MB0120120108 HS-450i Operator's Manual

HS-450i Operators Manual
MB012012-01-08
HS-450i Operator's Manual
Table of Content
1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 5.4 5.5 6 6.1 6.2 6.3 7 7.1 7.2 Safety Precautions Potential Hazards Safety Labels and Plates Safety Devices Safety Instructions Controls and Operations Electric Cabinet Operation Console Operation Panel Other Controls and Pushbuttons Starting and Ending Operation Emergency Stop Turning ON Power Machine Warm-up Turning OFF Power After Turning Off Power Measures in Power Failure Weekly Timer Manual Operation Zero Point Return JOG Feed Rapid Traverse Handle Feed Insertion/Removal of Spindle Tool Spindle Revolution and Stop MDI Operation MDI (Manual Data Input) Operation Spindle Revolution in MDI Spindle Orientation in MDI ATC Magazine Indexing and Tool Table Clamp/Unclamp in MDI Operation Automatic Operation Starting Automatic Operation Stopping & Restarting Automatic Door Safety Interlock ATC Operation Setting up ATC Magazine Tool Registration 4 4 5 24 24 29 29 31 33 59 66 66 66 67 69 69 70 72 74 74 75 76 77 78 79 80 80 81 82 83 84 85 86 87 89 92 92 92
AVEREX Automation Co., Ltd.
7.3 7.4 7.5 7.6 8 8.1 8.2 8.3 8.4 8.5 9 9.1 9.2 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 11 11.1 12 12.1 12.2 13 14 14.1 14.2 15 15.1 15.2 15.3 15.4
Single Arm Manual Operation Tool Exchange in MDI Operation Tool Exchange in Automatic Operation Tool Data Screen APC Operation Movement of APC Pallet Indexing Lever APC in Manual Operation APC in MDI Operation APC in Automatic Operation Emergency Stop Cases of Emergency To Release Emergency Stop Status Interference Workpiece Dimensions Travels of Axes Interference with Spindle Pallet Usable Area Limitation on Tools Dimensions Interference at ATC Pull Stud Functions Codes (M Codes) M Code List Alarm Message and Operator Message Alarm Messages Operator Message Custom Macro Program Chip Conveyor Controls Alarm Weekly Timer Setup Outline of Weekly Timer Same Operation Hours For Each Day Different Operation Hours For Different Day Operation Hours Span Over Multiple Days
98 99 101 104 106 106 106 108 110 111 112 112 112 113 113 114 117 120 121 122 124 125 125 128 128 132 135 136 136 137 138 138 141 144 149
1 Safety Precautions
Always keep this manual in a designated area, preferably nears by this machine, so that every personnel can read it and thoroughly understand all safety precautions. 1.1 Potential Hazards
When a maintenance operation requires that machine enclosures be removed or door interlocks be disabled, it creates a condition that personnel are potentially exposed to hazards. In such situation, all personnel must observe the best safety practice to avoid the potential dangers. During normal operations, door interlock devices must never be disabled or bypassed, and enclosures must never be removed. 1.1.1 Electric Shock HS-450i has several subsystems powered by high voltage electricity. The electricity is usually not hazardous during most operations. However, if for maintenance purpose, the enclosures are removed or door interlocks are disabled, the following few areas can endanger personnel with electric shock: Electric cabinet Coolant pumps Lubrication pump Spindle Oil Chiller Motors
Read all applicable manuals and follow their warnings to avoid accidental electric shock. Operators must never remove shields or panels, nor should operators bypass or otherwise disable locks. 1.1.2 Moving Machine Areas Because of the fast moving motions of the mechanisms, getting too close to the machine in the following areas can result in serious bodily injury to the personnel. Spindle head and column in motion.
AVEREX Automation CO., Ltd.
Spindle where a cutting tool in rotating motion. Nearby Automatic Tool Change Area where its mechanism is in motion. Nearby Automatic Pallet Change Area where its mechanism is in motion. Nearby Chip Conveyer in motion. 1.1.3 Sharp Edges on Material Be aware of potential dangers posed by sharp edges of materials or fixtures.
1.1.4 Cutting Tools Be aware of potential dangers posed by the cutting tool(s) in the spindle or in Automatic Tool Changer. 1.2 Safety Labels and Plates
These labels and plates are affixed on the enclosures of machine as depicted in the drawings. Some of these labels are used to emphasize the hazardous situations that could result in serious injury or death when using the machine. Read the warnings carefully and follow the instructions to avoid serious injury or death.
1.2.1 Locations of Labels and Plates
Front Side
Operator Side
Tool Magazine Side
Top
Back Side
Lifting Devices
Top View
10
Tool Changer
11
1)
Tool Specification Plate BBT Tool
12
CAT Tool
13
2)
Warning Moving Part Hazard
3)
Warning Rotating Mechanism Hazard
14
4)
Warning Opened Door Hazard
5)
M Code List
15
6)
Safety Instruction Plate
7)
Machine Warm-up Instruction
16
8)
Warning - Electric Shock
9)
Danger Electrical Shock Hazard
10) Manufacturer Plate
17
11) Solenoid/Limit Switch
18
12) Warning - Hot Surface
13) Maintenance Schedule
19
14) Lubrication Points
20
15) Lubrication Oil Instruction
16) Pneumatic Air Instruction
21
17) Axial Directions
Y+ X Z+
18) (Reserved)
(Space reserved)
19) Oil Drain
22
20) Lifting Point
21) Oil Filler
22) Lifting Point Forklift
23) Main Power Switch
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1.3
Safety Devices
HS-450i is equipped with various types of safety devices that are designed to protect personnel from accidental injuries. All personnel must learn to use these safety devices before operating or servicing the machine.
Safety Device EMERGENCY STOP pushbuttons
Where Located On the Operation Panel On the side of the Pallet set-up door On the side of the ATC door On the electric cabinet On the Pallet set-up door On the Operator side door On the ATC door Electric cabinet On the LCD display
Main Power Switch Door Safety Interlock
Key Alarm Messages
1.4
Safety Instructions
Safety Instructions are classified into three categories, DANGERWARNING, and CAUTION subjects to the degree of potential hazard to the personnel. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.
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1.4.1 General Instructions Wear proper apparel. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that might be caught in moving parts or areas of potential electric shock. Non-slip footwear is recommended. Tie long hair back and wear protective hair covering to contain long hair. Keep tools sharp and clean for best performance and to reduce the risk of injury. Follow instructions for lubrication and for changing accessories. Use the proper tools. Do not use tools or attachments to perform a job for which they were not designed for. Keep proper footing and balance at all times. Use a steady object for support when reaching over the machine. Do not operate the machine in an unsafe environment. Do not use the machine in damp or wet locations, or expose to rain. Keep the work area well lighted. The machine is not intended for use with flammable or harmful substances. Do not turn the machine on or try to operate it if there are explosive or flammable gases present. Use recommended accessories to avoid the risk of injury. Wipe up spills. Immediately cover with absorbent material and wipe up coolant and oil spills around the machine. Correct the cause of the leakage to prevent any hazards. The poly-carbonate viewing panels are an integral part of safety enclosure for the machine. They must be inspected regularly for any signs of reduced effectiveness (such as cracking or crazing) and replaced immediately, if such signs or other indications of reduced effectiveness are noticed.
1.4.2 Machine Installation Only factory authorized individuals from Akari Seiki or distributors of Akari Seki may install this machine. Any electrical installation of the machine must be done by a qualified electrician. When used to install this machine, cranes, forklifts, and alike must be operated by licensed operators. Use appropriate equipments to handle heavy objects.
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1.4.3 Before Powering On Before powering on the machine, check or inspect the following areas to ensure safe operations: All safety devices are functional. Lubrication tank has adequate lubrication oil. Coolant units have adequate coolant. Chips are not accumulated on the telescopic covers. No material or tool is left unintentionally in the machines moving areas. No damage in electrical wirings or components. Electrical cables and wires are connected securely. Electrical cabinet is securely closed and No leak in the pneumatic system. Only tools that meet the tool specifications are used Note Read and understand the Operators Manual before operating this machine. 1.4.4 Power On and Warming-up Any electrical installation of the machine must be done by qualified electricians. Check that all protective devices and door interlocks are functional. All guards are firmly in place and show no damages. Follow the procedure and instructions described in the Operators Manual to power on the machine. Execute machine warm-up procedure as described in Section 3.3 Machine Warm-up of HS-450i Operators Manual.
After the machine has been powered on, check the following items: No alarm is displayed on the LCD screen No abnormal sound from the motors and gear boxes The cooling fans in the electrical cabinet have been turned on. Spindle and guide ways are adequately lubricated.
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1.4.5 During Machine Operation Read the safety warnings supplied with all tooling. Keep doors closed while machining. Do not disconnect the front door safety switches. Under no circumstances should the operator open the door before the spindle stops rotating completely. Wear ANSI or CE approved safety glassed at all times when operating the machine. Everyday glasses are not designed for protection. Only ANSI or CE approved safety glasses have impact resistant lenses. Do not exceed the Manufacturers recommended maximum RPM for the tool. When tools are placed in the spindle, verify the current RPM recommended in the control before starting the spindle rotation. Always check all parts for binding, breakage, and any other condition that may affect the proper operation of the machine and/or increase the risk of injury. Damaged or missing parts must be repaired or replaced BEFORE operating the machine. Do not operate the machine under the influence of drugs, alcohol, or prescribed medication. Use proper safety gloves when handling sharp or jagged edges. Do not wear gloves around rotating machinery. Use standard machining practices for holding the material that is to be machined. Keep tools sharp and clean for best performance and reduction of the risk of injury. Follow instructions for lubrication and for changing accessories. Tools are designed to perform properly and safely at proper speeds. Take appropriate additional safety precautions and measures when working with magnesium, wood, or other combustible materials. Hearing protection must be worn when operations exceed 90 (85 CE) decibels. Protection is recommended when cutting operations are dusty or exceed the permissible exposure limit. Dust removal equipment is needed when working with dust-producing materials or procedures.
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1.4.6 Power Off Turn off the power to the machine before leaving the machine unattended. Never leave the machine until it has completely stopped.
1.4.7 After Powering Off
Keep work area clean. Good housekeeping practices encourage safety. Do not use air guns to blow away chips. Always wear gloves when removing chips. Insert a dummy tool into the spindle to prevent debris from entering. Be aware that the solenoid valves may remain hot for quite a while.
1.4.8 Maintenance Only qualified personnel are authorized to undertake maintenance work on this machine. Use signs indicating Maintenance in progress to warn people not to accidentally turn on the machine. Do not enter enclosure area for service or maintenance unless the machine has been powered off. Due to danger of slips or falls on a wet or oily surface, any table or enclosure floor that is to be used for maintenance access must be dry and clean. Never damage, remove, or relocate any part of the limit switches, door interlocks, or dogs. Wear a hard hat for maintenance or servicing. Always clean up the machine after maintenance work is done. Contact Akari Seiki or your local distributor for all repair parts and service.
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Controls and Operations
HS-450i is built with the following controls to allow certain operations to be performed by the operator: Electric Cabinet Operation Console Pallet Operation Control ATC Control 2.1 Electric Cabinet
CODE ACR C D F G INV K MC MCC
DESCRIPTION AC Line Reactor Capacitor Bridge Rectifier Circuit Breaker Switching Power Supply Inverter Relay Magnetic Contactor Magnetic Contactor
CODE MCP PSM SPM SVM R SK T TDON
DESCRIPTION Motor Circuit Breaker Power Supply Module Spindle Amplifier Module Servo Amplifier Module Resistor Surge Suppressor Transformer On-delay Timer
29
30
2.2
Operation Console
Manual Pulse Generator Fanuc LCD Display
Fanuc Main Panel
Operator PaneI
Green Red Yellow (lit) Yellow (blinking) Power lamp Main Power Switch
In the mode of Automatic Operation Alarm End of program execution Awaiting pallet setup to complete This lamp lights up whenever power is being supplied to the operation box. This switch turns on or off the supply of the factory power.
31
2.2.1
NC Pushbuttons
NC Power ON Pushbutton (0)
When this button is pressed, NC is powered on and "NOT READY" appears on the screen after a few seconds.
Note Power on the machine first before pressing NC Power ON pushbutton. NC Power OFF Pushbutton (00)
When this button is pressed, NC is powered off and LCD display disappears.
DANGER
Always press Emergency Stop pushbutton before pressing NC OFF pushbutton. Be sure to press NC OFF pushbutton before turning off Main Switch of the electric cabinet. If not, NC can potentially be damaged.
DANGER
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2.3
Operation Panel
10
11
41
42
43
5 67
12
14
15
44
45
46
29 23
30
31
22 68 69
21 70 32 24 33 34
25
26
56
57
28
27 71 62
94 37 38 39 40 47 48
95
96 72 73
49
50
51
52
53
54
97
98
99
63
64
65
33
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
EDIT Mode Pushbutton AUTO Mode Pushbutton REMOTE Mode Pushbutton MDI Mode Pushbutton HANDLE Mode Pushbutton JOG Mode Pushbutton RAPID Mode Pushbutton Zero Point Return Mode Pushbutton Single Block Pushbutton Optional Stop Pushbutton Block Skip Pushbutton Dry Run Pushbutton (Reserved) Machine Lock Program Restart (Reserved) (Reserved) (Reserved) (Reserved) (Reserved) X-axis Plus Feed Zero Return Pushbutton X-axis Minus Feed Pushbutton Y-axis Plus Feed Zero Return Pushbutton Y-axis Minus Feed Pushbutton Z-axis Plus Feed Zero Return Pushbutton Z-axis Minus Feed Pushbutton B-axis Plus Feed Zero Return Pushbutton B-axis Minus Feed Pushbutton Rapid Feed Override 0% Pushbutton Rapid Feed Override 8% Pushbutton Rapid Feed Override 15% Pushbutton Rapid Feed Override 25% Pushbutton Rapid Feed Override 50% Pushbutton Rapid Feed Override 100% Pushbutton (Reserved) (Reserved) Cutting Coolant Pushbutton Flood Coolant Pushbutton Shower Coolant Pushbutton Spindle Through Coolant Pushbutton
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 94 95 96 97 98 99
Spindle CW Rotation Pushbutton Spindle Stop Pushbutton Spindle CCW Rotation Pushbutton Spindle Speed Decrease Pushbutton Spindle Speed 100% Pushbutton Spindle Speed Increase Pushbutton B-axis Table Clamp Pushbutton B-axis Table Unclamp Pushbutton Door Open Request Pushbutton Auto Power-off Pushbutton Air Blow Pushbutton Oil & Air System Lubrication Oil Pushbutton Fluorescent Lamp ON/OFF Pushbutton Tool Data Display Pushbutton (Reserved) Cycle Start Pushbutton Feed Hold Pushbutton Spindle Tool Clamp/Unclamp Pushbutton (Reserved) (Reserved) (Reserved) Cutting/Jog Feed Override Switch Chip Auger Forward Pushbutton Chip Auger Stop Pushbutton Chip Auger Reverse Pushbutton (Reserved) Emergency Stop Pushbutton NC Ready Pushbutton Safety Pushbutton Memory Protect Switch Pallet Manual Selection Switch Pallet Set-up Pushbutton Pallet Start Pushbutton F1DT Pushbutton PBLK Pushbutton HINT Pushbutton SUNC Pushbutton JUNC Pushbutton F2 Pushbutton
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2.3.1
Mode Selection Pushbutton
Pushbuttons (1) to (8) are Mode selection pushbuttons. Press one of the pushbuttons to enter its designated mode. When pressed, its lamp will come on, and the machine will enter the selected mode until changed. EDIT Mode Pushbutton (1)
Press this button to enter Edit mode. In this mode, program steps can be modified, inserted, or deleted by using keys on the NC keyboard.
AUTO Mode Pushbutton (2)
Press this button to enter AUTO mode. In this mode, the program stored in the memory can be executed; program number search and sequence number search of the program in the memory are available.
REMOTE Mode Pushbutton (3)
Press this button to enter Remote mode. In this mode, the programs read via RS232C interface can be executed.
MDI Mode Pushbutton (4)
Press this button to enter MDI mode. In this mode, data input is available directly via keys on the NC Operators panel. The program entered through NC Operators Panel can be started by pressing Cycle Start pushbutton (56).
HANDLE Mode Pushbutton (5)

