RS 42, RS 51, RS 65, SR 150, and SR 200 -0009500-0489.pdf · OPERATOR’S MANUAL RS 42, RS 51, RS...

OPERATOR’S MANUAL

RS 42, RS 51, RS 65,

SR 150, and SR 200

MULTI-TASKING CNC LathesEquipped with a GE Fanuc

18i-T or 21i-T Control

Revised: June 4, 2008

Manual No. M-489 Litho in U.S.A.Part No. M -0009500-0489 February, 2007

TP7485

- NOTICE -

Damage resulting from misuse, negligence, or accident is not covered by theHardinge Machine Warranty.

Information in this manual is subject to change without notice.

This manual covers the operation of Hardinge RS and SR seriesMulti-Tasking CNC lathes equipped with a GE Fanuc 18i-T or 21i-T control.

In no event will Hardinge Inc. be responsible for indirect or consequentialdamage resulting from the use or application of the information in this man-ual.

Reproduction of this manual in whole or in part, without written permissionof Hardinge Inc., is prohibited.

CONVENTIONS USED IN THIS MANUAL

- WARNINGS -

Warnings must be followed carefully to avoid the possibility of personal injuryor damage to the machine, tooling, or workpiece.

- CAUTIONS -

Cautions must be followed carefully to avoid the possibility of damage to themachine, tooling, or workpiece.

- NOTES -

Notes contain supplemental information.

Hardinge Inc.One Hardinge Drive

P.O. Box 1507Elmira, New York 14902-1507 U.S.A.

www.hardinge.com

© 2007, Hardinge Inc. M-489

READ COMPLETE INSTRUCTIONS CAREFULLYBEFORE OPERATING MACHINE OR BAR FEED SYSTEM

When this instruction book was printed, the information given was current. However, since we areconstantly improving the design of our machine tools and bar feed systems, it is possible that the illus-trations and descriptions may vary from the machine or bar feed system you received.

- CHEMICAL HAZARD WARNING -

Occupational Safety and Health Administration (OSHA) Hazard Communica-tion Standard 1910.1200, effective May 25, 1986, and various state “employeeright-to-know laws” require that information regarding chemicals used withthis equipment be supplied to you. Refer to the applicable section of the Mate-rial Safety Data Sheets supplied with your machine when handling, storing, ordisposing of chemicals.

- BAR FEED WARNING -

Machine should only be used with a bar feed approved by Hardinge Inc.

- SPINDLE AND AXIS WARNING -

Non-CE Mark machines allow the main guard door to be opened while the ma-chine is in operation. The spindle(s) and axes will automatically decelerate andstop, but the potential for injury exists until all spindle and axis motionceases.

- SPINDLE TOOLING WARNING -

Hardinge HQC (Quick-Change) collets MUST NOT be used in applicationswhere the spindle is rotating without a bar or workpiece in the collet.

Rotating the spindle without a bar or workpiece in the Hardinge HQC colletcan result in the collet head being expelled from the spindle.

Failure to comply with this warning can result in serious injury or death.

M-489 i

HARDINGE SAFETY RECOMMENDATIONS

Your Hardinge machine is designed and built for maximum ease and safety of operation. However,some previously accepted shop practices may not reflect current safety regulations and procedures,and should be re-examined to insure compliance with the current safety and health standards.

Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tooloperators be advised of the importance of safe maintenance, setup, and operation of Hardinge equip-ment. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONSBEFORE PROCEEDING ANY FURTHER.

READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation ormaintenance of the machine. Make certain that you understand all instructions.

DON’T ALLOW the operation or repair of equipment by untrained personnel.

CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.

WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When necessary,wear respirator, helmet, gloves, and ear muffs or plugs.

DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly performed andthe equipment is known to be in good working order.

WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and informa-tion. Do not remove them.

DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other safetydevice.

DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration oc-curs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any dam-aged parts.

REDUCE SPINDLE SPEED if vibration occurs. Bar stock straightness will have an effect on vi-bration and balance of the spindle system.

NEVER OPERATE THE MACHINE SPINDLE without a work-holding device if the draw tube isin the spindle.

TIGHTEN ALL DRAW TUBE SCREWS before beginning spindle operation.

MAKE CERTAIN that the equipment is properly grounded. Consult National Electric Code andall local codes.

DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.

ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electricalequipment.

ii M-489

DON’T REACH into any control or power case area unless electrical power is OFF.

DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wetsurface.

REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.

ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before re-starting the machine.

KEEP THE AREA AROUND THE MACHINE well lighted and dry.

KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment.

HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustiblematerial and keep chips clear of the work area.

DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.

MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors are closed and se-cured.

TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at theleft end of the machine. Make certain that the guard door is in place before starting the ma-chine.

DON’T OPEN GUARD DOORS while any machine component is in motion.

MAKE SURE chucks, closers, fixture plates, and all other spindle-mounted work-holding de-vices are properly mounted and secured before starting the machine.

MAKE CERTAIN all tools are securely clamped in position before starting the machine.

REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before operat-ing the machine. Always check the machine and work area for loose tools and parts especiallyafter work has been completed by maintenance personnel.

REMOVE CHUCK WRENCHES before starting the machine.

BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that proper functionsare programmed and that all controls are set in the desired modes.

KNOW WHERE ALL stop push buttons are located in case of an emergency.

CHECK THE LUBRICATION OIL LEVEL and the status of the indicator lights before operatingthe machine.

MAKE CERTAIN that all guards are in good condition and are functioning properly before oper-ating the machine.

M-489 iii

INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condi-tion and are functioning properly before the cycle is started.

CHECK THE POSITION of the tool top plate before pressing the Cycle Start push button.

CHECK THE POSITION of any load/unload automation before pressing the Cycle Start pushbutton.

CHECK SETUP, TOOLING, AND SECURITY OF THE WORKPIECE if the machine has beenOFF for any length of time.

DRY CYCLE a new setup to check for programming errors.

MAKE CERTAIN that you are clear of any “pinch point” created by moving slides before startingthe machine.

DON’T OPERATE any equipment while any part of the body is in the proximity of a potentiallyhazardous area.

DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain that allmachine movements have ceased.

BE CAREFUL of sharp edges when handling a newly machined workpiece.

DON’T REMOVE OR LOAD a workpiece while any part of the machine is in motion.

DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, neck-ties, or long hair not contained by a net or shop cap.

DON’T ADJUST tooling or coolant hoses while the machine is running.

DON’T LEAVE tools, workpieces or other loose items where they can come in contact with amoving component of the machine.

DON’T CHECK finishes or dimensions of workpiece near running spindle or moving slides.

DON’T JOG SPINDLE in either direction when checking threads with a thread gage.

DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.

ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge Inc.must be reviewed by a qualified safety engineer before installation.

USE CAUTION around exposed mechanisms and tooling especially when setting up. Be care-ful of sharp edges on tools.

DON’T USE worn or defective hand tools. Use the proper size and type for the job being per-formed.

iv M-489

USE ONLY a soft-faced hammer on tooling and fixtures.

DON’T USE worn or broken tooling on machine.

MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.

INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operating con-dition. Replace any defective chuck before operating the machine.

Hardinge high speed spindles are balanced to an ISO G1.0 standard. High speed spindles re-quire a work-holding device balanced to G2.5 or better.

USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider weight, shape, andbalance of the workpiece.

USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece diam-eter that is larger than the gripping diameter.

DON’T EXCEED the rated capacity of the machine.

DON’T LEAVE the machine unattended while it is operating.

DON’T CLEAN the machine with an air hose.

KEEP TOTE PANS a safe distance from the machine. Don’t overfill the tote pans.

DON’T LET STOCK project past the back end of the collet closer or machine spindle withoutbeing adequately covered and properly supported.

FOLLOW each bar feed manufacturer’s guidelines. For performance and safe application, sizeand use feed tube bushings, pushers, and spindle liners according to bar feed information.

MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the barfeed is a floor-mounted type, it must be securely bolted to the floor.

DURING HIGH SPEED APPLICATIONS, the bar stock must be contained within the colletcloser and a bar feed not be used. Hardinge Inc. Recommends using a bar loader for feedingbar stock during high speed applications. Bar loaders feed the entire piece of bar stock into thespindle; then, the pusher is disengaged from the bar stock.

UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per-formed by one person. To avoid injury to yourself and others, be sure that all personnel areclear of the machine when opening or closing the coolant guard door and any access covers.

FOR YOUR PROTECTION - WORK SAFELY

M-489 v

- NOTES -

vi M-489

Table of Contents

CHAPTER 1 - OPERATOR CONTROL PANELS

Control Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Manual Data Input Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Control Interface Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17Stack Light [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18On-Line Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19P/S Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Methods of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Accessing the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Alarm Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Operation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Exiting the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

CHAPTER 2 - POWER-UP, POWER-DOWN, AND CONTROL STATUS

Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Reviewing Control Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Position Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Program Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Offset Setting Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5System Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Message Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

CHAPTER 3 - OPERATIONAL MODES AND EDITING

Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Single Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Word Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Word Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Editing a Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Altering a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Inserting a Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Deleting a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Deleting Up to an End of Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Deleting Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Deleting a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Edit Slow Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Continuous Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Incremental Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

M-489 vii

Manual Data Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Safe Start Subprograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Main Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Sub-Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Entering a Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . . . . 3-10Activating a Stored Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Running a Part Program for the First Time . . . . . . . . . . . . . . . . . . . . . . 3-11Stopping a Program Running in Automatic Mode. . . . . . . . . . . . . . . . . . . 3-12Restarting a Stopped Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Dry Run and Machine Lock Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Activating Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . 3-13Exiting Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Background Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Activating Background Edit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Editing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Creating a New Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . 3-14Ending Background Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Extended Part Program Editing [Option] . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Copy an Entire Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Copy Part of a Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Move Part of a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Merge a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Search and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Editing Machine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Displaying the Program Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

CHAPTER 4 - ESA TURRET TOP PLATE TOOLING

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Top Plate Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Tool Holder or Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Turret Top Plate Cleaning Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Tool Station Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Tool Station Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Square Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Reversible Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Installing Square Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Round Shank Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Tool Holder Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Maximum Z Axis Tool Extension for Sub-Spindle Operation . . . . . . . . . . . . . 4-11Installing Round Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

viii M-489Revised: June 4, 2008

CHAPTER 5 - VDI TURRET TOP PLATE TOOLING

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Top Plate Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Turret Tooling Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Tool Holder or Tool Station Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . 5-3Tool Station Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Square Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Reversible Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Installing Square Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Round Shank Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Tool Holder Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Maximum Z Axis Tool Extension for Sub-Spindle Operation . . . . . . . . . . . . . 5-9Installing Round Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Square Shank Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Main Spindle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Qualified Tool Holders for Main Spindle Operation . . . . . . . . . . . . . . . . 6-1Left-Hand / Right-Hand Tool Selection . . . . . . . . . . . . . . . . . . . . . . 6-2Installing Square Shank Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Between-Center Turning on RS 42 Lathes . . . . . . . . . . . . . . . . . . . . 6-4

Sub-Spindle Operation [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Cut-Off Tool Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Tooling Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Tooling Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Tool Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Tool Shank Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Mounting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Round Shank Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Round Shank Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Tool Setting Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Installing Round Shank Tools for Main Spindle Operation . . . . . . . . . . . . . . 6-10Installing Round Shank Tools for Sub-Spindle Operation. . . . . . . . . . . . . . . 6-12

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

CHAPTER 7 - WORK SHIFT

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Manually Establishing Z Axis Work Shift . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

VDI or ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Hardinge Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

M-489 ixRevised: February 5, 2008

CHAPTER 8 - TOOL OFFSETS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Storing Tool Geometry Offsets in Memory . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Setting Tool Offsets for Non-Center Working Tools on the Turret . . . . . . . . . . 8-9Setting Tool Offsets for Center-Working Tools on the Turret . . . . . . . . . . . . . 8-12

Tool Probe [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Manual Tool Probe Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14Semi-Automatic and Automatic Tool Probe Operation . . . . . . . . . . . . . . . . 8-16

Datuming the Tool Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16Tool Probe Datum Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Semi-Automatic Tool Probe Operation . . . . . . . . . . . . . . . . . . . . . . 8-19Automatic Tool Probe Operation . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Tool Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21Entering Tool Nose Radius Value and Orientation Code . . . . . . . . . . . . . . . . . 8-22Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Adjusting X and Z Axis Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . 8-23Rules for Adjusting Wear Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1Spindle Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2Hydraulic Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Adjusting the Main Spindle Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . 9-3Main Collet Closer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Chucking Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5Switching the Chucking Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Cleaning the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

RS 42, RS 51, SR150, and SR 200 Lathes . . . . . . . . . . . . . . . . . . . . . . 9-6Removing Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6Installing Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Collet or Step Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8Jaw Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

SR 200 BB (Big Bore) Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12Removing the Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12Installing the Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Spindle Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17Spindle Liner Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17Spindle Liner Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Boring a Bushing to Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18Installing or Removing the Spindle Liner . . . . . . . . . . . . . . . . . . . . . . . 9-19

x M-489Revised: February 5, 2008

CHAPTER 10 - TAILSTOCK

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Tailstock Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Fixed Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2Adjustable Home Position (Retract). . . . . . . . . . . . . . . . . . . . . . . . . . 10-2Rapid-to-Feed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2Overtravel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Tailstock Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Cycle Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Overtravel Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Tailstock Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Initiating Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Stopping Manual Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Programmed Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5Initiating Programmed Movement . . . . . . . . . . . . . . . . . . . . . . . . . 10-5Stopping Programmed Movement. . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Checking and Adjusting Tailstock Feedrate . . . . . . . . . . . . . . . . . . . . . . . 10-7Checking and Adjusting Tailstock Force . . . . . . . . . . . . . . . . . . . . . . . . . 10-8Removing and Installing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Removing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9Installing a Live Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

