Kafo hmc-500 OM
Kafo hmc-500 OM
Kafo hmc-500 OM
,LTD
1-1
Intended use
Machine life
2-2 Out-looking
HMC-400
2385
5410 4410
3820
1000
590
910
3290
3290 2385
590
560
485
1105
2020
367
652
2514
2-1
2830
6385
4630
1000
1050
755
755
685
448
1788
1710
1285
508
703
2-2
3150
870.5
5687.5
1000
4550
2-3
NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Name Built-in motor Work table B axis servo motor ATC Cam ATC Slowup Motor Hydraulic unit Air dryer Oil Cooler Electrical Cabinet Oil spray unit Oil infusion unit X axis servo motor Y axis servo motor Z axis servo motor Operation Cabinet Auto exchange table Coolant tank Chip conveyor Liquid-Chip Separator
Q`ty 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2-4
Remark 10000rpm/BT-50 FANUC-B160LL/13000i FMH-500P2(0.001) 22/3000i-4kw A505-ARM300 ATC-40T(BT-50) GF200-50-A2-1/4HP-1:90 DAT-10G HBO-2RPTSBM2 SHOWA-MOA-0 YET-C2-3L 30/3000i-5kw 30/3000i-5kw 22/3000i-4kw APC-T500 FCS-50L
2-4 Specification
AXES HORIZONTAL MACHINING CENTER X axis Y axis Z axis Rapid travel (X,Y,Z axis) Cutting speed Spindle nose to table Spindle nose to table center Table to floor X axis motor Y axis motor Z axis motor B axis motor Guide way Linear scale BALL SCREW(center coolant) Table working area Pallets Loading capacity Max. working area APC changing time Table index Linear scale Spindle speed Spindle transmission Spindle power Tool shank MAGAZINE Magazine capacity (ST) Magazine capacity (OP) Max. tool dia. Max. tool dia.(without adjacent tool) Max. tool length Max. tool weight Chip to Chip time Tool to Tool time CONTROLLER FANUC ACCESSORIES Tank capacity DIMENSIONS Floor areadth Machine Height Net Weight L mm mm kg 370 5410x3290 2830 9000 18i M standard option mm mm mm kg sec sec kw HMC-400 mm mm mm m/min m/min mm mm mm 630 560 560 24(40) 10 50-610 130-690 1100 4kw 4kw 4kw 3kw Linear option option 400x400 2 550 600/720 9 0.001 option 15000 Built-in 18.5/22 BT-40 40 60 75 150 300 8 9 3.5
Table
SPINDLE rpm
2-5
Table
SPINDLE rpm
2-6
Table
SPINDLE rpm
2-7
OPTIONS
1 2 3 4 5 6 COOLING THROUGH TOOL & TOOL HOLDER AUTO TOOL LENGTH MEASUREMENT WORK PIECE MESUREMENT SYSTEM LINEAR SCALE TRANSFORMER COOLANT THROUGH SPINDLE 7 8 9 10 11 CE SPEC. CSA SPEC. EMC SPEC. ALARM BEEPER RAPID SPEED 40MT/MIN
2-8
KAO FONG MACHINERY CO.,LTD 2-6 Work table and fixing holes
HMC-400
A-A(1:1)
B-B(1:1)
HMC-500
A-A(1:1)
B-B(1:1)
2-9
A-A(1:1)
B-B(1:1)
2-7
2-10
HMC-500/630 BT-50
HMC-500/630
CAT-50
2-11
KAO FONG MACHINERY CO.,LTD 2-8 Operation position and noise values
!
Danger area
2-12
KAO FONG MACHINERY CO.,LTD 2-9 Location of warning sign, label and nameplate
Warning sign
2-13
OD= 150 W= 8
mm Kg
OD= 250 mm W= 20 Kg
Designation sign
OD
OD
2-14
L
OD
OD= 150 W= 8
mm Kg
L
OD
OD= 250 mm W= 20 Kg
3AC MAX
220 50 96
v
Hz A 22 KVA
RATED CAPACITY
OD
MAX. OD =
W
H
700
mm
MAX. H =
800
mm
MAX. W =
800
kg
Max.spindle speed
10000 mm
-1
2-15
v
Hz A 22 KVA
RATED CAPACITY
MAX. OD =
W
H
700
mm
MAX. H =
800
mm
MAX. W =
800
kg
HMC-400 MAX D = 600 mm MAX H = 720 mm MAX W = 550kg HMC-500 MAX D = 700 mm MAX H = 800 mm MAX W = 800kg HMC-630 MAX D = 1050 mm MAX H = 1000 mm MAX W =1200kg
Manufacture nameplate
HORIZONTAL MACHINING CENTER
MODEL NO: HMC500 DATE: SERIAL NO: KAO FONG MACHINERY CO., LTD.
