Operation Manual GS 200 Series

OPERATION MANUAL

MODEL：GS-200/L Series

HEADQUARTERS：

No.13, 5TH ROAD, TAICHUNG INDUSTRIAL PARK, TAICHUNG, TAIWAN, R.O.C.

TEL:886-4-23591226 FAX:886-4-23590536

CENTRAL TAIWAN SCIENCE PARK BRANCH：

No.38, KEYUAN ROAD, CENTRAL TAIWAN SCIENCE PARK, SITUN DISTRICT,

TAICHUNG CITY, 40763, TAIWAN, R.O.C.

TEL：886-4-24636000 FAX：886-4-24630038

Original Instructions

INSTRUCTION MANUAL FOR CNC TURNING CENTER

GS-200/L Series

Thank you for your selection and purchase of our precision GS-200/L CNC Turning

Center. This instruction manual describes the instructions and cautions as to the installation, operation and maintenance in order to use this machine for longer years while exerting full performance of the delivered machine. Accordingly, it is hope to make perusal of this manual not only by the persons in charge but also by the actual operators.

In addition to this manual, refer to the instruction manuals and maintenance manuals issued by NC-maker for exact operation and maintenance of this machine.

* The specifications and descriptions given herein are subject to change without previous notice.

IMPORTANT

It is the responsibility of the user of this machine to be acquainted with the legal obligations and requirements in it's use and application.

Before attempting to install and use this machine, the owners, programmers, operators and maintenance personnel must carefully read and understand all the instructions and safety features given in this manual.

INSTALLATION

The machine must be installed in a safe operating position, with all service connecting pipes and cables clear of the walk area around the machine. Sufficient access space must be allowed for maintenance, disposal of swarf and oil, stacking and loading of components.

MACHINE GUARDING

The machine is provided with totally enclosed guards as standard. All moving transmission parts of the machine are covered with fixed guards, which must not be removed which the machine is in operation. The work area which contains moving parts directly involved in the machining process is completely enclosed by guards which can be moved to allow setting of the machine, loading of the un-machined component and unloading of the finished component. The guard door is provided with clear observation window, and is fitted with safety interlock device which immediately stop all parts of the machine which are in mode in the work area when the guard door is open including: the work spindle, feed slides, tool changer.

When the guard door is opened, very limited movement of the powered elements in the work area is permitted -- see information contained in the following chapters of this manual.

The guards and interlocks must be kept fully maintained and regularly tested and must not be removed or physically or electrically made in operative. Un-authorised interference or changing of the machine mechanics, electrics, control parameters or software may be hazardous and GOODWAY MACHINC CORP. and their authorised representative will not under any circumstance accept liability for un-authorised changes in these areas.

CONTENT

Page

1. Safety Precaution .............................................................................................. 1-1

1.1. General Safety Reminders ....................................................................... 1-1

1.2. Safety precaution for this machine ........................................................... 1-2

1.3. Safety precaution for electricity ................................................................ 1-4

1.4. Safety signs on this machine (for CE machine only) ................................ 1-6

1.5. Potentially dangerous area....................................................................... 1-8

1.6. Stopping the machine............................................................................. 1-12

1.7. Check and maintenance of safety critical item ....................................... 1-13

2. Overall description ............................................................................................ 2-1

2.1. Machine description ................................................................................. 2-1

2.2. Specifications ........................................................................................... 2-2

2.2.1.

Machine Specifications .................................................................. 2-2

2.2.2. NC control Specification FANUC system 0i-TD model................. 2-10

2.3.

0verall drawing ....................................................................................... 2-15

2.4. Main units ............................................................................................... 2-18

2.5. Power diagram of spindle and sub-spindle motor .................................. 2-19

2.6. Dimension of spindle nose ..................................................................... 2-20

2.6.1. Spindle nose of main spindle ....................................................... 2-20

2.6.2. Spindle nose of sub-spindle (op.) ................................................ 2-23

2.6.3. Relational diagram of chuck and cylinder .................................... 2-24

2.7. Tools information .................................................................................... 2-28

2.7.1.

Standard turret tooling system ..................................................... 2-28

2.7.2.

Power turret tooling system ......................................................... 2-35

2.7.3.

Turret head dimensional drawing ................................................. 2-40

2.8. Tooling interference ................................................................................ 2-43

2.9. Travels and working area ....................................................................... 2-50

2.9.1.

GS-200 Series travels and working area ..................................... 2-50

2.9.2.

GS-200L Series travels and working area ................................... 2-58

2.10. Jaw information ................................................................................... 2-68

3.1 Requirements of the space and operating position .................................. 3-1

3.2 Requirements of the foundation ............................................................... 3-2

3.3 Installation and storage requirements of the environment ........................ 3-4

I

3.4 Requirements of power source................................................................. 3-5

3.4.1

Power consumption ....................................................................... 3-5

3.4.3 No fuse breaker of main power switch........................................... 3-5

3.4.4 Wire size for power supply cable ................................................... 3-6

3.4.5 Check the supply voltage to the machine ...................................... 3-7

3.5 Oil requirement......................................................................................... 3-8

4. Handling、storage and installation.................................................................... 4-1

4.1. Handling and storage ............................................................................... 4-1

4.1.1. Safety regulation moved by crane ................................................. 4-1

4.1.2. Safety regulation moved by fork lift................................................ 4-1

4.1.3. Wooden Transportation ................................................................. 4-2

4.1.4. Transportation and lifting of machine ............................................. 4-3

4.1.5. Position of fixed plates................................................................... 4-6

4.2. Installation of leveling bolt ........................................................................ 4-7

4.3. Connection of power supply ..................................................................... 4-8

4.4. Dismantle ................................................................................................. 4-9

5.1 Machine level adjusting ............................................................................ 5-1

5.2 Cleaning and oil supply .............................................................................5-2

5.2.1 Cleaning ........................................................................................ 5-2

5.3 Safety checking procedure........................................................................5-3

6. Manual operation .............................................................................................. 6-1

6.1. Safety device and warming-up ................................................................. 6-1

6.1.1. Safety device ................................................................................. 6-1

6.1.2. Warming-up ................................................................................... 6-2

6.2. Switch and button on the operation panel ................................................ 6-3

6.2.1. Button and switches ...................................................................... 6-5

6.2.2. Buttons and Switches (For optional functions)............................. 6-15

6.3. M.D.I. (Manual Data Input) Keyboard function ....................................... 6-21

6.4. How to opening / closing the electrical cabinet door............................... 6-22

6.4.1. Open the Electrical Cabinet Door ................................................ 6-22

II

6.4.2. Closing the Electrical Cabinet Door ............................................. 6-24

6.5. How to turn on the power ....................................................................... 6-25

6.6. How to stop the machine........................................................................ 6-26

6.7. Manual Data Input (operation.)............................................................... 6-27

6.8. How to move the X, Y and Z-axis slides. ................................................ 6-30

6.9. How to perform the manual zero return.................................................. 6-33

6.10. How to operate the spindle.................................................................. 6-34

6.11. How to operate the turret indexing ...................................................... 6-37

6.12. How to move the tailstock.................................................................... 6-39

6.13. How to turn off the power .................................................................... 6-40

6.14. Procedure for the automatic operations............................................... 6-41

7. Preparation of the actual machining .................................................................. 7-1

7.1 Tooling (Procedure of fixing the tool) ........................................................ 7-1

7.1.1 How to mount the tool holder. ........................................................ 7-2

7.1.2

How to fix a cutting tool ................................................................. 7-2

7.2 Chuck (Jaw chuck & Collet chuck) ......................................................... 7-40

7.2.1 How to mount the chuck .............................................................. 7-40

7.2.5 Selection of chuck clamping direction.......................................... 7-47

7.3 Tailstock (Option).................................................................................... 7-52

7.3.2 Adjusting of the tailstock quill pressure........................................ 7-54

8. Tool offset.......................................................................................................... 8-1

8.1. Determining start position of machining ................................................... 8-1

8.2. Manual OFS/SET method ........................................................................ 8-5

8.3. The OFS/SET method of reference tool. .................................................8-11

8.4. Tool setter (option).................................................................................. 8-16

8.4.1. Introduction.................................................................................. 8-16

8.4.2. Tool setter construction................................................................ 8-17

8.4.3. Specification ................................................................................ 8-18

8.4.4. Operation..................................................................................... 8-22

III

8.5. Tool wear offset ...................................................................................... 8-33

9. Machining (Actual Cutting) ................................................................................ 9-1

9.1. Program registration................................................................................. 9-1

9.1.1. Registration form MDI/LCD panel (Manual registration) ................ 9-1

9.2. Program Edit ............................................................................................ 9-3

9.3. Program Check ........................................................................................ 9-5

9.4. Automatic operation without workpiece .................................................... 9-7

9.5. Actual Cutting ........................................................................................... 9-9

9.6. Measuring cutting size and other operations during automatic cycle. .... 9-10

9.7. Programmingable Tailstock (Moving by connection with Z-AXIS) Offset

Setting and Operation (OP) .................................................................... 9-12

9.8. Sub-spindle operation (OP.) ................................................................... 9-20

9.8.1. Note for operating sub-spindle..................................................... 9-20

9.8.2. Sample program of sub-spindle operation ................................... 9-22

9.9. M72 Workpiece ejector out for sub-spindle model (OP.) ........................ 9-32

9.9.1. Command .................................................................................... 9-32

9.9.2. Programming using M72.............................................................. 9-33

9.10. C axis operation for power turret model (OP.) ..................................... 9-34

9.10.1.

Command of c axis ................................................................... 9-34

9.10.2. Canned cycle for drilling ........................................................... 9-36

9.10.4. G07.1 (G107) Cylindrical Interpolation...................................... 9-44

9.10.5. G12.1 (G112), G13.1 (G113) Polar Coordinate Interpolation .... 9-51

9.11. Power Turret Operation(OP.) ............................................................... 9-55

9.11.1. Rotary Tool holder Direction ........................................................ 9-55

9.11.2.

Command of Power Turret........................................................... 9-56

9.11.3. How to offset Rotary Tool holder.................................................. 9-57

9.12. Y-AXIS operation ................................................................................. 9-61

9.12.1. Polar coordinate interpolation on c-x plane............................... 9-61

9.12.2. Cylindrical interpolation............................................................. 9-65

9.12.2. Cylindrical interpolation............................................................. 9-64

10. Setting and Adjustment ................................................................................... 10-1

10.1. Hydraulic pressure setting and adjustment...........................................10-1

10.2. Supplying Oil to the Lubricating Oil Tank ..............................................10-4

10.3. Belts of Spindle Adjustment ................................................................. 10-5

IV

10.4. Timing Belt Adjustment ........................................................................ 10-7

10.5. Main Spindle Center Adjustment ..........................................................10-8

10.6. Turret Adjustment .................................................................................10-9

10.7. Tapered gibs adjustment ....................................................................10-10

10.8. Tailstock Adjustment ........................................................................... 10-11

10.9. Backlash Adjustment ..........................................................................10-12

10.9.1. Backlash Measurement .......................................................... 10-12

10.9.2. Input of backlash compensation value.................................... 10-14

10.10. Reference Position Adjustment ......................................................... 10-15

10.11. Machine Level Check .........................................................................10-17

11. Maintenance.....................................................................................................11-1

11.1. General notes....................................................................................... 11-1

11.2. Maintenance cycle................................................................................ 11-2

11.2.1. Daily maintenance ........................................................................ 11-2

11.2.2. Weekly maintenance .................................................................... 11-2

11.2.3. Half-yearly maintenance ............................................................... 11-2

11.2.4. Yearly maintenance ...................................................................... 11-2

11.3. Lubrication system ............................................................................... 11-3

11.4. Hydraulic system .................................................................................. 11-5

11.5. Chuck ................................................................................................... 11-6

11.5.1. Lubrication .................................................................................... 11-6

11.5.2. Disassembly and cleaning ............................................................ 11-6

11.6.

Milling axle（For power-driven turret） ................................................ 11-7

11.7. Oil maintenance chart........................................................................... 11-9

11.8. Replacement of battery (For FANUC control)..................................... 11-10

11.9. Cleaning of heat-exchanger ............................................................... 11-13

11.10. List of Maintenance Check Point ........................................................ 11-14

11.10.1. Main spindle ............................................................................ 11-14

11.10.2. Main spindle drive unit ............................................................. 11-16

11.10.3. Hydraulic unit ........................................................................... 11-17

11.10.4. Main turret slide ....................................................................... 11-17

11.10.5. Slide cover ............................................................................... 11-20

11.10.6. Lubricating unit ........................................................................ 11-20

11.10.7. Coolant unit ............................................................................. 11-21

11.10.8. NC control unit ......................................................................... 11-21

V

11.10.9. Other........................................................................................ 11-22

12 Trouble shooting...............................................................................................12-1

12.1 Various alarms and their remedies ..........................................................12-1

12.1.1 PCDGN (PC diagnosis) ................................................................12-1

12.1.2 LCD without and display ...............................................................12-4

12.1.3 Remedies when alarm is not indicated .........................................12-5

12.1.4 Cycle start can not execute ..........................................................12-6

12.1.5 Main spindle hydraulic chuck not work .........................................12-7

12.1.6 Quill can not execute or (SUB spindle chuck can not execute) ....12-8

12.1.7 Coolant pump can not execute .....................................................12-9

12.1.8 Lubrication system out of order ....................................................12-9

12.2

Reset reference point ( when change battery ) .................................... 12-10

Appendix A ................................................................................................................ A

1 ALARM MESSAGE (for FANUC 0I-TD Controller) ...................................... A-1

1-1 Various alarms and trouble shutting ................................................. A-1

2 Turret resetting procedure......................................................................... A-16

Appendix B ................................................................................................................ B

1 G-Code and M-Code function ..................................................................... B-1

2 TIMER function ........................................................................................... B-7

3 Keep relay setting ....................................................................................... B-9

4 Counter function........................................................................................ B-36

5 DATA function............................................................................................ B-37

Appendix C OPTIONAL TOOL HOLDERS ................................................................ C

C.

Optional tool holders ...................................................................................C-1

C-1 Tool holders for CZ-3104/3304 turret head (lifting turret disk technology)

....................................................................................................C-1

C-2 Tool holders for CR-3004 turret head (non-lifting turret disk technology)

....................................................................................................C-9

Appendix D ................................................................................................................ D

Question & Answers of CEN-03 Type lubrication system ................................D-1

VI

1. Safety Precaution

1.1. General Safety Reminders

1. The operator to operate the machine should be properly trained.

2. Operation of the machine should not contradict with the instructions in operation manual.

3. The area where the machine is to be used should be well lit.

4. Keep the machine and work area neat, clean and orderly.

5. Do not store any articles around the machine that will impede the safety of the operation.

6. The operator should wear safety shoes to protect the feet and avoid slipping.

7. The operator operating the machine should wear safety glasses to protect the eyes.

8. Do not work with long hair that can be caught injury by the machine, tie it up at the back or wear a hat.

9. Do not operate the machine with gloves on.

10. Necklace and necktie should be taken off or put inside of clothes before operating the machine.

11. After drinking alcohol or if the body is not in good condition, do not operate or maintain the machine.

12. Do not clamber on to the machine, use the ladder if necessary.

13. Do not touch the turning part of the machine with hands or body.

14. Do not touch the turning part of the machine with handtools or the other article.

15. Do not open the electrical cabinet, wire terminal or any other protection covers.

16. Do not use screwdriver or handtools to hammer or pry.

17. Do not use air compressor to clean the machine, electrical cabinet or NC control.

18. Do not pull the chip by hand.

19. Do not wear magnetic accessory, which could influence the control unit of the machine.

1-1

1.2. Safety precaution for this machine

This machine is provided with a number of safety devices to protect personal and equipment from injuries and damages. So, the operator must fully under stand what special precautions to take.

It is assumed that the operator has been properly trained, has the requisite skill and is authorized to operate the machine. The following safety regulations which should be observed:

1. Before operating the machine, be sure people who are not operating the machine are kept away from the area which may caused danger during machine running.

2. Before operating the machine the operation manual should be peruse contact the manufactory for more details, if anything is unclear.

3. Please follow the instructions of the operation manual to check and maintain the machine.

4. Don't take off any protection covers or interlock functions.

5. Don't take off any warning plate on the machine, if discard or ambiguous please contact with manufacturer.

6. Before starting the machine, be sure of the ways to can stop the machine in case of emergency.

7. Before starting the machine, be sure which function will be executed after pressing the push button on the machine.

8. Be sure the illumination of halogen lamp exceeds 500 lux. Change the lamp if it is fail or broken.

9. Don't touch the tools and workpiece while the spindle motor and feed motors are running.

10. Don't use obtuse or damaged tools.

11. Don't clean or load/unload the workpiece while the spindle motor and feed motors are running.

12. Don't open the door while the spindle motor is running.

13. Before operating the machine, be sure the workpiece is properly clamped in the hydraulic chuck and running in a balance condition.

14. Be sure the tools are fixed in correct way fastened tightly.

1-2

15. Don't use the coolant with a low flash point.

16. Before starting the program, be sure there is no mistake in the program with the

Dry Run function.

17. Use the quill to help clamp long workpieces.

18. Don't release the quill before the hand catches the long shaft workpiece while the spindle is stopped.

19. If the weight of workpiece is over 10 kg then handling equipment should be used to assist loading and unloading.

20. Please follow the operation manual to remove the hydraulic chuck while using 2 centers to clamp the workpiece.

21. Don't cut the workpiece from spindle side to quill side while using two centers to clamp the workpiece between the spindle and quill, it may caused the center quill to retract and drop out the workpiece.

22. Before cutting the workpiece, be sure of the cutting condition between tools and workpiece.

23. Please don't try to use the hands to stop the spindle while it has not come to a complete stop.

24. Don't lean on the machine or operation panel which may caused the wrong operation.

25. Please don't try to maintain the machine without proper training or permission.

26. There should be a support for the shaft workpiece extending beyond the chuck cylinder, during operation, all people should keep away from this area.

27. The Max. speed is 4,800 rpm (8" chuck) or 4,000 rpm(10" chuck) , don't run the spindle at Max. speed if the spindle has not rotated in a long period.

28. There is a limitation in the hydraulic chuck pressure and spindle speed, it depends on the chuck, the weight and measurement of workpiece.

29. Don't use this machine to cut Magnesium material.

30. Don't use this machine in an explosive environment.

31. Replacement is necessary if coolant deterioration occurs.

1-3

1.3. Safety precaution for electricity

1. The required electrical source for the machine is 220V AC 3 Phase.

2. If the power supply voltage of the building where the machine is installed is higher than above voltage, transformer shall be used to get required voltage.

3. Enough space should be reserved to open the electrical cabinet for maintenance. There is an earth plate inside of the cabinet which should be connected with the earth line outside of the machine.

4. All maintenance and adjustment related with the electrical control should be executed by properly trained personal.

5. Before opening the electrical cabinet, the main power should be turned off.

6. Before replacing the electrical elements, be sure the power has been turned off.

7. To avoid turning the power on during the maintenance, put a warning plate in front of the machine.

8. Don't remove the connections which are related with the safety interlock functions.

9. Before operating the machine, be sure to peruse all warning plates and wire connection.

10. During the maintenance, be sure the power has been turned off and use tools with insulated material.

11. Replace any wires only if corresponding with the original standard specifications and colors.

12. Before turning on the power after completing the maintenance, be sure there is nobody on the machine for any operation.

13. Install an earth connection and connect to the machine, if there is no earth connection in public electrical source.

14. Don't put any article ( food .... ) inside of the electrical cabinet and on operation panel.

1-4

15. Make sure to contact GOODWAY before modifying the control unit and circuit.

Follow our instructions to avoid serious damage to the control system.

16. High voltage current flows inside the cabinet and operation panel. Receiving an electric shock may result in personal injury or death. The qualified servicing personnel always keep the cabinet keys and opens the cabinet door if need. In case of opening the cabinet door and removing the operation panel cover, always the qualified servicing personnel need to do them.

17. Keep the control unit away from any shocks or vibrations.

18. Do not give strong force to the connecting parts.

19. Please do not lean against the operation panel.

1-5

1.4. Safety signs on this machine (for CE machine only)

Fig. 1.4.1

1-6

Fig. 1.4.2

1-7

1.5. Potentially dangerous area

Under normal operation the area ( see drawing 1.5.1 ) will not caused any dangerous but the area which have rotating part and electrical elements might be dangerous under abnormal operation.

Fig. 1.5.1

1-8

1 Touch the X axis motor with high voltage to cause the electrical hazard

2 The saddle and turret head is moving to cause the crushing and impact hazard

3 Touch the Z axis motor with high voltage to cause the electrical hazard

4 The splashing plate is moving to cause the crushing hazard

5 Chain and wheel can cause hand hazard.

6 Touch the lubricating pump with high voltage to cause the electrical hazard

7 Touch the CRT with high voltage to cause the electrical hazard

8 The turret is rotating to cause the impact hazard and cause the stabbing hazard by tools

9 The chuck is rotating to cause the impact hazard and ejection hazard of workpiece

10 The belt is running to cause the entanglement hazard

11 Touch the spindle motor with high voltage cause the electrical hazard

12 Open the main switch or cabinet to cause the electrical hazard

13 Touch the coolant pump with high voltage to cause the electrical hazard

14 Touch hydraulic pump with high voltage to cause the electrical hazard

1-9

OPERATING POTENTIAL HAZARDS

When using the machine be FULLY AWARE of the following operating hazards detailed under the following instructions:

A) Problem of the skin caused by oil

Problem of the skin may be produced by continuous contact with oil; particularly with straight cutting oils, but also with soluble oils.

The following precautions should be taken:

1. Avoid unnecessary contact with oil.

2. Wear protective clothing.

3. Use protective shields and guards.

4. Do not wear oil soaked or contaminated clothing.

5. After work thoroughly wash all parts of the body that have come into contact with oils.

B) Safe operation of lathe chucks

Where details of operating speeds and of maximum recommended operating speeds are supplied these are intended only as a guide. Such details must be regarded as for general guidance only for the following reasons:

They apply only to chucks in sound condition.

If a chuck has sustained damage, high speeds may be dangerous. This applies particularly to chucks with gray cast iron bodies wherein fractures may occur.

The gripping power required for any given application is not known in advance.

The actual gripping power being used for any given application is not known by the chuck manufacturer.

There is the possibility of the workpiece becoming insecurely gripped due to the influence of centrifugal force under certain conditions. The factors involved include:

(a) Too high a speed for a particular application.

(b) Weight and type of gripping jaws if non-standard.

(c) Radius at which gripping jaws are operating.

(d) Condition of chuck - inadequate lubrication.

(e) State of balance.

1-10

(f) The gripping force applied to the workpiece in the static condition.

(g) Magnitude of the cutting forces involved.

(h) Whether the workpiece is gripped externally of internally.

Careful attention must be paid to these factors. As they vary with each particular application, a manufacturer cannot provide specific figures for general use, the factors involved being outside his control.

IF IN DOUBT CONTACT THE GOODWAY MACHINE CO.

TECHNICAL SALES DEPARTMENT.

1-11

1.6. Stopping the machine

The machining cycle can be stopped in a variety of ways under normal conditions for various reasons, such as checking the surface finish of the workpiece etc., in the normal manner of machining. This can be a achieved by a variety of methods as detailed below.

OBJECTIVE PROCEDURE a) Depress 'Feed hold'

1. To stop machine at any point.

Button then the led lamp of “Feed hold” lights up.

All axes motions cease, unless thread cutting is active.

RESULT

2. To resume cycle .

3. To resume operation after any programmed stop has been initiated. a) Depress 'Cycle Start' button on control panel. a) Move the curser to desired start block. b) Press “cycle start” button.

Machine operation continues.

The lamp above 'cycle start' button should illuminate. The cycle should continue.

4. Emergency Stop

If a potentially dangerous condition begins, the machine can be stopped most easily by depressing the large red push button. This suspends all active commands. The spindle stops and all machine motion ceases. If, you want to start the machine, please referent the operating manual.

5. Sliding Guard

The sliding guard is interlocked during automatic operation by means of a solenoid operated shot bolt. This is a safety device to prevent the guard being opened during cycle.

When the spindle comes to rest the shot bolt solenoid releases allowing the guard to be opened. To resume automatic operation close the guard and push cycle start. This will remove the interrupt condition, the spindle will start and the cycle will continue immediately.

1-12

1.7. Check and maintenance of safety critical item

It is important to make sure some of the critical safety devices are well functioned.

We strongly recommend that the function of following items to be checked prior to start machining work each day. If they are not functioned, maintenance will be required.

1. Emergency stop switch on control panel.

2. Door interlock switch.

3. Cabinet door interlock switch.

4. Emergency stop switch on chip conveyor.

Maintenance procedure.

1. Check wiring.

2. Check switch, replace if necessary.

3. Contact local agency.

1-13

2. Overall description

2.1. Machine description

The machine is a numerically controlled lathe of horizontal configuration. Both axes are driven by A.C. servo motors. The main slideways are induction hardened and ground. Lubrication of all surfaces is automatic. Manual jogging of the slides is effected using push button or handwheel.

The machine is equipped with auto. hydraulic clamp, it's main performance is chuck. Though the tailstock can clip workpiece auxiliary, user must not cut workpiece from main spindle side to tailstock in Z-axis direction. Because that will affect the precision or cause even hazard of projection of workpiece.

The machine has two operating models, i.e. AUTO, MANUAL, each has their own subfunction. Please don't change randomly operating model during cutting.

Before operating the machine, please peruse the instruction manual by the NC control manufacture and the operation manual provide by the manufacturer.

With regarding to cutting fluid, lubricant, hydraulic oil, all are contained in containers. the throwing away liquid depends on the local low to deal with.

Note 1. The material which can be machined in the machine are: Iron, casting iron, aluminum, copper, stainless steel and alloy steel. Please don't machine graphite, wood which may caused dust, and plastic, magnesium which may caused toxic or burning.

Note 2. Don't operate the machine without authorization.

2-1

2.2. Specifications

2.2.1. Machine Specifications

I. Standard features

A. General

1) Machine dimension without chip conveyor

(length×width×height)

2) Maintenance area without chip conveyor

(length × width)

3) Machine weight with tailstock approx.

4) Noise level measured at 1.6M high from floor and 1.0M aside from machine

B. Capacity

mm

(inch) mm

(inch)

GS-200：2795X1955X1890

(110X77X74.4)

GS-200Y：2795 X1970 X2260

(110X 77.6

X89)

GS-200L：3500X1900X1900

(137.8X74.8X74.8)

GS-200LY：3500X 2035X2385

(137.8

X80X93.9)

GS-200：3630X3940 (142.9X155.1)

GS-200Y：3630X3910 (142.9X153.9)

GS-200L：4700X3860 (299.2X152)

GS-200LY：4700X3940 (299.2X155.1) kg(lbs) GS-200：4800 (10582.2)

GS-200Y：5000 (11023.1)

GS-200L：5600 (12345.8)

GS-200LY：5800 (12786.8) dBA

Less than 78

1) Chuck dia. inch 8 / 10 ( op)

2) Swing over bed（mm）

3) Swing over saddle

4) Swing over front door

5) Max. turning dia.（mm）

6) Max. turning length

7) Max. workpiece weight mm

(inch)

ψ500 (19.7) mm

(inch)

φ500 (19.69) mm

(inch)

GS-200/L：ψ670 (26.4)

GS-200Y/LY：ψ600 (23.6) mm

(inch)

GS-200/L：ψ400 (15.8)

GS-200Y/LY：ψ340 (13.4) mm

(inch)

GS-200/Y：600 (23.6)

GS-200L/LY：1200 (47.2) kg(lbs) 240 (529.1) (with tailstock)

8) Distance between mm Refer to 2.9 Travels and working area

2-2

main spindle nose and turret face

9) Distance between main spindle nose and sub-spindle nose (op.)

C. Main Spindle

1) Designation

2) Chuck size

3) Spindle nose

4) Hole through spindle

5) Hole through draw tube

6) Front bearing inner dia.

7) Spindle speed

8) Speed range

Constant output area

Constant torque area

(inch) mm

(inch)

Refer to 2.9 Travels and working area inch 8 10 10

A2-6 A2-8 A2-8 mm mm mm

ψ66

ψ51

ψ100

ψ76

ψ65

ψ120

ψ90

ψ75

(ψ78 op)

ψ130 rpm 4800 4000 3500 rpm

48~4800

600～4800

48～600

40~4000

500～4000

40～500

35~3500

440~3500

35～440

9) Speed of low speed spindle

(OP)

10) Speed range

Constant output area

Constant torque area rpm 1200 1000 rpm

48~1200

400~1200

48~400

40~1000

335~1000

40~335

875

35~875

295~875

35~295

11) Drive motor continuous

30min. rating

KW

(HP)

αP22/6000i

7.5/15 (10 / 20)

11/15 (15 / 20)

12) Center height from floor

13) Access to spindle center from machine guards mm

(inch) mm

(inch)

1055 (41.53)

314 (12.36)

(10" Chuck option)

14) Standard chuck cylinder operation power = piston thrust

8" Chuck max. at 25kg / cm

2

(355psi) 2716kgf * at 90% efficiency

(HOWA) min. at 4kg / cm

2



2


2-3


2


15) Safety interlock for chucking failure

D. Saddle

1) Configuration

2) Feed motors

X axis

30° angle bed + flat saddle

AC 2.7 (3.6) (α12B/4000is)

Z axis

Y axis(op.)

KW

(HP)

AC 2.7 (3.6) (α12/4000is)

AC 2.7 (3.6) (α12B/4000is)

3) Thrust

X axis

Z axis

Y axis(op.)

Kgf

1282.3

961.8

X：961.8 / Y：1282.3

4) Effective slide travel

5) Rapid traverse

6) Ball screw dia. / pitch

X axis

Z axis

Y axis(op.)

X axis

Z axis

Y axis(op.)

X axis

Z axis

Y axis(op.) mm

(inch)

240 ( 9.45)

GS-200：630 (24.8)

GS-200M/Y：600 (23.6)

GS-200L/LM/LY：1230 (48.4)

X：270 ( 10.63)

Y：110 ( 4.3)

20 ( 787) m/min

(ipm)

24 ( 944)

10 (393)

Ø32 (1.26) / 6 ( 0.24) mm

GS-200/L:Ø36 (1.42) / 8 ( 0.31)

(inch) X:Ø 36 (1.41)/ 8 ( 0.31)

Y:Ø 32 (1.26)/ 6 ( 0.24)

E. Turret

1)Turret head type

2)No. of tool stations

3)Tool size

Drum st 12 mm

(inch)

□25 (1)

ψ40 (1.5)

4)Indexing drive with direction logic

5)Indexing time

for one station approx. gear + servo motor sec. 0.2

for 180 degree approx. sec. 1.0

* measured when hydraulic fluid gets 50°C

2-4

6)Curved coupling dia.

7)Turret clamping force

F. Hydraulic Unit

1) Pump motor

2) Tank capacity mm(inch) φ220 (8.66)

Kg ( lbs) 3950 ( 8700)

3) Line pressure in normal cutting

KW(HP) AC 1.5 ( 2) ( 4 poles)

L 30 kg/cm

2

35 (498)

(psi) liters/min 21/25

4) Pump delivery 50Hz / 60Hz

5) Pressure switch for power fault

G. Coolant (Cutting fluid) Unit

1) Pump motor

HP AC 0.5 (2 poles)

L 200

2) Tank capacity

H. Lubrication unit

1) Pump motor

KW(HP) 0.0012

2) Tank capacity

L 2.5

3) Max. delivery

4) Max. pressure

I. Machine Work Light

cc/min 130

Kgf/cm

2

15

1pcs 110 watts AC 13 volts

J. Splash Guards With Safety Door Interlock

K. Environment Conditions

1) Power supply

2) Total power connected volts AC 200/220 + 10% to -15%

AC 380/415/440/460/480 volts through a transformer to AC 220 volts

KVA GS-200：24.6 (Refer to 3.4.1)

3) Temperature

10 to 35∘C

4) Humidity relative less than 75%

2-5

II. Optional Attachments

A. Interface for LNS/SAMECA Bar feed

* Control voltage DC24 volts

B. Programmable Type Tailstock

Body & Quill movement

1)Type programmable

2)Distance between main

spindle nose and quill center

Refer to 2.9Travels and working area

with quill at retracted position

3)Quill center

4)Quill stroke

5)Quill dia.

6)Quill thrust

MT#3 Built-in type dead center

MT#4 Live center mm(inch) 120 (6.69) mm(inch)

ψ85 (3.35) kgf 69.4~173.5

C. Servo Tailstock

1)Type

2)Distance between main

spindle nose and quill center

with quill at retracted position

Body movement servocontrol

Refer to 2.9Travels and working area

3)Quill center

4)Z2 axis travel

5)Quill dia.

6)Z2 axis thrust

MT#3 Built-in type dead center

MT#4 Live center mm (inch) 1050 (41.34) mm(inch)

ψ80 (3.15) kgf 769.4

D. Parts Catcher

1) Type

2) Drive

3) Capacity cutoff part size

E. Chip conveyor

Auto. swing-in bucket type

Air cylinder mm(inch)

φ65X180 long (φ2.6x7.9)

* without chip collection bin to be supplied locally.

1) Drive motor

AC 220 volts 1/8HP (4 poles)

2) Outlet height from floor

3) Conveyor chain speed mm(inch) 1000 (39.37)

M/min.

50Hz 1.2

60Hz 1.4

2-6

F. High pressure coolant pump

* instead of standard pump

GRUNDFOS pump

1)Type

MTH2-30

2)Pump motor volts AC 220 (1/2HP)

G. Sub-spindle (op.)

1) Drive motor

KW(HP)

AC 5.5 (7.4) (continuous)

AC 7.5 (10) (30 min. rating)

2) Speed range rpm

60~6000

1500～6000

60～1500

Constant output

Constant torque

3) Designation

4) Spindle nose

5) Hole through spindle

6) Hole through draw tube

7) Front bearing inner dia.

8) Max. torque at spindle

rating

15 min.

rpm designation

A2-5 mm(inch)

φ46 (1.81) mm(inch)

φ39 ( 1.53) mm(inch)

φ80 ( 3.15)

Kg-m 35.2

47.7

9) HOWA standard chuck cylinder operation power = piston thrust


2



2


10) Feed motors Z2 axis

KW(HP) AC 1.8 (2.4) (β12/3000is)

11) Thrust Z2 axis

12) Effective slide travel

Z2 axis kgf mm(inch)

769.4 (rating)

GS-200S: 600 (23.62)

GS-200LS: 1050 (41.34)

13) Rapid traverse Z2 axis m / min

(ipm)

24. ( 944) (over drive)

14) Ball screw dia. / pitch

Z2 axis mm(inch) 36 (1.42) / 10 ( 0.39)

2-7

H. Power driven turret

1) Turret head type

2) No. of tool stations

3) Tool size

4) Live tooling shank size

5) Live tooling drive motor

6) Live tooling RPM range

7) Indexing drive with direction

logic

8) Indexing time

for one station approx.

for 180 degree approx.

9) Curvic coupling dia.

10)Turret clamping force

11)Index motor

I. C-Axis

mm

(inch)

KW(HP) rpm

Drum

12

□25 (1)

ψ40 (1.5)

ER-32

4.5 (6.1) (FANUC α22/4000is)

50～4000 gear + servo motor sec.

0.2

1.0

* measured when hydraulic fluid gets 50°C mm(inch)

φ220 (8.660)

Kg(lbs) 3950 (8700 )

KW(HP)

1.2 (1.63) (FANUC β8/3000is)

2)Servo Motor KW(HP) AC

3 (4.1) (α2/5000i)

J. Tool tip probing touch sensor

K. Automatic call up of alternate tool station

L. Automatic measuring system

M. Robot interface

type of Robot shall be specified

N. Auto. doors

O. Air blow off for chuck

P. Spindle locking device (Disk brake type)

* This is to facilitate chuck mounting only in set-ups.

Q. Cycle stop alarm light and buzzer

2-8

III. .Suggestive Equipment:(prepared by user)

A.Rake removing chip(without chip conveyor)

2-9

2.2.2. NC control Specification FANUC system 0i-TD model

* The specifications and descriptions given herein are subject to change without

previous notice.

I. Standard Features

A. Controlled Axis

1) Controlled axis

2~6 axis (X ,Z ,Z2, Y, C1, C2 ) simultaneous

Manually 1 axis at a time

2) Least input increment

X,Z, Z2 and Y axis

0.001mm 0.0001"

C1 and C2 axis

0.001∘

3) Least command increment

X axis 0.0005mm/p(0.001mm where radius programming on X axis is selected)

Z axis 0.001mm

C axis 0.001∘

4) Max. programmable dimension

/-9999.999mm +/-9999.999"

B. Interpolation Functions

1) Positioning

2) Linear interpolation

3) Multi-quadrant circular interpolation

G00

G01

G02 Clockwise (CW)

G03 Counterclockwise (CCW)

C. Feed Functions

1) Rapid traverse varies with machine models

2) Rapid traverse override

Low , 25%, 50% and 100%

3) Tool Manual pulse generator

4) Manual continuous feed 1 axis at a time

5) Cutting feed rate

G98(mm/min), G99(mm/rev.)