CHAPTER 11 - SUB-SPINDLE AND COLLET CLOSER [Option]

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1Cycle Start Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1Free Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1Controlling Sub-Spindle Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Automatic, Manual Data Input, or Single Mode . . . . . . . . . . . . . . . . . . . . 11-2E Data Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2Feedrate Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3Axis Direction Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Feedrate Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3Rapid Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3Moving the Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Handwheel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3Moving the Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4Removing Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4Installing Sub-Spindle Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Collet or Step Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6Jaw Chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

Sub-Spindle Collet Closer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10Hydraulic Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

Adjusting the Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 11-11Sub-Spindle Collet Closer Operation . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12Chucking Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Switching the Chucking Mode . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

M-489 xi

Main and Sub-Spindle Machining Set-Up and Operation. . . . . . . . . . . . . . . . . 11-13Sample Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

Set Up and Machine Main Spindle Operation . . . . . . . . . . . . . . . . . . . 11-14Set Up and Machine Sub-Spindle Operation . . . . . . . . . . . . . . . . . . . 11-15

CHAPTER 12 - VDI LIVE TOOLING [Option]

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Types of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Adjustable Dead Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2Live Tooling Collets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3Live Tooling RPM Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3Live Tooling Attachment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

Mounting the Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5Installing / Removing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

Live Tooling Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10Cross-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10End-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10Setting Tool Offsets for Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 12-11

Setting Offsets for End-Working Tools . . . . . . . . . . . . . . . . . . . . . . 12-11Setting Offsets for Cross-Working Tools . . . . . . . . . . . . . . . . . . . . . 12-13

Tool Nose Radius Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14Live Tooling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14Live Tooling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

CHAPTER 13 - ESA LIVE TOOLING [Option]

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1Live Tool Attachment or Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 13-1Types of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2Live Tooling Collets and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2Live Tooling Attachment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

Mounting the Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3Installing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6

Maximum Tool Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6Tool Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7

Live Tooling Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8Cross-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8End-Working Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8Setting Tool Offsets for Live Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 13-9

Setting Offsets for End-Working Tools . . . . . . . . . . . . . . . . . . . . . . 13-9Setting Offsets for Cross-Working Tools . . . . . . . . . . . . . . . . . . . . . 13-11

Tool Nose Radius Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12Live Tooling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12Live Tooling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12

xii M-489Revised: June 4, 2008

CHAPTER 14 - TOOL LIFE MANAGEMENT

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Tool Life Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Number of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Amount of Machining Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Tool Life Management Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2Bar Feed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

Determining Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . 14-3Verifying Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . 14-3Setting Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . . . . 14-3

Determining the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5Verifying the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5Switching the Measurement Unit . . . . . . . . . . . . . . . . . . . . . . . . . 14-5

Resetting a Tool Group Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6

CHAPTER 15 - INPUT/OUTPUT DEVICES

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Input/Output Device Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Input/Output Device Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

I/O Channel 0, 1, or 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2I/O Channel 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

RS-232 Serial Port (NC Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3Data Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Tape Parity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3Stop Bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Checking and Modifying Communications Parameters . . . . . . . . . . . . . . . . 15-4RS-232 Port Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Baud Rate Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5Stop Bit Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6RS-232 Serial Port (NC Data). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Uploading Data through the RS-232 Port . . . . . . . . . . . . . . . . . . . . . 15-6Uploading Control Parameters into Control Memory. . . . . . . . . . . . . . 15-6Uploading Part Programs into Control Memory . . . . . . . . . . . . . . . . 15-7Uploading Tool Offsets into Control Memory . . . . . . . . . . . . . . . . . 15-8

Downloading Data through the RS-232 Port . . . . . . . . . . . . . . . . . . . 15-9Downloading Control Parameters from Control Memory. . . . . . . . . . . . 15-9Downloading Part Programs from Control Memory . . . . . . . . . . . . . . 15-10Downloading Tool Offsets from Control Memory . . . . . . . . . . . . . . . 15-11

ATA Flash Card Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

M-489 xiii

CHAPTER 16 - OPTIONS AND MISCELLANEOUS FEATURES

Machine Run Time Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1Accessing the Run Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1Resetting the Run Time Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . 16-1

Machine Cycle Time Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1Accessing the Cycle Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Clock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2Resetting the Clock Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2

Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3Accessing the Parts Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . 16-3Resetting the Parts Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . . . 16-3

Thread Cutting Cycle Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4High Pressure Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4Bar Feed Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4English / Metric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5

Establishing English / Metric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5Axis Thrust Limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6Monitoring Axis Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6

Accessing the Axis Servo Tune Page . . . . . . . . . . . . . . . . . . . . . . . 16-7Adjusting Axis Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8

Parts Catchers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9Main Spindle Parts Catcher [Option] . . . . . . . . . . . . . . . . . . . . . . . . . 16-9

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9Parts Catcher Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9Typical Part Unload Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9Adjusting the Parts Catcher for Part Length . . . . . . . . . . . . . . . . . . . . 16-10Adjusting the Parts Catcher Extend / Retract Speeds. . . . . . . . . . . . . . . 16-11

Sub-Spindle Parts Catcher [Option]. . . . . . . . . . . . . . . . . . . . . . . . . . 16-12Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12Parts Catcher M Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-14Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-14Parts Catcher Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-15

Boring the Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-15Changing the Gripper Pads . . . . . . . . . . . . . . . . . . . . . . . . . . 16-16

Part Probe [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17Set-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17Datum the Part Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19

Datuming the Part Probe on the X Axis . . . . . . . . . . . . . . . . . . . . . . 16-19Datuming the Part Probe on the Z Axis . . . . . . . . . . . . . . . . . . . . . . 16-20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21Cleaning the Probe and OMM Unit Windows . . . . . . . . . . . . . . . . . . . . . 16-22Changing the Probe Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23

Sub-Spindle Part Present Detector [Option] . . . . . . . . . . . . . . . . . . . . . . . 16-24Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-24Extending the Part Present Detector . . . . . . . . . . . . . . . . . . . . . . . . . 16-25Range of Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25

xiv M-489

CHAPTER 17 - OPERATOR MAINTENANCE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Machine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Draining the Air Filter Bowls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Adjusting the Machine Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 17-2

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3Standard Hydraulic Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3

Filling the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3Hydrostatic Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4

Filling the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5Tramp Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-6Chip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7

APPENDIX ONE

Turret Travel SpecificationsX and Z Axes

ESA Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1VDI 30 Turret Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2Hardinge Turret Top Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3

Y Axis [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4Tailstock Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-5Sub-Spindle Travel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-5Work Envelope for Turning

Machine Equipped with Tailstock and ESA Turret Top Plate . . . . . . . . . . . . . A1-6Machine Equipped with Tailstock and VDI 30 Turret Top Plate. . . . . . . . . . . . A1-7Machine Equipped with Tailstock and Hardinge Turret Top Plate . . . . . . . . . . A1-8Machine Equipped with Sub-Spindle and ESA Turret Top Plate . . . . . . . . . . . A1-9Machine Equipped with Sub-Spindle and VDI 30 Turret Top Plate . . . . . . . . . . A1-10Machine Equipped with Sub-Spindle and Hardinge Turret Top Plate. . . . . . . . . A1-11

Sample Tooling Layouts12 Station ESA Turret. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1212 Station ESA Turret with Live Tooling . . . . . . . . . . . . . . . . . . . . . . . A1-1310 Station VDI 30 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1410 Station VDI 30 Turret with Live Tooling . . . . . . . . . . . . . . . . . . . . . . A1-1512 Station VDI 30 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1612 Station VDI 30 Turret with Live Tooling . . . . . . . . . . . . . . . . . . . . . . A1-1716 Station VDI 30 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-1816 Station VDI 30 Turret with Live Tooling . . . . . . . . . . . . . . . . . . . . . . A1-1912 Station Hardinge Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-20

Spindle Torque and Horsepower CurvesMain Spindle

RS 42 Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-21RS 51 and SR 150 Lathes

High Speed Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-22Low Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-23

RS 65 and SR 200 Lathes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24SR 200 BB Lathes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-25

Sub-Spindle [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-26Live Tooling (ESA and VDI 30 Turret Top Plates) . . . . . . . . . . . . . . . . . . A1-27

M-489 xvRevised: February 5, 2008

APPENDIX TWO

G Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1M Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-14

xvi M-489

- NOTES -

M-489 xvii

- NOTES -

xviii M-489

CHAPTER 1 - OPERATOR CONTROL PANELS

CONTROL DISPLAY PANEL

The control display panel is shown in Figure 1.1. The panel consists of the display screen with as-sociated soft keys.

- NOTE -

The operator can select CNC soft key functions through the use the soft keys or di-rectly by touching the soft key functions displayed on the screen.

SOFT KEYS

The ten unlabeled soft keys have various functions, depending on which function key isactive. The function keys are located on the Manual Data Input panel. The soft key functionsare displayed at the bottom of the control display screen.

LEFT-HAND SOFT KEY

This key is used to return to the initial state after a function has been accessed by press-ing a soft key.

RIGHT-HAND SOFT KEY

This key is used to display additional soft key functions that are not currently displayed.

M-489 1-1

Figure 1.1 - Control Display Panel

TP7302

MANUAL DATA INPUT KEYBOARD

The available Manual Data Input panels are shown in Figures 1.2 and 1.3. This panel consists ofkeys relating to data input, data editing, and monitoring control functions.

ALTER

This key permits changes to an existing entry in an active program while in Edit mode.Refer to Edit mode in Chapter 3.

CAN (Cancel)

This key is used to cancel or delete the last character or symbol which has been enteredinto the input buffer. It is also used, together with the appropriate function key, to clear thedata displayed on the screen.

CURSOR CONTROL KEYS

The � and � cursor control keys will shift the cursor forward or backward through theprogram one data word at a time.

The � and � cursor control keys will shift the cursor forward or backward through theprogram one data block (program line) at a time.

CUSTOM

This key has no function on the standard operator interface.

DATA INPUT KEYS

- NOTE -

Most alphabetic keys on the Manual Data Input keyboard are used to input morethan one character. The input from an alphabetic key is switched through the use ofthe Shift key.

These keys are used to manually enter data into the control. These keys input alphabetic,numeric, and other characters. In addition to these keys, the Alter, Insert, Delete, Input, EOB(End of Block), and Cancel keys are active. Data entered with the data input keys is indi-cated on a line near the bottom of the display screen.

1-2 M-489

DELETE

This key causes the selected data to be deleted. Refer to Edit mode in Chapter 3 for in-formation on using the delete function.

EOB

This key is used to input an End of Block (;) character.

GRAPH

This key is used to graphically display the tool path while the program is being executed.Machine motion will occur unless Machine Lock mode is active.

Refer to the GE Fanuc operator’s manual for a description of the graphics feature.

INPUT

This key is used to set data, which has been entered into the input buffer area, into theappropriate area in the control memory. Refer to Manual Data Input mode in Chapter 3.

INSERT

This key allows additional commands to be inserted in a program line while in Edit mode.Refer to Edit mode in Chapter 3.

HELP

This key allows the operator to access the machine on-line help system. Refer to page1-19 for information relating to the on-line help system.

MESSAGE

This key allows the operator to display alarm messages and operator messages issuedby the machine control due to NC programming errors or machine hardware failures.

OFFSET SETTING

This key allows the setting and display of offset values. Refer to:

Reviewing Control Status, in Chapter 2

Chapter 4 - Work Shift and Tool Offsets

M-489 1-3

1-4 M-489

Figure 1.2 - Manual Data Input Panel(Non-CE Mark Machines)

TI3818

Figure 1.3 - Manual Data Input Panel(CE Mark Machines)

TI3874

PAGE UP KEYS

PAGE DOWN KEYS

The Page keys are used to display information which requires more than one displaypage. Pressing Page � or Page � causes the control the display the previous or next page,respectively.

POS (Position)

Pressing the Position key will display the position data in one of three ways:

1. In the absolute mode of the work coordinate system by pressing the Absolute soft key.

2. In the relative coordinate system by pressing the Relative soft key.

3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to go, bypressing the All soft key.

Use the Page keys to switch between the various position display screens. Refer toChapter 2 for more information on the position display screens.

PROG (Program)

The Program function key allows the operator to perform the following:

In Edit mode - Edit and display program memory.In Manual Data Input mode - Input and display Manual Data Input data.In Automatic mode - Display the active part program.

RESET

This key can be activated any time while a part program is being executed. When the Re-set key is pressed, axis and spindle motion are stopped. The M and G codes are reset tothe power-up default status. The Reset key is also used to clear an alarm state after a faulthas been corrected.

- NOTE -

To return to the start of a main part program, select Edit mode and press Reset.

SYSTEM

This key allows the setting and display of parameters and diagnostic data. Refer to Chap-ter 2 for more information on the diagnostic and parameter screens.

M-489 1-5

OPERATOR CONTROL PANEL

- NOTE -

The functions described in this section are listed according to location on the opera-tor control panel, from left to right. Refer to Figure 1.4.

MISCELLANEOUS FUNCTIONS

AUX (Auxiliary)

No function.

COOLANT ON/OFF

This push button controls standard coolant operation. If coolant flow has been activatedby a programmed M08 (Coolant ON), M13 (Spindle Forward/Coolant ON), or M14 (SpindleReverse/Coolant ON), pressing this push button will stop the coolant flow. If coolant flow hasnot been activated by the program, pressing this push button will start coolant flow eventhough an M08, M13 or M14 has not been programmed. However, if the program is re-peated the push button will not be active. The indicator light is illuminated when this functionis active.

PARTS CATCHER

This push button allows the operator to alternately extend and retract the main spindleparts catcher when the machine is in Jog mode. The indicator light is illuminated when theparts catcher is extended toward the spindle.

Refer to page 16-9 for additional information on the main spindle parts catcher.

