HORIZONTAL MACHINING CENTER

OPERATION MANUAL

KAO FONG MACHINERY CO., LTD. NO.16,Keya Rd,Daya Townsip,Taichung County 42811,Taiwan R.O.C TEL: 886-4-25662116 FAX: 886-4-25608851 http://www.kafo.com.tw E-mail:elec@kafo.com.tw E02 edition in July of 2008

KAO FONG MACHINERY CO.,LTD FANUC 0I,18I,21I

1. 2. PREFACE INSTALLATION AND POWER ON 2.1 Input power ON 2.2 Specifications of electric appliances 2.3 The step of main power ON: OPERATORS PANEL 3.1 Operator panel 3.2 Soft operator's panel 3.3Machine operators panel: MANUAL OPERATION 4.1 MANUAL REFERENCE POSITION RETURE 4.2 MANUAL MOVEMENT OF 3-AXES: 4.3 OPERATION OF SPINDLE CLAMP/UNCLAMP: 4.4 MANUAL MAGAZINE OPERATION : 4.5 SPINDLE OPERATION: EXPLANATION OF ATC AND APC 5.1 CAM TYPE ATC: 5.2 HYDRAULIC TYPE APC: 5.3 SERVO MAG FUNCTION EXPLANATION OF OTHER INSTALLATIONS 6.1 LUBRICATION AND THE RELATED SETTING: 6.2 COOLER UNIT: 6.3 HYDRAULIC UNIT(HYD.) 6.4 CHIP CONVEYER (CHIP) 6.5 WORK LIGHT/ALARM LIGHT 6.6 SPINDLE OIL/AIR LUB UNIT AUXILIARY FUNCTIONS: 7.1 EXPLANATION OF M CODE: PLC SETTING 8.1 SETTING OF TIMER: 8.2 EXPANATION OF KEEP RELAY SETTING: 8.3 TO MODIFY THE SETTING: THE TROUBLESHOOTING 9.1 CHANGING SAFE UNIT 1-1 2-1 2-2 2-3 2-5 3-1 3-3 3-5 3-7 4-1 4-1 4-1 4-2 4-2 4-2 5-1 5-2 5-11 5-11 6-1 6-1 6-2 6-3 6-3 6-3 6-3 7-1 7-1 8-1 8-1 8-4 8-8 9-1 9-7

3.

4.

5.

6.

7. 8.

9.

KAO FONG MACHINERY CO.,LTD 1. PREFACE

This manual describes the operation and troubleshooting of KAFOs vertical machining center (about auxiliary function for M code ,sequence for operation and some related items like TIMER, KEEP RELAY that also will be described at chapter 7, 8 ). The function of vertical machining center is not only decided by machine tools company, the CNC computer and servo system also have serious influence. In this manual we have tried as much as possible to describe all the various functions. Therefore, function which are not provide in your machine may be optional function. Do not modify the machine designing or add any electric device without our permitting, otherwise it may cause serious problem. Note:1. The programming and maintenance of CNCplease refer to the programming and maintenance manual of FANUC. 2. The installation and points for attention of machine please refer to installation manual of KAFO.

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KAO FONG MACHINERY CO.,LTD 2. INSTALLATION AND POWER ON 2.1 Input power ON
Link power ON as show in fig 2.2 Note. Please make sure of power-off when connecting the power, and to cover lid when it link completely. Be sure have ground connection to prevent the noise to the NC unit.

Fig 2-1

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KAO FONG MACHINERY CO.,LTD 2.1 Input power ON

Link power ON as show in fig 2.2 Note. Please make sure of power-off when connecting the power, and to cover lid when it link completely. Be sure have ground connection to prevent the noise to the NC unit.

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KAO FONG MACHINERY CO.,LTD 2.2 Specifications of electric appliances

VMC-H500 distribution of consumption:
AC220V

MAIN POWER SWITCH 75A 96.18(A) AC220V

9.7(A)

53(A)

0.1(A)

6.5(A)

0.28(A)

4.2(A)

0.1(A)

TRANSFORM ER AC110V

SPINDLE MOTOR

OILER

HYDRAULIC HEAT EXCHANGE SPINDLE COOLER UNIT ON CABINT SYSTEM

FAN

AC24V 8.2(A)

22.2(A)

1.4(A)

(1.5A)

CONTROL POWER

SEVO MOTORS FOR 4-AXES

COOLANT PUMP

POWER

output Control power 4 SOL + 15 relay + 1 work light + 1 revolving lamp = 4 1.1 + 15 0.0369 + 1 2.9 + 1 0.4 = 8.2 Non-fuse breaker= 9.7 + 53 + 22.2 + 0.1 + 6.5 + 0.28 + 4.2 +0.2 = 96.18 Transformer: a = N1/N2 = V1/V2 = 220/110 = 2 2 = A = I2/I1 =9.7/I1 i1 = 4.85(A) 4.85(A) 220(V) = 1067(VA) P.S.: If input voltage of environments is 380V, please use 35KVA transformer.

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KAO FONG MACHINERY CO.,LTD 2.2.1 Requirement to power source

1. Outer power voltage: AC-22010V or AC-38010V 2. Outer power frequency: 601HZ or 501HZ 3. Outer power cable: 22 m 4. Outer power capacity: over 45KVA 5. Grounding: There is one NFB switch (refer diagram in sec 2.1) with one grounding copper plate marked PE. Please connect the outer power grounding wire to this. The grounding wire diameter should be higher grade than the outer power cable 22 m If there is now PE wire from the outer power system, there must be one additional one wire from the PE plate to the outside grounding to the outdoor space connecting to a copper bar berried under 1 meter in ground and the grounding resistant should be below 100.

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KAO FONG MACHINERY CO.,LTD 2.3 The step of main power ON:
Please use multi-meter to check if R.S.T. phases are shorted to ground connection? If machine oil tube is correct? And if the emergency stop button is pressed down that locates on operator panel? Be sure all those item that we mentioned are done, then turn main power ON. In this time the transformer, fan and the servo amp. are in stand-by state. You will see the power light on that displayed on the operators panel. After that please follow the step to turn main power ON: (1) press power ON push button that locates on the operator panel. (2) NC power ON (3) NC starts and screen on (that indicates an alarm message of EMG. Stop). If there is other alarm signal displayed in screen at this time. Please refer to alarm list of electric circuit. If NC alarm, then refer to operators manual of NC. When releasing emergency stop button there should be no alarm message on screen. And you could hear the voice of hydraulic unit that starts to work. If the hydraulic pressure does not increase, it means that phase of the input power is wrong(please see fig 2.1). Please turn power OFF, and exchange R and S then it will be restored. We will fix each-axis (especially Z-axis) to ensure every axis are firmer to avoid displacement during delivery. After finishing power connection, be careful to remove all firmer and move all axes and back to home point. No matter start or stop the NC have to be on EMG situation. It means that start NC first then release EMG when you turn power ON, and press EMG first then stop NC when you turn power OFF. After you success to power ON at the first time, you have to remove all firmer, level the machine and test each-function one by one during this time to avoid some unknown damage from delivery. If there are any question for main power ON please contact with us or our agent. After power ON, please checks the following items: (1) If each-axis has a normal? (2) If oiler consumes oil and works normally? (3) If spindle orientation is correct? (4) If z-axis tool change position is correct? (5) If T code and magazine work correct? (6) If low/high gear changes smoothly (7) Check other function like chip conveyer , coolant, work light, M30 light, Auto power out

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KAO FONG MACHINERY CO.,LTD 3. OPERATORS PANEL

10.4 Color LCD/MDI (Standard type, sheet key)

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KAO FONG MACHINERY CO.,LTD

FANUC 18I 8.4 COLOR LCD/MDI

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KAO FONG MACHINERY CO.,LTD 3.1 Operator panel

The operator panel is divided into two areas, the upper area is operator panel for MDI and CRT (please see page 3-1). 3.1.1 MDI keyboard functions: Item 1 Description
Power ON/OFF key
ON OFF

Function
Press this buttons to turn CNC ON and OFF

Rest key
RESET

Press this key to reset the CNC, to cancel an alarm, etc.

HELP key

Press this key to use the help function when uncertain about the operation of an MDI key.(help function)

HELP

Soft key

The soft key have various functions, according to the Applications. The soft key functions are displayed at the bottom of the CRT screen.

Address and numeric keys

Press these keys to input alphabetic, numeric, and other characters.

Shift key

Some key have two characters on their keytop. Pressing the SHIFT key switches the characters. Then the character indicated at the bottom right corner on the keytop can be entered.

SHIFT

INPUT key
INPUT

When an address or a numerical key is pressed, the data is input to the buffer, and it is displayed on the CRT screen. To copy the data register input tool offset memory by pressing INPUT key. This key is same as INPUT key of the soft keys, and either can be pressed to produce the same result.

Cancel key
CAN

Press this key to delete the last character or symbol.

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KAO FONG MACHINERY CO.,LTD

9
Program edit keys
ALTER INSRT INSRT DELET DELET

Press these keys when editing the program

ALTER

: Alteration : Insertion : Deletion

10

Function keys

Press theses keys to switch display screens for each function.

POS PROG

: Press this key to display the position screen. : Press this key to display the program screen

OFFSET : Press this key to display the offset/setting SETTING screen SYSTEM

: Press this key to display the system screen

MESSAGE :Press this key to display the message screen GRAPH

: Press this key to display the graphics screen : Press this key to display the custom screen (conversational macro screen)

CUSTOM

11

Cursor move keys

there are four different cursor move keys: :This key is used to move the cursor to the right direction in a character distance :This key is used to move the cursor to the left direction in a character distance :This key is used to move the cursor to the downward direction in a character distance : This key is used to move the cursor to the upward direction in a character distance :This key is used to changeover the page on the CRT screen in the forward direction. : This key is used to changeover the page on the CRT screen in the reverse direction.