35
Press this button to enter HANDLE mode. This mode is used to provide minute feed with Manual Pulse Generator (82). Once in this mode, Manual Pulse Generator (82) can be used to control the movements of the axes. On Manual Pulse Generator, Axis Selection Switch is used to select a particular axis to move; Handle Feed Scale Selection Switch is used set the amount scale of [x1 (=0.001 mm or 0.001o), x10 (=0.01 mm or 0.01o), or x100 (=0.1 mm or 0.1o)]. While turning the handle of Manual Pulse Generator (82), the selected axis moves at selected minute feed rate.
JOG Mode Pushbutton (6)
Press this button to enter JOG mode. This mode can be used to provide continuous feed by manual operation. Press one of the Plus Direction Feed pushbuttons for X-axis (21), Y-axis (23), Z-axis (25), or B-axis (27), the selected axis will move in the positive direction continuously until it is released. Press one of the Minus Direction Feed pushbuttons for X-axis (22), Y-axis (24), Z-axis (26), or B-axis (28), the selected axis will move in the negative direction continuously until it is released.
Note
The feed rate can be changed with Feed Rate Override and JOG Feed Setting Switch (62). In this mode, manual operations of ATC and APC are also allowed.
RAPID Mode Pushbutton (7) Press this button to enter RAPID mode. This mode is used to run axis at a rapid traverse.
36
Press one of the Plus Direction Feed pushbuttons for X-axis (21), Y-axis (23), Z-axis (25), or B-axis (27), the selected axis will move in the positive direction at a rapid traverse rate continuously until it is released. Press one of the Minus Direction Feed pushbuttons for X-axis (22), Y-axis (24), Z-axis (26), or B-axis (28), the selected axis will move in the negative direction at a rapid traverse rate continuously until it is released.
Note The feed rate can be changed with Rapid Feed Override pushbuttons (29) to (34).
Zero Point Return Mode Pushbutton (8)
Press this button to enter Zero Point Return mode. To execute Zero Point Return: 1) Press and hold one of the Plus Direction Feed (Zero Return) pushbuttons for X-axis (21), Y-axis (23), Z-axis (25), or B-axis (27).
2) Continue to hold down the pushbutton until its Zero Return Completion lamp is lit.
Note Rapid Feed Override pushbuttons (29) to (34) are available for use in this mode. Refer to Section 4.1 "Zero Point Return". An absolute type encoder is used on each axis of the machine; therefore, it is not required to execute Zero Point Return after powering on the machine. If a Zero Point Return becomes necessary, it should be performed at least 100 mm away from its Zero Point.
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2.3.2
Program Execution Pushbuttons
Pushbuttons (9), (10), (11), and (12) are Program Execution pushbuttons. Press one of the pushbuttons to enter one of program execution modes. When pressed, its lamp will come on, and the machine will enter that mode until changed. Single Block Pushbutton (9)
In AUTO or MDI mode, press this button to enter Single Block program execution mode. In this mode, the machine stops after executing one block of the program. Each subsequent press of Cycle Start pushbutton (56) results in executing one single block. During G28, G29, or G30, the machine stops at an intermediate point and Feed Hold pushbutton (57) lights up. In the canned cycle, the machine stops at the end of the rapid traverse to the point R and the lamp of Feed Hold pushbutton (57) comes on. (Refer to FANUC's "Operator's Manual".) During the time that the machine is temporarily stopped by a single block; manual and MDI operations are still available to be executed. To restart the suspended program, press Cycle Start pushbutton (56) in the original mode.
Note If a MDI operation is executed during automatic operation or vice versa, modal data affects the latter operation. If a Single Block is commanded during operation, the machine stops after it completes executing the current block. Do NOT press [RESET] key. If [RESET] key is pressed, the next block of information that has already been read into the buffer storage will be lost and consequently skipped.
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Optional Stop Pushbutton (10)
When in automatic operation, pressing this button causes the program execution to be in Optional Stop mode. In this mode, cycle operation is stopped after a block containing M01 is executed, and Program End Signal Light is lit. To restart cycle operation, press Cycle Start pushbutton (56).
Block Skip Pushbutton (11)
When in automatic operation, press this button for the program execution to enter Block Skip mode. In this mode, any block beginning with "/" is ignored. If not in this mode, any block beginning with "/" is executed. Optional Block Skip is identified when "/" is read into the buffer from the tape or memory.
Note If a block preceded by a slash has been read into the buffer before Block Skip pushbutton (11) is pressed, it does get executed.
Dry Run Pushbutton (12)
Press this button for the program execution to enter Dry Run mode. In this mode, all F codes specified in the program are ignored. With that, cutting feed is no longer controlled by the F code, but rather, determined by the JOG Feed rate which is set with Cutting JOG Feed Override switch (62). In tapping cycle, pressing this button has no effect. In rapid traverse cycle, this button usually is not in effect. However, by changing some parameters, this button can be made effective for rapid traverse cycle.
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Note If operation is stopped in Dry Run, after all axes have completed their movements, press this pushbutton (12) again to exit Dry Run mode.
Machine Lock Pushbutton (14)
Pressing this pushbutton causes the machine to enter machine lock state in which positional changes are displayed on the screen without the actual axial movements. When in Machine Lock state, M codes, T codes, and S codes are still being accepted and can be executed. Pressing the pushbutton (and Both Hands pushbutton simultaneously) again when in Machine Lock state will release the axial movements from the lock state.
Note Machine Lock pushbutton and Both Hands pushbutton need to be pressed simultaneously for machine lock to take place. Note Never release the machine from the Machine Lock State while a program is being executed.
Program Restart Pushbutton (15)
When a program execution has been stopped, pressing pushbutton allows the program to continue its execution.
Note Program Restart pushbutton and Both Hands pushbutton need to be pressed simultaneously for program restart to take place. 2.3.3 Direction Feed and Zero Return Pushbutton
Plus Direction
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X-axis: Y-axis: Z-axis: B-axis:
toward left (Column movement) upward (Spindle head movement) toward front side (Table movement) clockwise direction (Table turn)
X-axis Plus Direction Feed and Zero Return Pushbutton (21)
This pushbutton can be used to move the X-axis in the positive direction or to return the X-axis to zero point. When the machine reaches X-axis zero points as a result of the execution of zero point return either by manual operation or automatic operation (G28), the Zero Return Completion Lamp at the upper-right corner will light up.
X-axis Minus Direction Feed Pushbutton (22)
Pressing this pushbutton moves the X-axis in the negative direction.
Y-axis Plus Direction Feed and Zero Return Pushbutton (23)
This pushbutton can be used to move the Y-axis in the positive direction or to return the Y-axis to zero point. When the machine reaches Y-axis zero points as a result of the execution of zero point return either by manual operation or automatic operation (G28), Y-axis Zero Return Completion Lamp at the upper-right corner will light up.
Y-axis Minus Direction Feed Pushbutton (24)
Pressing this pushbutton moves the Y-axis in the negative

41
direction.
Z-axis Plus Direction Feed and Zero Return Pushbutton (25)
This pushbutton can be used to move the Z-axis in the positive direction or to return the Z-axis to zero point. When the machine reaches Z-axis zero points as a result of the execution of zero point return either by manual operation or automatic operation (G28), Z-axis Zero Return Completion Lamp at the upper-right corner will light up.
Z-axis Minus Direction Feed Pushbutton (28)
Pressing this pushbutton moves the Z-axis in the negative direction.
B-axis Plus Direction Feed and Zero Return Pushbutton (27)
This pushbutton can be used to move the B-axis in the positive direction or to return the B-axis to zero point. When the machine reaches B-axis zero points as a result of the execution of zero point return either by manual operation or automatic operation (G28), B-axis Zero Return Completion Lamp at the upper-right corner will light up.
B-axis Minus Direction Feed Pushbutton (28)
Pressing this pushbutton moves the B-axis in the negative direction.

42
Note At the completion of 2nd zero point return for a particular axis, the corresponding lamps will start blinking. One absolute type encoder is used on each axis of the machine; therefore, there is really no need to execute Zero Point Return after powering on the machine. These lights will not come on except for the execution of zero point return, even if the machine reaches to its zero point At the completion of 2nd zero point return, the corresponding lamp will blink.
2.3.4
Rapid Feed Override Pushbutton
Rapid Feed Override 0% Pushbutton (29)
Pressing this pushbutton, in any mode, cancels Rapid Speed Override on any of the 4 axes.
In any mode, the selection of the Rapid Speed Override of 8% on any of the 4 axes can be made by pressing this pushbutton.

43
Note Cutting/JOG Feed Override Switch (62) is not available for Rapid Feed Override.
44
2.3.5
Coolant ON/OFF Pushbutton
Cutting Coolant Pushbutton (37) Shower Coolant Pushbutton (38) Through Spindle Coolant Pushbutton (39) Flood Coolant Pushbutton (40)
When any of these pushbuttons is pressed, its light comes on and its corresponding coolant pump is turned on. Subsequent press of the same pushbutton turns off its coolant pump and light. These coolant pushbuttons are in effect regardless of mode selection. It is therefore possible to turn off and on the flow of coolant during machining process in any mode.
During AUTO, MDI, or REMOTE mode, coolant can also be turned on and off by using M-codes.
Cutting Coolant
M08 cutting coolant starts M09 cutting coolant stops, oil mist/air blow stops
Shower Coolant
M10 shower coolant starts M11 shower coolant stops
Spindle Through Coolant
M13 spindle through coolant starts

45
M14 spindle through coolant stops
Flood Coolant
M15 flood coolant starts M16 flood coolant stops
Note Shower coolant and flood coolant are automatically started when Cycle Start pushbutton (56) is pressed. Spindle through coolant is turned off when M6 or M106 is executed.
2.3.6
Spindle Operation
Spindle Forward Rotation Pushbutton (41)
This pushbutton can only be used in JOG Mode. When it is pressed, the spindle rotates clockwise. In any mode, whenever the spindle rotates forward, its lamp comes on.
Spindle Stop Pushbutton (42)
In HANDLE, JOG, RAPID or ZERO RETURN mode, when it is pressed, the spindle stops immediately.
Spindle Reverse Rotation Pushbutton (43)
This pushbutton can only be used in JOG Mode. When it is