TOOL PROBE

This push button allows the operator to alternately deploy and stow the optional toolprobe when the machine is in Jog mode.

Refer to page 8-14 for additional information on the tool probe.

1-6 M-489

SPECIAL MODES

BLOCK SKIP

Press this push button to alternately activate and deactivate Block Skip mode. When thismode is active, the control will ignore any data block preceded by a slash (/) code. The indi-cator light is illuminated when Block Skip is active.

DRY RUN

- NOTE -

This mode must be OFF for normal machine operation.

Press this push button to alternately activate and deactivate Dry Run mode. When thismode is active, programmed feedrates are ignored and cutting moves are performed at aJog feedrate of 50 inches per minute. The indicator light is illuminated when Dry Run is ac-tive. Refer to Chapter 3 for information on using Dry Run mode.

G00

This push button is a momentary switch. Pressing this push button releases the Edit Slowfeature. Refer to Chapter 3 for information on Edit Slow mode.

M-489 1-7

9

INDEX

TURRET STATION

1

2

3

54

67 8

16

13

1110

12

15

14

MACHINE

00 1

POWER

1

PROGRAM

1

PROTECT

0

MANUAL AXIS MOVEMENT

C1

X

Z

C2

Y

E

FANUC

- +

0

Z/ERAPIDTRAV

X/Y

X/Y

Z/E

OPEN/CLOSE

OPEN/CLOSE

SINGLE

AUTO

MDI

RAPID RD REF

MACHINE MODES

JOG

EDIT

REFRAPID

%% FEED RD RATE OVERRIDE

80

0%

20

40

60

150

F

120

100

140

FEEDHOLDSTART

CYCLE

% RAPID OD OVERRIDEF %

25

LOW1X 50

100

100X10X

PROGRAM SOURCE

DNCMEM AUX

CW

DECFREEMAIN

1

FREESUB

2

SUB

1

MAIN

2

INC

CCW

RUNDRY

BLOCKSKIP

MODEREPEAT

G00

STOPOPTION MACHINE

LOCK

AUX

ON/OFFCOOLANT

TOOLPROBE

PARTCATCHER

Figure 1.4 - Operator Control Panel TI5494

A

B

C

MACHINE LOCK

- NOTE -

This mode must be OFF for normal machine operation.

Press this push button to alternately activate and deactivate Machine Lock mode. Whenthis mode is active, all axis and spindle motion is inhibited. M, S, and T functions are alsoinhibited. The indicator light is illuminated when Machine Lock is active. Refer to Chapter 3for information on using Machine Lock.

OPTION STOP

- CAUTION -

It is the responsibility of the part programmer to program the appropriate com-mand to restart the spindle and coolant when program execution is resumedafter an Option Stop.

Press this push button to alternately activate and deactivate Option Stop mode. This func-tion causes the control to stop execution of the part program AFTER executing an activeblock which contains an M01 code. The M01 code is ignored when Option Stop is not ac-tive. This function may be activated before or during execution of the block containing theM01 code. The indicator light is illuminated when Option Stop is active. When a block con-taining an M01 code is encountered and this function is active, the following occurs:

The block is executed.

All slide motion and spindle motion stops.

The coolant pump turns OFF and Feed Hold turns ON.

Option Stop can be activated in Dry Run mode. To resume program execution, press theCycle Start push button. The Feed Hold push button light will turn OFF.

REPEAT MODE

Press this push button to alternately activate and deactivate Repeat mode. This functioncauses the active part program to cycle continuously. The indicator light is illuminated whenRepeat is active.

1-8 M-489

SPINDLE CONTROL

MAIN SPINDLE / SUB-SPINDLE

When Jog mode is active, this switch allows the operator to select the main spindle orsub-spindle as the spindle to be controlled by the push buttons in the Spindle area of themachine control panel.

MAIN SPINDLE FREE

Press this push button to alternately activate and deactivate Main Spindle Free. WhenMain Spindle Free is activated, the spindle brake is released and the operator may rotatethe main spindle by hand when Cycle Start is NOT active. The indicator light is illuminatedwhen Main Spindle Free is active.

SPINDLE CCW / SPINDLE CW

This switch allows the operator to select the direction for non-programmed spindle mo-tion (as viewed from the main spindle end of the machine) when the machine is in Jogmode. The spindle speed is controlled with the Spindle Increase Override and SpindleDecrease Override push buttons. The push button indicator light is illuminated when one ofthese functions is active.

SPINDLE INCREASE OVERRIDE

SPINDLE DECREASE OVERRIDE

These push buttons have two applications:

1. Controlling spindle speed for non-programmed clockwise or counterclockwise spindle motion:

A) Set the machine mode selector switch to Jog mode.

B) Use the Main Spindle / Sub-Spindle switch to select the appropriate spindle.

C) Use the Spindle CCW / Spindle CW switch to select the desired direction of rotation.

D) Initiate spindle rotation by pressing the Spindle Increase Override push button and releaseto begin spindle motion. The first time this switch is pressed and released, the spindle speedwill begin rotating at approximately 25 rpm.

Use the Spindle Increase Override push button to increase spindle speed. The spindlespeed will increase by approximately 25 rpm each time this key is pressed.

Press the Spindle Decrease Override push button to slow the spindle.

E) To stop spindle motion, press the Reset key or press and hold the Spindle DecreaseOverride push button until spindle motion ceases.

M-489 1-9

1 2

1

2. Override programmed spindle speed while spindle is active in Auto mode:

Press the Spindle Decrease Override push button and release to decrease the spindlespeed in ten percent increments to a minimum of 50%. This push button is illuminatedwhen actual spindle speed is lower than the programmed spindle speed.

Press the Spindle Increase Override push button and release to increase the spindlespeed in ten percent increments to a maximum of 120%. This push button is illuminatedwhen actual spindle speed is higher than the programmed spindle speed.

Press the Spindle Increase Override and Spindle Decrease Override push buttons simul-taneously to cancel the override function. The spindle speed will return to the pro-grammed rate.

SUB-SPINDLE FREE

Press this push button to alternately activate and deactivate Secondary Spindle Free.When Secondary Spindle Free is activated, the spindle brake is released and the operatormay rotate the secondary spindle by hand when Cycle Start is NOT active. The indicatorlight is illuminated when Secondary Spindle Free is active.

PROGRAM SOURCE

MEM

Programs stored in the control memory will be executed.

DNC

Programs stored on a computer that is linked to the machine control will be executed.

AUX

No function.

% FEEDRATE OVERRIDE

The Feedrate Override switch has a dual function. Depending on which mode has beenselected, the functions are as follows:

In Jog mode, the jog feedrate can be modified in predefined steps from 0 - 50 in/min[1270 mm/min].

In all other modes, the operator can modify programmed feedrates from 0% - 150%. Asetting of “0" will stop G01, G02, & G03 motion.

1-10 M-489

2

%F

% RAPID OVERRIDE

The Rapid Override switch has a dual function. Depending on which mode has been se-lected, the functions are as follows:

In Jog mode, the operator can select the jog increment to be active when moving anaxis with the manual pulse generator. The movement distance per division on the manualpulse generator is:

LINEAR AXES (E, X, Y1, Z)

X1 = .0001 inches [.001 millimeters]X10 = .001 inches [.01 millimeters]X100 = .01 inches [.1 millimeters]

ROTARY AXES (C1, C2)

X1 = .001 degreeX10 = .01 degreeX100 = .1 degree

In all other modes, the operator can modify the machine Rapid Traverse rate in stepsfrom Low to 100%. It is active in Positioning Mode (G00). The Rapid Override switch con-trols the E, X, Y, and Z axes.

CYCLE START

This push button is a latching type switch that initiates program execution when the con-trol is in Automatic mode or Single mode. An additional function of this switch is to executeManual Data Input commands. This push button is illuminated when Cycle Start is active.

FEED HOLD

This push button is a latching type switch that allows the operator to stop all programmedslide motion. However, the active spindle speed is not affected. Feed Hold can be activatedwhile in Automatic, Single Block, or Dry Run modes. Cycle Start turns OFF when Feed Holdis activated. To resume normal operation after a feed hold, press Cycle Start. This push but-ton is illuminated when Feed Hold is active.

M-489 1-11

F %

EMERGENCY STOP

- CAUTION -

DO NOT use the Emergency Stop push button to stop spindle rotation unlessan emergency actually exists.

- NOTE -

The operator must wait approximately ten seconds from the time the EmergencyStop push button is pressed before attempting to clear the Emergency Stop.

Emergency Stop push button “A”, Figure 1.4, is a latching type switch. When pressed,programmed slide motion and spindle rotation are stopped. The message “Emergency Stop”is displayed on the control screen. To return to normal operation:

1. Correct the problem that prompted the Emergency Stop condition.

2. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.

SUB OPEN / CLOSE

Pressing this push button while Cycle Start is NOT active will cause the work-holding de-vice in the secondary spindle to alternately open and close. The push button will blink whenthe work-holding device is open.

MAIN OPEN / CLOSE

Pressing this push button while Cycle Start is NOT active will cause the work-holding de-vice in the main spindle to alternately open and close. The push button will blink when thework-holding device is open.

1-12 M-489Revised: February 5, 2008

2

1

MACHINE MODES

AUTO

Automatic mode allows execution of the active part program and modification of part pro-grams using the Back Edit function. The indicator light is illuminated when automatic modeis active. Refer to Chapter 3 for an explanation of Automatic mode.

SINGLE (Single Block)

Single mode provides the operator with the ability to execute one block of data each timethe Cycle Start push button is pressed. Canned cycles are executed one pass at a time. Theindicator light is illuminated when Single mode is active. Refer to the programmer’s manual(M-488) for descriptions of the Canned Cycles.

MDI (Manual Data Input)

Manual Data Input mode allows manual input of a temporary program block. The indicatorlight is illuminated when Manual Data Input mode is active. Refer to Chapter 3 for an expla-nation of Manual Data Input mode.

EDIT

Edit mode allows the operator or programmer to edit a stored program when the ProgramProtect key switch is in the OFF position. To deactivate Edit mode, select another operatingmode. The indicator light is illuminated when Edit mode is active. Refer to Chapter 3 for anexplanation of Edit mode.

RAPID REFERENCE

Rapid Reference mode allows the operator to move the machine axes to their respectivereference positions through the use of the Rapid Reference push button.

The X axis must be moved to the reference position before the Y1 or Z axis can be com-manded to the reference position through the use of the Rapid Reference push button.

The Rapid Reference push button allows the machine operator to move the selected axisto the reference position. The axis to be moved is selected through the use of the ManualAxis Movement selector switch. Active in Rapid Reference mode.

The X axis must be moved to the reference position before the Y1 or Z axis can bemoved to the reference position.

JOG

Jog mode allows non-programmed movement of the axes. The indicator light is illumi-nated when Jog mode is active. Refer to Chapter 3 for an explanation of Jog mode.

M-489 1-13

MANUAL AXIS MOVEMENT

MANUAL PULSE GENERATOR

Manual pulse generator “B”, Figure 1.4, allows the operator to jog the selected axis byspecific increments. The axis to be jogged is selected with the Manual Axis Movementswitch and the increment is selected with the Rapid Override switch.

Z/E

The Z/E push buttons are momentary type switches that allow the operator to jog the se-lected axis in the indicated direction. The axis to be jogged is selected through the use ofthe Manual Axis Movement selector switch. Refer to Figure 1.5 for axis definitions. Active inJog mode.

X/Y

The X/Y push buttons are momentary type switches that allow the operator to jog the se-lected axis in the indicated direction. The axis to be jogged is selected through the use ofthe Manual Axis Movement selector switch. Refer to Figures 1.5 and 1.6 for axis definitions.Active in Jog mode.

RAPID TRAV (Rapid Traverse)

This push button is a momentary type switch. Pressing this push button while simulta-neously pressing one of the Jog directional push buttons causes the selected axis to moveat approximately 150 in/min [3800 mm/min]. Refer to Jog Mode, in Chapter 3.

- NOTE -

Refer to Figures 1.5 and 1.6 for illustrations showing axis definitions.

MANUAL AXIS MOVEMENT SELECTOR SWITCH

C1 Selects the C1 axis for manual axis control. The C1 axis is radial motion of the mainspindle.

Z Selects the Z axis for manual axis control. The Z axis is linear motion of the turret paral-lel with the spindle centerline.

X Selects the X axis for manual axis control. The X axis is linear motion of the turret par-allel with the spindle face and parallel with the machine bed.

Y Selects the Y1 axis for manual axis control. The Y1 axis is linear motion of the turretparallel with the spindle face and perpendicular with the machine bed.

E Selects the E axis for manual axis control. The E axis is linear motion of the tailstock orsub-spindle parallel with the spindle centerline.

C2 Selects the C2 axis for manual axis control. The C2 axis is radial motion of the optionalsub-spindle.

1-14 M-489

M-489 1-15

Figure 1.5 - E, X, and Z Axis Definitions(Shown with Optional Sub-Spindle)

TI4642A

+Z-Z

+X

-X

-E +E

Main Spindle Sub-Spindle

Turret

Figure 1.6 - X and Y Axis Definitions(Viewed from the Tailstock/Sub-Spindle End of the Machine)

TI4656

+Y

-Y

+X

-X

Spindle CenterlineM

achine

Bed

TURRET CONTROL

TURRET STATION

This rotary switch enables the operator to select the turret station to be indexed to the ac-tive position when the Turret Index push button is pressed.

INDEX

- CAUTION -

The operator must be sure no interference exists within the machine work en-velope before manually indexing the turret.

- NOTE -

The control must be in Jog mode to allow the Index push button to function.

Press the Index push button to command the turret to index to the station selected withthe Turret Station rotary switch.