12
Page change keys

PAGE

PAGE

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KAO FONG MACHINERY CO.,LTD 3.2 Soft operator's panel

Push MDI board. To
OPR
OFFSETSS ETTING

function button displayed

OFFSET

SETTING

WORK

panel.

PAGE

OPR to get into the screen of soft operators PANEL ON ON ON ON ON ON ON ON

OPERATORS

M/C LOCK : OFF DNC MODE : OFF MEMO KEY : OFF AUX LOCK : OFF PRO RESET : OFF MAN ABS : OFF HD.INT : OFF 4NG : OFF ACTUAL POSITION (ABSOLUTE) X 0.000 Y 0.000 Z 0.000 SO
NMACROO NSETTING O NOPRO

TO HAN

N OPR O

The function of operators panel are as shown below:

Operated mode ONOFF by cursor move key (1) M/C LOCK to select When the switch is set to ON position the machine and 3 axes do not move. The coordinates value still varies in CRT. (NOTE:Be sure X,Y,Z axes have to back to home position after OFF) (2)DNC MODE Data communication mode is used to transmit and execute simultaneously when the memory is for a large program. The program wont exist in the controls memory. Please set memory protect key to ON when you add, input, modify or delete program at EDIT MODE, even input or modify parameter at MDI MODE. When the switch is set to ON position the M.S.T.A.B code will be directly by passed and skip to next block.

(3) MEMO KEY

(4) AUX LOCK

(5) PRO RESET Program restart(Option, please see FANUCS SERIES 0-MC OPERATORS MANUAL). (6) MAN ABS This switch decides whether the amount of manual movement is to be added to the absolute value. (Suggestion: Keep the switch ON, otherwise the workpiece may have

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KAO FONG MACHINERY CO.,LTD

wrong shape.)

(7) Handle inserts(HD.INT):For any mode it can control 3-axis movemant by turnig hancl whed (8) 45 AXIS BYPASSINGOFF indicates uses the 4/5 axis (4NG) ON indicate noglect the fnuction for 4/5 axis

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KAO FONG MACHINERY CO.,LTD 3.3 Machine operators panel:

This section is to explain the function of every button and switch of operators panel.

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KAO FONG MACHINERY CO.,LTD

(1)POWER ON: This button turns the NC power ON.

(2)POWER OFF:This button turns the NC power OFF.

(3) EMERGENCY STOP: This button stops all machine motion in emergency To release it , turn it clockwise.

(4) EMG RELEASE: This button prevents the over travel from wrong setting of software limits or over travel situation of machine from wrong operation. When it works, the indicate light will on and all motion are the same as E-STOP condition.

The step of release: A: Check which axis(X YZ ) was over traveled. B: Select HANDLE MODE. C: Turn the axis switch to the over-traveled axis from hand wheel box, and press this button in the meanwhile. D: Press reset key to eliminate ALARM message, then re-execute 3-axes origination (re-zero). (5) MODE SELECT 1: This switch is used to specify an operation mode. There are the explanation of each mode as below: EDIT:This MODE is useed register,modify, add or delete of program and link personal computer to transfer parameter or program.

O T U A I D M T I D E

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KAO FONG MACHINERY CO.,LTD

M.D.I.: This mode can execute the command in register. AUTO: This mode is used to execute a program stored in memory. HANDLE: This mode can control 3-axes movement by turn hand wheel. The movement can be adjusted by incremental selector. JOG: In this mode, programmed of axis is controlled by FEEDRATE OVERRIDE and JOG FEEDRATE and the feed rate is displayed on operators panel. RPD: This mode is used to move axis in rapid traverse and is rapid speed adjusted by RAPID OVERRIDE %. ZRN: This mode is used to return 3-axes to machine zero and is moving speed adjusted by RAPID OVERRIDE %. (6) CYCLE START: Press this button, to start a program in auto mode and the lamp lights during the programmed operation. The function of CYCLE START for the following mode: AUTO MODE: To continue executing program. MDI MODE: To executed the input program of MDI. ZRN MODE: To return 3-axes zero simultaneously. SINGLE BLOCK MODE: To execute one block

(7) FEED HOLD: When this button is press, the program will pause automatically. Please notice that following situation: Rigid tapping: FEED HOLD is not performed until tapping cycle is finished. FEED HOLD: Could only stop the feed of 3-axes. (8) SPINDLE CLOCKWISE(M03): In handle mode, it will start spindle clockwise by pressing this button and the speed will be decided by the S command in the register (NC power ON must execute S command to use on MDI mode) (9) SPINDLE COUNTER CLOCKWISE(M04): In handle mode, it will start spindle counter clockwise by pressing this button. and the speed will be decided by the S command in the register (NC power ON must execute S command to use on MDI mode)

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KAO FONG MACHINERY CO.,LTD

(10) SPINDLE STOP(M05): To stop spindle by pressing the switch, if not in HANDLE MODE, press RESET key to stop spindle

(11) ORIENTATION: This switch will move the spindle to the orient position and then lock the spindle. To cancel the orientation, press M05. (12) COOLANT: To switch ON/OFF coolant pump. If safe door was opened or under maintenance mode This button will be no functional (13) WORK LIGHT: To switch ON/OFF work light.

(14) Z-AXIS LOCK: This function will lock Z-axis, the coordinate value of Z-axis still varies on CRT. After release, Z-axis have to return zero. This button should be pressed at least 3 seconds for function Action or release

(15) DRY RUN: When this button is ON, the feed and rapid traverse do not work, all movement is controlled by FEEDRATE OVERRIDE & JOG FEEDRATE.

(16) SINGLE BLOCK: When the switch is ON, the controller will execute one block and stop AUTO and MDI mode.

(17) BLOCK SKIP: When this button is ON, all block with slash / are ignored.

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KAO FONG MACHINERY CO.,LTD

(18) OPTION STOP: When this button is ON, the M01 code will works, the optional-stop will not be performed with only M01 code or with only this button on.

(19) CHIP CVYR: To ON/OFF chip conveyor. If safe door was opened or under maintenance mode This button will be + press switch use functional

(20) AUTO POWER OFF: When this button is ON, The main power of the machine will be switched OFF after executing M30 or M02 command.

(21) AXIS FEED DIRECTION: There are X Y Z 4 4 sets axis feed direction can be chosen.(To reform rapid traverse by pushing +4 -Y +Z
+X -4 +Y
-X

AXIS FEED DIRECTION AND RAPID button simultaneously)

-Z

(22) INDEX: Push this button once for magazine rotating one step, hold this button for continuous rotating.(INDEX can only make a clockwise turn.

(23) 0. SP TOOL/1. STAND-BY: When this button is ON, tool number of the stand by tool will be displayed at the tool number indicator. Otherwise the tool number of spindle tool will be shown. (24) RAPID OVERRIDE %: To adjust the rapid travel speed, it is available in the following modes:
%

Rapid travels of G00/G08/G30/G60 and canned cycle. The movement of RAPID & ZRN MODE

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KAO FONG MACHINERY CO.,LTD

(25) JOG FEEDRATE & FEEDRATE OVERRIDE %: To adjust the JOG FEEDRATE (a) Available in JOG & RUN mode (b) Range:0-1260mm/min The movement of PROGRAMMED FEEDRATE. (a)Available to F command that exists in program (b)Available range:0-150% (c)unavailable in tapping cycle. (26)SPINDLE OVERRIDE %: It can be adjusted in any mode.
% n i m x
n i m / % m m x

The range:50%-120%

(27) SPINDLE LOAD %: To display the actual load of spindle motor. Please pay attention when LOAD is over 120%.

150

(28) TOOL NO.: This indicator displays the number of SP TOOL or STAND BY TOOL.

(29) MAIN POWER LIGHT (L1): To indicate the main power is ON (The main power switch is located on right side of machine)

(30) ATC STAND-BY: The ATC does not work when the lamp does not light. When ATC works, the lamp wont light. The lamp lights when all the states of ATC are OK.

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KAO FONG MACHINERY CO.,LTD

(31) 4-AXIS UNCLAMP: To indicate the 4-axis is unclamped and can be operated. (The lamp does not light when there is no 4th-axis)

(32) LUB ALARM: It lights when Lub tank is empty or pump malfunction.

(33) GEAR H/L: To show the spindle gear position H. lamp light when spindle gear on high position. L. lamp light when spindle gear on low position. (There are no GEAR H/L lamp for the spindle of belt type)
L H

(34) MIRROR X/Y: X lamp will light during execute M71 command. Y lamp will light during execute M72 command.
X Y

(35) AXIS FEED DIRECTION RAPID BUTTON: To quick move every axis by combining with AXIS FEED DIRECTION. When in ZRN mode, the light will indicate whether the ZERO-RETURN is performed.

(36) OP1 :For customer add option.(When use CE operator panel for ENABLE button)

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KAO FONG MACHINERY CO.,LTD

(37)OP2: The axis feed direction ENABLE button at JOG/RAP or ZER mode,When use axis feed direction button must be enable OP2 button then can to move the axis.

(38)OP3: For customer add option.

(39)OP4: For customer add option.

(40) AIR BLOW(M07): Press this button to comply the M07 spindle side-flush command If safe door was opened or under maintenance mode This button will be no functional

(41) MODE SELECT SWITCH 2:

0 Normal mode under this mode the selection function of mode 1 coald be used randomly 1 Under this mode the movement of 3 axes will be limited with in 2mm/min and spindle speed will be stopped running to secare the safety of maintemance inside.

(42) PRESS SWITCHIf CE safe door was opened or under the maintemance mode chip conveyer function is needed the press switch and chip conveyor button should be pressed simutaneousiy.

