Operating manual

48V
48V APC
60-CNC
100-CNC
160-CNC

Issue: J | 08.2013
 CONTENTS
Page

1.1 INTENDED USE 3

1.2 IMPORTANT SAFETY NOTICE WARNING! 4
1.3 SAFETY LISTS ALL COUNTRIES 5
1.4 GUARD WINDOW SAFETY 7
1.5 BEFORE SWITCHING ON 8
1.6 WARRANTY INFORMATION 9
1.7 ROUTINE INSPECTION 9
1.8 MACHINE WARM UP 10
1.9 SPINDLE MAINTENANCE 13
1.10 BASIC GREASE SPINDLE OPERATING GUIDELINES 13
1.11 INTERRUPTING MACHINING 14
1.12 COMPLETING A JOB 14
1.13 SAFETY DEVICES 15

2.1 OPERATOR PANEL 16

2.2 MACHINE FUNCTIONS 18
2.3 INDICATOR LIGHTS 25
2.4 MACHINE POWER ON/ZERO RETURN 26
2.5 AXIS ENABLING DEVICES 27
2.5.1 MANUAL AXIS JOG 28
2.6 MPG OPERATION 29
2.7 SPINDLE OPERATION 30
2.8 DOOR INTERLOCK 31
2.9 M-FUNCTION CODES 32
2.10 LOADING A TOOL INTO THE SPINDLE 36
2.11 TOOL MAGAZINE DATA TABLES 37
2.12 MANUALLY CONTROLLING THE TOOL MAGAZINE 40
2.13 BIG TOOL SETTING 41
2.14 APC ALARM MESSAGE 42
2.15 TOOL CHANGER FAULT RECOVERY 43
2.16 MAGAZINE ALARM RECOVERY 47

Page 2
1.1 INTENDED USE

This machining centre is a numerically controlled machine tool designed to shape cold
metal by the application of rotating cutting tools capable of performing two or more
machining processes (e.g. boring, drilling, milling, thread tapping) at one set-up of a
workpiece and incorporating automatic facilities to:

Select and change tools from a magazine

Change the position of the workpiece relative to the spindle mounted cutter
Select and apply spindle speeds and axis feeds
Control ancillary services (e.g. coolant flow)

Page 3
1.2 IMPORTANT SAFETY NOTICE WARNING!

SAFE INSTALLATION
It is the customer’s responsibility to ensure the machine is installed in a safe operating
position, with all service pipes and cables clear of the operation area so as not to cause
a hazard. Access must be allowed for safe maintenance, swarf and oil disposal including
safe stacking of machined and un-machined components.

MACHINE GUARDING
SMSA fitted with completely enclosed guards as standard. In certain cases and tooling
applications additional guarding may have to be provided by the user.

The standard machine guarding has special safety interlocks on the guard doors that
comply with the Machinery Directive. Guards and interlocks must be kept fully
maintained and tested by the customer and shall not be removed.

The guards are made with clear observation windows having high impact resistance to
provide operator safety and a clear unobstructed view of the operations in process. The
opening of any guard door provides access to potential hazard areas. Opening of the
front working area guard doors is not allowed whilst the spindle is rotating but it is still
possible to manually initiate axis movements whilst these doors are open albeit at a
reduced traverse rate. Extreme care must therefore be used at all times.

SOFTWARE
Unauthorised changing of machines software or control parameters is hazardous and is
not permitted. Schaublin Machines SA will not accept any liability whatsoever for
unauthorized changes in this area.

AUTHORISED PERSONNEL AND TRAINING

Operating, service and maintenance engineers shall be authorised by the ‘User
Company’ and properly trained in the use of the machine.

SAFE WORKING PRACTICE

Workholding devices, lifting equipment, tooling and their use shall be the responsibility
of the user. It is the user’s responsibility to protect against the hazards caused by swarf,
leaking oil or coolant and their use.

Use of proprietary oil or coolant is the responsibility of the user. Special instructions
from the suppliers concerning their use should be carefully read and understood before
use.

To prevent bodily injury, safe working practices should be employed when operating or
servicing the machine.

Page 4
1.3 SAFETY LISTS ALL COUNTRIES

• It is the user’s responsibility to ensure all local regulations and safety instructions are
followed.
• Users should consult with their own safety representative to ensure that all such
regulations are known and acted upon.
• Additional safety notices may exist for certain specific countries for which Schaublin
Machines SA may be able to advise. Please ask.
• DON’T run the machine until you have made clear to your supervisor that you
understand the potential hazard of spindle rotation, the throwing of coolant and the
removal of swarf from the cutting process.
• DON’T run the machine until you have read and understood all manuals provided with
the machine.
• DON’T run the machine until you have read and understood all the machine and
control keys.
• DON’T run the machine for the first time without a qualified instructor. Ask your
supervisor for help when you need it.
• PROTECT your eyes. Wear safety glasses with side shields at all times.
• DON’T get caught in moving parts. Remove watches, rings, jewellery, neckties and
loose fitting clothes.
• PROTECT your head. Wear a safety helmet when working near overhead hazards.
• KEEP your hair away from moving parts.
• PROTECT your feet. Always wear safety shoes with steel toecaps and oil resistant
soles.
• Gloves are easily caught in moving parts. TAKE THEM OFF before you turn on the
machine.
• Loose objects can become flying projectiles. REMOVE all loose items (wrenches, chuck
keys, rags etc.) from the machine before starting.
• NEVER operate a machine tool after taking strong medication, using non-prescription
drugs, prescription drugs or consume alcohol which may impair concentration.
• ALWAYS make sure the working and cutting zone is safeguarded.
• PROTECT your hands. Make sure the spindle is stopped before manually changing a
tool or a workpiece.
• PROTECT your hands. Make sure the spindle is stopped before manually clearing away
swarf or oil. Use a brush or chip scraper. NEVER use your hands.
• PROTECT your hands. Make sure the spindle is stopped before manually adjusting the
work piece or fixture or coolant nozzle.
• PROTECT your hands. Make sure the spindle is stopped before you take
measurements.
• PROTECT your hands. Make sure the spindle is stopped before you move a safeguard.
Never reach round a safeguard.
• PROTECT your hands. Make sure the machine is switched off and electrically isolated
before making any mechanical adjustment.
• PROTECT your hands. Beware sharp edges of cutting tools when changing and
handling tools.
• PROTECT your hands. Beware of sharp edges on newly machined components. Wear
gloves when unloading.
• PROTECT your eyes and the machine. Never use a compressed air hose to remove
swarf or to clean out air vents.
• KEEP the work area well lighted. Ask for additional lighting if needed.
• DON’T slip. Keep your work area clean and dry. Remove swarf, oil and obstacles.
• NEVER lean on the machine. Stand away when machine is running.
• DON’T get trapped. Avoid pinch points caused between other machines and the
machine you are working.
• PREVENT objects from flying loose. Securely clamp and locate the workpiece.

Page 5
SAFETY LISTS ALL COUNTRIES (Cont.)

