GE Fanuc Operator Manual-2005.book

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.4 FLOOD COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.5 SPINDLE COOLER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2.0 OPERATOR PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1 POWER ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1.1 POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1.2 POWER OF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.2 SAFETY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2.2.1 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2.2.2 DOOR OVRD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 2.2.3 WORK LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2.4 ALARM MSG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3 OPERATION MODE SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3.1 AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3.2 EDIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3.3 MDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 2.3.4 REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.3.5 REF RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.3.6 JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.3.7 HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.0 MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3.1 MANUAL OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1.1 MANUAL REFERENCE POSITION RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1.2 JOG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.1.3 INC JOG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.1.4 HANDLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.1.5 JOG FEED RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.0 AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 4.1 AUTOMATIC OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 4.1.1 MDI OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.1.2 MEMORY PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 4.1.3 DNC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 4.1.4 MEMORY PROTECTION KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 5.0 TEST FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 5.1 TEST FUNCTION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.1.1 SINGLE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 5.1.2 BLOCK DELETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 iii TABLE OF CONTENTS MAN-0114R1 FADAL MACHINING CENTERS 5.1.3 OPTION STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 5.1.4 MC LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.1.5 DRY RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.0 MACHINE SETUP FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.1 SETUP MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 6.1.1 WORK MEAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 6.1.2 TOOL MEAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 6.1.3 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 6.1.4 HOME PSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 6.1.5 LOAD PSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.1.6 Z HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 7.0 TOOL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 7.1 MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7.1.1 DRUM FRWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 7.1.2 DRUM REV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 7.1.3 DRUM PSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 7.1.4 TOOL REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.1.5 TOOL CHNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 7.1.6 TOOL LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.1.7 REFERENCE THE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 7.2 AUTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 7.2.1 T-COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 7.2.2 TOOL CHANGER COMMAND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 7.3 TOOL MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 7.3.1 INIT MAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 7.3.2 TOOL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 7.3.3 TOOL BRKN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 7.3.4 EDIT THE TOOL/MAGAZINE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 7.3.5 TOOL ORDER PROCEDURE (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 7.3.6 TOOL LOADING (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 7.3.7 TOOL CHANGER (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8.0 COOLANT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 8.1 COOLANT CONTROL PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8.1.1 AUTO COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8.1.2 FLOOD COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8.1.3 MIST COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 9.0 SPINDLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 9.1 SPINDLE OPERATION PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 9.1.1 SPDL STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 9.1.2 SPDL CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 9.1.3 SPDL CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 9.1.4 MANUAL SPINDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9.1.5 M CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9.1.6 SPINDLE SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 9.1.7 SPINDLE OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 9.1.8 SPINDLE ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 JULY 2005 TABLE OF CONTENTSiv GE FANUC OPERATOR MANUAL 10.0 HMOP OPERATION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 10.1 HMOP OPERATION ON/ OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 10.2 OVERRIDE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 10.3 MEMORY OPERATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 10.4 MANUAL HANDLE FEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 10.5 MANUAL JOG FEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 10.6 MANUAL REFERENCE RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 10.7 MANUAL SPINDLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 10.8 KEY SHEET LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 10.8.1 TOOL REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 10.9 MESSAGE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 