KLS~184ON / KLS~266ONCNC LATHE

OPERATION MANUAL

(Electrical Manual)

NC CONTROL: FANUC Oi Mate-TD

SERIAL NO.:

CONTENTS

1. The lathe operation and Maintenance Instruction1. 1. General1.2. Operation1.2.1 . The preparation before stare machine

1. 2. 1. 1. Power supply

1. 2. 1. 2. Adjust the power sequence1. 2. 1. 3. NC power on and power off

1. 2. 1. 4. Other inspection and adjusting1.2.2. Caution

1.2.2.1. Reference position return

1.2.2.2. Reference position and setting

1.2.2.3. Replacement the battery

1.2.3. The function & operation of all button on operation panel

1. 2. 3. 1. Emergency stop

1.2.3.2. MEM protection

1.2.3.3. Mode selection

1. 2. 3. 3. 1. EDIT mode

1.2.3.3.2. AUTO mode

1.2.3.3.3. MDI mode

1.2.3.3.4. MPG mode

1. 2. 3. 3. 5. JOG mode

1.2.3.3.6. ZERO mode

1. 2. 3. 4. Overtravel

1.2.3.5. Spindle

1.2. 3. 5. 1. UP~ 1OO%~ DOWN

1.2.3.5.2. CW.. STOPS CCW

1. 2. 3. 5. 3 KLS266ON Spindle speed range shift control

1.2. 3. 6. COOL(Coolant)1. 2. 3. 7. Chuck

1.2.3. 8. TAIL(Tailstock)1.2.3.9. INDEX(Tooi turret index) operation

1.2.3.9. 1. Manual tool changing operation1.2.3.9.2. Manual tool changing sequence1. 2. 3. 10. F5 (Spindle JOG) operate1. 2. 3. 11. The instruction of some accessories

1. 2. 3. 11. 1. Automatic lubrication

1.2.3.11.2. Door guard

1.2.3. 11. 3. Handy Pulser

1.2.3.11.4. Tower light1.2.4. Cycle start

1.2.4.1. Selecting the needed program

1.2.4.2. M code

1.2.4.3. T code and tool post radius compensation

1.2.4.4. S code

1.2.4.5. G code

1.3. PMC ladder

1.4. Alarm & diagnosis

1.5. The maintenance of electric equipment

1.6. Workable environment

2. Electric equipment list

3. Appendix

3.1. Appendix 1: FANUC system parameter, PMC parameter setting

3.2. Appendix 2: FANUC memory card operation

3.3. Appendix 3: electric elements figure(electric elements part)3.4. Appendix 4: Operation procedures for copying parts machining programs from

FANUC Ui system to MCARD

i. The operation and maintenance introduction

1. 1. GeneralThis CNC lathe is equipped with PANUC Oi MateTD control system.With reference to the operation and programming of the control, please referto the relative manuals. FANUC OiD/Oi MateD operator s manual.The operation panel and LCD/MDI are located on the guard, and the CNC controlalong with the inverter and servo module is fitted in the cabinet, whichincludes the strong electric parts, such as: contactor, circuit breaker, fuseand so on.The standard RS232C interface is on the lathe operator s panel.The supply power for each part is required as follows:~ Singlephase AC llOV for contactor control. Singlephase AC 220V for cooling fans. Singlephase AC 24V for machine light.~ DC 24V (stabilized power supply DC24V, Vl) used for control unit and signal

input and output.

DC 24V for solenoid valve.1.2. Operation1. 2. 1. Preparing work1. 2. 1. 1. Power supply

The operator should read the manual carefully and check if the electricdev~re and all other plugs and screws are in good condition. And be sure toconfirm that the power before connecting it.

1. 2. 1. 2. Adjusting the power phaseUnder the normal condition, turn on the main power switch QF1 and take a lookat the hydraulic pump oil pressure, if it not good, the optional two phaselines should be changed, and the sequence of,the phase would be right if theoil pressure is normal. If have no hydraulic system, can adjust the powerphase by checking coolant pump.

1. 2. 1. 3. NC power on and power off1.2.1.3. 1. Power on

Close the electric cabinet door and turn on the main power switch QF1 , sothat the inverter, the control transformer TC2 is on; in the meantime, pressthe ON button on the under side of the LCD/MDI so as to make KM4, electrifiedthe CNC unit, servo unit and LCD/MDI unit be with electricity on.

1. 2. 1. 3. 2. Power off

When the indicative 1~ght~ ~for the circuit start goes out and the moving partsof the machine stops , the power can be cut off.

Press the OFF button on the under side of the LCD/MDI Then CNC unit,servo unit and LCD/MDI unit are off.1. 2. 1. 4. Other inspection and adjusting

Refer to the ELECTRIC THOERY FIGURE for checking all voltage values.Check the relative parameters for the NC, servo unit , spindle and PLC as perthe operation manual. Make sure all the switches and buttons are valid throughautomatic diagnosis. The light of NC NORMAL is lighting, and without any alarm,the first machine start is finished, The later start in known as normal start.1.2.2. Caution1. 2. 2. 1. Reference position return

The lathe s X axis and Z axis adopt absolute pulse code demodulator, sowhen the lathe power off, not needed the operation of regress to referenceposition.

If regressed to the reference position, you may turn MODE SELECT switch toMID mode, press PROG button, enter G28 XO ZO~ , press CYCLE START button;Then the system execute the orders, when finished ,X Z axis will stop ,anclthe LCD will show the absolute coordinates as 0. 000. Then, finished the operationof reference position return.1.2.2.2. The reference position and setting sequence

Note:For the lathe assembled hydraulic chuck, the CYCLE START button is effective

at the chuck in clamping way under AUTO and MDI mode.The reference position in the system: X axis position is equal to the surface

of slide and cross slide, Z axis keep 300mm in the end of the machinery surface.Before the operation of returning to the reference position, confirm the X~ Zaxis at the suitable station ;and the tailstock at the end of the bed slide, itis in order to prevent the bump between the slide and tailstock.