• PREVENT cutter breakage. Use correct cutter speed and axis feed rate for the job.
Make manual over ride adjustments of axis feed rate or spindle speed if you notice
unusual noise or vibration. Ask your supervisor for help if you need it.
• PREVENT cutter breakage. Rotate the spindle in a clockwise direction for right handed
tools, counter clockwise for left handed tools. Use the correct tool for the job.
• PREVENT work piece and cutter damage. Never start the machine when the cutter is
in contact with the work piece.
• Dull and damaged tools break easily. Inspect tools and tool holders. Keep tools sharp.
Keep overhang short.
• KEEP all lubrication reservoirs maintained at the correct level. Always keep to the
maintenance schedule.
• Certain materials such as magnesium are highly flammable in dust and chip form. See
your supervisor before working these materials.
• PREVENT fire. Keep flammable liquids and materials away from the work area and
from hot swarf.
• PREVENT the machine from moving unexpectedly. When leaving the machine
unattended, not producing, leave switched in the MANUAL mode, with the
EMERGENCY STOP button depressed.
• DON’T use the machine in a volatile atmosphere. Electrical devices fitted to the
machine are for normal factory use and are not explosion proof.
• ALWAYS keep the machine clean and do not let swarf collect.
• ALWAYS keep the area around the machine clean and tidy. Opening the guards
creates the potential for residual coolant and swarf to fall to the swarf tray and
possibly to the floor. Good housekeeping minimizes the potential for trips, slip or fall
of all personnel.
• DON’T reach into any control or power case, unless electrical power is OFF.
• DON’T touch electrical equipment when hands are wet or when standing on a wet
surface.
• ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters
before restarting the machine.
• This machine tool is a machining center, and is intended for the use in machining
materials with the work piece fixed to the table, and the cutting tool rotating in the
spindle. The machine should not be used for any other purpose.
• INFORM all other personnel who approach the machine about the hazards described
in this safety list.
• When making adjustments with spanners, always ensure that the required leverage is
safely applied. Always avoid slippage. Always apply the leverage by pulling, never by
pushing. Always use the correct size spanner. Ensure the spanner is not damaged.
• Do not use organic chemical solvents to clean the machine guards or compressed air
services equipment.
• This machine is intended for use in an industrial environment and must not be used in
the residential, commercial and light industrial environment.
• The windows fitted are manufactured from bulletproof polycarbonate sheet. This
material does deteriorate with age, and should be exchanged within the time period
described later in this manual.
• Any workholding device used in conjunction with this machining center must fit within
the working envelope available. Under no circumstances must any such workholding
device be used when it would require the need to override/defeat the safety
interlocks fitted as standard to this machine.

Page 6
1.4 GUARD WINDOW SAFETY

The majority of windows fitted to Schaublin Machines SA Machining Centers are

manufactured from the GE Plastics LEXAN® range of polycarbonate sheet, with a
hardened surface coating called Margard®. The hard coating gives protection against
minor scratching. Testing over the past few years has resulted in confirmation that the
impact resistance of polycarbonate degrades over time after exposure to the
metalworking fluids and lubricants used in the metalworking process. Although the
Margard® coating provides some protection against the cutting fluids, the
polycarbonate still degrades. Guidance on the replacement of windows is given in the
Operators Safety Manual, section 1.7.

Page 7
1.5 BEFORE SWITCHING ON

Training on all aspects of this machine tool is available from Schaublin Machines SA.
Please contact your Schaublin Machines SA representative for further details.

Cables, cords or electric wires of which insulation is damaged can produce current leaks
and electric shocks. Check their condition before connecting.

A qualified electrician should only carry out connection of the power cable to the
machine.

Ensure the power cable to the machine main isolator has sufficient current carrying
capacity to handle the electric power used.

Cables which must be laid on the floor, must be protected against chips, oil and
coolants penetration, which might cause damage.

In the event of power failure, turn off the main circuit breaker immediately.

Fuses and circuit breakers should be replaced only with suitably rated alternatives.
Safety devices should be replaced only with the machine manufacturers recommended
parts.

Protect the CNC unit, operating panel, and electric cabinet etc from shocks which could
cause a failure of malfunction.

Check the condition of the warning labels. If they are missing or become illegible, order
replacements from Schaublin Machines SA according to the part number on the label
plate. Do not remove warning labels.

After unpacking the machine clean all rust preventative from the machine with a non-
volatile cleaning fluid. Lightly lubricate each sliding part before trying to operate the
machine.

Use recommended oil brands and appropriate levels for all lubricating systems. See the
instruction plate at the rear of the machine.

The coolant system comprises a separate tank at the front of the machine and a coolant
pump located beneath the electrical cabinet.

Page 8
1.6 WARRANTY INFORMATION

Schaublin Machines SA warrants to the original purchaser only that all products
manufactured by it will be free from defects in materials or workmanship, such
warranty to remain in effect if and only if such products are used in accordance with all
instructions as to maintenance and operations set forth in manuals and instruction
sheets furnished by Schaublin Machines SA.

The machine manufacturer is not responsible for any danger or damage arising from
improper operation of the machine. Some examples of improper use are listed below.

1. Adding to or modifying the machine without consulting Schaublin Machines SA.

2. Operating the machine outside the machining range.
3. Improper use of a workpiece holding or peripheral device.
4. Using the machine with interlocks or protection covers removed.
5. Carrying out machine operation, programming or maintenance and inspection work
without thoroughly understanding the caution information, i.e. without having read
the instruction manuals carefully.

1.7 ROUTINE INSPECTION

The schedules below are based on single shift operations using coolant at all times.

Daily
1. Check pressure gauge reading.
Air pressure 5.5bar (80psi)
2. Check that there is sufficient oil in the air lubricator.
3. Check motors and other parts for abnormal noises.
4. Check the lubrication of sliding parts for evidence of proper lubrication.
5. Check safety covers and safety devices for proper operation.
6. Check coolant level and fill as necessary.
7. Clean dirt and chips from the axes and empty the swarf trays.

Weekly (In addition to daily routine)

1. Clean chips and dirt from the entire machine and wipe down.
2. Check the air filter at the rear of the electrical cabinet. Replace the filter element
if it is contaminated.
3. Check all polycarbonate vision panels for signs of damage – crazing, cracking etc.
or reduced visibility and replace if necessary. Contact your Schaublin Machines
SA representative for details.

Page 9
1.8 MACHINE WARM UP
If the machine is used to produce components
immediately after being started, following a long idle
period, sliding parts may be worn due to lack of oil and
thermal expansion of the machine can jeopardize
machining accuracy. To prevent this condition, always
warm the machine up.
Never start the spindle without a tool holder in place
and tooling with a balance level of G2.5 or better
should always be used.

We recommend that the machine is ‘Warmed up’ prior to first operation by running all
axes for 10 to 20 minutes at about half or one third the maximum speed in the
automatic operation mode before actual cutting.

This automatic operation program should cause each machine component to operate.
During this cycle check the correct function of these operations.

Be particularly careful to warm up the spindle.

SPINDLE WARM UP
It is essential that the spindle in the machine is correctly warmed up before use.

Short Term Spindle Warm up

If the machine has been idle for less than two weeks, run the spindle at 25% of the
maximum spindle speed for 15 minutes. Once this has been completed, the machine is
ready for operation

Long Term Spindle Warm up

If the machine has been idle for two weeks or more, run the spindle at 25% of the
maximum spindle speed for 20 minutes, then at 50% of the maximum speed for 30
minutes. Once this has been completed, the machine is ready for operation.