11.0 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 11.1 M CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 11.2 ALARM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 11.3 MACHINE COLD START PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 11.4 FANUC FILES BACKUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 12.0 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 1 of 53 1.0 PRESTART CHECKING STEPS MAN-0114R1 FADAL MACHINING CENTERS 1.0 PRESTART CHECKING STEPS 1.1 OIL RESERVOIR Examine the oil levels. Both levels should be filled up to one inch from the bottom of the reservoir. The spindle oil reservoir may have oil in it for up to six months. The way lube oil reservoir may run out of oil in one week. 1.2 AIR PRESSURE Visually inspect the air pressure gauge to verify that it is set to at least 80-100 PSI. Air is used to change belt ranges in the spindle, orient the spindle, activate the tool in-out cylinder, and it is, also, used for the air blast during a tool change. The tool changes gauge should not exceed 120 PSI. VMCs with linear way systems require grease. See the Maintenance Manual on specifications on the way lube and the spindle oil. NOTE: JULY 2005 1.0 PRESTART CHECKING STEPS2 of 53 GE FANUC OPERATOR MANUAL 1.3 WATER RESER- VOIR Most new VMC models release water collected in the water reservoir automatically. It is advisable to place an additional water trap in the air line going to the machine. 1.4 FLOOD COOLANT Replenish the flood coolant level to avoid running out of coolant during execution of the program. 1.5 SPINDLE COOLER RESERVOIR Examine the spindle cooler reservoir once a month. 3 of 53 2.0 OPERATOR PANEL LAYOUT MAN-0114R1 FADAL MACHINING CENTERS 2.0 OPERATOR PANEL LAYOUT 2.1 POWER ON/OFF 2.1.1 POWER ON 1.Turn On the main breaker To power on the machine, press the safety lock and turn the power switch in the clockwise direction. 2. Press the CNC ON push button. CNC will boot up and enter operating status. 2.1.2 POWER OFF Operator Panel B layout JULY 2005 2.0 OPERATOR PANEL LAYOUT4 of 53 GE FANUC OPERATOR MANUAL 1.Press the CNC OFF push button. 2.Turn off the main breaker. To power off the machine, turn the power switch in the counterclockwise direction. GE Fanuc 18i-MB5 control is equipped with cMain B d Operator Panel. 55 Push button layout is pictured above. Clear key caps and custom legends have been installed as presently defined for machine use. Unless otherwise noted, buttons fit with blank key caps (no legend) are not defined for user-customer use. 2.2 SAFETY FUNC- TIONS 2.2.1 EMERGENCY STOP SWITCH If you press Emergency Stop button on the machine operator 9s manual, machine movement stops in a moment. This button is locked when it is pressed, and can be unlocked by twisting it. When the emergency stop is pressed, the emergency stop command is applied to the machine, and the CNC is reset, spindle and XYZ axes are stopped, and the other actions are interrupted. CNC will display EMG STOP message on the screen. DRY RUN MC LOCK TOOL MEAS TOOL BRKN DRUM REV DRUM FWD DOOR OVRD WORK LIGHT OPT STOP BLOCK DELETE SINGLE BLOCK WORK MEAS MDI EDIT AUTO REMOTE LOAD PSN HOME PSN Z HOME INIT MAG WASH DWN DRUM PSN TOOL DATA X 100 X 10 X 1 X 1000 INC JOG JOG REF RETURN HANDLE 6 5 4 - TRVRS + Z Y X AUTO COOL FLOOD COOL MIST COOL PRG STOP CYCLE START CYCLE STOP ALARM MSG LOAD TOOL TOOL CHNG TOOL REL FUNC SPDL CCW SPDL STOP SPDL CW EMERGENCY STOP 5 of 53 2.0 OPERATOR PANEL LAYOUT MAN-0114R1 FADAL MACHINING CENTERS 2.2.2 DOOR OVRD This push button enables opening machine doors without generating Feed Hold & Cycle Start inhibits. While door override is applied, LED is flashing & Operator Message (2006 Door open override is active) is displayed to remind that override is active. Operation of Door Override push button may be selected as latching (default) or momentary style by user. Latching operation provides On/Off toggle function. Momentary function requires operator to hold push button while door override is required. 2.2.3 WORK LIGHT Operator control of machine 9s work light(s). Pressing push button toggles work light On/ Off. Machine work light is set to automatically turn on with power-up of machine. 2.2.4 ALARM MSG Pressing this button will reset the CNC and clear the PMC message. 2.3 OPERATION MODE SELECTION 2.3.1 AUTO Auto (Memory) Mode (Fanuc operator manual GFZ-63534EN Section 4.1) Auto Mode also is called Memory Mode. Automatic operation of part program selected from program files registered in control 9s program directory. 2.3.2 EDIT Edit Mode (Fanuc operator manual GFZ-63534EN, Section 9) Edit mode enables entering and editing of part programs stored in control 9s part program directory. Part programs stored on optional Data Server or memory card inserted in PCMCIA card slot are not available for editing. Programs must be edited before loading to storage media. 2.3.3 MDI Manual Data Input Mode (Fanuc operator manual GFZ-63534EN, Section 4.2) MDI mode is used for simple test operation. In the MDI mode, operator can create and execute a program consisting up to 10 lines from the MDI panel, which is in the same format as the normal program. JULY 2005 2.0 OPERATOR PANEL LAYOUT6 of 53 GE FANUC OPERATOR MANUAL 2.3.4 REMOTE Remote Mode (Fanuc operator manual GFZ-63534EN, Section 4.3, 4.13) Remote mode is also called DNC mode. In the mode, it is possible to perform machining while a program is being read in via reader/puncher interface, or remote buffer. Operator can, also, perform machining with execution of the program in the memory card, which is installed in the memory card interface, which is in the left side of the screen. 2.3.5 REF RETURNE Reference Return Mode (Fanuc operator manual GFZ-63534EN, Section 3.1) Reference Return gives an opportunity to return all the axes to the machine zero position. 2.3.6 JOG Continuous Jog Mode (Fanuc operator manual GFZ-63534EN, Section 3.3) In the continuous jog mode, pressing the direction switch on the operator 9s panel moves the tool along with the selected axes in the selected direction. 2.3.7 HANDLE Handle (MPG) Mode (Fanuc operator manual GFZ-63534EN, Section 3.4) In the handle mode, operator can move the axes by rotating the manual pulse generator on the operator 9s panel. 