The APC battery is located under the servo amplifier, the connect plug isCX5X. there is a APC3n6apc3n8 alarm signed on the LCD, when the voltage is toolow. please replace the battery between one and two month.

If the information of absolute station coder lost, connect the power , thereis a alarm signal 3nO . after replace the battery , you must reset the referenceposition. If you have a disassembly of servo motor or lead screw, or pull outthe plug of coder, you also need reset the reference position. Meantime, resetthe limi ted position parameter in No 1320 and Nol321 . The method of how

1. 2. 2. 3. The method of replace APC battery

f3 1SVSP2O/20-11CX5X

to setting the overtravel limited parameter refer to 1. 2. 3. 4. OVERTRAVEL part.The step of reference position setting: turn on the parameter switch, change

the parameter No1815ff4(APZ; X axis, Z axis) to O;cut off the power ;turn on Lhepower , showing need to return reference position. In JOG mode, move the latheto the reference position. Then, change parameter No1815ff4(APZ; X axis, Z axis)to l;turn off the parameter switch; cut off the power; turn on the power, then,finished the parameter position setting. (how to set parameter, refer to theappendix 1:FANUC system parameter. PMC parameter setting)

Advice: The battery be replaced once a year regardless of whether APC alarmsare generated.

Note:The method of replacing the battery: (details refer to FANUC OiD/Oi

MateD operator s manual)~j~) Open the electric cabinet door, turn on the power Take the cable connector plug, turn right about 15 ,draw hack

suitably, you can pull out. the cable connector plug. Turn toe battery case cover to left, for disconnect the hook.~ Replace the hattery(Note: put the plug connect cable to the slot in

the battery box, lest to cut the wire ) Put the case cover to the slot in the amplifier, then , move to the

right, fasten the cover. Insert the connect plug to CX5X in correct direction , finished the

battery replacement. Turn off the power, close the electric cabinet door.

The mode of battery(6VDC) supplied by FANUC is:AO6B6l14504 (for 13 iSVSP 20/2011)

\ I

Battery case

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1. 2. 3. Functions and operations of switches and buttons on the operation panel.The operation panel consists of LCD/MDI operation plate and the mechanical

operation panel, for the former one, please refers to the PANUC OiD/Oi Mate-Doperator s manual.Following are the instruction of buttons and switches.

(without Handy Pulser)

(with Handy Pulser)0 0

RAPIDINP6MODE SELECTION~ ON I F OVERRIDE 1 ~(~i~i~~(~~ii~ ~ (~53~N ~ 1~Th I~Th 0 0 0/-~ NC NC MACNINE FEED RATE OVERRIDE

~N~,_) L~J L~J~ [_~J I._~_J~ ~~ NURMAL ALARM ALARMAUX FUNCIION 91I I SI ~ IDE

4IL~~~-~i ~gPOWER (~~Th ~~~ 0

~ x~z~ ~

0 OFF ~ SPINDLE~m ~ ~X ~

~

F CHIP EON VEYOR ~POWER f~~Th~ (0FDR~ 1 STOP

~ w7 [E~ u LE D~>O(~) 0000

CIIUCE CYCLE START FEED HOLD DEEM PRDTECTIDNEMEROEFICY STOP

0 0

0 0 0 0

D ON

7 N

POWER

0 OFF

POWER

lODE SELECTIOI1 I F OVERRiDE 1 1i 0EDIT ~5~UT~ OMDIiNPO OJDO ~0ZERO C) ~E o 0

~j [,,~j ~j ~,NJ ~1 ~j ~J NORMAL ALARMI AUX FUNCTION

~5~K ODPIV OEDT ~5Th~P 0 NLK o o a a a

~ X~Z~

SPINDLEUP ~5~~ DOWEl DIDEX 0 COOL 0 ~ThL~.IJ~I] [~i[~ll~kJL~J H~EJ

r CHIP C000ENIIR1C)CW STOP OCCNI C~FOR ~POBACP

~J~] L~J L~~1~~ WN \ / 1

EMEPGEIICY STOP

FEED P4TE OVERRIDE

~ ~IOO110

2020j r-V r 13210W1 \,,_i0 150W

-/ _c~ ~

N~EI~7 \

CHOCE

U U7Th IN\i~J \,,,7

CYCLE START FEED HOLD MDII PPOTECTIOII

(2 0

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1. 2. 3. 1. Emergency stopThis button is used to stop all machine movement under the emergency

situation, if it is necessary to make it live again, the operator should turnit a certain angle in clockwise direction.1. 2. 3. 2. MEMORY PROTECTION

When MEM PROTECTION key switch on OFF station, it can alter parameter.edit program and input the program through the PC. Whereas , it can t do this.1.2.3.2. MEM PROTECTION

When MEM PROTECTION key switch on OFF station, it can alter parameter.edit program and input the program through the PC. Whereas , it can t do this.1.2.3.3. MODE SELECTION

There are EDIT , AUTO , MDI , MPG , JOG , ZERO modes in all.When machine start, the default mode is JOG ,when you select one mode ,theother mode will be cancel.1. 2. 3. 3. 1. EDIT mode

Select EDIT model by pressing EDIT button, the indicator light is on . Itcan be used to set up and edit the machining program in the [PROG] page.1. 2. 3. 3. 2. AUTO mode

Select AUTO model by pressing AUTO button, the indicator light ison . select the parts program stored in the memory set the switch under the AUTOmode, and press the CYCLE START button, the machine will be in automatic running.When FEED HOLD button is pressed, the machine would be in hold condition, andeach axis decelerates and stops. If press the CYCLE START again, it goes onautomatically. Under this condition, the select switch can be used to chooseany override value for FEED RATE OVERRIDE, RAPID OVERRIDE, SPINDLEOVERRIDE ,generaiiy 100%.

