Master_Instruction_Manual五轴加工中心操作手册master414（英文版） .doc

rel.09/2004 instructio n manual master 6 axes cnc working center instruction manual master 1 serial n.: year: v./hz.: instruction manual master ii note: this manual is property of p.bacci s.r.l the company does not consider valid any copy of this manual which shouldnt correspond to the one filed in its offices. instruction manual master iii index user interface 1 operating panels 2 cnc operating panel. 2 portable keypad . 4 left and right table buttons. 6 left and right table pedals 6 keyboard 7 guidelines for a correct use of the electrospindle.9 maintenance. 14 general rules 14 characteristics and frequency of inspections.14 scheduled long term inspections . 16 lubrication mechanical parts 17 pneumatic installation lubrication system.18 connections . 19 compressed air 19 electrical. 19 transportation 20 safety. 21 spindles . 21 mechanical parts 22 electrical installation. 22 pneumatic installation 22 perimeteral protection/cabin. 23 programming 23 general recommendations. 23 programming 24 general functions 25 preliminary operations 25 turning on the machining center 25 homing. 25 stop a machining cycle 25 turn off the working center. 25 basic programming notions 26 operating head configuration parameters28 part program management 30 instruction manual master iv line editor 32 program check. 33 bacci softkeys 34 management macros 35 plus management variables. 36 working macros . 36 geometric and compensation macros37 auxiliary macros. 37 dynamics 38 the master program. 38 masterpend example 39 automatic mode (auto) operating sequence .40 manual mode (manual) operating sequence.40 autoprogramming. 41 introduction 41 available parametric programs. 41 programming 44 how to create a part program. 44 programming with alphacam. 50 general tips 50 post processed program example 51 the tg post processor (rotating table vertical axis).53 transferring the program from pc to working center .55 digitizing part origin 55 insert program in master program 56 loading the program 57 activate the program 57 osai cn network configuration 58 error messages 60 solving problems 61 diagnostics. 65 error messages 66 drive error messages. 68 how to visualize the code from the nc 69 input/output list 70 input . 70 output 72 instruction manual master v installation 73 pneumatic installation 74 components list . 74 wiring diagram . 75 user interface instruction manual master user interface 2 operating panels cnc operating panel 1. stop button stops axes and spindle rotation. does not shut down the machine. 2. power supply lamp 3. selector for overstroke recover enables the recovering of an axis from overstroke. when an axis falls in overstroke, the machine shuts down and a message appears on the screen. the procedure to take the axis back within the operative limits is the following: pay attention to incorrect use ! instruction manual master user interface 3 switch the selector to the right hand position push the reset button turn on the machine, using button (9) switch the selector (11) to “manual” and move the axis in the proper direction within the limits switch back the selector (3) to the left hand position. 4. power on lh table vacuum pump button 5. power on rh table vacuum pump button 6. not applicable 7. emergency stop button shuts down the machine 8. not applicable 9. auxiliaries on button 10. not applicable 11. selector manual / automatic 12. vacuum pumps stop button 13. dust and chips belt conveyor on/off button (optional) the axis in overstroke must be clearly identified and the procedure must be followed carefully ! instruction manual master user interface 4 portable keypad 1. emergency stop button stops axes and spindles. does not shut down the machine. 2. x-manual movement button moves x axis in continuous manual mode in negative direction. 3. x+ manual movement button moves x axis in continuous manual mode in positive direction. 4. z-manual movement button moves z axis in continuous manual mode in negative direction. 5. z+manual movement button moves z axis in continuous manual mode in positive direction. 6. p-manual movement button moves p axis in continuous manual mode in negative direction. 2 6 43 10 13 12 11 14 155 9 8 7 1 16 instruction manual master user interface 5 7. p+ manual movement button moves p axis in continuous manual mode in positive direction. 8. a- manual movement button moves a axis in continuous manual mode in negative direction. 9. a+ manual movement button moves a axis in continuous manual mode in positive direction. 10.q- manual movement button moves q axis in continuous manual mode in negative direction. 11.q+ manual movement button moves q axis in continuous manual mode in positive direction. 12.c- manual movement button moves c axis in continuous manual mode in negative direction. 13.c+ manual movement button moves c axis in continuous manual mode in positive direction. 14.led portable keypad enabled the led is on if the keypad is enabled by the proper softkey. 15.digitize axis position button to be used in self-learning mode. 16.override potentiometer enabled when the keypad is enabled, both in manual and automatic mode. other buttons possibly present can be used to move additional axes (optionals). instruction manual master user interface 6 left and right table buttons 1. emergency stop button shuts down the machine. 2. start/ door button in manual mode: allows the opening and closing of the loading door. in automatic mode: allows only the closing of the loading door and the start of the working cycle. 