6) Cutting feed rate clamp

7) Feed rate override

0 to 150% at 10% increment

8) Tangential speed constant control

9) Automatic acceleration deceleration

Rapid traverse: Linear

Cutting feed: Exponential

10) Dwell

G04 0.001 to 9999.999 sec.

2-10

11) Dry run

12) Feed hold

13) Reference position return check

14) Return to reference position

G27

G28

15) Second reference point return

G30

G09

16) Exact stop

D. Spindle Functions

1) Spindle speed command

2) Constant surface speed control

E. Tool Functions

S-4 digit direct RPM designation

G96 and G97

2 digit tool No. + 2 digit offset No.

1) T-function

2) Tool offset memory

3) Tool nose radius compensation

+/-6 digits 16 pairs in memory

G40, G41, and G42

4) Direct input of measured offset value A

5) Incremental offset amount input

6) Counter input of offset amount

7) Tool geometry and wear offsets

8) Skip function

G31

9) Tool offset in memory

64 pairs

F. Miscellaneous Functions

1)M-functions

3 digits

G. Programming Functions

1) Coordinate system setting

2) Coordinate system shift

3) Automatic coordinate system setting

4) Work coordinate system shift

G50

5) Direct input of measured work coordinate system shift value

6) Combined use of absolute and incremental programming in the same block

7) Decimal point programming

8) X axis diameter or radius programming

2-11

9) Chamfering and corner R

10) Circular interpolation by radius programming

11) Canned cycles

G90, G92 and G94

12) Multiple repetitive cycles

G70 to G76

13) Thread cutting

G32

14) Program number

O with 4 digits

15) Program number search

16) Main program and sub programs

17) Sequence number display

N 4 digits

18) Sequence number search

19) Reader/punch interface

Program code

1.MEMORY CARD

2.EIA(RS-232)/ISO(R-840)

Automatic recognition

20) Optional block skip

1 Block

21) Buffer register

22) Program stop

M00

23) Optional stop

M01

24) Program end

M02 or M30

25) Single block

26) Part program storage & editing

1280M

27) Registerable programs

400 programs

28) Program protect key switch

H. Safety Functions

1) Emergency stop

2) Stored stroke check 1

3) Machine lock

4) Door interlock

I. Others

1) Manual data input (MDI)

2) 8.4" Color LCD character display

3) Self diagnosis functions

4) Programmable controller

Keyboard type

PMC-SB7

2-12

No. of steps 24000 steps

5) Language of display

English, German or French to be specified on order

Notes:

1)Power supply

Local voltage transformed to AC 220 volts through a transformer

2)Temperature

3)Humidity relative

0 to 45∘C less than 75%

2-13

II. Optional Functions

1) Portable tape reader without-reel type 250/300 ch/sec(50/60Hz)

Tape code EIA(RS-232)/ISO(R-840) Automatic recognition

*This is to store the program punched on a paper tape in the NC memory.

The operation by commands on NC tape is not possible.

2) FANUC PPR

Punch out / print out / tape reader

3) Spindle orientation A at one position

4) Graphic display with Conversational programming

*Displays tool paths for checkups

*Graphic scaling is possible

*Sequence number comparison and stop

*MDI soft keys 5 + 2

5) lnch/metric conversion

G20 and G21

6) Display of run hour and no. of parts

7) Play back

*not available for machine with two foot switches for chuck open/close

G code menu

8) Menu programming

9) Registrable programs

10) Offset value input by programming

G10 (Programmable data input)

11) External tool compensation

*This is used for automatic off-machine measuring system.

12) Automatic tool offset

G36 and G37

*This is used for automatic tool probing touch sensor.

*This is not available on machine with Goodway setter.

13) Custom macro

14) Special G codes

15) Thread cutting retract (thread cutting feed hold)

2-14

2.3. 0verall drawing

Fig. 2.3.1 GS-200/Y Machine Size

2-15

Fig. 2.3.2 GS-200L/YL Machine Size

2-16

Fig. 2.3.3 Machine Size

2-17

2.4. Main units

This machine is composed mainly of the parts and units shown below.

No. Name No. Name

13 Power Control Box 1 Chuck Cylinder

2 Frame

3 Chuck

4 Front Door

5 NC Control Panel and LCD

Display

6 Machine Control Panel

16 Leveling Block

17 Z-axis Servo Motor

18 Spindle Head Stock

7 Tailstock or sub-spindle(option) 19 Coolant

8 Turret Head 20 Coolant Pump

9 Cross slide

10 Saddle

11 Y-axis Servo Motor

12 X-axis Servo Motor

21 Lubrication Pump

22 Chip conveyor (option)

23 Hydraulic Unit

2-18

2.5. Power diagram of spindle and sub-spindle motor

Fig. 2.5.1 Spindle and sub-spindle speed / output / Torque Diagram

2-19

2.6. Dimension of spindle nose

2.6.1. Spindle nose of main spindle

Fig. 2.6.1 φ51mm Spindle (A2-6) (CH-2013A)

Unit:mm

2-20

Fig. 2.6.2 φ65 mm Spindle (A2-8)(CO-2649A)

2-21

Fig. 2.6.3 φ75 mm Spindle (A2-8)(CR-2213A)

2-22

2.6.2. Spindle nose of sub-spindle (op.)

Fig. 2.6.4 Sub-spindle (A2-5)(CR-9613 )

2-23

2.6.3. Relational diagram of chuck and cylinder

Fig. 2.6.5 ψ75 Spindle

2-24


2-25


2-26

Fig. 2.6.8 Sub-spindle

2-27

2.7. Tools information

2.7.1. Standard turret tooling system

Fig. 2.7.1 10/ 12 Stations tooling system (lifting turret disk technology)

*The information of tooling system please refer to Ch. 7.1.2

2-28

10 Stations

No. Part Name

1 Clamp piece

Part No. Spec. Part No. Spec.

CV-3046

2 Clamp piece

CV-3045

3 O.D. Cutting Tool Holder

CV-3096B

4

Face Cutting Tool Holder

(R) / (L)

CZ-3107

5 Boring Bar Holder

CZ-3108

□25 CV-3046

□25 CV-3045

□25 CV-3096D

□25 CZ-31A7

□1

□1

□1

□1

CJ-3016A

CJ-3016B

CJ-3016C

CJ-3016D

CJ-3016E

CJ-3014A

CJ-3014B

Metric (mm) British (inch)

Qty.

5

5

2

1

ψ40 CZ-31A8

ψ12 CJ-3112A

ψ1.5

ψ0.5

5

1

ψ16 CJ-3112B

ψ0.625

1

ψ8 CJ-3112C

ψ0.375 1

ψ10 CJ-3112D

ψ0.25 1

ψ6

CJ-3112E

ψ0.325 1

ψ20 CJ-3110A

ψ0.75

1

ψ25 CJ-3110B

ψ1

1

CJ-3014C

ψ32 CJ-3110C

ψ1.25

1

7 Drill Socket

8 Boring Bush

CV-3203A ψ16 CV-3204A

ψ1

1

CV-3203B ψ20 CV-3204B

ψ1.25

1

CV-3203C ψ25 -- --

CV-3203D ψ32 -- --

CJ-3010

MT-2 CJ-3107

MT-2

1

CJ-3011

2-29

No.

12 Stations

Part Name

1 Clamp piece

CV-3046

2 Clamp piece

CV-3045


CV-3096B

4

Face Cutting Tool Holder

(R) / (L)

CZ-3107

5 Boring Bar Holder

CZ-3108

CJ-3016A

CJ-3016B

7 Drill Socket

8 Boring Bush

Metric

Part No.

CJ-3016C

CJ-3016D

CJ-3016E

CJ-3014A

CJ-3014B

CJ-3014C

CV-3203A

CV-3203B

CV-3203C

CV-3203D

CJ-3010

CJ-3011

□25

British (Inch)

Spec. Part No. Spec.

□25

CV-3046

□25

CV-3045

□25 CV-3096D

□1

□1

□1

CZ-31A7 □1

Qty.

6

6

2

1

ψ40

CZ-31A8

ψ12

CJ-3112A

ψ1.5

ψ0.5

6

1

ψ16 CJ-3112B ψ0.625 1

ψ8 CJ-3112C ψ0.275 1

ψ10

CJ-3112D

ψ0.25 1

ψ6

CJ-3112E

ψ0.325 1

ψ20 CJ-3110A ψ0.75 1

ψ25

CJ-3110B

ψ1

1

ψ32 CJ-3110C ψ1.25 1

ψ16

ψ20

ψ25 CV-3204A ψ1 1

ψ32 CV-3204B ψ1.25 1

MT-2

CJ-3107

MT-3

CJ-3113

MT-2

MT-3

1

1

2-30

Fig. 2.7.2 12 Stations tooling system (non-lifting turret disk technology)


2-31

No. Part Name Part No. Spec.(mm) Qty. Qty.

2 Clamp piece

3 Clamp piece


5 Double O.D. Cutting Tool Holder CR-3074

6 Face Cutting Tool Holder

CV-3046 6 6

CV-3045

CR-3085

CR-3079

7 Face Cutting Tool Holder (long)

CR-3080

8

Boring Bar Holder /

Throw-away Drill Holder CR-3078

9 Boring Bar Holder (long)

CR-3076

10 Double Boring Bar Holder


CR-3073

CR-3084

CR-3075

□25 2 1

□25 -- 1

□25

□25

ψ40

ψ40

ψ32

ψ32

□25

6 6

1 1

-- --

6 4

-- --

-- 2

-- --

1 1

12 Cut-off Tool Holder

13

Cut-off Tool Holder

(Grooving type)

14 Boring Bush (OD:40mm)

15 Drill Socket(OD:40mm)

16 Boring Bush(OD:40mm)


CR-3096A

CJ-3016A

CJ-3016B

CJ-3016C

CJ-3016D

CJ-3016E

CJ-3014A

CJ-3014B

CJ-3014C

CV-3203A

CV-3203B

-- 1

3

ψ12 1 1

ψ16 1 1

ψ8 1 1

ψ10 1 1

ψ6 1 1

ψ20 1 1

ψ25 1 1

ψ32 1 1

ψ16 1 1

ψ20 1 1

ψ25 1 1

ψ32 1 1

CV-3203C

CV-3203D

CJ-3010 MT2 1 1

CJ-3011 MT3 1 1

CF-3055A

CF-3055B

ψ20 -- 1

ψ25 -- 1

CF-3052A

CF-3052B

ψ12 -- 1

ψ10 -- 1

2-32

CF-3052C

CF-3052D

CF-3052E

ψ16 -- 1

ψ8 -- 1

ψ6 -- 1

2-33

Part No. Spec.(Inch) Qty. No. Part Name Qty.

2 Clamp piece

3 Clamp piece


CV-3046 6 --

CV-3045 6 --

CR-3115

5 Double O.D. Cutting Tool Holder

CR-3110

□1 2 1

□1 -- 1

6 Face Cutting Tool Holder CR-3111


CR-3112

8

Boring Bar Holder /

Throw-away Drill Holder

CR-3106

□1 1 1

□1 -- --

ψ1.5 6 4



CR-3109

CR-3107

ψ1.5 -- --

ψ1.25 -- 2


CR-3114

CR-3105

ψ1.25 -- --

□1 1 1


13

Cut-off Tool Holder

(Grooving type)

CR-3096A 0.12 -- 1

14 Boring Bush

15 Drill Socket

16 Boring Bush

17 Boring Bush

(OD:1.5”)

(OD:1.5”)

(OD:1.5”)

(OD:1.25”)

CJ-3112A

φ0.5 1 1

CJ-3112B

φ0.625 1 1

CJ-3112C

φ0.375 1 1

CJ-3112D

φ0.25 1 1

CJ-3112E

φ0.325 1 1

CJ-3110A

φ0.75 1 1

CJ-3110B

φ1 1 1

CJ-3110C

CV-3204A

φ1.25 1 1

φ1 1 1

CV-3204B

φ1.25 1 1

CJ-3107 MT#2 1 1

CJ-3113 MT#3 1 1

CF-3104A

CF-3104B

CF-3105A

φ0.75 -- 1

φ1 -- 1

φ0.5 -- 1

CF-3105B

φ0.375 -- 1

CF-3105C

CF-3105D

φ0.625 -- 1

φ0.25 -- 1

2-34

2.7.2. Power turret tooling system

Fig. 2.7.3 12 Stations tooling system (non-lifting turret disk technology)


2-35

No. Part Name Part No.

Spec.

(mm)

Qty. Qty.

2 Clamp piece

CV-3046 6 6

3 Clamp piece

CV-3045

4 O.D. Cutting Tool Holder CR-3085


CR-3074

6 Face Cutting Tool Holder

CR-3079

7 Face Cutting Tool Holder (long) CR-3080

8

Boring Bar Holder /

Throw-away Drill Holder CR-3078


CR-3076


CR-3073


CR-3084

CR-3075 12 Cut-off Tool Holder

13

Cut-off Tool Holder

(Grooving type)

14 Boring Bush (OD:40mm)

15 Drill Socket(OD:40mm)


□25

□25

ψ40

ψ40

ψ32

ψ32

□25

6 6

□25 2

□25 --

1

1

-- --

1 1

-- --

6 4

-- --

-- 2

1 1

CR-3096A

CJ-3016A

CJ-3016B

CJ-3016C

CJ-3016D

CJ-3016E

CJ-3014A

-- 1

3

ψ12 1

1

ψ16 1

1

ψ8 1

1

ψ10 1

1

ψ6 1

1

ψ20 1

1

CJ-3014B

CJ-3014C

ψ25 1

1

ψ32 1

1

CV-3203A

ψ16 1

1

CV-3203B

ψ20 1

1

CV-3203C

ψ25 1

1

CV-3203D

ψ32 1

1

CJ-3010 MT2 1

CJ-3011 MT3 1

1

1

2-36


18 0° Power driven tool


CF-3055A

CF-3055B

CF-3052A

CF-3052B

CF-3052C

CF-3052D

CF-3052E

ψ20 -- 1

ψ25 -- 1

ψ12 -- 1

ψ10 -- 1

ψ16 -- 1

ψ8 -- 1

ψ6 -- 1

CR-3680 ER32 OP OP

CR-3660 ER32 OP OP

2-37

No. Part Name Part No. Spec.(Inch) Qty. Qty.

1 Block CR-3077

2 Clamp piece

CV-3046 6 --

3 Clamp piece


CV-3045 6 --


CR-3115


CR-3110

□1 2

1

□1 --

1

6 Face Cutting Tool Holder CR-3111


CR-3112

8

Boring Bar Holder /

Throw-away Drill Holder

CR-3106



□1 --

--

□1 1

ψ1.5 --

1

--

CR-3109

ψ1.5 6

4

CR-3107

ψ1.25 --

--

CR-3114

ψ1.25 --

2

CR-3105

□1 1

1


13

Cut-off Tool Holder

(Grooving type)

CR-3096A 0.12 -- 1

14 Boring Bush

15 Drill Socket

(OD:1.5”)

(OD:1.5”)

16 Boring Bush

17 Boring Bush

(OD:1.5”)

(OD:1.25”)

CJ-3112A

φ0.5 1

1

CJ-3112B

φ0.625 1

1

CJ-3112C

φ0.375 1

1

CJ-3112D

φ0.25 1

1

CJ-3112E

φ0.325 1

1

CJ-3110A

φ0.75 1

1

CJ-3110B

φ1 1

1

CJ-3110C

φ1.25 1

1

CV-3204A

φ1 1

1

CV-3204B

φ1.25 1

1

CJ-3107 MT#2 1 1

CJ-3113 MT#3 1 1

CF-3104A

φ0.75 --

1

CF-3104B

φ1 --

1

CF-3105A

φ0.5 --

1

CF-3105B

φ0.375 --

1

CF-3105C

φ0.625 --

1

CF-3105D

φ0.25 --

1

2-38



CR-3680

CR-3660

ER32

ER32

OP OP

OP OP

2-39

2.7.3. Turret head dimensional drawing

Unit: mm

Fig. 2.7.4 12 Stations for both standard and power-driven turret (CR-3004)

*Non-lifting turret disk technology.

2-40

Fig. 2.7.5 12 Stations standard turret (CZ-3104) (OP.)

* Lifting turret disk technology

Unit: mm

2-41

Fig. 2.7.6 10 Stations standard turret (CZ-3304) (OP.)

*Lifting turret disk technology .

Unit: mm

2-42

2.8. Tooling interference

Tooling interference may occur depending on a tool holder mounted to the turret head, cutting tool overhang amount, or tool combination.

The following points must be especially taken care of.

Fig. 2.8.1 GS-200 with standard 10 stations CZ turret (OP.)

2-43

Fig. 2.8.2 GS-200 with standard 12 stations CZ turret (OP.)

2-44

Fig. 2.8.3 GS-200 with standard 12 stations CR turret

2-45

Fig. 2.8.4 GS-200M with 12 stations

2-46

Fig. 2.8.5 GS-200Y with 12 stations

2-47


2-48


2-49

2.9. Travels and working area

2.9.1. GS-200 Series travels and working area

Fig. 2.9.1 GS-200 with CZ turret (OP.)

2-50

Fig. 2.9.2 GS-200S with CR turret

2-51

Fig. 2.9.3 GS-200M

2-52

Fig. 2.9.4 GS-200M

2-53

Fig. 2.9.5 GS-200MS

2-54

Fig. 2.9.6 GS-200Y

2-55

Fig. 2.9.7 GS-200Y

2-56

Fig. 2.9.8 GS-200YS

Fig. 2.9.9 GS-200YS

2-57

2.9.2. GS-200L Series travels and working area

Fig. 2.9.10 GS-200L with CZ turret (OP.)

2-58

Fig. 2.9.11 GS-200L with CZ turret (OP.)

2-59

Fig. 2.9.12 GS-200LMS

2-60

Fig. 2.9.13 GS-200LM

2-61

Fig. 2.9.14 GS-200LM

2-62

Fig. 2.9.15 GS-200LMS

2-63

Fig. 2.9.16 GS-200LY

2-64

Fig. 2.9.17 GS-200LY

2-65

Fig. 2.9.18 GS-200LYS

2-66

Fig. 2.9.19 GS-200LYS

2-67

2.10. Jaw information

Dimensions of standard Top Jaw.

A. Standard soft blank jaw it:

Chuck Size 12” 15”(18”) 24”

J1 50 62 65

J2 51 55 70

J3 111 165 180

J4 60 85 80

J5 30 43 60

J6 21 37 40

Serration

Pitch

1.5 1.5 3

2-68

3 Preparation for reception

3.1 Requirements of the space and operating position

Fig. 3.1.1 Maintenance space

3-1

3.2 Requirements of the foundation

The foundation has great effects on the accuracy of the machine, and machining accuracy by machine installation.

Therefore, a foundation site must be selected with full care.

* Dimension should be according to the conditions of the ground.

* Foundation strength: over than 35.8 kPa。

（GS-200/Y：35.8 kPa / GS-200L/LY：32.2 kPa）

Fig. 3.2.1

3-2

Fig. 3.2.2

3-3

3.3 Installation and storage requirements of the environment

1) Do not install the machine where it may be exposed to direct sunlight

2)Chips or other refuse, water, oil, etc. from other equipment.

3)Ambient temperature

4)Humidity

5)Altitude

0-45°C less than 30-95% (non-condensing) sea level -1000M

7)Electromagnetic compatibility less than IEC 810 level 3

3-4

3.4 Requirements of power source

3.4.1 Power consumption

Model

Power consumption (KVA)

Model

Power consumption (KVA)

3.4.2 Required input voltage

GS-200 GS-200M GS-200Y

25 40 40

GS-200S GS-200MS GS-200YS

35 50 50

3-Phase AC 200/220v ±10% 50/60 Hz±1%

If the power supply voltage of the building where the machine is installed is higher than above voltage, however, transformer shall be used to get required voltage as shown in the universal transformer connecting chart.

3.4.3 No fuse breaker of main power switch

The fuses below shall be provided in the factory main power switch for the machine.

A GS-200 GS-200S GS-200YS

220V 80 125 80 125 100 125

3-5

3.4.4 Wire size for power supply cable

(A) Power cable

Wire size shall be selected depending on power supply voltage of machine shop.

[Recommended wire size]

In case of 200-230V GS-200series:14 mm

2

(0.022 in

2

)

GS-200Sseries:22 mm

2

(0.034 in

2

)

In case of 380-460V GS-200series:8 mm

2

(0.012 in

2

)

GS-200Sseries:10 mm

2

(0.016 in

2

)

(B) Grounding

The machine should be ground by the power supply cable connected to the PE terminal as shown in Fig. 4.3.1.

(1) Wire size .............................. 22mm

2

(0.034in

2

) or more

(2) If it is not possible Ground the machine to the earth system and the grounding resistance is less than 100 OHMS.

3-6

3.4.5 Check the supply voltage to the machine

(A) Check the supply voltage to the machine

Measure the voltage across the phase wires.

Permissible supply voltage are within plus 10% and minus 15% to rated voltage.

If voltage is low, however, it will result in malfunctioning or trouble with controls.

Therefore it is better to maintain the voltage plus 10% and minus 0% to the rated voltage.

(B) Check the phase

In order to check a phase, fill the hydraulic tank and lubrication tank with the oil recommended first.

Then turn 'ON' the main power switch which is located at the electric cabinet and press the POWER ON button on the operation panel.

When the power is turned on to the NC unit, the hydraulic pump will start rotating by pressing "HYDRAULIC START" button..

If the power cable is connected properly, the indication of the pump pressure gauge will increase and point at 30-35kg/cm2 (430-500 PSI).

But if the indication of the pump pressure gauge does not increase, press the

POWER OFF button on the operation panel immediately.

Then, turn off the main power switch and switch the connections of the power cables which are connected to the terminals L1, L2 & L3 on the terminal block

(TB-1).

3-7

3.5 Oil requirement

No. Type of oil Place of oil supply

1 Grease Chuck

Fig. 3.5.1

Capacity

5g

3 Grease oil

Milling axle tank

Name of oil by company

Molykote EP grease

--- don't use the oil with law flash point.

No.68

Shell Retinax AM

FEBIS

No.2 K-68

68

6 Hydraulic oil Hydraulic tank 30L Tellus

No.32

DTE24 NUTO

H32

32

3-8

4. Handling、storage and installation

4.1. Handling and storage

4.1.1. Safety regulation moved by crane

1. The operator of crane equipment should have been trained.

2. Before the slinging and moving procedure, be sure of the followings: The weight and the center of gravity of the machine. Suitable lifting hooks and rope should be selected. Are there enough space for slinging and moving by crane. During the slinging and moving, take precaution not to damage the machine.

3. Be sure the safety of crane equipment before use.

4. Be sure all wire connections have been removed before slinging and moving.

5. Don't stand below the machine while slinging and moving by crane.

4.1.2. Safety regulation moved by fork lift

1. The operator of fork lift should have been trained.

2. Select the suitable fork lift.

3. Make sure the weight and the center of gravity of the machine.

4. The forks should extend under the full length of the machine body during transportation.

5. Be sure the balance and don't lift too high.

6. Be careful when climbing or descending down a slope.

7. Be sure all wire connections have been removed before moving.

8. Someone should to guide the operator of the fork lift.

4-1

4.1.3. Wooden Transportation

Machine weight approx: GS-200 ------- 5500 kgs (11000 lbs)

GS-200L ------- 6300 kgs (12700 lbs)

A. Moved by cran

B. Moved by fork lift

Fig. 4.1.1

Fig. 4.1.2

4-2

4.1.4. Transportation and lifting of machine

When transporting the machine, be careful not to give vibrations or shocks to it.

The fix block must to be mounted and locked. Please refer to Ch.4.1.5.

(Note)

Machine weight ..... . GS-200 Approx. 5000kgs (11000 lbs)

GS-200L Approx. 5800kgs (12700 lbs)

A. Slinging and moving by crane

(1) Move the slides to the proper position, turn off the power and remove power cable. * Tailstock slide is most retracted position.

(2) Slinging and moving of the machine to its selected floor should be made with due care.

Slings (Wire ropes) which show any sign of external or internal deterioration should never be used to avoid accidents.

(3) Place the slings through lifting hooks & frame of machine and put some protective pads such as rubber or rag between the slings and machine to avoid the damages before lifting.

(Note)

Slinging angle ...... 60 degree or less

(4) Lift the machine slightly up and stop to check if the balance is correct and the slings are in good position, then move the machine.

Finally place the machine carefully on its selected floor.

4-3

Fig. 4.1.3 Crane Bracket & Tube

4-4

B. When using a fork lift

(1) Fork lift truck must be a minimum of 5 ( 6) tons capacity.

(2) Fork the right position (under "fork here" signs) and make sure machine is in balance to avoid injury and the damage to the machine .

(3) Make sure that forks do not touch any delicate part of the machine, include the base of spindle motor.

Fig. 4.1.4

4-5

4.1.5. Position of fixed plates

Mount the fixed plates and tighten screws before transport

Fig. 4.1.5

Note: Before the first time putting the machine in use, please remove

these plates

4-6

4.2. Installation of leveling bolt

Put the machine down slowly when the machine in the correct position, mount the leveling bolts ( CF-1048 ) on the machine and be sure the leveling blocks

( CF-1047 ) are supporting the machine.

Fig. 4.2.1

4-7

4.3. Connection of power supply

A. Power Cable connections (Refer to Fig. 4.4.1)

1. The power cable (R,S,T) should be connected to breaker of the Universal

Transformer.

2. The cable form filter( R2,S2,T2 ) should be connected to the main power transformer.

3. The primary cable (R3,S3,T3) should be connected to the terminal block.

4. The cable from terminal block (R4,S4,T4) shall be connected to the main

Power Switch of NC control cabinet.

Fig. 4.3.1 Power supply cable and universal transformer connection chart

4-8

4.4. Dismantle

When removing this machine, reverse the installation procedure.

Fig. 4.4.1

4-9

5 Preparation for commissioning

5.1 Machine level adjusting

Make machine properly leveled because machining accuracy and machine life affected by poor leveling.

[Leveling]

1) Mount the leveling base (CY-3064) to the turret head.

2) Place a spirit level gauge on the leveling base. (At this procedure, do not rotate the turret head.)

3) Use a level with graduations in 0.02mm/m (0.00025 inch per foot).

4) Adjust level of X axis and Z axis direction with leveling bolts (CF-1048).

5) Finally, the permissible level value must under 0.02mm/m. When adjust mend is complete, secured all the bolts.

Fig. 5.1.1

5-1

5.2 Cleaning and oil supply

5.2.1 Cleaning

Do not move the saddle and tailstock until they have been completely removed.

1) Wipe off with a rag soaked in toluene or benzine the painted anti-rustive spread over each slide way carefully.

Therefore, apply lubricating oil thinly.

2) Wipe off carefully moisture stuck to the machine.

Do not use compressed air for cleaning the machine. If used, a foreign substance may be blown in a joint by the compressed air, and as a result, joint surfaces may be damaged.

5.2.2 Oil supply before starting operation

It is necessary to supply the recommended oil to the following units.

(Refer to chapter 3.5)

1. Hydraulic tank

2. Hydraulic pump (*)

3. Lubrication tank

(Note)

(*)-- Before starting the hydraulic pump, fill the pump case with the hydraulic oil initially to prevent an abnormal sound, vibrations and damaging the pump.

Amount of oil ........Approx.. 0.3L (0.08 US GAL)

5-2

5.3 Safety checking procedure

5.3.1 Before Power ON:

1. Be sure the power source is 3 phase 220V AC, if not the transformer must be used.

2. The power connection should be wired by 22mm

2

wires. (refer to ch.3.4.4 A)

3. Be sure the earth wire has been connected. (refer to ch. 3.4.4 B)

4. Be sure the fix block on machine has been removed. (refer to ch. 4.1.5)

5. Be sure the screws in hydraulic chuck has been tighten.

6. Be sure the leveling bolts and nuts have been fixed. (refer to ch. 4.2)

7. Be sure the coolant is in normal level.

8. Be sure the coolant hydraulic tubes and connection are in good condition.

9. Be sure the protection cover and door are in good condition.

10. Be sure the connection of lubrication is in good condition.

11. Check the hydraulic oil level in hydraulic oil tank.

12. Be sure there is nothing loose in turret disk.

13. Be sure the spindle drive belts have been installed and are in good condition.

14. Be sure there is no articles around the machine which will effect the operation.

5.3.2 After Power ON:

1. Be sure the hydraulic pump works and the hydraulic pressure is in normal condition.

2. Be sure the Emergency switch is in good condition.

3. Be sure the functions of the buttons for NC power on and power off.

4. Be sure all functions of push button works normally in manual mode.

5. Use manual mode to move the slide way to check if the lubrication oil is working properly.

6. Use manual mode to move the X / Z or Y axes to check the functions of the over travel switch

5-3

6. Manual operation

6.1. Safety device and warming-up

6.1.1. Safety device

The following devices have been equipped to maintain the safety operation.

Please check the Emergency stop button and door interlock switch is available before operating

NO. Name of device

Fig. 6.1.1

Function Location

1

2

3

4

6

Pressure switch

Chuck interlock device

(proximity switches)

Front door (guard)

Door interlock switch

Lub. Alarm lamp

To confirm spindle chuck pressure Aside spindle

To confirm proper gripping of workpiece

To prevent flashing out cutting chip and coolant

Front side of machine

To prevent electrical accident

To stop operation in emergency condition

To indicate the shortage of the lubrication oil

To confirm sub-spindle chuck pressure

Operation panel

8

10

Tailstock interlock

X & Z Axis soft limit

To confirm proper

To confirm Hydraulic system pressure

To determine the stroke of slide

Turret interference between chuck and tools

Aside sub-spindle

Rear of tailstock

Aside electric cabinet

NC software

NC software

6-1

6.1.2. Warming-up

There might be some possibility of faulty or damage of the machine if the machine is operated without warming-up after long period of machine stop for vacation, etc.

Therefore, warming-up shall be performed before machine is operated every day to maintain along life of machine.

INSTRUCTION OF WARMING-UP

1)Performed of warming-up : Minimum 15 minute

2)Spindle speed (5 min. each) : 500rpm -- 1000rmp -- Max. speed

3)Movement of slide : Max. stroke on each axis.

4)Turret indexing.

Remarks

(1)Check the distribution of lubrication oil during warming-up.

(2)Warming-up shall be performed for longer period in cold season.

6-2

6.2. Switch and button on the operation panel

Fig. 6.2.1 Operation panel

6-3

Fig. 6.2.2 Sub operation panel

6-4

6.2.1. Button and switches

"POWER ON" button and machine can be operated after approx. a few seconds.

2. POWER OFF button NC unit can be turned off by depressing

"POWER OFF" button.

3. MACHINE READY button

When press the " NC POWER ON " Button and release the " EMERG. STOP " button then press "

MACHINE READY " button, the NC system will get ready if without any abnormal condition. ( Machine

Alarm ).

4. MODE switch

Use this switch to select the mode of machine operation.

[ EDIT] Select this mode when loading NC tape data to the memory, punch out the NC data or editing the data in the memory.

6-5

(B) MANU. mode

[MEMORY RESTART]

Select this mode when continuous cycle memory operation is needed, using the bar feeder or other automatic loading device.

[MEMORY]

Select this mode when single cycle memory operation is needed, using the bar feeder or other automatic loading device.

[M.D.I.] Select this mode when machine operation by manual data input is needed.

[HANDLE] Select this mode when moving the slide by the handle (Pulse generator). x1 --- Incremental movement: 0.001mm/pulse x10 --- Incremental movement: 0.01 mm/pulse x100 --- Incremental movement: 0.1 mm/pulse

[JOG]

Select this mode when moving the slide by JOG buttons ( +-X , +-Z ). Speed of slide movement can be selected by changing "FEEDRATE OVERRIDE" switch.

[RAPID]

Select this mode when moving the slide with rapid speed by JOG buttons ( +-X , +-Z ). Rapid speed can be selected by "RAPID OVERRIDE" switch.

[ZERO RETURN]

Select this mode when moving manually the slide to the "ZERO RETURN " position.

6-6

5. HANDLE (Manual Pulse Generator)

By turning this handle with the mode switch selected either to HANDLE×1, HANDLE×10 or HANDLE×100, the slide can be moved at a fine speed in the direction to a corresponding to a selected axis.

6. AXIS DIRECTION button

By operating AXIS DIRECTION button, the slide will travel in the direction selected by it. If the mode switch has been selected to AXIS DIRECTION, the slide travels at a rate set by the FEEDRATE OVERRIDE switch, and if the mode switch has been selected to

RAPID, the slide travel at a rapid traverse rate.

7. FEEDRATE OVERRIDE switch

The feed rate of the slide can be set by this rotary switch.

[INCREMENTAL device (%)]

The switch can apply an override (%) to the feedrate specified by F-command in automatic operation by every 10% step within a range of 0--150%.

[EXTERNAL division (mm/min.)]

The switch can apply the feedrate of slide by using

JOG button in JOG mode.

Feedrate can be adjusted within a range of

0--1260mm/min.

(NOTE) 1.Feedrate with external division (mm/min.) can be effective when DRY

RUN switch is selected to "ON" position

2.Feedrate can not be changed by turning this switch during threading

cycle.

6-7

9. SPINDLE switch

Rapid traverse rate can be adjusted by 3 step of F0, 25%, 50% and 100% adjust a standard speed.

* F0--- 125mm/min

These buttons are used to operate (Forward Reverse and Stop)

[C.W.] --- Spindle rotates in the clock wise direction

(C.C.W.).

[C.C.W] --- Spindle rotates in the counter clock wise direction (C.W.).

[STOP] --- Spindle stops.

10. SPINDLE SPEED rotary switch

This switch is used to control a spindle speed. Spindle speed is displayed to the position display of CRT.

11. SPINDLE button

This switch is used to make the spindle run in the forward direction at a low speed for checking a runout of workpiece.

6-8

12. TOOL NO INDEX button

Function is different depend on a condition of switch lamp.

(Lamp on) Turret indexing can be performed manually by depressing this button. Turret goes on indexing when this button is held depressing.

Remarks: Automatic cycle can not be started if switch lamp is off.

13. TOOL NO. SELECT switch This switch selects needed No.of tool.

14. CYCLE START button

Automatic cycle can be started by depressing this button in AUTO mode and its lamp lights up at the same time.

(NOTE) Automatic cycle can not be started unless the

INDEX lamp and chuck close lamp lit up.

6-9

15. FEED HOLD button

Press this button to stop the machine feed temporarily during automatic operation. The slide stops moving and its lamp lights up.

(NOTE) M, S and T functions kept executed even if this button is depressed.

16. EMERG. STOP button

If this button is depressed, NC unit will immediately stop. Use this button when an abnormality takes place while operating the machines.

(NOTE) The NC unit remains an emergency stop mode unless the button is turned in the arrow indicated direction for resetting after the button was pressed.

17. COOLANT switch

[MANU] - Coolant is discharged by selecting this

MANU. position.

[AUTO]-- Discharging and stopping of coolant is controlled by programming command in the

AUTO mode.

18. SINGLE BLOCK switch

[ON] --- Program commands can be executed block by block in auto mode.

[OFF] --- Program commands can be executed

continuously.

6-10

19. DIYRUN switch

[ON]---Slide moves at the feedrate (mm/min or inch/min) set by the FEEDRATE OVERRIDE switch instead of the feedrate (mm/rev. or inch/rev.) set by the programming

F-command. Also, effective to the rapid

traverse.

[OFF]---Slide moves at the feedrate (mm/rev. or inch/rev.) set by the programming

F-command and FEEDRATE OVERRIDE

(%).

20. OPTIONAL STOP switch

[ON] --- The machine will temporary stop when

M01 command is read and the red lamp

* Also, spindle rotating and coolant discharging stop.

[OFF]--- The machine will not stop even if M01 has been commanded in the program.

(NOTE) This switch can be effective only when M01

21. BLOCK DELETE switch has been commanded in the program.

[ON] --- A block having "/" (Slash code) at its beginning will be ignored and next block

[OFF] --- A block having "/" at its beginning will be also executed.

(NOTE) This switch can not be effective unless a block has "/" (Slash code).

6-11

22. EDIT key switch

When this switch is turned off the following operations can not be executed.