7 of 53 3.0 MANUAL OPERATION MAN-0114R1 FADAL MACHINING CENTERS 3.0 MANUAL OPERATION 3.1 MANUAL OPERA- TION MODES 3.1.1 MANUAL REFER- ENCE POSITION RETURN Reference Zero: Manual reference position return is to move the tool to the reference position using switches and push buttons located on the operator 9s panel. Fadal machines are equipped with Absolute Encoders. Stored position information from the encoders will initialize the current machine position at power-up. Manual referencing of axes after power-up should not be required. When position is established by absolute feedback, REF RETURN MODE will simply command axes to Home position. Reference Procedure: 1.Select REF RETURN Mode 2.Select one axis to be referenced by X, Y, Z, 4, or 5 axes button. Machine axes will move at traverse rate to home position. When each axis has completed finding the reference position, the related machine coordinate will become to zero. Press the JOG, JOG INC, HANDLE or AUTO, MDI, and EDIT mode keys to exit the Reference mode. Pressing the POS key on the MDI panel will switch to different position display which includes machine coordinate, absolute coordinate, and related coordinate. For referencing of machine axes, including initialization of absolute encoder positions, please see separate maintenance procedure in Appendix. NOTE: FADAL machines do not use reference deceleration switches for establishing machine home posi- tion. Dog-less reference operation is provided for referencing axes without reference switches. Maintenance instructions for dog-less reference must be followed exactly, otherwise machine home position will not be repeatable. JULY 2005 3.0 MANUAL OPERATION8 of 53 GE FANUC OPERATOR MANUAL 3.1.2 JOG OPERATION 1.Select JOG Mode. 2.Select one axis to be manually jogged by X, Y, Z, 4 or 5 axes buttons. Axis selec- tion button does not have to be held down. LED will light indicating selected axis. Pressing any axis button will automatically de-select previously selected axis. It is implemented to prevent jogging of more than one axis simultaneously. 3.Press and hold + or - direction button for desired direction of travel. Axis motion will continue until direction button is released. Direction LED will be lit during motion. Machine axes will travel at jog rate 200 inch per minute. Feedrate Override rotary switch may be used to vary jog rate. 4.Pressing TRVRS during continuous jog move will increase axis jog rate to traverse speed (MAX 900IPM for XY axis, 700IPM for Z axis). Feed rate rotary switch is also used to override traverse rates. NOTE: If the feedrate is at 0%, no motion will occur when using the c+/- d jog button. 6030, 8030 have the Max 400ZPM for X. Y. Z. 9 of 53 3.0 MANUAL OPERATION MAN-0114R1 FADAL MACHINING CENTERS 3.1.3 INC JOG OPERATION Each time a + / - button is pressed, the tool moves by the predetermined distance. 1.Select INCR JOG Mode. 2.Select one axis by X, Y, Z, 4 or 5 axes buttons, as in JOG mode. 3.Select desired increment of travel by using X1, X10, X100 or X1000 push buttons. 4.Press + or - direction button for desired direction of travel. Incremental axis motion of selected distance will be commanded per each press of direction button. Direc- tion LED will be lit during motion. Incremental travel selection by multiplier setting (X1, X10, X100 or X1000) is based on the minimum command increment used by FADAL machine, 0.0001 inch or 0.001 mm. Selection of X1 will command 0.0001 d or 0.001mm for each press of direction button. X10 commanding 0.001 d or 0.01mm, (10 x 0.0001 d or 10 x 0.001mm) and so on. X1: 0.0001 inch (0.001mm) X10: 0.001 inch (0.01mm) X100: 0.01 inch (0.1mm) X1000: 0.1 inch (1.0mm) 3.1.4 HANDLE OPERATION Handle mode is also referred to as MPG Mode (Manual Pulse Generator). By rotating the manual handle, the tool moves by the distance corresponding to the degree of handle rotation. 1.Select Handle Mode. 2.Select one axis by X, Y, Z, 4 or 5 axes buttons, as in JOG mode. JULY 2005 3.0 MANUAL OPERATION10 of 53 GE FANUC OPERATOR MANUAL 3.Select desired increment of travel by using X1, X10, X100 or X1000 push buttons. X1: 0.0001 inch (0.001mm) X10: 0.001 inch (0.01mm) X100: 0.01 inch (0.1mm) 4.Rotate manual pulse generator (MPG) clock-wise or counter clock-wise for plus or minus motion, respectively. For each detent or cclick d of MPG handle, one selected increment or travel will be commanded. Direction LED will be lit during motion. NOTE: Increment travel selection by multiplier settings are used same as during INCR JOG mode. For example, selection of X10 increment with clock-wise rotation of 15 cclicks d on MPG will command 0.0150 d or 0.150mm of travel in plus direction. NOTE: When MPG hand wheel is rotated at a rate fast enough to exceed the axis traverse rate, the axis speed is claimped at the traverse rate and excess rotation of the hand wheel is ignored. In this case, the distance of axis travel will not equal the amount of hand wheel rotation. 3.1.5 JOG FEED RATE When the machine is in the JOG mode, the jog feedrate varies from 0 IPM to 240 IPM since the feedrate switch changes the feedrate from 0% to120%. For example, if Jog Feedrate Switch is at 100%, the feedrate changes to 200IPM. This switch affects the rapid speed since it is rapid speed override switch also. When the HMOP operation ON/OFF switch is turn off, the effective feed override/ feedrate is only related with main operator panel feed override switch. When the operation ON/OFF switch is turned on, the effective feed override/feedrate value is that HMOP override switch 9s value multiply main operator panel feed override switch 9s value. NOTE: If the feed override/feed rate is at 0%, no motion will occur when using the c+/- d jog button or execut- ing the program. 11 of 53 4.0 AUTOMATIC OPERATION MAN-0114R1 FADAL MACHINING CENTERS 4.0 AUTOMATIC OPERATION 4.1 AUTOMATIC OPER- ATION MODES 4.1.1 MDI OPERATION In the MDI mode, a program consisting of up to 10 lines can be created in the same format as normal programs and executed from the MDI panel. MDI operation is used for simple test operations. In order to complete this operation, follow the next procedure: 1.Press the MDI mode selection switch. 2.Press the PROG function key on the MDI panel to select the program screen. 