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KAO FONG MACHINERY CO.,LTD 4. MANUAL OPERATION 4.1MANUAL REFERENCE POSITION RETURE After NC power ON, the axes have to return to the reference position(home, zero). If not, the travel limit of the software will be useless for each axis. and it will cause machine in dangerous situation, and the RAPID traverse will not be available. There are two ways to return reference position as follows:
(1) In ZERO mode, press the OP2 button then press the push button of each axis to return ZERO. It works even push more than one buttons simultaneously. When the selected axis starts, the speed is controlled by RAPID OVERRIDE switch and the default direction are -X, +Y, +Z. When the limit switch of an axis contacts its dog, this axis will decelerate to a default low speed until LIMIT switch leaves dog and starts to finds ZERO signal of motors encoder. After that the axis will stop and the indicate lamp of that axis will light. When 3 axes have returned reference position, the RAPID lamp will light too. Thereafter no matter 3 axes at any position just select zero mode and all RAPID lamp will light to remind customer that have overridden. (2) In ZERO mode, press OP2 button tnen push CYCLE START button, Z-axis will move to reference position first. When Z-axis decelerates, the X, Y axes move to reference position in the same time. The detail action and time for lamps light-on are the same as above mentioned. Please note that: (I) Before pushing the cycle start button, make sure that the limit switches of the 3 axes do not contact their dogs, and the 3 axes are not on the ZERO positions. (II) Set KEEP RELAY K4.7=1 (Please refer to chapter 9)

4.2 MANUAL MOVEMENT OF 3-AXES:

(1) MANUAL HANDLE OPERATION: In HANDLE mode, select AXIS DIRECTION SWITCH and control the movement of 3-axes by HAND WHEEL. The movement can be controlled by INCREMENTAL FEED SWITCH. (2) JOG OPERATION (slow feed): In JOG/RPD mode, press OP2 button then push AXIS DIRECTION SWITCH + or - to move 3-axes, and to adjust the movement by FEEDRATE OVERRIDE & JOG FEEDRATE that is on operators panel. (3) RPD OPERATION(rapid traverse): IN JOG/RPD mode, press OP2 button then push RAPID and AXIS DIRECTIO SWITCH + - to move 3-axes, the movement
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KAO FONG MACHINERY CO.,LTD

is adjusted by RAPID OVERRIDE %.

4.3 OPERATION OF SPINDLE CLAMP/UNCLAMP:

There are only CLAMP/UNCLAMP button on the front of Operaters Panel, when press down this button is UNCLAMP and relieve it is CLAMP.

4.4 MANUAL MAGAZINE OPERATION :

(1) MAGAZINE RETURN HOME OPERATION: Select ZRN mode, push INDEX button that show on the panel. Then the magazine starts rotation until stopped at the position of 1. Stand by tool position. MAGAZINE ROTATIONG OPERATION: Select HANDLE mode, push INDEX button that show on the panel. Then moved one pot by clockwise move. If not relieve this button keep running. (3) The control box at the lower of magazine have two buttons
MG. for magazine forward CW and FOR MG. REV

(2)

for magazine reverse.

Push button once for move one pot. If not relieve the button it will keep running.

4.5 SPINDLE OPERATION:

(1) In MDI mode, to start by key in M03 or M04 and speed S
IN PUT

after started the speed adjust by SPINDLE OVERRIDE 50% 120%. (2) In HANDLE mode, to start when executed M3 (M4) S indication. Only press M3 and M4 then the spindle will rotate like S order that you have done

before.

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KAO FONG MACHINERY CO.,LTD 5. EXPLANATION OF ATC AND APC

ATC UNIT Please make sure that X/Y-axis reference position and spindle reference position are at the right point before execute M6 command. Especially, after you reinstalled X/Y-axis motor or orientation sensor. The compensation parameter for Z-axis tool change point is No.1241 The compensation parameter for spindle orientation point is No.4031 APC UNIT Please make sure that Z/A-axis reference position and APC reference position are at the right point before execute M16 command. Especially, after you reinstalled Z/A-axis motor or orientation sensor

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KAO FONG MACHINERY CO.,LTD 5.1 CAM TYPE ATC:

5.1.1) ATTENTION OF OPERATION: (1). ATC STAND-BY: The ATC will be in STAND-BY state, except executing tool change. If ATC is not stand-by, then M06 wont be executed and X/Y-axis will not move. When the LED(on operators panel) of ATC STAND-BY lights on, it means ATC is STAND-BY. When executing M06 the light is OFF. (2.) TOOL CHANGE CYCLE I. TOOL CHANGE OF MDI MODE To execute M06 or T code are available in MDI mode. In MDI mode, first press PROGRA , then key in M06 and press INPUT to execute M06. M M19 (spindle orientation) will start automatically when execute M06. So its not necessary to execute M19 spindle orientation. When tool change is done, the ATC STAND-BY will light on. II. MDI SINGLE BLOCK In MDI mode, when X,Y-axis back to 2TH reference position using single block to execute tool change is OK. But notice that CAM single block method is only provide for ATC calibration. During this time spindle tool and standby Tool doesnt change in the tool table. Before you use single block, first, set K5.3=1( please notice that setting K5.3=1 will have danger of operating). We suggest you take down of tools and turn POWER OFF then restart again when it finishes.( K5.3 will change to 0 automatically after POWER OFF and ATC STAND-BY lights ON.). We will explain how to set K5.3=1 at chapter 8.3. When it is finished on the
OFFSET SETTING

screen

PWE have to be set to 0. Otherwise, 100 P/S AL and MDI cant work. There are steps for MDI single block as follows: M19 : SPINDLE ORIENTATION M82: POT. FOR M83 : ARM CW, M89: ARMCCW M84 : SPINDLE TOOL UNCLAMP M83 : ARM CW, M89: ARMCCW M88 : SPINDLE TOOL CLAMP M90 : POT BACK Please turn POWER OFF and ON when finished otherwise STAND-BY light wont lights ON.
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KAO FONG MACHINERY CO.,LTD

Please execute M83 ARM CW if there are tools on spindle or POT. When execute M89 ARM CCW have to consider with if SPINDLE CLAMP/UNCLAMP finished. Suggestion: dont use tools during this time. M83 and M89 could use alternately, example: M83
ARM 90

M89
ARM 0

M83
ARM 90

M83
ARM 180 UP
(step 1.)

M89
ARM DOWN 180
(step 2.)

M89
ARM 0
(step 3.)

stop position

The above actions can operator by M83 or M89 in sequence. (3) TOOL CHANGE OF AUTO MODE: To execute M06 tool change in AUTO MODE ( MACRO), it means when executing M06 in program it will call the sub-program 09001 automatically. And after executed, it will back to main-program. Do not modify or delete the program of 09001. NOTE: DO NOT EDIT, MODIFY AND DELETE THE PROGRAM FROM 09000 TO 09999 0F FANUC 0M-C SYSTEM. THE MOTION OF SUBPROGRAM: cSimultaneously executing X,Y-axis returning to 2TH reference position, Z-AXIS returning to reference position , POT DOWN, SPINDLE ORIENTATION (M19). The customer doesnt have to write G91 G30 X0 Y0 ; G91 G28 Z0 ; and M19 commands before M06. But if tool have interference, please check that if tool withdraw and spindle orientation are necessary. dStart tool change mechanism, and to execute the cycle of tool change: POT.FOR => ARM 90{ => SPINDLE UNCLAMP, AIR BLOW => ARM DOWN => ARM 180{ => ARM UP => SPINDLE CLAMP => ARM 0{ => POT BACK => CHECK ATC => END M06 AFTER STAND-BY e If M07 or M08 or M12 is applied, the code of M09 is not necessary to be written down. M07 M08 M12 will pause during executing M06 tool change, and will start automatically.

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KAO FONG MACHINERY CO.,LTD

If use MACRO for tool change in AUTO mode, it is allowable M06 and T code in the same black. Suggestion: Do not write them together in one block to save time for tool change. (MODE 1) : M06 T07; :
TOOL NO.7 MACHINING PROCESS

M06 T08; :
TOOL NO.8 MACHINING PROCESS

(MODE 2) : M06; T08; :

TOOL NO.7 MACHINING PROCESS

M06; T09;

TOOL NO.8 MACHINING PROCESS

09001 is one block during executes M06 call sub-program 09001 in programming, At this time press FEED HOLD key the program will stop until l ATC tool changing finished. NOTE: Do not stop the process of tool change abnormally(like EMG STOP AIRPRESSURE DROP AND UNUSUAL POWER OFF etc.). Please RESET, and use M code to set ATC STAND-BY, then re-execute tool change.

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3) TOOL SEARCH: The way for tool management (MAG) is random. The tool doesnt correspond to any POT. When executing T code, first the controller decides the corresponding POT of tool, then starts magazine, uses the shortest path to decide MAG.CW or MAG.CCW , then puts tool on STAND-BY position. Do not stop ATC unusually during magazine rotation (Like EMG STOP, AIR-PRESSURE-DROP or UNUSUAL POWER-OFF). Otherwise tool counter will mistake. The tool registration have to be reset.( We will describe the way to reset registration at next chapter.) To search a tool is available for MDI or AUTO mode. In HANDLE mode, please refer to MANUAL MAGAZINE OPERATION (section 4.4) to see how to perform the movement of magazine.

