520
M26
IF[#504EQ1]GOTO520
G10L50
N1321P2R-50000
G11
N520
IF[#106EQ0]GOTO140
#107=0.03937(INCH)
GOTO150
N140
#107=1(MM)
N150
G00G90G53X[#501*#107+#24]Y[#502*#107+#25]
IF[#26EQ#0]GOTO151
G00G90G53Z[[#503*#107]+#26+[50.*#107]]
#31=2*#107
#32=3*#107
G04X1.
A-16
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
IF[#1015NE1]GOTO160
G91G01G09Z[50.*#107]
N160
G91G31Z-[100.*#107]F[1000*#107]
IF[#1015NE1]GOTO901
G01G09Z#31F[400*#107]
#3004=2
G31Z-#32F[50*#107]
G04
#21=#5063
M01
G01G09Z#31F[400*#107]
G31Z-#32F[50*#107]
M95
GOTO161
N151
#31=2*#107
#32=3*#107
G04X1.
IF[#1015NE1]GOTO152
G91G01G09Z[50.*#107]
N152
G91G31Z[#503*#107]F[2000*#107]
IF[#1015NE1]GOTO901
G01G09Z#31F[400*#107]
#3004=2
G31Z-#32F[50*#107]
G04
#21=#5063
M01
G01G09Z#31F[400*#107]
G31Z-#32F[50*#107]
M95
N161
#27=[#21+#5063]/2
#30=800/60000
#33=[#503*#107]
#28=[#27+#29]-#33+#30
IF[#11NE#0]GOTO162
#11=#149
N162
A. TOOL DETECTION A-17
IF[#109GT3]GOTO180
IF[#109GT1]GOTO170
#[#11+2000]=#28
GOTO200
N170
#[#11+2200]=#28
#[#11+2000]=0
GOTO200
N180
IF[#109GT4]GOTO190
#[#11+10000]=#28
GOTO200
N190
#[#11+11000]=#28
#[#11+10000]=0
N200
#3004=0
G00G91G28Z0
IF[#504EQ3]GOTO530
G28Y0
IF[#504EQ1]GOTO530
G10L50
N1321P2R50000
G11
M27
N530
G#101G#102
IF[#103EQ54.1]GOTO210
G90G#103
GOTO230
N210
G90G54.1P[#108]
N230
M95
M99
N900#3000=1(FORMAT ERROR)
N901#3000=2(TOOL NOT FOUND)
N902#3000=3(SKIP SIGNAL IS BREAK)
N903#3000=4(TOOL COMPENSATION NO. OVER)
N904#3000=5(MACHINE TYPE DATA ERROR)
%
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
A-18
NOTE 1：
#500：Tool compensation number.(preset value=2)
Not greater Greater than
than 200
200
Type A
Type B
Type C
1
2
3
4
5
6
#501：X axis machine coordinate of center of Sensor.
#502：Y axis machine coordinate of center of Sensor
#503：Z axis machine coordinate of center of Sensor
#504：Set machine type.
Type
MCH-500 MCH-800
#504
1
2
other
3
NOTE 2：
It must be set
(1)
37 in NO.6050 of parameter
(2)
(3)
1 in NO.6200.1(SK0)
1 in NO.3201.5(N99)
B. OPEN/CLOSE LINEAR SCALE
B-1
B.OPEN/CLOSE LINEAR SCALE
1. Move to the middle position for table that you want to specify’s
axis, and rapid mode switching to “L”.
2. The following table lists parameter related to the linear scale.
(1) ISB/ 3 digit after decimal point：
Pitch
10mm
12mm
Open
Open
PRM.NO Close
1005#1
(DLZX)
0
0
1
0
1
0
1
0
Close
LS176 LF191 LF192
0
0
Description
Open
Close
LS176 LF191 LF192
1815#1
(OPTX)
16mm
1
0
1
0
1
0
LS176 LF191 LF192
0
0
1
0
1
0
1
A separate
detector is:
0:not used
1: used
0
Function for
setting the
reference position
without dogs:
0:invalid
1:valid
2000#0
(PLC)
0
0
1
0
0
0
1
0
0
0
1
0
Velocity and
position pulses by
ten internally:
0:invalid.
1:valid.
2023
8192
8192
819
8192
8192
8192
819
8192
8192
8192
819
8192
Number of velocity
pulse.
2024
12500 10000 10000 20000 12500 12000 12000 24000 12500 16000 16000 32000
Number of
position pulse.
2084
1
1
1
1
3
1
1
1
4
1
1
1
Flexible feed gear.
(numerator)
2085
100
1
10
20
250
1
10
20
250
1
10
20
Flexible feed gear.
(denominator)
2185
0
0
0
10
0
0
0
10
0
0
0
10
Position pulse
conversion
coefficient.
1821
10000 10000 10000 10000 12000 12000 12000 12000 16000 16000 16000 16000
Reference counter
size.