MACHINE POWER

Switch “C”, Figure 1.4, turns the CNC control OFF when set to “0" and turns the CNCcontrol ON when set to ”1".

PROGRAM PROTECT

This switch is a two position, key operated switch. For normal operation, this switchshould be turned to the ON position. When this switch is turned to ON, parameters cannotbe edited and part programs cannot be edited or deleted. When this switch is turned toOFF, parameters can be edited and part programs can be edited or deleted. The key shouldbe removed except when part program or parameter editing is required. The key cannot beremoved from the switch when Program Protect is turned OFF.

1-16 M-489

CONTROL INTERFACE PORTS

The control interface is equipped with 3 data input/output ports:

• ATA Flash Card Port, Figure 1.7

• RS-232 Serial Port (25 pin), Figure 1.8

• Ethernet Port, Figure 1.8

Refer to Chapter 15 for information on using the ATA flash card and RS-232 ports.

Contact your network administrator for information on using the Ethernet port.

M-489 1-17

Figure 1.7 - ATA Flash Card Port

ATA FlashCard Port

TP7290

Figure 1.8 - RS-232 and Ethernet Ports

RS-232Serial Port

EthernetPort

TP7289

STACK LIGHT [Option]

The optional stack light, shown in Figure 1.9, is located above the operator control pendant. Thestack light is used to visually indicate the current status of the lathe.

The colors and definitions are listed below:

RED

Emergency Stop or alarm condition. Automatic cycle is stopped.

AMBER

The lathe is in Automatic mode, but automatic cycle is not active.

GREEN

Automatic cycle active. Normal operation.

1-18 M-489

Figure 1.9 - Optional Stack Light

TP7297

ON-LINE HELP SYSTEM

GENERAL DESCRIPTION

The on-line help system provides information and instructions relating to P/S alarms, methods ofoperation, and parameter tables.

P/S Alarms

- NOTE -

Only the more difficult to understand P/S alarms are supported by the on-line helpsystem.

Information and remedies concerning specific P/S alarms is supplied.

Methods of Operation

Information concerning CNC machining operations.

Parameter Table

Displays ranges of parameter numbers based on parameter functions.

ACCESSING THE ON-LINE HELP SYSTEM

Press the HELP key to access the on-line help system. The following menu will be displayed:

1. Alarm Detail

2. Operation Method

3. Parameter Table

- NOTE -

When viewing “Operation Method” or “Parameter Table” screens, the help systemwill display two numbers in the upper right-hand corner of the screen; for example,“¼". The upper number indicates the current page number and the lower number in-dicates the total number of pages for that particular topic.

Alarm Detail

1. Press the “1 Alm” soft key.

2. Key in the alarm number and press the Select soft key. The alarm number and a detailedexplanation will be displayed.

3. Repeat step 2 as needed.

4. Exit the on-line help system. Refer to “Exiting the On-Line Help System”.

M-489 1-19

Operation Method

1. Press the “2 Opr” soft key.

2. Key in the topic number and press the Select soft key. The selected topic and a detailedexplanation will be displayed.

3. Repeat step 2 as needed.


Parameter Table

1. Press the “3 Para” soft key. Page 1 of 4 will be displayed.

2. Use the page keys to view the various pages, as needed.


EXITING THE ON-LINE HELP SYSTEM

Press the Help key again or press any of the following function keys to exit the on-line help system:

- Message

- Offset / Setting

- Position

- Program

- System

1-20 M-489

- NOTES -

M-489 1-21

- NOTES -

1-22 M-489

CHAPTER 2 - POWER-UP, POWER-DOWN,AND CONTROL STATUS

- CAUTION -

The recommended operating temperature range is 50° to 95° F [7° to 35° C].

POWER-UP PROCEDURE

- NOTE -

It is important that the power-up procedure is followed as described to ensure safe,accurate, and repeatable machine operation.

1. Turn main disconnect switch “A”, Figure 2.1, ON.

2. Turn the main air valve on pressure regulator “B”,Figure 2.2, ON.

- NOTE -

Refer to Chapter 17 for information ondraining the air filter bowls and refillingthe coolant tank.

3. Drain air filter bowls “C” and “D”.

4. Check the coolant level. If necessary, add coolant.

- CAUTION -

When turning the Control ON/OFFswitch to ON, DO NOT press anyother push buttons or keys until theposition or alarm screen is dis-played. Some push buttons and keysare used for control maintenance orspecial operation commands.

5. Turn the Control ON/OFF switch to ON and waituntil the CNC display screen is ON.

6. Pull the Emergency Stop push button out to thefirst detent, wait two seconds; then, pull the pushbutton out to the end of travel and release.

7. Verify that the coolant guard door is closed.

8. Set the Machine Modes selector switch to Jog.

9. Set the Axis Selector switch to “E”.

10. Press the right-hand Z/E push button to move thetailstock or optional sub-spindle to the referenceposition.

M-489 2-1Revised: February 5, 2008

Figure 2.1 - Power Case Door

A

TP7299

Figure 2.2 - Air Control Assembly

TP4101

B

C D

11. Open and close the coolant guard door to perform the guard door switch verification and clearthe verification alarm.

12. Clear any additional alarms, as needed.

13. Press the Message soft key to view the spindle warm-up message.

- CAUTION -

If a chuck is installed on the main spindle, check the maximum speed rating ofthe chuck. The spindle warm-up routine will run the main spindle at the follow-ing speeds:

RS 42, RS 51, and SR 150 Lathes: 2000, 4000, and 6000 rpm.RS 65 and SR 200 Lathes: 2000, 3250, and 4500 rpm.SR 200 BB (Big Bore) Lathes: 2000, 3000, and 4000 rpm.

The spindle warm-up routine can be bypassed if necessary. Main spindlespeed should be limited to 3000 rpm If the spindle warm-up routine is by-passed.

- NOTE -

The spindle warm-up routine will run for approximately 9 minutes. The operator mes-sage will be cleared from the screen when the warm-up routine has been completed.

If the warm-up routine is interrupted by an alarm or by pressing the Reset key, itmust be restarted with the Cycle Start push button or bypassed as described below.

The spindle warm-up message will be displayed after the machine has been inEmergency Stop for one hour or more.

The machine operator can run an alternate warm-up program manually to accommo-date any spindle tooling limitation that may exist.

14. TO RUN THE SPINDLE WARM-UP ROUTINE

A) Press the Cycle Start push button. The control will ask the operator to verify the execution ofthe warm-up routine.

B) Press the Cycle Start push button a second time to execute the warm-up routine.

- or -

Press the Reset key to start over.

TO BYPASS THE SPINDLE WARM-UP ROUTINE:

A) Turn the Program Protect key to the OFF position.

B) Press the Feed Hold push button.

C) Press the Reset key to clear the operator message.

D) Turn the Program Protect key to the ON position.


POWER-DOWN PROCEDURE

1. Be sure “Cycle Start” is not active. The Cycle Start push button light will be OFF.

2. Be sure the program has been completed and that the spindle and slides are stationary.

3. Press the Emergency Stop push button.

4. Turn the Control ON/OFF switch to OFF.

5. Turn the main air valve on pressure regulator “B”, Figure 2.2, OFF

6. Turn main disconnect “A”, Figure 2.1, OFF.

M-489 2-3

REVIEWING CONTROL STATUS

The following descriptions refer to the control status displays. Refer to Chapter 1 for additional in-formation on the manual data input keyboard:

POSITION KEY

There are three (3) pages of position display data. After the Position key is pressed, the posi-tion display page that was last active will appear on the control display screen. To access theother position display pages, press the appropriate soft key. The three position display pagesare as follows:

1. ALL (Overall Position Display): This page shows the active program number and block numberare displayed in the upper right-hand corner of the control display screen if the control is inAutomatic mode.

A) Relative: The axis position on the Relative Coordinate System. Position is displayed as Uand W coordinates.

B) Absolute: Axis position on the Work Coordinate System. After power-up, the origin of theWork Coordinate System is the intersection of the spindle face and the spindle centerline.Position is displayed as X and Z coordinates. This display can be modified by any one of thefollowing:

Active set of tool offsetsPosition Reset operationWork Shift offset

C) Machine: Displays the turret reference position in relation to the origin of the WorkCoordinate System, which is the intersection of the spindle face and the spindle centerline.

D) Distance to Go: This is the distance remaining between current axis position and theprogrammed axis position. This register is displayed only while the control is in Automatic orManual Data Input mode.

2. Absolute Position Display. Refer to part “b” under “ALL (Overall Position Display)”.

3. Relative Position Display. Refer to part “a” under “ALL (Overall Position Display)”.

PROGRAM KEY

Press the Program soft key to display the active program number, and active block se-quence number and eleven blocks of the active program on the control display screen. To dis-play other pages of the program, select Edit mode and use the page keys to read through theprogram.

During execution of the active part program, the cursor will be positioned under the se-quence number of the active block.

If necessary, press the Reset key to return to the start of the program.

2-4 M-489

OFFSET SETTING KEY

When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed. From thefirst Offset Setting screen, press the soft key expansion key once to display the Macro soft key. Fromthe first Offset Setting screen, press the soft key expansion key twice to display the Work Shift softkey.

OFFSET SOFT KEY

Press the Offset soft key to access the geometry and wear soft keys.

One of the two chapters will be displayed on the control display screen. The displayed pagewill be the page which was active when the Offset display was last viewed. To display the otherchapter, press the corresponding soft key. Use the Page keys to view other pages within achapter.

The tool geometry and wear offset chapters display the following information:

X and Z Tool Offsets (32 pair)Tool nose radius valuesTool nose orientation numbers

SETTING SOFT KEY

Press the Setting soft key to access the system variables pages, which allows the operatoror programmer to assign the system variables listed below. To modify these variables, use thepage and cursor keys to move the cursor to the variable which is to be modified, enter the de-sired value, and press the Input key.

Parameter Write = _(0:Disable 1: Enable)

TV Check = _(0:OFF 1:ON)

Punch Code = _(0:EIA 1:ISO)

Input Unit = _(0:MM 1:Inch)

I/O Channel = _(0-4:Channel No.)

Sequence No. = _(0:OFF 1:ON)

Tape Format = _(0:No CNV 1:ON)

Sequence Stop = _(Program No.)

Sequence Stop = _(Sequence No.)

Parameter Write

This parameter allows the control parameters to be edited. When set to “0", parameterediting is disabled. When set to ”1", parameter editing is enabled. Refer to Chapter 3 forinformation on editing machine parameters.

TV Check

This parameter allows the activation or deactivation of parity checking. When set to “1",parity is checked from the beginning of each block to the beginning of the next block.When set to ”0", vertical parity checking is disabled.

M-489 2-5

Punch Code

This parameter allows the selection of EIA or ISO data input format through theRS-232 serial port. When set to “0", the data input format is set to EIA. When set to ”1",the data input format is set to ISO.

Input Unit

This parameter allows the selection of metric or inch operating mode. When set to “0",the operating mode is Metric. When set to ”1", the operating mode is set to Inch.

I/O Channel

This parameter allows the selection of the logical I/O to be used by the control. Thevalid selections for the I/O port assignments are 0, 1, 2, or 4.

I/O port assignments 0, 1, and 2 are used to select the RS-232 serial port andspecify the port configuration.

I/O port assignment 4 is used to select the ATA Flash Card port.

Refer to Chapter 15 for additional information on data input/output.

Sequence No.

This parameter allows the selection of “automatic sequence number insertion”. Whenactive, sequence numbers will be automatically inserted into a program which is enteredinto memory from the Manual Data Input keyboard. When set to “0", automatic sequencenumber insertion is inactive. When set to ”1", automatic sequence number insertion is ac-tive.

Tape Format

Not Active

Sequence Stop (2 entries)

These two entries are used together to provide the machine operator with the capabil-ity of stopping automatic part program execution after the program block specified hasbeen completed.

The first entry (Program No.) identifies the program to be monitored.

The second entry (Sequence No.) identifies the sequence number (N word) of the lastblock to be executed by the CNC control during normal automatic operation. Once thisblock is executed, the CNC control will stop program execution.

Press the Cycle Start push button to resume program execution.

2-6 M-489

MACROS SOFT KEY

Press the Macros soft key to display the macro variable registers.

WORK SHIFT SOFT KEY

Press the Work Shift soft key to display the work shift offset registers.

SYSTEM KEY

Press the System key to access the following information:

• Machine parameters and diagnostics

• PMC parameters, ladder, and diagnostics

• Control system configuration

One of four chapters will be displayed on the control display screen. The displayed page will be thepage which was active when the key was last deactivated. If necessary, press the soft key to displaythe desired chapter. Use the page keys to view other pages within a chapter.

PARAMETER SOFT KEY

Press the Parameter soft key to display machine parameters. These parameters establishmany of the characteristics, specifications, and functions of the machine tool. The page thatwas active when the parameter chapter was last exited will be displayed. To view other pageswithin the chapter, press the Page key to move to the desired page. Refer to Chapter 3 for in-formation on editing machine parameters.

DIAGNOSTIC SOFT KEY

Press the Diagnostic soft key to display the machine diagnostics chapter. The page that wasactive when the diagnostics chapter was last exited will be displayed. Use the Page keys toview other pages within the chapter.

PMC SOFT KEY

Press the PMC soft key to display the PMC information screen. The purpose of this screen isto view the PMC ladder, parameters, and diagnostics.

SYSTEM SOFT KEY

Press the System soft key to display the control system information screen.

M-489 2-7

MESSAGE KEY

If “ALM” is displayed at the bottom right-hand corner of the control display screen during machineoperation, press the Message key. After the Message key is pressed, one of the three chapters will bedisplayed. To display one of the other chapters, press the appropriate soft key.