46
pressed, the spindle rotates counterclockwise. In any mode, whenever the spindle rotates in the reverse direction, its lamp comes on.
Spindle Speed Decrease Pushbutton (44)
In any mode, each press of the pushbutton decreases the spindle speed by 10% until the maximum deceleration, 50%, is reached.
Spindle Speed 100% Pushbutton (45)
By pressing this button, Spindle speed set by Spindle Speed Deceleration pushbutton (44) or Spindle Speed Acceleration pushbutton (46) Spindle Speed is returned to its 100%. Its lamp comes on, when this pushbutton is pressed.
Spindle Speed Increase Pushbutton (46)
In any mode, each press of the pushbutton increases the spindle speed by 10% until the maximum acceleration, 150%, is reached.
2.3.7
B-axis Table Clamp/Unclamp
B-axis Table Clamp and B-axis Table Unclamp operations can only be done in JOG mode. B-axis Table Unclamp Pushbutton (47)
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In JOG mode, pressing this button causes B-axis Table to be unclamped. Its lamp comes on when B-axis Table is unclamped.
Note The B-axis Table can only be turned when it is unclamped.
B-axis Table Clamp Pushbutton (48)
In JOG mode, pressing this button causes B-axis Table to be clamped. Its lamp comes on when B-axis Table is clamped. When clamped, the B-axis Table cannot be turned.
2.3.8
Chip Auger Pushbutton
Chip Auger Forward Pushbutton (63) (Option)
This pushbutton is used to turn Chip Auger so that it moves the chips in the forward direction.
Chip Auger Stop Pushbutton (64) (Option)
This pushbutton is used to stop Chip Auger immediately.
Chip Auger Reverse Pushbutton (65) (Option)
This pushbutton is used to turn Chip Auger so that it moves the chips in the reverse direction.
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2.3.9
Miscellaneous Pushbuttons
Door Open Request Pushbutton (49)
Before opening Operator Side Door, its necessary to press Door Open Request Pushbutton (49). When pressed, the lamp is lit and the safety lock of the door is released. To lock Operator Side Door again, close the door completely. When the door is closed, the door will be locked automatically and this buttons lamp will go off.
Auto Power off Pushbutton (50)
Auto Power OFF function can be enabled by pressing Auto Power Off pushbutton (50). If pressed, its lamp will come on. With Auto Power OFF turned on, when an automatic operation ends (M30), the machine goes into the emergency stop state, NC is powered off, and finally the main switch is turned off. Note Remember to release this pushbutton, once the main power is turned back on. Air Blow (51)
In Manual Mode, when this pushbutton is pressed, Air Blow starts and its lamp comes on. Subsequent press of this pushbutton stops Air Blow and its lamp to go off. In MDI Mode or AUTO Mode, press this pushbutton to stop Air Blow if it has been turned on; or press this pushbutton to start Air Blow if it has not been turned on.
Note In MDI Mode or AUTO Mode, M09 command can be used to turn off Air Blow; and M07 command can be used to turn on Air Blow.
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Oil & Air System Lubrication Oil Pushbutton (52)
When this button is pressed, lubrication oil is supplied to ballscrews, linear guides, and the spindle for 6 seconds.
Note When NC is in ready state for operation, any axial movement or spindle rotation will trigger lubrication oil and air to be automatically supplied to ballscrews, linear guides, and the spindle. Air is continuously supplied whenever NC is in its ready state. Oil lubrication cycle repeats itself as described below: 1) Lubrication oil is supplied for 20 seconds. 2) Lubrication stops for 6 minutes. The lubrication oil can manually be turned on by pressing this pushbutton. Each press of this pushbutton triggers the oil lubricant to be dispensed to ballscrews, linear guides, and the spindle for 20 seconds.
Work Light ON/OFF Pushbutton (53)
This pushbutton is used to turn on/off the work light.
Tool Display Pushbutton (54)
Press this pushbutton to navigate the LCD display to Tool Data. As an example, in OPERATOR MESSAGE section, the following tool information are displayed: SPINDLE TOOL NO. = 2
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WAITING POT TOOL NO. = 1 MAGAZINE POT TOOL NO. = 0 The data are interpreted as below: Tool #2 in the spindle. Tool #1 in the waiting pot. There is no tool in the magazine pot.
Safety Both Hands Pushbutton (69)
This pushbutton is needed for safety reason. Pressing Machine Lock pushbutton or Program Restart pushbutton is only effective when this pushbutton is also pressed at the same time.
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2.3.10 Cycle Start Pushbutton
By pressing Cycle Start Pushbutton (56), an operation in AUTO or MDI mode is started. When a program is being executed, the lamp of Cycle Start pushbutton will come on and stay on. The lamp will go off, once the program execution is ended, when FEED HOLD is executed, or when the program execution is stopped or suspended.
In the following cases, Cycle Start pushbutton is ignored: Emergency stop is in effect. Mode selection is incorrect. Sequence number search is executing. Any alarm is not yet cleared. The numerical control system is not ready ("NC READY" is not displayed on LCD) APC or ATC unit has not yet returned to its home position. 2.3.11 Feed Hold Pushbutton
This Feed Hold Pushbutton (57) is used to stop an automatic operation in AUTO or MDI mode. When this button is pressed, the followings occur: The Cycle Start lamp goes off and the Feed Hold lamp comes on. All axial movements are decelerated and subsequently stopped. Dwell is suspended. For M and S functions, the machine stops after executing the current command. In the tapping cycle or counter tapping cycle, the machine stops when the cycle reaches its end although Feed Hold pushbuttons lamp remains lit.
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If Feed Hold pushbutton is pressed during the movement between the point R and the initial point, the movement stops immediately. While Feed Hold is in effect, spindle rotation and coolant system are not stopped; thus, manual operation is still permitted. While an automatic operation is being suspended, if the machine is operated manually, the axial positions may possibly be shifted. Therefore, before restarting automatic operation, return the axes to their prior positions.
Note To restart the operation, press Cycle Start pushbutton. MDI command is not available if the machine is suspended with Feed Hold. 2.3.12 Emergency Stop Pushbutton
Emergency Stop Pushbutton (67) is used to stop the machine immediately in case of emergency. Once this button is pressed, it remains latched in the STOP position. To release the button, turn it clockwise. When an emergency stop takes place, the power to the motors is interrupted, and all axial movements and spindle rotation are stopped.
Note Be sure to remove the cause of emergency stop before releasing Emergency Stop button. After releasing this button, pressing NC Ready pushbutton repeatedly until EMG message disappears. When the operation is restarted, all commands for axial movement or spindle rotation before the Emergency Stop occurred are lost.
CAUTION
All personnel must know the locations of all Emergency Stop

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buttons and how to use them in case of emergency.
2.3.13 Feed Rate Override Switch This Feed Rate Override and JOG Feed Override Switch (62) can be used for setting the feed rate override in JOG mode.
An override from 0 to 200%, at an interval of 10%, can be applied to the feed rate specified by the F function in automatic operation (AUTO, MDI). Normally, it is set to 100%.
Note: When Feed Rate Override switch is set at 0, no axial movement is permitted.
NC Ready Pushbutton (68)
With NC powered on or emergency stop released, press this button causes NC to enter its ready state. The lamp will light up when both numerical control and mechanical system are ready for operation.
2.3.14 Memory Protect Switch When Memory Protect Switch (70) is set to "CANCEL", registration and editing of a program is allowed. When this switch is set to "M LOCK" (Maintenance Lock), the memory is protected from any modification, consequently, registration or editing is prohibited. If the switch is set to OP LOCK (Operation Lock), the mode is temporarily locked to the mode previously selected; none of mode
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selection pushbutton is functional.
The table below lists the operations allowed or disallowed according to the mode selected by the Memory Protect Switch.
Program Edit/Transfer Tool Offset Workpiece Coordinate Offset Macro Variables Tool Life Management Mode Switch Axial Movement Tool Search/Tool Exchange Spindle Rotation Program Execution Peripheral Motor Action Message Display
1
Cancel Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No
Op Lock Yes Yes Yes Yes Yes No No No No No No Yes
M Lock No No No No No Yes Yes Yes Yes Yes Yes No
Op Lock
When Memory Protect Switch is set to Op Lock, the operations listed in the table above are allowed only if Keep Relay K0.6 is set to 1. Be sure to set this switch to "M LOCK" or OP LOCK after editing or registering a program in memory.
CAUTION
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2.3.15 Pallet Control and Pushbuttons Pallet Manual Selection Switch (71)
This switch is only meaningful in JOG mode. When Pallet Start pushbutton (73) is pressed, the operation selected by this switch is performed.
Note This switch is functional only when the machine is in the APC ready position.
Pallet Set-up Pushbutton (72)
After workpieces have been set up on the pallet, press this button to indicate to the machine that the workpieces on the pallet are ready. When this button is pressed, its lamp comes on and stays on. At this point, the pallet is in a set-up state and is awaiting the pallet change operation to start. When the pallet is in set-up state, the front set-up doors are locked. In AUTO mode, if the pallet is not in set-up state, the pallets will not be exchanged per any APC command; instead, the pallet change operation is suspended until this button is pressed. If the pallet is in already set-up state, press this button again will cancel its set-up state and its lamp also goes off. When pallets are exchanging, the lamp of Pallet Set-Up pushbutton will blink until the pallet change operation is completed. Once the pallet change operation is completed, the locks on the set-up doors are released.
CAUTION
Do NOT open the set-up door whenever the lamp of Pallet Set-Up pushbutton is blinking.
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Pallet Start Pushbutton (73)
In JOG mode, pressing this button will start the operation selected by Pallet Manual Selection Switch (71). When its lamp is lit, manual operations of APC are allowed.
2.3.16 Pushbuttons of Options F1DT Pushbutton (94)
To be designed.
PLBK Pushbutton (95)
To be designed.
HINT Pushbutton (96)
To be designed.
5UNC Pushbutton (97)
To be designed.
JUNC Pushbutton (98)
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To be designed.
F2 Pushbutton (99)
Reserved for future feature.
2.3.17 Manual Pulse Generator
In HANDLE mode, Manual Pulse Generator (82) is used to move the axes at finer steps. On Manual Pulse Generator, feed of 0.001 mm or 0.001o (x1), 0.01 mm or 0.01o (x10), 0.1 mm or 0.1o (x100) per scale can be selected.
To operate, select axis and scale, and then turn the handle. One rotation of the handle is equivalent of 100 scales.
Note The handle should not be turned more than five rotations per second.
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2.4 2.4.1
Other Controls and Pushbuttons Spindle Tool Clamp/Unclamp Pushbutton
Spindle Tool Clamp/Unclamp Pushbutton (58) This pushbutton is on the enclosure panel next to the operators side door for easy access.
In JOG mode, when the spindle tool is clamped, pressing this button causes the spindle tool to be unclamped. Similarly, when the spindle tool is unclamped, pressing this button causes the spindle tool to be clamped. The lamp comes on when the spindle tool is in the unclamped state.
Note Be sure to hold the tool by hand before unclamping it. Press and hold the button for at least one second. If not, Spindle Tool Clamp/Unclamp may not function properly. The spindle tool cannot be unclamped while the spindle is rotating. When the spindle is unclamping, it will clamp the tool if the hydraulic pressure suddenly drops because of either emergency stop or poweroff. If spindle rotation or spindle orientation is commanded while spindle tool is unclamped, the machine will enter Feed Hold state. The command for spindle rotation or spindle orientation should only be submitted for execution when the spindle tool is clamped.
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2.4.2
Pallet Setting Side
80
81
Pallet Set-up Pushbutton (80)
Same function as Pallet Set-up pushbutton (72) on the machine operation panel. Refer to Section 2.3.15.
Emergency Stop Pushbutton (81)
Same function as Emergency Stop pushbutton (67) on the machine operation panel. Refer to Section 2.3.12.
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2.4.3
ATC Magazine Side
75
76
78
77
79
Emergency Stop Pushbutton (75)
Same function as Emergency Stop pushbutton (67) on the machine operation panel. Refer to Section 2.3.12.
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ATC Manual Operation Switch (76)
In JOG Mode, the movement in ATC can be selected with this switch, followed by pressing ATC Manual Start Pushbutton to execute the selected ATC operation.
Double Arm Chucking
Tool Unclamp Double Arm Turn 180 Counter Clockwise
ATC Shutter Open Tool Pot to Double Arm Side Magazine Rotate Counter Clockwise Magazine Rotate Clockwise Tool Pot to Magazine Side
Tool Clamp Double Arm to Initial Position ATC Shutter Close
Double Arm Turn 180 Clockwise
There are limitations imposed on the actions of ATC that can be selected with ATC Manual Operation Select switch: Movements in (white) are available only in JOG Mode and when the spindle is in tool change position. Movements in (grey) are available in Automatic operation mode provided that ATC magazine has not been stopped.
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ATC Manual Start Pushbutton (77)
Pressing this pushbutton causes the operation selected by the ATC Manual Operation Switch to be started right away.
Note Make sure the door of ATC magazine is closed before pressing ATC Manual Start pushbutton.
Single Arm Manual Operation Switch (78)
In JOG mode, a Single Arm manual operation can be selected with this switch, followed by pressing Single Arm Manual Start pushbutton (79) to start the operation.
Note Manual continuous operation can be started in any operation mode.
Continuous Operation
Tool from Waiting pot to Magazine pot
Tool from Magazine pot to Waiting pot
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Single Operation
Tool chucking at Magazine pot
Tool chucking at Waiting pot
Grippers locked and Tool removed
Single arm from Magazine pot to Waiting pot
Single arm from Waiting pot to Magazine pot
Tool inserted and Grippers unlocked
Single arm to the initial position
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Single Arm Manual Start Pushbutton (79)
The operation that is currently selected by the Single Arm Manual Operation Switch can be started by pressing this button.
Note After the machine is powered on, make sure there is adequate hydraulic pressure before manually operating the single arm.
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Starting and Ending Operation
Before starting any operation, check the machine to ensure all safety regulations are enforced. (Refer to Safety Precautions) 3.1 Emergency Stop
Emergency Stop is used to stop the machine operation immediately. Emergency Stop is used to stop the machine operation immediately in case of emergency. There are three Emergency Stop buttons (67), (75), and (81). These buttons are effective in any mode.
3.2
Turning ON Power
Follow the procedure below to turn on the machine:
Make sure factory power is supplied to the electric cabinet.
Turn on Main Power switch on the electric cabinet . Power Lamp on the electric cabinet comes on. Ventilation fans in the electric cabinet are turned on. Spindle motor fan is turned on. Release all Emergency Stop pushbuttons (67), (75), and (81).
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Press NC Power ON pushbutton (0) The lamp of NC Power ON pushbutton lights up. The LCD displays System Configuration screen and NC is now powered. Press NC Ready pushbutton (68) and hold for a few seconds. The lamp of NC Ready pushbutton lights up. The machine is now ready for operation.
Items to check after the machine is powered on are: Items Motors Air unit LCD screen Check For Abnormal heat or noise Adequate air pressure (0.6 MPa) Alarm display
3.3
Machine Warm-up
Machine warm-up is mandatory in order to ensure smooth and proper operations of every component of the machine, and to minimize the effect of heat expansion on the machine accuracy. Lubrication After the machine is powered on, oil is automatically supplied to spindle, ballscrews, and linear guides, etc., where lubrication are needed. However, immediately after the machine is turned on, the spindle bearings are not sufficiently lubricated. In order to ensure that these parts are not damaged unintentionally, the following rules must be strictly enforced: If the machine has been turned off for less than 48 hours, do NOT turn the spindle for at least 20 minutes after the machine is powered on. If the machine has been turned off for more than 48 hours, do NOT turn the spindle for at least 40 minutes after the machine is powered on.
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CAUTION
Spindle can be damaged if it is rotated before its spindle bearings are adequately lubricated.
Hydraulic Circuit To warm up of the oil in the hydraulic circuit, use the following two M functions to increase the oil temperature: M83 - When room temperature is in the range of 5C~15C (40F~60F). M84 - When room temperature is less than 5C (40F) Note The oil in the hydraulic circuit, when it is cold, has high viscosity which can cause problems in certain operations, such as spindle tool clamp/unclamp. Grease Grease also needs to be warmed up so that it can permeate the parts and the components. For example, insufficient lubrication on the clamp pins of the double arm may result in a tool chucking problem. Warm-up Procedure without using Weekly Timer Two warm-up programs, O8930 and O8931, are installed on the machine before delivery. The elapsed time since the last power-off of the machine can be used to determine which one of the two programs to execute. If the machine has been powered off for more than 48 hours, execute warmup program O8931. If the machine has been powered off for less than 48 hours, execute warm-up program O8930. The execution time for O8930 is approximately 50 minutes. The execution time for O8931 is approximately 60 minutes.
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3.4
Turning OFF Power
Make sure that the light of Cycle Start pushbutton (56) is off.
If the light of Cycle Start pushbutton is not off, press Feed Hold pushbutton (57).
Press Emergency Stop pushbutton (67).
Press NC Power OFF pushbutton (00).
Turn off Main Power switch.
3.5
After Turning Off Power
Any cleanup work should only be carried out after the machine has been turned off. DANGER Be sure to turn off all power supply to the machine and to the devices such as chip conveyor before cleaning them.
Chips are flushed by coolant toward the chip pan sitting at the front of the machine. Make sure that chips are not over-accumulated in the chip pan. Chips left on the covers should be brushed off with soft brushes. Do NOT use air gun to blow chips away from the covers.
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Remove chips and wipe clean coolant left on the covers. Coolant and chips infiltrate underneath the covers can potentially damage machine components such as spindle bearings or ballscrews. Always wear gloves to clean chip debris. Be aware that solenoid valves will remain hot after the machine is powered off. Refrain from touching them for a while. If the machine will not be operated for a long time, insert a tool into the spindle to prevent foreign matters from entering. 3.6 Measures in Power Failure
When power failure occurs during machine operation, the NC unit and the electrical control units are all powered off; the machine goes into the emergency stop state. As a result, the commands stored in the NC buffer or input through the operation panel are cleared and lost. Below are the steps to take immediately following a power failure:
Press Emergency Stop pushbutton (67).
Turn off Main Power switch.
Below are the steps to take after power is restored:
Turn on Main Power switch on the electric cabinet. Refer to Section 3.2 Turning ON Power.
Release all Emergency Stop pushbuttons (67), (75), and (81).
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Press NC Power ON pushbutton (0)
Press NC Ready pushbutton (68) and hold for a few seconds.
Troubleshoot and remove the causes of alarms if any. Restore the machine, with manual operations, to the conditions before power failure.
WARNING
Corrective actions after power is restored must be carried out with manual operations. This is because the remaining pneumatic/hydraulic motion may be continued unexpectedly when these circuits are turned back on.
After power to the machine is restored, the states of the machine should be as follows: Before Power Failure Spindle tool clamped Spindle tool unclamped Spindle rotating Spindle stopped X/Y/Z/B axis feed ATC motion APC motion After Power is Restored Spindle tool clamped Spindle tool unclamped Spindle stopped Spindle stopped Unchanged Stopped/Unchanged Stopped/Unchanged
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3.7
Weekly Timer
This machine is equipped with a weekly timer. This weekly timer can be enabled or disabled by the key switch located on the door of the electric cabinet. By using the weekly timer, the machine can be automatically turned on and off at preset times. If the weekly timer is used to turn on the machine, warm-up programs of the spindle and other movable components will be automatically performed. ON Operation 1) At the preset ON time, AC power is supplied to the power supply module of the machine. 2) NC is turned on. 3) The machine gets in the Ready state for operation. (All emergency stop buttons must be released.) 4) Twenty minutes later, a spindle warm-up program (installed at factory) is started. It will take about 25 minutes to warm-up the 15,000 rev/min spindle. 5) When the spindle warm-up is finished, the machine warm-up program will be started. Note The key switch for the weekly timer must be set to ON (enabled) and the day selection switch for that day is set to ON.
OFF Operation 1) At the preset OFF time, the machine goes into the emergency stop state. Note If a program is being executed at preset OFF time, the machine will wait until the program complete its execution before entering the emergency stop state. 2) NC is turned off. 3) AC power supply to the power supply module is shut off, but the main power switch stays ON.
Prepare Weekly Timer for Next Day

