Service Training FZ/DZ12K

FZ DZ 12 K
CNC Machining Center
03 Tool Changer 06/2006
Service Technicians

Setting Instructions

FANUC

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07 Tool changer
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1 Tool changer 3
1.1 Automatic mode ...................................................................................................................................... 3
1.2 Tool change points… ......................................................................................................................... 3
2 Enabling for Tool changing position adjustment 4
3 Magazine cover 5
3.1 Magazine cover monitoring…………. ...................................................................................................... 5
3.2 Magazine cover alignment and repair………………………… .................................................................. 6
3.3 Changing Magazine cover……….............................................................................................................. 7
3.4 Change of the Cylinder respectively to the skid……................................................................................. 8
3.5 Removing the Bellow covers and the sheets on the skid ......................................................................... 8
3.6 Removing the stainless steel covers ....................................................................................................... 9
3.7 Changing the Door cylinder to the skid respectively…............................................................................ 9
4 Tool magazine alignment 10
4.1 Moving the Tool changer in the work area……...................................................................................... 10
4.2 Traverse Tool magazine chain [W] Axis ........... ………......................................................................... 10
4.3 Traverse Magazine axis (Linear) [V]-Axis…. ........................................................................................ 11
4.4 Precondition for aligning the Magazine………….................................................................................... 12
4.5 Determine the Index position ................................................................................................................. 12
4.6 Set the assembly tool BWM623001400 on the HSK tool holders…………............................................ 13
4.7 Setting of the Reference point for the magazine axis [W] ..................................................................... 14
4.8 Alignment of the tool magazine to the X-axis…………………. ............................................................... 15
4.9 Setting of the Tool change position…. ................................................................................................... 17
4.10 Setting Reference point for the Magazine axis [V].................................................................................. 19
5 Determine of the Spindle position 21
5.1 Determine the spindle position as follows ......................................................................................... 22
5.2 Determine the spindle position as follows ......................................................................................... 25
5.3 Calculate the values of the first and second measurements........................................................... 26
5.4 Tool change position (Z-Axis) ..................…………................................................................................ 27
5.5 Setting of the Tool change position………. ............................................................................................ 28
6 Change of a Proximity switch (empty pocket monitoring) 31
6.1 Disassembly of the Magazine wiper (black plastic bracket)…….. .......................................................... 31
6.2 Removal of the connector.…………........................................................................................................ 31
6.3 Disassembly of the bracket for the proximity switch…….. ..................................................................... 32
6.4 Take out the bracket ….….................... .................................................................................................. 33
6.5 Sensor assembly… ................................................................................................................................. 33
6.6 Check of the Sensor position……. .......................................................................................................... 34
7 Write protect enable 35

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1 Tool changer

1.1 Automatic mode

Tool selection in „Automatic“ or „MDI“ Operating mode

• T1 M6 Safe Tool change:

- The machine moves first to "Z0" and "Y0" and then to the tool changing position.

- Depositing of "old" tool and insertion of "new" tool.

- After the tool change Z-axis moves back to „Z0“

• T16 M16 Fast Tool change:

- The machine moves directly out of the current position to the tool changing position.
- Depositing of "old" tool and insertion of "new" tool.
- As soon the magazine is in the back position the tool change is finished

Attention:
Danger of collision during "Selection" and "Start" of a tool change (M6/M16)

Pay attention to the fixture

Note:

Subprogram MC12K_M6 („Safe“ tool change) is activated first when M6 is output, followed by
the change program „MC12K_M16“.
If M16 is output, the sub-program MC12K_M16 (tool change "quick") is called
Immediately.