Switch-ON Procedure for Siemens 24k Block Spindle:

After less than 4 hours standstill:
Switch-on conditions Clearance
Spindle Ready for operation
After less than 8 days standstill:
Switch-on conditions Clearance
Spindle at 25% limit speed 2 min. running time
Spindle at 50% limit speed 2 min. running time
Spindle at 75% limit speed 2 min. running time
Spindle Ready for operation
After more than 8 days standstill:
Switch-on conditions Clearance
Spindle at 25% limit speed 5 min. running time
Spindle at 50% limit speed 5 min. running time
Spindle at 75% limit speed 5 min. running time
Spindle Ready for operation
After more than 28 days standstill:
Switch-on conditions Clearance
Carry out the run-in cycle, see below "run-in cycle"
Spindle Ready for operation

Page 10
Note: There is a risk of grease deterioration and ‘standstill corrosion’ in spindles that
have been idle for long periods which can reduce the life of the spindle. To
prevent this, the spindle should be rotated manually, 5 to 10 times by hand
every 2 months. This action should be performed with the power removed from
the machine at the main isolator.

Page 11
1.9 SPINDLE MAINTENANCE
Daily Maintenance.
Clean the front nose of the spindle but do not use compressed air.
Check the taper for dirt. If necessary, use a cleaning arbor.
Check coolant level in spindle cooler and top up if necessary.
Check air supply.

Monthly Maintenance.
Test tool change function.
Check the spindle knock out distance. Activate the tool un-clamp pushbutton to check
that the knock out distance is as specified in the maintenance manual.
Note: prior to inserting a tool holder, ensure that the spindle taper is clean.

Spindle Tooling
Tooling with a balance level of G2.5 or better should always be used. Failure to do so
will reduce spindle life and surface finish and may void the machine warranty.
For safe operation, refer to the informative tag and make sure the tool holder and pull
stud combination meet the standard.

1.10 BASIC GREASE SPINDLE OPERATING GUIDELINES

Many customers use a combination of duty cycles that help to extend the spindle life.
The worst case is always when running any grease spindle at maximum RPM for long
periods of time.

The “guideline” we recommend to our customers (based on bearing supplier

recommendation) that must run continuously above 8,000 rpm is to reduce the speed
to anywhere between 2,000 - 4,000 rpm for a minimum of 10 minutes at each 4-hour
interval. Extended running time above 8,000 rpm longer than 4-hours will minimize the
bearing life and grease life of the spindle.

The spindle life will be significantly increased by following the above procedure. The
reason for running at a lower speed for a minimum of 10 minutes at each 4-hour
interval is to allow the grease that has been pushed to the outer race of the bearing
(due to high speeds) to fall back into the bearing to re-lubricate the ball track, whilst
also allowing the spindle bearings to cool at the slower speed.

The absolute worst case for any grease spindle is running at high speeds for extended
periods of time (without following the guideline as mentioned above). In this condition
the bearing failure is due to grease not being allowed to get back into the ball track for
re-lubrication.

As a “General Rule” in grease spindle design, we also recommend that a grease spindle
should be run at 80% of the “maximum designed spindle speed” to maximize spindle
life if the above “spindle operating guideline” is not followed.

Example: If the designed max spindle speed is 10,000 rpm we recommend that a
grease spindle should be run at 8,000 rpm to maximize spindle life if high
speeds are required for long periods of time and the above “spindle
operating guideline” is not followed.

For continuous max speed applications (that cannot use the above procedure) we
strongly recommend using spindles with air/oil lubrication since this provides the best
solution for extending spindle life at high speeds. This also comes at a higher machine
and/or option price.

Page 12
1.11 INTERRUPTING MACHINING

WARNING!

When leaving the machine temporarily after completing a job, turn off the power on the
operator panel with the Emergency Stop button and turn off the main isolator. Never
turn off power during automatic operation or with the spindle or axes running unless an
emergency occurs. It is better to interrupt the program by pressing the "Cycle Stop"
push button.

1.12 COMPLETING A JOB.

Always clean the machine and supporting equipment down after use. Remove and
dispose of chips and clean the covers and windows etc. Return each machine
component to its initial condition. Check wipers of axes waycovers for damage and
replace if necessary. Check coolants, hydraulic oils and lubricants for level &
contamination. Change them if you suspect they are contaminated. Clean the filter on
the top of the coolant tank. Turn off the power first on the control panel with the
emergency stop button and then at the main isolator before leaving the machine at end
of the shift.

Page 13
1.13 SAFETY DEVICES

Make yourself aware of the locations of the emergency stop push buttons, which should
be well known so that they can be operated at any time without the need to look for
them. Test the push buttons periodically for their correct operation.

Further safety devices are located at the following points around the machine:

The front door, APC front folding door and the toolchanger load station door have safety
interlock switches with guard door locking. (Note that only the 48V APC has a
toolchanger load station door.)

Over travel limit switches are present at each end of each axis stroke.
Stored stroke limit (Parameter setting): The control system will recognize when a move
is requested that will take the motion beyond the end of the machine stroke. This move
will not be allowed to start.
A 3 position Axis enabling Device for use in manual / handwheel mode is fitted to the
machines (for further information refer to page 22 of this manual)
Functional Explanation

Emergency Stop Circuit

A safety circuit is fitted in the machine through which the Emergency Stop Buttons are
wired. In addition to this, hard wired over travel switches are located on both ends of
all 3 axes to check whether the axis has travelled beyond the allowed boundary. If any
one of the Emergency Stop buttons is pressed, the machine will stop immediately and
go into an Emergency Stop condition.

CAUTION!
Once the emergency condition has been safely resolved and the emergency stop
buttons are released, the “RESET” button should be pressed to clear any error
messages within the control system.

Servo & Spindle Power Disconnect

Once the Emergency Stop button is pressed or any of the over travel limit switches
have been operated, the machine will stop and the power supply to the drives is
removed.

Door Safety Circuit

The machine has interlocked doors, the main access door at the front of the machine
and the toolchanger load station door at the left hand side of the machine. Both doors
are shot bolted shut and can only be opened once the spindle is stationary and there is
no program running. (Note that only the 48V APC has a toolchanger load station door.)

Power On Safety Circuit (Allows the operator to execute certain tasks whilst either
door is open)
Limited machine functionality is available to the operator whilst either door is open. The
handwheel and jog keys are able to move the machine axes at feed rates of 2m/min
and less. Spindle operation is prohibited whilst either door is open as the spindle
contactor is hard wired through the door interlock safety relay. Selection of automatic
program running is prohibited until the doors are shut. Rotation of the tool magazine is
also prohibited until the doors are shut.

Door Interlock of Electrical Cabinet Safety Circuit

When door interlock switch is on the position “0” and the cabinet doors are open, the
machine power will be kept ON. When door interlock switch is on the position “1” and
the cabinet doors are open, the machine power will be turned OFF.

Page 14
2.1 OPERATOR PANEL

48V Operator Panel 48V APC

Operator Panel

60-/100-CNC Operator Panel

51-5AX with Fanuc 18i-MB

Operator Panel

Page 15
2.2 MACHINE FUNCTIONS
Emergency Stop
When depressed, the mushroom cap Emergency Stop buttons stop all machine and chip
conveyor motions. Pull the Emergency Stop push button UP to release.

Rapid Override Switch

The switch can modify the machine rapid traverse rate on the X, Y, and Z axes in steps
from 0% ~ 100%. It is active in Positioning Mode (G00). It is also active during return
passes for machining cycles.