3.Prepare a program to be executed by an operation similar to normal program edit- ing. M30, specified in the last block can return control to the beginning of the pro- gram after operation ends. Word insertion, modification, deletion, word search, address search, and program search are available for programs created in the MDI mode. 4.To entirely erase created program in the MDI mode, use one of the following meth- ods: " Enter address, and then press the DELETE key on the MDI panel. " Alternatively, press the RESET key. 5.To execute a program, set the cursor on the head of the program. Push CYCLE START button on the operator 9s panel. By this selection, the prepared program will start. When the program end (M02, M30) or ER (%) is executed, the program will be erased and the operation will end. By command of M30, control returns to the head of the prepared program. 6.To stop or terminate MDI operation in midway through, follow the next steps: " Stop MDI operation. Press the feed hold switch on the machine operator 9s panel. The feed hold LED goes on and the cycle start LED goes off. " Terminate MDI operation. Press the reset key on the MDI panel. Automatic operation is terminated and the reset state is entered. When a reset is applied during movement, movement decel- erates then stops. JULY 2005 4.0 AUTOMATIC OPERATION12 of 53 GE FANUC OPERATOR MANUAL 4.1.2 MEMORY OPERATION (AUTO MODE) Programs are registered in memory in advance. When one on these programs is selected and the cycle start switch on the machine operator 9s panel is pressed, automatic operation starts, and the cycle start LED goes on. When the feed hold switch in the machine operator 9s panel is pressed during automatic operation, this operation is stopped temporarily. When the cycle start switch is pressed again, automatic operation is restarted. When the RESET key on the MDI panel is pressed, automatic operation terminates and the reset state is entered. To complete this operation follow the next procedure: 1.Press the MEMORY (AUTO) mode selection switch. 2.Select the program from the registered programs doing the following steps: " Press PROG to display the program screen. " Press c+ d soft key. " Press cDIR d soft key and the program library will be displayed. " Enter a program number using the numeric keys. " Press the O SRH soft key. 3.Press the cycle start switch on the machine operator 9s panel. Automatic operation starts, and the cycle start LED goes on. When automatic operation terminates, the cycle start LED goes off. 4.To stop or cancel memory operation midway through, follow the steps below: " Stopping memory operation. Press the feed hold switch on the machine operator 9s panel. The feed hold LED goes on and the cycle start LED goes off. The machine responds as follows: When the machine was moving, feed operation decelerates and stops. When dwell was being performed, dwell is stopped. When M, S, or T was being executed, the operation stopped after M, S, or T is fin- ished. " Terminating memory operation. Press the RESET key on the MDI panel. Automatic operation is terminated and the reset state is entered. When a reset is applied during movement, movement decelerates then stops. 13 of 53 4.0 AUTOMATIC OPERATION MAN-0114R1 FADAL MACHINING CENTERS 4.1.3 DNC OPERATION By activating automatic operation during the DNC operation mode (REMOTE) , it is possible to perform machining (DNC operation) while a program is being read in via reader/puncher interface, or remote buffer. If the floppy cassette directory display option is available, it is possible to select files (programs) saved in an external input/output unit of a floppy format (Handy file, Floppy Cassettes, or FA card) and specify (schedule) the sequence and frequency of execution for automatic operation. To use the DNC operation function it is necessary to set the parameters related to the reader/punch interface and remote buffer in advance. To complete this procedure follow the next procedure: 1.Search for the program to be executed. 2.Press the REMOTE switch on the machine operator 9s panel to set REMOTE mode, then press cycle start switch. The selected file is executed. During DNC operation, the program currently being executed is displayed on the program check screen and program screen. The number of displayed program blocks depends on the program being executed. DNC Operation procedure with memory card: JULY 2005 4.0 AUTOMATIC OPERATION14 of 53 GE FANUC OPERATOR MANUAL 1.Set the parameter of No.0020 to 4 in the setting screen in advance. 2.Change to REMOTE mode. 3.Press PROG function key on the MDI panel. 4.Push c+ d soft key twice. 5.When cDNC-CD d soft key is pressed, the following screen is displayed. The screen can be scrolled by page key. An arbitrary file number is input, and cF SRH d soft key is pressed. Then the arbitrary file name is displayed at the top of DNC operation (memory card) screen. 6.Input the file number which is going to be executed. 7.Press the cDNC-ST d soft key, the file name will be displayed in the right side of DNC FILE NAME: For example, DNC FILE NAME:O0053 8.Press the CYCLE START button to execute the program selected. 4.1.4 MEMORY PROTECTION KEY This key is used to prevent part programs, offset values, parameters, and setting data from being registered, modified, or deleted erroneously. When the key is in the On position cI d , the memory is protected and operator can 9t change any data in the CNC. When the key is in the Off position cO d operator is able to register/modify/delete the part programs, offset values, parameters and setting data. 15 of 53 5.0 TEST FUNCTION MAN-0114R1 FADAL MACHINING CENTERS 5.0 TEST FUNCTION 5.1 TEST FUNCTION MODES 5.1.1 SINGLE BLOCK Single Block (Fanuc Operator Manual GFZ-63534EN, III, Section 5.5) Single Block Mode executes part program block by block. Single block mode is implemented to toggle On/Off with press of button. Pressing the single block switch starts the single block mode. When the cycle start button is pressed in the single block mode, the tool stops after executing a single block in the program. Check the program in the single block mode by executing the program block by block. 5.1.2 BLOCK DELETE Block Skip (Fanuc Operator Manual GFZ-63534EN, II, Section 12.2) Skip execution of program Block (/). Multi level Block Skip is not supported. Block Delete is implemented to toggle On/Off with press of button. 