Under this model, can select AUX FUNCTION operation, the AUX FUNCTION canbe realized: the details refer to FANUC OiD/Oi MateD operator s manual

Select DRN function by pressing DRN button, the indicator light is on . PressDRN button again, the indicator light is off , cancel the DRN function.

Select SI3K function by pressing SBK button, the indicator light is on . PressSBK button again, the indicator light is off , cancel the SBK function.

Select BDT function by pressing BDT button, the indicator light is on . PressBDT button again, the indicator light is off , cancel the BDT function.

Select OSP (optional stop)function by pressingS OSP button, the indicatorlight is on .Press OSP button again, the indicator light is off , cancel

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the OSP function.Select MLK function by pressing MLK button, the indicator light is on . Press

MLK button again, the indicator light is off , cancel the MLK function.Can se]ect this function on JOG mode.Note: After use MLK function, the machine s mechanical position no

changed , but the system s mechanical position changed. By now, the referencepoint of machine changed, if still execute the program, it will be accident.So, if use MLK function, must recovery the mechanical coordinates, detailscheck below:Press POS -~ then press [ ABS I soft key~press [ OPRT I soft keyk

press[ WRKCD I soft key~press[ ALLAX I soft key_*Finished the mechanicalcoordinates recovery.

1.2.3.3.3. MDI modeSelect MDI model by pressing MDI button, the indicator light is on . Under

this condition, ten programs can he included at maximum, which can be executedunder the MDI mode as the same as common programs. Press CYCLE START button,execute the input programs.1.2.3.3.4. MPG MODE

Select MPG mocleJ by pressing MPG button, the indicator light is on . ByMPG OVERRIDE to select mode X 1, X 10, X 100 whose displacements for each

index are respectively l~t, lOii,lOOii ;Choose the X and Z axle with switch,and the machine will go forward positively by clockwise rotation of the handwheel,whereas, by counterclockwise, the machine will go in negative way. When machinestart, the default MPG OVERRIDE is XlOO.MPG OVERRIDE and RAPID OVERRIDE are used in same buttons. Under MPG mode,

Select Xl by pressing FO/Xl button, the indicator light is on .Thiscancels the original MPG OVERRIDE.

Select XlO hy pressing 25%/XlO button, the indicator light is on.This cancels the original MPG OVERRIDE.

Select XlOO by pressing 50%/XlOO button, the indicator light is on.This cancels the original MPG OVERRIDE.Note: If a handy pulser is equipped, the MPG axis selecting switch( X/Z ) onthe panel and override buttons ( *1 *10 *100 ) are invalid. While handypulser s axis selecting switch( OFF/X/Z ) and override selectors ( *1*10 *100 ) are valid.

1. 2. 3. 3. 5. JOG modeSelect JOG model by pressing JOG button, the indicator light is on . Under

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this mode, press X (+X), X (x), ~z (+Z), Z (Z) buttons, the machinewill move toward the selected direction after the feed axis and direction buttons,and manual continual feed speed can be adjusted with PEED RATE OVERRIDE switchwithin 0150%; if buttons of the feed axis and rapid switch are pressed at thesame time, this will make the axis go rapidly, the speed can be adjusted withRAPID OVERRIDE from P0%, 25%, 50% to 100%. When machine start, the default RAPIDOVERRIDE is 50%RAPIDOVERRIDEandMpGOVE1~RIDEare~Isedinsamebuttons Under AUTO, MDIMPG , JOG , ZERO mode,

Select P0 bypressing FO/Xl button, the indicator light is on.Cancelledoriginal RAPID OVERRIDE.Select 25% by pressing 25%/X1O button, the indicator light ison .Cancelled original RAPID OVERRIDE.Select 50% by pressing 5O%/X 100 button, the indicator light ison .Cancelied original RAPID OVERRIDE.Select 100% by pressing 100% button, the indicator light is on . Cancelledor iginai RAPID OVERRIDE.1. 2. 3. 3. 6. ZERO mode

Select ZERO model by pressing ZERO button, the indicator light is on . Asthe lathe adopts APC, so the setting of this mode is invalid.1.2.3. 4. OVERTRAVEL

This lathe adopts memory overtravel limit. The setting of positive directionof measure 1 at parameter No 1320, The setting of minus direction of measure1 at parameter No 1321.

If the machine is controlled by overtravel limit, the system will alarm,and NC alarm indicator will be on. At this time, select JOG mode or MPG modeand make the relative axle move toward the counter way for a distance, the limitwill be e[iminated, press RESET button, the indicative light of NC NORMAL is on.Note:

The steps for checking coordinate on positive and inverse direction ofevery axis overtravel~ return to the reference point (for the reference point has been built , so

it is no need)move the X and Z axis to the boundary of positive direction and writedown the reference coordinate value of the two axisesmove the X and Z axis to the boundary of negative direction and writedown the reference coordinate value of the two axises.

~DMovetheX~,Zaxis to the middle position, depart the boundary position.

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Setting the record coordinate value to the parameter No 13201321, (setting parameter, refer to appendix 1: FANUC system parameterPMC parameter setting)

Finished the parameter setting1. 2. 3. 5. SPINDLE1. 2. 3. 5. 1. UP~ iOO%~ DOWN

Use UP lOO%~ DOWN button to adjust the main spindle speed rate,everytime press UP button, the rate of spindle increase 10%, when the rateof spindle up to 120%, the UP button is invalid. Everytime press DOWNbutton, the rate of spindle decrease 10%, when the rate of spindle decrease to50%, the DOWN button is invalid. Press 100% button, the rate of spindleset to 100%, and the indicator light is on. When machine start, the default SPINDLEOVERRIDE is 100%1. 2. 3. 5. 2. CW, STOP, CCW

Under the MDI mode, input the spindle speed SEflD~ and rotation directionM03 or MO4 in the [PROG] page, then press CYCLE START, the spindle will workaccording to the selected speed and direction and the relative light will heon; input MO5, after press CYCLE START, the spindle stops and the indicativelight will be out. Under the JOF mode or MPG mode, press CW or CCW, the spindlewill rotate forward or reverse and the indicative light will be on. Press STOP,the spindle stops and light OFF. Under the AUTO mode , the spindle will workaccording to the selected speed and direction and the relative indicative lightwill he on when the program is performed to~ M03 and M04. When thespindle isrunning, thespeedcanbeadjustedbytheb~~~0~50f UP, 100%,DOWN to adjust SPINDLE OVERRIDE (50120%).