1. TV check (Tape vertical check).

2. Selection of ISO/EIA and INCH/MM.

3. Memorizing and editing a machining program.

23. MODE LOCK switch

When this switch is turned off all buttons and switches on main operation board or sub-operation board can not be executed. Also, NC unit will not be executed.

24. LAMP button

Turn on the light during necessary, for instance, tool setting, measurement & trouble shouting.

Turning off the light is important in need-less time for extending it's life.

25. MACHINE ALARM lamp

This lamp will light up when the machine becomes emergency condition.

6-12

26. SPINDLE ALARM lamp

The lamp will light up when an alarm signal is emitted from the spindle servo amplifier.

27. LUB. ALARM lamp

This lamp will light up when quantity of lubrication oil is short.

(NOTE) Refer to the Ch.10, Ch.11 and electric manual Ch.4, Ch.5 when the machine becomes above alarm conditions.

28. ZERO RETURN lamp

(Zero return completion pilot lamp.)

There lamp will light up when X slide reaches to the zero return position.

There lamp will light up when Z slide reaches to the zero return position.

There lamp will light up when B slide reaches to the zero return position.

There lamp will light up when Y slide reaches to the zero return position.

29. CHUCK CLOSED lamp

This lamp will light up when the chuck becomes chuck close condition and spindle can be operated.

(NOTE) Spindle can not be rotate even if the chuck closed lamp lights up when the proximity switch for chuck interlock is off.

6-13

30. AUTOMATIC POWER-OFF button

1) Function of the button and the lamp:

1. When the button is "ON", it means power-off function starts.

When the button is "OFF", it means power-off function stops.

2. When the button is "ON", the lamp lights on. When the button is "OFF", the light will turn off.

3. Lubrication unit starts after NC being ready, The lamp won't light on

4. The button will keep pressed, when the finger is off the button. The lamp keeps lighting on.

5. Under automation status, the automatic power-off button is useful.

2) Automatic power-off motion:

1. When the button is on, machine finishes working, and it oesn't reach T1 Time, machine will turn off automati cally if there is no further action. (set T1 = 30min.)

2. This button is useful in any condition.

6-14

6.2.2. Buttons and Switches (For optional functions)

1) QUILL IN/OUT Button

This button is used to operate the tailstock quill advancing and retracting in manual mode.

The button is used to operate the tailstock quill advancing with JOG in manual mode.

(NOTE) Normally the quill can not be operated during spindle run. However, the quill can be operated by changing the PC-parameter setting (D300-6) during spindle run.

2) Tailstock move forward / backward button

Servo tailstock (OP):

Press this button to move the tailstock go forward.

Press this button to move the tailstock go backward.

3) Tailstock connection button

Pin type(OP.):

This button is used to operate the tailstock pin advancing and retracting in manual mode. Press this button once to connect tailstock and slide. And LED lamp on, pin will advance. Press it again and LED lamp off, pin will retract. (This button is enable under tailstock mode on only)

6-15

When this button is "ON" under manual mode, LED lamp on and tailstock mode turned on.

4) Sub-spindle move button

By pressing “+ or -“, “ B ” button, the sub-spindle will travel in the direction selected by it. If the mode switch has been selected to AXIS DIRECTION, the slide travels at a rate set by the FEEDRATE OVERRIDE switch, and if the mode switch has been selected to

RAPID, the slide travel at a rapid traverse rate.

5) PARTS CATCHER button Catcher comes near to spindle if push the button, and it will retract when push again for setup usually.

6) CHIP CONVEYOR REVERSE button


1. The chip conveyor reverses when the button is pressed

"ON". The chip conveyor will stop working when the but ton isn't pressed.

2. The lamp lights on, when the button is pressed "ON". The light will disappear when the button isn't pressed.

3. Lubrication unit starts after NC being ready, the lamp of the function button will not shine.

4. The button won't keep pressed, so the chip conveyor stop when the button isn't pressed.

5. Under automation status, the reverse button isn't useful.

2) Reverse motion of the chip conveyor:

6-16

1. Reverse function isn't useful when the door is opened.

2. Under automation status, the chip conveyor reverses when

M62 is working.

3. This button is controlled by manual.

7) CHIP CONVEYOR STOP button


1. The chip conveyor stops immediately when the button is

"ON".

2. The lamp lights on when the button is "ON". The lamp keeps lighting on after the finger leaving the button.

3. Lubrication unit starts after NC being ready, the lamp of the function button will shine.

4. The button will keep pressed, so the chip conveyor stop when the button isn't pressed.

5. Under automation status, the stop button is useful.

2) Stop motion of the chip conveyor:

1. The chip conveyor won't stop working when the door is opened.

2. Under automation status, the chip conveyor stops when

M63 is working.


8) CHP CONVEYOR TURN button


1. The chip conveyor turns forward, when the button is ressed

"ON". The chip conveyor will keep turning when the button is pressed.

2. The lamp lights on when the button is "ON". The lamp keeps lighting on after the finger leaving the button.

3. Lubrication unit starts after NC being ready, the lamp of the function button will not shine.

6-17

GS-200

4. The button keep pressed , so the chip conveyor keep working when the button isn't pressed.

5. Under automation status, the turn button is useful.

2) Turning motion of the chip conveyor:

1. When the chip conveyor turns forward, it turns for a while and then stops temperately, till the stop button is "ON". T1,

T2 = set by manual.

2. When the door is opened, the motion stops, The chip conveyor works when the door is closed.

3. Under automation status, conveyor turns when M61 is working .


5. As to the different machines, the settings of T1 and T2 are as following:

Parameter NO.

Timer NO. 15

ADV. Stop Time

Parameter No.

Timer NO. 16

Remark

Use18I-TB or 0I-TC, TD controller

9) TOOL SETTER button Make the arm of tool setter send out or retrieve.

10) WORK SHIFT switch/input Perform manual X and Z axis reference point return by turning on the switch, making tool nose touch the workpiece face and pressing "INPUT" button in

"HANDLE FEED" mode

6-18

11) CF-AXIS MANUALLY ENGAGE button

[ON] --When this button is "ON" under manual

mode, the CF-AXIS will be active and the

lamp will become "ON".

[OFF] --When this button is "OFF" under manual

mode, the CF-AXIS will be cancel and the

lamp will become "OFF".

12) CF-AXIS MANUALLY ON button

[ON] --- When this button is "ON" under manual

mode, the CF-AXIS motor will search

reference position and engage the driven

gear. After engage the driven gear, the

lamp will become "ON".

[OFF] -- When this button is "OFF" under manual

mode, the CF-AXIS driven gear will be

disconnected. After disengage the CF-

AXIS driven gear, the lamp will become

"OFF".

13) Spindle override

The switch can apply an override to the turning rate of spindle by using manual and automatic operation within a range of 50% - 120%.

14) 1st STEADY REST button

1

[ON] -- When this button is "ON" under manual mode, the 1st steady rest will clamp the work piece and the lamp will become "ON".

[OFF] -- When this button is "OFF" under manual mode, the 1st steady rest will unclamp the work piece and the lamp will become "OFF".

6-19

15) 2nd STEADY REST button

2

[ON] --- When this button is "ON" under manual mode, the 2nd steady rest will clamp the work piece and the lamp will become "ON".

[OFF] --- When this button is "OFF" under manual mode, the 2nd steady rest will unclamp the work piece and the lamp will become

"OFF".

16) AUTOMATIC DOOR CLOSE button

When this button is "ON" under manual mode, the automatic door will close and the lamp will become

"ON".

17) AUTOMATIC DOOR OPEN button

When this button is "ON" under manual mode, the automatic door will open and the lamp will become

"ON".

18) H button When the spindle switches to high speed level, the lamp will become "ON".

19) G / L button When the spindle switches to low speed level, the lamp will become "ON".

20) SPINDLE NEUTRAL button

When the spindle switches to neutral level, the lamp will become "ON".

6-20

6.3. M.D.I. (Manual Data Input) Keyboard function

The keyboard functions shall be understood for the key operations and automatic operations.

The LCD/MDI panel, consists of a LCD display (8.4" color) and keyboard as in the following illustration.

Refer to the FANUC OPERATOR'S MANUAL for more details.

Fig. 6.3.1 MDI & LCD panel for FANUC SYSTEM 0i-TD

6-21

6.4. How to opening / closing the electrical cabinet door

To open the electrical cabinet door for maintenance, follow the procedure indicated below.

6.4.1. Open the Electrical Cabinet Door

I. Steps for how to open the cabinet door in power off

1) Turn off the power.

2) Turn off the power supply at the shop power distribution board.

3) Turn the key on the electrical cabinet door to release the electrical cabinet door lock.

4) Place the main switch in the OPEN /RESET position.

5) Open the electrical cabinet door.

6-22

II. Steps for how to open the cabinet in an uninterruptible power situation

1) Turn the key on the electrical cabinet door to release the electrical cabinet door lock.

2) Release the screw of main power switch with a screwdriver.

3) Open the electrical cabinet door.

(NOTE)

1. Before attempting maintenance and inspection inside the electrical cabinet, be sure to turn OFF the power at the circuit breaker for the entire plant. Even when the main power switch on the electrical cabinet is turned OFF, parts of the cabinet may still have potential and may give an electric shock if accidentally touched. If it is necessary to conduct maintenance with the power being supplied, confirm the state of power supply by checking the electrical circuit diagram and exercise extreme caution.

2. In order to open the electrical cabinet door, you must place the main switch in the

OPEN RESET position. If the main switch is at a position other than OPEN TESET it will not be possible to open the door. Attempting to force the door open in this situation could damage the electrical cabinet door or the main switch.

6-23

6.4.2. Closing the Electrical Cabinet Door

TR

IP

ON

1) Place the main switch in the OFF position.

2) Close the electrical cabinet door.

NOTE.

3) Turn the key on the electrical cabinet door

to lock the electrical cabinet door.

O

F

F

TR

IP ON

E

E A S

1.When the electrical cabinet door is completely closed , a click is heard.

2.If the electrical cabinet door is not completely closed, engage the position of the

main switch on the inside of the electrical cabinet door with the position of the

main breaker in the electrical cabinet, and then close the electrical cabinet

door.

6-24

6.5. How to turn on the power

Control power can be turned on as following steps.

1)

Reset the [EMERGENCY] button

Turn in the arrow-indicated direction for resetting direction for resetting.

2)

Turn on the [MAIN POWER

SWITCH ] on the electric cabinet

Cooling for motor of spindle motor and control cabinet will rotate.

3)

4)

Turn on the [NC POWER] button on the operation panel.

* Hydraulic pump by pressing MACHINE READY button.

*Check the main pressure gauge

*Confirm that the pressure gauge indicates normal pressure in

the range of 30-35 kgf/cm

READY TO OPERATE

2

.

6-25

6.6. How to stop the machine

Use the following button switches or key to stop the operation in case of emergency.

[FEED HOLD] button

This is effective during automatic operation.

The slides will stop by pressing this button.However, spindle and M-function will kept executing.

[RESET] key

This button is effective regardless of any mode.

Spindle, slide and M-functions will stop by pressing this key However, coolant will be kept flowing in case of manual operation

Note: Pressing RESET will delete relevant setting. For more information please refer to FANUC User's manual.

[EMERGENCY] button

This button is effective regardless of any mode.

NC unit will immediately stop and all functions will come to a complete stop.

6-26

6.7. Manual Data Input (operation.)

The command of single block or multiple blocks can be input from the MDI/CRT panel to the MDI buffer memory, and can be executed as same as automatic cycle.

(The capacity of the MDI buffer memory is 200 characters)

This MDI operation can be used for the following.

* Forming of the soft jaws.

* Simple machining of the workpiece.

(NOTE)

Precautions for starting operation.

Check the data registered to the MDI buffer memory

Set the "RAPID OVERRIDE" switch to the "LOW"

Set the "FEEDRATE OVERRIDE" switch to the "0%"

Press "START" key and change the "FEEDRATE OVERRIDE" switch to the required speed.

< Procedure of MDI operation for the sample below. >

Fig. 6.7.1

6-27

*** DATA ***

Spindle rotation and turret indexing S1000 M03 T0500

Rapid feed (A→B) G00 U-200. W-100.

1)Command of spindle rotation and turret indexing.

(1)Set the "MODE" switch to the " MDI " position.

(2)Press the "PROG” key

MEM.

RESTART

MEM.

AUTO.

M.D.I.

EDIT

(3)Input data using data keys and

INPUT key as follows.

ZERO

RETURN

X1

MANU.

HANDLE

X10

X100

RAPID

JOG

M03 INSERT

(4) Press the CYCLE START” button

* The turret starts indexing to station No.5.

* Spindle start to rotate at 1000 rpm.

* The turret starts indexing to station No.5.

* Spindle starts to rotate at 1000 rpm.

6-28

2) Command of the rapid feed from A to B.

(1)Input data using data keys and INPUT key as follows.

G00 INSERT

U-200. INSERT

W-100 INSERT

(2) Press the CYCLE START” button

X and Z-axis slide start to move from

A to B at rapid speed.

* Confirm the position of slides on the LCD screen.

3) Command of the cutting feed from B to C.

(1)Input data using data keys and INPUT key as follows.

G01 INSERT

W-50 INSERT

F0.3 INSERT

(2)Press the "CYCLE START" Button

Z-axis slide start to move from B to C at cutting speed of 0.3mm/rev.

* Confirm the position of slides on the CNC screen.

6-29

6.8. How to move the X, Y and Z-axis slides.

X and Z axis slide can be moved as the following operation.

And operate the slides with attention as shown in below.

(1)Interference between the turret (or tool) and the chuck.

(2)Interference between the turret (or tool) and the tailstock. (or sub-spindle)

(3)If the position of the slide is very close to the stroke end, move the slide in the opposite friction.

A. Operation by [G] buttons

1)Set the [ MODE ] switch to the

" JOG " or " RAPID " position.

2)Move the slide by depressing " JOG " button.

* The slide is held moving during

depressing [ JOG ] button.

6-30

**** Slide traverse ****

1) Before manual zero return is performed the slide will not move in the [ JOG ] and

[ RAPID ] mode.

2) After manual zero return is performed.

* [ JOG ] mode --- Controlled by setting " FEEDRATE OVERRIDE " switch in the range of 0--1260mm/min.

* [ RAPID ] mode --- Controlled by setting " RAPID OVERRIDE " switch.

(Low , 25 , 50 , 100%)

X-axis: 20m/min. at 100%

Y-axis: 10m/min. at 100%

Z-axis: 24m/min. at 100%

6-31

B. Operating by "HANDLE (Manual Pulse Generator)"

1)Set the "MODE" switch to the "HANDLE" (x1, x10, x100)

[x1] -- 0.001 mm/div

0.1 mm/rev.

[x10] -- 0.01 mm/div.

1.0 mm/rev.

[x100] -- 0.1 mm/div.

10.0 mm/rev

2)Select the axis (X, Y or Z) by toggle switch.

3)Turn the wheel in the direction required.

Use the [HANDLE] mode for the following

* Forming for the soft jaws.

* Machining of the workpiece with simple figure.

* etc.

6-32

6.9. How to perform the manual zero return

Manual zero return must be performed after the Machine lock switch is used.

Perform the manual zero return operation as shown in the following.

(NOTE) Move the slide in the opposite (-X, -Y, -Z )

direction of zero return once if slide

locates near the zero return position.

1) Set the "MODE" switch to the "ZERO RETURN" position.

2) Depress the " JOG " button. (+X, +Y and +Z)

If the both of +X and

+Z are depressed at same time,the both axis move together.

3)Completion of zero return

The green lamps will light up when ZERO RETURN is completed.

6-33

6.10. How to operate the spindle

Operate the spindle without the workpiece for safety unless actual machining.

1)Step the chuck foot switch to close the chuck

* The chuck can be operated

(Open and Close) by stepping

the chuck foot switch.

(NOTE) Confirm that the proximity switch for chuck interlock has been staying on.

* "CHUCK CLOSE" lamp will light

up for confirming the chuck close

condition.

Refer to 7.2.6

Chuck closed confirmation

PS-4 for REAR END position.

2) Set the "MODE" switch to the "MANU".

3)Turn the "SPINDLE SPEED" adjusting

knob counter-clockwise to prevent the accidental

acceleration of spindle.

To the next page

6-34

4)Hit the " FWD. " or " RVS " button to rotate the spindle.

The spindle speed can be changed by turning the " SPINDLE SPEED " knob.

6-35

* How to operate the "SPINDLE JOG" button.

The spindle rotates counter-clockwise at slow speed during this button is depressed.

Spindle speed has set by PC parameter (K12)

Standard JOG speed..... 193 rpm.

* How to operate the C axis by manual pluse generator.

1)

Input "M19" code by M.D.I operation (refer to CH.6.7) to enter the status of C axis control .

2)

Set the "AXIS" switch to "C" and the other procedures are same as CH. 6.8 B. (refer to CH. 6.8 B )

6-36

6.11. How to operate the turret indexing

Check the following items before the turret indexing is performed.

* Interference between the turret (or tool) and the chuck (or tailstock).

* Overhang of cutting tools from the holder or turret.

1) Set the "MODE" switch to the " JOG " position.

* Select the " MANU. " mode.

2)Move the X, Y and Z-axis slide to the safe area for indexing

by using the " JOG " button.

3)Hit the " INDEX " button on the operation panel.

To the next page

6-37

4)

Hit the " INDEX " button again for move indexing.

* Every time the " INDEX " button is pressed, turret does indexing to the next station.

* The turret does indexing forward direction.

* The "FEED HOLE" button is held pressing, than press

"INDEX" key, turret does counter rotating to the next station.

6-38

6.12. How to move the tailstock

1.Turn on the power. Move turret to X-axis

reference position.

2.Set the "MODE" switch to the "MANU".

3.Press “ TAILSTOCK MODE” button. Press “+Z”

button to, the tailstock will move to connecting

position automatically.

4.Press “tailstock pin” button therefore

tailstock connects to slide.

5.Move Z-aixs to bring the tailstock to the

destination.

6.Press “tailstock pin” button again to

disconnect the pin B.

7.Press “MODE” button again to cancel the tailstock mode.

8.Tailstock moving finished。

Note

Make sure the moving turret and tailstock won’t collide to any equipments or persons, especially pay attention to throw-away drill tool, or it may course damage.

6-39

6.13. How to turn off the power

Turn off the power as the following steps.

1)Move the X and Z-axis slides away from the chuck and tailstock.

2)Confirm that all motion have been stopped.

3)Depress the "EMERGENCY" button.

4)Depress the NC power "OFF" button.

5)Turn off the main power switch on the electric cabinet.

6)Turn off the main power switch of the machine shop.

7)Completion of turning off the power.

(NOTE) Clean up the machine when the job is finished.

6-40

6.14. Procedure for the automatic operations

The following procedure shall be executed for the automatic operations.

1)Manual zero return of X and Z-axis shall be executed.

* Refer to the item 6.8 for the manual zero return.

* It is not necessary to execute this operation if the green pilot lamps have been lit already.

* It is not necessary to execute this operation if this operation has been finished already.

2)Close the chuck by foot switch.

* Refer to the item 6.9 for this operation.

* It is not necessary to execute this operation if the chuck closed lamp has been lit already.

3)Make the "Turret indexing ready".

* Refer to the item 6.10 for this operation.

* It is not necessary to execute this operation if the index lamp has been lit already.

(NOTE)

Other operations are needed for actual machining in addition to the above. Therefore, refer to the item 8.4 for actual machining.

6-41

7. Preparation of the actual machining

7.1 Tooling (Procedure of fixing the tool)

Prepare the all toolings used for the machining.

Mount the tool holders first, then fix the tools.

Pay attention to the followings for safety operations.

7-1

7.1.1 How to mount the tool holder.

Locate the tool holder on the outer face of the turret and fix the tool holder with the cap screws (4 pcs) as shown in the layout below.

The tool holder is not needed for the turning tool.

7.1.2 How to fix a cutting tool

Mount a cutting tool determining a overhang amount by using the tool setting gauge or measuring instrument (Slide calipers, etc) in accordance with the tooling layout.

Then tighten the tool by the wrench.

7-2

I. Tools of standard turret

1) In case of the Turning Tool is mounted on the Turret head directly.

Tool size is 25× 25mm

* Both clamp pieces are standard on the turret head.

7-3

Part NO. NO. Part NO Part Name

P11

Size Qty

CV-3045 1 SE08030A Hex. Socket Head Cap Screw M8X30L 2

CV-3046 2 SI0810BB Hex. Socket Flat Head Machine Screws M8X10L 1

1 OA1011AP O-ring

CZ-3308

1

2

3 SI0615BB Hex. Socket Flat Head Machine Screws M6X15L 2

M12X45L 2

7-4

2) Face Cutting Tool Holder

Part NO A

CZ-3107 50mm

CZ-31A7 2”

7-5

NO. Part NO Part Name

1 SE01270A Hex. Socket Head Cap Screw

Size

2 CF-3048 Ball valve

3 SI0612BB Hex. Socket Flat Head Machine Screws M6X12L

Qty

M16X70L 4

2

2

4 UK1004PS Hexagon socket set screws

5 SF0610JA Countersunk Head Screw

1/4”PT

M6X10L

1

6

1

7-6

NO. Part NO

1 SE12070C Hex. Socket Head Cap Screw

2 SF1030JA

Part NO A

CR-3079 50mm

CR-3111 2”

Part Name

Countersunk Head Screw

Size

M12x70L

M10x30L

3 SI0816BB Hex. Socket Flat Head Machine Screws M8x16L

5 UK1004PS Hexagon socket set screws 1/4PT

Qty

4

6

2

2

1

1

7-7

3) Boring Bar Holder / Throw-away Drill Holder

Part NO A

CZ-3108 ψ40mm

NO. Part NO

CZ-31A8

ψ1.5”

Part Name


Size Qty


M12X70L 4

2



M10X35L 6


1/4”PT

1


M5X12L

3

7-8

NO. Part NO

Part NO

CR-3078

CR-3106

A

ψ40mm

ψ1.5

Part Name


Size Qty

M12x70L 4

2 SF1030JA Countersunk Head Screw M10x30L 6

3 SI0816BB Hex. Socket Flat Head Machine Screws M8x16L 2

2

5 CV-3097 Cover



1/4”PT

M5X8L

1

2

3

7-9

4) Double O.D. Cutting Tool Holder

Part NO A

CR-3074 50mm

NO. Part NO

CR-3110 2”

Part Name Size Qty

2


M12x60L 4

3 SI0612BB

Hex. Socket Flat Head Machine Screws M6x12L 2


5 UK1002PT Hexagon socket set screws

M8x30L

1/8PT

12

3

2

7-10

5) O.D. Cutting Tool Holder

Part NO A

CV-3096B 50mm

CV-3096D 2”

7-11




3 SI0612BB Hex. Socket Flat Head Machine Screws


Size Qty

M12X30L 2

2

M6X12L

1/8”PT

2

1

6

CV-3045 Clamp

7

CV-3046 Clamp

8

SE08030A Hex. Socket Head Cap Screw

9

SF1030JA Countersunk Head Screw

1

1

M8X30L

M10X30L

3

6

7-12

Part NO A

CR-3085 50mm

CR-3115 2”

7-13




Size Qty

M12X40L 4

M8X30L

M10x25L

2

8


2

6 UK1002PT Hexagon socket set screws 1/8”PT 3

1



1

M8X30L 3

M10X30L 6

7-14

6) Double Boring Holder

NO. Part NO

Part NO A

CR-3073

ψ32mm

CR-3107

ψ1.25”

Part Name Size Qty


2

M12x95L 4

3 SI0612BB





M8x10L

M8x16L

1/8”PT

6

6

2

7-15

7) Cut-off Tool Holder

NO. Part NO

Part NO A

CR-3075 25.5mm

CR-3105 1.024”

Part Name

2 SE12080C Hex. Head Cap Screw



Size Qty

M12X30L 2

M12X80L 2

M8X30L 5

1/8PT 2

7-16

Part NO A

CR-3096A 42.5mm

7-17





Size Qty

M12X35L 4

M4X25L 1

M5X25L 2


5 UK1002PT Hexagon socket set screws 1/8PT

6 CR-3096B Cover

4

2

1

7-18

8) Socket and fitments a. Boring Bar Sleeve

Part NO. CJ-3016A CJ-3016B CJ-3112A CJ-3112B

A

ψ12mm ψ16mm ψ0.5” ψ0.625”

B

C

D

ψ13mm ψ17mm ψ14mm ψ17mm

ψ40mm ψ40mm ψ1.25” ψ1.25”


E 44.5mm

44.5mm

Fitments of above sockets

NO. Part NO Part Name Size Qty

1 SF0816JA Countersunk Head Screw M8X16L 1


Part NO. CJ-3016C CJ-3016D CJ-3016E

A

ψ8mm ψ10mm ψ6mm



1 SF0612JA Countersunk Head Screw M6×12L 1


7-19


E

ψ0.375” ψ0.25” ψ0.3125”





Part NO. CF-3052A CF-3052B CF-3052C CF-3052D CF-3052E

A

ψ12mm ψ10mm ψ16mm ψ8mm ψ6mm

B


C 40mm 40mm 40mm 60mm 60mm

E


F 12mm 12mm 12mm 12mm 12mm

7-20

Part NO. CF-3105A CF-3105B CF-3105C CF-3105D

A

∅0.5” ∅0.375” ∅0.625” ∅0.25”

B

∅14mm ∅11mm ∅17mm ∅8mm

E

∅1.25” ∅1.25” ∅1.25”

∅1.25”



1 SF0612JA

Countersunk Head Screw M6×12L

1

2 SF0608JA

Countersunk Head Screw M6X8L

1

Part NO. CJ-3014A CJ-3014B CJ-3014C CJ-3110A CJ-3110B CJ-3110C

A

B

∅20 ∅25 ∅32 ∅0.75" ∅1" ∅1.25”

∅40mm ∅40mm ∅40mm ∅38mm ∅38mm ∅38mm

100mm 100mm 100mm 100mm




7-21

Part NO. CF-3055A CF-3055B

D

∅20mm ∅25mm





E

∅0.75”


∅1”



7-22

Part No. Taper/B A b. Throw-away Drill Socket

Part NO.. CV-3203A CV-3203B CV-3203C CV-3203D CV-3204A CV-3204B

A

B

φ16mm φ20mm φ25mm φ32mm φ1" φ1.25"

φ40mm φ40mm φ40mm φ40mm φ1.5" φ1.5"




7-23

II. Tools of power driven turret

1) In case of the Turning Tool is mounted on the Turret head directly.

Tool size is 25× 25mm

* Both clamp pieces are standard on the turret head.

7-24

Part NO. NO. Part NO Part Name Size Qty

CV-3045 1 SE08030C Hex. Socket Head Cap Screw M8X30L 2

CV-3046


2

CR-3077


3 OA1110AP O-ring P11 1

4 SE08055A Hex. Socket Head Cap Screw M8X55L 1

7-25

2) Face cutting Tool Holder

NO. Part NO


2 SF1030JA

Part NO A

CR-3080 50mm

CR-3112 2”

Part Name

Countersunk Head Screw

Size Qty

M12x70L 4

M10x30L 6


2

5 UK1004PS Hexagon socket set screws 1/4PT 1

7-26

3) Boring Bar Holder / Throw-away Drill Holder

Part NO A

NO. Part NO

CR-3076 ψ40mm

CR-3109

ψ1.5”

Part Name


Size

M12x70L

Qty

4

2 SF1030JA Countersunk Head Screw M10x30L 6


5 UK1004PS Hexagon socket set screws 1/4PT

6 CV-3097 Cover

7 SE05008A Hex. Socket Flat Head Machine Screws M5x8L

2

2

1

3

7-27

4) Double Boring Holder

Part NO A

CR-3084

ψ32mm

CR-3114

ψ1.25”



Size Qty

M12x95L 2

2 SI0612BB



M8x10L 6


M8x16L 6

3


1/8PT 2

7-28

5) Cut off tool Holder

NO. Part NO

Part NO A

CR-3075 25.5mm

CR-3105 1.024”

Part Name

2 SE12080C Hex. Head Cap Screw



Size Qty

M12X30L 2

M12X80L 2

M8X30L 5

1/8PT 2

7-29

Part NO A

CR-3096A 42.5mm

7-30





Size Qty

M12X35L 4

M4X25L 1

M5X25L 2


5 UK1002PT Hexagon socket set screws 1/8PT

6 CR-3096B Cover

4

2

1

7-31

6) OD cutting and drill

Part NO A

CR-3085 50mm

CR-3115 2”

7-32




Size Qty

M12X40L 4

M8X30L

M10x25L

2

8


2

6 UK1002PT Hexagon socket set screws 1/8”PT 3

1



1

M8X30L 3

M10X30L 6

7-33

7) Double O.D. Cutting Tool Holder

Part NO A

CR-3074 50mm

NO. Part NO

CR-3110 2”

Part Name Size Qty

2


M12x60L 4

3 SI0612BB




M8x30L

1/8PT

12

3

2

7-34

8) Socket and sleeve a. Boring Bar Sleeve

Part NO. CJ-3016A CJ-3016B CJ-3112A CJ-3112B

A

ψ12mm ψ16mm ψ0.5” ψ0.625”

B

C

D


ψ40mm ψ40mm ψ1.5” ψ1.5”


E 44.5mm

44.5mm






W

∅8mm ∅10mm ∅6mm





7-35


E

ψ0.375” ψ0.25” ψ0.3125”





Part NO. CF-3052A CF-3052B CF-3052C CF-3052D CF-3052E

A

∅12mm ∅10mm ∅16mm ∅8mm ∅6mm

B

∅13mm ∅17mm ∅11mm ∅10mm ∅7mm

C 40mm 40mm 40mm 60mm 60mm

E

∅32mm ∅32mm ∅32mm ∅32mm ∅32mm

F 12mm 12mm 12mm 12mm 12mm

7-36

Part NO. CF-3105A CF-3105B CF-3105C CF-3105D

A

∅0.5” ∅0.375” ∅0.625” ∅0.25”

B

∅14mm ∅11mm ∅17mm ∅8mm

E

∅1.25”

∅1.25” ∅1.25”

∅1.25”



1 SF0612JA

Countersunk Head Screw M6×12L

1

2 SF0608JA

Countersunk Head Screw M6X8L

1

Part NO. CJ-3014A CJ-3014B CJ-3014C CJ-3110A CJ-3110B CJ-3110C

A

B

∅20 ∅25 ∅32 ∅0.75" ∅1" ∅1.25"

∅40mm ∅40mm ∅40mm ∅38mm ∅38mm ∅38mm

100mm 100mm 100mm 100mm




7-37


D

∅20mm ∅25mm





E

∅0.75”


∅1”



7-38

Part No. Taper/B A b. Throw-away Drill Socket

Part NO.. CV-3203A CV-3203B CV-3203C CV-3203D CV-3204A CV-3204B

A

B

φ16mm φ20mm φ25mm φ32mm φ1" φ1.25"

φ40mm φ40mm φ40mm φ40mm φ1.5" φ1.5"




7-39

7.2 Chuck (Jaw chuck & Collet chuck)

CHUCK MODEL

Fig. 7.2.1

A B C

7.2.1 How to mount the chuck

Mounting methods are slightly different depending on type of chuck.

Refer to the following instructions and disassembled parts list when mounting the chuck.

Refer to the own instructions manual for other manufactures chuck.

7-40

A. HOWA CHUCK TYPE HO37M10-A8

1)

Remove the soft jaws [6] and cover [4] from the chuck [2].

2)

3)

4)

5)

6)

Advance the draw tube in the spindle by stepping the chuck foot switch.

Screw the joint tube [1] into the draw nut of the chuck [2].

Insert the joint tube [1] into the spindle lifting the chuck [2] by hand.

Turn the draw nut of the chuck by using the wrench [9] to connect the joint tube [1] to the draw tube in the spindle, supporting the chuck body [2].

Fix the chuck body [2] onto the spindle with the cap screws [3].

7)

Check a runout of the chuck.

8)

9)

Attach the cover [4] with the screw [5].

Attach the soft jaws [6] and T-nuts [7] with the cap screws [8].

Then tighten the cap screws [8] completely.

7-41

4 Cover

7 T-nut

9 Wrench

Fig. 7.2.2

1

1

6

1

3

3

3

6

1

7-42

7.2.2 Chucking pressure adjustment

When adjustment of chucking pressure is needed, adjust the pressure regulator valve which is located at left of the machine. Turn the adjust knob after loosening the lock nut as shown below.

* Turning clockwise ---- Increase the pressure

* Turning counterclockwise ---- Decrease the pressure

* Adjusting range of pressure: 10 -- 25 kgf/cm

2

7-43

7.2.3 Allowable maximum chuck pressure and speed

The chuck pressure and spindle speed is limited as shown in the following table depending on a chuck to be used.

TYPE

Max. chuck pres. kgf / cm

2

MAX. SPEED

RPM

8” H3KT8-A6 30.6 4800

10” H3KT10-A8 30.6 3500

(NOTE) Maximum spindle speed must be reduced depending on the size of workpiece and chucking condition for safety.

7-44

7.2.4 Chuck gripping force

The centrifugal force effect, which diminishes gripping force as speed increases, and the consequent maximum speed recommendation are affect by initial gripping force, jaw assembly mass and the position of the jaws when gripping the workpiece.

Refer to the Fig. 7.2.3 "CHARACTERISTIC GRAPH" of chuck.

(NOTE) The piston area of the cylinder

Chuck size Type area (cm

2

)

Extend Retract

* "CHARACTERISTIC GRAPH" shows the experimental valves of the gripping force per three (3) jaws at the max. operating chuck pressure when the outside end of standard soft jaws are positioned at the peripheral dia. of the chuck.

7-45

Fig. 7.2.3

7-46

7.2.5 Selection of chuck clamping direction.

Use the OPR. Selection to select the chuck clamping position as shown in the following.

1) Unclamp the chuck.

2) Press key.

3) Press or .

4) Until OPR appers, press . .

Next Page

7-47

5) Move cursor to [CHUCK IO], and select OFF (INSIDE CLAMP) or ON

(OUTSIDE CLAMP).

Chuck IO off

(NOTE)

Chuck IO ON

1.Clamping over of clamping direction should not be performed when the workpiece has been clamped.

2. Clamping over of clamping direction can not be completely by shifting the chuck clamp switch unless NC power is turn off once and turn on again.

7-48

7.2.6 Chuck interlock switch adjustment

Two proximity switches have been attached in the rear of the chuck cylinder and the dog has been attached on the end of draw tube as shown in the following sketch.

The switch PS4 is for confirming the chuck cylinder piston retracted and the switch

PS3 is for confirming the chuck cylinder piston advanced.

It is necessary to adjust location of switches in accordance with clamping stroke of the chuck and diameter of the workpiece.

Chuck closed confirmation PS3 for

FRONT END position

Check closed confirmation PS4 for REAR

END position.

In case [OUTSIDE] is selected on the chuck clamp switch:

PS4 becomes effective and adjust its position so that switch is turned on when the workpiece is clamped.

In case [INSIDE] is selected on the chuck clamp switch:

PS3 becomes effective and adjust its position so that switch is turned on when the workpiece is clamped.

(NOTE) 1. Spindle rotation and automatic cycle can not be started even if the chuck closed lamp lights up unless the proximity switch is turned on.

2. The machine becomes the "FEED HOLD" mode and the spindle stops when the proximity switch is turned off during automatic cycle.

7-49

7.2.7 Boring soft jaws

The soft jaws are designed to be bored on the machine to provide the maximum accuracy possible.

They are normally used for second operations where relatively light finish cuts are being taken.

They are also of benefit when marring of the workpiece surface by the teeth of a hardened jaw in undesirable.

The soft jaws can be bored by the following operations.

*** Using the manual pulse generator HANDLE or JOG feed buttons.

*** Using an automatic cycle or MDI operations.

(NOTE)

(1.) Do not permit jaws mounting to extend beyond the out side diameter of the chuck, and mount the jaws to the chuck without runout.

(2.) Bore the soft jaws under some chuck pressure as actual machining.

(3.) For external work, load the chuck jaws by gripping on a plug and bore to the dimension of the workpiece 0.05-0.1mm larger.

(4.) For extra heavy duty gripping force, it is advisable to bore to the dimension of the workpiece 0.5-1mm smaller or to finish the gripping surface slightly tapered.

7-50

(5.) Check contact between gripping surfaces of the jaws and the workpiece by inserting pieces of thin paper, etc. Full contact will give the best results.

(6.) Stamping the Number (1,2 and 3) on the soft jaws to match the master jaws.

7-51

7.3 Tailstock (Option)

7.3.1 Positioning of the tailstock side (Manual)

1)

Adjust the quill pressure.

Refer to the Ch. 7.3.2 for adjusting quill pressure.