ALARM SOFT KEY

Alarm Message chapter. This chapter displays alarms that create a feed hold condition. Onealarm will be displayed on the control display screen at a time. The display is formatted to indi-cate which tool station has generated the alarm. Descriptions of each alarm are given in thealarm list in Appendix 2.

MESSAGE SOFT KEY

Operator Message chapter. Operator messages do not initiate a feed hold condition. Theycall the operator’s attention to a specific machine condition.

HISTORY SOFT KEY

The control is capable of storing the last 25 alarms generated by the machine control. Thereare a maximum of five pages, with up to five alarms per page. Use the Page keys to displaynext or previous page.

- NOTE -

Alarm and Operator messages caused by an error generated in Background Editmode will have no affect on a part program that is executing in the foreground.

2-8 M-489

- NOTES -

M-489 2-9

- NOTES -

2-10 M-489

CHAPTER 3 - OPERATIONAL MODES AND EDITING

AUTOMATIC MODE

- CAUTION -

Before executing any part program in Automatic mode, it is recommended thatthe program be cycled through one time in Single mode. Refer to the instruc-tions for “Running a Part Program for the First Time”, page 3-11.

Automatic mode allows selection and execution of the active part program. When Automatic modeis active and the Program key is pressed, the following soft keys are displayed on the control displayscreen:

ProgramCheckCurrentNextOperator

Automatic mode is activated by the mode selector switch.

SINGLE MODE

Single mode allows the operator to execute one block of data each time the Cycle Start push buttonis pressed. Canned cycles are executed one pass at a time. Single mode is activated by the mode se-lector switch.

Refer to the programmer’s manual (M-488) for descriptions of the Canned Cycles.

EDIT MODE

Edit mode allows creation of new part programs or modification of existing part programs held inmemory. There are two ways to search through the program: Word Scan and Word Search.

WORD SCAN

The Word Scan function permits the operator to search through the program one word or one line ata time.

- NOTE -

The cursor is displayed below the address character of the selected word.

1. Use the cursor� and� keys to move the cursor word by word on the screen.

2. Use the cursor � and � keys to move the cursor line by line on the screen.

3. Continue pressing the cursor keys to make a continuous search.

4. Press the Page� or Page� key to display the preceding or following pages and search for thefirst word of that page.

M-489 3-1

WORD SEARCH

Word Search permits a specified word to be searched for from the current cursor position using thefollowing procedure:

1. Key in the data word to be searched for.

2. Press the cursor � key to search forward or cursor � to search backward. If the data wordentered in step 1 is located, the cursor will be displayed below the first character in the dataword.

EDITING A PROGRAM

- NOTE -

When Edit mode is active and the Program Protect key is turned OFF, Edit Slowmode is automatically activated. Refer to page 3-4 for information on Edit Slowmode.

1. Set the mode selector switch to Edit mode.

- NOTE -

The Program Protect key MUST be turned to OFF to allow creating, editing, or delet-ing of part programs.

2. Turn the Program Protect key to OFF.

3. Press the Reset key.

4. Activate the program as follows:

A) Press the Program key.

B) Key in the letter “O” followed by the number for the desired program.

Example: O1111

C) Press the cursor � key.

5. Search for the word to be modified using the Word Scan or Word Search function.

6. Alter, insert, or delete the word/block/program as described in the sections that follow.

- CAUTION -

If the Reset key is not pressed before selecting Automatic mode and the partprogram is executed, the program will begin executing at the point in the pro-gram where the cursor was located when Edit mode was exited.

7. Press the Reset key to “rewind” the part program back to the beginning.

8. Turn the Program Protect key to ON.

3-2 M-489

Altering a Word

- NOTE -

The cursor MUST be positioned under the data word to be altered.

1. Use the Word Scan or Word Search function to locate the data word to be changed.

2. Key in the letter address and the new value.

3. Press the Alter key.

Inserting a Word

- NOTE -

The cursor MUST be positioned under the word immediately preceding the locationof the new data word.

1. Use the Word Scan or Word Search function to find the data word or End of Block immediatelypreceding the point in the program where the new data word will be inserted.

2. Key in the data word to be inserted.

3. Press the Insert key.

Deleting a Word

- CAUTION -

The cursor MUST be positioned under the data word which is to be deleted.

1. Use the Word Scan or Word Search function to find the data word which is to be deleted.

2. Press the Delete key.

Deleting Up to an End of Block

1. Position the cursor at the point where the deletion is to begin.

2. Press the EOB (End of Block) key; then, press the Delete key.

- NOTE -

The data between the cursor and the next End of Block character will be deleted.The cursor will move to the address character of the next data word in the program.

M-489 3-3

Deleting Data Blocks

- NOTE -

In the procedure which follows, all data from the cursor to, and including, the blockspecified by the sequence number will be deleted. The cursor will move to the nextsequence number in the program.

1. Position the cursor at the point where the deletion is to begin.

2. Key in the sequence number (N word) where the deletion is to end.

3. Press the Delete key.

Deleting a Program

1. Press the Program key.

2. Key in the letter “O” and the number of the program to be deleted.

Example: O1111

3. Press the Delete key. The selected program will be deleted.

EDIT SLOW MODE

Edit Slow mode disables the Rapid Override switch and forces G00 positioning moves to be per-formed at 39 in/min [990 mm/min]. This will occur whenever Edit mode is selected and the ProgramProtect key is in the OFF position.

This mode will remain active until the G00 push button is pressed or an M30 (End of Program) isread by the machine control

JOG MODE

- NOTE -

Refer to Spindle Control, beginning on page 1-9, for information on non-programmedspindle motion.

The Y1 axis controls the optional Y axis on the turret.

The E axis controls the tailstock or optional sub-spindle.

Jog mode permits non-programmed movement of the axes. Jog mode is activated by setting themode selector switch to Jog. While in Jog mode, use the axis direction push buttons or the manualpulse generator to obtain the desired X, Y, Z, or E axis movement.

CONTINUOUS JOG

The Feedrate Override switch has a direct affect on the X, Y, Z, and E axis jog speeds. The jogfeedrate for the X, Y, Z, and E axes is approximately 25 in/min [635 mm/min] when the feedrate over-ride switch is set to 100% and approximately 37.5in/min [952 mm/min] when the corresponding switchis set to 150%. The Traverse push button will increase normal jog speeds. When the Traverse pushbutton is pressed along with one of the axis push buttons, the feedrate override switch is ignored andthe selected axis moves at approximately 236 in/min [6000mm/min]. Refer also to Incremental Jog.

3-4 M-489

INCREMENTAL JOG

The manual pulse generator permits the cross slide or carriage to be moved incrementally when-ever Jog mode is active. The axis to be moved is selected by using the selector switch in the ManualAxis Movement section of the operator control panel. The movement increment is selected with theRapid Override switch. The selected axis will move incrementally when the handwheel is rotated. Thedirection and distance is determined by the direction and amount of rotation of the handwheel.

- NOTE -

When moving the X axis with the machine in diameter mode, physical axis motionwill be one half the selected increment.

EXECUTING AN INCREMENTAL JOG

1. Set the mode selector switch to Jog mode.

- NOTE -

The X/Y and Z/E axis direction keys are also active and may be used to jog theaxes. Refer to Continuous Jog.

2. In the Manual Axis Movement section of the operator control panel, use the selector to selectthe desired axis.

3. Set the Rapid Override switch to select the desired increment. Refer to Rapid Override, page1-11, for information on increment selection.

4. To view axis position on the control display screen:

A) Press the Position key.

B) Press the Page key until the desired position display appears on the control display screen.

5. Turn the handwheel in the desired direction (+ or -). Observe the axis position registers todetermine when the axis has been moved the required distance.

If the X axis was selected in step 2, turn the handwheel in the plus direction to move thecross slide away from the spindle centerline and turn the handwheel in the minus directionto move the cross slide toward the spindle centerline.

If the Y1 axis was selected in step 2, turn the handwheel in the plus direction to move theturret away from the machine bed and turn the handwheel in the minus direction to movethe turret toward the machine bed.

If the Z axis was selected in step 2, turn the handwheel in the plus direction to move thecarriage away from the face of the main spindle and turn the handwheel in the minus direc-tion to move the carriage toward the face of the main spindle.

If the E axis was selected in step 2, turn the handwheel in the plus direction to move thetailstock or sub-spindle away from the face of the main spindle and turn the handwheel inthe minus direction to move the tailstock or sub-spindle toward the face of the main spin-dle.

M-489 3-5

MANUAL DATA INPUT MODE

Manual Data Input mode allows the operator to input a single block of non-stored data into the Man-ual Data Input memory. The data can then be executed by pressing the Cycle Start push button. Oncethe data in the Manual Data Input memory has been executed, it is erased from memory.

USING MANUAL DATA INPUT

- NOTE -

Pressing the Reset key clears the Manual Data Input buffer.

1. Set the mode selector switch to Manual Data Input mode.



4. Enter the data into the Manual Data Input buffer using the data input keys. Each data blockmust end with a valid End of Block character.

- NOTE -

If an error is made while keying in the data and the Insert key has not been pressed,press the Cancel key and key in the correct data.

5. Press the Insert key to input and display the data from step 4 into the Manual Data Inputmemory.

- NOTE-

To alter data after it has been entered into the Manual Data Input memory, place thecursor on the word, key in the correct data, and press the Alter key. If it is necessaryto delete a word, place the cursor on the word and press the Delete key.

The collet closer must be in the closed position before an Manual Data Input com-mand can be executed.

6. Close the coolant guard door and press the Cycle Start push button to execute the data.

3-6 M-489

SAFE START SUBPROGRAMS

Safe Start subprograms O1, O2, O3, O4, O998, and O999 have been developed by Hardinge Inc.to provide machine safety and to help simplify programming. These programs are loaded perma-nently into the control memory. The purpose of these programs is to reactivate start-up modes, for ex-ample: positioning mode, deactivate Tool Nose Radius Compensation, establish ipm feed, and movethe turret to the safe index position.

Refer to the programmer’s manual (M-488) for more information on the Safe Start programmingformat.

- CAUTION -

If the machine is to be run in metric mode, the Z entry (pullback) insubprogram O2 must be converted to a metric value.

The operator should be aware that program O999 is used for the main spindleONLY. To avoid crash situations, program O998 must be used for thesub-spindle.

(Continued on next page)

M-489 3-7

MAIN SPINDLE OPERATION

- CAUTION -

The Z axis coordinate defined in subprogram O999 MUST be programmed as aPOSITIVE number.

When machining on the main spindle, the safe index coordinates are defined by subprogram O999.The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe in-dex coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm].

Refer to Figure 3.1.

Subprogram O1 is used to exit the workpiece after performing an external machining operation onthe workpiece.

Subprogram O2 is used to exit the workpiece after performing an internal machining operation onthe workpiece.

Subprogram O999 is not called directly from the part program. Subprograms O1 and O2 callsubprogram O999, which is used to deactivate the tool offset and command the turret to the safe indexposition.

3-8 M-489

Figure 3.1 - Z Axis Safe Index Valuefor Main Spindle Operations

TI5445

+X

Safe Index = Z + 1” [25.4 mm]

+Z

Z

VDI Turret Top Plate ESA Turret Top Plate Hardinge Turret Top Plate

Z

Z

+X

+Z

+X

+Z

SUB-SPINDLE OPERATION

- CAUTION -

The Z axis coordinate defined in subprogram O998 MUST be programmed as aNEGATIVE number.

When machining on the sub-spindle, the safe index coordinates are defined by subprogram O998.The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe in-dex coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm].


Subprogram O3 is used to exit the workpiece after performing an external machining operation onthe workpiece.

Subprogram O4 is used to exit the workpiece after performing an internal machining operation onthe workpiece.

Subprogram O998 is not called directly from the part program. Subprograms O3 and O4 callsubprogram O998, which is used to deactivate the tool offset and command the turret to the safe indexposition.

M-489 3-9

Figure 3.2 - Z Axis Safe Index Valuefor Sub-Spindle Operations

TI5446

+X

Safe Index = Z + 1” [25.4 mm]

+Z

Z Z

Z

+X

+Z

+X

+Z

VDI Turret Top Plate ESA Turret Top Plate Hardinge Turret Top Plate

PROGRAMS

ENTERING A PROGRAM FROM THE KEYBOARD

- NOTE-

Refer to Chapter 1 of the programmer’s manual (M-488) for a description of the datawords used with this machine.

Refer to Chapter 15 of this manual for information on loading part programs fromtape, disk, or ATA flash card.




4. Key in the letter and the program number at the Manual Data Input panel.

Example: O1111


6. Press the EOB (End of Block) key.


8. Enter each data block as follows:

A) Key in the letter addresses and values.

B) Press the EOB (End of Block) key.

C) Press the Insert key.

9. Turn the Program Protect key to ON.

ACTIVATING A STORED PROGRAM

1. Set the mode selector switch to Automatic mode.


3. Key in the letter “O” followed by the number for the desired program.

Example: O100

4. Press the cursor � key.

3-10 M-489

RUNNING A PART PROGRAM FOR THE FIRST TIME

- CAUTION -

Before executing any part program, be sure that all offsets are correct and thatno interference exists in the working area of the machine tool.

Operator should check and if necessary alter the coordinate values pro-grammed in Safe Index Subprogram O998 or O999 to be certain that they aresufficient. Refer to “Editing a Program”, page 3-2, for instructions to edit anactive program.

When Cut-off and Feed Stock are the first operations on bar work, the operatormust make certain that the stock face is placed flush with the collet face be-fore starting the cycle. This will ensure that the turret tooling will not come incontact with workpiece and cause damage to either the turret tooling or theworkpiece.