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Check the following items before the Weekly Timer turns off the machine: The weekly timer is correctly set for the next operation day. All emergency stop buttons are released. AUTO Mode is selected. Single block switch on the operation panel is set to OFF. Make sure that no tool is in the spindle. This is important because if there is a tool in the spindle, it may cause problems during the next automatic spindle warm-up procedure. There is no tool or part unintentionally left in the machining area. All machine doors are closed (Door Open Request pushbutton is OFF). Feed rate override switch/pushbutton is set appropriately. The waiting pot is positioned at the spindle side (normal position), The main power switch is set to ON. Note Do not use the Auto Power Off function. Auto Power Off causes the main power switch to be turned off. The key switch for the weekly timer must be set to ON (enabled).
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4
4.1
Manual Operation
Zero Point Return
In this machine, every axis is equipped with an absolute type encoder for tracking its positions. Therefore, it is not required that the zero point return be executed after the machine is powered on. However, if any servo motor loses its zero point data because of low battery, executing the zero point return will become necessary for all axes. The zero point return procedure for B-axis is slightly different from that of X, Y, or Z axis. For X, Y, and Z axes, please refers to Section 11.6 Zero Point Setting of Axes in HS-450i Maintenance Manual. For B axis,
Press Zero Point Return Mode pushbutton (8). Its lamp comes on.
Select an appropriate rapid feed rate with one of Rapid Feed Override pushbuttons, 8%, 15%, 25%, 50%, or 100% (30) to (34).
Press and hold B-axis Plus Direction Feed and Zero Return Pushbutton (27) until its completion lamp is lit which indicates that B-axis has reached its zero reference point.
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When over-travel fault occurs, follow the steps outlined below to resolve the error: 1) Move every axis to the center of its travel path by manual operation. 2) Press the NC Power OFF pushbutton (00). 3) While pressing [P<] and [CAN] keys on NC keyboard, press NC Power ON pushbutton (0), until the position display appears on the LCD screen. 4) Execute zero point return on all axes. 4.2 JOG Feed
JOG feed is used to move each axis continuously at a JOG feed rate in manual operation. For X, Y, Z, and B axes, there are twenty one speed overrides, ranging from 0% to 200%, to choose from.
Press JOG Mode pushbutton (6) to put the machine in JOG mode. Its lamp will be lit.
Set a feed rate by turning the Feed Rate Override switch (62) to the desired feed rate override.
Press one of the Plus Direction Feed and Zero Return Pushbutton, (21), (23), (25) or (27), to move the selected axis in the positive direction. In case of B-axis (28), make sure B-axis is already in the unclamped state. If not, press B-axis Unclamp pushbutton (48). Or press one of the Plus Direction Feed pushbuttons (22), (24), (26), or (28), to move the selected axis in the negative direction. When one of these pushbuttons is pressed, the selected axis moves at the feed rate set by Feed Rate Override.
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Note Over-travel alarm is triggered whenever any axis travels past its over-travel limits. Axis itself cannot travel past its travel limits in either automatic mode or manual mode. To resolve Over-travel alarm, move the axis in the opposite direction in manual operation, and then press RESET button. 4.3 Rapid Traverse
Rapid traverse is to move each axis continuously at a rapid traverse rate. Override of 0, 25, 50 and 100% can be selected.
In any mode, the selection of the Rapid Speed Override of 0%, 8%, 15%, 25%, 50% and 100% on any of the 4 axes can be made by pressing the corresponding pushbutton.
Press RAPID Mode pushbutton (7) to put the Machine in RAPID Traverse mode. Its lamp will be lit. RAPID Mode Select the desired rapid feed speed of 0%, 8%, 15%, 25%, 50% and 100% by pressing one of the Rapid Feed Override pushbuttons, (29) to (34).
Press one of the Plus Direction Feed and Zero Return Pushbutton, (21), (23), (25) or (27), to move the selected axis in the positive direction.
Or press one of the Plus Direction Feed pushbuttons (22),