3. stop button stops axes and spindles rotation. does not shut down the machine. left and right table pedals the pedal allows to clamp / unclamp the pieces on their respective tables, with the following modalities: manual mode (selector and cn) pressing the pedal with the loading door open causes the blockage of the piece at low pressure (pneumatic clamps) and by vacuum (if the vacuum pump has been turned on); pressing the pedal again (with the loading door open) the piece will be unblocked. when the loading door is closed pushing the proper button, if the piece is blocked the clamping pressure goes up to high pressure. automatic mode (selector and cn) pressing the pedal with the loading door open causes the blockage of the piece at low pressure (pneumatic clamps) and by vacuum (if the vacuum pump has been turned on); pressing the pedal again (with the loading door open) the piece will be unblocked. when the loading door is closed pushing the proper button, if the piece is blocked the clamping pressure goes up to high pressure. 3 2 1 instruction manual master user interface 7 in automatic mode the opening of the loading door is driven by program (unblock command), then it is possible to unblock the piece using the pedal; the piece can be automatically unblocked inserting the auto-unblock command in the program. keyboard keyfunction move cursor one character left in the row move cursor one character right in the row scroll down pp, or select upper line scroll up pp, or select lower line move cursor up 9 rows move cursor down 9 rows move cursor at the end of the line move cursor at the beginning of the line move cursor at the beginning of the pp move cursor at the end of the pp pgup pgdn crtl crtl crtlhome crtlend instruction manual master user interface 8 delete first character on the cursor left delete the character on which the cursor is positioned cut selected line in the cursor position: characters on its left are moved to the next row. create a new row before the selected line when the cursor is placed on the first character. create a new row moving up the selected line. accept data inserted in input windows. back space del end instruction manual master user interface 9 guidelines for a correct use of the electrospindle heating up the heads must be heated up to 35c before using; to reach this temperature turn on the spindle at 3000 rpm for at least 10 minutes. this will let the bearing and the rotating parts operate at the optimal temperature. when the electrospindle is loaded at a lower temperature, the bearings will undergo an untimely consuming and will lose the preload. choosing the tool use only tools with a diameter and weight included in the table of page 11. tools and toolholders must be balanced in g1 and re-balanced after every sharpening. vibrations caused by an unbalanced tool can rapidly destroy the bearings. caution ! the use of elements (tool holder shafts, spacers etc.) which do not respect the indicated requirements, or their uncorrect assembly may cause the tool breaking during its rotation and the subsequent projection of metallic parts around the machine tool quality tools must always be sharpened in order to reduce the cutting forces and the spindle working temperature. heat generated by the spindle may overheat the bearings and the lubricant causing the evaporation of the lubricating components: this will result in life reduction for the bearings and thus for the spindle. instruction manual master user interface 10 cleanliness keep rigorously cleaned cones, shafts and tool calmping chucks. contamination by dust may cause a disalignment and an uncertain tool blockage: this will force the operator to lock the nuts with a torque higher than suggested, damaging shaft or toolholder screws. warnings on bearing lubrication the bearings are lubricated for life duration with kluber isoflex topas nb52 or lubcon l182. anyway for a possible bearings relubrication the same grease must be used: a different grease type in great quantity irretrievably damages the spindle. cooling use the spindle only when connected to the cooling system. use only 4 bar non lubricated air! instruction manual master user interface 11 caution! f example tool weight2.5 kg spindle speed15000 rpm error0.3 mm f = (2.5 x 15000 2 x 0.3) / 91000 185 kg (1850 n) instruction manual master user interface 12 tool suggested dimensions size max shaft diameter spindle speed (rpm) max tool diameter (mm) max tool weight (kg) 6000 / 900015010 9000 / 120001307 12000 / 150001105 er40 25 mm 15000 / 18000805 6000 / 90001404 9000 / 120001304 12000 / 150001102.5 er32 20 mm 15000 / 18000802.5 these data are just spindle related: for each tool the constructor maximum rpm must be respected too spacers suggested tolerances (see(see(see nextnextnext pagepagepage forforfor drawing)drawing)drawing) instruction manual master user interface 13 max 0.005 mm max 0.005 mm spindle shaft distanziali / spacers danger tool error instruction manual master user interface 14 maintenance general rules the master machine has been designed to reduce maintenance to a minimum. in order to avoid failures and troubles the rules below must be followed: keep the machine clean and in order avoid any possible damage do not let temporary remedies become definitive the strict observance of periodical maintenance interventions is extremely important: all the machine components must be regularly controlled in order to avoid possible failures. all the interventions must be compatible with and in strict observance of the operator safety rules. when an intervention on the electric installation is necessary, it is indispensable to put the main switch on the cabinet door in “off” position in order to guarantee the safe access to the cabinet when an intervention