Caution:For the lathe assembled hydraulic chuck, the operations can be done must

under the condition of chuck being clamped (CHUCK indicative light is on).1. 2. 3. 5. 3 KLS2660N Spindle speed range shift manual control

Set K4. 2l, the function of spindle speed range shift is effective.Spindle speed is designated by SDDDJ Shifts 14 are set by parameters

No3741, No3742, No3743, No3744. The max speed of the spindle is set by No3772. Shi fcan he selected according to actual working condition as follows. When themachine is started, the tacit shift is shift 1.

Instruction of KLS-266ON shift; total 4 shiftN23741= ; shift 1, high speed shift, M code is M4l, speed range: 325-2630

rpm

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NQ3742= shift 2, middle higher speed shift, M code is M42, speed range:I 60805 rpm

NQ3743= shift 3, middle lower shift, M code is M43, speed range: 55-270rpm

N23744= ; shift 4, low speed shift, M code is M44, speed range: 27135 rpm

Operation sample:KLS-2660N machine, under 3251630 shift, Spindle forward running with 500 rpm:One hand press P5 (spindle jog) and the other hand move the spindle speed

shift lever to the required position, then run the following block:M41;M03 S500;Caution: Only when the spindle has stopped running, can you manually move

the spindle speed shift lever. Only when the shift lever is at required position,can you run the spindle again except manual shift under jog function,otherwise, there will be a danger.1.2.3.6. COOL(COOLANT)

Under the JOG mode or MPG mode, the coolant and indicative light will heon by pressing COOL button one time; while it will be off by pressing oncemore. Under the AUTO mode, the cooling and light are on when the program isperformed to MO8, and they will be off till M09.1.2.3.7. CHUCK

Press CHUCK button or stop the foot pedal one time, the light for tight chuckis on, press again or stop the foot pedal. The light is off, indicating thatthe chuck is loose. In order to be safe, it is not allowed to loosen the chuckwhen spindle is rotating.

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Note:When the PMC parameter K8. 0 is 1, the function of hydraulic chuck is

valid, when the parameter is 0, the function of hydraulic chuck becancelled, and changed into manual chuck, the chuck is tight, CHUCKindicative light is on, clamping the chuck, CHUCK indicative light is off;The spindle is running must under the condition of chuck being clamped (CHUCKindicative light is on).after the spindle stops ,could unclamp the chuck.The chuck working mode defaulted by system is clamp outside surface of workpieces . now, the PMC parameterK4. 3 is 0 ;when you want change the workingmode to clamp inside surface of work pieces , please change the PMCparameterK4,3 to 1

1.2. 3. 8. TAIL(Tailstock)Press TAIL button or stop the foot pedal one time, the tailstock advance

and the light is on, while the tail stock retract and light is off after pressthe TAIL button or stop the foot pedal again. For safety, it is not allowed toact the taiistock when the spindle is rotating.1. 2. 3. 9. INDEX (Tool Turret index) operation1. 2. 3. 9. 1. Manual tool changing operation~ select JOG mode or MPG mode press INDEX button, tools are beginning to be changed The turret rotates to the next station, and the change is completed, The tool will he changed one time each time the INDEX button is pressed.1. 2. 3. 9. 2. Manual tool changing sequence

4-Station: l~2~3~4~l; 6-Statjon:~1. 2. 3. 10. F5 (Spindle JOG) operate

Under AUTO , MPG , JOG mode, press the key of F5 , then thespindle will running forward with the speed of. 15% (or 25%) under last time.Loosen the key of F5 , the spindle stop. For safety, when the machine iscvc].ing , or feed keeping, or spindle running , or hydraulic chuck unclamp, thekey of P5 is invalid.1.2.3. ii. The instruction of some accessories1.2.3. 11. 1. Automatic lubrication

The lubrication time can be set on the lubrication pump.1.2.3. 11.2. Door guard

Under AUTO mode, only closed the guard door, then you can press the button

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circle running , otherwise, it will be a alarm showing. Under the machinerunning, if the guard door be opened, the execute will pause, meantime, theindicate light of keeping feed will open, but the spindle still running:after closed the guard door, and press the circle running button, theparameter continue running.1.2.3. 11.3. Handy Pulser

If a Handy Puiser is equipped, the MPG switch (X/Z) on the operate boardand the keys of speed rate (*1, *10, *100) will be invalid, while the switch(OPF/X/Z)on the Handy Pulser, and speed rate switch (*l/*lO/*100) will be valid.1. 2. 3. 11. 4. Tower light

when alarm take place, the red lamp will light, and when the alarm cancelled,the red alarm lamp turn off; when the circle running finished, orange alarm lamplight, and press CYCLE START button again, the orange alarm lamp turn off,and when the machine is running ,the green alarm lamp lighting1.2.4. CYCLE START operation1. 2. 4. 1. Choose the needed program

Under the AUTO mode, choose the needed program, press CYCLE START button,and ~he program is started, press the FEED HOLD button, the program stops goingon, but press CYCLE START once more, the program will go on.1.2.4.2. M codeMOO program stop M03 spindle forwardMO1 optional program stop M04 spindle reverseM02 program end MO5 spindle stopM3O program ends up and returns to the start pointM08 coolant on M09 coolant offMlO chuck clamp Mu chuck unclampMl2 tajistock advance M13 tailstock retFactM19/Ml8 spindle orient / spindle orient cancel (serial spindle)

Note: if use M1O,Ml1,Ml2,M13 chuck & tailstock command, must use the delaycommand GO4 X ; in following.