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(24), (26), or (28), to move the selected axis in the negative direction. When one of these pushbuttons is pressed, the selected axis moves continuously at the rapid traverse rate selected in the previous step.
4.4
Handle Feed
Handle feed is to move each axis little by little using the Manual Pulse Generator (82). On Manual Pulse Generator (82), feed rate of 0.1, 0.01, or 0.001 mm/scale is available for X, Y and Z axes, while 0.1, 0.01, or 0.001 per scale is available for B axis. Each revolution of the dial equals 100 scales. The dial should only be turned at a speed less than 5 revolutions per second.
Press HANDLE Mode pushbutton (5) to enter Handle mode. Its lamp will be lit.
Select 1 (0.001mm), 10 (0.01mm), or 100 (0.1mm) using the Handle Feed Selection switch on Manual Pulse Generator (82).
Select an axis to move with the Axis Selection switch on Manual Pulse Generator (82). Whilst the pushbuttons (21), (23), (25), and (27) on Operation Panel are functional in HANDLE mode, the lamp of the selected axis using Axis Selection Switch will be lit. Turn the handle of Manual Pulse Generator (82) to move the selected axis. The amount of movement is calculated according to the number of turns and the selected handle feed rate.
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Note Manual Pulse Generator is only used in HANDLE Mode. 4.5 Insertion/Removal of Spindle Tool
To insert a tool into the spindle or to remove a tool from the spindle, follow the steps below: 1) Move spindle head toward the operator side using handle feed. 2) Press Door Open Request button (49) to open the door. 3) Press JOG Mode pushbutton to enter JOG mode.
Tool Removal
While holding the spindle tool firmly by hand, press Spindle Tool Clamp/Unclamp button (58). The tool will be unclamped and can be removed from the spindle.
Tool Insertion
Press Spindle Tool Clamp/Unclamp button (58). The lamp will come on indicating that the spindle is in an Unclamp position. Insert a tool into the spindle, then press Spindle Tool Clamp/Unclamp button (58) again. The tool is clamped in the spindle and the lamp of Spindle Tool Clamp/Unclamp button will go off to indicate as such.
Note Be sure to hold the spindle tool firmly by hand before pressing this button to unclamp it.
When pressing the button, keep it pressed securely for at least one second. If not, this button may not function correctly.
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When the spindle is in the unclamp state, it does not execute spindle rotation or spindle orientation command.
WARNING
Do not touch the cutting edge of tools by hand. away from a rotating spindle.
Be sure to stay
4.6
Spindle Revolution and Stop
Press JOG Mode pushbutton (6) to enter JOG mode. Its lamp will be lit. Press Spindle CW Rotation pushbutton (41) to rotate the spindle clockwise, or press Spindle CCW Rotation pushbutton (43) to rotate the spindle counter-clockwise. When Spindle CW Rotation pushbutton (41) or Spindle CCW Rotation pushbutton (43) is pressed, the spindle rotates at the speed specified in the "S" command that was executed previously in MDI or AUTO mode. If not a single MDI or AUTO operation has been executed since the machine was powered on, the spindle will not rotate because the spindle speed is undetermined. To resolve this, execute a spindle speed command in MDI mode before issuing any spindle rotation command. To change spindle speed, the speed override of 50% to 150% can be achieved using Spindle Speed Decrease pushbutton (44) or Spindle Speed Increase pushbutton (46). Press Spindle Stop pushbutton (42) to stop the spindle rotation. Note Spindle Stop pushbutton (42) is only functional in HANDLE, RAPID, or JOG mode.
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5
5.1
MDI Operation
MDI (Manual Data Input) Operation
In MDI mode, commands can be entered into MDI operation buffer memory through LCD/MDI panel.
Press MDI Mode pushbutton (4) to enter MDI mode. The lamp of MDI Mode pushbutton comes on and MDI screen is displayed on the LCD.
PROG
If any other screen is displayed, press [PROG] key or MDI soft key to navigate the display to MDI screen.
INSERT
EOB
Enter a block of commands and then press [EOB] key, followed by [INSERT] key.
Move the cursor to the top of the program or to the position where the program should start. Program starts from the top of block where the cursor is. Press Cycle Start pushbutton (56).
Note On the LCD screen, one page of program, up to 10 blocks, can be executed in the same manner as the normal program. While a program is being executed, to stop execution of the program immediately, press Feed Hold pushbutton (57). Program No. "O0000" is automatically added at the top of the program created in MDI mode. To clear the program created on the LCD, input "O" then press [DELETE] key. By parameter setting, [RESET] key can clear the program.
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For the first time the program is executed, it will start from the top of the block regardless of the cursor position. After the first run, however, it will start from wherever the cursor is. A program created in MDI mode can call sub-programs, but not macro programs. MDI operation is allowed only if there is enough memory to store the program. A MDI program is automatically deleted after the program execution reaches %. However, a MDI program is not deleted if it includes M02, M30 or M99 in the program. A MDI program in the memory is deleted under the following situations: EDIT Mode pushbutton (1) is pressed Background editing is completed Automatic operation is started.
5.2
Spindle Revolution in MDI
Press MDI Mode pushbutton (4) to enter MDI mode. The lamp of MDI Mode pushbutton will come on. Press [PROG] key on NC keyboard.
PROG
To specify the spindle speed in the command, key in S, followed by the desired spindle speed, then press [INSERT] Key. To request for spindle rotation in the command, key in M03 (Forward) or "M04" (Reverse), and [EOB], then [INSERT]. For example: To rotate the spindle at 900 rpm forward, enter:
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[S][9][0][0][INSERT] [M][0][3][EOB][INSERT] Press Cycle Start pushbutton (56). As a result of the execution of the commands entered previously, the spindle will rotate at the specified speed in the specified direction.
Note During ATC operations or when the spindle tool is unclamped, Spindle Revolution command is ignored.
5.3
Spindle Orientation in MDI
Press MDI Mode pushbutton (4) to enter MDI mode. The lamp of MDI Mode pushbutton will come on. Press [PROG] key on NC keyboard.
PROG
SP
Key in "M19" (orientation), [EOB], and [INSERT]
1
EOB
9
INSERT
Press Cycle Start pushbutton (56).
Note Spindle Orientation does not get executed when the spindle is unclamped. Spindles orientation is released when any ATC movement is completed and a Spindle Revolution command is executed.
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5.4
ATC Magazine Indexing and Tool
Press MDI Mode pushbutton (4) to enter MDI mode. The lamp of MDI Mode pushbutton will come on. To register tools, please refer to Section 7.2 "Tool Registration for instructions.
PROG
%
Press [PROG] key on NC keyboard.
0
EOB
1
INSERT
Key in the tool No. to be indexed. For example, to index tool No. 1, press [T] [0] [1] [EOB] [INSERT].
Press Cycle Start pushbutton (56). The tool is now indexed at ATC position. For ATC, move spindle head to ATC position. (Refer to Section 7.4 "Tool Exchange in MDI Operation.)
SP
M
EOB
6
INSERT
Key in [M] [6] [EOB] [INSERT]. Press Cycle Start pushbutton (56). The spindle tool is exchanged with the indexed tool.
Note T** commands and M6 must be executed in different blocks.
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5.5
Table Clamp/Unclamp in MDI Operation
In MDI operation, M61 can be used to command the B-axis to be clamped, while M62 and M63 can be used to command the B-axis to be unclamped. M61 This is the only command to can be used for B-axis clamping. M62 When M62 is executed in MDI mode, B-axis rotary table will be unclamped; it will be automatically clamped again once B-axis completes the rotation. This Auto-clamp function in AUTO/REMOTE mode works the same way as in MDI mode. Note If B axis is stopped by Feed Hold, it will remain unclamped.
M63 M63 is a single command for B-axis unclamping. M63 doesn't execute Auto-clamp function after B-axis completes its rotation. After M63 command is executed, M61 needs to be executed in order to clamp the B-axis. M62 can be used to clamp the B-axis if it is executed in the same block as the table rotation command. Note Even if the table is unclamped by M63, machining process can still continue, although, with inferior precision. For heavy cutting or cutting accurate, make sure the table is clamped. Note In Handle mode, when Manual Pulse Generators axis selection is set to 4, pressing either B-axis Plus Feed Zero Return Pushbutton or Baxis Minus Feed pushbutton (28) causes B-axis to be unclamped. When B axis is in the unclamped state, switching into Auto mode or MDI mode will cause B-axis to be clamped again, however, switching into JOG mode or Zero Return mode, B-axis will remain unclamped.
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Automatic Operation
Before entering automatic operation Check that the program is correctly entered. Check that all switches and pushbuttons are correctly set. Check that all doors are closed and that all covers are properly set. Check that no part of human body is and will be in the machine movable area. Check that no interference is and will be introduced between tools and workpieces or fixtures. Be sure to avoid any possibility of catching fire. During automatic operation Never open any door or any cover. Be sure that someone is ready to press Emergency stop pushbuttons in case of an emergency. After automatic operation Before opening any door or any cover, check to make sure that the automatic operation has stopped, and that all movements have completely stopped.
Alarms If an alarm appears and the machine has stopped, be sure to remove the cause of the alarm before restarting the operation. Failure to react to these warnings may result in serious bodily injury to personnel or serious damage to the machine.
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6.1
Starting Automatic Operation
Memory Operation (AUTO)
PROG
Press AUTO Mode pushbutton (2). Its lamp should come on. Press [PROG] key on NC keyboard. The program edit screen will be displayed on the LCD. Invoke a program with the following steps:
O 3
1 2
RESET
1. Press address key [O]. 2. Key in the program number with numerical keys. For example, press [0], [1], [3] and [2] or just [1], [3] and [2] for Program No. 0132. 3. Press DOWN cursor key. The program will be displayed on the LCD. 4. Press [RESET] key. Check that the program is correctly entered, and then press Cycle Start pushbutton (56) to execute the program. Its lamp is lit and the program is executed.
Remote Mode Operation
Setup a tape reader or a program transfer device using the RS232C interface so that program can be retrieved from these devices. Press REMOTE Mode pushbutton (3) to enter Remote mode. Its lamp should be lit. Press Cycle Start pushbutton (56). Its lamp is lit. The program is retrieved from the external device and then executed, although its blocks are not displayed on the LCD screen.
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6.2
Stopping & Restarting Automatic
Feed Hold (Halt)
Feed Hold pushbutton (57) is used to put the operation on a temporary stop. Feed Hold lamp lights up and the lamp of Cycle Start pushbutton (56) goes off. All movements are stopped. The dwell execution is halted. Immediately after the execution of M code or S code commands is completed, the machine stops. Feed Hold does not stop the spindle or coolant.
Single Block Stop
Single Block pushbutton (9) is used to execute one block of program at a time. Press Single Block pushbutton causes its lamp to come on. When an operation stops, the lamp of Cycle Start pushbutton (56) goes off. With this pushbutton (9) ON, each press of Cycle Start pushbutton (56) executes the next one block and stops the operation.
Suspension of Automatic Operation
Manual operation is allowed if automatic operation is stopped by Feed Hold.
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MDI operation is allowed if automatic operation is stopped by Single block.
Restart of Automatic Operation
Press AUTO Mode pushbutton (2) to put the machine back in automatic mode. Press Cycle Start pushbutton (56).
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6.3
Door Safety Interlock
Operator Side Door The operator side door has built-in safety lock. Open the Door To open this door during automatic operation,
Press Single Block Pushbutton (9). The lamp of Cycle Start pushbutton should go off. Press Door Open Request Pushbutton (63). Its lamp comes on. The door can now be opened.
Note Pressing Door Open Request causes the spindle to stop, if it was running, and the coolant pumps to stop pumping. It may take a while before the spindle stops completely. The door can only be opened after the spindle has completely stopped.
To Restart the Operation
Close the door. The lamp of Door Open Request should go off. The door is locked. In Auto mode, press Cycle Start Pushbutton (56). The spindle and the coolant systems are restarted.
Press Cycle Start Pushbutton (56) again. The program resumes from where it was stopped.
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Note The safety lock is fully engaged and functional even if the main power switch is off. The spindle restart is cancelled if RESET button is pressed, Emergency Stop button is pressed, or the power is turned off.
ATC Magazine Door The ATC magazine door is equipped with a safety lock. The door cannot be opened when ATCs double arm or single arm is in motion. The tool pot magazine is rotating. Unlike to open the operator side door, pressing Door Open Request pushbutton is not needed in order to open the ATC magazine door. Note When this door is open, no operation of ATC double arm, ATC single arm, or tool pot magazine is permitted. The safety lock is fully engaged and functional even if the main power switch is off.
Set-up Doors The set-up doors of this machine are equipped with safety locks. These doors are locked when: Pallet change operation is in process. The lamps of Pallet Set-up pushbuttons (72) and (80) are lit. Note In Auto mode or Manual mode, pallet change is allowed even if the set-up doors are open or not locked. However, it is advised that pallet change operation only be done with these doors closed. The safety lock is fully engaged and functional even if the main power switch is off.
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Summary of Door Interlocks When Operator door is open MODE ACTION Axis Spindle ATC APC Movement Revolution Tool clamp/unclamp Double arm Tool magazine Pallet change Pallet clamp/unclamp Auto and MDI No No No No No No No Handle/Jog/Rapid/ Zero Return Yes No Yes No Yes No Yes
When ATC magazine door is open ACTION Axis Spindle ATC APC Movement Revolution Tool clamp/unclamp Double arm Tool magazine Pallet change Pallet clamp/unclamp Auto and MDI Yes Yes Yes No No Yes Yes
When Set-up doors are open ACTION Axis Spindle ATC APC Movement Revolution Tool clamp/unclamp Double arm Tool magazine Pallet change Pallet clamp/unclamp All Modes Yes Yes Yes Yes Yes No Yes
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7
7.1
ATC Operation
Setting up ATC Magazine
Inserting tools into the tool pots or removing tools from the tool pots can be done using ATC Manual Operation switches. Note ATC magazine cannot be rotated if ATC magazine door is open.
How to Insert Tools Open the ATC magazine door; insert a tool into a tool pot until it is caught in the pot. The key groove of the tool holder comes in contact with the key on the tool pot. Note When adding tools to the tool magazine, it is advised that tools are evenly distributed throughout the magazine. Otherwise, unnecessary load will be exerted on the magazine chain, and can potentially cause problems during tool change operations.
How to Remove Tools To remove a tool from its tool pot, use a tool remover. WARNING To avoid bodily injury, always use a tool remover to remove a tool from the tool pot.
7.2
Tool Registration
Two types of tool management, Fixed Tool Pot and Random Tool Pot, are available in this machine. With Fixed Tool Pot, every tool has a designated tool pot, and for that reason, a tool after use is always returned to its own designated tool pot. With Random Tool Pot, the tool pots are exchanged between the spindle tool and the called-out tool.
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The default is set to Fixed Tool Pot when the machine is delivered. To change the tool management configuration, alter the data of keep Relay 2.7. Fixed Tool Pot: Set Keep Relay K2.7 to 0 Random Tool Pot: Set Keep Relay K2.7 to 1 In either configuration, there are two methods for tool registration. One method uses M101 and this other does not use M101. Tool Registration Using M101 When M101 is performed, every tool is assigned a number which is the number of its tool pot.
Insert tools into tool pots in the ATC magazine by following the next few steps. 1) Press JOG Mode pushbutton to enter JOG mode. 2) Set ATC Manual Operation Switch (76) to Magazine Rotation, and then press ATC Manual Start pushbutton (77) to send the desired tool pot to the setup area.
3) Insert a tool into the tool pot waiting in the setup area. 4) Repeat Step 2 and 3 until all tools are added.
Set Memory Protect switch (70) on the operation panel to CANCEL, and then press MDI Mode pushbutton (4) to enter MDI mode.
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SP
1 1
INSERT
0
EOB
Key in M101;, press [INSERT], then press Cycle Start pushbutton (56). The tool numbers are registered in the manner that the number of each tool matches the number of its tool pot. Tool Pot No. 1 2 3 .. .. 79 80 Tool No. 1 2 3 .. .. 79 80
For Random mode, spindles tool number is 81, and for Fixed mode, spindles tool number is 0. Set Memory Protect switch (70) to M LOCK.
Note If M100 is executed with Memory Protect Release switch (67) set to CANCEL, all tool numbers are reset to 0. After execution of M101, tool numbers are assigned to all tool pots regardless of whether tools are actually present in the tool pots. Note Performing M100 will reset all the tool numbers to 0. Only with Random Tool Pot configuration can a tool be inserted into the spindle. If a tool is inserted into the spindle in Fixed Tool Pot configuration, Alarm No. 1120 will be triggered at any T command after executing M101.
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Tool Registration without Using M101 Tool numbers can be registered one by one without using M101.
Insert tools into tool pots in the ATC magazine by following the next few steps. 1) Press JOG Mode pushbutton to enter JOG mode. 2) Set ATC Manual Operation Switch (76) to Magazine Rotation, and then press ATC Manual Start pushbutton (77) to send the desired tool pot to the setting area.
3) Insert a tool into the tool pot in the setting area. 4) Repeat Step 2 and 3 until all tools are added. Set Memory Protect switch (70) on the operation panel to CANCEL, and then press MDI Mode pushbutton (4) to enter MDI mode.
Navigate to the Data screen by pressing the following MDI key and soft keys at the bottom of the screen. SYSTEM ( > ) ( > ) (PMC MAINTE) (DATA) At the Data screen, press PAGE a few times to display a table.
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Where NO. is tool pot number and DATA is tool number. Move the cursor to desired tool pot number with [] or [] key. Key in a tool number into DATA field and press [INPUT]. Wait approximately ten seconds, and then set Memory Protect switch to M LOCK.
Note Any number in the range of 0000 and 9999 can be used as a tool number. However, 0000 is reserved for tool pots that do not hold any tool. If a tool number is registered for two different tool pots, Feed Hold lamp (57) will flick and Error message No. 2051, DUPLICATE TOOL NUMBER REGESTERED, will be displayed on
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the LCD for approximately ten seconds. Keep an eye on Feed Hold lamp and the LCD while entering tool numbers.
Large Diameter Tools When large diameter tools (95 mm or more) are used on HS-450i, interference between the tool in the waiting pot and the tools in the magazine pots can potentially occur, especially under the following conditions: If both tools have a diameter that is larger than 130 mm. If one of the tools has a diameter that is larger than 165 mm. To avoid such interference, this machine has a feature that can be turned on. To turn on this feature, change the keep Relay No. K31.7 to 1. When this feature is turned on, if magazine rotation command is executed with a tool in the waiting pot, the waiting pot is automatically swung to the spindle side; the magazine will proceed to start its rotation. Note Tools of large diameter can only be used if ATC is configured for Fixed Tool Pot. Make sure that the keep-relay No. K2.7 is set at 0. Do not insert tools into the magazine pots adjacent to a large diameter tool.
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7.3
Single Arm Manual Operation
Continuous Operation
Verify that Single Arm Manual Start pushbutton (79) is lit.
Set Single Arm Manual Operation switch (78) to 1 or 2.