5.1.3 OPTION STOP Optional Stop on M01 (Fanuc Operator Manual GFZ-63534EN, II, Section 11.1) Option Stop is implemented to toggle On/Off with press of button. Executing program will stop at M01 when option stop button is On. Operator needs to push CYCLE START button to restart the program. It does not affect the program when the option stop button is Off 5.1.4 PROGRAM STOP M00 or M01 Program Stop (Fanuc Operator Manual GFZ-63534EN. III, Section 40.1) Program Stop indicator LED is lit when part program execution is stopped by M00 or M01 part program. 5.1.5 MC LOCK Machine Lock (Test Mode) (Fanuc Operator Manual GFZ-63534EN, III, Section 5.1) JULY 2005 5.0 TEST FUNCTION16 of 53 GE FANUC OPERATOR MANUAL Machine Lock enables execution of part program without axis motion, but M/S/T command still is able to execute. This button is for test purposes. Machine lock is implemented to toggle On/Off with press of button. 5.1.6 DRY RUN Dry Run Feed Rate (Fanuc Operator Manual GFZ-63534EN, III, Section 5.4) This feed rate forces program federate to fixed cdry run d rate to speed non-cutting testing of part programs. Dry Run is implemented to toggle On/Off with press of button. The tool is moved at the feed rate specified by a parameter regardless of the feed rate specified in the program. This function is used for checking the movement of the tool under the state that the workpiece is removed from the table. Press the Dry Run switch on the machine operator 9s panel during automatic operation. The tool moves at the feed rate 900/700 IPM when the feed rate is overridden by 100%. The rapid traverse switch can also be used for changing the feed rate. The Dry Run feed rate changes as shown in the table below according to the rapid traverse switch and parameters. NOTE: When the machine is in the Auto/Remote mode, operator can only turn on Dry Run by pressing Dry Run & Func key at the same time. For X and Y axis, when the DRY RUN button is cON d. Program command Rapid traverse button Rapid traverse Feed ON 700IPM 500IPM OFF 900* Feedrate override IPM 500*Feedrate override IPM *1 For Z axis, when the DRY RUN button is cON d. Program command Rapid traverse button Rapid traverse Feed ON 700IPM 500IPM OFF 700* Feedrate override IPM 500*Feedrate override IPM *1 *1. Speed is Clamped to maximum feedrate 500IPM 17 of 53 6.0 MACHINE SETUP FUNCTION MAN-0114R1 FADAL MACHINING CENTERS 6.0 MACHINE SETUP FUNCTION 6.1 SETUP MODES 6.1.1 WORK MEAS Work Offset Setting (Fanuc Operator Manual GFZ-63534EN, III, Section 11.4.14) This measurement simplifies setup of work/fixture offsets using Measurement B feature. Please refer the Fanuc operator manual for the details. 6.1.2 TOOL MEAS Tool Length (Fanuc Operator Manual GFZ-63534EN, III, Section 11.4.14) This measurement simplifies setup of tool length offsets using Measurement B feature. Please refer the Fanuc operator manual for the details. 6.1.3 FUNCTION Function button FUNC Horizontal mounting of Operator Panel in Fadal pendant exposes operator buttons to a more varied environment. To prevent accidental activation of selected operator panel operations, the FUNC button is required to be pressed in combination with desired operator panel function. Operator Panel functions currently requiring FUNC button are: HOME PSN LOAD PSN Z HOME INIT MAG TOOL DATA TOOL CHNG LOAD TOOL SPDL CCW SPDL CW TOOL BRKN 6.1.4 HOME PSN Macro Program Positioning Axes to Home Position FUNC Pressing this button will call the macro program which commands axes to machine position of X0.0 Y0.0 Z0.0 using G53 traverse moves. Program will command Z-axis to 0.0 first, before X & Y axes motion are commanded. FUNC button must be pressed simultaneously with HOME PSN to execute program. JULY 2005 6.0 MACHINE SETUP FUNCTION18 of 53 GE FANUC OPERATOR MANUAL 6.1.5 LOAD PSN Macro Program Positioning Axes to Table Load PSN FUNC Pressing this button will call the macro program which commands axes to machine position of X0.0, Z0.0, and Y plus limit position using G53 traverse moves. Table position is in front and center. When control is set for metric operation, macro program will automatically command to X0.0, Y+Limit, Z0.0 in mm units FUNC button must be pressed simultaneously with LOAD PSN to execute program. 6.1.6 Z HOME Macro Program Positioning Axes to Table Load PSN FUNC Pressing this button will call the macro program which commands Z-axis to machine position of Z0.0 using G53 traverse move. FUNC button must be pressed simultaneously with Z HOME to execute program. 19 of 53 7.0 TOOL OPERATION MAN-0114R1 FADAL MACHINING CENTERS 7.0 TOOL OPERATION 7.1 MANUAL OPERA- TION 7.1.1 DRUM FWD Manual Index of Tool Drum in Forward Direction Commands are manually jogging or indexing of the tool drum in forward direction. Forward direction is defined as indexing of tool pots in rising order:... 23, 24, 1, 2, 3,... Rotating is counter clock-wise when looking at the back of tool operator station. Jog Mode is required. Operator may hold down button for indexing of multiple tool pots, or press momentarily to index one tool. DRUM PSN button can be used to display tool pot at tool change (bottom) position. Operator message will update while tool carousel is being manually rotated. 7.1.2 DRUM REV Manual Index of Tool Drum in Reverse Direction Commands are manually jogging or indexing of the tool drum in reverse direction. Reverse direction is defined as indexing of tool pots in decreasing order:... 3, 2, 1, 24, 23,... Rotating is clock-wise when looking at the back of tool drum from the operator station. Jog Mode is required. Operation is same as used for DRUM FWD . 7.1.3 DRUM PSN Display of Tool Drum Position by Operator Message Use of this button activates display of Operator Message containing tool pocket number at tool change (button) position of carousel. DRUM PSN message is set to automatically turn on with power-up of machine. Position of Tool Drum is maintained in battery backed PMC Data table while machine is powered down. Operator may turn the message On/Off at any time using DRUM PSN push button. JULY 2005 7.0 TOOL OPERATION20 of 53 GE FANUC OPERATOR MANUAL 7.1.4 TOOL REL Tool Release (Draw Bar Open) This button is for manually loading/uploading a tool holder. Operator must be prepared to catch tool from spindle cartridge immediately upon pressing button. Spindle air is turned on along with release of tool. Draw bar will open after pressing the button more that 1 second and remain open while push button is still held. Spindle must be stopped with control in JOG or HANDLE modes to enable tool release. Unloading tool