NO.2 LANE 128, SECTION 1, CHUNG CHIN ROAD, TAYA, TAICHUNG, TAIWAN, R.O.C. P.O.BOX:2248 TAYA, TAIWAN, R.O.C. TEL: (04)25662116 FAX: (04)25671001
Max.spindle speed
10000 mm
-1
2-16
Designation sign
Hydraulic required
Spindle Tool APC A AXIS B AXIS ATC 35 60 50 50 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2
Pneumatic required
Pneumatic required 5~7 Kg/cm2
Lubrication inlet
An outlet
Earthed point
Isolator
2-17
Spindle Running-in Procedures Case 1 Ordinary operation 2 Spindle rests over 72 hours Spindle speed (Percentage of max. speed) 20% 1. 25% 2. 50% 1. 2. 3. 4. 20% 40% 60% 80% Max. speed Warning Time (min) 10 10 10 15 15 *30 *30 *40 Check points 1.Temperature-rise Within 20C 2.Vibration 3.Noise 1.Temperature-rise Within 20C 2.Vibration 3.Noise 1.Temperature-rise Within 20C 2.Vibration 3.Noise 4.Proceed to next stage after temperature stabilizes
(2)If temperature-rise is over 20C , reduce spindle speed to 800rpm , then restart the procedure after the spindle temperature has cooled off to within 5C above the ambient temperature
Usually, there are some chips under rotary table and on APC plate. Thus, please use air gun to clean the chips on daily shift or clean them regularly.
Z
(1) Cutting oil check from time to time. (check the level through meter) (2) Clean chips and dirt remained in the tank as well as the filter plate. (3) Clean chips on the filter plate cyclically.be careful to wear safety gloves and use tools like clamp to do this work.
2-18
Main machine Unit Item HMC-400 HMC-500 HMC-630 A(cm) 4340 515 620 B(cm) 2885 350 342 C(cm) 3080 340 360 Weight (kgw) 11000 17500 22000 Forks(m) 2 2.4 3
Option equipment Unit Item HMC-400 HMC-500 HMC-630 A(cm) 273 303 410 B(cm) 224 224 300 C(cm) 215 215 220 Weight (kgw) 1800 2100 3000 Forks(m) 2 2.4 3
C (cm)
3-19
Transportationunpackage
Machines hang up
1. Hang machine on positions shown drawing below. 2. Ensure all hang up wires and cables are qualified in duty. 3. Carefully with all machines pipes, cables, wires, units during hanging up. 4. Check & locking all hydraulic & lubrication units to preventing oil leaking. Required cables:A:25L3200mm;B:25L3300mm;C:25L3600mm
3-20
HMC-500
Concrete
Broken stone
3-21
5.Do not install the machine on a slope or unstable place. 6.Please connect the electric power and make sure the ground wire is connected correctly
3-22
1000
Dimension
Type
KAO FONG MACHINERY CO.,LTD 3-5 Instruction for how the initial test and examination of the machine 3-5.1 Fixing frames remove
1. Remove the fixing frames when machine positioned (located as drawing shows) Attention: Make sure the frames removed before test running start.
Fixing Frame Fixing Frame Fixing Frame
Fixing Frame
Fixing Frame
2. Steps of positions adjustment: firstly positions1234, and secondly positions 5678. (refer to drawing below)
3-24
Lifting Block(Up) Adjust Bolt Lifting Seat Lifing Block(Down) Foundation Block
Base Blot
3. Set the work table into position and precise leveling adjust through axes moving.
(O)
(X)
10 10 15 15 30 30 40
3-26
KAO FONG MACHINERY CO.,LTD 3-5.7 Operation of spindle clamp/unclamp clamp/unclamp button in spindle This is only used in probe or small tools, do not put on normal tools hear.