2)

Press the "MODE'' selection switch "JOG" or "RAPID".

Refer to Ch.6.11

3)

Load the workpiece on the chuck.

4)

Press the " " switch. The tailstock is unclamped and the joint pin extends form the tailstock so that it is connected to the saddle.

5)

Slide the tailstock toward the workpiece by pushing or pressing the "← " button until the center locates approx. 25mm away from the workpiece.

6)

Press the " " switch. The tailstock is clamped; it is disconnected from the saddle.

7-52

7)

Advance the quill by pressing the "QUILL".

8)

Opening and closing of chuck shall be performed for better gripping by stepping the chuck foot-witch.

END

7-53

7.3.2 Adjusting of the tailstock quill pressure.

When adjustment of quill pressure is needed, adjust the pressure regulator valve which is located at right of machine.

* Adjusting range of pressure : 4 --- 10 kgf/cm

2

(55 --- 215 PSI)

Turn the adjust knob after loosening the lock nut as shown below.

Turning clockwise --- Increase the pressure.

Turning counterclockwise --- Decrease the pressure.

Proper quill pressure shall be set accordance with the work rigidity or cutting conditions.

Tighten the lock nut slightly after adjusting pressure.

The relation between the quill pressure and quill thrust force is shown in the following graph.

7-54

8. Tool offset

8.1. Determining start position of machining

It is very important to check a start position of the tools before starting actual cutting to prevent machine collision.

There are two ways to determine the start position of the tools, which are

"Automatic coordinate system setting (G50)" functions.

At first it is necessary to figure out the start position (G50 amount) of the each tools to be used.

G50 amount of each tools can be figured out as following steps.

A. How to figure out the start position (G50 X (A) Z (B))

1)

Move the X and Z-axis slide to the zero return position.

* X=0, Z=0 shall be shown in the

MACHINE position display.

2)

Call up the total to be used by indexing.

3)

Load the workpiece on the chuck.

4)

Turn the face of workpiece by using

"HANDLE" mode.

* Skin cutting

8-1

5)

Move the tool in the direction of +X away from the workpiece and stop the spindle.

(Do not move in the direction of Z-axis after turning.)

6)

Read the Z-amount of [MACHINE] on the position display.

Let [a] = Z amount

When finishing allowance still remains on the face,

Let [d] = finishing allowance.

7)

Turn the outer diameter (or inner diameter) of workpiece.

8)

Move the tool in the direction of Z away from the workpiece and stop the spindle.

9)

Read the X-amount of [MACHINE] on the position display.

Let[b] = X amount

10)

Measure the actual turning diameter.

Let[c] = Actual turning diameter.

11)

* In case of using reference position as start position.

Let [b] + [c] = X amount of G50, [a] + [d] = Z amount of G50

G50 X [b + c] Z [a + d]

Normally closer position to the workpiece is used as start position instead of reference position to reduce the idle time.

8-2

12)

* In case of using close position where is shifted 100mm/dia. in

X-axis and 200mm in Z-axis away from zero return position.

Let ([b + c] – 100. ) = X amount of G50,

([a + d ] – 200. ) = Z amount of G50.

G50 X [b + c - 100.] Z [a + d - 200.]

Sample program:

%

O1234

N100 G28 U0. W0.

T100

G50 X[b

1

+ c

1

] Z[a

1

+ d

1

]

G99G0G97Sssss

G0 Xxxx Zzzz

:

Cutting

:

N200 G28 U0. W0.

T200

G50 X[b

2

+ c

2

] Z[a

2

+ d

2

]

G99G0G97Sssss

G0 Xxxx Zzzz

:

Cutting

:

N300 G28 U0. W0.

T300

G50 X[b

3

+ c

3

] Z[a

3

+ d

3

]

:

M5

G28 U0. W0.

M30

%

13)

Find out G50 X,Z of other tools as above procedure

(2) --- (12).

* X and Z amount of G50 will become coordinate amount of each tools start position.

8-3

B. How to move the slide to the start position.

There are two ways to move the slide to the start position

Which are by manual operation and automatic operation.

The following shows the way using automatic operation.

(Example program for moving the slide to the start position.)

O1000;

/ G28 U0;

/ G28 W0;

/ G00 W-200.;

/ U-100.;

/ M00;

NOTE

This program can be executed when "

BLOCK DELETE " switch has been turned off.

(Example program for machining.)

N100 G50 X

A

Z

B

S3000;

N101 G96 G40 S150 T0101 M03;

：

：

N200 G50 X

A

' Z

B

';

N201 G97 S1000 T0202 M03;

：

：

A = ([b] + [c]) - 100.

B = ([a] + [d]) - 200.

A ‘= ([a'] + [b']) - 100.

B ‘= ([a'] + [d']) - 200.

* Perform the program for moving the slide to the position when the power is turned on or start position is not correct.

(NOTE) When G50 (Coordinate setting) is used in the program, X and Z amount for return position shall be same as start position.

Therefore, actual position of each tools for indexing is always same regardless of tool stations.

8-4

8.2. Manual OFS/SET method

* OD TOOL (imagine nose of tool direction=3):

(1)

To clear the value of work shift, then do zero return of x-axis and z-axis.

(2)

To install the required tools. (the interference when processing and the balance of turret disc should be considered.

(3)

To clamp the work piece with proper pressure and to rotate it with proper speed.

(4)

Index to the designate tool no. (For example: T0101)

(5)

Switch to “HANDLE” mode, to move the tool to the 2mm outside of the work piece then move to touch the work piece slowly.

(6)

Switch to “HANDLE X10 “ mode, to downward the nose of tool to touch the

OD of the work piece.( see

○

(7)

Cutting the rough part by proper feedrate in “–Z button” under JOG mode or

Continue

T0101

8-5

(8)

To push the “+Z” button to let the tool move away from work piece along the z-axis.(

(9)

To push the button ,spindle would be stopped.

(10)

Using the micrometer to measure the O.D which cut in step 7 and record the diameter value. For example:50.755mm

(11)

To push OFS/SET->[tool offset] function key to show the tool offset screen, please see below .

(12)

To put the [offset] function key and move the cursor to the group no. which correspond with the present tool no.

Continue

8-6

(13)

(14)

(15)

(16)

To push the “X” then input the value which you measure from the step 10.

Then push the [MEASUR] key; machine would input the value automatically to the computer, the X-axis tool offset of T01 is completed.

To rotate the spindle with proper speed.

Switch to “HANDLE” mode to move the tool to the 1mm right side of the work piece. Then using “HANDLE X10” to move the nose of tool to the left to make the nose touch the right side of work piece, please refer to below drawing.

To cut the right side of work piece a little bit by proper feedrate.

To move the nose of tool along with the +X direction until away from the O.D of work piece.

T0101

Continue

8-7

(17)

To move the cursor to the group no. which correspond to the present tool no.

(18)

To push the “Z0” first then push the[MEASUR]; machine would input the value automatically to the computer, the Z-axis tool offset of T01 is completed.

(19)

To move the turret to the suitable position (base on the no interference location when doing x-axis zero return);then doing x-axis zero return.

Continue

8-8

(20)

Choosing the next tool no. and repeat the step 4~step 19; until all tools are set completed. Please see below.

(21)

To check if the processing program is correct or not, if the processing parts are without problem then can be mass production.

END

8-9

<NOTE>

Tool compensation can be executed by commanding T-code as following.

Turret station number: 01 -- 12

When the position of tool is shifted by changing insert by using input the offset value as following procedure.

< Example >

Tool offset number : 01 -- 64

The position of tool attached to the turret was shifted 0.04 mm

(0.08mm in dia) in the direction of -X axis ,and

0.07mm in the direction of + Z axis.

Therefore, the input offset value will be in the followings.

8-10

8.3. The OFS/SET method of reference tool.

I. Setting the reference tool.

(1)

Choosing one tool as the reference tool , for example T0101.

(2)

To clamp the work piece first then rotate the spindle with proper speed; to move the reference tool to touch the right end of work piece, please refer to below drawing.

T0101

To move tool to touch the surface of work piece

T0202

T0303

(3)

To push the [POS] function key many times until the relative coordinates screen appeared.

Continue

8-11

(4)

To push the “W” key then push [ORIGIN] soft key to zero the W to record the present position

(5)

After pushing the [ORIGIN] key, the value of W will be zero, please see below drawing.

W be zero

(6)

To move the turret to exact location (based on no interference when changing tools) ; spindle stop.

(7)

Index to the next tools, for example: T0202.

(8)

To rotate the spindle with proper speed; to move the nose of tool to touch the right end of work piece.

Continue

8-12

(9)

Changing screen to [OFFSET/SET].

(10)

To push the [OFFSET] key then below drawing will appeared.

(11)

To push the [GEOM] key to next screen.

(12)

To move the cursor to the Z axis of G02.

(13)

Pushing “Z” key then “INP.C”.

(14)

Computer will input the difference which between T02 and reference tool into the Z-axis tool offset. Please see below drawing.

Continue

8-13

(15)

(16)

(17)

(18)

To repeat step 6~13 until all tools are set completely.

To move the reference tool (only the tools which designated in step 1) to touch the right end surface of work piece, please see below drawing.

Changing to [OFS/SET] screen then push “ “ many times to find

[ WORK SHIFT ].

To move the cursor to the [MEASUREMENT].

Continue

T0101

To move tool to touch the surface of work piece

T0202

T0303

8-14

(19)

To push Z0 .

then push [INPUT], the computer would calculated automatically and input the value to the work shift column. The tool offset procedure is finished.

END

8-15

8.4. Tool setter (option)

8.4.1. Introduction

This Manual is composed of specification of the tool setter, operations, and caution of operations.

Therefore, the operator is requested to thoroughly read the following precautions and operate the machine without overestimating the safety devices.

*The specifications, illustrations and descriptions given herein are subject

to change without previous notice.

8-16

8.4.2. Tool setter construction

Fig 8.4.2 Tool setter construction

8-17

8.4.3. Specification

A. Outline of the setter

Setter is composed of tool nose touch sensor mainly, and, it is equipped with tool setter function and tool offset function when the tool tip is changed.

1. Function of the tool setter.

When the tool setter is provided, the tool offset value is automatically settable to the tool offset memory simply by moving the tool to make contact with the swing type touch sensor (3 point sensor) in manual operation.

Therefore, the work coordinate system, setting command (G50) IS unnecessary to use in program.

Fig. 8.4.1

8-18

B. Tool setter limitation of tool overhang length

1) Turning tools

2) Facing & grooving tools

3) Boring tools

Fig. 8.4.2

8-19

C. Specification of the touch sensor

1) Type

1. Swing-in type Renishaw HPMA

2. Removal type Renishaw HPRA

2) Sense directions 4 directions (＋/－Ｘ and ＋ /－Ｚ)

3) Offset increment

X axis 0.005mm (on Rad.)

Z axis 0.005mm

4) Measuring frequency at point

5) Static repeatability

X axis 0.010mm (on dia.)

Z axis 0.010mm

* Measured via 10 time trials at 10 mm/min (0.4 ipm) slide speed

* This is not a figure for machining dimensions.

6) Chuck size 165mm 6” max. overall length of chuck and jaws 216mm 8.5”

7) Tool size square 25mm×25mm （1"×1"） round φ32mm （1.25”）/ φ40mm （1.5"）

* overhang length limited

8) Setting accuracy ±0.01mm

8-20

9) Others

* Air blow off unit for the sensor is furnished.

* NC function Direct input of measured valve B (tool setter) is furnished.

* On machine with tailstock, the distance between main spindle nose and quill center shall be kept over A (refer to CH 2-9 Travels and working area for distance

A).

* On machine with tailstock, where boring or drilling tools are measured, the overhang length will be limited by location of tailstock and/or mounting of quill center: Ex. where tailstock is located at the most retracted position and quill retracted (refer to CH 2-9 Travels and working area for distance B).

Fig. 8.4.3

8-21

8.4.4. Operation

A. Confirmation of the machine conditions

Following descriptions are required to confirm before start to operate the tool setter.

(1) The spindle shall be stopped.

(2) Tailstock and Quill shall be retracted position.

(3) Tool overhand length shall be set to suitable length as showing on Fig.

8.4.3.

(4) X and Y-axis shall be return to reference position.

Note: The cover must be mounted completely , or the electric parts will burn down while coolant water get into the base.(type 1)

8-22

B. Tool setter construction (For RENISHAW HPMA)

(1)

To clear the value of work shift and do zero return for each axis (X and Z)

(2)

To install the needed tools.( the interference while processing or the balance of turret disc should be considered.)

(3)

To choose the tools no. which need to be set then push index button to rotate the turret disc to the assigned tool no. position.

(4)

To push the button to move the tool setter arm to the measure position. When arm put down to the measure position, the LED light would turn to green. If the LED not on or turn to red, there is failure need to eliminate.

LED light

* O.D right hand tool(imagine tool direction=3):

(5)

Under “HANDLE X100” mode, to move the tool to close to the 2mm above of the sensor.

Continue

8-23

(6)

Changing to JOG mode and choosing feedrate as 12.6 mm/Min.

(7)

To push “–X” button to move the tool closed to the sensor until tool touch the sensor. The LED light would change to red and X-axis offset value of tool will be input to the computer automatically.

(8)

After the x-axis offset value of tool input completely, please push “+X” to let the tool leave the sensor until the LED turn to green.

(9)

Changing to Handle X100 by mode selected button and moving the nose of tool to the 2mm right side of center of sensor.

(10)

To push –Z button to let the nose of tool close to the sensor until nose of tool touch the sensor. When the LED on the arm turn to red , machine will input the calculated coordinate value to the computer automatically.

Continue

8-24

(11)

After the tool offset value setting completely, to push the “+Z” to let the nose of tool leave the sensor until the LED turn to green.

(12)

Under HANDLE X100 mode, to move the turret to suitable position (based on there is no interference when doing zero return).

(13)

Zero return of X-axis.

(14)

To repeat the step 3-13 until all tools are set completed. (the routes of kinds of tool are showed below.)

OD TOOL

ID TOOL drill

(15)

To push the arm active button to let the arm move to the upper position.

Continue

8-25

(16) To clamp the work piece with the chuck and rotate spindle with proper speed.

(17)

To choose any one of the tools as reference tool and use HANDLE mode to approach the surface (right end) of the work piece and cut the surface a little

T0101

To move tool to touch the surface of workpiece

(18)

To push the “WORK SHIFT MODE” button (old panel: to switch on the DIP switch ) , screen will turn to WORK SHIFT.

Continue

8-26

NEW

OR

WORK SHIFT

OLD

(19)

When work shift screen appears then push “WORKSHIFT INPUT”, machine will input the work shift value to computer.

NEW

OR

WORK SHIFT

OLD

(20)

After inputting the work shift value, please switch off the [work shift mode] button to avoid crash which due to touch the work shift input key accidentally during processing.

(21)

After work shift value input completely then machine can run the processing program to machine work piece.

END

8-27

C. Automatic OFS/SET:

(1)

The tool setter arm could downward to the measure position by command

M35.

(2)

The tool setter arm could be retraction position by M36.

(3)

To install the needed tools.(the interference when processing and balance of turret disc should be considered.)

Move X-axis to reference position.To put the tool setter arm down to the

(4) measure position , the LED is green. If the LED not on or turn to red, there is failure need to trouble shoot.

Continue

8-28

(5)

According to the step of “OFS/SET of tool setter arm” to set the tool length for each tool.

(6) Choosing one tool as reference tool (for example:T0101), to move the tool nose to 6mm within the tool setter sensor by HANDLE mode.

To execute following programs to calibrate and measure stylus position.

(Following programs should be under MDI mode and execute by single block mode.)

G65 P9011 K2. T1. H3 ----to calibrate stylus position

M30

G65 P9011 T1. H3.

:

----(without Kk) to measure the stylus position.

Continue

8-29

Explanation：

P9011 --Login the sensor program

K2. --Login the position of side of sensor and its subtense. enter the

K1. or K2. Input to indicate that a calibration cycle is required:

K1--calibrate by two tool with imagination tool direction H1and

H3 or H2 and H4.

K2--calibrate by calculate with stylus dimension. Before use of K2 , to input correct stylus dimensions in

#530 and #531 is necessary.

T1. --tool no.(only two digit no. is acceptable)

H3. --Imagine nose of tool direction，

H3=OD TOOL (please refer to below drawing)

(8)

Zero return X-axis, and retract the tool setter arm.

Continue

8-30

O1024

G28 U0.

T0101

-----------

X axis zero return

-----------

Choosing tool no. 1

M35

------------ put the arm down

G65P9012 H3.

----------- Call sub-command O9012 to execute tool length and assign the shape as OD TOOL.

G28U0.

M36

M30

％

------------

X axis zero return

------------ To withdraw the tool setter arm

Note: Operator should input the tool length to the geometry screen by manual mode before doing automatic tool length OFS/SET.

Continue

8-31

(10)

Example program :before using variable #500~#599, operator must confirm that the variable in system can’t be taken up.

O4096

#100=10

#501=[#3901-#500]

IF[#501LT#100]GOTO1000 --------

N100(MEASURE 1ST-TOOL)

T0202

G28U0.

G30W0.

M35

G65P9012T2.H3.

G28U0.

G30W0.

N200(MEASURE 2ND-TOOL)

G28U0.

G30W0.

T0404

M35

G65P9012T4.H2.

N99

#500=#3901

G28U0.

G30W0.

M36

N1000

： (Cutting-1)

M01

N2000

： (Cutting-2)

M01

M30

%

END

(Before setting #500,please execute program from

N99)

(Every 10 work piece do OFS/SET)

(CURRENT MACHINED PART

If processing q’ty is over #100 then execute auto too

Tool length OFS/Set. tool no.2 OFS/SET

(T2=tool no. 2, H3= imagination tool nose direction c for OD tool.

Tool no.4 OFS/SET

(T4tool no. 4,H2imagination tool nose direction c for OD tool.

#500=current counter value, #501 would be zero)

(Cutting-1)

(Cutting-2)

8-32

8.5. Tool wear offset

★The tool insert may be worn and dimensions of work piece would have difference after period of cutting. Operator can use “wear compensation” function to correct the work piece size when tool is still can be used.

(1)

To measure the work piece dimension and compare with the drawing.

Tool no.:T0303 ;

The work piece dimension is 0.007mm smaller than the drawing. (offset value=+0.007)

(2)

To push [OFS/SET] function key to display the tool offset screen .

(3)

To move the cursor to the OFS/SET position. (W03, X-axis),to input 0.007。

(3-1)

Increment OFS/SET: to push [+input], machine would plus the input value and original value together and input to the OFS/SET position.

Continue

8-33

(3-2)

Absolute OFS/SET: to put [input], machine would input the value to the

OFS/SET .

(4)

OD OFS/SET completed, using the same way to do OFS/SET of Z-axis.

(5)

To repeat step 2~4 for all tool need to do OFS/SET; then can continue processing.

END

8-34

9. Machining (Actual Cutting)

It is very dangerous to start actual cutting without precaution.

Therefore start the actual cutting is accordance with the following procedure for safety.

9.1. Program registration

Operator can create a NC program through MDI/LCD panel.

9.1.1. Registration form MDI/LCD panel (Manual registration)

1)

2)

3)

Set the " EDIT KEY" key switch to " OFF " position.

Set the "MODE" switch to " EDIT " position.

Press "PROGRAM" key and display "PROGRAM" page.

To the next page.

MEM.

RESTART

EDIT

AUTO.

MEM.

EDIT KEY

M.D.I.

MANU.

HANDLE

X1

X10

ZERO

RETURN

X100

JOG

RAPID

9-1

4)

Key in Program No.(O ) by using

"ADDRESS" and " NUMERICAL" key.

Do not press [EOB] key.

(EX.) Key in [O1000]

5)

6)

7)

8)

Press "INSERT" key.

Key in program to be stored by using

"ADDRESS" and "NUMERICAL" key.

Press “EOB” key in end of each block.

(EX.) N100

Press "INSERT" key.

Repeat operation 6), 7) for more program input.

9-2

9.2. Program Edit

4)

3)

2)

Editing the program stored can be made by following procedure.

1)

Set the " EDIT " key switch to " OFF " position.

EDIT KEY

Set the " MODE " switch to " EDIT ".

MEM.

RESTART

EDIT

AUTO.

MEM.

M.D.I.

MANU.

HANDLE

X1

X10

X100

JOG

Press the " PRGRM " key to display "

PROGRAM " page.

ZERO

RETURN

RAPID

Move the CURSOR to the WORD to be edited by using " CURSOR SHIFT " keys.

To the next page.

9-3

* Editing operation

Alteration of word ?

Key in word to be altered.

Press "ALTER" key.

Insertion of word ?

Key in word to be inserted.

Press "INSERT" key.

Deletion of word ?

Press "DELETE" key

Editing is finished

Note: The following variables have already been used in macro program of machine tool builder. When editting the program, please don't use or

change those variables. Otherwise, it will occur an unpredictable damage or injury.

Goodway Used:

#503, #504, #505, #506, #507,#517, #518, #519, #520, #521

Renishaw Tool Setter Used:

#509, #522, #523, #524, #525, #530, #531

9-4

9.3. Program Check

Check the program stored in the NC memory by following procedure.

1)

Set the machine to automatic operating condition.

Refer to 6.13

2)

Clamp the chuck without workpiece by stepping the chuck foot switch.

3)

Set the "MODE" switch to the " MEM ".

4)

Turn on the " MLK " (machine lock ) soft switch and " SINGLE BLOCK " switch.

BDT

DRN

5)

Press "PROGRAM" key to display the

"PROGRAM" page.

6)

Press "O" (Oh not zero) key. Input the desired program number.

To the next page.

SBK

9-5

7)

Press down side cursor key or [O SRCH] soft key to load program.(Upper side cursor key does not work)

* Confirm the cursor locates at begin of program.

8)

Press" CYCLE START " button to start cycle.

9)

Confirm the motion and position display comparing with the program sheet.

Program check is finished.

9-6

9.4. Automatic operation without workpiece

Start automatic cycle without workpiece by using program for actual cutting after confirming all functions to be performed and the following conditions.

(ITEMS TO BE CONFIRMED)

* Tool mounting condition and tool stations,

* Setting amount of tool offset.

* Setting of "FEEDRATE OVERRIDE" switch.(100% shall be set)

* Condition of switches.

"SINGLE BLOCK" & "OPTIONAL STOP" ---to be "ON"

"DRY RUN" ---to be "ON"

"MLK" soft switch of [OPR] screen.

* Location of tailstock slide.

---to be "ON"

* Starting position of tool.

* Starting block of program to be executed.

1)

Set the "MODE" switch to " MEM " position

MEM.

RESTART

EDIT

AUTO.

MEM.

M.D.I.

MANU.

HANDLE

X1

X10

X100

JOG

2)

Press "PROGRAM" key.

RAPID

Display the program to be executed on the LCD monitor.

To the next page.

ZERO

RETURN

9-7

3)

4)

Confirm the program has been returned to the starting block.

If the program has not been returned. set the mode switch to "EDIT" and press "RESET" key to make the cursor return to the begin of program.

Press " CYCLE START " button to execute single block.

Repeat pressing " CYCLE START" button until all blocks are executed.

Operation is finished

9-8

9.5. Actual Cutting

Try to make actual cutting with workpiece in accordance with the following procedure after all functions are confirmed.

1)

Confirm the all items shown in 9.4 are performed.

2)

Confirm chuck pressure and mounting condition of chuck jaws.

3)

Grip the workpiece and check a run-out of the workpiece by using " SPINDLE JOG " button.

4)

Set the "MODE" switch to " MEM " position.

Press " CYCLE START "button to execute single block and cycle start lamp will light up.

Cycle start lamp will light off when single block is executed.

*Repeat pressing "CYCLE START" button until all programms are executed.

Cutting is finished

MEM.

RESTART

EDIT

AUTO.

MEM.

SP. JOG

M.D.I.

MANU.

HANDLE

X1

ZERO

RETURN

X10

X100

JOG

RAPID

9-9

9.6. Measuring cutting size and other operations during automatic cycle.

Optional stop (M01) function can be used to stop the cycle in the middle of operation for measuring cutting size and removing cutting chips as following procedure.

1)

Set the " OPTIONAL STOP " switch to "ON" position

M01

2)

Press" CYCLE START " button.

3)

Operation will stop when M01

(Optional stop) command is executed, and optional lamp will light up.

M01

4)

YES

*Remove cutting chips

*Measure cutting size.

Start the cycle again?

NO

All programms were executed?

YES

From next page

To the next page

NO

Press " RESET" key.

To the next page

9-10

To previous page

5)

6)

7)

From previous page

Cycle is finished

From previous page

Execute last operation again?

YES

Move the tool to the start position.

Search a starting sequence

No. to be performed.

NO

Input offset value to be compensated.

Refer to the Ch. 8.3

9-11

9.7. Programmingable Tailstock (Moving by connection with Z-AXIS) Offset

Setting and Operation (OP)

1. Tailstock offset by manual operation：

Light On

PIN retract

The setting by manual procedure

Switch to manual mode and move

Z-axis to connection position that pin and hole as aim as possible

Set K30.1 to be 1.

Push TSMOD button

Push TSPIN button

Pin stretch sensor

Xxx=* ?

YES

Push TSPIN button

A by JOG、RAPID or

HANDWHEEL

Pin will be activated in any position

Light On

Pin can stretch or retract

Light On

Pin stretch

NO

*For GS-200 series and FANUC 18i controller, Xxx=X8.6(=1)

For GA-2000 series and FANUC 0i controller, Xxx=X0.6(=1)

For GS-200 series and FANUC 0i controller, Xxx=X0.6(=1)

For GS-400 series and FANUC 18i controller, Xxx=X8.5(=0)

Slight move Z-axis by handwheel to help pin and hole connected

Check or adjust Pin stretch sensor

Xxx until signal be confirmed push RESET Key will clear message when signal be confirmed

9-12

A

Set K30.1 to be 0.

Light Off

Push TSMOD button

Following procedure is necessary to confirm tailstock setting position

Push the button of Z-axis(+or-direction) or use handwheel to move off from etting point.

Push TSMOD button

Light On

Push the button of

Z-axis(+or-direction) to get into PMC control axis mode

Z-axis will back to tailstock setting position

Push TSPIN button

Light On

Pin stretch

Pin stretch sensor Xxx=* ?

NO

Setting fail, please setting again from first step

YES

Push TSPIN button

Light On

Pin retract

Push TSTMOD button

Light Off

TSMOD OFF

Tailstock position setting complete

9-13

2. Tailstock -O.T.(Minus Over Traverse) setting：

TAILSTACK TRAVEL

LIMIT SETTING

Tailstock -O.T. setting

Change the screen

Choose 'TAIL -O.T.' and set it to be 'ON'

Change to

Manual Mode

Push TSMOD button

Reference 6.

Display alarm message:

GS-200 series, 18i or 0i, without power turret:

2061 Tailstock -O.T. setting ON

GS-200 series, 18i, with power turret:


GA-2000 series, 0i:


GS-400 series:

2024 Tailstock -O.T. set enable

Light On

Push the button for Z-axis(+ or - direction) and back the connecting position

Push TSPIN button

Move the Z-axis to desirous end position

Push TSPIN button

B

Tailstock +O.T. setting

(fixed setting value 2000)

Z-axis back to connecting position

Light On

Pin stretch

Light On

Pin retract

9-14

complete

B

Push TSMOD button

Push TSPIN button 3 seconds

If light Off means the end position(-O.T.) setting

Push TSMOD button

Push TSPIN button

Light Off

Light blink will keep 3 seconds

Light On

Light On Pin stretch to connect

Move +direction by Manual mode, Z-axis move away from this setting point

Change the screen to OPR.

Choose 'TAIL-O.T.' and set it to 'OFF'

-O.T. setting complete

9-15

3. Tailstock manual operation：

Tailstock manual operation procedure

Switch to manual mode

Push TSMOD button

Push the button for

Z-axis(+or-direction)

Push TSPIN button

Move Z-axis to desirous position

Push TSPIN button by JOG、RAPID or HANDWHEEL

Light On

Z-axis move to connecting position

Light On

Pin stretch to connect

1. Use handwheel

2. Use RAPID mode

Light On

Pin retract

Push TSMOD button Light Off

Tailstock moving complete

1.Push TSMOD button，light Off.

2.Push the button for Z-axis(+or-direction) to desirous

position.

3.Push TSMOD button，light On.

9-16

4. Tailstock Operation in AUTO Mode：

1.M60: Call Sub-program O9020.

2. V: Tailstock move to desirous position (Machine coordinate).

EXAMPLE:

O0001;

：

：

.......

.......

M60 V-100; (tailstock move to -100 machine coordinate)

：

：

.......

.......

M30;

9-17

5. Tailstock over traverse release：

The procedures of tailstock over traverse release

Choose

'RAPID' Mode

Push [+Z] or [-Z]

+O.T. Over Traverse, push [-Z].

-O.T. Over Traverse, push [+Z].

O.T. release complete

9-18

6. Tailstock O.T. Setting Function Button (TAIL OT-) Monitor:

Push [OFFSET/SETTING] key

Hit soft-key

Select OPR.

Hit

PAGE

Choose the screen of operation panel

Press up & down key

Press right & left key

Operation Complete

Choose [TAIL

OT-]

Press right key [TAIL OT-] ON

Press left key[TAIL OT-]OFF

9-19

9.8. Sub-spindle operation (OP.)

9.8.1. Note for operating sub-spindle

1) The data sheet of M code please refer to Appendix A

2) While work piece is in the sub-spindle for second process, please use

M203(C.W.) or M204 (C.C.W.) for sub-spindle rotation.

Ex: N2 G0 G97 S1500 T101 M3;

:

:

:

G0 G97 S2000 T816 M203;

M205;

M30;

3) Don't let both spindles camp the work piece simultaneously before main spindle & sub-spindle are synchronized (M43, M44) or stop (M45), or it may damage work piece. (The spindle and sub-spindle may be rotate in opposite direction and make scrapping on workpiece surface during synchronization. ).

Therefore, please synchronize (M43 or M44) first. Then subspindle can camps the work piece

Ex: N1 M11;

N2 M5;

:

N8 M210;...........Sub-spindle keep unclamp

N9 M43 S0; .......Synchronization with 0 RPM

N10 S1000; .........Rotate by desired speed

N11 M211;

4) When a work piece is machined in main spindle and would like to transfer to sub-spindle. Please make sure the following.

(1) Before moving, please do G28 U0 first to the home position.

(2) Make sure sub-spindle is unclamp to avoid collision during workpiece transfer from main spindle to sub-spindle.

(3) Moving B-Axis (sub-spindle) to your setting point and give G01 to the position to take work piece.

9-20

(4) After sub-spindle chuck is clamp (M211), please give G04 U2.; (Dwell 2 sec.) to make sure clamping process is finished for safety.

When a work piece is machined in main spindle and would like to transfer to sub-spindle. Coolant pump must stop working (M09).When it equipped air blow

(M20, M220), please rotate main & sub-spindle very slowly to help air blow clean chuck. However, if it doesn't have air blow, please rotate the main or sub-spindle in a high speed to clean the chuck which can make sure high accuracy machining.

When there has power turret and sub-spindle in same system of controller

(when it is signal system),both cannot work (rotation) at the same time but one.

For instance, sub-spindle is working (M203 or M204), power turret will not activate. When power turret is working (M73 or M74), sub-spindle cannot do

M203 or M204 and indexing.

9-21

9.8.2. Sample program of sub-spindle operation

1. work piece

2. Working process

1)process 1:

Machining 1st (right) side process.(a finished work piece has been gripped at sub-spindle last time)

O2001 (program NO.)

︰

︰

︰

M01;

9-22

2)process 2:

Return to the home position first, sub-spindle moves to the position of unloading part. Then the parts catcher activated. Eject part with part ejector.

Assuming:

B-630. part ejecting position = B-450.

Sub-spindle approaching position =

Sub-spindle clamping position = B-660.

N9000 (PART UNLOAD)

G28 U0 B0 M09;

G0 B-450.

M68;

G04 X1. ;

Move X and B to reference position. part ejecting position = B-450.

Part catcher active.

3)process 3:

Sub-spindle chuck unclamp, and dwell to ensure unclamping completely. Active the part ejector, part falls into the parts catcher and the catcher returns.

9-23

M210;

G04 X2.;

M72

M69;

G04 X2. ;

M01;

4)process 4: sub-spindle chuck unclamp

Dwell time 2 sec. eject the part. part catcher retract.

.

.

Air blow of main spindle enable to clear work piece. Then sub-spindle's enable to clear the chuck.

N9

G28 U0;

(Cutoff)

M20; (Air blow of main spindle on)

B-630. ;

M05;

M21;

M220;

(Sub-spindle moves to the position of

Sub-spindle approaching position

(Air blow stop)

(Air blow of sub-spindle on)

G04 X3. ;

M205;

M221; (Air blow stop)

9-24

5)process 5:

Both spindle in synchronous control and the sub-spindle grips the work piece.

M44 S0; Main spindle and sub-spindle synchronized

G98 G01 B-660. F600; Move sub-spindle to clamping position.

M211 G99;

G04 X2.;

6)process 6:

The work piece is cut off and the sub-spindle home return.

G50 S1500;

G96 S120;

(Setting spindle speed)

G0 X44.; cutting off)

(Tool moves to preparatory position of

G75 X-1. P3000 F0.12; (Cut off)

G0 X44.; (Tool return)

G28 B0 M45; (Sub-spindle home return, and synchronous control off)

M09;

G30 U0 W0;

M01;

(coolant off)

(2nd reference point return)

9-25

7)process 7:

Machining 2nd (left) side of work piece process.

N10

︰

︰

9-26

3. Program

O2345

G40C22.F500;

Process 1

G113;

G0X5.M18;

G28U0M75;

M01;

N9000(UNLOADER); Process 2

G28B0U0M9;

G0B-450.; part ejecting position = B-450.

M68;

G4X1.;

Process 3

M210;

G4X2.;

M72;

M69;

G4X2.;

M01;

N9(CUTOFF)

Process4

G28U0;

T828M210;

G0Z-48.6;

M20

M03S20;

Use offset #21~#32 for sub-spindle

B-630.M21;

Tool offset for axis B is not available.

Sub-spindle approaching position =

9-27

M220;

G04X3.;

M205;

M221;

M44S0;

Process 5

Specify clamping position at this block.

G98G1B-660.F600;

Sub-spindle clamping position = B-660.

M221G99;

G4X2.;

G50S1500;

G96S120;

Process 6

G0X44.;M08;

G75X-1.P3000F0.12

G0X44.

G28U0M45;M09;

G28B0;

G30U0W0;

M1;

N10(FACE);

G28B0;

G50S3000;

G0G96S300T0121M8;

M204;

X44.Z1.5;

Process 7

G1X40.F0.2;

Z0.R1.F0.15;

X-1.F0.1;

G0X150.Z-100.;

9-28

M1;

N11(Center);

G0G97S2000T1030M8;

M204;

X0Z-1.5;

G1Z2.7F0.08;

G0Z-50.;

M1;

G0G97S2000T1232M8;

M204;

X0Z-1.5;

G1Z27.F0.09;

G0Z-5.;

X150.Z-50.M205;

M1;

N13(4-4.5D PCD 32) (center) Process (only for Power

driven turret)

G0G97S1800T1131M8;

M73

X32.Z-1.5;

M219;

G0C0;

M98P2002;

to subprogram for center drilling

C90.;

9-29

M98P2002;

C180.;

M98P2002;

C270.;

M98P2002;

M218;

G0Z-50;

M1;

G0T0929G97S2000M73;

X32.Z-1.5;

M219;

G28C0.

G0C0;

M98P2003;

to subprogram for drilling

C90.;

M98P2003;

C180.;

M98P2003;

C270.;

M98P2003;

M218;

G30U0W0;

M30;

%

9-30

%

O2002(02001 Sub-program)

(Center) (N13)

%

O2003(02001 Sub-program)

(4.5D Drill) (N14)

M237; M237;

G4X0.5; G4X0.5;

G98G1Z2.3F[0.08*1800]; G98G1Z8.F[0.1*2000];

G99G0Z-2.2; G99G0Z-1.4;

M238; M238;

M99 M99;

% %

9-31

9.9. M72 Workpiece ejector out for sub-spindle model (OP.)

9.9.1. Command

The M72 command is used to eject the workpiece, finish in the spindle 2, from the chuck.

M72; .........Specifies the workpiece ejector OUT.

(Note)

(1) The M72 command can be used only for the sub-spindle series machines.

(2) Usually, the M72 command is used in combination with the M68 parts catcher OUT command and M69 parts catcher in command. For the machine equipped with the loader, these M codes (M72, M68 and

M69) are optional.