5.1.2 BRIEF INTRODUCTION FOR EVERY CONFIGURATION

L1 LOCK PIN IN POSITION DETECT L2 POT IN POSITION DETECT L3 POT OUT POSITION DETECT L4 MAG. HOME POSITION DETECT L5 COUNT SENSOR A L6 COUNT SENSOR B L7 CAM STOP POSITION DETECT L8 CAM CHECK POSITION DETECT L9 CAM STAND BY POSITION DETECT L10SPINDLE CLAMP POSITION DETECT L11SPINDLE UNCLAMP POSITION DETECT L12SPINDLE HIGH GEAR POSITION DETECT L13SPINDLE LOW GEAR POSITION DETECT L14SPINDLE ORIENTATION SENSOR M1MAG. MOTOR M2CAM. MOTOR B1CAM MOTOR FAN TROPELLER H1CLUTCH FOR HANDLE BREAKER P1MG FORWARD PUSH BUTTON P2MG REVERSE PUSH BUTTON P3SPINDLE CLAMP PUSH BUTTON P4SPINDLE UNCLAMP PUSH BUTTON

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KAO FONG MACHINERY CO.,LTD

THE RELATED ITERS FOR STAND-BY: To execute M06,the ATC must be in STAND-BY situation, and has to satisfy the following items:

0I AND 18I .21I AIR PRESS. LOCK PIN IN POT IN POT OUT TOOL CLAMP TOOL UNCLAMP CAM STOP CAM CHECK CAM HOME COUNTER A SENSOR COUNTER B SENSOR

L1 L2 L3 L10 L11 L7 L8 L9 L5 L6

X6.0 ON X5.4 X5.5 ON OFF X5.6 ON X5.0 OFF X5.1 OFF X7.2 ON X7.3 ON X7.4 X6.1 ON X6.2 ON

SERVO MAG NO USE

SERVO MAG NO USE SERVO MAG NO USE

When the ATC STAND-BY lamp doesnt light during maintenance. please use DGNOS to examine above items. make sure that every limit switch is correct.(Please refer to the ELECTRIC CIRCUIT MANUAL for more help in finding the source of malfunction)

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KAO FONG MACHINERY CO.,LTD 5.1.3 M06 CANT BE DONE

There are two situations as below: I. Stop after POT OUT: (1) (2) (3) (4) Z-axis has not returned HOME Spindle orientation has not finished POT OUT LIMIT has not ON Tool search error(Tool registration has some mistake.

(5) Air pressure is not enough Try to find the reason as mentioned items. Then use MDI to execute M90 (POT IN), and back to ATC STAND-BY. After it re-execute M06. II. Stop during ATC ARM motion (1) (2) (3) (4) (5) (6) (7) (8) POWER OFF during M06 tool change EMG emergency stop happened during M06 tool change ARM not stop at right position ARM sensor L7L8L9 have malfunction TOOL CLAMP/UNCLAMP ( L10L11) not finished The message for finished spindle orientation are mission. CAM motor overload The breaker for CAM motor didnt work.

There are a few ways to solve those problems but in any case have to observe the following principles: i. ii. POWER OFF during M06 cant be done. Take off tools for safe reason

iii. Be sure follow the below steps indeed: (1) Troubleshooting by MANUAL: Please use this reliable and safe way to solve the problem If the engineer are not familiar with logic of tool change. The steps are as below: i) POWER OFF(It only execute in POWER OFF situation) ii) Take out the cover of CAM motor. Please refer to sketch (E)(H). iii) Release the device of motor breaker. Please refer to sketch(H1).(There are some modes breaker are different). iv) In motor breaker released situation, use spanner to wrench CW or CCW until ARM back to 0 position. Be sure there are no tool on the ARM. Because of it will be very danger when spindle is on CLAMP while POWER OFF. v) After ARM back to 0 position, wrench motor breaker to original place,
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KAO FONG MACHINERY CO.,LTD

then turn POWER ON again.

vi) To execute M90 POT UP In MDI mode. When ATC STAND-BY lights on. then its done. (2) Troubleshooting by ARM JOG K5.3 can execute each M83M89 change that we mentioned as 5.2. 1)(2)II., but it is not suitable in ATC M06 cant be done. Because this keep relay will separated movement into three steps. So it is only use when ATC calibration. There are keep relay for ARM JOG:K5.0=1 to star ARM JOG function Operation: c Please turn POWER OFF POWER ONEMG. d To set K5.0=1 (Please refer to Chapter 8.3) setting screen 2, PWE =0 otherwise, 100 P/S Al will cause MDI cant be operating. NOTE: Dont set K5.0 and K5.3 =1 at the same time or commands will no use at all. eSelect HANDLE mode, CYCLE START
FEED HOLD

lights ON means SPINDLE CLAMP lights ON means SPINDLE UNCLAMP

f Push Push

CYCLE START FEED HOLD

, ARM JOG + , ARM JOG

g In JOG procedure, If there are tool on ARM or POT please notice that spindle CLAMP/UNCLAM position and release all tools. You also would use MDI mode to execute M84( tool UNCLAMP)M88(tool CLAMP) M82(POT FOR)M90(POT BACK). h Use JOG moves ARM to 0 In MDI mode, to execute M90 POT BACK then ATC will back to original position. iPOWER OFF after ATC back to original position, then K5.0 will automatic set =0 and ATC STAND-BY will light ON, otherwise M06 cant be executing.

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KAO FONG MACHINERY CO.,LTD 5.1.4 TO SET TOOL REGISTRATION:

Setting tool registration must be in MDI mode, and set write-down protection (PWE)= 1 , then set tool registration in DATA page. Please refer to ELECTIC CIRCUIT PAGE N1The addresses of tool registration. Here are descriptions for setting tool registration as bellows: C01: To set the amount of tool. If magazine are 30 tools, set 30. If 40 tools just set 40(Be sure to set the right numbers, otherwise it will cause the machine to select the wrong tools) The pot number in STAND-BY position: Setting at D10: Setting spindle tool number. D11~D40:To set the tool number for POT No. 1~30, D11 is corresponding to Pot No. 1, etc. Be sure the tool number should not be bigger than 99 (for 24-tool magazine, D35~D40 should be kept empty). If ATC has tool-selection mistake, please re-check the tool registration and correct the mistake. Otherwise there will be some alarm when executing T code.
CURRENT

of counter screen of PMC

5.1.5 USING & NEGLECTING OF MACRO FOR TOOL CHANGING:

MACRO 09001 is for M06 tool change, the benefit for using MACRO is as follows: 1. In AUTO mode, it will be able to execute M06 and T CODE in one block. 2. G91, G28, Z0 and G91 G30 X0 Y0 is not necessary before M06. 3. To reduce the time for tool change. Simultaneously executing POT-FOR & SPINDLE ORIENTATION AND X,Y,Z-AXIS returning to the point of tool change. For special reasons, if you dont want using MACRO to execute tool changing. There is explanation of neglecting MACRO in next section 5.1.5.1

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KAO FONG MACHINERY CO.,LTD

(1) SUBPROGRAM OF TOOL CHANGE:
% O9001(..MO6 SUB-PROGRAM.) THE NUMBER OF PROGRAM AND EXPANATION. #3003=1 SINGLE BLOCK IS DISABLED. #3004=1 FEED HOLD IS DISABLED. T#4120 SEARCH T-CODE; IF[#1000EQ1] GOTO 70 TO DECIDE IF T IS SPINDLE TOOL IF[#1003EQ1] GOTO 10 TO DECIDE IF IN MDI MODE. N10 #103=#4003 SAVE THE CURRENT G-CODE OF THIRD GROUP #1100=1 SPINDLE ORIENTATION AND POT DOWN G91G30Z0 Z-AXIS RETURNS 2TH HOME #1100=0 CANEL MACRO #1100 M06 EXECUTING TOOL CHANGING N70 G#103 #3003=0 SINGLE BLOCK IS AVAILABLE #3004=0 FEED HOLD IS AVAILABLE M99 RETURN TO MAIN PROGRAM

(2) neglect of macro tool change: 1. 2. Select MDI mode Press

OFFSET SETTING

key parameter key set PWE=1

3.

Change the setting of parameter 6071(No.6071=0 to neglect this MACRO, No.6071=6(M6) uses MACRO) Set PWE=0

4.

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KAO FONG MACHINERY CO.,LTD 5.2 HYDRAULIC TYPE APC:

5.2.1) ATTENTION OF OPERATION: (1). APC STAND-BY: 1). APC STAND-BY: The APC will be in STAND-BY state, except executing table change. If APC is not stand-by, then M16 wont be executed. When the LED(on APC panel) of APC ALARM lights on, it means ATC is NO STAND-BY. (2.) TABLE CHANGE CYCLE I. TABLE CHANGE OF MDI MODE To execute M16 are available in MDI mode. In MDI mode, first press PROGRA , then key in M16 and press INPUT to execute M16. But,must execute G30 Z0 and G28 A0 before execute M16 command II. MDI SINGLE BLOCK In MDI mode, when z,a-axis back to change position using single block to execute table change is OK. But notice that APC single block method is only provide for APC calibration. There are steps for MDI single block as follows: M64 : TABLE UNCLAMP M63: TABLE UP M17 : APC 0D M18 : APC 180D M62 : TABLE DODN M65 : TABLE CLAMP

5.3 SERVO MAG FUNCTION 5.3.1 SERVO MAG SETING PARAMETER

MDI MODE SYSTEM 3 PMM SYSTEM PARAM Relative parameters120 P11#0#7 Setting absolute origin point. Please set 0 for test. After confirming the origin point, set 1. (At origin point setting mode, K10.1 must be 1. after turn off/on power, it becomes 0 automatically.) P41 Setting 300 When the tool origin marks coincide, this is the speed for adjustment. P68 ALL TOOL NUMBER 90 P105 SDMR1 500 P106 SDMR2 1 P109 BACKLASH
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KAO FONG MACHINERY CO.,LTD 5.3.2 90T Tool magazine single step M code
M40 : M41 : M42 : M43 : M44 : M45 : M46 M47 M66 TRVCLAMP TRVUNCLAMP TRV AIN TRV AOUT TRV BIN TRV AIOUT TRVUP TRVDOWN MOVE THE STAND BY POCKET AT THE SPINDLE SIDE BACK TO TOOL MAGAZINE SIDE

90T SERVO magazine single 18I & 21I & 0IC AIR PRESS.