1
Press Single Arm Manual Start pushbutton (79), Operation 1: A tool is moved from the waiting pot to a magazine pot. Operation 2: A tool is moved from a Magazine pot to the waiting pot.
Note Single Arm operations, 3 to 9, are primarily used for maintenance.
Single Operation If Single Arm is stopped by Emergency Stop pushbutton during Single Arm operation, take the following steps to restore Single Arm.
Tool chucked at Magazine pot
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Tool chucked at Waiting pot.

4
Grippers locked and the tool is removed.

5
Single arm swings from Magazine pot to Waiting pot.

6
Single arm swings from Waiting pot to Magazine pot.

7
Tool inserted and Grippers is unlocked

8
Return Single arm to its initial position

9
Note Before releasing Emergency Stop pushbutton or alarm status, make sure the cause of the problem has been resolved. In the case that Single Arm stopped at somewhere between the Magazine Pot and the Waiting Pot, because of Emergency Stop pushbutton, once Emergency Stop pushbutton is released, Single Arm will slowly drift back to the Waiting Pot. After remove the cause of the problem, set Single Arm Manual Operation Switch (78) to Single Arm movement in the desired direction, release Emergency Stop pushbutton, followed by pressing Single Arm Manual Start pushbutton (79).
7.4
Tool Exchange in MDI Operation
Press MDI Mode Pushbutton (4) to enter MDI mode. Its lamp should come on. Press [PROG] key, then enter the following statements for Second Zero Point Return of X, Y and Z axes:
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G91 G30 Z0; G91 G30 X0 Y0; Input the tool number to exchange. e.g. Enter T8 for Tool number 8
Input M code: e.g. M6; M106; (for tool weight: 0 to 5 kg) (for tool weight : 5 to 8 kg)
Press Cycle Start pushbutton (56), and the tool specified in T code and the tool in the spindle are exchanged.
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7.5
Tool Exchange in Automatic Operation
Press AUTO Mode pushbutton (2) to enter AUTO mode. Its lamp should come on. Below is a sample program for tool exchanges in Automatic Operation: O1000; M06 T01 T02 M06 T03 M6 M30
Note M106 can be used to exchange heavy tools (5 Kg and more). Alarm No. 1125 will be triggered, when M6 or M106 command is issued but the specified tool is not in Magazine pot, Waiting pot or Spindle.
Tool Exchange with an Empty Pot *Applicable to Fixed Tool Pot only. Usually an empty pot cannot be called to the spindle. However, if it is necessary, please follow the steps below:
Set PARAMETER WRITE to 1: ENABLE. Change Keep Relay No. K53.0 to 1. Set PARAMETER WRITE to 0: DISABLE.
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Press MDI Mode Pushbutton (4) to enter MDI mode.
Enter a T code and M6 to execute a tool change operation with an empty pot: e.g. T10; M6;
With this operation, the tool in the spindle tool is registered as Tool No. 10 although Tool No. 10 does not physically exist. If it is preferred not to register a non-existent tool for the spindle, the following codes can be executed to set both the tool number of the spindle and the tool number of Immediate pot to 0. T0; M6; G4 X1; T0; M6; Set PARAMETER WRITE at 1: ENABLE. Change Keep Relay No. K53.0 to 0. Set PARAMETER WRITE at 0: DISABLE.
Note Make sure Keep Relay No. K53.0 is reset back to 0. If it is not set to 0, the machine will not check for the presence of tool in the tool pot, consequently, errors such as machining with no tool can potentially occur.
How to Insert a Special Tool into Spindle *Applicable to Random Memory Tool only Special tools, such as test bars, need be inserted to the spindle directly since they cannot be placed in the magazine pots. To insert a special tool into the spindle:
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Press MDI Mode pushbutton to enter MDI mode. Execute the following statements: (G91 G30 X0 Y0 Z0;) T0; M6; The spindle tool will be moved to the Waiting pot. Press JOG pushbutton to enter JOG mode. In JOG mode, use Spindle Tool Clamp/Unclamp pushbutton (58) to insert the special tool into the spindle.
To remove the special tool from the spindle, do the following: Txxxx; (xxxx is the tool No. in the Waiting pot) M6; The tool in the Waiting pot will be inserted into the spindle, and the special tool that was in the spindle will be returned back to the Waiting pot.
Note Do not perform ATC when a special tool is in the spindle. Be sure to return the tool in the Waiting pot to the spindle, otherwise, Alarm No. 1120 will be triggered when another tool is requested for the spindle.
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7.6
Tool Data Screen
To access tool data such as the tool number in the spindle, the tool number in the waiting pot, the tool number in the magazine pot, etc., navigate to Tool Data Screen. Press the keys in sequence as below: SYSTEM ( > ) ( > ) (PMC MAINTE) (DATA) A data table will be displayed. From this data table screen, press soft key (ZOOM), followed by PAGE keys a few times, and a table similar to the one below is displayed. This is the tool data screen.
The tool data that are critical to the ATC operations are listed in the following table. ADDRESS D5562 DATA Tool number of the tool in the waiting Pot
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D5564 D5568 D5570 D5572 D5574
Total count of magazine pots T code number Tool number of the magazine pot at ATC position Pot number of the magazine pot at ATC position Tool number of the tool in the spindle
0 in D0388, D0396, or D0400 is used to indicate that tool is absent in the designated tool pot.
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8
8.1
APC Operation
Movement of APC
1. The clamp pins (Mechanical lock) of the rotary table at the machining side are unlocked and the Pallet Changing Arms move up to raise the pallets. 2. Pallets turn 180 degrees. 3. The Pallet Changing Arms move down and both pallets are seated. 4. The clamp pins of the rotary table lock the pallet onto the rotary table.
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8.2
Pallet Indexing Lever The pallet indexing lever which is located in the front of the pallet can be used to position or release axial movement of a pallet.
Before turning the pallet, push down the pallet indexing lever until it is locked at the bottom.
To lock the pallet, return the pallet approximately to its home position (the zero-degree plate comes in front).
Pull up the pallet indexing lever. If the pallet lock pin does not go into place correctly, turn the pallet slightly by hand and lock it with the indexing lever.
Note Turning the pallet forcefully with the pallet indexing lever pulled up can result in damage to the pallet lock pin.
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8.3
APC in Manual Operation
Perform the second zero point return (G91 G30 Z0 B0 M62;) on Z axis and B axis. When Z axis and B axis reach the second zero point, Zero Return Completion lamps (23) and (24) will start blinking. Press JOG Mode pushbutton (6) to enter JOG mode. Its lamp will be lit. Verify that the lamp of B-axis Table Clamp pushbutton (47) is lit. Verify that the lamp of Pallet Start pushbutton (73) is lit. (When this lamp is on, the pallet is in ready status.) If the lamp is not lit, check the following areas: Are all covers and doors closed? Is the ATC Double Arm in its home position? Is the pallet of the loading side in its home position? Is the B-axis clamped? Set Pallet Manual Selection switch (71) to UNCLAMP, and press Pallet Start pushbutton (73). The pallet on the machining side is unclamped.
Set Pallet Manual Selection switch (71) to UP, and press Pallet Start pushbutton (73). The two pallets are raised.
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Set Pallet Manual Selection switch (71) to CW or CCW, press and hold down Pallet Start pushbutton (73) until the pallet changing arms complete a 180 degree turn.
Set Pallet Manual Selection switch (71) to DOWN, and press Pallet Start pushbutton (73). The two pallets descend.
Set Pallet Manual Selection switch (71) to CLAMP, and press Pallet Start pushbutton (73). The pallet on the machining side is clamped.
Note Check the interference between the spindle/covers and the workpiece before pressing Pallet Start pushbutton (73). To perform APC, all doors except for the magazine door must be closed.
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8.4
APC in MDI Operation
Press MDI Mode pushbutton (4) to enter MDI mode. Perform the second zero point return on Z-axis and B-axis so that the pallet moves to its APC home position. G91 G30 Z0 B0 M62; Input pallet No. to be transferred to the machining side. M71; Pallet No. 1 to the machining side. M72; Pallet No. 2 to the machining side.
Press Pallet set-up pushbutton (72).
Press Cycle Start pushbutton (56). The pallet changing arms made a 180 degree turn. And as a result, the pallet at the setup side is rotated to the machining side.
Note Check the interference between the spindle/covers and the workpiece before pressing Pallet Start pushbutton (73). To perform APC, all doors except for the magazine door must be closed.
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8.5
APC in Automatic Operation Press AUTO Mode pushbutton (2) to go into AUTO mode. Its lamp lights up.
PROG
To input programs on LCD. 1. 2. 3. 4. Press Press Input Press [PROG] key. Address key [O]. program number. cursor key [].
e.g. G91 G30 Z0 B0 M62; ;Z and B axes go to the APC home position. M71; Pallet No. 1 is at the machining side. G90 G00 G54 X Y M S T ; ;Machining program of Pallet No. 1. M1; Optional Stop. G91 G30 Z0 B0 M62; M72; Pallet No. 2 is at the machining side. ;Machining program of Pallet No. 2. M30; Program end. Press Pallet set-up pushbutton (72) when new workpieces are set. Press Cycle start pushbutton (56) to start the Automatic operation. The lamp of Cycle Start pushbutton should come on. Note When M71 or M72 is executed, pallets will not exchange if Pallet set-up pushbutton lamp (72) is not lit. Be sure that workpieces are set on Pallet before pressing Pallet setup pushbutton (72). Make sure that the operation door and set-up doors are both closed when executing APC commands.
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9
9.1
Emergency Stop
Cases of Emergency
Emergency stop will be triggered under the following conditions: Hydraulic pump is overloaded (the thermal relay actuated). Coolant pump is overloaded (the thermal relay actuated). Emergency Stop pushbutton is pressed. Spindle motor has encountered problems. The NC has encountered problems. When an emergency stop occurs, the power supply to the NC will be cut off and NOT READY status of NC will be displayed on LCD. 9.2 To Release Emergency Stop Status
After the cause of the problem has been resolved, the machine operations can be resumed by following the procedure described in Section 3.2 Turning ON power.
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10 Interference
10.1 Workpiece Dimensions The maximum workpiece dimensions are defined as below:
Max. Height Max. Diameter
1000 mm [39.4] 750 mm [29.5]
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10.2 Travels of Axes X-axis Travel limit for X-axis is 640 mm [25.2]
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Y-axis Travel limit for Y-axis is 610 mm [24.0]
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Z-axis Travel limit for Z-axis is 680 mm [26.8]
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10.3 Interference with Spindle For 400 mm Pallet Machines
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For 500 mm Pallet Machines (Option)
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Note This is the area where interference between the spindle and the pallet can occur. Keep the spindle (Y-axis) and the pallet (Z-axis) out of the shaded areas that are marked on the drawing. If the spindle (Y-axis) or the pallet (Z-axis) enters this area while the other axis is already in the area, the machine will slow down gradually, and then stop.
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10.4 Pallet Usable Area
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10.5 Limitation on Tools Dimensions With adjacent tools
Without adjacent tools
Maximum Weight: 8 kg.
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10.6 Interference at ATC Side View
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Top View
123
10.7 Pull Stud CAT 40
BT40 (JIS 40P)
Note The diameter of the through spindle coolant hole must be less than 7 mm, otherwise, coolant may leak through it.
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11 Functions Codes (M Codes)