Feedrate / Jog Override Switch

The switch can modify programmed feedrates from 0% ~ 150% when In Automatic or
Manual Data Input mode. A setting of “0" will stop G01, G02, & G03 motion.
When in Jog mode, the switch establishes the rate of axis motion. A setting of “0" will
inhibit axis motion. When the Override switch is set to 100%, the rate of motion is:
Inch mode: 0 ~ 787 inches/minute
Metric mode: 0 ~ 2000 millimeters/minute

Spindle Override Switch

The switch can modify programmed spindle speeds from 50% ~ 120%.

Manual/Auto Mode Switch I

The switch limits the operator under manual mode or in auto mode. CE mark version
only.

READY (for EM Released Confirm) READY

After pulling the Emergency Stop button to release and pressing the Emergency Stop
Reset button for axis movement, the circuit of Emergency will not be reset. Need to
press the READY button firstly, and then press the RESET button in order that the
circuit of Emergency is actually reset.

Mode Selector
Described as follows:

Edit Mode
When pressed or select this button on the Mode Selector, Edit mode allows the operator
or programmer to enter a new program or edit a stored program. To deactivate Edit
mode, select another operating mode.

Automatic Mode
Turn the "Manual/Auto Mode Switch" to AUTO and closed the front door. When pressed
or select this button on the Mode Selector, Automatic mode allows execution of a part

Page 16
program stored in control memory and modification of part programs using the
Background Edit function.

Page 17
MACHINE FUNCTIONS (cont.)

Manual Data Input Mode

When pressed or select this button on the Mode Selector, Manual Data Input mode
allows manual input of a temporary program block.

Direct Numerical Control (DNC) Mode

When pressed or select this button on the Mode Selector, Direct Numerical Control
mode allows execution of a part program read directly from an input device connected
to the machine control.

Jog Mode
When pressed or select this button on the Mode Selector, Jog mode allows non-
programmed movement of the axes through the use of the axis direction push buttons.

Handwheel (Manual Pulse Generator) Mode

When pressed or select this button on the Mode Selector, this switch setting activates
Handwheel mode. The override feedrate only allowed is x1/x10/x100 and maximum
feedrate is 1.9m/min.

Zero Return Mode

When pressed or select this button on the Mode Selector, Zero Return mode allows the
selected axis to be moved to the “Home” position. This mode is activated automatically
at Power-Up.

Rapid
Activating manual rapid traverse mode with Jog mode active and pressing one of the
axis directional push buttons move the selected axis at the rapid jog rate. The Rapid
Override switch can be used to adjust the rapid traverse rate.

M01 (Option Stop)

The push button can activate and deactivate Option Stop alternately. The indicator light
is illuminated when Option Stop is active. The function causes the control to stop
execution of the part program AFTER executing an active block that contains an M01
code. The M01 code is ignored when Option Stop is not active.

The function may be activated before or during execution of the block containing the
M01 code.

To resume program execution, press the Cycle Start push button. The Feed Hold push
button light will turn OFF. Program M03, M04, M13, or M14 to restart the spindle and
coolant.

Page 18
MACHINE FUNCTIONS (cont.)

BDT (Block Skip)

The push button can activate and deactivate Block Skip alternately. The indicator light
is illuminated when Block Skip is active. The function ignores any program data block
preceded by a slash (/) code.

SBK (Single Block)

The indicator light is illuminated when Single Block is active. Single Block allows the
operator to execute one block of data each time the Cycle Start push button is pressed.

MLK (Machine Lock)

The mode must be OFF for normal machine operation.

The push button can activate and deactivate Machine Lock mode alternately. The
indicator light is illuminated when Machine Lock is active. The function inhibits all axis
and spindle motions. M, S, and T functions are also inhibited.

ZMLK (Z Axis Machine Lock)

The push button disables all Z axis motion. When a part program is executed, all other
machine activity will occur as programmed. This push button is illuminated when Z Axis
Machine Lock is active.

DRN (Dry Run)

The mode must be OFF for normal machine operation.

The push button can activate and deactivate Dry Run mode alternately. When the mode
is active, programmed feedrates are ignored and cutting moves are performed at a Jog
feedrate of 50 inches [1260 millimeters] per minute. The indicator light is illuminated
when Dry Run is active.

Coolant ON
The push button turns the coolant pump ON, regardless of the programmed M codes for
coolant control. Coolant ON deactivates Coolant Automatic and Coolant OFF.

Coolant OFF
The push button turns the coolant pump OFF, regardless of the programmed M codes
for coolant control. Coolant OFF deactivates Coolant Automatic and Coolant ON.

Page 19
MACHINE FUNCTIONS (cont.)

Coolant Automatic
Coolant is turned ON when an M08, M13, or M14 is read from the part program by the
control. Coolant is turned OFF when an M00, M01, M02, M05, M09, or M30 is read from
the part program. Coolant Automatic deactivates Coolant OFF and Coolant ON.

MACHINE FUNCTIONS (cont.)

Chip Conveyor ON/OFF

The push button can turn the chip conveyor ON or OFF. The push button is illuminated
when the chip conveyor is ON.

Chip Conveyor Reverse

The push button reverses the direction of the chip conveyor motion. The push button is
illuminated when the chip conveyor is running in the reverse direction.

Chip Flush
The push button can activate and deactivate the optional coolant chip flush alternately.
The push button flush chips from the machine table into the chip pans or chip conveyor.
Chip flush is an optional feature on standard machining centers.

Spindle Jog Speed Control

The variable switch adjusts the spindle speed while jogging the machine spindle.

Clockwise Rotation
The push button jogs the machine spindle in the clockwise direction (as viewed from
the top of the machine)

Spindle Stop
This push button cancels the spindle jog.

Counterclockwise Rotation
The push button jogs the machine spindle in the counterclockwise direction (as viewed
from the top of the machine)

Page 20
MACHINE FUNCTIONS (cont.)
Spindle Mode

Manually rotate spindle by pressing "Jog Move" and , then spindle

rotation in CW/CCW simultaneously. Here the maximum limitation of spindle speed is
below 50 rpm.

Jog Mode

To using the Jog Mode machine mode Selector must be set into Jog position.

Jog Move
When the Manual mode is selected and the front door is open. Press this button and
one of the Axis Direction push button simultaneously to move the work table. Note that
the maximum feedrate is limited to 1260mm/min.

Work Light
Turns the work light ON or OFF.

Alarm Cancel
The push button cancels the audible alarm.

Emergency Stop Reset

When pressed and held, the Emergency Stop Reset push button jogs the axes out of an
over travel condition. Using the push button to reset the control once the Emergency
Stop push button has been released and the problematic condition has been corrected.

Cycle Start
The push button is a latching type switch that initiates program execution when the
control is in Automatic mode or Manual mode. An additional function of this switch is to
execute Manual Data Input commands.

Feed Hold
The Feed Hold push button stops all programmed slide motion. However, the active
spindle speed is not affected. Feed Hold can be activated when in Automatic, Single
Block, Dry Run, or Machine Lock modes.

Press Cycle Start to resume normal operation after a feed hold. The push button is
illuminated when Feed Hold is active.

Page 21
MACHINE FUNCTIONS (cont.)
DOOR
INTERLOCK
1
0

Electrical Cabinet Door Interlocks

When the electrical cabinet door interlock is position at “0” (only allowed for the
qualified and competent engineers with door-key), power can be turn ON while the
electrical cabinet door is open. When the electrical cabinet door interlock is position at
“1” (normal operating condition), power cannot be turn ON while the electrical cabinet
door is open.