procedure: 1.The tool holder must be held in the left hand with the thumb and the first finger grasping the holder below cV d groove. No other fingers should have contact with the holder or the tool in the holder. The area below the cV d groove is called the safe zone. The safe zone is the only place where the tool holder should be held. RETENTION KNOB V GROOVE SAFE ZONE 2.Press the TOOL REL button. Keep the TOOL REL button pressed until the tool is completely out of the spindle. Loading tool procedure: 1.The tool holder must be held in the left hand with the thumb and the first finger grasping the holder below the cV d groove. No other fingers should have contact with the holder or the tool in the holder. The area bellow cV d groove is called the safe zone. The safe zone is the only place where the tool holder should be held. 21 of 53 7.0 TOOL OPERATION MAN-0114R1 FADAL MACHINING CENTERS 2.Place the holder into the spindle after pressing the TOOL REL button, not before. The keys on the nose of the spindle must fit into the key-ways on the tool holder flange. 3.Release the TOOL REL button to lock the tool into the spindle. NOTE: When loading a holder into the spindle, inspect the taper for chips and dents. Remove any chips or dents from the taper with a flat stone. Confirm the retention knob is securely tightened before placing the tool in the spindle. After load a tool holder info the spindle, operator needs to edit the magazine management to write the spindle tool number into the SPDL1 column, and then use the TOOL CHNG to load the spindle tool into the magazine/carousel. 7.1.5 TOOL CHNG Macro Program Execute Tool Change FUNC (Only for DATC ) Pressing this push button will execute macro program O8988. Program executes swap of tool between spindle cartridge and current position of TOOL DRUM . This button is for manually unloading of tools between spindle and tool drum, or loading of tool to specific tool drum pot. Operator can position tool drum prior to use of TOOL CHNG button. During tool loading, operator may input tool number into spindle window on Tool Magazine screen. Tool Change cycle will move tool number to magazine. Alternatively, operator may edit magazine table once tools are loaded. Upon removal of tool from spindle, operator should delete tool number from spindle window on Tool Magazine screen. FUNC button must be pressed simultaneously with TOOL CHNG to execute program. 7.1.6 TOOL LOAD Macro Program for Loading Tools FUNC Machine with DATC: Pressing this push button will execute the macro program O8989. Program searches for and positions to empty tool pot in tool drum. Then executes swap of new tool from spindle cartridge into empty tool pot. This function is provided for manual tool loading from to tool drum. Operator to input tool number from spindle window on Tool Magazine screen so that tool number can be loaded to magazine, or edit magazine and spindle tool data after tools are loaded. FUNC button must be pressed simultaneously with LOAD TOOL to execute program. FUNC+LOAD TOOL procedure " Manually load the tool to the spindle according the TOOL REL procedure. " Press JOG or HANDLE mode. " Press OFFSET/SETTING key on the MDI panel. " Press c+ d soft key below the LCD screen. JULY 2005 7.0 TOOL OPERATION22 of 53 GE FANUC OPERATOR MANUAL " Press TL-MNG soft key. " Press MAG to enter the tool data management screen. " Press cOPRT d soft key. " Press EDIT soft key, the EDITING will be displayed on the screen. " Move the cursor to the most right column: SPDL1. " Input the tool number of the current spindle tool into the Spindle Tool column. " Press INPUT , the tool number will be displayed in the SPDL1 column. " Press FUNC+LOAD TOOL , tool will be loading the magazine automatically, and the MAG management will be updated. " Press OPRT. " Press END to end the tool management editing. NOTE: Operator need register the tool into the management first before load the new tool. Machine with ATC: Press the push button with FUNC button will execute the macro program O8989. Program positions to specific tool pot in tool drum, and then load the spindle tool into the specific tool pot. This function is provided for manually loading tools from spindle to TOOL DRUM . Operator input tool number from spindle window on Tool Magazine screen so that tool number can be loaded to magazine, or edit magazine and spindle tool data after tools are loaded. FUNC button must be pressed simultaneously with LOAD TOOL to execute program. FUNC+LOAD TOOL procedure " Manually load the tool to the spindle according the TOOL REL procedure. " Press JOG or HANDLE mode. " Press OFFSET/SETTING key on the MDI panel. " Press c+ d soft key below the LCD screen. " Press TL-MNG soft key. " Press MAG to enter the tool data management screen. " Press cOPRT d soft key. " Press EDIT soft key, the EDITING will be displayed on the screen. " Move the cursor to the most right column: SPDL1. " Input the tool number of the current spindle tool into the Spindle Tool column. " Press INPUT , the tool number will be displayed in the SPDL1 column. " Press FUNC+LOAD TOOL , tool will be loading the magazine automatically, and the MAG management will be updated. " Press OPRT. " Press END to end the tool management editing. NOTE: Operator need register the tool type into the management first before load the new tool. 23 of 53 7.0 TOOL OPERATION MAN-0114R1 FADAL MACHINING CENTERS NOTE: If the tool management screen, MAG has the same tool already, operator should clear this maga- zine pot using EDIT and take the tool out from that magazine manually first before try to load another tool. 7.1.7 REFERENCE THE DRUM (ONLY FOR DATC) 1.Press REF RETURN button. 2.Press X1 button. The drum will automatically move to the number 1 . 7.2 AUTO OPERATION 7.2.1 T-COMMAND (TOOL NUMBER) Eight digit T-Word may be programmed in block with or without M06 code. T-Word programmed in block by itself will position tool carousel with position tool carousel with programmed tool at 6 o 9clock position (DATC) for next tool change. Rotation of carousel will not inhibit continued execution of part program (FIN) as carousel is away from work area. For DATC, this enables cycle time reduction of part program execution, by allowing next tool to be immediately ready for tool change. Programming T-Word after M06 will command positioning of carousel, followed by immediate tool change. T-Word must be programmed following M06 in block, as T- Word is argument passed to M06 macro program. Programming T-code of tool that is already at tool change (6 o 9clock) position will command no activity by tool carousel, as requested tool, is already at tool change position. T-Word may be used to position tool carousel by pocket number when combining with M100 miscellaneous code. M100T5: Position carousel to tool pocket #5. Pocket #5 will be selected regardless of tool number in pocket, or if pocket empty. 