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
B-2
(2) ISC/ 4 digit after decimal point：
Pitch
10mm
12mm
Open
Open
PRM.NO Close
1005#1
(DLZX)
0
1
0
0
1
0
1
0
Close
LS176 LF191 LF192
0
0
Description
Open
Close
LS176 LF191 LF192
1815#1
(OPTX)
16mm
1
0
1
0
1
0
LS176 LF191 LF192
0
0
1
0
1
0
1
A separate
detector is:
0:not used
1: used
0
Function for
setting the
reference position
without dogs:
0:invalid
1:valid
2000#0
(PLC)
0
0
1
0
0
0
1
0
0
0
1
0
Velocity and
position pulses by
ten internally:
0:invalid.
1:valid.
2023
8192
8192
819
8192
8192
8192
819
8192
8192
8192
819
8192
Number of velocity
pulse.
2024
12500 10000 10000 20000 12500 12000 12000 24000 12500 16000 16000 32000
Number of
position pulse.
2084
1
10
1
1
3
10
1
1
4
10
1
1
Flexible feed gear.
(numerator)
2085
10
1
1
2
25
1
1
2
25
1
1
2
Flexible feed gear.
(denominator)
2185
0
0
0
10
0
0
0
10
0
0
0
10
1821
100000 100000 100000 100000 120000 120000 120000 120000 160000 160000 160000 160000
Position pulse
conversion
coefficient.
Reference counter
size.
Note：1. Detect unit 1μ for “LS176”; detect unit 0.1μ for “LF191”; detect unit
0.05μ for “LF192”.
2. If it generates “AL.410 servo excess error：xx axis”, please setting
PRM.2018#0 (The signal direction for the separate detector).
3. If it generates “AL.445 soft disconnection alarm”, and check “FSSB” if
setting.
3. Turn off the power on again, then mode select switch change to
“HANDLE”.
B. OPEN/CLOSE LINEAR SCALE
B-3
4. Turning the plus/minus direction slow to check speed if normal
for specify axis just now.
5. If handle mode is normal, then test Jog→Rapid→Zero Return etc.
6. It is successfully after finish above action.
7. After finish above action, setting the PRM.1005#1(DLZX) to “1”,
then to prevent coordinate shift.
NOTE：If it close linear scale, you must check your program
coordinate if shift. (very important)
C. SETTING OF 4th & 5th AXIS
C-1
C. SETTING OF 4th & 5th AXIS
1.Axial diagram
The axial of leftside is MCV type, the
nomenclature of axial usually by the rotate
direction which the axes surround.
1) The axis which surround X axis definition A axis
2) The axis which surround Y axis definition B axis
3) The axis which surround Z axis definition C axis
th
th
Normally, 4 5 axes will have
(Tilt axis) and (Rotate axis)
2. Nomenclature of axial on MCV
Z
X
Y
The diagram of left was generally MCV.
From diagram could see 4th 5th axis was
surround X axis and Z axis.
◎Tilt axis(T) definition A axis
【surround X axis】
◎Rotate axis(R) definition A axis
【surround Z axis】
C-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
3.The 4th 5th axis control button on operate panel
4.Describe of control button
◎A axis（4 thaxis、Tilt axis）surround X axis and
rotate by clockwise(C W)
◎A axis reference point return.
◎A axis（4 thaxis、Tilt axis）surround X axis and
rotate by counter clockwise(CC W)
◎C axis（5 thaxis、Rotate axis）surround Z axis and
rotate by counter clockwise(CC W)
◎C axis reference point return.
◎C axis（5 thaxis、Rotate axis）surround Z axis and
rotate by counter clockwise(CC W)
C. SETTING OF 4th & 5th AXIS
5. Setting of servo parameter
◎PRM.1020 and PRM.1022
◎PRM.1023
6.Setting of FSSB servo control
C-3
C-4
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
7. The power ＆ signal cable of 4th 5th axis
Only forFANUC 18iMB、21iMB、OiMB及OiMC
◎Power cable of the 4th axis(inside)
MS102A 28-11P
(front connect)
J
insulator
color
back connect
brown
UA
K
blue
VA
L
M
A
B
C
black
yellow/green
white
WA
G
24V
339
338
R
black
24V
S
white
303
N
black
2
P
white
45A /45B
black
red
note
Motor power cable
4th axis
clamp/unclamp
signal