1.2 Tool change points

• Preconditions for setting the tool change points:
- Zero point in the X-axis is defined
- Zero point in the Y-axis is defined
- Zero point in the Z-axis is defined
- Main spindle – Orientation is adjusted (see Chapter: "Adjust Spindle Position")

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2 Enabling for Tool changing position adjustment

• Selection:

- In the operating mode „MDI“ and Key switch to position [3] call the Function „M555“
(Service mode).
- If an "NC Alarm" is registered, no further M-function can be input.
For this case, there is the possibility of activating this “M555” function with a key combination

1.) Select Key switch position [3]

2.) Press the button „JOG“ and „Increment“ simultaneously for at least 5 seconds
The “Rapid Key “ is blocked if this function is selected.
Now you can move the Axis carefully in „JOG“ .
-
With M555 each axis can be moved limitlessly in any direction to determine the tool change positions.

Note

:
- The function "M555" (service mode) is deleted again with the following conditions:
- Speed input (M3 / M4)

- Select “Automatic“ operating mode

- Select Key switch position [3]

- Control off

Attention:
Danger of collision when moving. All monitoring in the changing area
is deactivated with this function.
Traverse the axes with special care.

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3 Magazine cover
• Function:
- M 620 = open magazine cover
- M 621 = close magazine cover
Precondition: the tool magazine is in Home position
• Activation:
- The magazine cover is opened and closed by actuating the valve.
- The final position damping is adjusted on the cylinder.
- The speed is set with the throttle.

3.1 Magazine cover monitoring

• Magazine cover open:
- A proximity switch on the cylinder monitors the
1
“open” end position.
2
- A tool change is impossible if the "magazine cover
open" signal is not active.

1. Pneumatic Cylinder
2. Proximity Switch

• Magazine cover closed:

2 3
- A proximity switch on the cylinder monitors the 1
“closed” end position. Machining isn't possible
without the signal "magazine cover closed"
(Feed & Speed Stop). With the key
[Tool ch.home pos.] The magazine cover
can be additionally closed.
(Provided the tool magazine is in the home
position)

1. Magazine cover
2. Proximity Switch
3. Cylinder

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3.2 Magazine covers alignment and repair

Adjustment of Speed an moving behavior of the magazine cover

To make this adjustment the machine must be moved to X=0. The left X-bellow cover has to be taken
off from the left mounting side of the column than move the bellow cover to the left side.
Now you can reach the float control valve.

• Machine on X=0
• Remove the bolts for the
bellow cover (7x).
• Move left bellow cover to
the left side.

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3.3 Change the Magazine Cover

• To change the magazine cover the machine
has to be moved to X -550. 1
Open the bellow cover on the right side on the
Column than move the cover to the right
Now you are able to reach the bolts for the cover
2

1. Bellow cover
2. recess

• Move bellow cover to the right.

1
• loosen up the countersunk head screw
to remove the left cover

1. Left Cover

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3.4 Change of the Cylinders to the skid respectively

to change the skid unit following steps has to be done:

• remove the left and right Laser cover

.
take out the 4 flathead screw’s M6X10
1
-
1
- remove the covers upwards.

1 Laser cover

3.5 Removing the Bellow Covers and the Sheets on the Skid
• Take the left and right bellow cover completely off 2 1
- Remove the cover sheets on the skid .To do
so:
- Move Y Axis to –320 mm.

1.Bellow Cover
2. Cover Sheet

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3.6 Removing the stainless steel cover

• remove Cover
• Remove upper bolts
(4 Countersunk head screw M5X10mm) .
1
• Remove lower Bolts
(4 Countersunk head screw M6X16mm).

• Get the Cover through the side door out of the

machine .
2

1. upper Bolts
2. Lower Bolts

3.7 Changing the Door cylinder to the skid respectively

- the units can be changed now
- 1
- Assembly in reverse order

1. Skid

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4 Tool Magazine alignment

For the Tool magazine alignment the front pockets have to be lined up.
This isn't aligned during the first installation of the chain magazine in the base. This can only happen
when the machine zero point is set and the machine axes can be moved.