on the pneumatic installation is necessary, it is indispensable to disconnect the machine from the general installation using the lever near the frl group characteristics and frequency of inspections dailydailydaily maintenancemaintenancemaintenance lubricator operating check (pneumatic installation) lubricator oil level check (pneumatic installation) check and empty out the condensate tank in the frl group check the lubricating oil level in the tank of the pneumatic installation pump carefully clean the machine, avoiding air blasts that may bring chips into the dust protections substitute the damaged components weeklyweeklyweekly maintenancemaintenancemaintenance carefully clean inside the electric cabinet with a vacuum cleaner instruction manual master user interface 15 check the operation of every button and pedal check the correct operation of the lubricating pump check the axes correct operation clean the noise filter under the z axis balancing cylinder monthlymonthlymonthly maintenancemaintenancemaintenance carefully clean with a vacuum cleaner inside the machine and under the dust protections check the operation of every button and pedal check proximity and microswitches correct operation check the axes correct operation check the pneumatic installation correct operation check the chain of the z axis balancing device and grease it if necessary it is strongly recommended to change the chain of the z axis balancing system every year. we remind you that the scheduled maintenance has to be integrated with special interventions, when necessary. moreover we entrust the operator working on the machine to report any problem to the ones responsible for maintenance and installation. instruction manual master user interface 16 scheduled long term inspections visual check of the installation (wires, parts, cable carrier chains) and replacement of damaged parts if needed. six months check installation functionality (emergency stops, buttons etc.) six months check electrical, electronic and electro mechanic components, and electrical cabinet wirings. one year electrical installation check operating head electrical collector and change brushes one year visual check of the installation (pipes, valves, etc) six months clean the installation18 monthslubricating system check installation functionality and pump delivery head six months visual check of the installation (pipes etc.) six months check electrovalves correct functioning (overheating and/or stops) and replacement if needed. one year pneumatic installation check of frl groups and replacement if needed one year visual check of mechanical components (slides, sliding blocks, main screws) and wearing components (dust covers and other protections) six months check correct tension of transmission belts one year mechanics check tightening of mechanical parts (lock nuts, flanges, other components) one year instruction manual master user interface 17 lubrication mechanical parts the master machine is equipped with an automatic centralized lubrication system; the lubrication time intervals are controlled by the cnc. periodically check the working and efficiency of the automatic lubrication system! for the automatic lubrication system refilling, the use of one of the following products is recommended: nlgi-0 (or equivalent) nlgi-1 (or equivalent) use only grease resistant to high pressure. otherwise if oils and soaps inside grease are separated, soaps can solidify and obturate the pneumatic installation. instruction manual master user interface 18 pneumatic installation lubrication system the lubricant in the pneumatic installation must be periodically checked and in case refilled with one of the products listed here, or with an hydraulic oil class iso/uni f or iso/uni h. agip oso 10 esso nuto h 5 mobil velocite oil no.4 q8 puccini 4p texaco 300 oil 5 total azolla zs 15 tab.2 there are no noticeable differences between the oils here indicated. pneumatic system lubrication here pneumatic oil from tab.2 instruction manual master user interface 19 connections compressed air suggested diameter for compressed air tube = 1/2“ optimal line pressure = 6,5 bar pipe connection diameter = 25 mm outer / 17 mm inner air consuming at 6 bar = 200 l/min for 2 spindles version 360 l/min 4 spindles version electrical nominal voltage = 380 volts / 50hz or external autotransformer (optional) connection type = 3 phases + 1 ground connection maximum resistance to the ground = 20 ohm maximum installed power = (see label on left side of the upright) plant view of a typical master layout note: the machining center auxiliaries can be turned on only if both connections (compressed air and electricity) are present! instruction manual master user interface 20 instruction manual master user interface 21 transportation when transported in a container the biggest part of the machine (basement and operating head) must be unloaded using a crane, by means of 4 ropes each 4m long and 2 poles to be inserted in the provisional holes in the basement. uplifting ropes and poles are not supplied with the machine and must be properly dimensioned, like the crane and any other component used for this operation. the ropes anchored to the poles on the basement rear part (the opposite side with respect to the operating head) must be aside the basement, while those on the fore part must be placed approximately 400mm away from the basement in order to balance the moment due to the machine weight distribution. uplifting scheme: the holes for uplifting poles have a diameter of 80mm. machine weight is about 4000kg. once uloaded with the crane, the basement can be moved with a forklift expediently