When testing an operation that uses a self-releasing tap or die holder, activateAutomatic mode immediately before the block containing the spindle reversal.After the Option Stop (M01) is read at the end of the tap or die operation, acti-vate Single mode to test the remainder of the program.



3. Activate the desired program.

4. Set the mode selector switch to Single mode.

5. Close the guard door.

6. Press the Check soft key.

- NOTE -

Program Check displays the Absolute Position and Distance to Go to complete themove.

7. Press the Option Stop push button.

- NOTE -

Single mode is used for first part set up (Block-by-Block execution). Automatic modeis used to run part programs in automatic mode.

8. Turn the Rapid Override switch to LOW.

9. Turn the Feedrate Override switch to 10%.

- NOTE -

Setting the Rapid Override switch to LOW causes non-cutting linear moves (G00) tobe made at 39 in/min [990 mm/min].

Turning Feedrate Override switch to “0" stops X, Y, Z, and E axis motion. When theswitch is turned to another setting axis motion will resume.

10. Press the Cycle Start push button to execute each block of data.

M-489 3-11

STOPPING A PROGRAM RUNNING IN AUTOMATIC MODE

- CAUTION -

Pressing either the Reset key or the Emergency Stop push button while a pro-gram is running in Automatic mode will leave the tool against the workpiece ifperformed at the wrong time. DO NOT stop the program with a tool against theworkpiece unless absolutely necessary. Damage to the workpiece and/or tool-ing may result.

There are several ways to stop a program running in Automatic mode:

1. Program a stop command in the part program where it is to be stopped.

2. Press the Feed Hold push button.

- NOTE -

Automatic operation can be restarted by pressing the Cycle Start push button whenthe Feed Hold push button has been used.


4. Press the Emergency Stop push button

RESTARTING A STOPPED PROGRAM

If the program was stopped by pressing the Emergency Stop push button, perform steps 1 through4.

If the program was stopped by pressing the Reset key, perform steps 3 and 4.



3. If restarting the program at the beginning, key in the letter “O”; then, press the cursor � key.The control will go to the beginning of the program.

If restarting the program at a point other than the beginning:

- CAUTION -

Be sure the block selected in the next step is a safe starting point for the de-sired operation.

A) Key in the letter “N” and the block number for the restart point. For example, “N5".

B) Press the cursor � key. The control will search the program for the block specified in theprevious step.

4. Press the Cycle Start push button. Program execution will resume at the block specified in step4.


DRY RUN AND MACHINE LOCK MODES

- CAUTION -

If Machine Lock is not activated with Dry Run, slide motion will occur at a jogfeedrate that is controlled using the Feedrate Override switch. The operatormust make certain that no interference exists between the tooling, workpiece,or spindle before running the machine in Dry Run.

- NOTE -

Feedrate override has a direct affect on the Dry Run feedrate. When Dry Run modeis active, axis motion will occur at a feedrate of 100 in/min [2540 mm/min] when thefeedrate override is set to 100%. When the feedrate override is set to zero, axis mo-tion and program execution are inhibited.

Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. Acti-vating Dry Run and Machine Lock modes together allows the operator to execute part programs with-out axis or spindle motion.

ACTIVATING DRY RUN AND MACHINE LOCK

1. Set the mode selector switch to Automatic mode.

2. Activate the program.

3. Press the Machine Lock push button and Dry Run push button.

4. Close the coolant guard door.

5. If it is desired to run the program block-by-block, set the mode selector switch to Single mode.

- NOTE -

If Single mode is active, the Cycle Start push button must be pressed for each pro-gram block.

6. Press the Cycle Start push button.

EXITING DRY RUN AND MACHINE LOCK

1. Press the Machine Lock push button and Dry Run push button to deactivate Dry Run andMachine Lock modes.

2. Turn the control OFF, wait a few seconds; then, turn the control ON.

M-489 3-13

BACKGROUND EDIT

The Background Edit function enables the operator or programmer to edit or create a part programwhile a second program is being executed by the machine tool. An alarm or warning in BackgroundEdit mode does not affect the program being executed in the foreground or vice-versa.

ACTIVATING BACKGROUND EDIT MODE

1. Turn the Program Protect key to the OFF position.


3. Press the Operator soft key.

4. Press the Background Edit soft key.

- NOTE -The editing functions which may be performed in Background Edit mode are the same as the fore-

ground editing functions. Descriptions of the foreground editing functions begin on page 3-3.

EDITING AN EXISTING PROGRAM

1. Activate Background Edit mode.

2. Key in the letter “O” and the desired program number.

3. Press the cursor � key.

CREATING A NEW PROGRAM FROM THE KEYBOARD

1. Activate Background Edit mode.

2. Key in the letter “O” and the desired program number.




6. Refer to “Entering a Part Program from the Keyboard”, page 3-10.

ENDING BACKGROUND EDITING

- CAUTION -

If the Reset key is pressed while Background Edit is active, the part programthat is being executed will stop and the offset will be canceled. The operatormust escape Background Edit (Press the Background End soft key) to returnto the main program. With the main program displayed, the operator must jogthe turret to a safe area and restart the program at the beginning of the tooloperation.

1. Press the Background End soft key.

2. Turn the Program Protect key to the ON position.

3-14 M-489

EXTENDED PART PROGRAM EDITING [Option]

INTRODUCTION

Extended Part Program Editing provides the following capabilities:

• Copy or move all or part of a program to another program

• Merge a program at any location within another program

• Search for or replace a data word in a program

COPY AN ENTIRE PROGRAM

This procedure creates a new program by duplicating an existing program.

1. Select Edit mode.



4. If necessary, activate the source program as follows:


B) Key in the letter O followed by the number for the desired program.

Example: O1111

C) Press the Cursor � key.


6. Press the right-hand soft key.

7. Press the Extended Edit soft key.

8. Press the Copy soft key.

9. Press the All soft key.

10. Key in only the number for the new program. DO NOT key in the letter “O”.

11. Press the Input key.

12. Press the Execute soft key.

13. If editing is complete, turn the Program Protect key to the ON position.

M-489 3-15

COPY PART OF A PROGRAM

This procedure creates a new program by duplicating part of an existing program.







Example: O1111





8. Press the Copy soft key.

9. Select the beginning of the range to be copied by moving the cursor to the beginning of therange and pressing the CRSL~ soft key.

10. Select the end of the range to be copied by:

Moving the cursor to the end of the range and pressing the ~CRSL soft key.

- or -

Pressing the ~BTTM soft key to indicate the end of the program as the end of the range tobe copied.





3-16 M-489

MOVE PART OF A PROGRAM

This procedure creates a new program by extracting part of an existing program. The selectedrange will be removed from the original program.







Example: O1111





8. Press the Move soft key.

9. Select the beginning of the range to be moved by moving the cursor to the beginning of therange and pressing the CRSL~ soft key.

10. Select the end of the range to be moved by:

Moving the cursor to the end of the range and pressing the ~CRSL soft key.

- or -

Pressing the ~BTTM soft key to indicate the end of the program as the end of the range tobe moved.





M-489 3-17

MERGE A PROGRAM

This procedure inserts a copy of the specified existing program within the currently active program.







Example: O1111





8. Press the Merge soft key.

9. Select the location where the specified program will be inserted by:

Moving the cursor to the position where the program is to be inserted and pressing the~CRSL soft key.

- or -

Pressing the ~BTTM soft key to indicate the end of the program as the position where theprogram is to be inserted.

10. Key in only the number for the program to be inserted. DO NOT key in the letter “O”.




3-18 M-489

SEARCH AND REPLACE

This procedure locates or replaces the specified data.




4. If necessary, activate the program as follows:



Example: O1111





- NOTE -

Be sure the cursor is located at the appropriate position in the program. The searchor replace function will begin at the cursor position.

8. Move the cursor to the desired position in the program.

9. Press the Change soft key.

- NOTE -

A maximum of 15 characters can be input when specifying the Before or After Data.

Data words specified as Before or After Data must be valid Data words.

10. Key in the data word to be replaced.

11. Press the Before soft key.

12. Key in the new data word.

13. Press the After soft key.

14. Press the Execute soft key to replace all occurrences of the specified data word.

- or -

Press the Execute Single soft key to individually replace each occurrence the specifieddata word.

- or -

Press the Skip soft key to search for the first occurrence of the specified data word.

15. When editing is complete, turn the Program Protect key to the ON position.

M-489 3-19

EDITING MACHINE PARAMETERS

- CAUTION -

Use extreme caution when editing machine parameters. Making incorrectchanges in the parameter table may disable the machine or cause undesirablemachine behavior.

1. Press the Offset Setting key.

2. Press the Setting soft key.

3. If necessary, use the page up/down keys to display the Setting page that contains theParameter Write field.

4. If necessary, use the cursor keys to move the cursor to the Parameter Write field.

5. Set the mode selector switch to Manual Data Input mode.


7. Key in the number “1" to enable parameter editing.


- NOTE -

The control is placed in P/S alarm No. 100.

9. Press the System key.

10. Press the Parameter soft key.

11. Use the page and/or cursor keys to position the cursor on the parameter to be modified.

12. Key in the new parameter value.


14. Repeat steps 11 through 13 as needed.



17. If necessary, use the page up/down keys to display the Setting page that contains theParameter Write field.

18. If necessary, use the cursor keys to move the cursor to the Parameter Write field.

19. Key in the number “0" (zero) key to disable parameter editing.


21. Turn the Program Protect key to the ON position.

3-20 M-489

22. Press the Reset key to cancel P/S alarm No. 100 .

- NOTE -

Depending on which parameters have been modified, the control may output P/Salarm No. 000. If this alarm message is displayed, it will be necessary to re-initializethe control using the following procedure:

A) Press the Emergency Stop push button.

B) Press the Control OFF push button.

C) Wait approximately ten seconds.

D) Press the Control ON push button.

E) Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull thepush button out to the end of travel and release.

DISPLAYING THE PROGRAM DIRECTORY

Use the following procedure to display program memory:



3. Press the Library soft key. The program library (directory) will be displayed.


- NOTES -

3-22 M-489

CHAPTER 4 - ESA TURRET TOP PLATE TOOLING

INTRODUCTION

RS and SR series lathes are available with ESA, VDI, or Hardinge turret top plates.

Refer to Chapter 5 for information on tooling for VDI turret top plates.

Refer to Chapter 6 for information on tooling for Hardinge turret top plates.

TOP PLATE CONFIGURATION

The ESA turret top plate is a 12 station top plate capable of supporting live tool operations on all toolstations.

TOOL HOLDER OR PLUG REMOVAL

- WARNING -

When removing a tool holder or plug from a top plate, have a firm grip on thetool holder or plug when releasing it from the top plate.

- NOTE -

Button "A", Figure 4.2, must be pressed to release a tool holder or plug from the tur-ret top plate.

The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The airpressure in the turret may cause the tool holder or plug to begin moving out of the top plate when it isreleased from the top plate.

M-489 4-1Revised: June 4, 2008

TURRET TOP PLATE CLEANING PLUGS

- CAUTION -

DO NOT clean the turret top plate until all turret stations are protected by acleaning plug, tool station plug, or tool holder.

The aluminum cleaning plugs are NOT to be used during machining opera-tions. Use tool station plugs, page 4-3, for protecting unused turret stationsduring machining operations.

Four aluminum cleaning plugs are supplied with the machine. These plugs are to be used whencleaning the turret top plate during the process of removing or installing turret tooling. A cleaning plugis shown in Figure 4.1.

TYPICAL APPLICATION

1. Thoroughly clean the tool holder or tool station plug.

2. Remove the tool holder or tool station plug from the turret top plate.

3. Insert cleaning plug "B", Figure 4.2, into the turret top plate.

4. Verify button "A" snaps out the same distance as the other release buttons

5. Clean the turret top plate as needed.

6. Remove the cleaning plug.

7. Install the required tool holder or tool station plug.

4-2 M-489Revised: June 4, 2008

Figure 4.1 - Turret TopPlate Cleaning Plug

TP7629

Figure 4.2 - Cleaning PlugsInstalled for Machine Shipment

TP7628

A

B

TOOL STATION PLUGS

INTRODUCTION

- CAUTION -

Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool.

Install a tool station plug at each turret tool station not equipped with tooling. Refer to Figure 4.3 foran illustration of a ESA tool station plug.

TOOL STATION PLUG INSTALLATION

1. Thoroughly clean the top plate and tool station plug.

2. Check the O-ring on the tool station plug to be sure the O-ring is in good condition.

3. Insert tool station plug "D", Figure 4.4, into the turret top plate.

4. Verify button "C" snaps out the same distance as the other release buttons.

5. Tighten rear clamp screw "F", Figure 4.5.

6. Install and tighten four face screws “E”, Figure 4.4.


Figure 4.3 - Tool Station Plug

TI5413


Figure 4.4 - Tool Station Plug Installed on Top Plate

TI5435

C

E

D

Figure 4.5 - Rear Clamping Screw

F

TP7130

LEFT-HAND / RIGHT-HAND TOOL SELECTION

Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing thecutting forces into the machine base will result in maximum tool life.

Making the selection between left-hand or right-hand tooling should be based on:

• the position of the tool in relation to the spindle

• the direction of spindle rotation

SQUARE SHANK TOOLING

BASIC CONFIGURATION

Square shank ESA tool holders obtained from Hardinge Inc. that are designed for RS and SR se-ries lathes are available for ¾", 1”, 20 mm, or 25 mm tooling.

Square shank tools are held in the tool holder by clamping block “J”, Figure 4.6. Clamp screws “G”and “I” apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw “H” isused to hold the clamp block in place when tension is removed from the clamping screws.