Work Set Finish

When job setup is finished. The APC associated push button activates changeover each
time the Cycle Start is pressed. The push button is illuminated when Work Set Finish is
active.

APC Hinge Arm Open

When spindle is stopped, folding door is closed and pallets are clamped by the APC, the
push button allows the operator to open the APC Hinge Arm for tool loading in
Handwheel mode. The push button is illuminated when APC Hinge Arm Open is active.

Lift up and move the locking handle to the right to open the APC Hinge Arm. Open until
the safety linkage is fully extended. To return, pull the olive-shaped knob out, engage
the locking handle and deactivate the push button to resume machine operation.

Manual Door Open/Close Button

When spindle is stopped, press “Door Open” button to open front door manually which
is available in 48V series and equipped with auto-door facility.
Under manual/auto mode, manual door close operating is only available to press “Door
Close” button and “Feed Hold” simultaneously. (In auto mode, M48 is only for door
open. For safety reason there is no M code for door close.)

Axis Direction Push Buttons and Indicator Lights

The X, Y, Z, and 4th axis push buttons allows manual axis movement in Jog mode. The
X, Y, and Z axis push buttons are also used in conjunction with the Jog Feedrate switch.

MPG Enabling Device Bypass Switch (Only for North America Market):

MPG Bypass Switch

Whilst the bypass switch is located on the "Handle" mode position, then the axis
enabling device is disabled and only using the MPG can be used activate any desire axis
movement as below (a). Otherwise if this switch is located in the "Jog" mode position,
then the operator needs to use two hands (hold to run) to operating the axis direction
push buttons and the axis enabling device simultaneously for any axis movement as
below (b). Operating method as follows:

Page 22
MACHINE FUNCTIONS (cont.)

(a) Select the position on the mode selector and locate in the "Handle" mode
position in the MPG bypass switch. Select the axis direction for desired movement in
axis selector switch. Operating the MPG dial in CW for positive axis motion and in
CCW for negative axis motion.

(b) Select the position in the mode selector and locate in the "Jog" mode position
in the MPG bypass switch. Press the axis direction for desired movement on
operating panel and also press the axis enabling device simultaneously.

SOFTWARE OPERATOR PANEL

The software operator panel, shown in Figure as below, provides the operator with the
following control functions:

Accessing the Software Operator Panel

1. Press the Offset/Setting Function key.

2. Press the Far Right softkey.
3. Press the OPR softkey.
4. Press the Page Down key to access the operator software screen.

Function Descriptions

Key Switch

The Key Switch softkey is intended to prevent accidental changes to programs. To

Change the Setting:

1. Access the software operator panel.

2. Move the cursor to the “Key Switch” line on the screen.
3. Set the cursor to ON to allow changes to programs or set the cursor to OFF to lock
out changes.

Software Operator Panel

Page 23
2.3 INDICATOR LIGHTS

DISPLAY INDICATOR LIGHTS

COL. (Coolant) - Indicates that the coolant pump is ON.

M19 - Indicates that the spindle is oriented to the tool change position.

ATC (Automatic Tool Changer) - Indicates that Tool Change mode is active.

TCL (Tool Clamp) - Indicates that a tool is clamped in the spindle.

ALARM INDICATOR LIGHTS

EM (Emergency Stop) - Indicates that an Emergency stop condition exists.

ATC (Automatic Tool Changer) - Indicates that an alarm associated with the tool
magazine has occurred.

OL (Overload) - Indicates that a servo drive or electrical overload has occurred.

AL (Alarm) - Indicates that a general machine alarm has occurred. Refer to the control
display screen for the specific alarm message.

MAIN POWER ON INDICATOR LIGHT

The light turns ON when the main disconnect switch is turned ON.

SPINDLE SPEED RANGE INDICATOR LIGHTS

NOTE – Available only on High Torque machining centers.

The spindle speed range is selected through the use of M codes.

H-GEAR (High Gear) - Indicates that the spindle drive is in high gear, which provides
more speed and less torque to the spindle.

L-GEAR (Low Gear) - Indicates that the spindle drive is in low gear, which provides
less speed and more torque to the spindle.

Page 24
2.4 MACHINE POWER ON/ZERO RETURN

POWER ON MACHINE
1. Be sure the coolant guard door is closed.
2. Turn main isolator on the power case ON.
3. Press the Control ON push button and wait until the control display screen is ON.
4. Pull the Emergency Stop push button OUT to release.
5. If necessary, release the Emergency Stop push button(s) located next to the
manual index push buttons for the tool magazine(s).
6. Press the "Ready" button
7. The machine is now ready for the Zero Return (Reference Home) procedure.

AXIS ZERO RETURN

1. Select Zero Return mode.
2. Press the +Z push button. The Z axis will move to the Home position.
3. Press the -X push button. The X axis will move to the Home position.
4. Press the +Y push button. The Y axis will move to the Home position.
5. If the machine is equipped with an optional rotary table, press the +4 push button
to index the rotary table to the Home position.

Page 25
2.5 Axis enabling Device

This device will only be active in the setting mode (Mode 2) and will need to be pressed
to allow each axis to move in either ‘Jog’ or ‘Handwheel’ mode when the operator doors
are open.

The enabling device (figure 1) has 3 positions of operation;

Position 1 - Button not pressed. In this position, the machine axes cannot be moved
with the door open even if the jog keys are pressed or the handwheel rotated.

Position 2 - Button pressed halfway. Held in this position, the machine axes can be
moved at a maximum of 2 m/min by pressing the appropriate Jog key or by turning the
handwheel.

Position 3 - Button fully pressed. In this position, the machine axes cannot be moved
with the door open even if the jog keys are pressed or the handwheel rotated.

Figure 1

Page 26
2.5.1 MANUAL AXIS JOG

Select

In Jog mode, the following buttons can be used to manually move an axis:

The feedrate can be controlled using the feed override dial.

For rapid feed press the rapid feed selection key

Note: To move an axis in jog mode with the guard door open, the door safety selector
switch must be set to ‘1’. Set the switch back to ‘0’ when the operation is completed.
With the guard door open, the jog feed rate is reduced.

Note; Axis enable device must be used in this mode.

Page 27
2.6 MPG OPERATION

Select

AXIS SELECT SWITCH

Axis selector switch “B” determines which machine axis will move.

INCREMENT SELECT SWITCH (“C”)

X1 The incremental jog rate per division on the dial is .0001 inches in English mode
or .001 mm in Metric mode.
X10 The incremental jog rate per division on the dial is .001 inches in English mode
or .01 mm in Metric mode.
X100 The incremental jog rate per division on the dial is .01 inches in English mode
or .1 mm in Metric mode.

MANUAL PULSE GENERATOR DIAL (“A”)

Clockwise: Positive Axis Motion
Counter-clockwise: Negative Axis Motion

To move an Axis

Select the desired axis using the axis selection switch

Select the required movement factor using the switch
Rotate the handwheel in the required direction

Note: To move an axis in MPG mode with the guard door open, the door safety
selector switch must be set to “1”. Set the switch back to “0” when the
operation is completed. With the guard door open the x100 movement factor is
not available.

Note: Axis enable Device must be used in this mode.