11.1 M Code List Code M00 M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M13 M14 M15 M16 M17 M18 M19 M29 M30 M37 M38 M48 M49 M61 M62 M63 M68 M69 M71 M72 M75 M76 M78 M79 M83 Function Program stop Optional stop End of program Spindle CW rotation start Spindle CCW rotation start Spindle rotation stop Tool change Cutting air blow start Cutting coolant start Cutting coolant and air blow stop Shower coolant start Shower coolant stop Spindle through coolant start Spindle through coolant stop Flood coolant start Flood coolant stop Spindle through air blow start Spindle through air blow stop Spindle orientation Rigid tap End of program Spindle tool load monitor start Spindle tool load monitor stop Feed rate override valid Feed rate override invalid B axis clamped B axis unclamped (for one movement only) B axis unclamped (continuous) Auto tool probe up [Option] Auto tool probe down [Option] Pallet No. 1 transferred to machining area Pallet No. 2 transferred to machining area Spindle probe mode [Option] Automatic tool measurement mode [Option] Spindle override valid Spindle override invalid Hydraulic unit warm-up (5 min.)
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M84 M86 M87 M89 M98 M99 M100 M101 M103 M104 M106 M117 M118 M119 M161 M162 M164 M165 M166 M167 M168 M169 M170 M171 M172 M199 M200 M201
Hydraulic unit warm-up (10 min.) Chip conveyor start [Option] Chip conveyor stop [Option] Spindle tool life check Sub-program call End of sub-program and program repeat Tool numbers all cleared Tool numbers set in order Pot set for big tool Big tool pot cancelled Heavy tool ATC (Tool weight = 5kg or more) Tool magazine rotation prohibited Tool magazine rotation half speed Tool magazine rotation full speed Tool chucking Spindle tool unclamped Double arm 180 forward rotation Double arm 180 backward rotation Spindle tool clamped Maintenance Double arm returned to home position use Tool pot turned to magazine side only Tool pot turned to double arm side Magazine rotation ATC shutter open ATC shutter close Test of all the lamps on the operation panel Automatic tool length measurement mode [Option] Automatic tool breakage detection mode [Option]
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M00, M01, M02, M30, M98 and M99 M00, M01, M02, M30, M98 and M99 commands can be executed only after axis moving commands, while the rest of M commands can be executed alongside with the axis moving commands. M00 Operation stops after executing a block containing M00. case of Single Block, the modal data is maintained. M01 When Optional Stop pushbutton (10) on the operation panel is ON, operation stops after executing a block containing M01. M02, M30 M02 and M30 are used to indicate the end of the program. The machine is brought into the state of reset and the program is reset to the top. M06, M106 When M06 or M106 is submitted for execution while the spindle is not in the correct position for ATC, an alarm message ATC ALARM will be displayed on the LCD and the lamp of Feed Hold pushbutton (57) will blinks. Resolve the problem, press [RESET] key on the NC keyboard, and then move the spindle to the ATC position in MDI mode. M06 Only use M06 when the tool in spindle and the tool to be exchanged are both less than 5 kg. M106 Use M106 when either the tool in spindle or the tool to be exchanged is heavier than 5 kg. M19 M19 needs to be executed after the spindle is stopped as a result of M05 execution.
Similar to the
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12 Alarm Message and Operator Message

12.1 Alarm Messages
NO. 1000 1001 1002 1003 1004 1005 1006 1007 1008 MESSAGE HYDRAULIC CIRCUIT BREAKER OFF<MCP7> Y-AXIS BRAKE CIRCUIT OFF AC200V BREAKER OFF HYDRAULIC MAGNET COIL DOWN PUMP CIRCUIT BREAKER OFF CUTTING COOLANT PUMP OVERLOAD<MCP1> SHOWER COOLANT PUMP OVERLOAD<MCP2> COOLANT THROUGH PUMP OVERLOAD<MCP3> FLOOD COOLANT PUMP OVERLOAD<MCP4> AIR PRESSURE IS LOW<PR16> NOTE
1010
Maintain air pressure at 0.6 MPa. Low air pressure may cause serious damages to the machine. Adjust the air pressure to 0.6 MPa when the machine is stopped. Check the air filter and replace the air element if necessary. This alarm appears, after 8 hrs of operation, with Message 2017 on the screen. To delete this message, simply press Reset button. Pallet Up/Down limit switches are not functional. Check and adjust the position of limit switches. Input correct M code. Press [RESET] key first. Overtime of Magazine rotation, M06 movement, Double arm turn, Tool unclamp, etc. Move Double Arm to the initial position and press [RESET] key. More detail is specified by Message No. 1031 through No. 1035. Overtime of ATC movement from M06 command to its completion. Delay in ATC double arm movement upon completion of spindle clamp/unclamp. Indicates a delay in spindle tool clamp/unclamp movement
1011
CHANGE AIR FILTER ELEMENT
1015 1020
PALLET UP/DOWN NO-DETECT <LS51,52> M CODE NOT APPLICABLE
1030
STOP AT ATC ALARM
1031 1032 1033
ATC MOVEMENT OVERTIME<TMR15> DOUBLE ARM MOVEMENT OVERTIME<TMR16> SPINDLE TOOL CLAMP/UNCLAMP ALARM <TMR17>
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1034 1035 1036 1037 1038 1040 1041 1042 1043 1044 1045 1046 1047 1048 1050 1060 1061 1062 1063
TOOL POT MOVEMENT OVERTIME<TMR94> SPINDLE ROTATION ALARM DOUBLE ARM INVERTER UNIT ALARM <INV> ATC SHUTTER MOVEMENT ALARM <TMR25> SPINDLE COMMANDED WITH DOOR OPENED TOOL SEARCH OVERTIME ALARM<TMR14> STOP AT HOME POSITION STOP AT TOOL CHUCKING STOP AT TOOL UNCLAMP STOP AT 180 DEG TURN STOP AT TOOL CLAMP STOP AT RETURNING TO HOME POSITION AT ATC SHUTTER CLOSE <PX39,SOL43> AT ATC SHUTTER OPEN <PX38,SOL42> T CODE ERROR IN M6 COMMAND AT TOOL CLAMP<LS1,SOL0> AT TOOL UNCLAMP<LS2,SOL1> AT SINGLE ARM MOVING TO MAGAZINE<PX64,SOL50> AT SINGLE ARM MOVING TO WAITING POT<PX65,SOL50,SOL52>
Indicates a delay in tool pot movement Tool clamp signal or double arm home position signal went off during spindle rotation. Indicates a fault has occurred in inverter motor, such as overload. Delay in ATC shutter movement
ATC magazine rotation timeouts. Press [RESET] key to remove the message.
T00 is specified in M6 command or the tool number specified in the T code has not been registered.
1070
STOP AT APC ALARM
1071 1072 1073 1074 1075 1076
AT PALLET UNCLAMP<PR54,SOL33> AT PALLET CLAMP<PR53,SOL32> AT PALLET ASCENT<LS51,SOL34> AT PALLET DESCENT<LS52,SOL35> AT PALLET ROTATION 1 <PX47,SOL36> AT PALLET ROTATION 2 <PX48,SOL37>
Pallet rotation timeouts or pallet up/down timeouts. Return pallets to APC initial position in manual mode, then press [RESET] key. More detail is specified by Message No. 1071 through No. 1076. Delay in movement of unclamping pallet at machining side Delay in movement of clamping pallet at machining side Delay in ascending movement of pallet Delay in descending movement of pallet Delay in CCW rotating movement of pallet. Delay in CW rotating movement of pallet.
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1080 1090 1100 1101 1102 1103 1110 1120 1125 1128 1131 1132 1133 1134 1135 1136 1137 1138 1139 1140 1141 1142 1200 1210 1211 1212 1213
INAPPROPRIATE S CODE K57.2=1 IS BEING SET MAGAZINE BETA UNIT ALARM<SVU> ABSOLUTE PULSE CODER BATTERY LOW NC MEMORY BACKUP BATTERY LOW SPINDLE TOOL SPECIFIED BY M103 SPINDLE ORIENTATION OVERTIME ATC SINGLE ARM ALARM M6 COMMAND WITH NO TOOL IN MAGAZINE POT SAME TOOL NUMBER IN WAITING POT AND SPINDLE AT MAGAZINE TOOL CHUCKING <PX64> AT PULLING OUT FROM MAGAZINE POT <PX67> AT MOVING FROM MAGAZINE POT TO WAITING POT<PX65> AT INSERTING INTO WAITING POT<PX66> AT RETURNING TO HOME POSITION <PX63> AT WAITING POT TOOL CHUCKING <PX64> AT PULLING OUT FROM WAITING POT<PX67> AT MOVING FROM WAITING POT TO MAGAZINE POT<PX64> TOOL NOT PRESENT IN MAGAZINE POT<PX69> AT MAGAZINE POT RETURNING TO HOME POSITION SINGLE ARM GRIPPER UNLOCK ERROR SINGLE ARM GRIPPER LOCK ERROR THERMAL RELAY OVERLOAD<OL1,3> LUBRICATION OIL PRESSURE LOW<PR15> LUBRICATION AIR PRESSURE LOW<PR17> THERMAL RELAY OVERLOAD<OL2,4,9R,9L> SPINDLE LUBRICATION PRESSURE FAILED<PR21>
Press [RESET] key first. Then input S code except S00. Reset K57.2 = 0 Low battery in Absolute pulse coder. Replace the battery.
More detail is specified by Message No. 1131 through No. 1140. M6 is commanded, but ATC magazine cannot locate the specified tool. The same tool number is entered for both the waiting pot and in the spindle. Delay in single arm movement of chucking tool in magazine pot. Delay in single arm movement of pulling tool in magazine pot. Delay in single arm movement from magazine pot to waiting pot Delay in single arm movement of inserting tool in waiting pot. Delay in single arm movement from waiting pot to the home position Delay in single arm movement of chucking tool in waiting pot Delay in single arm movement of pulling tool in waiting pot. Delay in single arm movement from waiting pot to magazine pot. Delay in single arm movement of inserting tool in magazine pot Delay in single arm movement from magazine pot to the home position
Thermal relay of lubrication pump or coolant pump trips. Remove the cause.
130
1214 1260 1300 1400 1410 1411 1412 1500 1510 1511
SPINDLE AIR SEAL PRESSURE FAILED<PR32 COOLANT LEVEL LOW NO PALLET SITTING<PR57> SETUP SIDE DOOR OPENED DURING APC B-AXIS CLAMP/UNCLAMP ALARM B-AXIS CLAMP ALARM<PR5,SOL4> B-AXIS UNCLAMP ALARM<PR6> SENSOR DETECTED WRONG PALLET NO 6-PALLET BETA UNIT ALARM<SVU2> BETA PALLET UNIT BATTERY LOW (Option) Check the pallet No. If it is correct, check the sensors for pallet No. detection. (Option) (Option) Beta amplifier battery for the pallet rotary unit is low. (Refer to Maintenance Manual) (Option) Over time during the movement of pallet change or up/down movement on the set-up side. After removing the cause of the trouble, bring the pallet changing arms to the original position manually and press Reset key. (Option) Delay in ascent movement of setup side pallet. (Option) Delay in descent movement of setup side pallet. (Option) Delay in CW rotation movement of setup side pallet. (Option) Delay in C CW rotation movement of setup side pallet. (Option) Delay in movement releasing lock of pallet on the pallet rotating table. (Option) Delay in movement locking pallet on the pallet rotating table. (Option) Delay in ascent movement of the positioning pin on pallet rotating table. (Option) Delay in descent movement of the positioning pin on pallet rotating table. (Option) After removing the cause of the problem, manually bring 6-Pallet APC Unit to the correct position, and then press [RESET] key. Delay in movement of machining side pallet at clamp/unclamp (Option) Coolant level of core cooling unit is low.
1520
SETUP SIDE APC ALARM
1521 1522 1523 1524 1525 1526 1527 1528
6APC IN PALLET ASCENT<LS650,SOL682> 6APC IN PALLET DESCENT<LS651,SOL683> 6APC IN CW TURN<LS654,SOL685> 6APC IN CCW TURN<LS653,SOL684> ROTARY TABLE UP ERROR<LS648,SOL680> ROTARY TABLE DOWN ERROR<LS649,SOL681> ROT-TB POS-PIN UP <LS68, SOL47> ROT-TB POS-PIN DOWN <LS67, SOL46> M700 TO M1599 EXE.OVERTIME<TMR121> EMERGENCY STOP DURING AUTO OPERATION. TOOL LIFE LIMIT IS REACHED TOOL MEASUREMENT CYLINDER UP/DOWN ALARM<PX1001,PX1002> SPINDLE OVER TORQUED
1530
1600 1700 1868 1880
(Option)
131
12.2 Operator Message