X6.0

TRV A IN LS L1 ON X102.0 TRV A OUT LS L2 OFF X102.1 TRV B IN LS L3 ON X102.2 TRV B OUT LS L4 OFF X102.3 TRV UP LS L5 OFF X102.4 TRV DOWN LS L6 ON X102.5 TRV CLAMP LS L8 OFF X102.6 TRV UNCLAMP LS L7 ON X102.7 POT IN L10 ON X5.5 POT OUT L9 OFF X5.6 CAM STOP L17 OFF X4.3 CAM CHECK L16 ON X4.4 CAM HOME L15 OFF X4.5 TOOL CLAMP L18 ON X5.0 TOOL UNCLAMP L19 OFF X5.1 When using single step function for clamping in tool magazine trouble, K1.4 must be set into 1. (after power off/on, it becomes 0 automatically). According to the signal of ON/OFF in 90T signal table, turn off the power when the grasp arm returns to normal position. Restart the machine, the ATC STAND-BY light will be on and the system can work normally now.

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LS-4 TRV-B OUT

LS-3 TRV-B IN

LS-2 TRV-A OUT

LS-1 TRV-A IN

LS-9 TRV-UNCLAMP

LS-8 TRV-CLAMP

LS-5 TRV UP

LS-6 TRV DOWN

LS-10 POT TO MAG

LS-9 POT TO SP

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KAO FONG MACHINERY CO.,LTD 5.3.3 SERVO TYPE 90T TOOL CHANGE SUBPROGRAM DESCRIPTION:
% O9001 #3003=1 SINGLE BLOCK IS DISABLED FEED HOLD IS DISABLED #3004=1 #1101=0 G4X0.5 #1101=1 T-CODE CHEACK G4X0.2 #1101=0 IF[#1005EQ1]GOTO70 TO T-CODE CHEACK IF[#1000EQ1]GOTO70 TO DECIDE IF T IS SPINDLE TOOL IF[#1003EQ1]GOTO10 TO DECIDE IF IN MDI MODE N10 SAVE THE CURRENT G-CODE OF THIRD GROUP #103=#4003 #1100=1 SPINDLE ORIENTATION AND POT DOWN G91G28Z0 Z-AXIS RETURNS HOME G91G30X0Y0 XY-AXIS RETURNS 2th HOME #1100=0 M06 EXECUTING TOOL CHANGING N70 G#103 #3003=0 SINGLE BLOCK IS AVAILABLE FEED HOLD IS AVAILABLE #3004=0 M99 RETURN TO MAIN PROGRAM %

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6. EXPLANATION OF OTHER INSTALLATIONS

This chapter is to describe operation and explanation of other functions. Because the new software is updated too fast and there are many different requests from customers. Therefore, we only describe the standard function. About the optional functions, please refer to the attached information.

6.1 LUBRICATION AND THE RELATED SETTING:

6.1.1 The oil lubrication system is very important for machine tools. And the OILER is like the heart for oil lubrication system. If lubrication is not good it will cause servo motor a heavy load and abnormal current. If the oil supply of slideways is short for a long time, it will cause bad accuracy and servo motor vibration, noise, heat etc. If serious, it will injure the slidewats. When power ON, after releasing EMG the LUB will retain the pressure immediately at the first time. Retain pressure time is set by PLC TIMER 2. The standard value is 15 sec. After the pressure detecting time(TMR12,10 sec), If the pressure is still not enough, the LUB PRESSURE MISS alarm will be displayed. If the pressure is normal, the oil will start filling and the time intermittent counter will start to count. Same as the above condition, the pressure has to release within 10sec from filling oil. Otherwise 2010 ALARM will be displayed. When retain pressure and fill oil are all right, the time intermittent counter TMR1 and TMR3 will decide the time for next retain pressure. In auto mode, the intermittent time TMR1 is 10 minutes. In handle mode, the intermittent time TMR3 is 20 minutes. As above description, The cycle for oilier is as follows: ON RETAINS PRESSURE PRESSURE DETECTS FILLS OIL PRESSURE DETECTS INTERMITTENT RETAINS PRESSURE (For the detail of setting PLC TIMER, please refer to page 8-1) 6. 1.2 HOW TO TAKE CARE OF THE OILER PROBLEMS: If the machine does not ON for a long time. The sideways are dry. Please use MANUAL PUSH BUTTON to start oiler a few times after machine ON. About the question of OILER we will explain as following:

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1. ALARM 2009

ALARM 2009 is oil not enough. When ALARM happens, please fill oil within 30 minutes. If not, it will change to FEED HOLD. In auto mode, Single block is automatically engaged and the indicate lamp E4 will light. At this time, to fill oil and reset is the only way to solve this problem. If it still not works, maybe there are some other parts malfunctioned. Please ask the engineer of agent to help. 2. ALARM 2010 ALARM 2010 IS PRESSURE DETECTION ERROR. It happens mostly with the problems of oil tube. If happens during retain pressure, it means the pressure can not retained in time. try to increase TMR12 and TMR2 (the maximum is 40 minutes). please notice that value of TMR12 should be larger than TMR2. If the problem still exists, it means the problem of oil tube or pressure switch or the pump.

6.2 COOLER UNIT:

COOLER UNIT is to provide cooling and lubrication to spindle head during high speed rotation. We have gear and belt type spindles which use different type cooler units. but the principle and motion are almost the same as below: A pump withdraws warm oil from spindle head, and send it back to cooler. The detector will check whether the oil temperature is higher than the setting value. If yes, the compressor will start automatically to cool down the oil until the temperature is lower than the setting. The compressor will stop. Because the cooling oil is a close-loop circulation system, the pump is non-stop, but the compressor works intermittently. The cooler unit starts work when power is ON and EMG is released. If alarm 1004 SPINDLE GEAR OIL AL is displayed at the first POWER ON, but coolers panel displays nothing. It means phase of the input power is wrong. For the rest of problems, the 1003 ALARM will be displayed when cooler doesnt work. If the problem is not same as the above, please check the panels display. and refer to the operations and troubleshooting manual of oil cooler unit. Besides, the operation temperature range is also written in the manual of cooler unit. usually, the temperature setting is room temperature adds the value that we set. For example, now the room temperature is 25{, and the value is +5 , so the temperature is not over 30{. If over 30{ , the compressor will start.

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KAO FONG MACHINERY CO.,LTD 6.3 HYDRAULIC UNIT(HYD.)

HYDRAULIC UNIT is to provide the power for hydraulic equipment of machine tools, including ATCAPCAUTO DOOR AND COUNTER BALANCE for Z-AXIS(for some models) Etc. When releasing EMG button, the hydraulic unit will start work and the pressure goes up. When pushing EMG button the hydraulic unit will stop. Basically, there is no electric controller which can control the pressure of hydraulic. But the work have to suit the EMERGENCY STOP CONTECTOR (ELECTRIC CIRCUIT C1). About the time for changing oil, to use what kind of oil and the adjustment of pressure please refer to maintenance manual.

6.4 CHIP CONVEYER (CHIP)

CHIP CONVEYER starts manually(a push button which shows on operators panel) or by M code (M68 ON and M69 OFF),please refer to chapter 7.

6.5 WORK LIGHT/ALARM LIGHT

The equipment for light is a 24V light (quartz), it locates beside head. It starts manually by the push button on the operators panel. Alarm light not only lights on the end of M02M30, when some ALARM happens it will light too. (Set K4.5=1)

6.6 SPINDLE OIL/AIR LUB UNIT

The oil/air lub unit is import for high speed spindle. When power ON, after releasing EMG the OIL/AIR LUB will retain the pressure immediately at the first time.The standard value is 30 sec. If the pressure is still not enough, or oil not enough and spindle is running, then the AL2016 will be displayed.

6.7 THERE LAYER ALARM LIGHT DESCRIPTION

RED LAMPAbnormal warning Urgent situetion YELLOW LAMP Programing in process or M30 programing ending signal incoming GREEN LAMPProgram runing status

6.8 RS232 AC110V INTERFACE

Only for power supply of the Notebook and prohiditted for other spare parts

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KAO FONG MACHINERY CO.,LTD 6.9 HAND PASS SAFE DOOR INTER LOCK
When the machine is in the condition of power bisconnection or maintainance 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.

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7. AUXILIARY FUNCTIONS:
This chapter will describe the auxiliary functions. We follow the idiomatic usage to edit the common M codes(like M3M4M5M19etc.). About the other M codes we edit it as convenient as we can. Please refer to the list of this chapter or the ELECTRIC CIRCUIT MANUAL(page. M1). If you have special request of M code, please contact with us.

7.1EXPLANATION OF M CODE: (THE MARKS * IS FOR OPTION FUNCTION)

M00 M01 PROGRAM STOP OPTIONAL STOP, IT WORKS ONLY WHEN OPTION STOP BUTTON ON THE OPERAORS PANEL IS PRESSED.