(Note)

(1) When specifying the M72 command, it is necessary to stop spindle 2 by specifying the M205 command. The workpiece ejector does not start if the spindle is not stopped.

(2) The chuck on spindle 2 is M210 unclamped before the M72 command is specified.

9-32

9.9.2. Programming using M72

O0001;

：

： Machining program

：

： (machining of a workpiece in spindle 2)

M205 ; ........................................Stopping spindle 2

(G28 B0;)....................................Returning the B-axis to zero point

(G30 U0;)....................................Returning the X-axis to the 2nd zero point

G00 B--- workpiece is dropped into the parts catcher

(Note)

The parts catcher operates disregarding of the turret position.

For the coordinate value of the B-axis, specify the position where the parts catcher can receive the workpiece correctly without causing interference between the moved out parts catcher and sub-spindle , turret head, etc.

Note that parts catcher OUT operation is not possible If the B-axis is at a position 40 mm or more in the negative side in the machine coordinate system.

M68 ............................................Parts catcher OUT

M210 ..........................................sub-spindle unclamp

M72 ............................................Workpiece ejector OUT

G04 U_; .....................................Dwell

G28 B0; ......................................Moving sub-spindle to the machine zero point

(G28 U0;) ...................................Returning the X-axis to the machine zero

point

M69 ............................................Parts catcher IN

M220 ...........................................sub-spindle air blow ON (sub-spindle)

G04 U-; .......................................Dwell

M221 .............................................sub-spindle air blow OFF (sub-spindle)

：

9-33

9.10. C axis operation for power turret model (OP.)

9.10.1. Command of c axis

1. Command of c-axis status

Before living tool executes milling or drilling/tapping, change the spindle status to C-axis status.

Command Function

M18

M19

Spindle C-axis function off (select spindle mode)

Spindle select C axis mode

EX.

O0123;

N3 M19;

G28 C0.

T_____ S_____ M_____ ;

G00 X60. Z2. M8;

M01 ;

N6 M18 ;

T_____ S_____ M_____ ;

G00 X60. Z2. M8 ;

M30 ;

2. Command of tool rotating.

(1) command

S_____

(2) limit of speed depend on the turret type

3. Direction of tool rotating.

Direction of tool rotating depend on the live tooling type, so must dry run the live tooling to confirm the rotating direction before the first time in use.

M73 ...... Rotary tool FWD. run

M74 ......Rotary tool RVS. run

9-34

M75 ......Rotary tool STOP

4. M code function for c axis operation

Command Function

M18

Spindle status (C-axis status cancel)

M19

C-axis status

M22

Living tool free (just for servo motor)

M37

Main spindle brake on

M38

Main spindle brake off

M73

Rotary tool FWD. run

M74

Rotary tool RVS. run

M75

Rotary tool stop

5. G code for c axis traverse

(1) G00.....................rapid traverse format :

G00 C_______ (absolute)

G00 H_______ (incremental)

(2) G01.....................feed traverse format ;

G98 G01 C_______ F_______ (absolute mm/min)

G98 G01 H_______ F_______ (incremental mm/min)

9-35

9.10.2. Canned cycle for drilling

The canned cycle for drilling simplifies the program normally by directing the machining operation commanded with a few blocks, using one block including

G-function.

G Code

Drilling

Axis

Hole Machining operation

G80 ---- ---- axis

Cutting feed/ intermittent

G84

G85

G88

Z axis

Z axis axis

X axis

Cutting feed

Cutting feed

Cutting feed/ intermittent

Cutting feed

Operation in the bottom hole position

----

Dwell

Dwell→ spindle CCW

----

Dwell

Dwell→ spindle CCW

Retraction operation

Application

---- Cancel

Rapid Front drilling traverse cycle

Cutting feed

Cutting feed

Rapid traverse

Cutting feed

Front tapping cycle

Front boring cycle

Side drilling cycle

Side tapping cycle

G89 X axis Cutting feed Dwell Cutting feed

Side boring cycle

If depth (Q____) of cut is not specified for each drilling, the normal drilling cycle is used. If depth (Q___) is specified, the peck drilling cycle is used.

9-36

1) Drilling cycle (G83~G85)

2) Side tapping cycle (G87~G89)

9-37

EX1 Drilling on end face

＜Part drawing＞

＜Cutting conditions＞

Process T code Tool mame Spindle speed(rpm) Feedrate (mm/min)

N1 101 NC center drill 2000 150

N2 303 6.8 mm dia. drill 1500 200

600 750

9-38

Sample program for servo motor drive type power turret:

O2234 ;........................................ Program number (for GS-2000 turret –spindle

.................................................... motor drive type power turret)

N1 (NC CENTER DRILL) ; .......... Drilling with center drilling

G98 ;............................................ Specifying the feed per minute mode.

M19 ;. .......................................... Spindle 1 as the C-axis

G28 H0. ;.. ................................... Returning the C-axis to the machine zero point

G00 T0101 ; ................................ Selecting the No. 1 tool

G97 S2000 M74 ; ........................ Starting the rotary tool spindle in the normal

X120. Z20.C0. ;. .......................... Positioning at the hole machining start position ...................................... at a rapid traverse rate

G83 H60. Z-5. R-17. F150 K6 M37; .Executing the face spot drilling cycle (G83)

H60.................. Incremental value

........................ Present position →B→C→D→E→F→A

* Z-5 ................ Z coordinate value of the point Z (hole bottom)

* R-17 .............. Distance and direction from the initial point to the point

........................ R

* F150.............. Feedrate of 150 mm/min

* K6 ................. Number of repetitions : 6 times

*M37................ M code for C–axis clamp (When it is needed.)

G80 ;............................................ Canceling hole machining canned cycle

G00 X200. Z100. M75 ; ............... Stopping the rotary tool spindle

M18 ; ........................................... .Canceling the C-axis connection

G99 ;............................................ Specifying the feed per revolution mode

M01 ; ........................................... Optional stop

N2 (6.8 DRILL) ;.......................... Drilling with 6.8 mm dia. drill

G98 ;............................................ Specifying the feed per minute mode

M19 ; ........................................... Spindle 1 as the C-axis

G28 H0. ; ..................................... Returning the C-axis to the machine zero point

G00 T0303 ; ................................ Selecting the No. 3 tool

G97 S1500 M74 ; ........................ Starting the rotary tool spindle in the normal.

.................................................... direction at 1500 rpm

9-39

X120. Z20.C0. ; ........................... Positioning at the hole machining start position ...................................... at a rapid traverse rate

G83 H60. Z-18. R-17. F200 K6 M37;

.................................................... Executing the face spot drilling cycle (G83)

* H60. .............. Incremental value


* Z-5 ................ Z coordinate value of the point Z (hole bottom)

* R-17 .............. Distance and direction from the

........................ initial point to the point R



*M373.............. M code for C–axis clamp (When it is needed.)

G80 ;............................................ Canceling hole machining canned cycle

G00 X200. Z100. M75 ; ............... Stopping the rotary tool spindle

M18 ;.. ......................................... Canceling the C-axis connection


M01 ;. .......................................... Optional stop

N3 (M8 P1.25 TAP) ;. .................. Tapping with M8×P1.25 tap


M19 ; ........................................... Spindle 1 as the C-axis

G28 H0. ;. .................................... Returning the C-axis to the machine zero point

G00 T0505 ;. ............................... Selecting the No. 5 tool

G97 ;............................................ Specifying the constant spindle speed

.................................................... command

X120. Z20.C0 ; ............................ .Positioning at the hole machining start

.................................................... position at a rapid traverse rate

M29 S300; ................................... Rigid taping on

G84 Z-20. H60. R-15. F150 K6 M37; Executing the face tapping cycle (G84)

H60.................. Incremental value


* Z-20. ............. Z coordinate value of the point Z (hole bottom)

* R-15. ............. Distance and direction from the initial point to the

........................ point R


9-40


*M37................ M code for C–axis clamp (When it is needed.)

G80. ;........................................... Canceling hole machining canned cycle

G0 X200. Z100. M75 ; ................. Stopping the rotary tool spindle

M18 ; ........................................... Canceling the C-axis connection

M30 ; ........................................... .Program end

;

;

9-41

9.10.3. G84 / G184 Format

G84 Front (Z-axis) Tapping Cycle /G88 Front (X-axis) Tapping Cycle

This cycle performs tapping. In this tapping cycle, when the bottom of the hole has been reached, the A-AXIS is rotated in the reverse direction.

Format

G84 Z (W)_R_P_F_K_M_; or G88 X(U)_R_P_F_K_M_;

Z(W)_or X(U) : The distance from point R to the bottom of the hole.

R_ :The distance from the initial level to point R level.

P_ :Dwell time at the bottom of a hole.

F_ :Cutting feedrate

K_ :Number of repeats (When it is needed.)

M_ :M code for C-axis clamp (when it is needed.)

G84 G88

9-42

%

O1436(MAIN)

G99

M11

M19

G4X1.

G28C0.

G0C45.

G0X0.Z10.

M74

M98P1437

M18

G80

G0Z10.

M75

G28U0.W0.

M30

%

Main-program Sub-program

%

O1437(SUB)

M37

G4X2.

M74

M29S800

G84Z-20.R-5.P2000H60.K6F1.25

G80

G0Z10.

M38

M75

M99

%

9-43

9.10.4. G07.1 (G107) Cylindrical Interpolation

In some of applications, it is required to mill a straight or curve groove on O.D of workpiece. However, to unroll a cylinder into a plane is complex and may cause mistakes. The cylindrical interpolation function can convert the travel amount of rotary axis specified by angle into a distance of a linear axis along the circumference of workpiece. The linear interpolation or circular interpolation on outer surface of cylinder can be performed with a linear axis. To use of cylindrical interpolation can make curve or circular grooving on circumference of workpiece easily.

(Note)

The G07.1 (G107) command is for power turret model (model name with

M or Y) only. The G07.1 (G107) command is not available for model

1) Format of cylindrical interpolation function:

G07.1 (107) C_ (or H__ );

·G07.1 (G107) …Switch cylindrical interpolation mode ON.

·C (or H__)………Specify the radius at groove bottom of the workpiece.

Specify C0. means switching cylindrical interpolation mode OFF.

9-44

(Note)

(1) The circular interpolation G02 or G03 is available in cylindrical mode. Before performing circular interpolation in cylindrical interpolation mode, select a correct work plane is necessary. The above work plane is depending on setting of rotary axis (C axis) of parameter P1022:

If the C axis of P1022 is set as 5 (parallel to X-axis) the work plane should be set as G18 Z__ C__

If the C axis of P1022 is set as 6 (parallel to Y-axis) the work plane should be set as G19 Z__ C__

(2) In cylindrical interpolation mode, radius of arc must be specified with R and can not be specified with I, J, K. The unit of radius is length (mm or inch) not degree (DEG. ) for example:

G02 Z_ C_ R5.0; (radius 5 mm)

(3) If specify cylindrical interpolation in automatic tool nose compensation mode, the circular interpolation is not execute correctly!

(4) To specify circular interpolation, automatic tool nose compensation in cylindrical interpolation mode, specifying a correct work plane is necessary.

(5) Positioning operations (G0, G28 and cycles with rapid travel like

G80~G89) is not available under cylindrical interpolation mode.

(6) It is not correct to perform cylindrical interpolation under automatic tool nose compensation mode. To perform automatic tool nose compensation in cylindrical interpolation, cancel automatic tool nose compensation first then specify automatic tool nose compensation after calling cylindrical interpolation.

(7) In cylindrical interpolation mode, all of work coordinate systems

(G50, G54 - G59), machine coordinate system (G53), and local coordinate system (G52) are not available.

9-45

2) Cylindrical interpolation Programming G07.1 (G107)

(Note)

1. Fig. 2 is a unrolled drawing of Fig. 1.

2. The cylindrical interpolation command position is determined from the

unrolled drawing (Fig. 2) of shape on circumference of workpiece.

3. The Fig.2 is unrolled drawing of the cylinder circumference that is

specifying in the Z-C plane.

4. After performing the cylindrical interpolation mode with the G07.1

(G107)command, specify the command positions according to ‧mark.

9-46

Fig.4

Command values of point

○

Command

Point

Z (mm) C(°)

Assume:

Work piece diameter =130. mm

The groove depth=5. mm

The diameter of groove bottom = 120. mm

The end mill diameter = 10. mm

Fig.5

If the position value of points Ca ~ Cd be determined, the program can be created.

The radius of corners in the tool path is 5.0 mm.

Calculate position Ca ~ Cd in "mm" then convert them into angles (°).

Convert position A (120°) and position B (240°) into “mm” for calculation with 5mm radius of corners in the tool path.

Fig.6

9-47

Length on circumference of the workpiece:

ψ120 × π ＝ 376.991 (mm)

This means 376.991 (mm) corresponds to 360°.

Converting position A (120°)

Æ

376 .

991

×

120

°

360

°

=

125 .

664 (

mm

)

Converting position B (240°)

Æ

376 .

991

×

240

°

360

°

=

251 .

327 (

mm

)

Calculate values of position Ca ~ Cd in "mm" as fowling:

Ca = 125.664 － 5 ＝ 120.664 (mm)

Cb = 125.664 ＋ 5 ＝ 130.664 (mm)

Cc = 251.327 － 5 ＝ 246.327 (mm)

Cd = 251.327 ＋ 5 ＝ 256.327 (mm)

Now, the position Ca ~ Cd are known in mm. But, in cylindrical interpolation, the unit of C-axis have to be angle (degree). So, convert position Ca ~ Cd into angle is necessary. Convert the points Ca ~ Cd into degree (angle) as following.

Ca

Cb

Cc

Cd

Æ

Æ

Æ

Æ

Ca

°

360

°

Cb

°

360

°

Cc

°

360

°

Cd

°

360

°

=

=

=

=

120

130

376

246

376

256

376

.

.

.

.

.

.

.

664

664

991

327

991

327

991

mm

376 .

991

mm mm mm mm mm mm mm

Æ Ca=115.225°

Æ Cb=124.775°

Æ Cc=235.225°

Æ Cd=244.775°

Fig.7

9-48

After determine the value of point Ca ~ Cd, finish the program as fowling:

O1234;

N100;

M19;

G28 H0;

G00 T0101;

G97 S200 M73;

X125.0 Z-10.0 S800;............................................................................1.

G98 G01 X120.0 F80...........................................................................2.

G19 W0 H0;.........................................................................................3.

G07.1 (G107) C60.0;............................................................................4.

G01C115.225;...............................................……………..Point “Ca”...5.

G02 Z-15.0 C120.0 R5.0;...............................................…...................6.

G01 Z-35.0;.....................................................................…...................7.

G03 Z-40.0 C124.775 R5.0;.............................................Point “Cb”......8.

G01 C235.225;.................................................................Point “Cc”......9.

G03 Z-35.0 C240.0 R5.0;.....................................................................10.

G01 Z-15.0;..........................................................................................11.

G02 Z-10.0 C224.775 R5.0;..............................................Point “Cd”...12.

G01 C360.0;.........................................................................................13.

G07.1 (G107) C0.;.................................................................................14.

G98 G1 X125.0 F500 M09;

G99 G00 X250.0 Z120.0 M75;

G18

M18;

M01;

1) Block 1. Positioning to the start point of grooving.

2) Block 2. Start grooving.

3) Block 2. Specify the feedrate 80 mm/min in G98 mode (feed per minute).

4) Block 3. Selecting Z-C plane as the machining plane. To select a correct machining plane is necessary for performing circular command (G02 or G03) between the rotary axis (C-axis) and linear axis (Z-axis) in the cylindrical interpolation mode.

9-49

5) Perform “G19 W0 H0;” if the Z and C-axis movements are not required.

6) Block 4. Specifying the cylindrical interpolation mode. The argument C (or H) follow G7.1 command should specify as radius of workpiece. For example, the workpiece diameter is 120 mm, the radius “C” (or H) is 60.

7) Block 5.～13. Groove milling is performing by synchronizing spindle (workpiece) rotation and Z-axis (tool) movement.

8) Block 14. Cancel the cylindrical interpolation mode by performing “G7.1 C0.”

(G7.1 C0. means cancel the cylindrical interpolation mode)

9-50

9.10.5. G12.1 (G112), G13.1 (G113) Polar Coordinate Interpolation

The Polar Coordinate Interpolation function is using a linear axis (X-axis as radius of the specified position) and a rotary axis (C-axis as angle of the specified position) in synchronize control mode to emulate a virtual work plane like

X-Y. It can make square, arc… on face of workpiece without Y-axis. In polar coordinate interpolation mode, just specify the X and C-axis according to the drawing as two linear axes (Cartesian coordinate). The angle of workpiece will be rotate according to the virtual work plane (that simulated with X and C-axis) automatically by controller.

(Note)

The G12.1 (G112) and G13.1 (G113) command are for power turret model (model name with M or Y) only. The G12.1 (G112) and G13.1

(G113) command is not available for model

1) Format of polar coordinate interpolation function:

G12.1 (G112);……… Enable the polar coordinate interpolation mode.

G13.1 (G113);……… Cancel the polar coordinate interpolation mode.

9-51

(Note)

1. The G12.1 (G112) and G13.1 (G113) must be performed in a block without other commands.

2. The linear axis and rotation axis of polar coordinate interpolation have to be set in parameter P5460 and P5461 (for FANUC i -series controller).

3. If the program is terminated in G12.1 mode, the program can not be restart from terminated block.

4. Before use of polar coordinate interpolation, the center (on linear axis) of axial direction rotary tool must be aim at spindle center. If the center of axial direction rotary tool is not aim at spindle center, the straightness of a straight line will be off.

5. In the polar coordinate interpolation mode, X-axis value have to be specified in diameter and C-axis value should be specified in "mm” or “inch" in radius, not in angle.

6. In polar coordinate interpolation mode, the coordinate system G50, G52,

G53 and G54 ~G59 must not be changed.

7. It is not correct to perform cylindrical interpolation in automatic tool nose compensation mode. To perform automatic tool nose compensation in cylindrical interpolation, cancel automatic tool nose compensation first then specify automatic tool nose compensation after calling cylindrical interpolation.

8. Positioning operations (G0, G28 and cycles with rapid travel like G80~G89) is not available in polar coordinate interpolation mode. Only G01, G02,

G03, G04, G40, G41, G42, G65, G66, G67, G98, G99 can be performed in

G12.1 mode.

9. To perform a circular interpolation in the polar coordinate interpolation mode, the addresses for specifying the radius of arc is determined according to the linear axis following:

If the linear axis is X-axis :

The circular interpolation be performed in the X-Y plane, use addresses I and J to specify the arc radius (default setting).

If the linear axis is Z-axis :

The circular interpolation be performed in the Z-X plane, use addresses K and I to specify the arc radius.

The arc radius can be specified using address R.

9-52

2) Ex. Programming using G12.1 (G112) and G13.1 (G113)

+

%

3

O1235;

N100

N101 G28 U0.

N102 G00 G97 T1010 S600;

4

1, 8

2

*9

X54. C-12. *Start

N103 M73

N104 G40 X54. Z2. M8;

N105 M19;

N106 G28 H0;

5

6

30mm

7

X64. C12. *End

+X

N107 G50 C0;

N108 G112;

N109 G98 G42 G01 X54. C-12.F1500;---*Start

N110 Z-10.;

N111 G02 X30. C0. R12. F75; -----------1

N112 G01 C8.66; --------------------2

N113 X0 C17.32; --------------------3

N114 X-30. C8.66; --------------------4

N115 C-8.66; --------------------5

N116 X0 C-17.32; --------------------6

N117 X30. C-8.66; -----------7

N118 C0; -----------8

N119 G02 X54. C12. R12.; -----------9

N120 G01 G40 X64. C12. F1500;----------*End

N121 G113;

N122 G99 G00 Z2. M9;

N123 X200. Z100. M18;

N124 M01;

N125 M75

M30;

%

9-53

~ N108 : G12.1 (G112) Performing the polar coordinate interpolation mode

~ N109 : Positioning to the point where milling is started tool nose compensation mode G42 turned ON.

~ N110 : Cutting into Z-10.

~ N111 : Start milling according the following tool path:

START

Æ1Æ2Æ3Æ4Æ5Æ6Æ7Æ8Æ*9ÆEND. The spindle rotates synchronized with the feedrate of the cutting tool.

~ N120 : automatic tool nose compensation mode OFF. Move tool to X46.

C12.

~ N121 : G13.1 (G113) Cancel the polar coordinate interpolation mode

~ N123 : Cancel C-axis mode, switch to spindle mode. Retract to X200. Z100.

~ N125 : Stop the rotary tool.

9-54

9.11. Power Turret Operation(OP.)

9.11.1. Rotary Tool holder Direction

When use rotary tool holder to make machining, please make sure the direction is correct to maximum the machining power and avoid damage. The 0 deg. rotary tool holder C.W. is in commend M73.and C.C.W is in commend M74. The

90 deg. rotary tool holder is opposite, C.W. is in commend M74 and C.C.W. is in commend M73. Please see the drawing as below for more information.

0 Deg.

M73

G88 X(U)_R_P_F_K_M_.

C.W.

0 Deg.

M74

G88 X(U)_R_P_F_K_M_

C.C.W.

90 Deg.

M74

G84 Z (W)_R_P_F_K_M_.

C.C.W.

90 Deg.

M73

G84 Z (W)_R_P_F_K_M_

C.W.

9-55

9.11.2. Command of Power Turret

Commend Function

M73

Milling axis FOR.

M74

Milling axis REV.

M75

Milling axis STOP

M22

Living tool free(just for servo motor)

*1

G84

G84 Front (Z-axis) Tapping Cycle*2

G88

G88 side (X-axis) Tapping Cycle*2

Remark:

*1. In some models such as GLS-200M, GLS-150M, GTS-200M and GA-2000M, owing to the different design, the motor will keep power on which is not possible to rotate and release tooling by hand. Operator can gives M22 to power off motor and release tooling (it will shown ALARM in monitor). After change tooling, please press “RESET” to cancel M22. Then the turret can start indexing.

*2. For 0I-TD controller, because the different design, in some models such as -M series model, GTX-150MMX and GTS-150XY should use G84/G88 to do tapping , however, GTS-200XY and -YS series model should use G184/188 to do tapping.

9-56

9.11.3. How to offset Rotary Tool holder

A. Axial Direction (0 Deg) Rotary tool holder Resetting Procedures

1. Please make a light cut on the surface of workpiece and measure the outer diameter.

2. Please hold the main spindle disk brake.

3. Index to the designate tool no.

4. Please select milling axis on spindle selection and press spindle forward or reverse to make it rotates.

5. By use milling tool or drilling tool and touch workpiece lightly.

6. Change the monitor to [OFFSET] and input the value that get from procedure

1 to X and press [measure]. Now X-axis offset is done.

7. Move milling tool or drilling tool to the end of workpiece and touch lightly.

To next page

9-57

8. Press Z and input radius value of tool (ex: 8mm drilling tool=4mm, input

“Z4.”). Press [Measure]. Now Z-axis offset is done.

9-58

B. Radial Direction (90 Deg)Rotary tool holder Offsetting Procedures

1) Please make a light cut on the surface of workpiece and measure the outer diameter.

2) Please hold the main spindle disk brake

3) Index to the designate tool no.

4) Please move tool on the rotary tool holder and align it to the spindle center. ex: X-370 and key in –370 to X-axis offset. Press INPUT. Now the X-axis offset is done.

5) Please select milling axis on spindle selection and press spindle forward or reverse to make it rotates.

6) Please move tool to the right end of workpiece and touch it lightly.

To next page

9-59

7) Press “Z0” and [MEASURE]. Now the Z-axis reset is done.

9-60

9.12. Y-AXIS operation

9.12.1. Polar coordinate interpolation on c-x plane

I. Polar coordinate active and cancel:

Active: G112 (or G12.1) active polar coordinate.

Cancel : G113 (or G13.1) cancel polar coordinate.

Example:

M19 ；

G28 H0

G0 X100. Z2. M74；

.

.

G112 ；

G98 G42 G1 X60. C25. F250 ；

G113 ；

II. Coordinate

X-AXIS: Horizontal，diameter programming.

C-AXIS: Vertical, radius programming.

Position 1 2 3 4 5 6 7 8 9

Coordinate

X20 X-20 X-20 X20 X20 X0 X-20 X0 X0

C10 C10 C-10 C-10 C0 C10 C0 C-10 C0

9-61

SAMPLE 1: USE TOOL T0101(END MILL ,RADIUS: R5.0 T0)

Side length of square L=100mm

Endmill diameter=10mm

Use C-X plane,

X-AXIS programming in diameter/ ;C-AXIS programming in radius

C

P2 P1

P1: X1=100. ; C1=50.

P2: X2=-X1= -100. ; C2=C1=50.

P3: X3=-X1= -100. ; C3=-C1= -50.

P4: X4=X1 =100. ; C4=-C1= -50.

N3 (Polar coordinate interpolation);

◎G0 G40 G97 S1000 T0101;

P3 P4

M19 ; (Turn on c-axis mode)

G28 H0. ;

◎G0 X140. Z10. ; (Approach position:depend on p1 position)

◎M74 (Rotate dirtion, specify m73/m74 depend on 0˚. or 90˚. tool holder)

M37 (Turn on spindle brake to avoid vibration whendrilling or milling)

M8 (Coolant on)

G112 (G12.1) (Polar coordinate on)

◎G98 G42 G1 X100. C50. Z2. F1200 (USE “G01 G98 (mm/Min.)” Feed command only in polar interpolation mode. If use g00 in polar interpolation mode, Alarm

No.146 will be appear)----move to P1

◎G1 Z-1. F120(F=Flute*RPM*mm/REV)

(For example: 4 flutes, 0.03mm/FLUTE: F=1000*4*0.03=120mm/Min.)

M38 (Spindle brake off)

◎X-100. C50 F120.; (P2,)

※X-100. C-50. ;(P3)

※X100. C-50. ;(P4)

※X100. C50.; (P1)

※X99.;(TOOL Radius compensation end position)

※G40;( Cancel tool radius compensation)

9-62

◎G1 Z2. F1000 (Move tool away from workpiece)

G113 (G13.1)(Cancel polar coordinate mode)

M75 (Rotary tool stop)

◎G99 G0 X200. Z100.

M18

M1

M30

NOTE:

◎Means decide milling tool speed, feedrate and tool number by user.

※Means decide position according to shape of workpiece.

PLEASE NOTE:

1.USE M18 to cancel M19 mode

2.USE M38 to cancel M37

3.USE G113(G13.1) to cancel G112 (G12.1)

4.USE G99 to cancel G98 mode

※If feeding mode is not return to G99 after milling cycle, alarm

NO.011 will be appear when turning cycle is performed.※

9-63

SAMPLE 2:

N5

G00 G97 T1010 S600;

G40 X54. Z2. M8;

M19;

/G28 H0;

G50 C0;

M74 ;

G112 (G12.1);

G98 G42 G01 X54. C-12.F1500;----*Start

Z-8.;------------------------------------------cutting depth

G02 X30. C0 R12. F75 ;-----------------1

G01 C8.66 ;---------------------------------2

X0 C17.32 ;----------------------------------3

X-30. C8.66 ;--------------------------------4

C-8.66 ;---------------------------------------5

X0 C-17.32 ;---------------------------------6

X30. C-8.66 ;--------------------------------7

C0;---------------------------------------------8

G02 X54. C12. R12.;----------------------9

G01 G40 X64. C12. F1500 ;------------*End

G113 (G13.1);

G00 Z2.;

X200. Z100.;

M01;

.

M30;

9-64

9.12.2. Cylindrical interpolation

For Y model, select plane before using cylindrical interpolation. Beside G18 and

G19 mentioned in 9.10.4, G17 can use to set X-Y plane。

G17 = X-Y plane

G18 = X-Z plane

G19 = Y-Z plane

Convert angle from rad. To deg. Before use cylindrical interpolation.

S r

θ

=

S

θ

=

S

(

rad

)

r

θ

×

180

π

=

ANGLE

(

DEG

.)

θ r

9-65

POSITION Z(mm) C（º）

1 -10 0

2 -10 C1

3 -14 100

4 -36 100

5 -40 C2

6 -40 C3

7 -36 200

8 -14 200

9 -10 C4

10 -10 360

工件圓周長: ø100 *π=314.1593mm (360°

=314.1593mm)

A(100° ):314.1593*100/360=87.266mm

B(200° ):314.1593*200/360=174.533mm

Position Calculation Length Calculation Angle

C1 87.266 - 4 83.266 mm C1:360° :314.1593=C1:83.266 95.416°

C2 87.266 + 4 91.266 mm C2:360° :314.1593=C2:91.266 104.583°

C3 174.533 - 4 170.533 mm C3:360° :314.1593=C3:170.533 195.416°

C4 174.533 + 4 178.533 mm C4:360° :314.1593=C4:178.533 204.584°

9-66

.

O2346;

M01;

N6 (Cylindrical interpolation)；

M19;

G28 H0.;

G00 T0101;

G97 S1000 M73;

X115. Z-10. S500;

G98 G01 X100. F50;

G19 W0 H0;

G107(G07.1) C50.;

C95.416;

G02 Z-14. C100. R4.;

G01 Z-36.;

G03 Z-40. C104.583 R4.;

G01.C195.416;

G03 Z-36. C200. R4.;

G01 Z-14;

G02 Z-10. C204.584 R4.;

G01 C360.;

G107(G07.1) C0;

X115.;

G00 G99 X200. Z100. M75;

G18 M18;

M01;

. .

M30;

9-67

Functio n

C-AXIS

Instruction Description

ABSOLUTE: C

INCREMENTAL: H

CW : ＋

CCW: －

G40, 5) 1 G40 : Cancel tool nose

G41,

G42 compensation

6) 2 G41 Left side

Tool compensation nose 7) 3 G42 Right side compe compensation nsation 8)

9) 1 Please be careful of start position and end position of tool nose compensation

10) 2 Please be careful of tool nose radius (or tool radius)

9-68

Function Instruction

G17,G18,G

19

Plane selection

G17 X-Y plane

G18 X-Z plane

G19 Y-Z plane

Description

Use tool nose compensation as necessary

Milling

1 G01,G02,G03

2 Programming in G98 mode

Keyway milling

1 Rough milling

2 Fine milling both side

WIDTH OF SLOT、symmetry

Driven tool drilling

G83 Face drilling

G87 Side drilling

G80 Cancel drilling cycle

1. Use M37 (spindle brake) if necessary.

2Maximum drilling size: Ø12

3Sample:

:0102 ( lochabstand 20.MM bohren)

N1G40G98T0909

G97S2500M73

G0X52.Z-35.Y10.M8

G87X-5.R-5.Q7000F120

Z-55.Y10.Q4000

Z-55.Y-10.Q4000

Z-35.Y-10.Q4000

G28U0V0M9

G30W0M75

M30

%_

9-69


Driven tool tapping

G84 Face tapping

G88 Side tapping

Refer to 9.10.3 for program of

G84/G88

Description

1 M29 Command is unnecessary

2 Maximum size: M8*P1.25

3 Specify pitch by mm/REV.

Sample:

N9 (M6*P1.0 tapping)(X AXIS)

G0G40G99G97S300T808

M19

C180.

X106. Z28.5M37

Y28.5 M16

G88X75.R8000F1.0

Z-28.5

G88X75.R8000F1.0

G0X172. M75

M38

M18

G30U0W0

M30

9-70


Outter(inner

) circle interpolatio n

1 Full circle interpolation

2 Helical interpolation steps:

Inner(outer)side of circle—another arc.—start cutting position—circle interpolation—arc—exit.

Tool radius< r arc. radius< r machining radius

SAMPLE:

N7(20D endmill)(finishing)

G0G40G98G97S600T606

X170.Z55.Y0

M19

G50C0

M37

G19

Z0 M73

G1X118.F1000

G1G41Z38.F100

G3K-38.

G40G1Z0.

G0X170.

Z55.M75

G0Y0

G18

G30U0W0

M30

Description

O0001;

N1;

G98;

M45;

(G28 U0 W0;)

G28 H0;

(M321;)

G00 T0101;

G97 S500 M13;

G00 X10.0 Y10.0;

G01 Z-_ F100;

G17 X17.072 Y13.536;

G42 Y23.536;

G02 X31.214 Y20.607 R10.0;

I-21.214 J-10.607;

X37.072 Y13.536 R10.0;

G40 G01 X17.072;

G00 X10.0 Y10.0;

Z20.0;

(G28 U0 W0;)

M05;

(M320;)

M01;

9-71

EXAMPLE:

Drilling Tapping

N4 (DRILL 2.5)

G0 G98 G97 S2500 T303 M8

M19

G28 H0

C0

M74

X30. Z10.

G83 Z-22. R-8. Q5000 F100 M37

C90.

X45. C135.

X30. C270.

G80

M38

G99 G0 X200. Z100.

M75

/M18

M9

M1

N5 (TAP M3*0.7)

G0 G99 G97 S1000 T303 M8

M19

G28 H0

C0

X30. Z2.

M29 S500；

G84 Z-16. P1000 F0.

C90.

M29 S500；

G84 Z-16. P1000 F0.

X45. C135.

M29 S500；

G84 Z-16. P1000 F0.

X30. C270.

M29 S500；

G84 Z-16. P1000 F0.

G99 G0 X200. Z100.

G99 G0 Z100.

M75

M18

M9

M1

9-72

Milling a square

N8 (End mill)

G0 G40 G98 G97 S1400 T707 M8

X70. Z2.

M19

G28 H0.

G0 Z-4.

M74

G112

G1 G42 X12.C0. F1000

X8. C4. F1000

X-8. F150

C-4.

X8.

C4.

X15. C20. F1500

G40

G113

G0 G40 X80. M75

Z30. M18

M1

9-73

2.

Main-program

O2345

.

.

.

N3(ø13 END MILLING)

G98M19

G30 U0 W0 H0

G00 T303

C0

M37

G97 S600 M73

X50. Z20. M8

Y11.

M98 P2233

M38

C180.

M37

M98 P2233

G00 G99 X50.Z20. M38

G28V0

X200.Z100.M75

M01

.

M38

M18

M1

.

.

.

M30

N5(ø8.0 DRILL)

G98 M19

G00 T505

C0

M37

G97 S1200 M73

X50. Z20. M8

G01 X40.Z-20.F600

G87 X-38. Y8. R-7. Q4000 F144

W-20. Q4000

Y-8. Q4000

W20.Q4000

G99 G00 X50. Z20. M9

G28V0

X200. Z100. M75

9-74

Sub-program

O2233 (Sub program --- O2345)

G01 X34. Z10. F500

Z-53.5 F75

Y0

Z10.

Y-11.

Z-53.5

Y20.

G0 X35. Z10.

Y9.

G1 X30. F500

Z-53.5 F75

Y-3.

Z10.

Y-15.

Z-53.5

Y20.

G00 X50. Z20.

Y11.

M99

9-75

10. Setting and Adjustment

10.1. Hydraulic pressure setting and adjustment

The hydraulic chuck, turret are driven by the hydraulic unit. The hydraulic tank located the right side of the machine. Before operate the machine, please refer to the circuit diagram of hydraulic system ( Fig. 10.1.1 ) and be sure the following:

1 The main hydraulic pressure can be adjusted at hydraulic pump unit, the hydraulic pressure has been fixed at 35 kg/cm

2

for normal operation.

2 The clamp force of Turret is supplied by main hydraulic pressure directly which can't be adjusted.

3 The hydraulic pressure of quill which can be adjusted by hydraulic valve of quill, the hydraulic pressure can be adjusted from 4 ～10 kg/cm

2

depends on the parts requirement. Please refer to ch.7.3.2.

4 The clamp force of chuck which relate with the hydraulic pressure of chuck cylinder, the hydraulic pressure of chuck which can be adjusted by pressure reducing valve of chuck, the hydraulic pressure can be adjusted from 8~25 kg/cm

2 depends on the parts requirement. Please refer to Chapter 7.2.2.

Warring: Don't cut the workpiece from spindle side to quill side while use two centers to clamp the workpiece between the spindle and quill, it may caused the center quill backward and drop out the workpiece.

5 Fill up the hydraulic oil into tank when the level indicator of hydraulic oil below the low level mark . Please refer to the Chapter 3.5 to fill the oil.

Warring: It can be caused the damage of workpiece and the dangerous which drop out the workpiece if the workpiece not clamp properly while spindle is running, Be sure the door is closed while spindle running.