NO. 2000 2001 2002 2003 2016 MESSAGE PLEASE PUSH NC READY BUTTON<PB64> PLEASE RELEASE EMERGENCY STOP. <PB59,PB76,PB77,PB78> MACHINE IS READY FOR OPERATION. FAN CIRCUIT DOWN LUBRICATION OIL LEVEL LOW<LV14> NOTE Press NC Ready pushbutton (68).
(reserved) Fill up Oil Lubricator. At intervals of 10 days of operation, this message appears. Check the air filter, and replace the air element if necessary. Press RESET key to delete the message. Also refer to Alarm 1011.
2017
CHECK AIR FILTER
2018
2023 2030 2031 2032 2034 2040 2045 2050 2051 2055 2063 2067 2086 2087 2088
BECAUSE BETA UNIT BATTERY IS LOW, OR DUE TO DISCONNECTION OF CABLE, PLEASE RESET MAGAZINE ZERO POINT RETURN SPINDLE AND HYDRAULIC WARM UP REQUESTED (PROGRAM O8900) DOUBLE ARM IS NOT AT INITIAL POSITION OR SPINDLE TOOL IS NOT CLAMPED. ATC MAGAZINE DOOR IS NOT CLOSED. <LS10> SPINDLE SPEED IS ABNORMALLY LOWER THAN A COMMANDED VALUE. OPERATION KEY LOCKED BETA MAGAZINE UNIT ALARM<SVU> OIL SKIMMER MOTOR OVERLOAD<MCP6> T CODE ERROR. COMMANDED TCODE NUMBER NOT FOUND IN MAGAZINE. CHECK TOOL NUMBERS. DUPLICATE TOOL NUMBER REGESTERED NO TOOL IN THE SPECIFIED MAGAZINE POT AT TOOL SEARCH. SPINDLE LOAD CHECK EEROR. SPINDLE OVER TORQUED CALLED PALLET IS NOT SET UP SETUP SIDE PALLET IS NOT AT INITIAL POSITION <LS56> MOTOR THERMAL OVERLOAD (RESERVED)
Set the Double Arm to its initial position with M code or clamp the spindle tool in JOG mode.
A duplicate tool number is inputted for tool number registration.
132
2089
CHIP CONVEYOR IN MANUAL MODE. PALLET SETUP DOOR IS NOT CLOSED. <LS12> OPERATOR SIDE DOOR IS NOT CLOSED. <LS8.LS9> NO PALLET SITTING CONFIRMATION <PR57> PALLET CHANGE CONDITIONS NOT READY - PLEASE EXECUTE 2ND ZERO POINT RETURN FOR Z AND B AXES. PALLET CHANGE CONDITIONS NOT READY - WAITING PALLET (FRONT PALLET ) IS NOT AT INITIAL POSITION. - PLEASE MANUALLY ROTATE IT TO INITIAL POSITION AND PUSH UP THE LOCKING LEVER. PALLET CHANGE CONDITIONS NOT READY - ATC SLIDE COVER IS NOT CLOSED. PLEASE CLOSE IT BY USING #REF! CODE. PALLET CHANGE CONDITIONS NOT READY - ATC DOUBLE ARM IS NOT AT HOME POSITION OR - SPINDLE TOOL IS NOT CLAMPED. PALLET CHANGE CONDITIONS NOT READY - MARPOSS IS NOT AT DOWN POSITION. CYCLE START IS PROHIBITED BECAUSE KEEP RELAY K57.2=1, PALLET UP AND DOWN SENSORS ARE IGNORED. - SET K57.2=0 FOR NORMAL OPERATION. OPERATOR SIDE DOOR NOT LOCKED <LS8,LS9> CHIP CONVEYOR OVERLOAD <MCP8> SINGLE ARM IS NOT AT HOME POSITION DISCHARGE PRESSURE OF COOLANT THROUGH SPINDLE DROPPED. PLEASE CHECK ITS FILTER. DISCHARGE PRESSURE OF COOLANT THROUGH SPINDLE DROPPED.
2090
2091
2092
Close pallet setup door. Press Cycle Start pushbutton (56) and the APC movement will be executed. Press Cycle Start pushbutton (56) again, the machining program will be started. Close the operator side door and press Cycle Start pushbutton (56). Pallet sitting on the rotary table is not confirmed. In manual mode, unclamp the pallet, move it up, down, and then clamp it.
2093
2094
2095
2096
2097
2098
2099 2100 2130
2150
2151
133
2200 2300 2400
2500
2501 2510 2520 2800 2801 2802 2911 2912 2921 2922 2931 2932 2940 2996
SPINDLE OIL CHILLER ALARM DETECTED SPINDLE CORE CHILLER ALARM DETECTED. (reserved) FILTER OF SPINDLE OIL CHILLER CLOGGED PALLET CALLED FOR CUTTING SIDE APC HAS NOT RECEIVED SET-UP PROCEDURE. PLEASE BRING IT TO SETUP SIDE AND SET-UP THE PALLET. PALLET OF PRIORITY IS CALLED. BETA PALLET UNIT ALARM. <SVU2> BETA PALLET UNIT BATTERY IS LOW PROBE ERROR(RENISHAW) PROBE BATTERY VOLTAGE LOW(RENISHAW) TOOL MEASUREMENT OVER TRAVEL Z-AXIS MINUS MOVEMENT INTERLOCK X-AXIS PLUS MOVEMENT INTERLOCK X-AXIS MINUS MOVEMENT INTERLOCK Y-AXIS PLUS MOVEMENT INTERLOCK Y-AXIS MINUS MOVEMENT INTERLOCK Z-AXIS PLUS MOVEMENT INTERLOCK Z-AXIS MINUS MOVEMENT INTERLOCK B-AXIS MOVEMENT INTERLOCK NEED TO PESS BOTH HANDS SIMULTANEOUSLY
(Option) (Option) (Option) (Option) (Option) (Option) Move X axis in + direction with Manual Pulse Generator. Move X axis in - direction with Manual Pulse Generator. Move Y axis in + direction with Manual Pulse Generator. Move Y axis in - direction with Manual Pulse Generator. Move Z axis in + direction with Manual Pulse Generator. Move Z axis in - direction with Manual Pulse Generator. Move B axis in CCW direction with Manual Pulse Generator.
134
13 Custom Macro Program

The list of Custom Macro programs have been installed in the machine at factory:
Program No. O9001 O9002 O9003 Application M6: ATC (regular tools) M106: ATC (heavy tools) M71: APC (pallet No. 1 transferred to the machining area) M72: APC (pallet No. 2 transferred to the machining area) Automatic Zero Return of B-axis for APC APC and program number search Parameter No. Value 6071 6 6072 106 6073 71 Remarks
1 2 3
For 2-pallet machines only For 2-pallet machines only Called by O9003 and O9004 For 6-pallet machines only
O9004
6074
72
5 6
O9023 O9029
Note Do not make any changes to these programs.
135
14 Chip Conveyor
Chip conveyor has a 4 buttons control, Forward, Reverse, Stop, and Emergency Stop.
14.1 Controls Chip Conveyor Forward Pushbutton By pressing this button, the belt of the chip conveyor starts to move in the forward direction. This is the direction in that the chip conveyor transports the chips into the chip bucket.
Chip Conveyor Reverse Pushbutton By pressing this button, the belt of the chip conveyor starts to move in the reverse direction.
Conveyor Stop Pushbutton
136
This button is used to stop the belt movements of the chip conveyor immediately.
Chip Conveyor Emergency Stop Pushbutton Pressing this pushbutton causes the chip conveyor to stop any movement immediately. The power supply to the NC will be cut off and NOT READY status of NC will be displayed on LCD.
14.2 Alarm Chip conveyor alarm (message No. 2100) will be triggered, if excessive current is detected on the conveyor motor or if the conveyor has not moved over a period of time while the conveyor motor is ON. Note Press Emergency stop pushbutton to stop the machine before checking and resolving the cause of the alarm. Once the cause of the problem has been removed, press the reset pushbutton on the NC panel to restore the machine back to its normal condition.
137
15 Weekly Timer Setup

15.1 Outline of Weekly Timer
11 : 25
SUN MON TUE WED THU FRI SAT
ON
4 H
TIME AUTO PROG
OFF 5 M 6 SET
10
ON AUTO OFF
WEEK 7
MV 8
C 9
11
1 2 3 4
Display Section Day On/Off Switch Mode Switch H[our] M[inute] SET WEEK MV
Details to be described later. On/Off selection for each day of the week. TIME, AUTO, or PROG For setting HOUR of the present time or the program start time. For setting MINUTE of the present time or the program start time. To confirm settings/selection For setting days of the week. To check the programmed time.
5 6 7 8
138
9 10 11
C[lear] R[eset] Output Switch
To clear the programmed time. To reset the timer or to select DAY, PULS, or LONG mode. ON, AUTO, or OFF
Mode Switch TIME AUTO PROG Output Switch ON AUTO OFF Display Section Manually on Automatic Timer off For setting time and day. Automatic operation according to the program and day switch settings. To assign programs
DAY 1 PULS LONG 2 3
ON 5
OFF 6
18 : 45
7 4
1 2 3
DAY PULS LONG
Appears when the schedule is the same for every day. Appears when short-time pulse operation is set. Appears when long-time timer operation is set.
139
4 5 6 7
Day of Week ON OFF Time Display
Indicates the present day or the programmed day. Appears when setting for ON and output is ON. Appears when setting for OFF and output is OFF. Displays the present time or the programmed time.
Note Err is displayed in the time display section when any of the settings (not limited to) below is attempted: Overlapped program On/Off time setting. Nested program On/Off time setting. Program Off time is not set. Note End is displayed when the number of operations in the program exceeds 16 for DAY setting, 31 for PULS setting, and 16 for LONG setting. When a preset time is no longer needed, it can be deleted by pressing C[clear] key. To delete a preset program, press C[lear] and SET key simultaneously. MV (memory verification) can be used to review the preset times of a program. Selection of DAY, PULS, and LONG
TIME AUTO PROG
Set Mode Switch to PROG.
Press the R[eset] key with a pen tip until DAY is displayed.
DAY PULS LONG

Press the R[eset] key again, PULS is displayed. Press the R[eset] key again, LONG is displayed.
140
To Set Current Time

TIME AUTO PROG
Set Mode Switch to TIME.
Press H[our] key until the desired hour number is displayed in the hour position.
Press M[inute] key until the desired minute number is displayed in the minute position.
11 : 25
WEEK
(example)
Press WEEK key until the desired day of the week is displayed.

SET
Press SET key to complete the setting.
Note Upon completion of setting up a program, be sure to check the validity of the program with MV key. An Err displayed on the screen indicates that a program has not been setup correctly.
15.2 Same Operation Hours For Each Day

As an example, to turn on the power at 8:00 AM and turn off at 17:00 PM for Monday through Friday.
141

ON OFF 8:00 8:00 8:00 8:00 8:00 17:00 17:00 17:00 17:00 17:00
TIME AUTO PROG
Select DAY mode with R[eset] key. The display will prompt for the ON time setting.
DAY ON
--:-SUN MON TUE WED THU FRI SAT
Press H[our] key until the desired hour number is displayed in the hour position, then, Press M[inute] key until the desired minute number is displayed in the minute position.
H
DAY ON
8 : 00
SET
Press SET key to complete the ON time setting. The display will then prompt for the OFF time setting.
142
DAY
OFF
H
DAY OFF
17 : 00
SET
Press SET key to complete the OFF time setting. The display will prompt for ON time setting again.
DAY
ON
TIME AUTO PROG
Set the Mode Switch to AUTO to activate the preset programs. The current time is displayed.
143
DAY
ON
10 : 34
To enable the preset time for a particular day of the week, set its Day On/Off Switch to ON. In this example, Monday through Friday.
ON
OFF
15.3 Different Operation Hours For Different Day

As an example, lets setup the timer so that it turns on the power at 8:00 AM on Monday, and turns it off at 17:00 PM on the same day, it then turns it on again on Tuesday at 17:00 PM, and turns it off at 8:00AM on Wednesday.

ON OFF 8:00 17:00 17:00 8:00
144
TIME AUTO PROG
Select LONG mode with R[eset] key.
LONG
ON
LONG
--:--
ON
LONG
8 : 00
Press WEEK key repeatedly until the indicator appears above MON.
ON
WEEK
LONG
8 : 00
145
SET
OFF
LONG
--:--
OFF
LONG
17 : 00
OFF
WEEK
LONG
17 : 00
SET
146
ON
LONG
--:--
H
ON
M
LONG
17 : 00
Press WEEK key repeatedly until the indicator appears above TUE.
ON
WEEK
LONG
17 : 00
Press SET key to complete the ON time setting. The display will prompt for the OFF time setting.
147
OFF
LONG
--:--
H
OFF
LONG
8 : 00
Press WEEK key repeatedly until the indicator appears above TUE.
OFF
WEEK
LONG
8 : 00
SET
148
ON
LONG
--:--
TIME AUTO PROG
LONG
ON
10 : 34
Note The Day On/Off Switch cannot be used as long as different operation hours are set for different days.
15.4 Operation Hours Span Over Multiple Days To set the operation hours from Monday 8:00 AM to Friday 17:00 PM:

ON OFF
8:00 17:00
149
Select LONG mode with R[eset] key.
LONG
ON
LONG
--:--
ON
LONG
8 : 00
ON
WEEK
LONG
8 : 00
SET
150
OFF
LONG
--:--
H
OFF
LONG
17 : 00
Press WEEK key repeatedly until the indicator appears above FRI.
OFF
WEEK
LONG
17 : 00
SET
151
ON
LONG
--:--
TIME AUTO PROG
ON
LONG
10 : 34
152

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1.2.1 Locations of Labels and Plates

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Tool Magazine Side

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Tool Specification Plate BBT Tool

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Warning Moving Part Hazard

Warning Rotating Mechanism Hazard

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Warning Opened Door Hazard

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Safety Instruction Plate

Machine Warm-up Instruction

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Warning - Electric Shock

Danger Electrical Shock Hazard

10) Manufacturer Plate

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11) Solenoid/Limit Switch

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12) Warning - Hot Surface

13) Maintenance Schedule

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14) Lubrication Points

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15) Lubrication Oil Instruction

16) Pneumatic Air Instruction

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17) Axial Directions

19) Oil Drain

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20) Lifting Point

21) Oil Filler

MB0120120108 HS-450i Operator's Manual

MB0120120108 HS-450i Operator's Manual