M02/M30 END PROGRAM, IF COMBINING WITH AUTO POWER OFF BUTTON, THE NC WILL POWER OFF AUTOMATICLY. THE DIFFERENCE BETWEEN M2 AND M30 IS THAT M2 ONLY ENDS THE PROGRAM, M30 WILL END AND REWIND THE PROGRAM. M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M13 M16 M17 M18 M19 M21 SPINDLE CW ON SPINDLE CCW ON SPINDLE OFF IN MDI OR AUTO MODE, TO EXECUTE TOOL CHANGE. MIST ON COOLANT ON MIST(M07),COOLANT(M08),THROUGH TOOL COOLANT(M12) OFF THE 4TH CLAMP THE 4TH UNCLAMP THROUGH TOOL COOLANT ON SPINDLE CW AND M08 COOLAND PUMP ON AUTO APC CHANGE APC CW 0D APC CCW 180D SPINDLE ORIENTATION SPINDLE SWITCH TO LOW GEAR

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KAO FONG MACHINERY CO.,LTD

M22 M31 M32 M40 M41 M42 M43 M44 M45 M46 M47 M62 M63 M64 M65 M66 M68 M69 M70 M71 M72 M75 M76 M80 M81 M82 M83 M84 M88 SPINDLE SWITCH TO HIGH GEAR CALL TABLE A CALL TABLE B TRV-CLAMP (SERVO MAG-90T ONLY) TRV-UNCLAMP (SERVO MAG-90T ONLY) TRV-A IN (SERVO MAG-90T ONLY) TRV-A OUT (SERVO MAG-90T ONLY) TRV-B IN (SERVO MAG-90T ONLY) TRV-B OUT (SERVO MAG-90T ONLY) TRV-UP (SERVO MAG-90T ONLY) TRV-DOWN (SERVO MAG-90T ONLY) APC TABLE DOWN APC TABLE UP APC TABLE UNCLAMP APC TABLE CLAMP MOVE THE STAND BY POCKET AT THE SPINDLE SIDE BACK TO TOOL MAGAZINE SIDE (SERVO MAG-90T ONLY) CHIP ON CHIP OFF CANCEL MIRROR FUNCTION X-AXIS MIRROR ON Y-AXIS MIRROR ON TS-27(ITI) AIR BLOW ON(OPTION) TS-27(ITI) AIR BLOW OFF(OPTION) AUTO DOOR UP AUTO DOOR DOWN POT FOR,X,Y-AXIS HAS TO RETURN ZERO AND ATC STAND-BY LIGHT ON ARM 90{. EXECUTE M82 AND M19 BEFORE THIS COMMAND. SPINDLE TOOL UNCLAMP SPINDLE TOOL CLAMP

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M89 M90 M92 M93 M94 M95 M98 M99 ARM 0{ . FIRST, HAVE TO EXECUTE SPINDLE CLAMP POT. BACK. FIRST, HAVE TO EXECUTE ARM 0{ TS-27(ITI) UP(OPTION) TS-27(ITI) DOWN(OPTION) USE OMP60(OPTION) USE TS-27(ITI) (OPTION) SUB-PROGRAM CALL IF USED IN SUBPROGRAM IT WILL RETURN TO MAIN PROGRAM. IF USED IN MAIN PROGRAM IT WILL REPEAT EXECUTING THE PROGRAM

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8.

PLC SETTING

The PLC setting are including TIMER and KEEP RELAY, the detail of to set TIMER and KEEP RELAY is described at section 3 in this chapter. What is PLC ? It means control by LOGIC. That is to say, it is HUMAN INTERFACE. We try to modify PLC more user-friendly and safety for customers request. Because every company has different design. Please read the manual carefully for the best performance of the machine. Before shipping the machine, we have checked an run machine completely, and the relative values are all set. To prevent missing the data, We copy it in ELECTRIC CIRCUIT(page L1~L3 and M1), and about the machine parameter we save in NC memory. Because the life of battery(lithium) is 5 years for machine (if machine are not works, the battery life only 3 months), if overtake the battery life the parameter will be lost. So we copy two set, one for the customer and one for us to ensure the parameter will not be lost. Please be careful to keep the items as blows: zELECTRIC CIRCUIT zLADDER DIRGRAMM zTHE DATA SHEET FOR SYSTEM PARAMETER zTHE DATA SHEET FOR MACHINE PARAMETER zTHE FLOPPY DISK FOR PARAMETER In section 3 of this chapter well mention about how to modify and setting PLC and machine parameter. But please be sure not to modify them without our approval.

8.1SETTING OF TIMER:
8. 1.1 TIMER FOR LUB:
TIMER NO. TMR 3 IN MANUAL MODE, THE TIME FOR INTERMITTENCE. TMR 12 THE TIME FOR DETECT THE PRESSURE OF LUB. TMR 2 TMR 1 THE TIME FOR LUB MOTIONS AND FILLER IN AUTO MODE, THE TIME FOR INTERMITTENCE. 10000 (10 seconds) 15000 (15 seconds) 600000 (10 minutes) DESCRIPTION STANDARD VALUE 1200000 (20 minutes)

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8.1.2 TIMER FOR CAM ATC

TIMER NO. DESCRIPTION STANDARD VALUE FORH500 0 0 0 0 0 0 0 0 0 0 0 STANDARD VALUE FORH630 0 0 0 0 0 0 0 0 0 0 0

TMR 9 TMR 10 TMR 19 TMR 20 TMR 21 TMR 22 TMR 23 TMR 24 TMR 26 TMR 35 TMR 36

MAGAZINE INDEX STOP T CODE STOP CHECK POT TO MAG POT TO SPINDLE SPINDLE CLAMP SPINDLE UNCLAMP ARM UP/CW/DOWN ARM 0{ ARM 90{ ATC DOOR UP ATC DOWN DOWN

DO NOT CHANGE THE VALUE OF TIMER FOR ATC BY YOURSELF TO PREVENT MALFUNCTIONS.

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8.1.3 TIMER FOR OTHERS :
TIMER NO. DESCRIPTION THE VALUE FOR STANDARD TMR4 TMR 5 TMR 13 TMR 14 TMR 15 SPINDLE STOP TIME BUZZER ON TIME FLASH AT HOME POINT 1 FLASH AT HOME POINT FLASH 2 THE TIME FOR M02/M30 CALL LIGHT TMR 16 TMR 17 TMR 18 TMR 30 TMR 31 TMR34 RIGID TAPPING THE TIME FOR EMG STOP M29 COMMAND DELAY THE TIME FOR ONE SHOT(MAG) SPINDLE AIR BLOW OPT2 P.B USE TIME 100 (0.1 sec.) 50 (0.05 sec.) 50 (0.05 sec.) 350 (0.35sec.) 500 (0.5sec.) 30000 (30sec) 150000 (150sec) 60000 (60sec) 500 (0.5 sec.) 500 (0.5 sec.) 50 (0.05 sec.)

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KAO FONG MACHINERY CO.,LTD 8.2 EXPANATION OF KEEP RELAY SETTING:

In according with different part of electric equipment or different control logic of customer. For convenience choice, there are some addresses we will design for KEEP RELAYS to control the different motion. Only the situation that mentions as below would change KEEP RELAY: 1. 2. 3. 4. Lose NC control, reset KEEP RELAY To change KEEP RELAY to suit the electric equipment Disable the protection when adjust ATC to change the motion which is permitted to be selected

Of cause in this kind of setting and modifying the operator should contact with our engineer to ensure the safety. The meaning of KEEP RELAY will be described as below, but for the actual values, please refer to the page L1~L4 of electric circuit manual.

8.2.1 KEEP RELAY OF CAM ATC K0 ADDRESS STANDARD ACTUAL SETTING NO SETTING K0.0 0 SAFE DOOR INTERLOCK SWITCH K0.1 1 W-60 POSITION MACHINE LOCK K0.2 0 PLAY BK (STEP MODE) K0.3 0 MN MODE K0.4 1 EACH MODE COOLANT ON K0.5 1 4-AXIS CLAMP USE M10 COMMAND K0.6 0 4-AXIS CLAMP USE EXTRANAL LIMIT SWITCH K0.7 0 SAFE DOOR OPEN SPINDLE STOP K1 ADDRESS STANDARD ACTUAL SETTING NO SETTING K1.0 0 RIGID TAPPING M29 COMMAND NO USE S K1.1 K1.2 K1.3 K1.4 K1.5 K1.6 K1.7 0 0 0 0 0 0 0
FUNCTION RIGID TAPPING M29 COMMAND TIMER SPINDLE STOP ARM0 M6 FINISH Z-AXIS NO ZERO POINT RETURN ATC OPERATOR SEQENCE CONTROL POT UP KEEP RELAY POT DOWN KEEP RELAY

1KEEP 0UNKEEP

1KEEP 0UNKEEP

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K2 ADDRESS STANDARD ACTUAL SETTING NO SETTING K2.0 0 K2.1 1 K2.2 0 K2.3 0 K2.4 0 K2.5 0 SPINDLE CLAMP KEEP RELAY K2.6 0 SPINDLE UNCLAMP KEEP RELAY K2.7 0 SPINDLE AIR CEL KEEP RELAY K3 ADDRESS STANDARD ACTUAL SETTING NO SETTING K3.0 1 0=15800-21100M/C 1:850~15800 K3.1 0 NO ATC UNIT K3.2 0 ATC OKI Z-AXIS ZERO RETURN G30 X0 Y0 K3.3 K3.4 K3.5 K3.6 K3.7 K4 ADDRESS STANDARD ACTUAL SETTING NO SETTING K4.0 0 NO USE K4.1 0 NO USE K4.2 0 M50 FINISH BY X8.6 K4.3 0 M52 FINISH BY X8.7 K4.4 0 LUB. TYPE SELECT K4.5 0 ALARM CALL LIGHT K4.6 0 M00/M01 SPINDLE STOP K4.7 1 3-AXIS AUTO ZERO RETURN K5 ADDRESS STANDARD ACTUAL SETTING NO SETTING K5.0 0 K5.1 1 SPEED OVERRIDE SWITCH TYPE K5.2 1 CHIP PUSH-BUTTOM TYPE K5.3 0 1:CAM STEP BY HAND MODE CY/FD K5.4 0 CAM SENSOR TYPE 1:NPN 0:PNP K5.5 0 USE DATA MAG ONE PNP SENSOR K5.6 0 NO USE AIR PRESSURE CHECK K5.7 0 NO USE 1 0 1 0 0
POINT NOT HIGH/LOW GEAR 0:USE LUB PRE DET FUNCTION 4-AXIS NEG 1=ZBK 0=CO BK X-AXIS + ZERO PONIT