Reference signal
detect
Power cable of
electromagnetic
valve
C. SETTING OF 4th & 5th AXIS
C-5
◎ Power cable of the 5th axis(inside)
MS102A 28-11P
(front connect)
J
insulator
color
back connect
brown
UB
K
blue
VB
L
M
A
B
C
black
white
WB
G
24V
465
466
R
black
24V
S
white
304
N
black
2
P
white
84
U
black
100
V
white
200
D
black
101
E
white
101A
yello/green
black
red
note
Motor power cable
5th axis
clamp/unclamp
signal
Reference signal
detect
Power cable of
electromagnetic
valve
EMG release
+/- direction limite
cancel
C-6
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
◎Signal cable of 4th 5th axis(inside)
FI-20-CV5(AMP側)
A side(20pin）
insulator
color
FI-20-CV5(AMP側)
B side(military connect）
12
yellow
N
14
walnut
T
9
red
J
20
green
K
7
blue
R
5
black
F
6
white
G
quarantine
quarantine
H
parallel
parallel
◎ Signal cable of 4th 5th axis(outside)
MS3106B 20-29S
A side
insulator
color
CVS08DA 20-29SW
Bside
N
yellow
N
T
walnut
T
J
red
J
K
green
K
R
blue
R
F
black
F
G
white
G
H
quarantine
H
parallel
parallel
D. CALL A/B PALLET PROGRAM
D-1
D1. CALL A/B PALLET PROGRAM
(FOR CHAIN TYPE APC)
9004(CALL A-PALLET-M601)
#100=#4003
G91G28X0
IF[#1013EQ1]GOTO1(A PALLET FOR INSIDE)
IF[#1014EQ1]GOTO2(B PALLET FOR INSIDE)
IF[[#1013+#1014]EQ0]GOTO3(WITHOUT PALLET FOR INSIDE)
GOTO1
N2G30Y0
M63
G28Y0
M64
GOTO1
N3G28Y0
M56
M58
M66
M59
M57
GOTO1
N1G#100
M99
9005(CALL B-PALLET-M602)
#100=#4003
G91G28X0
IF[#1014EQ1]GOTO1(B PALLET FOR INSIDE)
IF[#1013EQ1]GOTO2(A PALLET FOR INSIDE)
IF[[#1013+#1014]EQ0]GOTO3(WITHOUT PALLET FOR INSIDE)
GOTO1
N2G28Y0
M61
G30Y0
M62
GOTO1
N3G30Y0
M56
M58
M68
M59
M57
GOTO1
N1G#100
M99
%
NOTE：PRM.6074=601；PRM.6075=602.
D-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
D2. CALL A/B PALLET PROGRAM
(FOR GEAR TYPE APC)
9004(CALL A-PALLET-M601)
#100=#4003(G90/G91)
IF[#1013EQ1]GOTO1(A PALLET FOR INSIDE)
IF[#1014EQ1]GOTO2(B PALLET FOR INSIDE)
IF[[#1013+#1014]EQ0]GOTO3(WITHOUT PALLET FOR INSIDE)
GOTO1
N2G30G91P3Y0
G10L50
N1321P1R-85000
N6950R-88000
G11
G91G30X0
M61
G91G30P2Y0
M62
G53G90X0
G10L50
N1321P1R-3000
N6950R-6000
G11
GOTO1
N3G91G30P2Y0
G10L50
N1321P1R-85000
N6950R-88000
G11
M59
G30X0
M56
M58
M66
M59
M57
G53G90X0
G10L50
N1321P1R-3000
N6950R-6000
G11
GOTO1
N1G#100
M99
D. CALL A/B PALLET PROGRAM
9005(CALL B-PALLET-M602)
#100=#4003(G90/G91)
IF[#1014EQ1]GOTO1(B PALLET FOR INSIDE)
IF[#1013EQ1]GOTO2(A PALLET FOR INSIDE)
IF[[#1013+#1014]EQ0]GOTO3(WITHOUT PALLET FOR INSIDE)
GOTO1
N2G91G30P2Y0
G10L50
N1321P1R-85000
N6950R-88000
G11
G91G30X0
M61
G91G30P3Y0
M62
G53G90X0
G10L50
N1321P1R-3000
N6950R-6000
G11
GOTO1
N3G91G30P3Y0
G10L50
N1321P1R-85000
N6950R-88000
G11
M59
G30X0
M56
M58
M66
M59
M57
G53G90X0
G10L50
N1321P1R-3000
N6950R-6000
G11
GOTO1
N1G#100
M99
%
NOTE：PRM.6074=601；PRM.6075=602.
D-3
E. Z AXIS RETURN WHEN AUTO TOOL CHANGE FOR MACRO PROGRAM
E-1
E. Z AXIS RETURN WHEN AUTO
TOOL CHANGE FOR MACRO
PROGRAM
%
:9000
#100=#4003(G90/G91)
IF[#1008EQ1]GOTO100(SPINDLE TOOL JUDGE)
T#149
N100M31
G#100
M99
:9003
#100=#4003(G90/G91)
IF[#1008EQ1]GOTO100(SPINDLE TOOL JUDGE)
G91G28Z0
IF[#1008EQ1]GOTO100(SPINDLE TOOL JUDGE)
G4X0.5
M6T#20
N100M31
G#100
G49
M99
%
NOTE： 1. If magazine is HYD. or CAM type, set parameter 6001#5(TCS) to “1”
、NO.6073=6, KEEP RELAY K10#6 set to “1”.
2.It is only applied to HYD. or CAM type magazine above macro
program.
E-2
MACHINING CENTER OPERATION AND MAINTENANCE MANUAL
%
O9020
#100=#4003
IF[#20EQ#0]GOTO200
N100IF[#20EQ#999]GOTO300
G91G28Z0
T#20M6
#999=#20
GOTO300
N200IF[#4120EQ#999]GOTO300
G91G28Z0
T#4120M6
#999=#4120
N300G#100
M99
%
NOTE：1.It is only applied to DRUM type magazine above macro program.
2.PRM.6080 set “6”.