7.2.2 TOOL CHANGER COMMAND ATC: M06 Txx command from part program executes tool change cycle for carousel type ATC tool changer. M06 command calls macro program O9021, which executes required Z-axis motion commands & special Miscellaneous Codes (M- Codes) for execution of the tool change cycle. Tool number (T-Command) must always follow M06 code in program block. M06 programmed in block without T-Code following, or T-Code preceding M06 is illegal syntax for this machine. M06 T10: Proper Command Syntax M06: Illegal, Macro Error 3020 will result T05 M06: Illegal, Macro Error 3020 will result JULY 2005 7.0 TOOL OPERATION24 of 53 GE FANUC OPERATOR MANUAL NOTE: Tool changer syntax on other makes/models of machines using GE Fanuc or Fanuc controls may differ. Operation of syntax on this machine is as listed above, and not selectable. WARNING ! 1.Special M-Codes contained in macro program O9021 must never be used in end- user part programs without specific permission of Fadal Machining Centers. Any use other than in O9021 macro cycle is the responsibility of the machine user/oper- ator/programmer. Machine damage can occur. 2.End-user should always refer to Fadal Machining Centers Operator Manual: appli- cable to this machine, for proper M-Codes to be used during part programming. 3.Macro program O9021 must never be edited without permission of Fadal Machin- ing Centers. Machine damage can occur. DATC: M06 command from part program executes tool change cycle for cdual arm d type DATC tool changer. M06 command calls program O9020, which executes required Z-axis motion commands & special Miscellaneous Codes (M-Codes) for execution of the tool change cycle. Tool number (T-Command) must follow M06 code in program block, when M06 and Txx code are programmed in the same block. T-Code preceding M06 in same block is improper syntax for this machine. T-Code may be programmed alone, in previous block to provide positioning of TOOL DRUM prior to tool change. This method improves part program cycle time. T10: Tool Drum positions, following operations will continue while drum. G01 X . . ., Positions to Tool from pocket containing T10 tool. . . . , . . . , M06: Tool change. T10 will be inserted into spindle, old tool to empty pocket. D and/or H codes must be added after tool change for offsets as required. M06:T4 Legal. Tool Drum will position during tool change. T05M06: Illegal command. Tool changes as intended will not occur. Programming M06, without programming a new tool number, will not command a swap of tools between the carousel and spindle. When no new tool number has been specified, and the active tool is already in the spindle, it is expected that no tool change is required. \x2 25 of 53 7.0 TOOL OPERATION MAN-0114R1 FADAL MACHINING CENTERS NOTE: Tool changer syntax on other makes/models of machines using GE Fanuc or Fanuc controls may differ. Operation of syntax on this machine is as listed above, and not otherwise selectable. WARNING ! 1.Special M-Codes contained in macro program O9020 must never be used in end- user part programs without specific permission of Fadal Machining Centers. Any use other than in O9020 macro cycle is the responsibility of the machine user/oper- ator/programmer. Machine damage can occur. 2.End-user should always refer to Fadal Machining Centers Operator Manual: appli- cable to this machine, for proper M-Codes to be used during part programming. 3.Macro program O9020 must never be edited without permission of Fadal Machin- ing Centers. Machine Damage could occur. 7.3 TOOL MANAGEMENT 7.3.1 INIT MAG Macro Program Initial Tool Magazine Data FUNC Pressing this push button will execute macro program O8986 which initials tool data from magazine. Tool numbers in all tool drum pots are initialized to the related pocket number. Tool number in the spindle is initialized to c0 d indicating no tool in the spindle. So, operator should take the tool off from the spindle after execution of this function. FUNC button must be pressed simultaneously with INIT/CLR MAG to execute program. NOTE: Please take off the spindle tool after execute this function since this function clears the spindle tool number to zero. Ignore this note to take off the tool from the spindle will cause tool changer crash. 7.3.2 TOOL DATA Macro Program Loads Tool Management Data FUNC Pressing this push button will execute macro program O8987 which demonstrates loading of tool management data by part program command. Tool numbers 1-24 (1- maximum of tool pocket numbers) are loaded as well as tool groups demonstrating tool life setting by count and by time. The default setting is not tool management for those tools of this function. FUNC button must be pressed simultaneously with TOOL DATA to execute program. NOTE: User may setup the tool management function by manually setup the tool management screen according their requirement. \x2 JULY 2005 7.0 TOOL OPERATION26 of 53 GE FANUC OPERATOR MANUAL 7.3.3 TOOL BRKN Tool Broken FUNC Pressing TOOL BRKN and FUNC button at the same time is a shortcut to mark active tool as broken/ damaged in the tool management. This function enables operator to mark tool as damaged without editing Tool Management Data. Tool management will not select a damaged tool for use, from the tool group. 7.3.4 EDIT THE TOOL/ MAGAZINE LIST Edit the tool data: " Press MDI button. " Press OFFSET/ SETTING . " Press c+ d soft key. " Press TL-MNG soft key. " Press TOOL soft key to enter the tool data page. " Press OPRT soft key. " Press EDIT soft key to start editing the tool data. " Press OPRT soft key gain after editing is finished. " Press END soft key to exit tool data the editing mode. Edit the Magazine data: " Press MDI button. " Press OFFSET/SETTING. " Press c+ d soft key. " Press TL-MNG soft key. " Press MAG soft key to enter the magazine data page. " Press OPRT soft key. " Press EDIT soft key to start editing the magazine data. " Press OPRT soft key again after editing is finished. " Press END soft key to exit magazine data the editing mode. 7.3.5 TOOL ORDER PROCEDURE (ONLY FOR ATC) Procedure: 1.Move the drum to the number 1. 