FADAL VMC 3020 Manuel utilisateur

SIEMENS CONTROL

Operator Manual

Fadal

2 : October 2000

SIEMENS CONTROL

Operator Manual

Fadal

Table of Contents

Siemens Manual Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pre-start-up Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pendant Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pendant Hard Keys Function Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Finding Machine Reference (Cold Start) . . . . . . . . . . . . . . . . . . . . . 16

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Manual Data Automatic (Submode of Manual display) . . . . . . . . . . 19

Jog Modes Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Position Readout Display In Jog Mode. . . . . . . . . . . . . . . . . . . . . . 20

Incremental Jog Using The MPG Or JOG Keys . . . . . . . . . . . . . . . . 21

Setting the Increment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Using MPG hand wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Jog and Rapid Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Tool, Manually Loading & Unloading a Holder. . . . . . . . . . . . . . . . 25

Tools, Loading a Holder from the ATC . . . . . . . . . . . . . . . . . . . . . . 26

Establishing Spindle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Spindle Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Spindle Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Settable Frames - Workpiece Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Machine Coordinate System vs. Work Coordinate System: . . . . . . . 29

Definitions of Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Base Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Zero Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Tool Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Using the SET BASE soft key to set the Base Offset . . . . . . . . . . . . . 33

Using the MEASURE WORKPIECE soft key to set Base/Zero Offsets . 36

Using the MEASURE TOOL soft key to set the Tool Offset . . . . . . . 41

Using the ZERO OFFSET soft key to set the Base and Zero Offsets . . 44

Using the TOOL soft key to set the Tool Offsets . . . . . . . . . . . . . . . 46

Setting Tool Length Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Tool Diameter Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Tool Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Magazine Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

R Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Coolant, Using the Coolant 1 and Coolant 2 Buttons . . . . . . . . . . . 53

To Create a New Program for Auto. . . . . . . . . . . . . . . . . . . . . . . . 55

Editing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Choosing a Program to Run in Auto . . . . . . . . . . . . . . . . . . . . . . . . 57

Auto, Running a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Mid-tape (Program) Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Dual Arm Tool Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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Operator Manual

Fadal

Important Safety Information

Siemens Manual Safety Notices

Warning The following notes are given to ensure your safety and to prevent any risk

of damage to the product described or other units connected to the

machine.

Warning When electrical equipment is in operation, certain parts are bound to

reach hazardous voltage levels.

The intermediate circuit of all SIMODRIVE modules remains at a hazardous

voltage level for 5 minutes after all voltages have been disconnected. See

the Instruction Manual for more details.

Only qualified personnel should perform maintenance on the device/

system. Failure to comply with warnings can result in severe injury or

material damage. Only suitably qualified personnel trained in the setup,

installation, commissioning or operation of the product should work on

the device/system.

Further Notes Whenever measuring or testing has to be performed on live equipment,

the regulations of Safety Code VBG 4.0 must be observed, in particular §

8 “Permissible Deviations when Working on Live Parts”. Suitable

electronic tools should be used.

Danger This symbol appears whenever death, severe bodily injury or substantial

material damage will occur if the appropriate precautions are not taken.

Warning This symbol appears whenever death, severe body injury or substantial

material damage could occur if the appropriate precautions are not taken.

Caution This symbol appears whenever minor body injury or material damage can

occur if the appropriate precautions are not taken.

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Important This symbol appears in the documentation whenever attention has to be

paid to something of particular importance.

Note This symbol appears in the documentation whenever a reference is made

to another subject.

Warning Repairs on equipment supplied by Fadal may only be carried out by Fadal

Service or repair centers authorized by Fadal using authorized genuine

Fadal supplied parts. Any defective parts or components are to be

replaced only by parts contained in the relevant spare parts list.

Disconnect the power supply before opening the equipment.

Emergency Stop facilities according to EN 60204 IEC 204 (VDE 0113) must

remain operative in all operating modes of the automation equipment.

Any disengaging of the Emergency Stop facility must not lead to

uncontrolled or undefined restart.

Whenever faults occurring in the automation equipment can lead to

substantial material damage or even grievous bodily injury, (i.e. are

potential dangerous faults), additional external precautions must be taken

or facilities must be provided ensuring or enforcing safe operation even

when a fault occurs (e.g. independent limit switches, mechanical

interlocks, etc.)