1KEEP 0UNKEEP

1KEEP 0UNKEEP

1KEEP 0UNKEEP

1KEEP 0UNKEEP

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K6 ADDRESS STANDARD ACTUAL SETTING NO SETTING K6.0 0 1:4/5 AXIS UNCLAMP SERVO OFF K6.1 0 1:USE 3 MPG K6.2 0 1:5th AXIS BY PASS K6.3 0 1:M00/M01 LIGHT ON K6.4 0 1:USE CYTECSP15000RPM K6.5 0 NO USE K6.6 0 1:CYTECSP20000RPM K6.7 0 JOG/DRY OVERRIDE O~200% K7 ADDRESS STANDARD ACTUAL SETTING NO SETTING K7.0 0 1:H/L GEAR RELAY KEEP ON K7.1 1 1: USE AIR H/L GEAR CHANGE K7.2 0 K7.3 0 K7.4 0 K7.5 0 K7.6 0 1:AXIS MOVE BY PASS OPT2 PB K7.7 0 K8 ADDRESS STANDARD ACTUAL SETTING NO SETTING K8.0 0 K8.1 0 K8.2 0 K8.3 0 K8.4 0 1:M30 USE OPT2 PB TO ENABLE K8.5 0 1:BY PASS APC AIR P.S CHECK K8.6 0 1:BY PASS APC UNIT K8.7 0 1:MDI MODE USE APC M CODE K9 ADDRESS STANDARD ACTUAL SETTING NO SETTING K9.0 0 1USE M23 TOOL DATA AUTO SET K9.1 0 1NO USE APC.PB K9.2 0 NO USE K9.3 0 NO USE K9.4 0 NO USE K9.5 0 1 USE 630 TYPE ONLY K9.6 0 1MAG INTER LOCK BY PASS K9.7 0 1:APC DOOR INTERLOCK CANCEL

1KEEP 0UNKEEP

1KEEP 0UNKEEP

1KEEP 0UNKEEP

1KEEP 0UNKEEP

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KAO FONG MACHINERY CO.,LTD

K10 ADDRESS STANDARD ACTUAL SETTING NO SETTING K10.0 0 1=OIL/WATE SPLITTER USE TIMER K10.1 0 1=PMM SERVICE MODE JOG+/JOGK10.2 0 1=BT40/0=BT50 K10.3 0 1=USE AUTO/HANDLE MODE K10.4 0 1=USE ITI FUNCTION K10.5 0 K10.6 0 K10.7 0

1KEEP 0UNKEEP

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8.3 TO MODIFY THE SETTING:

When our engineer ask you to modify the setting on the telephone, please follows the method that we mentioned as below. Once again well remind you to contact with service people before modify. 8. 3.1 MODIFY PLC 1. PRESS EMG STOP BUTTON 2. IN MDI MODE
OFFSET

3. 4. 5. 6. 7.

AFTER PRESSING SETTING , THERE ARE(OFFSET),(SETTING)AND (WORK) SHOWING BELOW THE SCREEN. PRESS SETTING KEY, USE CURSOR KEY TO MOVE CURSOR TO PWE=0 (0:can not write 1:can write) KEY IN 1
INPUT

AT THIS TIME 100 P/S ALARM WILL HAPPENED THERE ARE(PARAMATER)(DIAGNOS)(SYSTEM)WHICH

8.PRESS

SYSTEM

SHOWS BELOW THE SCREEN

9.PRESSED

PMC KEY, THERE ARE(PMCLAD)(PMCDGN)(PMCPRM)

WHICH SHOWBELLOW THE SCREEN.. 10.PRESS

PMCPRM

KEY THERE ARE (TIMER)(COUNTER)(KEEPRL)

(DATA)(SETTING)WHICH SHOWBELLOW THE SCREEN. 11USE CURSOR KEY TO MOVE CURSOR TO WHICH PARAMATER WANT TO MODIFY, KEYIN THE VALUE THEN PRESS MODIFY.
INPUT

KEY FINISH THE

12.IF WANT TO MODIFY THE KEEPRELAY,ACCORDING THE STEP 10 TO PRESS (KEEPRL)KEY,THEN DEPEND STEP 11 TO MODIFY THE VALUE.BECAUSE THE KEEP RELAY IS THE BIT TYPE ,SO CAN ONLY MODIFY ONE BIT. 13.WHEN FINISHING MODIFYING, RETURN TO SETTING PAGE AND CHAGE PWE TO 0, SO 100 P/S ALARM CAN BE ELIMINATED AFTER RESETTING.

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KAO FONG MACHINERY CO.,LTD 8. 3.2 MODERFY PARAMETER

1. 2. 3. PRESS EMG STOP BUTTON IN MDI MODE AFTER PRESSING SETTING, THERE ARE (OFFSET) AND (SETTING) DESPLAYING BELOW THE SCREEN. PRESS (SETTING), USE CURSOR KEY TO MOVE CURSOR TO PWE=0 (0:can not write 1:can write) KEYIN 1
INPUT OFFSET

4. 5. 6. 7. 8.

AT THIS TIME 100 P/S ALARM WILL HAPPENED

PRESS (PARAMETER) WITCH SHOWS AT THE BOTTON OF THE SCREEN PRESSED MODIFY
NO

9.

KEY, AND KEY IN THE NUMBER THAT YOU ARE GOING TO , KEY IN THE NUMBER THAT YOU ARE GOING

10. AT NUMBER xxxx= TO MODIFY

11. WHEN FINISHING MODIFYING, RETURN TO SETTING PAGE AND CHAGE PWE TO 0, SO 100 P/S ALARM CAN BE ELIMINATED AFTER RESETTING.

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TIMER SETTING LIST

TIMER NO. DESCRIPTION STANDRD VALUE ACTUAL VALUE

TMR1 TMR2 TMR3 TMR4 TMR5 TMR6 TMR7

LUB DEVICE ACTION INTERVAL TIMER(AUTO MODE) LUB DEVICE ACTION TIMER LUB DEVICE ACTION INTERVAL TIMER(HANDLE MODE)
SPINDLE STOP TIMER

600000 15000 1200000 150000 60000 0 0 0 10000 500 500 500 100 50 50 0 0 0 0 0 0 0 0 0 300 200 350 550 30000 0 0 0 0 0 0

BZ STOP TIMER OIL/WATE SPLITTER ON TIMER OIL/WATE SPLITTER OFF TIMER

TMR10 T-CODE STOP CHECK TMR12 THE TIME WHEN LUB PRESSURE IS UNUSUAL TMR13 FLASH LAMP 1 TMR14 FLASH LAMP 2 TMR15 CALL HIGHT RIUING TIMER TMR16 RIGID TAPPING M29S COMMAND TMR17 EMERGENCY STOP RELEASE POLSE TMR18 M29 COMMAND DELAY TIMER TMR19 POT BACK TMR20 POT FOR TMR21 SPINDLE CLAMP TMR22 SPINDLE UNCLAMP TMR23 W-ARM UP/CW/DOWN TMR24 W-ARM 0 TMR25 TRV A IN DELAY TIMER TMR26 W-ARM 90 TMR27 TRV A OUT DELAY TIMER TMR28 TRV B IN DELAY TIMER TMR29 TRV B OUT DELAY TIMER TMR30 ONE-SHOT TIMER TMR31 SPINDLE AIR CELEAR TMR34 JOG/RAP/ZER MODE ENABLE TIMER TMR35 ATC DOOR UP TMR36 ATC DOOR DOWN TMR37 TRV UP DELAY TIMER TMR38 TRV DOWN DELAY TIMER TMR39 TRV CLAMP DELAY TIMER TMR40 APC DOWN DELAY TIMER
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TMR41 TRV UNCLAMP DELAY TIMER TMR43 A TABLE CHECK DELAY TIMER TMR44 B TABLE CHECK DELAY TIMER TMR45 APC UP AIR DELAY TIMER 0 600 500 500

DATA TABLE SETTING

NO. ADDRESS DATA NO.

0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 0020 0021 0022 0023 0024

D0010 D0011 D0012 D0013 D0014 D0015 D0016 D0017 D0018 D0019 D0020 D0021 D0022 D0023 D0024 D0025 D0026 D0027 D0028 D0029 D0030 D0031 D0032 D0033 D0034

SPINDLE NO. T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 T19 T20 T21 T22 T23 T24

*IF MAFAZINE TOOL CAPACITY 90 TOOLS SET DATA TABLE ADDRESS FOR D100 (T100)

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MAGAZINE TOOL CAPACITY (30) SETTING PMC DATA TBL CONTROL #001 NO. 001 ADDRESS D0010 PARAMETER 00000001 GROUP TABLE COUNT=1 TYPE 0 DATA OF NO. 31

PC COUNTER MAGAZINE TOOL CAPACITY (30) PMC PRM (COUNTER) #001 NO. 001 ADDRESS C00 PRESET 30 CURRENT VARIABLE

*MAGAZINE TOOL CAPACITY 30 TOOLS SET 31 *CURRENT DATA VALUE IS STAND-BY TOOL POT NUMBERIF YOU WANT RESET ITS COUNTENTPLEASSE CHANGE THIS VALUE

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KAO FONG MACHINERY CO.,LTD 9. THE TROUBLESHOOTING

When malfunction happened, please use this chapter trying to fix the basic problem. And gather the information as following items. We will do our best to recover the machine as soon as possible. 1. 2. Machine serial number, Mode, Control system and delivery date? The responded massage of machine: what is the alarm message and alarm number of servo? Does fuse fail? Is over load escaped? What happens: In which mode? If it happens constantly? If it happens during executing some G code or M.S.T. code? If it happen at the particular machine coordinate? Are there any signs abnormally? Check the frequency of occurrence: what is the frequency? When did the problem first occur? What did you do after malfunction? Outline of environment: Is the voltage stable? Have you updated the program ? Have you changed the operator? Have you updated the tools and clampers? Is the temperature and quake of environment normal? Before malfunction happened: have you edited program or changed auxiliary equipment? Do you adjust or remove the machine?

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

1.Turn power OFF MOL ALARM 2.Open the door of electric Motor for outside cabinet and check the part have OVERLOAD. 3.Push the RESET overload BUTTON which is on situation overload. 1.Is filter too dirty? Use OIL ALARM water, neutral cleaner or Spindle coolant compressed air to clean pressure detect up and air-dry in overcast. 2.if not work, please call alarm the cooler maker

the TEL of the cooler maker is on the cooler unit plate and the manuals of cooler unit.