When installing or removing square shank tooling, do not remove spring-loaded screw “H”.Clamping block “J” is held in the tool holder by the spring-loaded screw.

REVERSIBLE TOOL HOLDERS

Square shank ESA tool holders obtained from Hardinge Inc. that are designed for RS and SRseries lathes are capable of using left-hand or right hand tooling. Refer to “Left-Hand / Right-HandTool Selection”, above.

1. Carefully remove screw “H”, the spring, andclamp block “J”.

2. Remove clamp screws "G” and “I”.

3. Thoroughly clean the tool holder body and allcomponents that were removed.

4. Install clamp block “J”, the spring, and screw“H” on the upper or lower side of the tool holder,as needed.

5. Install clamp screws “G” and “I”.


Figure 4.6 - Basic SquareShank Tool Holder

TI5415

G H I J

MAXIMUM TOOL EXTENSION

- CAUTION -

When installing square shank tooling, the maximum X axis tool extensionmust not exceed the values listed in the table shown below. Refer also to Fig-ure 4.7.

Y Axis OptionMaximum Tool Extension

Inches [Millimeters]

No 3.639 [92.43]

Yes 2.259 [57.38]


Figure 4.7 - Maximum Square Shank Tool Extension

TI5459

Maximum ToolExtension

Tool Oriented forMain Spindle Operation

Recommended ToolMounting Position



Tool Oriented forSub-Spindle Operation

INSTALLING SQUARE SHANK TOOLING

- NOTE -

Hardinge recommends that tooling be selected that will direct all cutting forces intothe machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 4-5.

The recommended tool mounting position is to have the tool seated against the edgeof the tool holder, as shown in Figure 4.7.

1. Thoroughly clean the top plate, tool holders, and tooling.

2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.

3. If it is necessary to index the turret:

A) Move the turret to a safe index position.

B) Index the turret to the desired tool station.

4. Move the turret to a convenient position for installing tools.

5. Lightly stone the face of the top plate, the sides of the locating slot, and the tool holder.

6. Loosen rear clamp screw "F", Figure 4.5.

7. Slide the tool holder straight onto the turret top plate and engage into the top plate. Refer toFigure 4.8.

8. Verify release button "K", Figure 4.8, snaps out the same distance as the other release buttons.

9. Carefully pull on the tool holder to be sure it is totally engaged with the top plate.

10. Inspect face mounting screws “L”, Figure 4.9, and associated washers to be sure they are notwarped or damaged. Replace hardware as needed.

11. Install washers and face screws “L” until the screws are approximately ¼ inch from the face ofthe tool holder.

- CAUTION -

DO NOT overtighten clamp screw "F", Figure 4.5.

12. Tighten rear clamp screw "F", Figure 4.5, until it stops turning.



Figure 4.8 - Mounting a Square Shank Tool Holder

TI5418

K

Figure 4.9 - Square Shank Tool Holder with Tool

TI5419

L

M

13. Incrementally tighten four face screws “L”, Figure 4.9, in a cross pattern as follows:

A) Inner face screw.

B) Opposite side outer face screw.

C) Second inner face screw.

D) Second outer face screw.

E) Repeat steps A through D until the tool holder is fully seated in the slot.

14. Using the pattern outlined in step 13, torque the face screws to within the following range:

MinimumTorque Value

MaximumTorque Value

English: 22 lb-ft 30 lb-ft

Metric: 30 N•m 40 N•m

- CAUTION -

Be sure the cutting tool sits squarely in the slot of the tool holder.

Refer to the maximum tool extension table on page 4-6. Refer also to Figure4.7.

15. Mount the cutting tool in the tool holder and tighten two clamp screws “M”, Figure 4.9.

16. Repeat as needed for additional tooling.


ROUND SHANK TOOLING

TOOL HOLDER CAPACITIES

- NOTE -

Refer to the appropriate tooling catalog for information on tool holders and bushings.

Round shank ESA tool holders obtained from Hardinge Inc. that are designed for RS and SR serieslathes are available with the following maximum tool shank capacities:

English Tool Holder: 1¼ inches

Metric Tool Holder: 32 or 40 millimeters

When using round shank tooling with a diameter equal to the capacity hole of the tool holder, thetool can be mounted directly in the tool holder. When using round shank tooling with a diameter otherthan the sizes specified above, it will be necessary to use a tool holder bushing.

4-10 M-489Revised: June 4, 2008

MAXIMUM Z AXIS TOOL EXTENSION FOR SUB-SPINDLE OPERATION

- CAUTION -

DO NOT exceed the maximum Z axis tool extension defined in this section.

When installing round shank tooling for sub-spindle operations, the maximum Z axis tool extensionis 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location. Refer toFigure 5.8.

M-489 4-11Revised: June 4, 2008

Figure 4.10 - Maximum Round Shank ToolExtension for Sub-Spindle Operations

Inches[Millimeters]

TI5420A

5.481[139.22]

8.375[212.73]

INSTALLING ROUND SHANK TOOLING

- CAUTION -

When installing round shank tooling for sub-spindle operations, maximumtool extension is 8.375 inches [212.73 mm] from the centerline of the turret topplate tool mounting location. Refer to Figure 4.10.

- NOTE -



2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition.




C) Move the turret to a convenient position for installing tools.


5. Loosen rear clamp screw "F", Figure 4.5.


7. Verify release button "N", Figure 4.11, snaps out the same distance as the other releasebuttons.

8. Carefully pull on the tool holder to be sure it is totally engaged with the top plate.

9. Inspect face mounting screws “O”, Figure 4.12, and associated washers to be sure they are notwarped or damaged. Replace hardware as needed.

10. Install washers and face screws “O” until the screws are approximately ¼ inch from the face ofthe tool holder.

- CAUTION -

DO NOT overtighten clamp screw "F", Figure 4.5.

11. Tighten rear clamp screw "F", Figure 4.5, until it stops turning.

4-12 M-489Revised: June 4, 2008

M-489 4-13Revised: June 4, 2008

Figure 4.11 - Mounting a Round Shank Tool Holder

TI5421

N

Figure 4.12 - Round Shank Tool Holder Mounted on Top Plate

TI5436

O

12. Incrementally tighten four face screws “O”, Figure 4.12, in a cross pattern as follows:





E) Repeat steps A through D until the tool holder is fully seated in the slot.

13. Using the pattern outlined in step 12, torque the face screws to within the following range:

MinimumTorque Value

MaximumTorque Value



14. Place setting bar “S”, Figure 4.13 or 4.14, in the tool holder and tighten set screws “U” so thatthere is a slight drag on the setting bar when it is rotated in the holder.

15. Loosen thumb screw “R” enough to allow locating bar “Q” to slide.

16. Place the machined side of tool setter support “P” flat against the side of tool holder "T".

17. Rotate setting bar “S” until the machined flat is in line with the flat surface of locating bar “Q”, asshown in view #2.

18. Tighten thumb screw “R” when the following conditions are met:

A) The machined side of tool setter support “P” is flat against the side of the tool holder.

B) The flat on setting bar “S” is perpendicular to locating bar “Q”. Refer to view #2.

19. Loosen set screws “U” and remove gauge “S”.

20. If required, install the appropriate tool bushing in the round shank tool holder.

- CAUTION -

When installing tooling for sub-spindle operation, DO NOT exceed the maxi-mum tool extension specified on page 4-11.

21. Install and adjust the tool for length.

22. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder.

23. Tighten set screws “U” just enough to apply a slight drag on the tool shank.

24. Place the machined side of tool setter support “P” against the side of tool holder "T".

25. Rotate the tool until the tool tip touches locating bar “Q”.

26. Tighten set screws “U” to secure the setting.

27. Repeat steps 3 through 26 for additional tools, as necessary.

4-14 M-489Revised: June 4, 2008

M-489 4-15Revised: June 4, 2008

Figure 4.13 - Tool Setting Gauge Oriented for Main Spindle Tooling

TI5437

U

R

Q P

S T U

QP

R

S

T

VIEW #1 VIEW #2

Figure 4.14 - Tool Setting Gauge Oriented for Sub-Spindle Tooling

TI5438

U

R

QP

STU

QP R

S

T

VIEW #1 VIEW #2

- NOTES -

4-16 M-489

CHAPTER 5 - VDI TURRET TOP PLATE TOOLING

INTRODUCTION


Refer to Chapter 4 for information on tooling for ESA turret top plates.

Refer to Chapter 6 for information on tooling for Hardinge turret top plates.

TOP PLATE CONFIGURATIONS

- CAUTION -

Refer to page 5-2 for information concerning turret tooling for lathes equippedwith the following options:

• 16 station VDI 30 top plate

• Sub-spindle part present detector

RS and SR series lathes are available with the following VDI top plate configurations:




M-489 5-1

TURRET TOOLING CONSIDERATION

- CAUTION -

A potential interference condition exists on lathes equipped with the followingoptions:



When machining on the sub-spindle or performing a cut-off and transfer operation, the position ofthe part present detector could cause interference with the tool in the turret station immediately abovethe active turret station. Refer to Figure 5.1.

It is possible to avoid this potential interference condition by doing either of the following:

• Install a short tool holder in the turret station immediately above the active turret stationif all turret stations are required for tooling

• Install a tool plug in the turret station immediately above the active turret station if allturret stations are not required

Refer to Chapter 16 for additional information relating to the optional part present detector.

5-2 M-489

Figure 5.1 - Sub-Spindle Part Present Detector andTool Probe Viewed from Left End of Machine

TI5498

Part PresentDetector Retracted

Active Turret Station

Potential Interferencewith this Tool Holder

Turret Top Plate

Sub-Spindle

TOOL HOLDER OR TOOL STATION PLUG REMOVAL

- WARNING -

When removing a tool holder or tool station plug from a top plate, have a firmgrip on the tool holder or tool station plug while loosening the clamp screw inthe top plate.

The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The airpressure in the turret may cause the tool holder or tool station plug to begin moving out of the top platewhen the clamp screw is loosened.

TOOL STATION PLUGS

- CAUTION -

Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool.

DO NOT use the plastic tool station plugs when operating a machine equippedwith high pressure coolant.

All RS and SR series lathes equipped with a VDIturret top plate are shipped with plastic tool stationplugs installed in the turret top plate.

Lathes equipped with the high pressure coolantoption are also supplied with steel tool station plugs.The steel tool station plugs must be used in place ofthe plastic plugs on machines equipped with highpressure coolant.

Install a tool station plug at each turret tool stationnot equipped with tooling. Refer to Figure 5.2 for an il-lustration of a VDI tool station plug.

PLUG INSTALLATION

1. Thoroughly clean the top plate and tool stationplug.

2. Check the O-ring on the tool station plug to besure the O-ring is in good condition.

3. Aligning tool station plug “B” with coolantbutton “C”, insert the plug into the turret topplate as shown in Figure 5.3.

4. Tighten clamp screw “A”.

M-489 5-3

Figure 5.2 - Tool Station Plug

TI4263A

Figure 5.3 - Installing a Tool Station Plug

TI4681

B

C

A

LEFT-HAND / RIGHT-HAND TOOL SELECTION

Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing thecutting forces into the machine base will result in maximum tool life.

Making the selection between left-hand or right-hand tooling should be based on:

• the position of the tool in relation to the spindle

• the direction of spindle rotation


BASIC CONFIGURATION

Square shank VDI tool holders obtained from Hardinge Inc. that are designed for RS and SR serieslathes are available for ¾", 1”, 20 mm, or 25 mm tooling.

Square shank tools are held in the tool holder by clamping block “G”, Figure 5.4. Clamp screws “D”and “F” apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw “E” isused to hold the clamp block in place when tension is removed from the clamping screws.

When installing or removing square shank tooling, do not remove spring-loaded screw “E”.Clamping block “G” is held in the tool holder by the spring-loaded screw.

REVERSIBLE TOOL HOLDERS

Square shank VDI tool holders obtained from Hardinge Inc. that are designed for RS and SR serieslathes are capable of using left-hand or right hand tooling. Refer to “Left-Hand / Right-Hand Tool Se-lection”, above.

1. Carefully remove screw “E”, the spring, andclamp block “G”.

2. Remove clamp screws “D” and “F”.

3. Thoroughly clean the tool holder body and allcomponents that were removed.

4. Install clamp block “G”, the spring, and screw“E” on the upper or lower side of the tool holder,as needed.

5. Install clamp screws “D” and “F”.

5-4 M-489

Figure 5.4 - Basic SquareShank Tool Holder

TI4158

D E F G

MAXIMUM TOOL EXTENSION

- CAUTION -

When installing square shank tooling, the maximum X axis tool extensionmust not exceed the values listed in the table shown below. Refer also to Fig-ure 5.5.

Y Axis OptionMaximum Tool Extension


No 4.426 [112.42]

Yes 3.046 [77.37]

M-489 5-5

Figure 5.5 - Maximum Square Shank Tool Extension

TI5458


Tool Oriented forMain Spindle Operation




Tool Oriented forSub-Spindle Operation

INSTALLING SQUARE SHANK TOOLING

- NOTE -


The recommended tool mounting position is to have the tool seated against the edgeof the tool holder, as shown in Figure 5.5.


2. Check the O-ring on each tool holder to be sure the O-ring is in good condition.

- CAUTION -

Be sure the tool holder is mounted flush against the side of the turret topplate, as shown in Figure 5.7.

3. Aligning tool holder “H” with coolant button “I”, insert the tool holder shank into the turret topplate as shown in Figure 5.6.

5-6 M-489

Figure 5.6 - Mounting a Square Shank Tool Holder

TI4674

H

J

I

- NOTE -

Maximum torque for the clamp screw is 17 lb-ft [23 N•m].