4.1 Moving the Tool changer in the working area

4.2 Traverse Tool magazine chain [W] Axes
• Following Conditions must be met:

- Operation mode „JOG“ selected

- The “Manual Tool Change“ Function must be active
- The Tool Magazine must be between the Home – and the Spindle position
(V = 170mm to max. 225mm).

- Axis Selection [ A ] or [4] or must be active.

• The Magazine can now be moved with the directional keys

- The Magazine moves with slow speed in ascending number of tool places

- The Magazine moves with slow speed in descending number of tool places

- or are used with the directional keys together the magazine will move with rapid feed
• If you push the directional key once the Chain will move one pocket.
• By holding the directional key down the Chain will move constantly

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4.3 Traverse Magazine Axis (Linear) [V]-Axis

• Following Condition must be met:

- Operating mode „JOG“ selected

- The “Manual tool Change“ Function must be active
- The Magazine Chain (W) must be in position
- The Magazine cover must be open
- The X-and Z-Axis must be outside the Danger area
(Service position X-Axis all the way left [-550.000 mm] and Z-Axis all the way up [0.000mm]).
- The Side doors (protective doors ) must be closed.

- Axis select key [ U ]or [5] or must be active

- With the directional keys[ + ] or [ - ] the magazine axis can now be moved

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4.4 Precondition for aligning the Magazine

• The front 2 or 4 Tool pockets have to be loaded

with tool holders
• Position the magazine so that places 1 and 2, or
1, 2, 3 and 4, are in the transfer position
1 2

1. Tool Holder Nr. 2

2. Tool Holder Nr. 4

4.5 Determine the Index position

• Turn the tool places into position roughly by

1 2
hand. When doing so, the recess can be
felt into which the bearings of the tool place are
pressed.

1. Position recess
2. Position recess

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4.6 Set the assembly tool BWM623001400 on the HSK Tool Holder’s

• set the assembly tool BWM623001400 (DZ- 2 3

Machine) reps. BWM623001600 (FZ-
Machines) on the HSK Tool holder 1
• When all boreholes of the assembly tool fit over
the HSK tool holder and the gap between the
assembly tool and guide rail is parallel, then the
position is correct. If necessary, shift the tool
places back and forth a little by hand.
After aligning the chain set the Reference for the
Chain [W]
1. Tool holder
See Chapter : 4.7 Page 14 2. Assembly Tool BWM623001400 (DZ)
3. Parallel Gap

• Control of the Index position 1 2

• By pushing the index block toward the rear 3
(chain index retracted), it is checked whether the
index block can be moved easily all the way 4
back.

1. Message that Chain index is extended.

2. Message that Chain index is retracted.
3. Chain Index Cam
4. Chain index Cylinder

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4.7 Setting the Reference point for the Magazine axis [W]
• To set the Reference point just follow those steps:
- Write protect must be enabled (see chapter l: „Write protect enable“)

- Select Key [MDI]

- Press Soft key [SYSTEM] {PARAM}
- put in 1815
- press Soft key {No Search }

- Machine off
- Parameter 1815 Bit 4 (APZ) to 0 on the related Axis
- Shut the machine off on the Main switch wait approximately 15 sec. switch the Machine back on
- Set Parameter 1815 Bit for to 1 (Reference point will be set at this position)
- Shut machine of on the Main switch wait approximately 15 sec. Switch machine back on
-

- Switch Control on n.
- Check position.

Attention:
After setting the Reference position take out the Assembly tools
BWM623001600 resp. BWM623001400 of the magazine

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4.8 Checking parallelism of the Tool magazine to the X-axis

• Index Tool magazine

M41= extend the Chain index

M42 = Index the Chain index

(only woks with Service function M88)
1
• Loosen the fastening screws of the tool magazine
in the machine base and place the screws in
position without tightening.
• Leave the front middle screw tightened (as a pivot).
• For machines with 2x32 tools, the 4 connecting
screws with the motor support are to be loosened.