10-1

Fig. 10.1.1 Circuit diagram of hydraulic system

10-2

NO. Name

1 Oil level lndicator LS-3"

600X400X270

3 Oil Cover (with Filter)

5 Motor

6 Filter (W Type)

AB1165

FPC-30

2HP

W08

10 Directional Control Valves

CV-04

HPP-VC2V-F14A3

HF3H-W-Y1-025

HD3-2S-BCA-025A-WYD2

100 kg/cm2

PT-03


14 Pressure Reducing Valves

HD3-2W-BGA-025A-WYD2

HG3H-P-D3-025


HD3-2WD-BGA-025A-WYD2

16 Check Valves HK3H-P-40K-025

17 Pressure Switch JCD-02S

1

1

1

1

1

3

1

1

1

0

4

1

1

1

1

1

1

10-3

10.2. Supplying Oil to the Lubricating Oil Tank

If oil level in the lubricating oil tank is lowered, an alarm indicating is given. If low lubricating oil level alarm is given, supply the lubricating oil.

1) Check the lubricating oil tank volume with the oil level gage installed on the lubricating oil tank.

2) Remove the cap on the oil supply port.

3) Supply the specified lubricating oil by using the oil jug while checking the oil level with the oil level gage.

10-4

10.3. Belts of Spindle Adjustment

It will caused the low efficiency of transmission, increase the heat of friction, reduce the life of belts, increase the load of spindle bearings and effect the accuracy when the belts are too tight between the spindle and drive motor.

The belts will slip during the heavy cutting if the belts are too loose between the spindle and drive motor. The correct tension is required. Replace the new belts or tighten the belts which under long period of operation.

There is an adjustment device on the spindle motor base which can adjust the tension of the belts between the spindle and drive motor.

Please follow the below instruction to adjust:

1) Turn off the power and lock the power switch in off position.

2) Remove the cover of spindle motor.

3) Release the Hex. Socket Head Cap screws of spindle motor base a little.

( Don't take out the screws )

4) Release the Adjusting Nut and adjusted the Adjusting Screws in the Adjusting

Bracket to make the belts in correct tension.

(GS-200 Series V Belt: F=4Kg E=12mm refer to Fig. 10.3.1).

5) Tighten the Hex. Socket Head Cap screws of spindle motor base.

6) Fix the Adjusting Nut of Adjusting Bracket.

7) Check the parallel of pulleys between spindle and drive motor.

8) Put on the cover of spindle motor.

9) Be sure there is nothing will caused the dangerous around the machine before turn on the power and rotate the spindle.

Warring: During the replacement and adjustment, be sure the power switch is turned off and should avoid the other people to turn on the power.

Warring: Be sure the cover has been mounted before turn on the power, after completed the adjustment.

10-5

Fig. 10.3.1

10-6

10.4. Timing Belt Adjustment

6 Turn off the power and lock the power switch in off position.

7 Remove the cover.

8 Release the Hex. socket head cap screws of Adjusting bracket a little. ( Don't take out the screws )

9 Adjusted the adjusting screw to make the timing belts in correct tension. ( GS-200

Series Timming Belt: P=1Kg E=4mm refer to Fig. 10.4.1)

10 Put on the cover.

11 Be sure there is nothing will caused the dangerous around the machine before turn on the power and rotate the spindle.

12 Tighten the 4pcs Hex. socket head cap screws of Adjusting bracket.

Fig. 10.4.1

10-7

10.5. Main Spindle Center Adjustment

When colliding shock between turret head and rotating work piece or chuck is particularly great, adjustment of spindle headstock may be necessary as following procedures.

1) Loosed down the chucks and clean the spindle nose.

2) Attach the inspecting fixture and spindle test bar and line it up with spindle.

3) Attach the test indicator with base. Move the slides and putting test indicator into contact with side of spindle test bar as shown in the fig 10.5.1.

4) Move the slide along Z-axis for about 300mm (12") and check the difference of indicator readings. Set the indicator zero at the end of test bar and if the reading at other end closer to the spindle is positive or more than 0.01mm

(0.0004inch) negative, then it requires adjustment.

5) Loosing the fixing bolts of the headstock and adjust the alignment by adjust screws.

6) Check the alignment again as step 4) and adjust it until the reading becomes not positive and within 0.01mm (0.0004inch) negative.

7) Tighten the fixing bolts of the headstock firmly and loosen adjust screw.

Fig. 10.5.1

10-8

10.6. Turret Adjustment

When Turret head collides with the chuck, work piece or tailstock, adjustment of alignments of turret may be necessary.

In usual collision, the index unit slip around the fulcrum pin as a center.

Alignment of turret is adjusted as following procedures.

(1) Remove Cover.

(2) Fix the adjusting block on the base of turret.

NOTE: For adjustment of index unit, remove one of tailstock adjusting block and put it back to tailstock until after adjustment. Refer to Ch.9.8.

(3) Attach a dial gauge base to the spindles nose and mount a test indicator.

(4) Move the turret head by jog feed and handle feed and put the test indicator into contact with the face of turret head.

(5) Move the turret head along Z-axis for full disk surface and check the difference of indicator readings. If the difference is more than 0.01mm, it requires adjustment.

(6) Loosen Nuts which fixed the turret base a little. ( Don't take out the Nuts )

(7) Adjusted the adjusting screws of adjusting block until the difference of indicator reading become within 0.01mm (0.0004Inch) for full disk surface.

(8) Tighten the nuts which fix the turret base.

(9) Put on the Cover and remove the adjusting block.

Fig. 10.6.1 Turret Adjustment

10-9

10.7. Tapered gibs adjustment

1) To take up wear of slide guide ways, which will be inevitable after the machine has been used for a long time, one each Tapered gib for X, Z axis.

2) Whenever necessary, adjust these Tapered gibs in the following manner.

3) Loosen the adjusting screw (A) of Tapered gib by three or four turns.

4) Tighten the adjusting screw (B) of Tapered gib until the tapered gib is fully working.

5) Loosen the adjusting screw (B) of Tapered gib by about one turn.

6) Tighten the adjusting screw (A) of Tapered gib.

[ CAUTION ]

1) Only qualified person allowed to maintain.

2) If the tapered gib is tightened too strongly, it will cause lost lub-oil film and as a result in quick wear of ways.

Note:

Interval of gib adjustment

Requirement of gib adjustment will depend on how the machine is run.

As a general thumb rule, please check, and if necessary, adjust gibs:

1) at the time of machine installation.

2) three months after installation.

3) six months after installation, and after that,

4) once every 12 months.

*Tapered gib adjusting screws (A, B) are located at the both sides of the saddle.

10-10

10.8. Tailstock Adjustment

1) Insert a standard test bar into taper hole of tailstock

2) Release the fix screws of tailstock.

3) Measure the value of test bar by indicator.

4) There is a fix block and gib in under the tailstock. Normally, the parallelism controlled by the fix block and will not be off. If the parallelism of tailstock is off, it needs to scrap the gib of tailstock to adjust the parallelism of tailstock.

5) There are two adjust screw in front side and rear side of tailstock. The front on is for pulling the tailstock move down. The rear one is for pulling the tailstock move up.

6) Place a set of center and test bar between spindle and tailstock. Measure the horizontal direction difference between center of spindle and tailstock with the test bar.

7) Adjust the adjusting screw to correspond the accuracy (see the accuracy report), tighten the fix screws of tailstock.

Fig. 10.8.1

10-11

10.9. Backlash Adjustment

When the slide of the NC machine moves, it is necessary to adjust backlash in order to compensate the mechanical lost motion (backlash) of a required drive mechanism.

Although this backlash adjustment is normally not require, backlash check and setting may be necessary when carrying out maintenance or adjustment on a slide drive unit.

10.9.1. Backlash Measurement

Measure a backlash amount in the following procedure and Fig. 10.9.1

1) Move the turret slide to a position where has been usually more frequency used.

2) Put a dial gauge into contact with the turret head from the stationary section of this machine in order to measure X-axis and Z-axis shifts. (For the dial gauge to be used, its measuring unit is preferably of 0.001m)

3) Select the MODE switch to HANDLE-X1 and shift the axis select toggle switch to X or Z to make X-axis and Z-axis measurements and settings.

4) After shifting the X axis and Z axis by about 0.5mm (0.02inch) continuously in the minus direction by handle feed, set a dial gauge indicator to 0.

5) Next, shift the handle one graduation by one graduation (one pulse by one pulse) in the plus direction. If backlash has been properly set, the indicator of the dial gauge will shifts by the minimum travel amount (X axis: 0.0005mm

0.00005", Z axis: 0.001mm 0.0001") of each axis when the handle is turned by one graduation in the plus direction.

If the indicator of the dial gauge does not shift when the handle is turned by one graduation until the indicator of the dial gauge has shifted by the minimum travel amount. Take note graduations required to set a backlash compensation value by adding this graduation number to an NC unit parameter for backlash adjustment. (Unit of parameter setting is always

0.001mm)

When turning the handle in the plus direction by initial one graduation, if the indicator of the dial gauge shifted more than the minimum travel amount, it indicates that the backlash compensation value is too large.

10-12

in this case, make a backlash compensation value setting by subtracting a surplus from a value currently set for the NC unit backlash adjustment parameter

Fig. 10.9.1

10-13

10.9.2. Input of backlash compensation value

Measure value of backlash can be compensated through set to parameter as fowling steps.

A.NC controller for 0i-T or 18i-T

X-axis: PRM 1851

Z-axis: PRM 1851

Set the parameter in the following procedure.

1) Select the mode switch to MDI mode

2) Set the parameter data PWE=0 (For 0iT or 18i ) to "1" to enable the parameter setting.

3) Select the backlash compensation parameter using the page and cursor keys.

4) Input the backlash compensation value to the parameter and press INPUT.

5) After completion of the parameter setting, make sure to set the parameter data

PWE=1 (For 0iT or 18i ) to "0"

10-14

10.10. Reference Position Adjustment

When adjusting the parallelism of headstock, dimensions from the spindle end face, the distance between spindle center and the reference position may change. It can cause the drill bit damaged during Z-axis direction drilling with spindle rotation. In this case, making an adjustment as follows to correct the reference position is necessary.

A. Setting X-axis (and Y-axis) reference position:

1) Install an ID (internal) tool holder onto turret

2) Place a dial meter on chuck to locate turret center.

3) Adjust X direction (horizontal) first, let the difference of indicator reading between face to +X and face to –X direction less than 0.01mm; now I.D holder is line up to spindle center.

4) Repeat Step 3 until difference of indicator’s reading keep less than 0.01mm.

5) After finding the turret center (Both tool holder and spindle centers are in-line), press “U” and [Origin]. Now the screen will show U=0.

6) Move X-axis to position U=200mm for GS-200/L/M/ML. (U=160mm for

GS-200Y/LY)

7) Set parameter 1815.4(APZ) X to 0 (alarm display on screen now), set

Parameter 1815.4(APZ) X to 1 (Now X-axis machine position will turn to 0)

8) Restart machine.

9) X-axis home position setting completed.

10) Repeat step 3)~5), and select Y direction. Set V=0.

11) Set parameter 1815.4(APZ) Y to 0 (alarm display on screen now), set

Parameter 1815.4(APZ) Y to 1 (Now Y-axis machine position will turn to 0)

12) Restart machine.

13) Y-axis home position setting completed.

10-15

B. Setting Z-axis reference position

1. Move the Z-axis to make the red mark of Z-axis way cover matching to red

mark of tailstock waycover.

2.Set parameter 1815.4(APZ) Z = 0 (alarm display on screen now) ,

3.Set parameter 1815.4(APZ) Z = 1 (Now Z-axis machine position will turn to

0)

4. Restart machine.

5. Z-axis home position setting completed.

Move Z-axis to match the arrow (Zero position)

10-16

10.11. Machine Level Check

The level of the bed has effects on the machining accuracy of the machine. If the leveling of machine is not correct, it may cause the accuracy and stability off. Therefore, pay full attention to maintain the level of the bed.

For first 6 months after installation of the machine, check the level at least once a month. Adjust the level if necessary to keep, the machine in good operating condition.

After 6 months, extend a check period gradually depending on its condition. If a level change does not occur frequently, check it once or twice a year periodically.

As shown in the Fig. 5.1.1, put a precision leveling gauge on the Z-axis slide.

Then, check the level of the machine in the parallel direction and right angle direction against the spindle.

For measurement, use a precision leveling gauge with accuracy of 2/100mm

(8/10000") per 1m (39.73") and set the level of the bed within accuracy of

4/100 mm (16/10000") per 1m (39.73").

If the level of the machine bed is not within accuracy of 4/100 mm (16/10000") per 1m (39.73" ). Then it requires adjustment. Please refer to Ch.5.1 Machine level adjusting.

10-17

11. Maintenance

11.1. General notes

1) Place of installation which should avoid the sunshine and heating to ensure the accuracy.

2) Place of installation which should be selected at dry and ventilation.

3) Place of installation which should away from the crane equipment, electrical welding machine and electrical arc area.

4) Place of installation which should away from the water vapor.

5) Don't use the irregular lubrication oil.

6) Don't hit the workpiece or machine during loading.

7) Be sure turn off the power and clean the machine after finish the job.

8) Turn on the "MACHINE LOCK" switch before adjustment and maintenance.

Take away the key to prevent people from operating machine.

11-1

11.2. Maintenance cycle

11.2.1. Daily maintenance

1) Clean the machine and oil the slide way after daily used.

2) Check the oil level and fill up according to the oil table ( see 3.5 ) before start the operation.

3) Lubrication pump provide lubrication oil Max. 130cc/min.

4) Use manual to pump the lubrication oil before start the operation while the machine power off in a long period.

11.2.2. Weekly maintenance

1) Clean and wash the filter of electrical cabinet each week, shorten the clean period if the surrounding full of dust.

11.2.3. Half-yearly maintenance

1) Check all cables connectors inside of cabinet if loose.

2) Be sure the battery of NC control in function which to keep all memory, replace the new battery when alarm shows the low battery.

Note: Replace the battery which must in NC ready status otherwise will lose all data in memory.

11.2.4. Yearly maintenance

1) It should be adjust the machine leveling after 3 months of new installation then each year the leveling should be readjusted.

2) Replace the new coolant while the coolant change into white color.

3) Change the hydraulic oil if the hydraulic oil became inferior.

4) Clean the filter of coolant pump.

5) Be sure all oil seal still in good condition otherwise replace the new one.

6) Open the hydraulic unit to release the air in hydraulic circuit which can be avoid the noise and vibration.

11-2

11.3. Lubrication system

In order to maintain the service life and performance of the machine and to make the most of its performance, pay special attention to oil supply and carry out daily maintenance work.

For oil supply to each section of the machine, be sure to use specified oils or equivalent ones. (Refer to Ch.3.5)

As a part of daily maintenance, the condition of lubrication on slides and ball screws shall be checked every day. If there is any sign of lubrication problem, first check the lubrication pump, piping and flow proper unit. The flow proper units are located on the lubrication oil distribution panel right above the X-axis feed motor on back of the machine. If any one of them is faulty, replace it immediately.

If lubrication is used with much dust and dirt, it can make lubrication problem.

Clean lubrication tank may be necessary. As follow process:

< Cleaning interval>

Every 1000 hours of operation for the lubricating oil tank.

Every 500 hours of operation for the suction filter and the oil supply port.

<Procedure>


2) Remove the lubricating oil tank. (Be careful to avoid spilling the lubricant oil when removing the tank.)

3) Clean and remove chipping of the lubricating oil tank inside with the detergent.

4) Remove the suction filter from the suction pipe.

5) Clean the suction filter with kerosene.

11-3

6) Clean the suction filer with compressed air.

7) Mount the suction filter to the suction pipe.

8) Remove the filter of the oil supply port.

9) Clean the filter of the oil supply port.

10) Mount the filter of the oil supply port.

11) Mount the lubricating oil tank.

12) Fill the lubricating oil in the tank according to the oil level gage.

11-4

11.4. Hydraulic system

After installing this machine, when performing a trail run with the hydraulic oil supplied, or when replacing the hydraulic oil, fill up the hydraulic pump with the hydraulic oil through the oil inlet port of the hydraulic pump located on the hydraulic unit in the rear of this machine and start the hydraulic pump. An oil supply amount is approximately 300cc.

If air is mixed inside the pump and piping, it will cause vibrations. therefore side of the pump and perform inching operation to remove the air.

For the hydraulic oil, user a specified one and never let dust, etc. mix with it.

1. CPC circulation oil R32 is used for this machine. The different oil can't be mixed.

Unless change the oil completely. Refer to Ch.3.5

2. Examine the oil gauge everyday.

3. Clean filter every three months.

4. Change new oil and clean impurities every year.

5. The filter density of oil filter is 10u,and the paper can't clean. It needs to change new one after machine is used 100 hours. And then change new one every 500 hours to keep oil clean.

Fig. 11.4.1

11-5

11.5. Chuck

11.5.1. Lubrication

The most frequent cause of chuck failure is insufficient or improper lubrication. If lubrication is insufficient or if a nonspecified lubricant is used, not only will wear be accelerated, the gripping force will be inadequate, with the possibility of the workpiece coming off during the cutting operation.

Pour into grease one time everyday, about 2-3c.c. for each jaw. The usable oil could be Mobiltemp 78 and shell alvania EP grease2

Fig. 11.5.1

11.5.2. Disassembly and cleaning

Even with proper lubrication, fine chips or scale can enter the chuck to jam the area of the jaw guide or wedge plunger, thus preventing smooth operation.

Disassembly and cleaning must be done on a regular basis every 1000 hours.

When doing so, inspect carefully for parts wear and breakage, replacing as necessary.

Dismantling and reassembly of chuck please refer to the menu of chuck maker.

11-6

11.6. Milling axle（For power-driven turret）

The milling axis will lose some grease during high speed running，regular grease supplement can extend machine life and also increase stability of machine。

Please prepare M6 and M5 Alan Key for lose cover before you fill in grease and the procedure is as below：

1. Lose 6 pcs M6 screws of cover.

2. Take off cover.

Attention：

After take off cover, please keep O-ring with it all the time to avoid any damage or lost.

3. Lose 6 pcs M6 fix screws.

4. Take off plate and seal. Now you will

see driven gear。

Next page

11-7

5. Apply some grease all over the driven gear.

6. Put the plate and seal back. Then tight 6 pcs M6 fix screws.

7. Put the cover back and tight 6 pcs M6 screws.

8. Completed

Attention：

Please check the O-ring and replace if any damage.

11-8

11.7. Oil maintenance chart

Note:

1. The oil requirement please refer to Ch. 3.5

2. Inspection and renewal cycle are based on a 8 hour day. These cycles should be adjust in according to actual operation hours.

3. Do not mix the oil with different grades and makes.

D: Day W: Week M: Month

No. Type of Oil Place of oil supply

Method of oil supply

Inspect ion cycle filter cleaning cycle

1 Grease Chuck Manual 1D ---

Renewal cycle

1D

Tank 1W Deterioration axle --- 1M

4 Lubrication Lubrication oil oil

Manual 1M 1M

Gear ----

Lower

When executing maintenance

Manual 1M 3M 6M

Tank

11-9

11.8. Replacement of battery (For FANUC control)

Memory backup battery replacement

When replacing the memory backup batteries, keep the power to the machine

(CNC) turned on, and apply an emergency stop to the machine. Because this work is performed with the power on and the cabinet open, only those personnel who have received approved safety and maintenance training may perform this work.

When replacing the batteries, be careful not to touch the high–voltage circuits

(marked and fitted with an insulating cover).

Touching the uncovered high–voltage circuits presents an extremely dangerous electric shock hazard.

NOTE: The backup battery is mounted on the control unit at shipping. This battery can maintain the contents of memory for about a year. Thus recommends that the battery be replaced periodically, once a year, regardless of whether a battery alarm is issued.

NOTE: The CNC uses batteries to preserve the contents of its memory, because it must retain data such as programs, offsets, and parameters even while external power is not applied.

If the battery voltage drops, a low battery voltage alarm is displayed on the machine operator’s panel or LCD screen.

When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the contents of the CNC’s memory will be lost.

1. To replace the battery please contact your Local Dealer or FANUC

2. Procedure:

13) Preparing FANUC 3V battery.

14) Loosen the two set screws on right side of operation panel to open the operation panel. (Replace the battery must in NC ready status otherwise all data in memory will be lost.)

15) Remove the battery from battery case of NC unit (on back side of LCD display).

16) Install new battery into the battery case.

17) Close the operation panel.

Fig. 11.8.1 Back side of LCD.( 0I-TD )

11-10

Replacing the battery of servo unit:

The absolute pulse coder uses batteries to preserve its absolute position.

If the battery voltage drops, a low battery voltage alarm is displayed on the machine operator’s panel or LCD screen. When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the absolute position data held by the pulse coder will be lost.

1. To replace the battery please contact your Local Dealer or FANUC

2. Procedure:

1) Preparing 4 1.5V batteries.

2) Turn on the NC power. (Replace the battery must in power on status otherwise reference position data of each axes will be lost.)

3) Remove the cover of battery box and disconnect the connector, put the new battery on and reconnect. (Be sure the pole of battery must correct.)

4) Mount the cover.

Note: If the power is off during replacing batteries, the set machinery origin of coordinate and limit would be eliminated, so have to reset it. (Refer to

Ch.11.1.2 )

Note :

When replacing the memory backup batteries, keep the power to the machine

(CNC) turned on, and apply an emergency stop to the machine. Because this work is performed with the power on and the cabinet open, only those personnel who have received approved safety and maintenance training may perform this work.

11-11

When replacing the batteries, be careful not to touch the high–voltage circuits

(marked and fitted with an insulating cover).

Touching the uncovered high–voltage circuits presents an extremely dangerous electric shock hazard.

11-12

11.9. Cleaning of heat-exchanger

For this cooling unit, the only driving part is the fan, thus reducing the need of the maintenance to the minimum; but regularly carry out the following maintenance / inspections.

Cleaning interval

Procedure

Every 50 hours of operation

Air filter 1) Electrical cabinet 1) Turn off the power.

2) Remove the filter cover.

3) Clean the filter using neutral detergent.

4) Dry the filter.

5) Mount the filter cover to the elec trical cabinet

6) Turn on the power.

Every 1000 hours of

Fan 1) Electrical

2) Machine side cover


2) Remove the fan cover. operation 3) Hydraulic pump 3) Apply compressed air to the fan.

Regulate the frequency of cleaning filters and fan surface depending on each case.

Fig. 11.9.1

11-13

11.10. List of Maintenance Check Point

11.10.1. Main spindle

ENFORCEMENT POINT

PLACE ITEM

METHOD OF

INSPECTION &

ADJUSTMENT

Front bearing

Radial clearance

Check with dial gauge

Rear bearing

Abnormal noise at running

Abnormal heat rise

Thrust clearance



Abnormal heat rise

Hearing check

Touch check

Hearing check

Touch check

INSPECTION

CYCLE

CHECK BY

OPERATOR-OS

ERVICE-S

Daily

Daily

1 year

O,S

S

S

STANDARD OF JUDGMENT

METHOD OF

REPAIRING OR

ADJUSTMENT,

WHEN ABNORMAL

BY SERVICER

Compare with noise when the machine was installed

After running at 3000 rpm, temperature should stay within room temperature + 59°F(15°C)

Replacement of bearing

Within 0.00008" (2μm)

1 year

Daily

Daily

S

O,S

S

Within 0.00008" (2μm)

Compare with noise when the machine was installed

After running at 3000 rpm, temperature should stay within room temperature + 59°F(15°C)

Replacement of bearing

Radial clearance


1 year S Within 0.00008" (2μm)

11-14

Runout of Runout of outer spindle diameter nose Runout of face


Wear of chuck

Collet system

(OPTION)

Wear of chuck sleeve

Wear of chuck cap

Visual check and accuracy of workpiece



Chuck opening and closing time


Use stop watch

Hearing check

6 months

1 month

6 months

6 months

1 month

Daily

Chuck cylinder

Abnormal heat rise Touch check Daily

Oil level in drain Visual check 1 month

11-15

S

S

S

S

S

O,S

S

O

Max. 0.0004" (10μm) Overhaul

No one-side wear when disassembled

Replacement


Replacement


Replacement

Within 1.0 sec. under 72 lb/in

2

(5 Disassembling and kgf/cm') chucking pressure cleaning

No abnormal noise

Within 167°FK(75°C)

Disassembling and replacement of parts

Disassembling and r eplacement of parts

Compare with oil level at installation. 0.4 Gal/min.

(1.5l/min)122°F (75°C),

362 lb/in

2

(25 kgf/cm

2

)


Tension of synchro belt

Wear of synchro belt

Visual and touch check

Visual check

Abnormal noise at

Hearing check running

1 year

1 year

S

S

Should be no play

No damage or break

Adjustment

Replacement

Position coder

Abnormal heat rise

Touch check

Daily

1 year

O,S

S

Compare with noise then the machine was installed

After running at 3000 rpm, temperature should stay within the room temperature + 59°F

(15°C)



11.10.2. Main spindle drive unit

ENFORCEMENT POINT METHOD OF

PLACE ITEM

INSPECTION &

ADJUSTMENT

Belts Tension of belts

INSPECTION

CYCLE

6 MONTHS

Wear

Pulley Wear

AC variable

Speed motor

Visual check 6 MONTHS

Visual check 6 months

Rotating sound Hearing check

Function of cooling fan motor

Touch check

Daily

Daily

CHECK BY

OPERATOR-OSE

RVICE-S

S

STANDARD OF

JUDGMENT

METHOD OF REPAIRING

OR ADJUSTMENT, WHEN

ABNORMAL BY SERVICER

Adjustment Not loosened compared with the time of delivery of Belt tensions is given by fare the machine weight of motor

S

S

O,S

S

No damage or break

No abnormal wear

No abnormal noise

Proper ventilation to motor

Replacement of parts


Contact with GOODWAY

Clean up or replacement of fan motor

11-16

11.10.3. Hydraulic unit

ENFORCEMENT POINT

PLACE

Pump

ITEM

Abnormal noise under operation

Variation of pump pressure

METHOD OF

INSPECTION &

ADJUSTMENT

INSPEC

TION

CYCLE

Hearing check Daily

CHECK BY

OPERATOR-O

SERVICE-S

O,S

STANDARD OF JUDGMENT METHOD OF REPAIRING OR

ADJUSTMENT, WHEN


No abnormal noise inspection of strainer and pump

Pressure gauge Weekly O No fluctuation. Confirm pressure setting

Disassemble and check.

Adjust pressure

Solenoid Confirmation of valve operation

Reducing Variation of valve pressure

Piping Oil leak

Neon lamp

Pressure gauge

Visual check

Daily

6 months

Daily

O

S

O

Neon lamp should be lit when its on

Confirmation of pressure setting. Lock nut is not loosen

Is there oil leak from piping and joints?


Replacement of parts.

Cleaning. Readjustment

Tightening

11.10.4. Main turret slide

ENFORCEMENT POINT

PLACE ITEM

Turret

Indexing

Mechanism

Indexing motion

METHOD OF

INSPECTION &

ADJUSTMENT

Visual check

Hearing check

INSPECTI

ON CYCLE

Daily

CHECK BY

OPERATOROS

ERVICES

O,S

STANDARD OF

JUDGMENT

METHOD OF REPAIRING

OR ADJUSTMENT, WHEN


Smooth indexing motion Adjustment

11-17

Slide

clearance

Backlash of driving system

Confirmation of reference point of the machine

Measure with dial gauge



1 year

1 year

1 year

X-axis slide Abnormal noise of

Hearing check

SERVO motor

Loosen connector Touch check

Abnormal noise when

Hearing check slide is moving

Right angle degree between movement of slide and main spindle center line


Repeating accuracy


Daily

Daily

1 year

1 year

11-18

S

S

S

O,S

S

S

S

Within 0.00008" (2μm). Adjustment of gib

Resetting of parameter

Set a plain head on the turret position and move it to the center of main spindle.

Measure the difference between spindle center and turret center


No abnormal noise

Contact with FANUC or

GOODWAY

Tightening

No abnormal noise Contact with GOODWAY

Max. 0.0004"(10μm).

Refer to "Machine accuracy test report.

Max. 0.0004"(10μm).

Refer to "Machine accuracy test report.



X-axis slide Positioning accuracy


Slide clearance

Backlash of driving system


Measure with dial indicator

Z-axis slide

Abnormal noise of

Servo motor

Hearing check

Loosen connector Touch check

Abnormal noise from

Hearing check moving slide

Parallelism between movement of slide and main spindle center

Assume by workpiece accuracy. (A taper is provided.)

Repeating accuracy


1 year

1 year

1 year

Daily

Daily

1 year

1 year

Positioning accuracy


1 year

S

S

11-19

S

S

S

O,S

S

O,S

Max. 0.0004" (10μm).

Refer to "Machine accuracy test report."


Within 0.00008" (2μm). Adjustment of gib

No abnormal noise

No abnormal noise

Reset parameter

Contact with FANUC or

GOODWAY

Tightening



Max. 0.0002" (5μm).


Max. 0.0004" (10μm).





Others

11.10.5. Slide cover

ENFORCEMENT POINT

PLACE ITEM

Bolt

Turret indexing repeating accuracy

Loosen bolt

Check of flow proper unit

Accuracy of workpiece

METHOD OF

ADJUSTMENT

1 year

INSPECT

ION

CYCLE

Touch check 6 months

1 year

CHECK BY

OPERATOR-O

SERVICE-S

S

S


STANDARD OF

JUDGMENT


METHOD OF REPAIRING OR

ADJUSTMENT, WHEN


Tightening

Replacement of parts Wiper Wear of wiper Visual check 6 months S No abnormal wear

11.10.6. Lubricating unit

ENFORCEMENT POINT

Lubricating oil unit

Consumption rate

METHOD OF

PLACE ITEM

ADJUSTMENT

INSPEC

TION

CYCLE

Visual check Weekly

CHECK BY

OPERATOR-O

SERVICE-S

O

STANDARD OF

JUDGMENT

Whether being more or less as compared with the

Condition of oil supply to

Visual check 3 months lubricating points

Oil level Visual check Weekly

O

O

METHOD OF REPAIRING OR

ADJUSTMENT, WHEN


Adjustment of discharge rate time of delivery of machine

Oil supply condition of each Replacement of flow proper unit. lubricating points Replacement of pipings

Oil level should be above the center of oil gauge

Oil supply

Flow proper unit should not Replacement of flow proper unit be clogged

11-20

11.10.7. Coolant unit


INSPECTION &

ADJUSTMENT

INSPEC

TION

CYCLE

Filter Clogged filter Visual check Weekly

Cutting oil Quality of cutting oil Visual check Weekly

CHECK BY

OPERATOR-O

SERVICE-S

O

O

STANDARD OF

JUDGMENT

Not deteriorated as compared with new oil

Others Contamination of inside tank

Confirmation of discharge rate

Visual check

Visual check

3 months

Daily

O

O

No chip to be accumulated

With cock fully open

11.10.8. NC control unit


INSPECTION &

ADJUSTMENT

INSPECT

ION

CYCLE

Battery for Battery alarm Replace it when Every

CHECK BY

OPERATOR-O

SERVICE-S

S

STANDARD OF

JUDGMENT

Battery alarm is lit memory power supply is connected one year

Electrical control unit

Loosen screws of terminals

Check with the power supply disconnected

6 months S Not be loosen

11-21

METHOD OF REPAIRING

OR ADJUSTMENT, WHEN


Cleaning of filter

Replacement

Regular cleaning

Replacement of pump piping.Check filter

METHOD OF REPAIRING

OR ADJUSTMENT, WHEN


Replacement of battery

Tightening

11.10.9. Other


INSPECTION &

ADJUSTMENT

INSPECT

ION

CYCLE

Handtools Deformation Visual check 3 months

CHECK BY

OPERATOR-O

SERVICE-S

S

STANDARD OF

JUDGMENT

METHOD OF REPAIRING

OR ADJUSTMENT, WHEN


No deformation or wear Replacement of parts

Wear

Quantity Visual check 3 months S Whole number must be present


Steel-Wire Wear of parts Visual check

Hose Loosen bolt Touch check

6 months

3 months

O

S

No abnormal wear

No loosening

Replacement

Tightening

11-22

11.10.10. Optional Accessories


INSPECTION &

ADJUSTMENT

INSPECT

ION

CYCLE

Chip Abnormal noise Hearing check Daily

CHECK BY

OPERATOR-O

SERVICE-S

O,S

STANDARD OF

JUDGMENT

No abnormal noise

Conveyor

Parts Motion

Catcher

Visual check Daily O,S Smooth operation

Air Below Volume of discharged air

Air leakage of

Piping

Touch check

Touch check

Daily

3 months

S

O,S

METHOD OF REPAIRING

OR ADJUSTMENT, WHEN


Check by reversed rotation

Cleaning

Is there any difference as Adjustment. Inspection of compared with the time of piping machine delivery?

No air leakage from piping Tightening and fittings Replacement of hose

11-23

12 Trouble shooting

12.1 Various alarms and their remedies

12.1.1 PCDGN (PC diagnosis)

The machine is controlled by control device called PC.

Cause of a trouble can be quickly detected by the self-diagnostic function of PC, which is called as PCDGN (PC diagnosis). PC parameter number is consisted of an address number which includes alphabet and numerics and bit number.

X 0 1 2. 3

Bit number (0 to 7)

Address number (alphabet and numerics)

The alphabet of address number is determined as follows.

X: Signal from push button switch and limit switch to PC

Y: Signal from PC to indicator lamp, relay, etc.

F: Signal from NC to PC

G: Signal from PC to NC

R: Internal relay

D: Data of maintaining type memory (PC parameter, timer, etc.)

Refer to the maintenance section for address of input signal of push button switch and limit switch and output signal of lamp, relay, etc.

Refer to the maintenance section for detail of PC parameter. For other addresses, refer to the ladder diagram in the drawing bag of NC box. this paragraph, leading 0 of address of PCDGN is omitted.

In addition, in actual operation, it can be omitted.

For example, X012.3 represented as X12.3.

12-1

An address and bit number of internal relay can be seen from the ladder diagram of

ELECTRICAL MANUAL. ON or OFF condition can be judged from the screen.

Display method:

1. Turn on the power.

2. Press SYSTEM button to enter PATARMETER screen.

3. Press for 3 times and find the softkey, PMCMNT. to next page

12-2

4. Press PMCMNT.

5. Press STATUS.

6. Key in X12.3 and press SEARCH.

7. The condition of address and bit number will shown on.

12-3

12.1.2 LCD without and display

ITEM TROUBLE CHECKING SOLUTION

1 Without 3 phase Use voltmeter to check the

220V AC source power source

2 Without DC24V input

1.Check if DC 24V power is output from AC 220V

Æ

DC24V power supplier (G4)

Check power line

1.Replace the AC220V to DC24V power supply (G4).

2.Be sure if there is DC24V output from power supply

3.Check if there is DC24V input into LCD module.

2.Reconnection

3 Fuses burn down

4 Display not turned ON after power ON.

Check if the fuse (FU 7) of AC Replace the new fuse

220V to DC 24V power supplier (FU 7) is broken?

1.Check if the relay KA 32 is active.

2.Check if the wires

ON/OFF/COM of power ON push button are connected correctly?

3.Check if the pin X22 on relay

1. Replace the relay KA

32.

2. Reconnect the wire of power ON button.

3. Reconnect the X22 pin of relay board of electric cabinet. board is connected correctly?

12-4

12.1.3 Remedies when alarm is not indicated

(A) Machine alarm when press the indexing button

ITEM TROUBLE

1

Tool no running

CHECKING

11 Dgn. X7.0 / X7.1

SOLUTION

Correct the wiring of

(0I-TD, 31I, Mate-TD) must in 1 when turret

X7.1 and readjust the head in clamp position.

proximity switch X7.0,

12 Dgn. X7.0 / X7.1

X7.1

(0I-TD, 31I, Mate-TD) proximity switch X7.0, must in 1 when turret head in unclamp position.

(B) Tool N0.1 search problem after stop during turret running

ITEM TROUBLE CHECKING

1

Tool No. resetting (if the

1. Press “FEEDHOLD” & “SPINDLE STOP” at tool number is off) the same time in manual mode to unclamp turret disk.

13 Change K7.5 to 1.

14 Press + / - button and JOG button at the same time to set the current tool as tool

No.1.

15 Change K7.5 to 0.

16 Select mode switch in “Zero Return” mode.

17 Press RESET button to clamp the turret disk.

2

Turret return operation

2. Press HYDRAULIC START button.

18 Rotating TOOL NO. SELECT switch to needed No. of tool.

19 Press TOOL NO INDEX button

12-5

12.1.4 Cycle start can not execute

ITEM TROUBLE CHECKING

1

Mood error

SOLUTION

Mode switch must in AUTO. Select mode button to position. AUTO. position or connect the cable.

2

Push button out of order

Be sure Dgn.X100.0 in 1 when press cycle start

Replace the push button or connect the cable. button.