Caution Connecting and signal lines must be installed so as to safely prevent

inductive and capacitive interference from affecting automation functions.

Warning Correct transport, storage, erection and mounting as well as careful

operation and maintenance are essential for proper and safe operation of

the equipment. Non–compliance with warnings can result in severe bodily

injury or material damage.

Warning The modules contain electrostatically sensitive components. Before

touching an electronic module, it is necessary to be electro-statically

discharged. The simplest way of doing this is to touch an electrically

conducting grounded object (e.g. a bare metal part of a switchboard or a

plug socket protective conductor) before touching an electronic module.

October 2000 Important Safety Information: Electrostatically Sensitive Modules 5

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ESD notes Electrostatically Sensitive Modules

Important!

Handling of ESD modules:

When handling electrostatically sensitive devices, make sure that operator,

workplace and packing material are properly grounded.

Generally, electronic modules must not be touched unless work has to be

carried out on them. When handling PC boards make absolutely sure that

you do not touch component pins or printed conductors.

Touch components only if

–you are permanently grounded by means of an antistatic chain,

–you are wearing ESD (Electro Static Device) boots or ESD boots

with grounding strips in conjunction with ESD flooring.

Modules may only be placed on electrically conductive surfaces (tables

with ESD tops, conductive ESD foam plastic, ESD packing bags, and/or

ESD transport containers).

Keep modules away from visual display units, monitors or TV sets (the

minimum distance from screen must be more than 10 cm).

Modules must not be allowed to come into contact with electrically

insulating materials such as plastic films, insulating table tops or clothing

made of synthetic fibers.

Measurements on modules are allowed only if:

–the measuring instrument is properly grounded (e.g. equipment

grounding conductor), or

–the probe is briefly discharged before measuring with a potential-

free measuring instrument (e.g. touch the unpainted metal parts

of the control housing)

The equipment may be used only for the applications stated in the manual

and only in conjunction with devices and components recommended and

authorized by Fadal.

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Should any questions or problems arise in studying this manual, please

contact the Fadal Service Department.

Safety Warnings

1) WARNING! WEAR ANSI OR CE APPROVED SAFETY GLASSES AT ALL

TIMES. Everyday glasses are not designed for protection. Only ANSI or CE

approved safety glasses have impact resistant lenses. Hearing protection

must be worn when operations exceed 90 decibels (85 decibels-CE) .

2) KEEP DOORS CLOSED WHILE MACHINING.

3) WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties,

rings, bracelets, or other jewelry that might get caught in moving parts or

areas of potential electric shock. Non-slip footwear is recommended.

4) CONTAIN LONG HAIR. Tie long hair back and wear protective hair

covering to contain long hair.

5) USE A NIOSH OR CE APPROVED DUST MASK OR RESPIRATOR.

Protection is recommended when cutting operations are dusty, or exceed

the permissible exposure limit.

6) KEEP WORK AREA CLEAN. Good housekeeping practices encourage

safety.

7) Read SPINDLE, MANUALLY LOADING & UNLOADING A HOLDER in the

Operator’s Manual.

8) DO NOT OPERATE THE MACHINE UNDER THE INFLUENCE OF DRUGS

OR ALCOHOL, PRESCRIBED OR OTHERWISE.

9) READ THE SAFETY WARNINGS SUPPLIED WITH ALL TOOLING.

10) MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best

performance and to reduce the risk of injury. Follow instructions for

lubrication and for changing accessories.

11) REMOVE ADJUSTING KEYS AND WRENCHES. Always check that keys

and wrenches are removed from tools and tooling before starting the

machine.

12) DO NOT EXCEED THE MANUFACTURER’S RECOMMENDED

MAXIMUM RPM FOR THE TOOL. When tools are placed in the spindle,

October 2000 Important Safety Information: Important! 7

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Operator Manual

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verify the current RPM commanded in the control before starting the

spindle.

13) SECURE TOOLS PROPERLY IN THEIR HOLDERS.

14) SECURE WORK. Use common machining practices for holding

(fixturing) material to be machined.

15) REMOVE ALL TOOLS FROM THE SPINDLE AND TOOL CHANGER before

servicing and changing accessories such as tooling, fixtures, indexers, the

tail stock of a fourth axis and any fourth axis or fourth-fifth axis

combination, etc.