1.2.4.3. T code and tool post offsetThe r code of tool post is~ when use gang tools ,the T code is

TO1LID.The former two codes are tool numbers 0104 (or 16) ; while the later two

are tool Offset numbers 0104 (or 16)

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Note:For details about the tool bit offset, please refer to PANUC OiD/Oi MateD

operator s manual, the relative parts.For turning cylindrical surface, use G42, presumed bit station(OPT) is number

3; for boring turn, use G4l, presumed bit station (OFT) is number 2; cancel toolpost offset, use G40; For example:

G42 GOl X50.O Z50.O FO.2;G40 GOO XiOO.O ZlOO.Q;

G41 GOl X3O.O Z30.O FO.2;G40 GOO X100.O ZlOO.O;The tool bit radius offset value (OFGR) is the actual value of the tool hit

radius R.The presumed bit station (OFT) and the tool bit radius offset value (OFGR)

are set in page of tool offset.1.2.4.4. S code

Spindle speed is set by SDflE~, the spindle electrical gear ratio is setby parameters N23741, N23742, N23743, NQ3744.1.2.4.5. G code

About G code , details refer to FANUC OiD/Oi Mate~-D operator s manual.1.3. PMC LADDER (The sequence control)

The operation sequence have been set before the machine is delivered out,If some of them should be changed, please contact us.1.4. The alarm and diagnose

The operation sequence have been set before the machine is delivered out,If some of them should he changed, please contact us. details refer to FANUCOi MateTD maintenance manual.

The client s alarm message as below:

ADDRESS ALARM MESSAGE~

AO.l EX100I EMERGENCY STOP IS ACTIVATEDAO. 2 EX1002 INVERTER FAULT~

AD. 3 EX1003 LOW LEVEL OIL PUMPAO. 4 EX1004 WON T START WITH THE GUARD OPEN-~

A1.O EX1O1O COOLANT MOTOR OVERLOAD--

Al. 1 EX1O11 TOOL TURRET MOTOR OVERLOAD

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EX1O12 HYDRAUC BUMP MOTOR OVERLOADEX1020 TOOL SINGLE LINES ERROREX1O21 TOOL INDEX OVERTIMEEX1022 NO SUCH TOOLEX1022 TOOL INDEX FAULTEX1O3O WON T START WITH THE CHUCK OPENEX1O31 WONT T RUN WITH THE CHUCK OPENEX1O32 SP IS RUNNING MlOM13 CAN T EXEEX1O33 SP IS RUNNING, MlO13 CAN T EXECEX1O34 CHUCK OPEN, M03 M04 CAN T EXECEX1O4O MACHINE LOCK IS USEDEX1O61 NEED REPLACE CNC BATTERYEX1062 NEED REPLACE APC ABTTERY

1. 5. Repair and maintenance of the electric partsPleElse refer to the attached operation manual for repair and maintenance

of LCD/MDI unit, servo motor, driver module, I/O module, frequency variablemotor and inverter.The regular and daily maintenance of the machine is listed as follows:

~iD the machine should be connected to the ground system independently andreliably in accordance with the standard.

The screws for wire end plugs and sockets and socket should be checkedregularly to avoid to be loosening.

The contact points of the contactor, relay, and stroke limit switches andbuttons should be checked timely.

surge absorber should be checked regularly, if any abnormal phenomenonappears, it should be changed immediately

when the machine is working the cabinet door should be closed, avoiding thechips, oil, water and some other wastes entering it

The inner of the cabinet should be always cleaned, and it must be clean anddry all the time.

Please pay attention to the movement of cooling fans , it should be changed,if it is not normal.1. 6. workable environmentsTemperature: O~45CDampness: ~75%RH (No leak)

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Librat ion: ~O. 50Situation: ~lOOQm(height above sea level) room(no caustic gas and dust, have

a low contain in the air of coolant and organic liquid )Electricity net voltage:

2. Electricity parts listList of Electric Elements (1)Code Name Description ________________________

Ml 1M12

TYPE

P iSVSP 20/2011 A06B6164H2Q2~58O

L~chnica1 dataI 30 ~220V 60Hz

Servo motor P is8/3000 AO6B-OO75-B1O3Servo motor f3 isl2/2000 AO6B0077Bl03

Qty.

30 ~220V 11. 2kW, 7Nm 11. 4kw, llNm 1

FANUC 01 MateTD AO2B032lB500 1

Battery AO6B61l4504 6VDC 1Position encoder 1Pulse generator UFO012Z199 1Handy Puiser OPOperator s panel KDKBO1 1Tower light TPWF773ROG/24V DC24V/AC24V, +1Stabilized PowerVI S-l45-24 AC22OV/DC24v, 145W 1Supply

Spindle motor A06B1446BlOO~QlQ2Ml 7. 5/11kw 1P i I B/l0000sp A06B-l446-B2O0~O1O2

M2 Coolant pump motor 0. 09kW 1M3 Tool turret motor 0. l2kW/Q. 18kW 1M4 Hydraulic pump motor 1. 5kw, +1M6,M7 Cooling fan motor SJ1238HA2 AC22OV,25VA 2E2 Heat Exchanger EA1AF AC22OV, 0. 4A OPM1O Lubricate pump motor AC22OV 1Ml4 Servo module fan AC200V 1MiS Fan motor of serial motor 30, AC200V 1QFl Circuit Breaker DZ1550 50A 1

.~ Miniature0F2 QF4 DZ4763 10, 1A 1+2Circuit Breaker

QF5 Circuit Breaker 3VU16 30, 3652A 10F6 Circuit Breaker DZ1O820 30 46. 3A 1FR1 Overload Relay 3UA59 0. 40. 63A 1FR2 Overload Relay 3UA59 1. 01. 6A 1FR:3 Overload Relay 3UA59 5. 08. OA +1SQl Guard switch QKS8 1SQ~3 Tail limit switch JW211FJ/Wl 1EM1Th, 5 Contactor 3TB40 AC11OV, 9A 3+1