1. Front fastening screws of the tool magazine

2. Back fastening screws of the tool magazine

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• Fix the dial gauge to the spindle stock with the

magnet holder. 1
• Measure the extreme place on the left and right
position and align the tool changer so that the
maximum difference from right to left is 0.05
mm. 2
• If the changer cannot be aligned, another pivot
must be selected.

Note:

Tighten the screws with the right 3

torque!
(See assembly drawing)

1. Right tool pocket

2. Magnet base
3. Left tool pocket
4. Indicator

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4.9 Setting of the Tool change position

• To adjust the Tool change position you need

the special tool nr BWM623002000
• The chain index must be indexed 1
Reason: The chain place is clamped
and then it has a fixed position.
• The indexing can be output with the help
functions M41and M42 in connection with
M88.

1. Special tool BWM 623002000

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• Move the machine to position X=0, Y=0 and 1

Z=0.
• Clamp the top half of the setting tool in the
spindle (for DZ machines, in the right spindle
SP2) 2
• Output the function "M555".
See chapter: „Enabling for tool changing
position adjustment“ page 4
The magazine cover is opened when the function
is selected. This can only be closed again after the
„M555“ function has been deleted.

1. Spindle
2. Upper Part of the special Tool

Attention:
Danger of collision when moving. By activating M555, all monitors in the
changing area are deactivated.
Move the Axis carefully

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1

• Move the magazine [V] out of the machine

base.
2
• Insert the lower half of the setting tool in place
on the far right.
• By traversing the X-, Z- and Magazine [V}-axes,
3
the two halves of the setting tool are brought
together, one half over the other.
• This is checked from the outside with the hand,
or with the bolt in the setting tool.
Note:
Don't traverse with the Y-axis, since the
4
tool change position must be at Y=0 mm.

The determined X-axis value is entered in the

Axis Position under TOOL CHANGER
POSITION
See Chapter: 5.5 Setting of the Tool change
1. Main spindle
position 2. Upper part of the Special tool
3. Lower part of the Special tool
4. Bolt

4.10 Setting Reference point for the Magazine axis [V]

• Follow those Steps:
- enable Write protect (see chapter: „Write protect enable“)

- Press the Key [MDI]

- Press the Soft key [SYSTEM]

- {PARAM}
- Switch Machine off

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- put in 1815
- press soft key{No Search }
-Parameter 1815 Bit 4 (APZ) to 0 on the
related Axis
- Shut the machine off on the Main switch
- wait approximately 15 sec. switch the
- Machine back on

- set “Parameter Write” to 1

Set Parameter 1815 Bit 4(APZ) to 1

(Reference point will be set on this
position)

- Machine off

- Machine on .

- Check Position.

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5 Determine of the Spindle Position

- Insert Tool holder in Spindle 1 (DZ Machines

also Spindle 2) and turning the tool in a
counter clock wise direction before clamping it in
the Spindle

Note:
The precondition is that M19 has
already been set.

- M19 output (Diagnose Parameter Nr.

445/446 will be activated with M19)
- put in M555
- Move slowly to tool change position
- Move Magazine Axis [V] slowly to 1.000 mm
before tool change position, pay attention to the
Spindle position.

Note:
When traversing with the Magazine
axis, pay attention to the spindle
position.

Attention:
Danger of collision when moving. When M555 is activated, all monitors in the
changing area are deactivated.
Move the axes with special care.

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- Determine the spindle positions by lightly

turning the spindle in the magazine.
2
1

1 Turn Counter clockwise.

2 Turn Clockwise

5.1 Determine the spindle position as follows

-Spindle position readout

-System >DGNOS > 445 > NO SRH (Spindle 1
Status) 2
Turn spindle 1 clockwise as far as it can go

- Read off the spindle position value and write

this down. :
SPINDLE-1 POSITION DATA = 1177 Grad
- Turn spindle 1counter clock wise as far as it can
go
- Read off the spindle position value and write this
down. :
1- Spindle
SPINDLE-1 POSITION DATA = 1124 Grad
2- Read out value spindle 1