Page 28
2.7 SPINDLE OPERATION

Spindle Control Buttons:

The above buttons allow spindle operation in MPG or Jog mode.

Spindle Speed Override Dial:

In all modes, the override dial allows the programmed spindle rpm to be manually
adjusted from 50 - 120%. When adjusting the spindle rpm during program run, there
may be a slight feed hold to allow the machine to achieve the new spindle speed before
continuing.

Page 29
2.8 DOOR INTERLOCK
The guard door is fitted with an interlock to prevent the door from being opened when
the machine is running.

To unlock the guard door press the button.

The guard door will automatically lock when it is closed.

It is not possible to unlock the guard door when the machine is in motion.

In addition, the machine is fitted with a Mode Selection switch to allow the machine
axes to be manually moved when setting etc.

Manual/Auto Mode Switch I

‘Mode Switch’ set to AUTO

Provided guard door is closed, any program can be started via CYCLE START when key
is set in this mode
The key can be removed in this position by a Supervisor
When guard door is opened – Servos are turned OFF and all axes and spindle
movement is disabled

‘Mode Switch’ set to MANUAL

A program cannot be started via CYCLE START when key is in this mode
The key cannot be removed in this position (used for setting purposes only)
When guard door is opened – only axes Servos remain turned ON and all axis
movement is limited to 2m/min maximum.

Page 30
2.9 M-FUNCTION CODES

M Word Definition

M00 Program Stop

M01 Optional Stop

M02 End of Program

M03 Spindle Forward

M04 Spindle Reverse

M05 Spindle Stop

M06 Automatic Tool Change

M08 Coolant Pump ON

M09 Coolant Pump OFF

M10 Rotary Table Brake ON

M11 Rotary Table Brake OFF

M13 Spindle Forward / Coolant Pump ON

M14 Spindle Reverse / Coolant Pump ON

M15 Spindle Stop / Coolant OFF

M16 Spindle Air Blast OFF

M17 Spindle Air Blast ON

M19 Spindle Orient

M20 Spindle Orient Cancel

M21 X Axis Mirror Image ON

M22 Y Axis Mirror Image ON

M23 Mirror Image Cancel

M24 Work Light ON

M25 Work Light OFF

M26 Tool Probe Interface Select (for 18iMB Interface)

M27 Tool Probe Interface Select (For 0iMD Interface)

M29 Rigid Tapping Mode ON

M30 End of Program

M32 Spare M- Code 3 ON

M33 Spare M- Code 3 OFF

Page 31
M-FUNCTION CODES (cont.)

M Word Definition

M34 OTS Tool Probe Interface

M36 OMP40 Part Probe Interface

M38 Tool Air Blow ON

M39 Tool Air Blow OFF

M41 Spindle Low Gear (High Torque Machine only)

M42 Spindle High Gear (High Torque Machine only)

M44 CTS Air ON

M45 CTS Air OFF

M46 Free time ON

M47 Free time OFF

M48 Door Open in Auto Mode (Auto Door)

M49 Door Close in Auto Mode (Auto Door)

M51 Chip Coolant ON

M52 Chip Coolant OFF

M53 Thru-Spindle Coolant ON

M54 Thru-Spindle Coolant OFF

M60 APC Pallet Change

M68 Chip Conveyor ON

M69 Chip Conveyor OFF

M71 Magazine 1 Arm In (For Drum Type) Pocket Down (Swing Arm)

M72 Magazine 1 Arm Out (For Drum Type) Pocket Home (Swing Arm)

M73 Spindle Tool Clamp

M74 Spindle Tool Unclamp

M76 Tool Change Mode (For Drum/Turret Type)

M80 Auto Power OFF

M81 Magazine 2 Arm In (For Twin Mag.)

M82 Magazine 2 Arm Out (For Twin Mag.)

M85 Search Spindle Tool No. For Mag. 2 (For Twin Mag.)

M88 Return The Big Tool To Magazine From Spindle

M90 Index Table On

M91 Index Table OFF

Page 32
M-FUNCTION CODES (cont.)
M Word Definition

M106 Oil Mist Collector ON

M107 Oil Mist Collector OFF

M108 Active pocket 17 as Big Tool, pocket No. 16, 18 disabled

M109 Cancel Big Tool pocket No. 17

M110 Active pocket 19 as Big Tool, pocket No. 20 disabled

M111 Cancel Big Tool pocket No. 19

M112 Active pocket 21 as Big Tool, pocket No. 22 disabled

M113 Cancel Big Tool pocket No. 21

M114 Active pocket 23 as Big Tool, pocket No. 24 disabled

M115 Cancel Big Tool pocket No. 23

M180 Spare M-Code M180 (Y18.0=ON)

M181 Spare M-Code M181 (Y18.0=OFF)

M182 Spare M-Code M182 (Y18.1=ON)

M183 Spare M-Code M183 (Y18.1=OFF)

M184 Spare M-Code M184 (Y18.2=ON)

M185 Spare M-Code M185 (Y18.2=OFF)

M186 Spare M-Code M186 (Y18.3=ON)

M187 Spare M-Code M187 (Y18.3=OFF)

M188 Spare M-Code M188 (Y18.4=ON)

M189 Spare M-Code M189 (Y18.4=OFF)

M190 Spare M-Code M190 (Y18.5=ON)

M191 Spare M-Code M191 (Y18.5=OFF)

M192 Spare M-Code M192 (Y18.6=ON)

M193 Spare M-Code M193 (Y18.6=OFF)

M194 Spare M-Code M194 (Y18.7=ON)

M195 Spare M-Code M195 (Y18.7=OFF)

M210 5th Axis Clamp

M211 5th Axis Unclamp

Page 33
M-FUNCTION CODES (cont.)

M Word Definition

M301 Parts Probe Enable (For Omi-2t Interface)

M302 Tool Probe Enable (For Omi-2t Interface)

M303 Probe Disable (For Omi-2t Interface)

Page 34
2.10 LOADING A TOOL INTO THE SPINDLE

Select or or to load the correct tool number into the Spindle.

Open front guard door of machine.

While holding the tool, press and hold

the clamp/unclamp button “A” on the
machine head to release the tool (See
illustration). Replace tool and release A
the button to clamp.

Close guard door of machine.

Note: Not all models have a tool release button. Without this button, tools have to
be loaded directly into the carousel.

Page 35
2.11 TOOL MAGAZINE DATA TABLES
The tool location table monitors the position of the tool magazine and the location of
the tools installed on the machine. Diagnostic registers are used to store the tool
number data.
The tools are loaded into the tool magazine such that the tool number matches the
pocket number of the tool magazine. The valid ranges of programmable tool numbers
are:
48V Drum Magazine 1 [Standard]: 1 to 16
(40 Taper) Swing Arm Magazine [Option]: 1 to 20
48V (30 Taper) Swing Arm Magazine [Standard]: 1 to 20
Drum Magazine [Standard]: 1 to 16
48V APC (40 Taper) Swing Arm Magazine [Option]: 1 to 20
48V APC (30 Taper) Swing Arm Magazine [Standard]: 1 to 20
Drum Magazine [Standard]: 1 to 20
60-/100-CNC
Swing Arm Magazine [Option]: 1 to 24
(40 Taper)
Swing Arm Magazine [Option]: 1 to 30
160-CNC Swing Arm Magazine [Standard]: 1 to 30
(40 Taper) Swing Arm Magazine [Option]: 1 to 40
160-CNC Swing Arm Magazine [Standard]: 1 to 24
(50 Taper) Swing Arm Magazine [Option]: 1 to 32

TOOL CHANGE POSITION

The tool change position for drum tool magazines is the position aligned with the tool
change position.
The tool change position for the swing arm tool magazines is the lowest tool position
in the magazine, as illustrated below:

Page 36
TOOL MAGAZINE DATA TABLES (cont.)
DIAGNOSTIC ADDRESSES
Sample Tool Data for Drum Magazine (Standard)
Address D0000 contains the number of the tool currently in the spindle.
Address D0001 contains the number of the tool located at the tool change position.
Address D0002 contains the number of the tool pocket located at the tool change
position.