-16-

List of Electric Elements (2)

. Technical dataCode Name Descr].pt]on 1YPE Qty.30 220V 6OFIz

KM4 Contactor 3TF4622 AC11OV, 45A 1

,,. MiniatureKA1 KA14 FIH52PFL DC24V, 1A 5+7Control RelayMiniature

TP58X1 5+7Control Relay baseFU1 Fuse RT14(RT1832) RT14--lOA (16A) 3FU2~5 Fuse RT14(RT18-32) RT14-3A (4A) 2+2

Fuse base RT1832A 5+2EL Machine Light AC22OV, 18W 1VC 1OA +1SA6,SA7 Foot Switch +2lRC1~5 TM3 4+1:3RCr3 SMi 2+1El Surge absorber 1XT5 Terminal strip JH92~5/i5 1XT Terminal strip JF56/7+2. 5/30 1XT2 Fx50B 1

Input: 220VSingle Phase Output: 220V(200VA)TC2 JBK5400TH 1Control Transformer 11OV(l2OVA)

24V (80vA)

-17-

3. appendix3.1 appendix l:FANUC system parameter.. PMC parameter setting

(Note: the sequence of parameter is ~7 ~6 ~5 ~4 ~3 ~2 ~l ~O)PMC PRM ~in~] Description1(3.0 0 0/1 Alarm of CNC battery or APC battery, valid / invalid1(4.0 0/1 0/1 Tool turret of 4T / Tool turret of 6T1(4.1 0 0/1 Without tower light system / With tower light system1(4.2 0/1 0/1 Spindle speed range shift (M directives M41-M44,

Inval icl/Valid1(4.3 0 0/1 Chuck hold the surface of parts / Chuck hold the inner surface1(4. 4 1 0/1 Without tailstock limit system / With tailstock limit system1(4. 5 1 0/1 Without guard door switch / With guard door switch1(4. 6 1 0/1 With variable frequency spindle / Without variable frequency

sp i nd 1 e1(4. 7 0 0/1 Valid the DISPB in the PMC / Invalid the DISPB in the PMCKS Spindle feed rate step1(6.0 0 0/1 Absolute mode / Mechanical return reference point1(6.4 0 0/1 Without turret locked signal / With turreted lock signal

(UNIVERALS AK3O series)1(6.7 0 0/1 Invalid of X. Z axis limited / Valid of X.Z axis limited1(8.0 0 0/1 Without hydraulic chuck / With hydraulic chuckK8.1 0 0/1 Without hydraulic tailstock / With hydraulic tailstock1(8.2 0 0/1 Without chip conveyor / With chip conveyor1(8.3 1 0/1 Without auto lubrication / With auto lubrication1(8. 4 0/1 0/1 Use electric turret / Use gang tools1(8. 5 0 0/1 Invalid of M, S. T AUX function lock / valid (F] button

on the operator s board)1(8. 7 0 0/1 Open the guard door only keeping feed / keeping feed

spindle stop , coolant stop1(9.2 0 0/1 The speed of spindle JOG compare with running speed 15% /25%K9.3 1 0/1 Without serial spindle / With serial spindle1(9. 4 0 0/1 Invalid of the alarm of pressure function / valid of alarm of

pressure1(9. 5 0/1 0/1 Use the MPG on the operator s panel / Use Handy Pulser1(11.0 0/1 0/1 Spindle direction

T04 1200 / 1488 The delay time of tool post reverse (KLS1840N/KL52660N)710 7968 Electric turret, the Max time of change tools (4T,6T)718 496 The delay time of spindle clutch valves activeT2O 496 The delay time of chuck valves active722 496 The delay time of tailstock valves active

- 18-

3, 1. 1. Procedures for parameter setting~ Turn on the parameter writein switch: Select mode switch to MDI. Press

function key ~SET/SETT1~ press [SETTING] soft key at the bottom of thescreen, move thecursorto PARAMETERWRITE , press 1 ,thenpress LINi~1to produce 100 alarm which can be canceled by pressing r~i~ ~

Setting the value of parameter: Press function key~ , then presssoft key [PARAM] to enter the system parameter page. Enter parameter numberNo ____ press the soft key [NO. SRH] at the bottom of the screen, enter theset value ____ press INPUT1 key. With a bit parameter, use ~ key (or ~key) to move the cursor to the relative bit of the parameter, enter 1 (or 0),and press key for revision.

Turn off the parameter writein switch: Move the cursor to PARAMETERWRITE ,press 0 key, press L~PUT , press ~SET key to cancel 100alarm. After parameter setting, if there is a 000 alarm, the machine powermust be cut off. After 3 minutes, turn on the power again.3. 1. 2. Procedure of system K parameter setting

Press function key ~STEM , press [ + ] soft key three times, press softkey [PMCMNT], press soft key [+1, press soft key [KEEPRL] to enter the PMCrelay hold parameter page, that is K parameter page.

If the chuck is to hold the inner surface of a workpiece, use ~] key andkey to move the cursor to #3 of K0004. Enter set value 1 , press INPUT!

key. (Note: the sequence of parameter is #7 #6 #5 #4 #3 #2 #1 #0)3. 1. 3. Procedure of system T parameter setting

Press function key SYST~~ , press [ + ] soft key three times, press softkey [ PMCMNT ], press soft key [ + ], press soft key [TIMER] to enter the PMCtiming parameter page, that is T parameter page.

If the delay time of tool post reverse is to be revised, move the cursor toNo 3 T0004; enter the set value, such as 1200 press JNPUT key.Note: On KEEPRL and TIMER pages, just use PAGE UP and PAGE DOWN

on MD[ panel to turn pages.3.2. Appendix 2: read or write the FUNUC memory card

For the operation of reading or writing FANUC memory card you may refer toFANUC 0iD/Oj MateD maintenance manual.