2.Execute the M11 to establish the tool order (the pocket number1) in the MDI mode. 3.Cycle the power. NOTE: If user does not cycle the power after M11, that may cause the tool changer crash happening. 7.3.6 TOOL LOADING (ATC) Turret (ATC) open for loading: 1.Change the machine to the MDI mode and execute the M150. 27 of 53 7.0 TOOL OPERATION MAN-0114R1 FADAL MACHINING CENTERS M150 M-Code is provided to emulate Fadal control operation for manual tool change. M150 will return tool in the spindle to carousel pocket and raise Z-axis to clear tools. Carousel in left cout d position, enables operator to rotate carousel to next tool. NOTE: M151 command may be used to pick up next tool, if desired. M150 will position above carousel when no tool is in the spindle to be returned. 2.Change the mode to Jog, and use the DRUMFWD/DRUM REV button to rotate the turret. Operator can press FUNC+DRUM POS button to display the drum current position. 3.Change the machine to the MDI mode and execute the M151. M151 M-Code is provided to emulate Fadal control operation for manual tool change. M151 will proceed from position machine left by M150 cycle. After operator has manually indexed tool carousel to desired new tool, executing M151 will pick up operator-selected tool from carousel and return carousel to home position. NOTE: When user loads tools into the turret, they can place tools in the turret and use DRUM FWR/DRUM REV button to put the next tool in the turret until all the tools are placed in the turret. Rotate the turret until the first tool is in the number one position before setting the tool order (using M11 to establish tool order). WARNING ! 1.M150 is provided for MDI use only to return tool to carousel. Use of the M150/M151 commands is responsibility of the machine operator. Machine damage may occur in unintended use. 2.M151 is provided for MDI use only after M150 command for return of active tool to carousel, and positioning of Z-axis above the carousel. Use of M150/M151 is the responsibility of the machine operator. Machine damage can occur during unin- tended use. 3.M150/M151 commands should never be used during Automatic execution of part programs. 7.3.7 TOOL CHANGER (RECOVERY ATC) 1.Press the RESET to disable the alarm. NOTE: If the alarm can not be disable, operator may cycle the power to clear the alarms. 2.Execute the M186 in the MDI mode to get the turret to the home position if the Z axis still is in the home position. \x2 JULY 2005 7.0 TOOL OPERATION28 of 53 GE FANUC OPERATOR MANUAL NOTE: User may move the Z axis to the safe area before return of the slide according to the real situation. 3.Move to the cold start position using either REF RETURN or G28. 4.Use the DRUM FWD/DRUM REV button to rotate the turret to the number 1. 5.Execute the M11 to establish the drum number 1. Cycle the power. 6.Double check the tool management to see if it is right. Edit it to make it right if it needs. 29 of 53 8.0 COOLANT OPERATION MAN-0114R1 FADAL MACHINING CENTERS 8.0 COOLANT OPERATION 8.1 COOLANT CON- TROL PUSH BUTTONS 8.1.1 AUTO COOL AUTO COOL push button selects automatic control of coolant by programmed M-Code. AUTO COOL button toggles on/off, as indicated by LED. While AUTO COOL is active, manual coolant control buttons MIST COOL AND FLOOD COOL are inhibited. AUTO COOL cOFF d enables control of coolant. AUTO COOL is defaulted to cON d condition at power-up. When AUTO COOL is on, the following M-Code is used to control the coolant system: M-Code: M7: Mist coolant ON; Coolant though spindle ON M8: Flood coolant ON M9: Mist coolant, Flood coolant, coolant though spindle OFF 8.1.2 FLOOD COOL FLOOD COOL turns on/off the flood coolant pump when the AUTO COOL is off. 8.1.3 MIST COOL MIST COOL turns on/off the mist coolant pump and coolant through spindle solenoid when the AUTO COOL is off. NOTE: FLOOD COOL and MIST COOL may be turned on simultaneously. MIST COOL also turns on the coolant through spindle pump if the machine has this option. JULY 2005 9.0 SPINDLE OPERATION30 of 53 GE FANUC OPERATOR MANUAL 9.0 SPINDLE OPERATION 9.1 SPINDLE OPERA- TION PUSH BUTTONS 9.1.1 SPDL STOP Manual Spindle Stop SPDL STOP applies stop to spindle running in either CW or CCW direction. SPDL STOP button is inhibited when CYCLE START LED is on, indicating automatic cycle is active. SPDL STOP does not cancel active spindle speed cS d word command. SPDL STOP may be used from any automatic or manual mode. 9.1.2 SPDL CW Manual Spindle Start Clock-Wise & Spindle Jog CW FUNC SPDL SW provides dual functions, based on operating mode of control. 9.1.3 SPDL CCW Manual Spindle Start Counter Clock-Wise & Spindle Jog CCW FUNC SPDL CCW, also, provides dual function, based on operating mode of control. JOG Mode MDI, AUTO or REMOTE Mode X Jog Spindle in CW direction SPDL CW X Spindle Start in CW direction X Jog Spindle in CCW direction SPDL CCW X Spindle Start in CCW direction 31 of 53 9.0 SPINDLE OPERATION MAN-0114R1 FADAL MACHINING CENTERS 9.1.4 MANUAL SPINDLE SPEED Spindle jog speed is defined in PMC data table. Spindle Speed Override rotary switch is applied to spindle jog speed. Spindle will jog while FUNC+ SPNDL CW/CCW button is held. Spindle will stop when CW/CCW button is released. 9.1.5 M CODE / S CODE M command: M3: Spindle CW rotate. M4: Spindle CWW rotate. M5: Spindle Stop. M41: Spindle low gear range. M42: Spindle high gear range. S command: Spindle rotation speed command The spindle speed can be specified directly by address S followed by a maximum five- digit value (min-1). The unit is rotation per minute (RPM). The S command must be specified with M3/M4 command in the same block to run the spindle. Using M5 command or pressing RESET can stop the spindle. Example: S10000; spindle rotation speed is 10000RPM. M3 S2000 (Spindle CW, 2000RPM). M4 S2000 (Spindle CCW, 2000RPM). M5 Spindle stop. NOTE: Use of FUNC+SPDL CW/CCW as spindle start in MDI, Auto & Remote Modes is inhibited when Cycle Start LED is on, and also by state of door interlock. Programmed cS d word must be active for use of buttons for spindle start. Care should also be

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