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KAO FONG MACHINERY CO.,LTD

E3 SPINDLE ALARM heck it the feed rate and spindle speed are correct. 1.If not, turn power OFF and RESET. 2. If yes, use a screwdriver to open the door of electric cabinet (do not turn power OFF) and check the alarm number on the 7-segment decoder of spindle driver (at upper row, the second from the right side),and contact with the agent or FANUC. Please check the follow items:

E4

LUB ALARM LUB oil not enough

1.Is the oil enough? 2.If yes, maybe the oil detector is
broken. please check in according to electric circuit manual.

1002

SPINDLE DRIVER ALARM spindle driver overload alarm

same as E3

1003

EMERGENCY STOP ALARM

1.Overtravel: press the EMG

RELEASE button on control panel. In EMG RELEASE mode: Switch to handle mode, use hand wheel to return original point, and RESET.

2.Motor overload(MOL. ALARM):

the same as E1(RESET)

3.EMG not release

1004 1005 SPINDLE GEAR OIL ALARM ATC STAND-BY LS ATC not at stand by situation Please follows the chapter 5 or ATC stand-by instruction of electric circuit manual the same as E2

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KAO FONG MACHINERY CO.,LTD

1007 SPINDLE CLAMP Please check the following items: 1.Is spindle unclamping? LS 2.Does spindle clamp limit switch touch the dog. 3.If yes, check if it have touched exactly and stable.

2002 2003

TOOL SEARCH ERROR ARM 60{ M/C LOCK

1.Are T code all right. 2.Check the tool registration. 1.RESET NC. 2.Turn ON manual operation of ATC. (K5.0=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.

2004

SAFE DOOR INTERLOCK CHECK ZPZ POSITION

2007

2006

2008

1. During ATC tool change, Z-axis does not return to original point . 2. Please return Z-axis back to original position. AIR PRESSURE Check whether the air pressure is miss? MISS 2.If the pressure is enough, check if the pressure switch is broken. 1.Is spindle on clamp? CHECK Is ARM on 0{ ? SPINDLE OK 2.Check if LIMIT switch are stable LIST that we mentioned before. SPINDLE LOAD 1.Are feed-rate and spindle rate TOO MUCH OK? 2.RESET NC

2009

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KAO FONG MACHINERY CO.,LTD

2010 2011 LUB OIL MISS LUB PRESSURE MISS WAIT FOR RIGHT TOOL The same as E4 1.Is pressure of LUB enough? If yes, please delay the time of pressure D330= 15000 1. May be the tool are not STAND BY 2.If the magazine keeping rotation, please call agent. XY-axes must back to second reference points.

2012

2013 2014

GO G30 X0 Y0 FIRST

MAGAZINE 1. Check count A and count B PARITY ERROR Sensor SP NO TOOL CANT ROTATION 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 Please install tool then can start Only 10000rpm spindle High speed sp 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.

2015

2016 2017

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KAO FONG MACHINERY CO.,LTD

2018 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 SP stop over 2 hour please check sp tool, if ok press CYCLE START P.B to start sp warm up.

2020

2020 Please check Z lock P.B in auto ADMONISH!TH mode E Z AXIS LOCK P.B IS ON.ARE YOU SURE?YES,PLE ASE HIT CYCLE START P.B TO CONTINUE.NO, PLEASE 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 2021 APC AIR PRESSURE MISS 2025 Y,-Z PROTECT AREA Push OP2 P.B to enable JOG/RAP/ZRN mode

2021

2022 2023 2024

Push M19 P.B to enable SPINDLE UNCLAMP mode Please check APC LS Please check APC AIR PRESSURE LS Please check Y,-Z POINTS

2025

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KAO FONG MACHINERY CO.,LTD

2026 AIR DRYER ALARM There is warning inside of air dryer. Please check the elements of the dryer and exhaust the problem. Please turn on the power of the air dryer. The alarm will be eliminated. Please close the APC door. Then the table changes can be done. If the APC door is NOT closed, the table change action can NOT be done.

2027

PLEASE PUSH AIR DRYER ON P.B APC DOOR OPENED,IF YOU WANT TO RUN TABLE CHANGE,PLEA SE YOU CLOSED THE APC DOOR MISS T CODE

2028

2030

Press RESET button, re-call T Code. Then perform M06 command. The T code is called, the pocket moved to the spindle side for waiting. It must perform M06 command or use M66 to move the pocket back to magazine. Check the LED status on the servo amplifier and inform the agent or FANUC Tel: +886-(04)2359-0522 Please replace the absolute battery. Close the magazine door. It can perform the removing tool action. When the tool magazine door open, the magazine can not rotate and call the tool. Close the door. The magazine can work correctly.

2031

MISS M06 CODE

2032

ATC PMM UNIT ALARM

2033

PMM UNIT BATTER ALARM PLEASE CHECK MODE FOR MAG MAG SAFE DOOR INTERLOCK

2034

2035

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KAO FONG MACHINERY CO.,LTD

2036 ITI UP DO NOT CHANGE APC UNIT The tool measure device is on up status to interrupt the APC. Please perform M93 first and make it down to allow the APC action.

9.1 CHANGING SAFE UNIT

While changing the safe unit as bellows. have to make confirmation of review and signal with KAFO circuit diagram in order to maintain the function of safe circuit. HOW TO CHEAK THE I/O LOCSTION
SYSTEM

PMC ] [ PMCDGN ] [ STATUS ] KEYIN

X8

[ SEARCH ] Then you can see the signal as follows.

EMERGENCY STOP SWITCH RELAESE SAFE DOOR INTER LOCK ON

X 8.4 = 1 X 8.1 = 1

.After safe mode changing. Power turned on,enter the turn-on scrren.release the emerygency botton on the penel and put ENABLE botton then you can release emergency circuit it will be the normal situation.

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CONTENTS
1. ELECTRICAL CABINET................................................................................................. A 1.1 ELECTRICAL CABINET .......................................................................................A1 1.2 ELECTRICAL BOARD LAYOUT.............................................................................A2 1.3 NC UNIT DIAGRAM .................................................................................................A3 1.4 SERVO AND POWER SUPPLY DIAGRAM............................................................A4 1.5 GROUND DIAGRAM ................................................................................................A5 1.6 PCB6 LAYOUT...........................................................................................................A6 1.7 PCB1,2,3 LAYOUT.....................................................................................................A7 1.8 PCB4,7,8 LAYOUT........................................................................................... A8,A8-1 1.9 PCB5A,PCB5B,PCB5C I/O IN OUT..... A9 1.10 OPERATION PANEL .....................................................................................A10,A11 1.11 SYMBOL OF CIRCUIT..........................................................................................A12 2. POWER..................................................................................................................................B 2.1 MAIN POWER ..........................................................................................B1,B2,B3,B4 2.2 POWER SUPPLY AC 110V & AC 24V.....................................................................B5 2.3 OIL/AIR LUBRICATION DEVICE ..B6,C2 2.4 POWER SUPPLY AC 110V .......................................................................................B7 2.5 AC 110V & MOTOR CONTACTOR .........................................................................B8 2.6 POWER SUPPLY AC22V,24V ..................................................................................B9 2.7 POWER SUPPLY DC24V & POWER ON/OFF PUSH-BUTTON ........................B10 3. EMERGENCY STOP CONTACTOR .................................................................................C1 4. RELAY CIRCUIT............................................................................ D1,D2,D3,D4,D5,D6,D7 5. I/O PORT CONNECTIONS PCB5A .................................................................E1,E2,E3,E4 6. I/O PORT CONNECTIONS PCB5C....E5,E6,E7 7. SOLENOID VALVE ...........................................................................................F1,F2,F3,F4 8. I/O PORT CONNECTIONS.........................................................................................G1,G2 9. OPERATOR PANEL LAMP ...............................................................................................H1 10. OPERATOR PANEL................................................................................................ I1,I2,I3 11. CABLE ..................................................................................................................................K 11.1 CB150-B I/O CABLE................................................................................................K1 11.2 CB150-1 I/O CABLE ................................................................................................K2 11.3 CB150-2 I/O CABLE ................................................................................................K3 11.4 CB150-3 I/O CABLE ................................................................................................K4 11.5 CB150-B1 I/O CABLE..............................................................................................K5

11.6 MS1 CABLE..............................................................................................................K6 11.7 HAND CABLE..........................................................................................................K7 11.8 K8 CABLE CXA2A-CXA2B....................................................................................K8 11.9 K9 CABLE JYA2 ......................................................................................................K9 11.10 K10 CABLEJYA3 .................................................................................................K10 11.11 K11 CABLE JF1-JF2-JF3......................................................................................K11 11.12 K12 CABLE JY1 ...................................................................................................K12 11.13 K13 CABLE CX1A ...............................................................................................K13 11.14 K14 CABLE CX3 ..................................................................................................K14 11.15 K15 CABLE MAG AMP-K8 ................................................................................K15 11.16 K16 CABLE JA7A-JA7B......................................................................................K16 11.17 K17 CABLE JA3 ...................................................................................................K17 11.18 K18 CABLE CP1A-CN2.......................................................................................K18 11.19 K19 CABLE JDA1-JD1B......................................................................................K19 11.20 K20 CABLE JD36A-RS232 ..................................................................................K20 11.21 MAG SERVO K1 CABLE.K21 11.22 MAG K9 CABLE...K22 11.23 MAG SERVO K4, K5....K23 11.24 MAG SERVO JA72K24 12. KEEP RELAY LIST.................................................................................L1,L2,L3,L4,L5,L6 13. TIMER LIST................................................................................................................ M1,M2 14. MAGAZINE TOOL CAPACITY............................................................................N1,N2,N3 15. M CODE LIST...............................................................................................................O1,O2 16. ALARM LIST................................................................................................................. P1,P2

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Revision curriculum vitae of service manual Edition E02 200807 Revise newly Date Revise the chapter page Revise the content and explanation