(Parameter file name:SRAMBAK.OOl;the Ladder file name: PMC1. 000)For example: Copy parameter file from memory card to CNC:

NC power off, open the memory card cover of LCD/MDI unit, put the memory card

-19-

into the slot (the surface with label to left, otherwise it can t be put intothe slot) ;press the two soft keys at the right bottom part of the system screentogether, meantime, turn on the power[press the power switch key ON(greenone)] ; the system is electrified, and show the surveillant picture of system (thefollowing operations can -follow the system s indication) ; press the soft key[DOWN] continuously, move the cursor to 7.SRAM DATA UTILITY; press soft key[SELECT], move the cursor to 2. SRAM RESTORE (MEMORY CARD~CNC) ;press soft key[SELECT], press soft key [YES], press [YES] again; after finishing loading, presssoft key [SELECT] to return to main page; move the cursor to the 1. END ,presssoft key [SELECT], press [YES], the system begins to run; confirm the lathe havea normal work, then cut off the machine power, and remove the memory card.

A~ From CNC~memory card; copy the information from lathe to memory card

parameter: cursor to 7.SRAM DATA UTILITY~[5ELECT]~cursor to 1. SRAMBACKUP (CNC~MEMORY CARD) ~ [SELECT] ~ [YES] ~ [SELECT]

PMC file: cursor to 6. SYSTEM DATA SAVE ~[SELECT]~[ + ]~cursor to47 PMCI ~ [SELECT] -~ [YES] ~ [SELECT] -~cursor to 49 END ~

[SELECT]B~ From memory card ~CNC: copy the information from memory card to lathe

~ parameter: cursor to 7. SRAM DATA UTILITY~ [SELECT] ~cursor to 2. SRAMRESTORE (MEMORY CARD~CNC) [SELECT] * [YES] ~ [YES] [SELECT]

PMC file: cursor to 2. USER DATA LOADING ~ [SELECT] ~~*cursor to PMC1. 000fi ie-~ [SELECT] -~ [YES] -~cursor to END -~ [SELECT]

3.3. Appendix 3: electric elements figure(refer to the parts of electricelements)

3.4. Appendix 4: Operation procedures for copying parts machining programs fromFANUC Oi system to MCARD

3. 4. 1. insert the Mcard into the slot at the left side of the display screen(with the side of label to the left, otherwise it can not be inserted.) Set thesystem parameter No. 204. This indicates data exchange is performed byMcard. (If No. 20=0, this indicates data exchange is performed by RS232C.)

3.4.2. CNC - Mcard operation: (Copy programs from CNC to Mcard.)

~ Output single program: Select EDIT mode Press SYSTEM functional key~Press H] soft key Press [ALL 10] soft key, files in the M-CARD and programin CNC system are displayed.

- 20 -

i/O (PROGRAM) -~

NO. PILE NAME SIZE DATA0001 000880002 ALLPROC. TXT

[PROGRAM]00011 00012 00013

~Press [OPRT] soft key ~Enter needed program name, such as 00011 (Note: thefirst bit is letter 0) -~Press [F OUTPUT] soft key ~Press soft key [EXEC] ~OUTPUT will glimmer at the right bottom of the screen. When the transmitting

is finished, it goes out. The program name in the Mcard is also 00011.

~Output all programs: Select EDIT mode Press function key SYSTEMPress H ] soft key Press [ALL 10] soft key, files in the M-CARD and programsin CNC system are displayed. ~Press [OPRT] soft key ~Enter 0-9999 (Note: Thefirst bit is letter 0, not number 0.) ~ Press [F OUTPUT] soft key ~Press softkey [EXEC] ~ OUTPUT will glimmer at the right bottom of the screen. Whenthe transmitting is finished, it goes out. The program name in the Mcard isALLPROC. TXT.

3.4.3. CNC ~ Mcard operation: (Copy programs from Mcard to CNC.)ED Input single program: Confirm no alarm for the machine ~ Turn the key

switch to OFF position Select EDIT inode.~ Press function key SYSTEM~ Press soft key [ + ] Press soft key [ ALL 10], files in the MCARD andprogram in CNC system are displayed. ~Press [OPRT] soft key Press [F INPUT]soft key ( Read according to file number) ~ Enter needed program s relevantfile number, (for instance, program 00088 s relevant file number is 1),thenenter 1 ~Press [F SET] soft key, the bottom of the screen will display

INPUT FILE NO.= 1PROGRAM NO. =

~-Press soft key [EXEC] INPUT will glimmer at the right bottom of thescreen. When the transmitting is finished, it goes out. The present program inCNC is the input program of the same name.

Input all programs: Confirm no alarm for the machine ~ Turn the keyswitch to OFF position Select EDIT mode ~ Press function key SYSTEM~Press soft key H] Press soft key [ALL 10], files in the M-CARD and programin CNC system are displayed. ~Press [OPRT] soft key Press [F INPUT] softkey ( Read according to file number) ~ Enter all needed program s relevantfile number, (for instance, ALLPROG s relevant file number is 2),then enter2 -~Press [F SET] soft key-~Press soft key [EXEX] -~ INPUT will glimmerat the right bottom of the screen. When the transmitting is finished, it goes

-21 -

out.Caution: When you copy programs from Mcard to CNC, there should not be

any program in CNC which has the same name as the input program. Otherwise analarm will occur.

3. 4. 4. Through PCMCIA card slot on a notebook computer, programs can be directlywrote into or read out from the Mcard.

Remove the CF card from Mcard, through CF card adaptor and USB interfaceon a PC this kind of operation can also be performed.

Caution: File system in Mcard must be of FAT format, otherwise the filecannot be used by CNC. Mcards are all set to FAT format before delivery.

3. 4. 5. If program 00088 in a M-card is re-named by PC as 00088. txt, it can beopened as follows:

Start with [ % j00088 (Program name, the first bit is letter 0)GOOXIOO.ZiOQ. [EOB(;)] No need inputGOlXl5O. Z150. FO. 2 No vacant check between address signsM99

Endwith [%]3. 4. 6. Programs edited on a PC should also adopt the above format. The file nameshould be 0****. txt. After edition, it can be transmitted without being renamedas 0****.