The method of clamp/unclamp (1)Step the tool to right position when it stopput on with two hands Be careful: it is very dangerous when you put on the tools by one handplease put on the tools with two hands because the tools can reach 20 Max mass
3-27
3-28
Separator
Oil Cooler
Hydraulic
Air Dryer
EA EC EB
Electric Box
EF
ED
EE
EI
EH EG
EL EK EJ
Item 1 2 3 4 5 6 7 8 9 10 11 12
No
EA EB EC ED EE EF EG EH EI EJ EK EL
Name Air Dryer Hydraulic Motor Oil Cooler Separator Moter C.T.S Coolant Pump(Type:CRK2-180) Separator Interlock Front Ceiling shower coolant Rear Ceiling shower coolant Suction pump Chip conveyor Separator Moter Spindle coolant
Chip conveyor
3-29
Separator
Oil Cooler
Hydraulic
Air Dryer
OA OB OC OD OE OF OG OH
OJ(DOWN)
OI(UP)
Oil Cooler-IN
Oil Cooler-OUT
B-Axis OUT B-Axis IN ATC OUT ATC IN Spindle OUT Spindle IN APC OUT APC IN
CE
Spindle coolant
(Type:SPK2-3/5)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
No
OA OB OC OD OE OF OG OH OI OJ CA CB CC CD CE
Name B-Axis OUT B-Axis IN ATC OUT ATC IN Spindle OUT Spindle IN APC OUT APC IN Oil Cooler-OUT Oil Cooler-IN Front Ceiling shower coolant Rear Ceiling shower coolant Suction pump Spindle coolant C.T.S Coolant Pump(Type:CRK2-180)
3-30
Front Pedestal
Cover
(3) Hang up Front Pedestalput it down on top of the chip conveyor and the coolant tank. (4) Connect Electrical joint of the chip conveyor and test its function.
3-31
Alarm Lights
Operator Panel
Oiler
4-32
Make sure available spaces in all units are enough. (as drawings below) 1. Chip remove cyclically & keep cutting oil in as standard position always.
Oiler Slowup Motor Oil-Air Spindle Lub X-axis Linear way Auto Pallet Change Pallet(B-axis) Z-axis Linear way
Air Dryer
Hydraulic Unit
Cooler
Dimension
Type
Tool magazine
1 2 3 4 5 6 7 8 9 10
Spindle oil R10 Mobil Velocite no.6 Spindle oil (R10) Mobil Velocite no.6 By neutral agent or water
Spindle
HO6
HO6
name plate
HO6
HO6 HO6
3~5kgf/cm
Air unit
HO6
Vent
Remarks: 1. Pump set up: times/16 min 2. Lubrication oil : Mobil Velocite no. 10(R22) 3. Oil filter before spray mixing: within 30 4. Air supply dryer: as required & with filter within 0.5 5. Air pressure: 0.29~0.49Mpa (pump pressure & oil quantity as connected) 6. Spray oil quantity of distributor: 0.03cc (0.01cc as marked 1)
4-35
R22
Oil-Air Distributor
HO6
HO6
HO6
KAO FONG MACHINERY CO.,LTD 4-7 Hydraulic system (spindle tool B axis APC)
4-36
KAO FONG MACHINERY CO.,LTD 4-8 Hydraulic unit of tool magazine system
4-37
Kennzeichnung
Name of COMP.
DIN51502
Bettbannoei 68 FEBIS K 68 Shell Tonna Ol TX 68 Castrol Magna BTH68 BP Maccurat 68 D BP Energol HP-C 68 D AVILUB RSL 68-SU Aral Deganit BW 68
4-38
KAO FONG MACHINERY CO.,LTD 4-10 Exchange table operation and maintenance
Preparing unit
Foot Switch
switch seat sensor adjust block lock nut withanti water gel M5 bolt sensor adjust block
Questions and Solutions When proximity switch has no action which might caused: 1 . Proximity switch damaged. 2 . Distance between proximity switch& sensor are to far.(The ideal distance are1.5~2mm) AttentionDischarge the oil before proximity switch take out and add. oil when mounted.
4-40
4-12
4-41
table movement micro switch on micro switch off origin (stop point desired) table stop point
0 position return
4-13
1. 2.
start point
4-42
division tolerance
Attention Seriously when lock work piece on and make sure lock thghtly enough.
4-14
Gaps adjustment: Turning both right & left side screws close to screw wheel.(ideal condition around 0.005~0.008mm) Attention When gap sets on 0.005mm , must turm rocker arm manually for make sure titting rotary table rotation. Normallythe gaps have already set up when machine finished and please refer to Steps following when adjust requied. Gap Measurement Fixing measurement meter on position as drawing shown below.
First , insert steel bar as drawing shown ( keep 100 mm over as shown too) and forwarding it as clock way. (note the data of meter). Secondly, reversing it as against clock way again(note the data of meter). Plus both data = gap AttentionMake sure no more rotate on both screw and screw bearing otherwise the gap are unable to measure.
4-43
1.18 N.m
4-44
1 2
5 6
4-45
Chip conveyor
Front Pedestal
Coolant tank
(3) lift the conveyor out of the coolant tank, and then move it away.
Cover
(4) unscrew the fasteners, then open the cover plate of the coolant tank and pump. (5) sluice out the coolant in the tank completely. (6) clean chips and dirt remained in the tank as well as the filter plate. be careful to wear safety gloves and use tools like shovels to do this work.