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-Turn SP2 counter clock wise as far as you can go 1

2
- Read off the spindle position value (446) and
- Write it down :
-
- SPINDLE-2 POSITION DATA SP2 = 1176 Grad
- Turn SP 2 clock wise as far you can go
- Read off the spindle position value and write
it down
SPINDLE-2 POSITION DATA SP2 = 1057 Grad

1- Spindle SP2
2- Readout spindle 2

Move the magazine away from the tool change position (Magazine [V] 100.000 mm )

- Eject the tool holder from spindle 1 (for DZ

machines, also from spindle 2) and turn the
tool in the clockwise direction before clamping
in the spindle.

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- use M555
- Move to Tool change Position
- move Magazine Axis [V] slowly to 1.000mm
before the Tool change position pay attention to
the Spindle position
-

Note:
When traversing with the Magazine axis
[V], pay attention to the spindle position.

Attention:
Danger of collision when moving. When M555 is activated, all monitors in the
changing area are deactivated.
Use Precaution when moving the Axis

-Determine the spindle position by slightly turning

the Spindle in the Magazine
1 2

1 Turn Counter clock wise.

2 Turn Clock wise

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5.2 Determine the Spindle position as follow

-Turn SP1 counter clock wise as far as you can go
1
- Read of the Spindle position Value(445) and write. 2
it down :
SPINDLE-1 POSITION DATA SP1 = 1084 Grad
Turn SP1 clockwise as far as you can go

- Read out the spindle position Value and write

- it down
SPINDLE-1 POSITION DATA SP1 = 1076 Grad

1- Spindle SP1
2- Readout Spindle 1

- Turn SP 2counterclock wise as far as you can go

1
Read off the Spindle position Value(446) and
-
write it down.
2
SPINDLE-2 POSITION DATA SP2 = 1176 Grad.
- Turn SP2 clockwise as far as you can go
-
- Read off the spindle position value and write it down.

SPINDLE-2 POSITION DATA SP2 = 1076 Grad.

1- Spindle SP2
2- Read out Spindle 2

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5.3 Calculate the values of the first and second measurements

Counter clock wise Clock wise Result 1 Result 2

Spindle 1 :(1177 + 1124) / 2 Spindle 1 : (1084 + 1076) / 2 Spindle 1 Spindle 1
= 1150 = 1080 (1150+1080)/2 (1116+1126)/2
Spindle 2 :(1176 + 1057) / 2 Spindle 2 : (1176 + 1076) / 2
= 1116 = 1126 = 1115 = 1121
SPINDELPOSITION (1115 + 1121)/2 = 1118 (#4077 - 1118) / 11,3778
=XX,XXX°

5.3.1 calculating the Difference from the Average Value and M19

For instance: Result [1118] with the Value of „Parameter 4077“ [example: 2041], the
Value M19 „Position 0°“ and the „Tool change position “ must be calculated
Example:
Spindle position 0° = Parameter 4077 = 1248 Units
Tool change position = Diagnose 445 (Average) = 1118 Units
Difference = 130 Units
130 Units : 11,3778 = 11,4257 == 11,425°
Note:
360 ° = 4096 Units equals 1° = 11.3778 Units

Calculated value 11,425 has to be put in ACHS-POSITION „SPINDELPOSITION“ .