Addresses D0010 through D0029 contain the tool numbers and do not change.

Diagnostic Address
Location Tool Number
Number
Tool in Spindle D0000 14
Tool Number in Change Position D0001 3
Tool Pocket in Change Position D0002 3
Position 01 D0010 1
Position 02 D0011 2
Position 03 D0012 3
Position 04 D0013 4
Position 05 D0014 5
Position 06 D0015 6
Position 07 D0016 7
Position 08 D0017 8
Position 09 D0018 9
Position 10 D0019 10
Position 11 D0020 11
Position 12 D0021 12
Position 13 D0022 13
Position 14 D0023 14
Position 15 D0024 15
Position 16 D0025 16
Position 17 D0026 17
Position 18 D0027 18
Position 19 D0028 19

Position 20 D0029 20

Page 37
TOOL MAGAZINE DATA TABLES (cont.)
Sample Tool Data for Swing Arm Magazine [Option]
Address D0000 contains the number of the tool currently in the spindle.
Address D0001 contains the number of the tool located at the tool change position.
Address D0002 contains the number of the tool pocket located at the tool change
position.

Addresses D0010 through D0033 contain the tool numbers and do not change.

Diagnostic Address
Location Tool Number
Number
Tool in Spindle D0000 14
Tool Number in Change Position D0001 3
Tool Pocket in Change Position D0002 3
Position 01 D0010 1
Position 02 D0011 2
Position 03 D0012 3
Position 04 D0013 4
Position 05 D0014 5
Position 06 D0015 6
Position 07 D0016 7
Position 08 D0017 8
Position 09 D0018 9
Position 10 D0019 10
Position 11 D0020 11
Position 12 D0021 12
Position 13 D0022 13
Position 14 D0023 14
Position 15 D0024 15
Position 16 D0025 16
Position 17 D0026 17
Position 18 D0027 18
Position 19 D0028 19
Position 20 D0029 20
Position 21 D0030 21
Position 22 D0031 22
Position 23 D0032 23
Position 24 D0033 24

Page 38
2.12 MANUALLY CONTROLING THE TOOL MAGAZINE

INDEXING DRUM TOOL MAGAZINE

Select or or for application in indexing tool magazine clockwise or

counter-clockwise, as viewed from the top of the machine.

- NOTE -

Push buttons for indexing

48V

Push buttons for indexing

SWING ARM TOOL MAGAZINE (OPTION)

Select or or
Set dial “C” to the desired setting.
Press bush button “D” to initiate the selected action.

Index the tool magazine clockwise or

counter-clockwise, as viewed form
the control panel

Lower or raise the tool pocket

Exchange the tool in the spindle and

the active station of the magazine

Disable magazine push button

Controls for Swing

Arm Tool Magazine

Page 39
2.13 BIG TOOL SETTING

For 160-CNC (Standard) & 60-/100-CNC (Option)

Page 40
2.14 APC ALARM MESSAGES

2024 APC HYDRAULIC MOTOR OVERLOAD

Cause: APC hydraulic motor was drawing excess current.
Solution: Check the motor and related equipment, and then RESET the overload MC7.

2025 APC IN ADJUST MODE

Cause: APC Adjustment Mode is for the machine builder only.
Solution: Exit the mode and press the RESET key.

2026 APC IN PALLET RECOVERY MODE

Cause: Pallet changer has stopped with an incomplete pallet change.
Solution: (1) With Handwheel mode active, press ALARM, SBK, and FEEDHOLD
simultaneously to return pallets to position.
(2) Press RESET key.

2027 WORK SET FINISH NOT CONFIRMED OR

APC FRONT FOLDING DOOR NOT CLOSED
Cause: (1) APC front folding door not fully closed.
(2) WORK SET FINISH not active before CYCLE START.
Solution: (1) Close the APC folding door.
(2) Press WORK SET FINISH and then CYCLE START buttons.

2028 PALLET CALL ERROR

Cause: Wrong code, M101 or M102 used to call the pallet into working zone.
Solution: Press RESET key

2029 APC ACTION TIME OUT

Cause: Pallet change not completed within the time allowed.
Solution: (1) Check the pallet changer and machine for faults.
(2) Check timer No33.
(3) Press RESET key.

2030 APC HYDRAULIC PRESSURE LOW

Cause: APC hydraulic pressure is low.
Solution: Check the Hydraulic pump and pipe work.

2032 APC UNIT SEPARATION ERROR

Cause: (1) The APC hinge door out of position.
(2) The APC front folding door not completely closed.
Solution: (1) Check the APC hinge door.
(2) Close the APC front folding door.
(3) Press RESET key.

2033 APC SELF DETECTION DIAGNOSTIC

Cause: SENSOR error during self-diagnostic test.
Solution: (1) Check for machine faults.
(2) Press RESET key.

2034 APC NOT IN POSITION

Cause: Pallet not in position.
Solution: (1) Check the position of the pallet. (2) Press RESET key.

2035 PALLET UNIT DEPARTURE

Cause: The APC hinge door fault during pallet change
Solution: (1) Check the APC hinge door. (2) Press RESET key

Page 41
2.15 TOOL CHANGER FAULT RECOVERY

DRUM TOOL CHANGER 1

1. Press the Reset key.
2. Select Manual Data Input mode.
3. Press the Program key.
4. Cancel tool change mode:
a) Key in M77.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
5. Activate tool change mode:
a) Key in M76.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
6. Clamp the tool:
a) Key in M73.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
7. Move the tool magazine to the home position:
a) Key in M71.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
8. Cancel tool change mode:
a) Key in M77.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
9. Press the Reset key.
10. Press the Offset Setting key.
11. Press the Setting soft key.
12. Change Parameter Write Enable (PWE) to 1.
13. Press the Input key. The control is placed in alarm No. 100.
14. Press the System key.

15. FANUC 18i

15-1. Press the PMC soft key.
15-2. Press the PMCPRM soft key.
15-3. Press the Data soft key.
15-4. Press the G.Data soft key.

15. FANUC 0i-MD

15-1. press ► 3 times.
15-2. press PMCMNT.
15-3. press DATA.
15-4. press OPRT.
15-5. press ZOOM.

16. Check the value of D00 and D01.

D00 is the number of the tool in the spindle.
D01 is the number of the pocket in the tool change position.
17. Verify that D00 and D01 are both equal to the number of the tool pocket at the
tool change position. Modify D00 and D01, if necessary.
18. Press the far left soft key.

Page 42
19. Press the Counter soft key.
20. C00 and C04 should be set to show what tool is in the spindle & which pocket is
facing spindle.
PRESET is set to number of pockets in carousel. (16 or 20 etc)
21. Press the Offset Setting key.
22. Change Parameter Write Enable (PWE) to 0.
23. Press the Input key.
24. Press the Reset key.