16) ALWAYS DEBUG A NEW PROGRAM before running it in the AUTO

mode. (See DEBUG PROGRAM in the User’s Manual.)

17) The machine tool MUST be connected to a grounded, metal,

permanent wiring system, or to a system having an equipment-grounding

conductor.

18) DO NOT OPERATE THE MACHINE IN AN UNSAFE ENVIRONMENT. Do

not use the machine in damp or wet locations, or expose to rain. Keep the

work area well lighted.

19) DO NOT FORCE TOOL. Tools are designed to perform properly and

safely at proper rates. Keep tools sharp.

20) USE THE CORRECT TOOL. Do not attempt to use tools or attachments

to perform a job for which they were not designed.

21) DON’T OVERREACH. Keep proper footing and balance at all times.

Use a steady object for support when reaching over the machine.

22) REDUCE THE RISK OF UNINTENTIONAL STARTING. Power off the

machine at the main disconnect switch and use the proper lockout/tagout

procedures while working within the chip enclosure, or when there is

potential for a release of energy.

23) POWER OFF THE MACHINE AT THE MAIN DISCONNECT SWITCH AND

LOCK OUT WHEN WORKING INSIDE ANY OF THE ELECTRONIC CABINETS.

24) USE RECOMMENDED ACCESSORIES. Refer to the User’s Manual for

FADAL recommended accessories. Unapproved accessories increase the

risk of injury.

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25) NEVER STAND ON OR IN THE MACHINE. Besides the risk of slipping or

falling, serious injury could occur if a tool is unintentionally contacted.

26) CHECK FOR DAMAGED PARTS. Always check all parts for binding,

breakage, and any other condition that will affect the proper operation of

the machine and/or increase the risk of injury. Damaged or missing parts

must be repaired or replaced BEFORE operating the machine.

27) NEVER LEAVE THE MACHINE UNATTENDED. Turn the power off to the

machine when leaving the machine unattended. Never leave the machine

until it comes to a complete stop.

28) DO NOT DISCONNECT THE FRONT DOOR SAFETY SWITCHES.

29) WIPE UP SPILLS. Immediately cover with absorbent material and wipe

up coolant and oil spills around the machine. Correct the cause of the

leakage to prevent any hazards.

30) ELECTRICAL INSTALLATION OF THE MACHINE MUST BE DONE BY A

QUALIFIED ELECTRICIAN.

31) ONLY FADAL OR FADAL DISTRIBUTOR FACTORY AUTHORIZED

INDIVIDUALS MAY INSTALL THE MACHINE.

32) USE PROPER SAFETY GLOVES WHEN HANDLING SHARP OR JAGGED

EDGES. Do not wear gloves around rotating machinery.

33) DO NOT USE AIR HOSES TO BLOW CHIPS OFF YOUR BODY OR

CLOTHES. Serious injury to your eyes, hearing, and skin could result. Do

not blow towards others.

October 2000 Fadal/Sinumerik 810D CNC: Power On 9

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Operator Manual

Fadal

Fadal/Sinumerik 810D CNC

Power On

Pre-startup Checks

1) Examine the oil levels. Both should be filled before the levels are

one inch from the bottom of the reservoir. The spindle oil

reservoir may have oil in it for up to six months. The way lube oil

reservoir may run out of oil in one week.

Note: VMCs with linear way systems require grease. See the Maintenance

Manual for specifications on the way lube and the spindle oil.

2) Visually inspect the air pressure gauge to verify that it is set to at

least 80-100 PSI. Air is used to change belt ranges in the spindle,

orient the spindle, activate the tool in-out cylinder, and for the

air blast during a tool change. The tool changer gauge should

not exceed 120 PSI.

3) Most new VMC models release water collected in the water

reservoir automatically. It is advisable to place an additional

water trap in the air line going to the machine.

10 Fadal/Sinumerik 810D CNC: Power On October 2000

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Operator Manual

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4) Replenish the flood coolant level to avoid running out of coolant

during execution of the program.

5) Examine the spindle cooler reservoir once a month.

6) To power on the machine, press the safety lock and turn the

power switch in the clockwise direction.

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