3 Interlock function 1. Turret index no ready

2. Chuck unclamp

3. Tool setter down

4. Parts catcher in chuck position

5. Lubrication alarm

6. Feed hold

7. Door interlock

8. No zero return

9. Spindle alarm

10. machine alarm

1. Index turret

2. Clamp Chuck

3. Retract tool setter

4. Retract parts catcher

5. Fill up lubrication oil

6. Release feed hold

7. Close door

8. Make X/Z Axis Zero return.

9. Check FANUC alarm message.

10. Check PMC program ladder.

12-6

12.1.5 Main spindle hydraulic chuck not work

ITEM TROUBLE CHECKING SOLUTION

1 Foot switch out of order

Be sure Dgn.X12.4

(0i-TD, 31i, Mate-TD) in 1

Reconnect the signal wire or replace the foot switch.

when step the foot switch.

2

Solenoid valve out

1. Be sure there is DC24V 1. Reconnect the wire or of order power on Y1.0 (wire replace relay.

No.6, No.209 ) and

Y1.1 (wire No.6,

No.210).

2. Check if the solenoid valve is clog?

2. Clean the valve or replace coil of solenoid.

3 Broken of draw tube

1. Be sure the function of 1. Replace draw tube chuck cylinder and no function in chuck side.

2. Check if the pressure of 2. Correct the operation hydraulic cylinder is exceeds the limit? pressure of hydraulic cylinder.

12-7

12.1.6 Quill can not execute or (SUB spindle chuck can not execute)


1

Push button out of order

Be sure Tsmod, Tsuclp, Ts- Replace push clp, Push button signal.X4.55 button in 1 after pressure button.

2

Relay out of order There is 24VDC on the replay Replace relay board but relay did not execute.

3

Solenoid valve out of Be sure Relay KA11 and order KA12 is execute, and there is

24VDC on the connector of

Replace the coil.

4

Tailstock interlock

(Manual Mode) solenoid valve which check wire No.6&211. 6&212

Be sure while the spindle is rotating, or Mode not in

Manual mode or X-AXIS no in

ZERO position.

Stop spindle

12-8

12.1.7 Coolant pump can not execute

ITEM TROUBLE

1

Over load trip

CHECKING

1. Check if the capacity

SOLUTION

1. Replace the thermo of thermo relay [KM 3] relay [KM 3]. is exact.

2. Be sure thermal relay 2. Preset over load is in normal position. button.

2

Coolant pump out of order

After preset the over load Replace coolant pump. relay [FR 3] and it trip again after switch on.

3

No coolant out and

1. Check if the coolant is

Fill up coolant to pump no alarm message. enough. and try switch on again or

2. Be sure the coolant change the phase of motor is rotating in power line. correct direction.

12.1.8 Lubrication system out of order


1

Without lubrication

1. Motor without rotating oil flow

2. Low level of oil

3. Clog of filter

4. Fill wrong type of oil

5. Worm and gear

1. Check the power connection .

2. Fill up oil

3. Clean the filler.

6. O-ring of position broken.

4. Replace the correct engaged and can not rotating. lubrication oil.

5. Clean and repair.

6. Replace the O-ring.

2

Leakage of oil Brake of oil tank. Repair or replace the oil tank.

3 With alarm after the low oil level

Check the wire connection or check the floater switch.

Connection wire or replace floater switch.

12-9

12.2 Reset reference point ( when change battery )

When replace four 1.5 V batteries, the set machinery origin of coordinate and limit would be eliminated, so have to reset it.

<Condition 1>Red arrow exist in machine (X-axis located on the turret, Z-axis located in back of the machine, please open the cover of maintenance.) And list steps of adjusting below:

Trouble shooting

For machine without Y axis:

(1)Parameter setting

<1-1>

1.Press the key "SYSTEM" on the board. And then the

"PARAM" located on the left corner,

2.Press "PARAM" key .

<1-2>

1.Key in "1815".

2.And then the "NO.SRH" located on the left corner

Press "NO.SRH" key .

<1-3>

Move the cursor to the "APZ" .

<1-4>

Set the "MODE" switch to the " M.D.I." position.

<1-5>

Press the key "ON:1" on the left corner to set X, and Z to be 1.

12-10

Trouble shooting

(2)Set the MODE switch to the "HANDLE" position.

(3)Select " Control axis" to be X-axis.

(4)By turning "Handle" to make two arrows aim at each other.

(5)Select " Control axis" to be Z-axis.

(6)By turning hand wheel to make two arrows of

Z1-axis to aim at each other. (The red arrow of

Z-axis and X-axis are located on the antichip plate of Z axis and X axis.)

(7) Parameter Setting

<7-1>


"PARAM" located on the left corner.


12-11

Trouble shooting

<7-2>

1.Key in "1815".


Press "NO.SRH" key.

<7-3>

Move the cursor to the "APZ" .

<7-4>

Set the "MODE" switch to the " M.D.I." position.

<7-5>

Press the key "OFF:0" on the left corner to set X, and Z to be 0.

(8)Power off and power on.

<8-1>

Repeat <7-1>~<7-4>

<8-2>

Press the key "ON:1" on the left corner to set X, and Z to be 1.

(9)Power off and power on, now will be able to do

"H1 ZERO RETURN".

12-12

<Condition 2>The plate have took off or lose that could not aim at each other. List steps for adjusting below:

Trouble shooting

(1)Install the internal tool holder on the turret (take the station 1 as center).

(2)Install the indicator/dia gauge on the chuck

(3)Move X1-axis and Z1-axis to the indicator and

Z1-axis must allow the top of indicator into to contact with the bore of tool holder.

(4)Put top of indicator/ dia gauge into to contact with he bore of tool holder, and rotate spindle to the half difference of indicator reading (please adjust at horizontally)

-------------------------------------------------

For model with Y axis, follow the steps(5)~(6).

(5)Parameter Setting

<5-1>

1.Press the key "POS" on the keyboard, and a coordinate will appear on the LCD character display.

2.After pressing the key "REL".

3.Press the key "V" on the keyboard. Now the "V" on the LCD character display would flash.

12-13

Trouble shooting

<5-2>

Press the key "ORIGIN" so that "V" value would be eliminated to be zero.


<6-1>




<6-2>

1.Key in "1815".

2.And then the "NO. SRH" located on the left corner

Press "NO. SRH" key .

<6-3>

Move the cursor to the "APZ" and set Y to be 0 by using cursor shift key. And then set Y to be 1 again.

---------------------------------------------------------------------


<7-1>



3.Press the key "U" on the keyboard. Now the "U" on the LCD character display would flash.

12-14

Trouble shooting

<7-2>

Press the key "ORIGIN" so that "U" value would be eliminated to be zero.

Refer to 2.9 Travels and

(8)Shaft X1-axis up about 200 mm for

GS-200/M/L/ML and 160 mm for GS-200Y.

working area

(9)Shaft Z1-axis to the distance of 155 mm for

GS-200/M/Y and 162.5/180.5 mm for

GS-200L/ML/LY from the spindle cover. (Take the surface of turret as reference).

Refer to 2.9 Travels and working area


<10-1>



3.Press the key "W" on the keyboard. Now the "W" on the LCD character display would flash.

<10-2>

Press the key "ORIGIN" so that "W" value would be eliminated to be zero.

12-15

Trouble shooting

(11)Shaft Z1-axis up about 570 / 1170 mm for

GS-200/L series.

(12)Set the MODE to the "M.D.I." position.


<13-1>




<13-2>

1.Key in "1815".


Press "NO.SRH" key .

<13-3>

Move the cursor to the "APZ" and set X, Y and Z to be

0 by using cursor shift key. And then set X, Y and Z to be 1 again.

Refer to 2.9 Travels and working area

12-16

Trouble shooting

(14)Power off and power on and then do "H1 Zero

Return".

(15)Check "H1" X-axis up about 200 mm for

GS-200/M and 160 mm for GS-200Y.

***[Program check is finished]

Refer to 2.9 Travels and working area

12-17

Appendix A.

Content

1 ALARM MESSAGE (for FANUC 0I-TD Controller)

...........................A-1

1-1 Various alarms and trouble shutting

.............................A-1

2 Turret resetting procedure

..............................................................A-16

A

1 ALARM MESSAGE (for FANUC 0I-TD Controller)

1-1 Various alarms and trouble shutting

ADDRESS

A0.6

ALARM

NUMBER

DESCRIPTION

T-CODE ERROR

(A0.0)

OVER LOAD

CHECKING POINT &

TROUBLESHOOTING

T CODE COMMAND .> D50

T code command must be under than D50(D50=amount of tool +1 )

Check Hyd/Coolant MCC overload switch

(A0.1)

PRESSURE

(A0.2)

Check the value of hyd. Pressure is

35kg/mm2 or the pressure switch is normal.

Contrast to the alarm No. on the amplifier LED display for alarm reason.

EMERGENCY

STOP (A0.4)

NO PRESSURE

Emergency stop signal (X8.4=1)

Check Pressure switch signal

(A0.5)

1006 SET K4.2=0 (A0.6)

Set K4.2=0 after Install chip conveyor

SAUTER TURRET

ALARM (A0.7)

Sauter turret alarm

A-1

ADDRESS

ALARM

NUMBER

DESCRIPTION

CHECKING POINT &

TROUBLESHOOTING

MANUAL ERROR

(A2.0)

Auto mode or manual mode select error for operation.

Check turret is clamped or tool number index is correct and tool select button is to “ON”.

NO ZERO RETURN

(A2.2)

Check servo axis at home position and home position light will shine

Safe-door is not closed indeed.

(*X4.1(**X5.4=1)when safe-door is closed)

Check tool setter arm in up position and signal *X3.6=0(**X7.6=0),

*X3.5=0(**X7.5=1).

A2.5 2005

ERROR (A2.5)

Feed hold push button signal is off.

SPINDLE CHUCK

NO CLOSE (A2.6)

Chuck is not closed.

Check signal *X0.1=1(**X8.0=1) when chuck is inside closed.

Check signal *X0.2=1(**X8.1=1) when chuck is outside closed.

TOOL SETTER

To operate Renishaw tool setter just only in JOG mode.

(A2.7)

ADDRES

S

A3.1

ALARM

NUMBER

DESCRIPTION

Spindle stop push button signal was off.

CHECKING POINT &

TROUBLESHOOTING

SPINDLE STOP

OPEN (A3.0)

2009 LUB ALARM (A3.1) Lubrication oil empty.

MACHINE LOCK

ACTIVE (A3.2)

BATTERY ALARM

(A3.3)

Check if machine lock switch “on”.

NC’s battery low alarm.

Arrival at the counter of setting parts.

Reset the counter.

A3.6 2014

ERROR (A3.6)

A3.7 2015

LOCK (A3.7)

Turn the edit key to off position.

Return the parts catcher and check signal *X1.7=1(**X5.7=1).

Spindle in run status. Command is lock.

A-2

ADDRESS

ALARM

NUMBER

DESCRIPTION

TURRET

ALARM (A4.0)

CHECKING POINT &

TROUBLESHOOTING

Signal *X3.0=0(**X7.0=0) when turret is in unclamp status. Check turret proximity switch position.

To force turret unclamp and No.1 tool search by jog.

Chuck is not closed.

Check signal

SPINDLE CHUCK *X0.1=1(**X8.0=1)when chuck is

(A4.3) inside closed.

Check signal

*X0.2=1(**X8.1=1)when chuck is outside closed.

AUTO MODE

(A4.6)

Check bar-feeder alarm state.

K0.0 must be set to 1 when tool setter is used.

Auto mode or manual mode select error for operation.

K0.2 must be set to 1 when tool setter is used.

A-3

ADDRESS

A5.0

ALARM

NUMBER

2024

DESCRIPTION

QUILL ALARM (A5.0)

CHECKING POINT &

TROUBLESHOOTING

Check quill sensor *X0.3

(**X8.2) *X0.4 (**X8.3)

PLEASE MOVE X.Z AXIS Move X & Z axis by wheel handle when X or Z axis is in

A5.1 2025

REFERENCE POINT BY

HANDLE MODE (A5.1) home position at the machine lock status.

STOP!!! WARNING!!!

STOP!!! DOOR

INTERLOCK

DEACTIVATED!OPERAT

R MACHINE IN THIS

MODE! THIS MODE IS

This alarm message displays at maintenance status.

A5.2 2026

GOODWAY SERVICE

PERSONAL USE

ONLY !FAILURE TO

COMPLY WITH THIS

WARNING MAY PESULT

IN SERIOUS DANGER!

(A5.2)

TOOL LIFE ALARM

(A5.3)

Ckeck the tool life value at tool life table.

T CODE CAN NOT BE

A5.5

BLOCK WITH M30 (A5.4)

2029 B/F ALARM (A5.5)

B/F SIGNAL NO READY

(A5.6)

ADD M64 AT FIST

BLOCK OF THE

AUTOMATIC DOOR IS

MOUNTED (A5.7)

Check bar feeder status.

Check bar feeder status.

Check if the auto door close complete and M64 code at first block of the program.

A-4

ADDRESS

A6.0

ALARM

NUMBER

DESCRIPTION

2032 LOAD ALARM (A6.0)

A6.1 2033

(A6.1)

TAILSTOCK -OT

(A6.2)

Z AXIS NOT IN

(A6.3)

TAILSTOCK PIN

(A6.4)

TAILSTOCK –OT

SETTING ON (A6.5)

A6.6 2038

ZERO POINT (A6.6)

QUILL OUT LOCK

(A6.7)

CHECKING POINT &

TROUBLESHOOTING

Check if spindle load setting values too small.

Check if tool was worn.

Please push reset key and move nagetive direction by jog.

Please push reset key and move positive direction by jog.

Check if the pin position is correct with the pin hold on z-axis.

Check if the pin had interfered with pin hold and couldn’t to draw out.

This alarm message displays when need to set the nagetive direction max travel of PMC tailstock.

Please exit this mode when setting complete.

Check if x axis is at home position.

Pin and quill can’t be at stretch out position at the same time.

A-5

ADDRESS ALARM

NUMBER

DESCRIPTION

C AXIS MODE CAN

(A7.0)

A7.1 2041

OUT LOCK (A7.1)

TAILSTOCK PIN

OUT LOCK (A7.2)

MILLING

INTERLOCK (A7.3)

(WARNING):THE

MACHINE IS

MANUFACTURE

FOR

WELL-TRAINED

OPERATOR. TO

AVOID IN-JURY, DO

NOT OPERATE THE

CHECKING POINT &

TROUBLESHOOTING

Please cancel (turn off) the

CF-axis mode before spindle turnning.

Please retract the quill before using the tailstock driven pin.

Please unclamp the tailstock driven pin before using the quill.

Please check if the live tooling is rotating.

A7.5

YOU HAD

UNDERSTAND ALL

INFORMATIONS IN

THE

MANUALS.BEING

AWARE OF THIS

WARNING

PRESS[RESET]KEY

2045 MODE LOCK (A7.5)

LUB PRESSURE

LOW (A7.6)

STEADY

Check if the mode lock keyswitch is released.

Please check if the pressure of

LUB. System is too low.

Please check if the pressure of steady-rest is too low.

(A7.7)

A-6

ADDRESS

ALARM

NUMBER

DESCRIPTION

TAILSTOCK OVER

TRAVEL (A8.0)

HYD.MOTOR NO

START (A8.1)

A8.2 2050

LOCK (A8.2)

A8.3 2051

LOCK (A8.3)

MUST RUN QUILL

CHECKING POINT &

TROUBLESHOOTING

Check if the distance between steady rest and tailstock is to short. Please press “RESET” to cancel the alarm then move the tailstock to positive direction.

The hydraulic pump is not active. Please press hyd. ST button to active the hydraulic system.

Check if the pin of steady rest unclamp complete.

Inexact operation (for example: cycle start, quill out,…) after tailstock pin out, it may cause machine damage.

Please press quill ADV. Button.

QUILL JOG (A8.4)

A8.6 2054

LOW (A8.6)

SPINDLE BRAKE

ON (A8.7)

Check if the steady is too close to the tailstock press “RESET” key to cancel the alarm then move the steady rest to nagetive direction.

Check if the air pressure is too low.

Check the air pressure switch.

Check if the air pressure signal

*X1.5=0(**X5.5=0).

Check if spindle brake is “ON”.

Please release spindle brake before run spindle.

A-7

ADDRESS

ALARM

NUMBER

DESCRIPTION

PARTS CATCHER

OUT/TOOL SETTER

CHECKING POINT &

TROUBLESHOOTING

Live tool rotating speed is over limit, please reduce live tool rotating speed.

Check the turret clamp sensor signal *X3.0(**X7 0).

Check if turret was combined completely.

Parts catcher out or tool setter arm down on MDI operation mode must run in single block mode, please setting it.

A9.2 2058

OPERATE ON

SINGAL BLOCK

MODE (A9.2)

SPINDLE

INTERLOCK (A9.3)

TOOL SET DOWN

(A9.4)

PARTS CATCHER

OUT (A9.5)

"MILLING SERVO

OFF".PLEASE PUSH

MILLING SERVO ON

(A9.6)

SUB SPINDLE

CLOSE(A9.7)

When spindle synchronous is running,it can not change rotate direction, please cancel spindle synchronous command at first.

Tool setter can not use with part catcher at the same time , please to turn back the tool setter before using the part catcher.

Part catcher can not use with tool setter at the same time, please to turn back the parts catcher before using the tool setter.

Can not use the bar pusher when sub spindle chuck clamp, please to unclamp the sub spindle chuck at first.

A-8

ADDRESS ALARM

NUMBER

DESCRIPTION

SUB SPINDLE

(A10.0)

A10.1 2065

LOCK (A10.1)

SUB SPINDLE

(A10.2)

SUB SPINDLE C

A10.3 2067

NOT RUN SPINDLE

(A10.3)

SPINDLE

RUN LOCK (A10.5)

SPINDLE

SYNCHRONOUS

CAN NOT ALL OPEN

(A10.6)

CHECKING POINT &

TROUBLESHOOTING

Sub spindle can not running when chuck was unclamped , please to clamp the sub spindle chuck at first.

Sub spindle running and locking , please stop sub spindle before running others.

Sub spindle chuck interlock, please check if the chuck sensor is normal.

When sub spindle running on c axis mode, others sub spindle function can not run, please to turn off the c axis mode first.

When sub spindle brake was clamped, other sub spindle function can not run, please to release the brake at first.

When spindle synchronous is running the any other function about spindle can not run.

Please stop spindle synchronous running.

When spindle synchronous is running the chuck of spindle and sub spindle can not unclamp at the same time.

GEAR NO READY

(A10.7)

The gear position of speed change did not confirm, please check if the sensor is normal.

A-9

ADDRESS ALARM

NUMBER

A11.0 2072

DESCRIPTION

ERROR (A11.0)

*X0.6=1(**X8.6=1)

PLEASE SETTING

TAILSTOCK MODE

(A11.1)

TAILSTOCK PIN

CHECKING POINT &

TROUBLESHOOTING

Check air pressure value of lubricator.

Check signal *X10.4(**X24.4) and *X10.6(**X24.6).

Tailstock connect pin is at out position, please to turn back the connect pin.

A11.3 2075

COOLANT (A11.3)

TAILSTOCK BRAKE

CLAMP, PLEASE

Tailstock connect pin is acting, please set to the tailstock mode.

Sub-SP. coolant using(k24.4=1)

,must turn coolant ON.

Check

BRAKE RELEASED

ON NOT!(A11.4)

AIR CHUCK

(A11.7)

*For FANUC 0i-T series controller signals

**For FANUC 18i-T series controller signals

A-10

ADDRESS ALARM

NUMBER

DESCRIPTION

SP TOOL LIFE VALUE

OVER (A12.0)

SP TOOL BREAK VALUE

OVER (A12.1)

A12.2 2082

A12.3 2083

A12.4 2084

A12.5 2085

A12.6 2086

A12.7 2087

CHECKING POINT &

TROUBLESHOOTING

ADDRESS ALARM

NUMBER

A13.0 2088

A13.1 2089

A13.2 2090

A13.3 2091

A13.4 2092

A13.5 2093

A13.6 2094

A13.7 2095

DESCRIPTION CHECKING POINT &

TROUBLESHOOTING

A-11

ADDRESS ALARM

NUMBER

A14.0 2096


TROUBLESHOOTING

A14.1 2097

A14.2 2098

A14.3 2099

A14.4 2100

A14.6 2102

PLEASE SELECT

QUILL DIRECTION

BY PUSH BUTTON

ON MANUAL MODE

AFTER HYD.MOTOR

STARTED (A14.5)

END OF WORKPICE

LOADING WITHOUT

MATERIAL

LOADING OR UNLOADING IS

BREAK OFF

ADDRESS ALARM

NUMBER

A15.0

A15.1

A15.2

A15.3

A15.4

A15.5

A15.6

A15.7

2104

2105

2106

2107

2108

2109

2110

DESCRIPTION

LOADING TIME

OVER (A15.0)

THE LOCATION OF

PIN IS

WRONG(A15.1)

WORKPIECE

CUT-OFF

DETECTION

ALARM(A15.2)

COOLER

ALARM(A15.3)

COOLANT FLOW

ALARM(A15.4)

CUT OFF RETURN

SENSOR

ERROR(A15.5)

TAILSTOCK_ARRIV

E TO END

2111

CHECKING POINT &

TROUBLESHOOTING

LOADING OR UNLOADING IS

OVERTIME

Check the location of pin sensor

Check the status of workpiece

Check cooler

Check coolant pump and coolant

Check the status of cutting sensor.

Check the status of workpiece

Check the location of tailstock

A-12

ADDRESS ALARM

NUMBER

DESCRIPTION

INPUT WRONG

NUMBER, YOU

CHECKING POINT &

TROUBLESHOOTING

PLEASE INPUT AGAIN

100 IN THIS

RANGE(A16.0)

THE POSITION

INPUT ERROR, YOU

MUST INPUT

PLEASE INPUT AGAIN

LIMIT(-) AND SMALL

THAN

LIMIT(+)(A16.1)

INPUT NUMBER

PLEASE INPUT AGAIN

12000 (A16.2)

INPUT NUMBER

PLEASE INPUT AGAIN

(A16.3)

INPUT THE ERROR

POSITION ,PLEASE

PLEASE INPUT AGAIN

AGAIN(D<C<B<A)

(A16.4)

A16.5 2117

A16.6 2118

A16.7 2119

ADDRESS ALARM

NUMBER

DESCRIPTION

WARNING!! AUTO

CHECKING POINT &

TROUBLESHOOTING

Close auto door

(A18.0)

A18.1 2129

INTERLOCK(A18.1)

A18.2 2130

A18.3 2131

A18.4 2132

A18.5 2133

A18.6 2134

ABSOLUTE POSITION

Check the location of robot

Replacement of battery

ALARM(A18.7)

A-13

ADDRESS ALARM

NUMBER

DESCRIPTION

SELECT T1 AND

BUTTON(A19.0)

SPINDLE CYLINDER

CLOSE(A19.1)

A19.2 2138

A19.3 2139

A19.4 2140

A19.5 2141

A19.6 2142

A19.7 2143

CHECKING POINT &

TROUBLESHOOTING

Check spindle cylinder above cover.

ADDRESS ALARM

NUMBER

A22.0 2160


TROUBLESHOOTING

AIR CONDITIONER

ERROR(A22.1)

GEAR BOX OIL FLOW

RATE TOO LOW(A22.2)

Check air conditioner

Check gear box oil motor

SPINDLE GEAR

CHANGE OVER TIME

OR SENSOR NOT

DETECTION(A22.3)

Please shift gears again and check the gear sensor.

A22.4 2164

ERROR(A22.4)

Please separate again and check the gear.

ZF HIGH/LOW CHANGE

ERROR(A22.5)

Please shift gears again.

DOOR LOCK SIGNAL Check the door interlock

DETECTION(A22.6)

AUTOMATIC DOOR

STOP AT WRONG

POSITION@A1@FPLEA

SE PULL THE DOOR

TO THE CORRECT

POSITION

MANUALLY@A1@C(A2

2.7)

Please pull the door to the correct position manually

A-14

ADDRESS ALARM

NUMBER


TROUBLESHOOTING

A23.0 2168

SPINDLE /LIFETOOL

ON(A23.1)

SPINDLE POWER LINE

ALARM(A23.2)

Can’t rotate spindle / livetool manually on spindle / livetool synchronous mode

Check the power line of spindle

Check the power line of sub-spindle

A23.4 2172

A23.5 2173

A23.6 2174

A23.7 2175

A-15

2 Turret resetting procedure

I. Resetting turret reference position:

The turret indexing operation might be interrupted by following:

(1) Press EMERGENCY STOP button.

(2) Power OFF.

(3) Collision.

If the turret indexing operation is interrupted, it may cause the turret index incorrect or incomplete. The turret index button light becomes

OFF and the turret is not ready for indexing. It is necessary to perform “Resetting turret reference position” procedure as following:

1. Set K7.5 to 1 （Switch turret into JOG mode）as following steps：

Fig.1

Fig.2

A-16

Fig.3.

A-17

Set

K7#5=1

Fig.4.

2. Set the “MODE” switch to “HANDLE” posititon.

3. Press “FEED HOLD” and “SPINDLE

STOP” at the same time. Then turret is unclamp.

4. Press +X button（CW）or –X button（CCW） to rotate the turret to TOOL NO. 1.

Note:

Check turret parameter No. 41 and set to 1 as turret head without rotation.

A-18

5. After the red arrow which are on cover and turret match each other, press [RESET] key to clamp the turret head.

Fig.5

A-19

6. Set K7.5 to 0（return to normal mode）.

The turret reference position is set, please perform the “Tool No

Resetting” procedure as following:

7. Press “FEED HOLD” and “SP. STOP” button at the same time. Then turret head is unclamping.

8. Set the “MODE” switch to “ZERO RETURN” position.

9. Press “FEEDHOLD”,

“+X” or “-X” button.

(To set the current tool as tool no.1)

A-20

10. Press “RESET” to clamp the turret.

11. Restart the machine.

A-21

II. Tool number resetting

If the tool no. is incorrect, it may cause collision between tool and workpiece or chuck. It is necessary to perform “tool number resetting procedure” as following:

1. Set the “MODE” to “HANDLE” position.

2. Rotate turret to TOOL NO.1 (the nameplate shows NO.1 but the

“TOOL NO. SELECT” switch may not select NO.1)

3. Press “FEED HOLD” and “SP. STOP.” at the same time. (Press the right side “FEED HOLD” to operator thr right turret.)

4. Set the “MODE” switch to “ZRN” position.

A-22

5. Select TOOL NO.1.

6. Press “INDEXING” button. Then turret rotates to TOOL NO.1.

7. Press “RESET” key to clamp the turret.

8. The tool no. resetting procedure is completed.

A-23

Appendix B.

G、M、T、K- Code function

(for FANUC 0I-TD Controller)

Content

1 G-Code and M-Code function........................................................... B-1

1-1 G-Code function .......................................................... B-1

1-2 M-Code function

.......................................................... B-5

2 TIMER function

................................................................................. B-7

3 Keep relay setting

............................................................................. B-9

4 Counter function

............................................................................. B-36

5 DATA function

................................................................................. B-37

B

1 G-Code and M-Code function

1-1 G-Code function

G code system(Note 7)

Group

A B C

◤G00 ◤G00 ◤G00

Function

Positioning (rapid traverse)

G01 G01 G01

01

G02 G02 G02

G03 G03 G03 Circular interpolation CCW

Dwell G04 G04 G04

G07.1

(G107)

G07.1

(G107)

G07.1

(G107)

G08 G08 G08

00

G10 G10 G10

G11 G11 G11

G12.1

(G112)

◤G13.1

(G113)

G17

G12.1

(G112)

◤G13.1

(G113)

G17

G12.1

(G112)

◤G13.1

(G113)

G17

21

◤G18 ◤G18 ◤G18

16

G19 G19 G19

G20 G20 G70

G21 G21 G71

06

G22 G22 G22

G23 G23 G23

09

G25 G25 G25

G26 G26 G26

08

G27 G27 G27

G28

G30

G28

G30

G28

G30

G31 G31 G31

00

Cylindrical interpolation

Look –head control

Programmable data input

Programmable data input mode cancel

Polar coordinate interpolation mode

Polar coordinate interpolation cancel mode

XpYp plane selection

ZpXp plane selection

YpZp plane selection

Inch data input

Metric data input

Stored stroke check function on

Stored stroke check function off

Spindle speed fluctuation detection off

Spindle speed fluctuation detection on

Reference point return check

Return to reference point return

2nd, 3rd, 4th reference point return

Skip function

B-1


Group

A B C

G32 G33 G33

G34 G34 G34

01

G36 G36 G36

G37

G37.1

G37

G37.1

G37

G37.1

00

Function

Variable–lead thread cutting

Automatic tool compensation X (When the bit 3 (G36) of parameter No. 3405 is set to

0)

Automatic tool compensation Z

Automatic tool compensation X

G37.2 G37.2 G37.2

G39 G39 G39

◤G40 ◤G40 ◤G40

G41 G41 G41

G42 G42 G42

07

G50 G92 G92

00

G50.3 G92.1 G92.1

◤G50.2 ◤G50.2

◤G50.2

(G250)

G51.2

(G250)

G51.2

(G250)

G51.2

(G251) (G251) (G251)

G52 G52 G52

20

G53 G53 G53

00

◤G54 ◤G54 ◤G54

G55 G55 G55

Automatic tool compensation Z

Corner circular interpolation

Tool nose radius compensation cancel

Tool nose radius compensation left

Tool nose radius compensation right

Coordinate system setting, max. spindle speed setting

Workpiece coordinate system preset

Polygonal turning cancel

Polygonal turning

Local coordinate system setting

Machine coordinate system setting

Workpiece coordinate system 1 selection

G56 G56 G56

G57 G57 G57

G58 G58 G58

14

G59 G59 G59

G60 G60 G60

G65 G65 G65

00

G66 G66 G66

◤G67 ◤G67 ◤G67

12






Single direction positioning

Macro calling

Macro modal call

Macro modal call cancel

B-2


Group Function

A B C

G70 G70 G72

G71 G71 G73

G72 G72 G74

G73 G73 G75 00

Stock removal in turning

Stock removal in facing

End face peck drilling G74 G74 G76

G75 G75 G77

G76 G76 G78

G71 G71 G72

Multiple threading cycle

G72 G72 G73

01

Traverse direct constant–dimension grinding cycle

(for grinding machine)

G73 G73 G74

G74 G74 G75

◤G80 ◤G80 ◤G80

G83 G83 G83

Oscilation direct constant–dimension grinding cycle

(for grinding machine)

Canned cycle for drilling cancel

Cycle for face drilling

G84

G86

G87

G88

G89 G89 G89

G90 G77 G20

G92 G78 G21

G94 G79 G24

G96 G96 G96

◤G97 ◤G97 ◤G97

G98

-

-

G84

G86

G87

G88

G94

G84

G86

G87

G88

G94

◤G99 ◤G95 ◤G95

◤G90 ◤G90

G98 G98

10

01

02

05

03

11

Cycle for face tapping

Cycle for face boring

Cycle for side drilling

Cycle for side tapping

Cycle for side boring

Thread cutting cycle

End face turning cycle

Constant surface speed control

Constant surface speed control cancel

Per minute feed

Per revolution feed

Absolute programming

Incremental programming

Return to initial level

Return to R point level

B-3

(Note 1) G codes marked " ◤" are initial G codes when turning power on.For G20 and G21, the G code before turning power off remains. G00 or G01 can be selected by parameter setting.

(Note 2) G codes of group 00 are not modal. They are only effective in the block in which they are specified.

(Note 3) If a G code not listed on the table of G codes is inputted, or optional Gcode not specified in the system is commanded, an alarm (No. 010) is displayed.

(Note 4) A number of G codes can be specified in the same block. When more than one G code of the same group is specified, the G code specified later is effective.

(Note 5) If any G code of group 01 is specified in a canned cycle mode, the canned cycle is automatically cancelled and the G80 condition is entered. However a G code of group -1 is not affected by any of the canned cycle G codes.

(Note 6) A G code is displayed from each group.

(Note 7) G code system B and C are options. Whether G code system B or C is set by parameter No.0036 : GSPC.

(Note 8) The earlier program has executed command G50 coordinate system setting. When program is not completely executed like stopped during program execution, and operator does not execute reference point return, will cause error positioning in the next program that leads to collision.

B-4

1-2 M-Code function

M- code

DESCRIPTION M- code

M00 Program stop

M01 Option stop

DESCRIPTION

M41 Spindle low speed gear

M42 Spindle high speed gear

M02 End of program M43 Spindle synchronous on clockwise

Spindle synchronous on

M03 Main spindle rotate on clockwise M44 counter-clockwise

M04

Main spindle rotate on counter-clockwise

M05 Main spindle stop

M45 Spindle synchronous stop

M46 Call b/f allow

M08 Coolant on

M09 Coolant off

M10 Main chuck unclamp

M11 Main chuck clamp

M12 Tailstock forward

M13 Tailstock backward

M14 Tailstock quill forward

M15 Tailstock quill backward

M16

M17

Tailstock quill forward on pressure #2

Tailstock quill backward on pressure #2

M47 Bar feeder m code

M48 Bar feeder MCODE (loading)

M49 Bar feeder MCODE

M50 Bar feeder MCODE

M58 Option hight- pressure pump on

M59 Option hight- pressure pump off

M60 PMC tailstock mode

M61 Chip conveyor forward

M63 Chip conveyor stop

M64 Auto door close

M18 C-axis function off

M19 C-axis function on

M20 Main air blow on

M21 Main air blow off

M22

Living tool free(just for servo motor)

M23 Chamfering on

M65 Auto door open

M68 Parts catcher out

M69 Parts catcher in

M70 Spindle center air blow off

M71 Spindle center air blow on

M24 Chamfering off

M73 Living tool rotate on clockwise

Living tool rotate on

M74 counter-clockwise

M25 In-position check valid

M26 In-position check invalid

M27 Check on of chuck air seal

M28 Check off of chuck air seal

M29 Rigid taping on

M30 End of program & reset

M35 Auto toolset down

M36 Auto toolset up

M37 Main spindle brake clamp

M38 Main spindle brake unclamp

M40 Spindle in neutral gear

M75 Living tool stop

M76

M77

Living tool control from PMC trans to

NC

Living tool control from NC trans to

PMC

M80

M81

Two-sides of pneumatic chuck simultaneity on

Two-sides of pneumatic chuck simultaneity off

M82 Spindle chuck unclamp pressure #2

M83 Spindle chuck clamp pressure #2

M84 Steady rests #1 clamp

M85 Steady rests #1 unclamp

M86 Steady rests #2 clamp


B-5

M- code

DESCRIPTION M-

M88 Steady rests #3 clamp code

DESCRIPTION

M220 Sub air blow on


M90

M91

Out-side pneumatic chuck simultaneity on

Out-side pneumatic chuck simultaneity off

M221 Sub air blow off

M227

M228

Sub-spindle center jet out water on

Sub-spindle center jet out water off

M97 Same with m0, and chuck stop M237 Sub spindle brake clamp

M98 Call sub program

M99 Sub program end

M238 Sub spindle brake unclamp

M270 Sub spindle through air blow off

M108 Spray washing on

M109 Spray washing off

M124 Torque limit skip ON

M125 Torque limit skip OFF

M138 PMC TAILSTOCK PIN CLAMP

M139 PMC tailstock pin unclamp

M159-

M166

8 m code

M196 Load monitor function on

M145 Arbitrary speed threading ON

M146 Arbitrary speed threading OFF

M147 Re-machining thread ON

M148 Re-machining thread OFF

M149 Thread measurement

M197 Load monitor function off

M203 Sub spindle rotate on clockwise

M204

Sub spindle rotate on counter-clockwise

M205 Sub spindle stop

M210 Sub chuck unclamp

M271 Sub spindle through air blow on

M272 Sub spindle push bar

M282

M283

M300

-M399

Sub spindle chuck unclamp pressure #2

Sub spindle chuck clamp pressure

#2

Communication between head 1 and head 2.

M500 –M

599

M1000 –

M1360

M20000-

M24096

Spindle load setting

1 degree indexing of main spindle

M10000

–M14096

0.088 degree indexing of main spindle

M2000 –

M2360

1 degree indexing of sub-spindle

0.088 degree indexing of sub-spindle

M211 Sub chuck clamp

M218 Sub spindle c-axis function off

M219 Sub spindle c-axis function on

B-6

2 TIMER function

No.

DATA

ADDRESS

1 T00

OUTPUT

ADDRESS

DESCRIPTION

R812.2 PARTS CONVERYOR TIME.

3 T04 R53.6

OUT. (TAILSTOCK BY PMC CONTROL)

4 T06 A7.4 POWER “ON” ALM DISPLAY DELAY TIME.

7 T12 R1032.5

TIME.