- 22 -

3 I 4 5 I 6 S

Power supply Master switch Servo rnoudle~ Spindle Servo power supply Coolant pump H Tool turret motor I Hydraulic pu~1~ fan fan motorl motor FOR I REV motor (option)

~0

>

JE

m

I I MachineKLS1 840N/KLS2660N

_________ L2-~-- p

pXT

A

02/02

02/83

B

c

Note:For serial spindle

0

03/81

Note: For KLS-1840N / KLS-2660N,FANUC 01 Mate-ID

I

0.0 9kW

1

-M2 -M3 -M~0.l2kW/0.1BkW 0.7SkW/1.5kW

rT ~izrS

tAYDITMARK SCA~~S

slAlCi rcui t Di o.grarn

KLSOi MoteTDOiF

72 3 4 S 6 8

Ci rcui -t iJi agroiiKLSOi MoteIfJ03

E

2~V powar AC24V power AC11OV power AC22OV power~ +24V power NC and servo unit Hydraulic pump Coolant pump I Tool turret motor control Ifor valves for NC turnon I motor control motor control~ FOR REV

01/08

AC11OV120 VA

A

B

04/A6 04/06 04/A2 04/02

C

(+24V) toy)O1/B3 Cl.O1/B301/83 85

0

F

8

IHeat Coohng fan Lubricate Chuck valves conrtol Tailstock valves conrtol I~ Machine light jexchange~ motor I Clamp j Unclamp I Advance Retrac~1

-KA9 -KAio

~17 11/ES 11/ES 17XT -~

03/01 ~ J

03/01--24V powerfor valve

-KA~11/E2

A

03/03

B

C

D

E

Ci rcui lii ~gronKLS-Oi MoteTB04

F

8

1 2 ~ZJ..ZSZ.JZ~Z~~24V power Red lamp Orange lamp Green lamp L TOWER LIGHT

~ 2~V COM (alarm DSP.) )M02/M30 DSP.) (cycle start) I Red Orange I Greeni ___________(option)

Note: For TOWER LIGHT (option)

(option>

-KAiz -KA13 -KAi~

B3 84 84

E

A

B

CES6 (Interface module 1)03/03 03/D3

+24V OV -K~ -KA13 -KAi~V

06 D6 07

- X Ts

60 68 85 86 87 88

-XTs 60 68 85 86 87 88

(balck) Ibalck) (purple) (red) (orange) (green)1Power + Power Purple red orange green

ContinuousCOM

TOWER LIGHT

OICOM5A22 B14 A24 B24 A25 B

024V

z~zEtv.vi

1 2 3

Machine

DRAWN(AuDIT

4

MARK SCALEJMASS

(DATE I I

Circuitljiagrarn FIKLS-Ol~MQ~e~4A~

85 6 7

Li Li

EANUC Oi MateTD (AO2B~-O321B5OO)

XT3~prs

piSVSP 20/2011(AO6B6164H202#580)

A0686078-K814

Position encoder 1

FO6BOO01~KOO6

AO6B-6078-K811

2Cycle Feed MEMX/Z axiol S~rt j hold

Ci rcui -I; lii agrariKLSOi MoteTD06

B

U

E

Feed direction selection*z I z I Chuck Chi conve or control F3 Tail Re id/MPO overridebutton FOR Stop BACK button button FOI~i 25%/~1O 5O%/~~1QO 100% A

F

8

3 I 4 I 5 I 6 8

:1.: ~EJI~7MARK SCALE~1ASS

S~AI

AA

B

Chip F2 P5 CooLant! F4 Tool Spindle control Spindle override Mode selection Fl I MLK asp GOT ORN j SBI~~1~ conveyor

FOR button button button button index CW Stop COW Up I 100% I Down I ZERO I JOG MPG MDI AUTO I EDIT button button! button buttonj button button

T

C

B

C

a

B

MachineKLSl 840 N/KLS2660N

IAUDIT

I I Ci rcui P I ugram FKLSOi MoteTB07

2 3 I 5 6 7 I 8

I Chuck Cycle star~)Feed hold Tail Chip conveyor Iamp~j F2 Coolant Machine NC alarm NC normal X axis z axis L Rapid/MPG override lamo~l[j~np lamp lamp lamp FOR BACK I lamp lamp alarm lamp lamp lamp Zero lamp zero lampi FOI~I I 25%I~1O SO%/~1OO I 1OO~~~

[$6 OnterfaCe modue 2)Y16.O Y16.2 Y16.4 Y17.O Y17.2 Y16.6 Y17.4 Y17.6 Y16.1 Y16.5 Y16.7 Y17.1 Y16.3 Y17.7 Y17.3 Y18.1 Y17,S

A16 A17 A18 A20 jA2l j,A19 1A22 A23 B16 ~B18 B19 jB2l

A

B

C

HLi HLz HL3 HL4 HL5 HLG HLi HL8 HLp HLio HLii HL12 HL13 HL14 HLis HL16 HL17

0

E

Ci rcui -~ Bi agror~KLSOi MoteTB08

F

8

4, 3 5

DOCOM

AOl A24 824 A25 B25

~j2sB~1L+-XSi

(+24V)

Circuit Bi agrcimKLSOi M~teTBO9

- X T4

E

Spindts control Inmps Spindle 50%/~10o Mode selection lamps Fl MLK DSP SOT DRN 581_~_LL~

A0

FANUC O~ MateID operators panel

Uperotor s PanelKLSOi MoteTD16

A

8

C

D

E

FEED RATE OVERRIDE

Note: XT4 connect with Interface module 2 cE57

Note ~XT3 connect with Interface module 2 ~CE56XT3

Interface module 2(Type : A2OB20020521,

[ ~j~JD1A

0MEM PROTECTION

00FEED HOLD CYCLE START EMERI3ENCY STOP

F

8