DRUM TOOL CHANGER 2 [Option]

1. Press the Reset key.
2. Select Manual Data Input mode.
3. Press the Program key.
4. Cancel tool change mode:
a) Key in M77.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
5. Activate tool change mode:
a) Key in M76.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
6. Clamp the tool:
a) Key in M73.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
7. Move the tool magazine to the home position:
a) Key in M81.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
8. Cancel tool change mode:
a) Key in M77.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
9. Press the Reset key.
10. Press the Offset Setting key.
11. Press the Setting soft key.
12. Change Parameter Write Enable to 1.
13. Press the Input key. The control is placed in alarm No. 100.
14. Press the System key.
15. Press the PMC soft key.
16. Press the PMCPRM soft key.
17. Press the Data soft key.
18. Press the G.Data soft key.
19. Check the value of D00, D01, and D02.
D00 is the number of the tool in the spindle.
D01 is the number of the pocket in the tool change position for magazine 1.
D02 is the number of the pocket in the tool change position for magazine 2.
20. Verify that D01 matches the tool pocket at the tool change position for magazine1.
Verify that D02 matches the tool pocket at the tool change position for magazine2.
Modify D01 or D02, if necessary.
21. Press the far left soft key.
22. Press the Counter soft key.

Page 43
TOOL CHANGER FAULT RECOVERY (cont.)

DRUM TOOL CHANGER 2 [Option] (continued)

23. Check the values of C00 and C04 Preset and Current.
C00, C04, C08, and C12 Preset should be 20.
C00 Current and C04 Current should equal to the number of the tool pocket at the
tool change position for magazine 1.
C08 Current and C12 Current should equal to the number of the tool pocket at the
tool change position for magazine 2. (1 = T21, 2 = T22, ...)
Modify C00 Current, C04 Current, C08 Current, and C12 Current, if necessary.
24. Press the Offset Setting key.
25. Change Parameter Write Enable to 0.
26. Press the Input key.
27. Press the Reset key.

Note: C08 and C12 are for dual magazines

TO RESET CAROUSEL TYPE TOOLCHANGER (0i-MD DRUM)

1. Set PWE Key to a 1.

2. Press SYSTEM Key.
3. Now Cursor across to PMC MNT soft key & press.
4. Press COUNTERS.
5. C00 & C04 should be set to show what tool is in the spindle & which pocket is
facing spindle.
6. PRESET is set to number of pockets in carousel. (16 or 20 etc).

SWING-ARM TOOL CHANGER [Option] – When Arm has reached Spindle

1. Correct the condition that caused the fault.
2. Press the Reset key to clear condition alarms.
-.NOTE –
After resetting the condition alarm, the “ATC Arm Not In Position” alarm will
remain active. The Cycle Start and Feed Hold lights will be flashing.
3. Switch the mode selection key switch to Manual then select manual mode on the
control (Jog or Handwheel or Zero return mode).
4. Press and hold the Coolant OFF push button until the tool change sequence is
completed and the ATC arm and tool pocket return to their correct positions.
5. Select Manual Data Input (MDI) mode.
6. Select the System hardkey.
(1) Press the Right Arrow softkey (x3 times) until PMCMNT (8.4 Inch Screen)
is shown
(2) Press the Right Arrow softkey (x3 times) until PMC Mainte (10.4 Inch
Screen) is shown
Press the PMCMNT softkey
Press the Right Arrow softkey once
Press the Data softkey
Press the Zoom softkey
7. Note the values of D0000, D0001 and D0002.
D0000 = Tool in spindle
D0001 = Tool number in change position
D0002 = Tool pocket in change position
8. Press (x2 page down) to check D10~D39 depending on the tools in the magazine
9. Physically verify these are correct.
10. Press the far left softkey.

Page 44
11. Press the COUNTR softkey
12. Check the values of C00 and C04 Preset and Current.
The Preset values should be 1 less than the total number of tool pockets.
Example: If the machine has 20 tool pockets. C00 and C04 Preset value will be 19.
The Current values should be 1 less than the tool pocket at the change position.
Example: If pocket 5 is at the change position. C00 and C04 Current value will be 4.
Preset Current
C00 19 4

C04 19 4

If the values in the Current column needs to be altered,

you must first turn on the parameter write enable.
If changes are not required, the recovery procedure is
finished. DO NOT Proceed to step 13.

Press RESET Button

13. If these values are not correct select Manual Data Input (MDI) mode.
14. Press the Offset hardkey.
15. Press the Setting soft key.
16. Change the value of PWE (parameter write enable) to 1.
17. Alarm SW0100 will be displayed.
18. Repeat steps 6-11 make corrections as needed.
19. When finished, repeat steps 13-16 and change PWE back to 0.
20. Press the Reset key to clear the PWE alarm.
21. If the alarm does not clear & the cycle start and feedhold lights continue to flash
but the arm appears to be in position press the +X axis jog key & coolant off
button alternatively several times.

22. Press RESET Button

NOTE
If D0000, D0001 or D0002 is changed please reset up the total table

SWING-ARM TOOL CHANGER [Option] – When Arm has not reached Spindle

1. Correct the condition that caused the fault.

2. Press the Reset key to clear condition alarms.
-.NOTE –
After resetting the condition alarm, the “ATC Arm Not In Position” alarm will remain
active. The Cycle Start and Feed Hold lights will be flashing.

3. Switch the mode selection key switch to Manual then select manual mode on the
control (Jog or Handwheel or Zero return mode).
4. Press and hold the +X axis jog key

5. Press RESET Button

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2.16 MAGAZINE ALARM RECOVERY

＊ALARM 1: MAGAZINE NOT IN POSITION

1. Switch to jog with key at manual.

2. Press to rotate and re-position magazine.

3. Press Reset.

＊ ALARM 2: MAGAZINE COUNTER C1 NE C2 ALARM

1. Correct counter for magazine pocket. Using the following "Checking 2: Magazine
Counter" procedure.
2. Press Reset.

Once the magazine alarm is fixed, use the following procedures to avoid picking the
wrong tool.

Checking 1: Tools In The Pocket Of Magazine

Checking 2: Magazine Counter

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***** Reference Diagram *****

Checking 1: Tools In The Pocket Of Magazine

Check the whether tool number is corresponding to the pot number in reality

POCKET NUMBER

EXAMPLE SWING ARM 30 TOOLS

POT_1 POT_13 POT_25

POT_2 POT_14 POT_26

POT_3 POT_15 POT_27

POT_4 POT_16 POT_28

POT_5 POT_17 POT_29

POT_6 POT_18 POT_30

POT_7 POT_19

POT_8 POT_20

POT_9 POT_21
POT_10 POT_22

POT_11 POT_23

POT_12 POT_24

TOOL NUMBER

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Checking 2: Magazine Counter

Check whether the Magazine Counter is correct in reality

SWING ARM TYPE : CAROUSEL TYPE:

C02 = 0 POT number 1 C02 = 1 POT number 1
C04 = 0 POT number 1 C04 = 1 POT number 1

C02 = 1 POT number 2 C02 = 2 POT number 2

C04 = 1 POT number 2 C04 = 2 POT number 2

EXAMPLE SWING ARM 30 TOOLS

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