THE STOP TIME OF LUBRICATOR OIL OF

PRESSURE RELIEF TYPE

10 T18 R813.7

OF PRESSURE RELIEF TYPE.

11 T20 R826.2 DH-65 B/F –Z DELAY

12

13

14

T22

T24

T26

R826.3

R826.4

R826.5

DH-65 B/F –Z TIMER

DH-65 B/F –Z FINISH DELAY

DH-65 LOADING FINISH DELAY

B-7

No.

15

DATA

ADDRESS

T28

OUTPUT

ADDRESS

R22.4

DESCRIPTION

CHIP CONVEYOR C.W. TIME

16 T30 R22.5 CONVEYOR C.W. STOP TIME

17 T32

M15 FINISH TIME (JUST FOR GS-200

SERIES)

18 T34 R52.7

SERIES)

19 T36

PROXIMITY SIGNAL DELAY CHECKING

TIME OF SUB-CHUCK.

20 T38

TAILSTOCK ADV. DELAY TIME.

21 T40 R76.7

TAILSTOCK BRAKE DELAY TIME.

22 T42

LUBRICATION OIL SPRAY ACTION

TIMER (JUST FOR GS-400 SERIES)

23 T44

LUBRICATION OIL SPRAY STOP TIMER

(JUST FOR GS-400 SERIES)

24 T46

ST

PNEUMATIC CHUCK UNCLAMP

DELAY FINISH TIME

25 T48

ST

R845.6

PNEUMATIC CHUCK CLAMP DELAY

FINISH TIME

26 T50

2

ND

PNEUMATIC CHUCK UNCLAMP

DELAY FINISH TIME

27 T52

ND

PNEUMATIC CHUCK CLAMP

DELAY FINISH TIME

28 T54 R403.2

TIME

29 T56

TMR40

~TMR73

LOAD MONITOR FUNTION

30 T58 R865.5 WASHER MOTOR ON TIME

31 T60 R856.6 WASHER MOTOR OFF TIME

B-8

3 Keep relay setting

K00 7 6 5 4 3 2 1 0

DRLK HYDSW CKPS SPDRN HYDST PTCH STCK TLSTEP

NAME&BIT DESCRIPTION

BIT 0

1: TOOL SETTER IS EQUIPPED.

0: TOOL SETTER IS NOT EQUIPPED.

BIT 1

1: ENABLE “CYCLE START” WHEN CHUCK IS UNCLAMP

0: DISABLES “CYCLE START” WHEN CHUCK IS UNCLAMP

BIT 2

1: PARTS CATCHER IS EQUIPPED.

0: PARTS CATCHER IS NOT EQUIPPED.

BIT 3

1: HYD. PUMP START BUTTON IS UNUSED

0: HYD. PUMP START BUTTON IS USED

BIT 4

BIT 5

BIT 6

1: THE SPINDLE WILL NOT ROTATE WHEN PROGRAM IS

RUNNING IN “ DRY RUN “ CONDITION.

0: THE SPINDLE RUNNING ENABLEIN “ DRY RUN

“ CONDITION.

1: CHUCK CLAMP/UNCLAMP CONFIRMATION SWITCH IS

EQUIPPED.

0: CHUCK CLAMP/UNCLAMP CONFIRMATION PROXIMITY

SWITCH IS NOT EQUIPPED.

1: I/O LINK TURRET CLAMP/UNCLAMP CONFIRMATION IS

EQUIPPED WITH SINGLE PROXIMITY.

0: I/O LINK TURRET CLAMP/UNCLAMP CONFIRMATION IS

EQUIPPED WITH TWIN PROXIMITY.

BIT 7

B-9

< KEEP RELAY >

K01 7 6 5 4 3 2 1 0

DH65 QLPS LTCO


BIT 0

1: USER COUNTER IS EQUIPPED, USE M-CODE (M30).

0: USER COUNTER IS EQUIPPED, USE M-CODE (M69).

BIT 1

1: LIVETOOL CONFIRM THE ORIGINAL POSITION BEFORE

TOOL CHANGE.

0: LIVETOOL DISCONFIRM THE ORIGINAL POSITION

BEFORE TOOL CHANGE.

BIT 2

1: QUILL PROXIMITY IS EQUIPPED.

0: QUILL PROXIMITY IS NOT EQUIPPED.

BIT 3

1: THE AUTO DOOR IS EQUIPPED.

0: THE AUTO DOOR IS NOT EQUIPPED.

BIT 4

1: CHUCK COMMAND M10/M11 IS EFFECTIVE ,WHEN THE

SPINDLE IS ROTATING.

0: CHUCK COMMAND M10/M11 IS NOT EFFECTIVE , WHEN

THE SPINDLE IS ROTATING.

BIT 5

1: LUBRICATOR IS PRESSURE RELIEF TYPE.

0: LUBRICATOR IS MICROELECTROMIC TYPE.

BIT 6

1: THE AIRBLOW CONFIRMATION SWITCH IS NOT

EQUIPPED ON THE TAILSTOCK BY PMC AXIS CONTROL.

0: THE AIRBLOW CONFIRMATION SWITCH IS EQUIPPED

ON THE TAILSTOCK BY PMC AXIS CONTROL.

BIT 7

1: SPINDLE SPEED ARRIVAL SIGNAL IS CHECKED.

0: SPINDLE SPEED ARRIVAL SIGNAL IS NOT CHECKED.

B-10

< KEEP RELAY >

K02 7 6 5 4 3 2 1 0

MR BFM48


BIT 0

1: PARTS CATCHER OF GS-200 TYPE.

0: STANDARD PARTS CATCHER TYPE.

BIT 1

1: QUILL OF GS-200 TYPE.

0: STANDARD QUILL TYPE.

BIT 2

1: FOUR PROXIMITY ON PARTS CATCHER FOR GS-200

SERIES.

0: TWO PROXIMITY ON PARTS CATCHER FOR GS-200

SERIES.

BIT 3

1: 0I-T AUTO DOOR KEY SELECT.

0: 18I-T AUTO DOOR KEY SELECT.

BIT 4

1: USE COOLANT LOW LEVEL DETECTION

0: UNUSE COOLANT LOW LEVEL DETECTION

BIT 5

1: SIGNAL IS TRIGGERED WHEN CHUCK CLAMPED FOR

LNS B/F.

0: SIGNAL IS TRIGGERED WHEN CHUCK UNCLAMPED FOR

LNS B/F.

BIT 6

1: TAILSTOCK SETTING OF GCL-2 PLUS TYPE.

0: OTHER TAILSTOCK SETTING.

BIT 7

1: MEMORY RESTART IS NOT EECTIVE.

0: MEMORY RESTART IS EECTIVE.

B-11

< KEEP RELAY >

K03 7 6 5 4 3 2 1 0


BIT 0

1: SUB-CHUCK PROXIMITY IS EQUIPPED.

0: SUB-CHUCK PROXIMITY IS NOT EQUIPPED.

BIT 1

1: SUB-SPINDLE SPEED ARRIVAL SIGNAL CHECKING.

0: SUB-SPINDLE SPEED ARRIVAL SIGNAL NOT CHECKING.

BIT 2

1: GS-400 STEADY REST PIN SET

0: STANDARD

BIT 3

BIT4

BIT 5

BIT 6

1: PNEUMATIC CHUCK.

0: STANDARD HYDRAULIC CHUCK.

1: PNEUMATIC CHUCK CONFIRMATION PROXIMITY

SWITCH SIGNAL CHECK ON OUTSIDE AND INSIDE (TWIN

CHUCK).


SWITCH SIGNAL CHECK ONLY ON THE INSIDE.


SWITCH IS NOT EQUIPPED.


SWITCH IS EQUIPPED.

1: NON-INDUCTION CHECK OF CHUCK PROXIMITY

SWITCH.

0 INDUCTION CHECK OFCHUCK PROXIMITY SWITCH.

BIT 7

1: CHUCK AND SUB-CHUCK IS CONTROLLED

RESPECTIVELY.

0: CHUCK AND SUB-CHUCK IS CONTROLLED TOGETHER.

B-12

< KEEP RELAY >

K04 7 6 5 4 3 2 1 0

TLHPMA TLTND

NAME&BIT

BIT 0

DESCRIPTION

1: X-AXIS ZERO RETURN IS UNNECESSARY WHEN TOOL

SETTER IS USED.

0: X-AXIS ZERO RETURN IS NECESSARY WHEN TOOL

SETTER IS USED.

BIT 1 1: TOOL SETTER WITH AUTOMATIC.

0: TOOL SETTER WITH MANUAL.

BIT 2

1: EMERGENCY STOP ON CHIP CONVEYOR IS NOT

EQUIPPED.

0: EMERGENCY STOP ON CHIP CONVEYOR IS EQUIPPED.

BIT 3

1: 0I-T STEADY REST KEY SELECT.

0: 18I-T STEADY REST KEY SELECT.

BIT 4

1: USE PUSH BUTTON WITH MANUAL SPINDLE SELECT.

0: USE ROTARY SWITH WITH MANUAL SPINDLE SELECT.

BIT 5

1: THE KEY CAN CONTROL THE LED OF AXES DIRECTION.

0: PLC CONTROL THE LED OF AXES DIRECTION.

BIT 6

1: TO SET KIRIU COOLANT

0: TO SET 10 BAR COOLANT

BIT 7

1: TOOL CHANGE BEFORE Y AXIS MUST IN ORIGIN POINT

0: TOOL CHANGE THAT Y AXIS DO NOT NEED TO BACK

ORIGIN POINT

B-13

< KEEP RELAY >

K05 7 6 5 4 3 2 1 0

PAT


BIT 0

1: EXTERNAL HANDWHEEL IS EQUIPPED.

0: EXTERNAL HANDWHEEL IS NOT EQUIPPED.

BIT 1

1: 2 nd

STEADY REST

0: WITHOUT 2 nd

STEADY REST

BIT 2

1: M02 CODE IS HOLDING PROGRAM AND NOT RETURN

TO PROGRAM HEAD.

0: M02 CODE IS HOLDING PROGRAM AND RETURN TO

PROGRAM HEAD.

BIT 3

POSITION SELECTION OF THE BOTTON OF OIL

PRESSURE PROGRAMMABLE TAILSTOCK KEY

BIT 4

BIT 5

1: AFTER SUB-SPINDLE BRAKED, SECOND C AXIS OFF.

0: AFTER SUB-SPINDLE BRAKED, SECOND C AXIS NOT

OFF.

1: AFTER SUB-SPINDLE BRAKED, SECOND C AXIS

POSITION MEMORY

0: AFTER SUB-SPINDLE BRAKED, SECOND C AXIS

POSITION NOT MEMORY

BIT 6

BIT 7

1: WHEN SECOND PNEUMATIC CHUCK(OUTSIDE)

UNCLAMP, THE SPINDLE CAN’T RUN.

0: WHEN SECOND PNEUMATIC CHUCK(OUTSIDE)

UNCLAMP, THE SPINDLE CAN RUN.

B-14

< KEEP RELAY >

K06 7 6 5 4 3 2 1 0

SPORC CSRD


BIT 0

1: LOAD MONITOR WITH TOOL LIFE MANAGEMENT.

0: LOAD MONITOR WITHOUT TOOL LIFE MANAGEMENT .

BIT 1

BIT 2

1: THE STATE OF OPERATE KEY WILL KEEPING WHEN DO

RESTART

0: THE STATE OF OPERATE KEY WILL CAN NOT KEEPING

WHEN DO RESTART

BIT 3

SPINDLE RIGID TAPPING DIRECTION SETTING (FOR BZ

SENSOR) (UNNECESSARY CHANGE).

BIT 4

1:C AXIS SERVO OFF AFTER SPINDLE BRAKED.

0: C AXIS SERVO NOT OFF AFTER SPINDLE BRAKED.

BIT 5

1: C AXIS SERVO POSITION MEMORY AFTER SPINDLE

BRAKED.

0: C AXIS SERVO POSITION NOT MEMORY AFTER

SPINDLE BRAKED.

BIT 6 SPINDLE DIRECTION SET (UNNECESSARY CHANGE).

BIT 7

1: SPINDLE ORIENTATION CANCEL BY “RST” IS

EFFECTIVE.

0: SPINDLE ORIENTATION CANCEL BY ”RST” IS NOT

EFFECTIVE.

B-15

< KEEP RELAY >

K07 7 6 5 4 3 2 1 0

LNKJG TE


BIT 0 TURRECT ERROR STATE ( UNNESSARY CHANGE )

BIT 1

BIT 2

1:THE SPINDLE NOT STOP WHEN BREAK VALUE ARRIVE.

(FOR LOAD MONITOR FUNCTION)

0:THE SPINDLE STOP WHEN BREAK VALUE ARRIVE.

(FOR LOAD MONITOR FUNCTION)

BIT 3

BIT 4

BIT 5

1: THE SET FROM JAPANESE CUSTOMER REQUEST (NO

DISPLAY EMG ALARM)

0: STANDARED

1: I/O LINK TURRET MANUAL ADJUST BY JOG IS

EFFECTIVE.

0: I/O LINK TURRET MANUAL ADJUST BY JOG IS NOT

EFFECTIVE.

BIT 6

BIT 7

B-16

< KEEP RELAY >

K08 7 6 5 4 3 2 1 0


BIT 0

BIT 1

BIT 2

BIT 3

BIT 4

BIT 5

BIT 6

BIT 7

B-17

< KEEP RELAY >

K09 7 6 5 4 3 2 1 0

SPRNMSH SPRNMSG SPRNMSF SPRNMSE SPRNMSD SPRNMSC SPRNMSB SPRNMSA


BIT 0

1: SPINDLE RUNING COMMAND M10 (CHUCK

UNCLAMP ) ,SPEED RANGE B

0: STANDARD SETTING

BIT 1


UNCLAMP ) ,SPEED RANGE C

0: STANDARD SETTING

BIT 2


UNCLAMP ) ,SPEED RANGE D

0: STANDARD SETTING

BIT 3


UNCLAMP ) ,SPEED RANGE E

0: STANDARD SETTING

BIT 4


UNCLAMP ) ,SPEED RANGE F

0: STANDARD SETTING

BIT 5


UNCLAMP ) ,SPEED RANGE G

0: STANDARD SETTING

BIT 6


UNCLAMP ) ,SPEED RANGE H

0: STANDARD SETTING

BIT 7


UNCLAMP ) ,SPEED RANGE I

0: STANDARD SETTING

B-18

< KEEP RELAY >

K10 7 6 5 4 3 2 1 0

MEG SBOTS BF542


BIT 0

1: STANDAR B/F (542) IS NOT EQUIPPED,

0: STANDAR B/F (542) IS EQUIPPED.

BIT 1

1: DH-65 B/F WITH PLC CONTROL IS EQUIPPED.

0: DH-65 B/F WITH PLC CONTROL IS NOT EQUIPPED.

BIT 2

1: IEMCA B/F IS EQUIPPED.

0: IEMCA B/F IS NOT EQUIPPED.

BIT 3

1: ARGENTINA B/F IS EQUIPPED.

0: ARGENTINA B/F IS NOT EQUIPPED .

BIT 4

1: MAGAZINE B/F IS EQUIPPED.

0: MAGAZINE B/F IS NOT EQUIPPED .

BIT 5

1: LNS B/F IS EQUIPPED.

0: LNS B/F IS NOT EQUIPPED .

BIT 6

1: USE TOPTEK’S LOADING & UNLOADING

0: NOT USE TOPTEK’S LOADING & UNLOADING

BIT 7

B-19

< KEEP RELAY >

K11 7 6 5 4 3 2 1 0

SRT


BIT 0

1: SAUTER TURRET ORIENTATION MODE SELECT.

0: SAUTER TURRET STANDARD MODE SELECT.

BIT 1

BIT 2

1:SOFT START STOP CANCEL SIGNAL IS USED

0: SOFT START STOP CANCEL SIGNAL IS UNUSED

BIT 3

BIT 4

BIT 5

BUILT IN SPINDLE AIR COOLANT SETTING

1: ACTIVE WHEN MACHINE READY

0: ACTIVE WHEN SPINDLE ROTATING

1:SPINDLE AND LIVE TOOL SYNCHRONIZATION

0: SPINDLE AND LIVE TOOL NON-SYNCHRONIZATION

BIT 6

1: FOR SPINDLE RUNNING TEST

0: STANDARD SETTING

BIT 7

1: SPINDLE TOTAL RUNNING TIME RESET IS EFFECTIVE.

0: SPINDLE TOTAL RUNNING TIME RESET IS NOT

EFFECTIVE.

B-20

< KEEP RELAY >

K20 7 6 5 4 3 2 1 0

M159 M151 BF SPLD IOLNK STTS


BIT 0

1: STANDAR TAILSTOCK IS NOT EQUIPPED.

0: STANDAR TAILSTOCK IS EQUIPPED.

BIT 1

1: I/O LINK TURRET IS NOT EQUIPPED.

0: I/O LINK TURRET IS EQUIPPED.

BIT 2

1: TAILSTOCK BY PMC AXIS CONTROL IS NOT EQUIPPED.

0: TAILSTOCK BY PMC AXIS CONTROL IS EQUIPPED.

BIT 3

1: SPINDLE LOAD MONIT IS EFFECTIVE.

0: SPINDLE LOAD MONIT IS NOT EFFECTIVE.

BIT 4

1:BAR FEEDER IS EQUIPPED.

0: BAR FEEDER IS NOT EQUIPPED.

BIT 5

1: LOAD MONITOR FUNCTION IS EQUIPPED.

0: LOAD MONITOR FUNCTION IS NOT EQUIPPED

BIT 6

BIT 7

1: M159~M166 CODE IS USED.

0: M159~M166 CODE IS NOT USED.

B-21

< KEEP RELAY >

K21 7 6 5 4 3 2 1 0

NAME&BIT

BIT 0

DESCRIPTION

1:DH-65 B/F WITHOUT PLC CONTROL IS EQUIPPED.

0: DH-65 B/F WITHOUT PLC CONTROL IS NOT EQUIPPED.

BIT 1

BIT 2

1:STEADY IS EQUIPPED.

0: STEADY NOT EQUIPPED.

BIT 3

1:SAUETR TURRET IS EQUIPPED.

0: SAUETR TURRET IS NOT EQUIPPED.

BIT 4

1: HYDRAULIC PROGRAMABLE TAILSTOCK IS EQUIPPED.

0: HYDRAULIC PROGRAMABLE TAILSTOCK IS NOT

QUIPPED.

BIT 5

1:EXTERNAL COUNTER IS EQUIPPED.

0: EXTERNAL COUNTER IS NOT EQUIPPED.

BIT 6

1:10 BAR COOLANT IS EQUIPPED.

0: 10 BAR COOLANT IS NOT EQUIPPED.

BIT 7

1: RIC POSITION CHUCK

IS EQUIPPED

0: RIC POSITION CHUCK

IS NOT EQUIPPED

B-22

< KEEP RELAY >

K22 7 6 5 4 3 2 1 0

NAME&BIT

BIT 0

DESCRIPTION

1:SUB-SPINDLE IS EQUIPPED.

0: SUB-SPINDLE IS NOT EQUIPPED.

BIT 1

1:LIVE TOOLING BY SERVO MOTOR.

0: LIVE TOOLING BY SPINDLE MOTOR.

BIT 2

1: CS AXIS CONTROL IS EQUIPPED.

0: CS AXIS CONTROL IS NOT EQUIPPED.

BIT 3

1: CF AXIS CONTROL IS EQUIPPED.

0: CF AXIS CONTROL IS NOT EQUIPPED.

BIT 4

1: LIVE TOOLING (E) IN 3TH.

0:OTHERS

BIT 5


0: OTHERS

BIT 6


0: OTHERS

BIT 7


0: OTHERS

B-23

< KEEP RELAY >

K23 7 6 5 4 3 2 1 0


BIT 0

1: B AXIS DEFINE IN 3TH.

0: OTHERS

BIT 1


0: OTHERS

BIT 2


0: OTHERS

BIT 3


0: OTHERS

BIT 4


0: OTHERS

BIT 5


0: OTHERS

BIT 6


0: OTHERS

BIT 7


0: OTHERS

B-24

< KEEP RELAY >

K24 7 6 5 4 3 2 1 0


BIT 0

1:HYDRAULIC TURRET IS EQUIPPED.

0: HYDRAULIC TURRET IS NOT EQUIPPED.

BIT 1

1:GS-400 SERIES SPINDLE HIGH/LOW SPEED IS

EQUIPPED.

0: OTHERS.

BIT 2

1:PARTS CATCHER IS EQUIPPED.

0: PARTS CATCHER IS NOT EQUIPPED.

BIT 3

1: SPINDLE CHUCK SECOND PRESSURE IS EQUPPID.

0: SPINDLE CHUCK SECOND PRESSURE IS NOT EQUPPID.

BIT 4

1:SUB-SPINDLE COOLANT IS EQUPPID.

0: SUB-SPINDLE COOLANT IS NOT EQUPPID.

BIT 5

BIT 6

BIT 7

1: SECOND PNEUMATIC CHUCK(OUTSIDE) IS EQUIPPED.

0: SECOND PNEUMATIC CHUCK(OUTSIDE) IS NOT

EQUIPPED.

1: ZF HIGH/LOW IS EQUIPPED

0 ZF HIGH/LOW IS NOT EQUIPPED

1: SPINDLE COOLANT IS EQUIPPED

0: SPINDLE COOLANT IS NOT EQUIPPED

B-25

< KEEP RELAY >

K25 7 6 5 4 3 2 1 0


BIT 0

1:SECOND C AXIS DEFINE AT 5

TH

.

0:OTHERS.

BIT 1

1: SECOND C AXIS DEFINE AT 6

TH

.

0: OTHERS.

BIT 2


TH

.

0: OTHERS.

BIT 3

BIT 4

BIT 5

BIT 6

BIT 7


TH

.

0: OTHERS.

1:LIVE TOOL IS EQUIPPED.

0:LIVE TOOL IS NOT EQUIPPED.

1: C

S

AXIS MODE IS NOT CANCEL BY RESET KEY

0: C

S

AXIS MODE IS CANCEL BY RESET KEY

1: SPINDLE OIL COOLANT IS EQUIPPED

0: SPINDLE OIL COOLANT IS NOT EQUIPPED

1: MANUAL STEADY IS EQUIPPED

0: HYDRAULIC STEADY IS EQUIPPED

B-26

< KEEP RELAY >

K30 7 6 5 4 3 2 1 0

PMCOF PMCPO


BIT 0

BIT 1

BIT 2

1:CHUCK ACTIVE WHEN FOOTSWITCH STEP ON

0: CHUCK ACTIVE WHEN FOOTSWITCH RELEASE

1:TAILSTOCK CONNECTION PIN CAN BE OUT AT ANY

POSITION Z-AXIS.

0: TAILSTOCK CONNECTION PIN CAN NOT BE OUT AT

ANY POSITION , JUST ONLY AT MEMORY POSITION

FOR Z-AXIS.

1:TAILSTOCK PIN-OUT SENSOR IS EFFECTIVE.

0: TAILSTOCK PIN-OUT SENSOR IS NOT EFFECTIVE.

BIT 3

BIT 4

BIT 5

1: PMC TAILSTOCK BRAKE WITH PROXIMITY SWITCH.

0: PMC TAILSTOCK BRAKE WITHOUT PROXIMITY SWITCH.

1:SPLASH PLATE IS NOT EQUIPPED BETWEEN STEADY

AND TAILSTOCK

0: SPLASH PLATE IS EQUIPPED BETWEEN STEADY AND

TAILSTOCK

1: FOLLOW REST IS EQUIPPED

0: FOLLOW REST IS NOT EQUIPPED

BIT 6

BIT 7

B-27

< KEEP RELAY >

K31 7 6 5 4 3 2 1 0


BIT 0

BIT 1

BIT 2

BIT 3

1:COOLANT FLOW CHECK IS EQUIPPED

0: COOLANT FLOW CHECK IS NOT EQUIPPED

1:HARDWARE TYPE WORKPIECE CUT CHECK

0: SOFTWARE TYPE WORKPIECE CUT CHECK

1: BUILT IN ROBOT IS EQUIPPED

0: BUILT IN ROBOT IS NOT EQUIPPED

BIT 4

BIT 5

1: RENISHAW LTO2 WORKPIECE MEASUREMENT IS

EQUIPPED

0: RENISHAW LTO2 WORKPIECE MEASUREMENT IS NOT

EQUIPPED

BIT 6

BIT 7

B-28

< KEEP RELAY >

K32 7 6 5 4 3 2 1 0

M=2


BIT 0

1: COOLANT LEVEL SENSOR TYPE SETTING (NORMAL

OPEN)

0: COOLANT LEVEL SENSOR TYPE SETTING (NORMAL

CLOSE)

BIT 1

1: AIR CONDITIONER ERROR SENSOR TYPE SET

(NORMAL OPEN)

0: AIR CONDITIONER ERROR SENSOR TYPE SET

(NORMAL CLOSE)

BIT 2

BIT 3

BIT 4

1:LIVE TOOL DEFINE AS 2

0: LIVE TOOL DEFINE AS 3

ND

RD

SPINDLE

SPINDLE

BIT 5

BIT 6

BIT 7

B-29

< KEEP RELAY >

K33 7 6 5 4 3 2 1 0


BIT 0

BIT 1

BIT 2

1:TWO COOLANT MOTORS ARE INDEPENDENT OF

CONTROL

0:SECEND COOLANT MOTOR IS DEPENDENT ON FIRST

MOTOR

1: GEAR BOX WITH NEUTRAL

0: GEAR BOX WITHOUT NEUTRAL

BIT 3

BIT 4

BIT 5

BIT 6

BIT 7

1: GEAR LUBE WITH PRESSURE SENSOR

0: GEAR LUBE WITHOUT PRESSURE SENSOR

1: ARBITRARY SPEED THREADING ENABLE

0: ARBITRARY SPEED THREADING DISABLE

1: BANNER ULTRASONIC LEVEL SENSOR IS EQUIPPED.

0: BANNER ULTRASONIC LEVEL SENSOR IS NOT

EQUIPPED.

1: B AXIS TORQUE LIMIT SKIP FUNCTION ENABLE

0: B AXIS TORQUE LIMIT SKIP FUNCTION DISABLE

B-30

< KEEP RELAY >

K34 7 6 5 4 3 2 1 0

LDMSL SSPR


BIT 0

BIT 1

SUB SPINDLE ROTATE SELECT

1:M203:CCW, M204:CW

0:M203:CW, M204 CCW

BIT 2

BIT 3

BIT 4

BIT 5

BIT 6

BIT 7

1:SPINDLE CYLINDER COVER SENSOR IS EQUIPPED

0: SPINDLE CYLINDER COVER SENSOR IS NOT EQUIPPED

1: AIR CONDITIONER ALARM CHECK IS EQUIPPED

0: AIR CONDITIONER ALARM CHECK IS NOT EQUIPPED

1:

0:

1: USE LOAD MONITOR DURING CUTTING

0: LOAD MONITOR IS NOT EQUIPPED

B-31

< KEEP RELAY >

K35 7 6 5 4 3 2 1 0

SPLMT LVTL=3 LVTL=2 PUSH SVTS SPLFL

NAME&BIT

BIT 0

DESCRIPTION

1:SPINDLE LUBUCATE FLOW CHECK IS EQUIPPED

0: SPINDLE LUBUCATE FLOW CHECK IS NOT EQUIPPED

BIT 1

BIT 2

BIT 3

BIT 4

BIT 5

BIT 6

BIT 7

1:NEW TYPE SERVO TAILSTOCK IS EQUIPPED

0: NEW TYPE SERVO TAILSTOCK IS NOT EQUIPPED

1:CR CYLINDER PARTS EJECT IS EQUIPPED

0: CR CYLINDER PARTS EJECT IS NOT EQUIPPED

1:SERVO MOTOR LIVE TOOL DEFINE AS 2

ND

SPINDLE

0:FANUC FUNCTION “SPINDLE CONTROL WITH SERVO

MOTOR” IS NOT EQUIPPED

1: SERVO MOTOR LIVE TOOL DEFINE AS 3

RD

SPINDLE

0:FANUC FUNCTION “SPINDLE CONTROL WITH SERVO

MOTOR” IS NOT EQUIPPED

1: THE GEAR BOX OF SPINDLE USE MOTOR TYPE TO

LUBRICATION

0: NO LUBRICATOR OR THE GEAR BOX IS NOT EQUIPPED

B-32

< KEEP RELAY >

K36 7 6 5 4 3 2 1 0

XHZH ZF=34 SRSN AMSPR


BIT 0

BIT 1

BIT 2

BIT 3

1:SPINDLE WILL NOT STOP ROTATE WHEN AUTO MODE

SWITCH TO MANUAL MODE.

0: SPINDLE STOP ROTATE WHEN AUTO MODE SWITCH

TO MANUAL MODE.

THE CRUSHPROOF TYPE OF TAILSTOCK AND STEADY.

1:NORMAL OPEN TYPE

0:NORMAL CLOSE TYPE

BIT 4

BIT 5

BIT 6

BIT 7

1: ZF H/L FOR 3&4 GEAR SETTING

0: STANDARD SETTING

1:

0:

1:Z AXIS CAN RETURN TO ZERO POINT AFTER X AXIS

RETURN TO ZERO POINT .

0: Z AXIS CAN RETURN TO ZERO POINT WHEN X AXIS AT

ANY POINT.

B-33

< KEEP RELAY >

K37 7 6 5 4 3 2 1 0

TSBK CLIND2

NAME&BIT

BIT 0

DESCRIPTION

1: TWO COOLANT MOTORS ARE INDEPENDENT OF

CONTROL

0:COOLANT 1 AND COOLANT 2 ARE INTERLOCK.

BIT 1

BIT 2

1:

0:

1: TAILSTOCK BRAKE SOLENOID AND PIN OUT SOLENOID

ARE INDEPENDENT OF CONTROL.

0:. TAILSTOCK BRAKE SOLENOID ACTIVE WHEN PIN OUT

SOLENOID ACTIVE AT THE SAME TIME .

BIT 3

BIT 4

BIT 5

BIT 6

BIT 7

B-34

< KEEP RELAY >

K38 7 6 5 4 3 2 1 0

SSPLLH SPLLH DSCAI SMMS 3CFS ADNYS


BIT 0

BIT 1

BIT 2

1: AUTO DOOR CAN’T BE ACTIVE WHEN SENSOR NO

DETECTION

0: AUTO DOOR CAN BE ACTIVE WHEN SENSOR NO

DETECTION

1:

0:

1: 3 COLORS LAMP SELECT ALWAYS ON TYPE

0:.3 COLORS LAMP SELECT FLASH TYPE

BIT 3

BIT 4

1: SPINDLE AND LIFETOOL CAN TURNING

SIMULTANEOUSLY

0:. SPINDLE AND LIFETOOL CAN’T TURNING

SIMULTANEOUSLY

1: ALL AXES ARE INTERLOCK WHEN DOOR OPEN

0: ALL AXES ARE NOT INTERLOCK WHEN DOOR OPEN

BIT 5

BIT 6

BIT 7

1: SPINDLE HIGH/LOW POWER LINE IS EQUIPPED

0: SPINDLE HIGH/LOW POWER LINE IS NOT EQUIPPED

1: SUB SPINDLE HIGH/LOW POWER LINE IS EQUIPPED

0: SUB SPINDLE HIGH/LOW POWER LINE IS NOT

EQUIPPED

B-35

4 Counter function

No.

DATA

ADDRESS

1 C1

POWER “ON”.

DESCRIPTION

2 C2

TRIP.

15 C56

WHEN SETTING VALUE ARRIVAL

B-36

5 DATA function

DATA ADDRESS

D50

DESCRIPTION

T-CODE ALARM SETTING

D59

D62

D70

D72

D74

D75

D51

D52

D53

D54

D55

D56

D57

D58

SPINDLE JOG SPEED (LOW BYTE)

SPINDLE JOG SPEED (HIGH BYTE)

SPINDLE MANAUL SPEED (LOW BYTE)

SPINDLE MANAUL SPEED (HIGH BYTE)

TOOL SETTER NUMBER SETTING

SUB-SPINDLE MANAUL SPEED (LOW BYTE)

SUB-SPINDLE MANAUL SPEED (HIGH BYTE)

OPERATE PANEL STATUS STORAGE

OPERATE PANEL STATUS STORAGE

CHUCK AND QUILL STATUS STORAGE

TOOL NUMBER SETTING

LIVE TOOL MAXIMUX SPEED SETTING

LIVE TOOL MANAUL SPEED (LOW BYTE)

LIVE TOOL MANAUL SPEED (HIGH BYTE)

B-37

Appendix C

OPTIONAL TOOL HOLDERS

Content

C.

Optional tool holders ..................................................................... C-1

C-1 Tool holders for CZ-3104/3304 turret head (lifting turret disk technology)

.................................................................................C-1

C-2 Tool holders for CR-3004 turret head (non-lifting turret disk technology)

.................................................................................C-9

*Please refer to Ch 2.8 Tooling interference to avoid damage of machine or oprator when chosing optional tool holders.

C

C. Optional tool holders

C-1 Tool holders for CZ-3104/3304 turret head (lifting turret disk technology)

Part NO CZ-3107B Part Name Face Cutting Tool Holder

Part NO CZ-3107X Part Name Face Cutting Tool Holder

C-1

Part NO CZ-3129 Part Name O.D. Cutting Tool Holder

Part NO CZ-3130 Part Name O.D. Cutting Tool Holder

C-2

Part NO CZ-3098 Part Name Double Boring Bar Holder

Part NO CZ-3099 Part Name Double Boring Bar Holder

C-3

Part NO CZ-3108A Part Name

Boring Bar Holder / Throw-away

Drill Holder

Part NO CZ-3108B Part Name


Drill Holder

C-4

Part NO CZ-3108X Part Name


Drill Holder

Part NO CZ-3108Z Part Name


Drill Holder

C-5

Part NO CZ-3120 Part Name


Drill Holder



Drill Holder

C-6



Drill Holder



Drill Holder

C-7

Part NO CZ-31A8B Part Name


Drill Holder

Part NO CZ-31A9 Part Name


Drill Holder

C-8

C-2 Tool holders for CR-3004 turret head (non-lifting turret disk technology)

Part NO CR-3111A Part Name Face Cutting Tool Holder

Part NO CR-3105A Part Name Cut-off Tool Holder

C-9

Part NO CR-3085A Part Name O.D. Cutting Tool Holder

Part NO CR-3085B Part Name O.D. Cutting Tool Holder

C-10


Part NO CR-3081 Part Name O.D. Cutting Tool Holder

C-11


Part NO CR-3071 Part Name


Drill Holder

C-12

Part NO CR-3071A Part Name


Drill Holder



Drill Holder

C-13

Part NO CR-3087 Part Name


Drill Holder

Part NO CR-3084A Part Name Boring Bar Holder

C-14

Part NO CR-30F8 Part Name


Drill Holder

Part NO CR-30F7 Part Name Boring Bar Holder

C-15

Part NO CR-30F3 Part Name Boring Bar Holder

Part NO CR-3084B Part Name Boring Bar Holder

C-16

Part NO CR-3089 Part Name Boring Bar Holder


C-17

Part NO CR-3084C Part Name Boring Bar Holder

Part NO CR-3084D Part Name Boring Bar Holder

C-18




Drill Holder

C-19


Part NO Part Name

C-20

Appendix D

Content

Question & Answers of CEN-03 Type lubrication system ....................................... D-1

D

Operation Manual GS 200 Series

OPERATION MANUAL

MODEL：GS-200/L Series

INSTRUCTION MANUAL FOR CNC TURNING CENTER

3 (4.1) (α2/5000i)

θ

θ

θ

π

Appendix A.

1 ALARM MESSAGE (for FANUC 0I-TD Controller)

1-1 Various alarms and trouble shutting

2 Turret resetting procedure

1 ALARM MESSAGE (for FANUC 0I-TD Controller)

2 Turret resetting procedure

I. Resetting turret reference position:

4. Press +X button（CW）or –X button（CCW） to rotate the turret to TOOL NO. 1.

“+X” or “-X” button.

II. Tool number resetting

Appendix B.

(for FANUC 0I-TD Controller)

1-2 M-Code function

2 TIMER function

3 Keep relay setting

4 Counter function

5 DATA function

1 G-Code and M-Code function

1-1 G-Code function

1-2 M-Code function

2 TIMER function

3 Keep relay setting

4 Counter function

5 DATA function

Appendix C

OPTIONAL TOOL HOLDERS

C-1 Tool holders for CZ-3104/3304 turret head (lifting turret disk technology)

C-2 Tool holders for CR-3004 turret head (non-lifting turret disk technology)

C. Optional tool holders

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