4-46
(7) restore the conveyor, tank and pedestal in backward procedures as described above. (8) refill clean coolant to accomplish the coolant replacement.
1. Uses the tool (broom, , dont use the air-gun) to collect chips to waste recycling. 2. Dump rubbish into waste recovery yard. 3. Return the oil tank above the water tank. 4. lay up the water tank under filing exportation wearing gloves.
4-47
Operated Door
4-48
KAO FONG MACHINERY CO.,LTD 4-20 Release of person trapped in the machine
When the machine is in the condition of power disconnection or maintenances status The inter lock in the status of (CLAMP) in case the maintenance person is closed in The interior of the machine and can not open the safety door to get out as the power Can not be operated to discharge the circuit of inter lock of the door. The way to get out is by usmg hand tools to open the door by force. As shown in the picture please Find the component near by the inter lock and then turn the LOCK position to UNLOCK. After the person left safely. Please remember to restore the inter lock to LOCK position on Account of to prevent any person is endangered when the power is on because after the safety Door was opened by force. It would stay at unlocked status.
4-49
3.
4.
5.
6.
We hope to solve the problem immediately and completely. The above question is very helpful for us to find the problem. Any answer may be the key point to recover the machine. If during the telephone contact step, you could tell us the detail situation of machine. It will be more easier to find the reason of malfunction and recover it as soon as possible.
ALARM NUMBER E1
DESCRIPTION
STEP OF RECOVER
REMARKS
Better waiting 2-3 minutes, usually it happens because of too much chips in chip -conveyor through.
E2
MOL ALARM 1.Turn power OFF Motor for outside part 2.Open the door of electric have overload cabinet and check the situation OVERLOAD. 3.Push the RESET BUTTON which is on overload. OIL ALARM Spindle 1.Is filter too dirty? Use water, coolant pressure neutral cleaner or compressed detect alarm air to clean up and air-dry in overcast. 2.if not work, please call the cooler maker
5-1
the TEL of the cooler maker is on the cooler unit plate and the manuals of cooler unit.
E4
1.Is the oil enough? 2.If yes, maybe the oil detector is
broken. please check in according to electric circuit manual.
1002
1003
SPINDLE DRIVER ALARM spindle driver overload alarm EMERGENCY STOP ALARM
same as E3
1004 1005
SPINDLE GEAR OIL ALARM ATC STAND-BY LS ATC not at stand by situation
5-2
2002 2003
1.Are T code all right. 2.Check the tool registration. 1.RESET NC. 2.Turn ON manual operation of ATC. (D500.1=0.1 D503.3=1 D503.4=1) 3.In MDI mode, used M code to return ATC to stand-by situation step by step. 4.Turn manual operation of ATC. 5.Return Z-axis to ZERO 1.Close safety door 2.If not works, please check if it is a problem of fuse. 1. During ATC tool change, Z-axis does not return to original point . Please return Z-axis back to original position. Check whether the air pressure is miss? 2.If the pressure is enough, check if the pressure switch is broken. 1.Is spindle on clamp? Is ARM on 0 ? 2.Check if LIMIT switch are stable that we mentioned before. 1.Are feed-rate and spindle rate OK? 2.RESET NC The same as E4 1.Is pressure of LUB enough? If yes, please delay the time of pressure D330= 15000
5-3
2004 2007
2006
2008
SPINDLE LOAD TOO MUCH LUB OIL MISS LUB PRESSURE MISS
For VMC-650800
SP NO TOOL CANT Please install tool then can start ROTATION spindle OIL/AIR LUB. ALARM SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN FIRST START SP SP WARM UP FOR 3000RPM PLEASE CHECK TOOL AND HIT CYCLE START P.B TO CONTINUE THEN WAIT 5MIN WHEN SP STOP OVER 2 HOUR 2020 ADMONISH!THE Z AXIS LOCK P.B IS ON.ARE YOU SURE?YES,PLEASE HIT CYCLE START P.B TO CONTINUE.NO,PLE ASE CHECK THE Z AXIS LOCK P.B. 2021 PLEASE PUSH OP2 P.B TO ENABLE JOG/RAP/ZRN MODE 2022 PLEASE PUSH M19 P.B 2023 APC ALARM OIL/AIR LUB SIGNAL NO OK CHECK OIL/AIR LUB. UNIT Please check sp tool,if ok press CYCLE START P.B to start sp warm up.
2018
SP stop over 2 hour please check sp tool,if ok press CYCLE START P.B to start sp warm up.
2020
2021
2022 2023
Push M19 P.B to enable SPINDLE UNCLAMP mode Please check APC LS
5-4
5-5
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