See Chapter: 5.5 Setting of the Tool change position

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5.4 Tool Change Position (Z-Axis)

• Move Machine to Position X=0, Y=0 and Z=0

• Activate the M555 Function.
2
See Chapter 2: „Enabling for Tool changing 1
Position adjustment“
• Insert the upper half of the assembly tool BWM
623002000 in the spindle and move the tool to the
tool change position.
Carefully position the MAGL1 tool magazine to the
position 0. 3
Insert the lower half of the assembly tool BWM
623002000 in the place to the far right.
Position the Z-axis carefully into the tool change
position and determine the position in the Z-axis
with the 0.500 mm feeler gauge.
Note that the assembly tool length is 40 mm
Example:
Screen Display Z – Position: - 42,900 mm
used feeler gauge: - 0,500 mm
Assembly tool length: - 40,000 mm MB6131015007
Tool change Position
Of the Z -Axis: - 83,400 mm 1 Assembly Tool
Enter this Value into Axis-POSITION : 2 Spindle
Tool change position Z = –83.40mm 3 Feeler gauge 0,500 mm

See Chapter : 5.5 Axis - Position For

Tool changer

- Close Magazine cover with FunctionM621

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5.5 Setting Tool changer position

- The Tool change position for the Axis
and the Spindles has to be put in the
following Menu.
- You have to be in „JOG“ and the

Key switch in position (3)

- You can find the Menu for the Position
under:

[CUSTOM] ► (Maybe use Soft key

[+ ] ► [Set up] ►
[Axis-POSIT] ► [Tool Changer.]

With the use of the Soft key

[Change] the Cursor for the Input will show up

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- To actuate the Value you must press

„Input“
- after the position is changed , the soft key
[Accept] pops up.

Press the Soft key

[Accept] , now you will see the Soft key [OK]
Press this one to start the Program

The Macro Program (O9107) will be started

automatically in the Back round
- This Macro Program will update the
Cam and Variables allocated to the
positions
- After the successful run of the Program the
- Message
( 3145 Cam Set) will pop up
If this is not done correctly: the Message
A29.0 (SETUP WZW NOT FINISHED) will
show up

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Attention:
The Set up must be done in Metric
.

• Example „Tool change position“:

AXIS-POSITION „HSK“ Not

POSITION X -130.000 mm Variable
POSITION Y 0 Set
POSITION Z -81.000 mm Variable
Z-Axis Lift up 50.000 mm Set
SPINDLEPOSITION 11.000 mm Variable
X-Distance Toolc LE-RT 250.000 mm Variable
Magazine Rear Homepos 366.000 Set

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6 Instructions for exchanging an inductive proximity switch (empty pocket monitoring)

6.1 Disassembly of the Magazine wiper (black plastic bracket)

• take the tools out of the front places 1
• open Magazine cover with M620 2
• Take of the fastening Bolts from the wiper

• Take off the Magazine wiper.

1. Fastening Bolt
2. Magazine wiper

6.2 Disconnect the Connector

- Disconnect the connector for the Proximity Switch 1
(located in the back part of the column) 2
- Disconnect the hose for the Auto lube on the
distributor for the guide shoe

1. X-Axis Guide
2. Connector

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6.3 Dismantle the complete take-up sheet with proximity switch.

• Move the Magazine manual with the
Ball screw to the back stop
1
2

Note:

Do not push past the end of the Ball screw

- Take out the fastening Bolts

1. Fastening Bolts
2. Proximity Switch

• Take the Bolts off in the Back

1
2

1. Fastening Bolt
2. Bracket

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6.4 Take out the Bracket

- Remove the complete Bracket with the Sensors
- from the front

6.5 Sensor Assembly

Push the sheet with sensors from the
front into the magazine shaft
Stick the central lubrication line into the front
guide shoe. Make sure the line is correctly laid
so that it isn’t kinked or pinched off
Fix the sensor sheet in place.
Plug in the connector.
Carry out sensor function test.
Mount cover sheet (magazine panel).
Mount scraper strip.

Connector

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6.6 Check of the Sensor Position

- Set the sensor to the right depth.

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7 Write protect enable

Use Key switch position [3]

Operation mode MDI

Press „OFFSET SETTING“

Press Soft key SETTING .►
To change PARAMETER WRITE =
from 0 to 1 :
Follow these Steps
Select PARAMETER WRITE
Put in 1 than hit Input
Alarm 100 will pop up
This Alarm can be canceled with

Can +Reset +

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