4. Tighten clamp screw “J”.

- CAUTION -

Be sure the tool sits squarely in the slot of the tool holder.

Refer to the maximum tool extension table on page 5-5. Refer also to Figure5.5.

5. Mount the tool in the tool holder and tighten two clamp screws “K”, Figure 5.7.

M-489 5-7Revised: September 24, 2007

Figure 5.7 - Square Shank Tool Holder with Tool(Viewed from the Main Spindle)

TI4675

K

Be sure the tool holder is flush againstthe side of the turret top plate.

ROUND SHANK TOOLING

TOOL HOLDER CAPACITIES

- NOTE -

Refer to the appropriate tooling catalog for information on tool holders and bushings.

Round shank VDI tool holders for RS and SR series lathes are available from Hardinge Inc. in thefollowing capacities:

EnglishCapacities

MetricCapacities

¾ inch 20 millimeters

1 inch 25 millimeters

1¼ inch 32 millimeters

When using round shank tooling with a diameter equal to the capacity hole of the tool holder, thetool can be mounted directly in the tool holder. When using round shank tooling with a diameter otherthan the sizes specified above, it will be necessary to use a tool holder bushing.


MAXIMUM Z AXIS TOOL EXTENSION FOR SUB-SPINDLE OPERATION

- CAUTION -

DO NOT exceed the maximum Z axis tool extension defined in this section.

When installing round shank tooling for sub-spindle operations, the maximum Z axis tool extensionis 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location. Refer toFigure 5.8.

M-489 5-9


TI5460

6.997[177.73]

8.375[212.73]

INSTALLING ROUND SHANK TOOLING

1. Thoroughly clean the turret top plate, tool holders, and tooling.

2. Check the O-ring on each tool holder to be sure the O-ring is in good condition.




C) Move the turret to a convenient position for installing tools.

- CAUTION -

Be sure the tool holder is mounted flush against the side of the turret topplate.

- NOTE -

Hardinge recommends that tooling be selected that will direct all cutting forces intothe machine base, resulting in maximum tool life. Refer to Left-Hand / Right-HandTool Selection, page 5-4.

4. Loosen two screws “M”, Figure 5.9.

5. Aligning tool holder “L” with coolant button “N”, insert the tool holder shank into the turret topplate as shown in Figure 5.9.

5-10 M-489

Figure 5.9 - Mounting a Round Shank Tool Holder(Viewed from the Main Spindle)

TI4677

M

O

N

L

6. Press the tool holder against the turret top plate and tighten two screws “M”.

- NOTE -


7. Tighten clamp screw “O”.

8. Place setting bar “S”, Figure 5.10 or 5.11, in the tool holder and tighten set screws “U” so thatthere is a slight drag on the setting bar when it is rotated in the holder.

9. Loosen thumb screw “R” enough to allow locating bar “Q” to slide.

10. Place the machined side of tool setter support “P” flat against the side of the tool holder.

11. Rotate setting bar “S” until the machined flat is in line with the flat surface of locating bar “Q”, asshown in view #2.

12. Tighten thumb screw “R” when the following conditions are met:

A) The machined side of tool setter support “P” is flat against the side of the tool holder.

B) The flat on setting bar “S” is perpendicular to locating bar “Q”. Refer to view #2.


Figure 5.10 - Tool Setting Gauge Oriented for Main Spindle Tooling

TI4678

U

R

Q P

S T U

Q P

R

S

T

VIEW #1 VIEW #2

13. Loosen set screws “U” and remove gauge “S”.

14. If required, install the appropriate tool bushing in the round shank tool holder.

- CAUTION -

When installing tooling for sub-spindle operation, DO NOT exceed the maxi-mum tool extension specified on page 4-8.

15. Install and adjust the tool for length.

16. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder.

17. Tighten set screws “U” just enough to apply a slight drag on the tool shank.

18. Place the machined side of tool setter support “P” against the side of tool holder.

19. Rotate the tool until the tool tip touches locating bar “Q”.

20. Tighten set screws “U” to secure the setting.

21. Repeat steps 1 through 20 for additional tools, as necessary.

5-12 M-489

Figure 5.11 - Tool Setting Gauge Oriented for Sub-Spindle Tooling

TI4686

U

R

QP

STU

QP R

S

T

VIEW #1 VIEW #2

- NOTES -

M-489 5-13

- NOTES -

5-14 M-489

CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING

INTRODUCTION


Refer to Chapter 4 for information on tooling for ESA turret top plates.

Refer to Chapter 5 for information on tooling for VDI turret top plates.


MAIN SPINDLE OPERATION

Hardinge turret top plates are designed to use qualified square shank tool holders. Since thesetools are length, width, and height qualified, both set-up time and downtime due to tool replacementare greatly reduced.

Qualified Tool Holders for Main Spindle Operation

Qualified tool holder dimensions are held to ±.003 inch [.076 mm]. A left-hand square shank quali-fied tool holder is illustrated in Figure 6.1. Refer to Table 6.1 for qualified tool holder dimensions.


Figure 6.1 - Qualified Tool Holder

TI2701A

A

B

C

F

E

H

Dimension English (in.) Metric (mm)

A 1.000 25.00

B 1.000 25.00

C 6.000 150.00

E 1.250 36.00

F 1.250 32.00

H 1.000 25.00

Table 6.1 - Qualified Tooling Dimensions

Left-Hand / Right-Hand Tool Selection

- CAUTION -

Read this section thoroughly before mounting square shank tooling for mainspindle operations on the turret top plate.

When using square shank tooling, Hardinge recommends the exclusive use of left-hand tools forthe following reasons:

1. The use of left-hand tools insures that allcutting forces will be directed into the machinebase and will result in maximum tool life.

2. In the event that a right-hand tool and aleft-hand tool are mounted in adjacent toolstations, as shown on Figure 6.2, aninterference situation is created. Both toolsWILL NOT be able to locate against the toolstop on the turret. Refer to the close-up inFigure 6.3. This could create a potential safetyhazard and MUST be avoided.

Right-hand tooling can be used IF A CHAMFER ISMACHINED ON THE CORNER OF THERIGHT-HAND TOOL HOLDER. Figure 6.4 showsthe location and minimum size of the chamfer re-quired to allow for safe use of right-hand tooling.

6-2 M-489

Figure 6.2 - Tool Interference Illustration

TI2499

1.500[38.10]

1.500[38.10]

English[Metric]

Figure 6.3 - Interference Close-Up

English[Metric]

0.063[1.60]

TI2500

Figure 6.4 - Tool Shank Chamfer

English[Metric]

TI2501

0.063[1.60]

45� CH x 0.011 [2.8] Flat

Installing Square Shank Tooling

- CAUTION -

The shank of the tool holder should be positioned firmly against the tool stopon the turret top plate, as shown in Figure 6.5. The notable exception is out-lined in “Between-Center Turning on RS 42 Lathes”, on the next page.

- NOTE -

When using square shank tooling, Hardinge recommends the exclusive use ofleft-hand tools. This insures that all cutting forces will be directed into the machinebase, resulting in maximum tool life.

The wedge clamp can be located on either side of the tool slot centerline to accommodate bothright-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedgeshould bear against the tool shank with the arrow pointing toward the tool shank.

1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed.

2. Install the tool holder on the top plate and tighten the wedge clamp screws. This willautomatically set the tool tip to the correct height as long as qualified tooling is used.

M-489 6-3

Figure 6.5 - Tool Shank PositionedAgainst the Tool Stop

TI4936

Tool Shank AgainstTool Stop

Figure 6.6 - Tool Clamp Orientation

TI1908

ToolShank

ToolShank

WedgeClamp

Between-Center Turning on RS 42 Lathes

- CAUTION -

Read this section thoroughly beforemounting square shank tooling forbetween-center turning operations.

- NOTE -

The information in this section appliesonly to RS 42 lathes.

When using a standard live center for be-tween-center turning near the tailstock, a potential in-terference condition exists between the coolant ringon a Hardinge turret top plate and the tailstock enclo-sure. Refer to Figure 6.7.

The minimum diameter that can be turned is 218

inches [54 millimeters].

If it is necessary to turn a smaller diameter near thetailstock, two solutions are available:

1. Use an extended nose center, as shown inFigure 6.8.

- or -

2. Extend the tool away from the tool stop adistance equal to:

Tool Extension2.125 Finished Diameter

2�

�


Example: Finished Diameter = 1.75 inches

Tool Extension2.125 1.75

2.1875�

��

6-4 M-489

Figure 6.7 - Turning Near the Tailstockwith a Standard Live Center

TP4982

CoolantRing

TailstockEnclosure

Figure 6.8 - Turning Near the Tailstockwith an Extended Nose Live Center

TP4983

CoolantRing

TailstockEnclosure

Figure 6.9 - Extending the ToolAway from the Tool Stop

ToolExtension

TI4937

SUB-SPINDLE OPERATION [Option]

Maximum Tool Extension

- CAUTION -

Turret tooling for sub-spindle operation MUST NOT extend more than 4¼inches [108 mm] from the turret top plate on the X axis.

An interference condition can exist if sub-spindle turret tooling extends more than 4¼ inches[108 mm] from the turret top plate on the X axis. Be sure all sub-spindle turret tooling does not extendbeyond this limit

Cut-Off Tool Operating Limits

When using a cut-off tool during a cut-off and transfer operation from the main spindle to thesub-spindle, the following operating limits must be observed:

• the tip of the cut-off tool MUST extend 3.94 inches [100 millimeters] from theedge of the turret top plate.

• the face of the sub-spindle must be at least 1.80 inches [45.7 millimeters] fromthe face of the main spindle.


Refer to the chart on the next page to identify the correct square shank cut-off tool holder.

M-489 6-5

Figure 6.10 - Cut-Off Tool Operating Limits

TI4925

3.94[100]

1.80 [45.7]

Inches [millimeters]

TurretTop Plate

Main Spindle Optional Sub-Spindle

Square Shank Cut-OffTool Holder Required

Model Numbers for Square Shank Cut-Off Tool Holders

Machine Model English Top Plate Metric Top Plate

RS 42 Lathe SG-CE SG-CEM

RS 51 & SR 150 Lathes CL-CE CL-CM

RS 65 & SR 200 Lathes CL-CE CL-CM

SR 200 BB Lathes CL-CE CL-CM

Tooling Configuration

Sub-spindle operations require ¾ inch square shank tooling on English top plates and 20 millimetersquare shank top plates on Metric machines.

Tooling Location

Square shank tooling for sub-spindle operations can only be mounted at odd numbers tool stations.


Tool Mounting Position

Square shank tooling for main spindle operations is mounted on the -Z face of the turret top plateand square shank tooling for sub-spindle operations is mounted on the +Z face of the turret top plate.Refer to Figure 6.11.

M-489 6-7

Figure 6.11 - Hardinge Turret Top Plate(Sub-Spindle Machines Only)

TI2737A

-Z Turret TopPlate Face

+Z Turret TopPlate Face

Square Shank ToolSlots for Main SpindleOperations

Square Shank ToolSlots for Sub-SpindleOperations(Odd Numbered ToolStations Only)

Toward Main Spindle Away from Main Spindle

Tool Shank Modification

- CAUTION -

Failure to modify the length of thetool holder shank may result in poorsurface finish.

The length of the tool slots used for sub-spindleoperations is 1-13/16 inches [46 mm]. Due to thelength of the tool slots, it will be necessary to shortenthe shank of the tool holder to position the tool tip at adistance of 1-1/4 inches [31.8 mm] from the edge ofthe turret top plate. The final length of the tool, aftermodification, will be 3-1/16 inches [77.8 mm] from thetool tip to the end of the tool shank. Refer to Figure6.12.

Mounting Tools

- NOTE -

When using square shank tooling for sub-spindle operations, Hardinge recommendsthe exclusive use of right-hand tools. This insures that all cutting forces will be di-rected into the machine base, resulting in maximum tool life.

The wedge clamp can be located on either side of the tool slot centerline to accommodate bothright-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedgeshould bear against the tool shank with the arrow pointing toward the tool shank.

1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed.

2. Install the tool holder on the top plate and tighten the wedge clamp screws.

6-8 M-489

Figure 6.12 - Tool Length Modification

TI2774

1.81[46.0]

1.25[38.1]

English[Metric]

ROUND SHANK TOOLING

Round shank tools 1½ inches or 40 millimeters in diameter can be mounted directly into the op-tional English or Metric round shank tool holders, respectively. Round shank tools in specific sizesranging from 1/32 inch [1 millimeter] up to ¾ inch [20 millimeters] can be mounted in the round shanktool holders using the Hardinge Double-Angle Tool Holder Collet and Tool Holder System.

Round shank tools in specific sizes ranging from ½ inch [12 millimeters] up to 1¼ inch [32 millime-ters] can be mounted in the round shank tool holders using Hardinge HDC-12 bushings.

ROUND SHANK TOOL HOLDERS

RS 42 LATHE

Hardinge drill holders are qualified at 1.250 inches [31.75 mm] from the hole center to theturret face. Hardinge boring bar holders are qualified at 2.000 inches [50.80 mm] from the holecenter to the turret face.

RS 51, RS 65, SR 150, SR 200, and SR 200 BB LATHES

Hardinge drill holders are qualified at 1.500 inches [38.10 mm] from the hole center to theturret face. Hardinge boring bar holders are qualified at 2.813 inches [71.44 mm] from the holecenter to the turret face.

Refer to the appropriate Hardinge tooling catalog for additional information.

TOOL SETTING GAUGES

- NOTE -

Two separate tool setting gauges are supplied with RS and SR series lathes. Onegauge is used to set tools for main spindle operation. The other gauge is used to settools for sub-spindle operation.

Tool setting gauges are used to place the tool nose of round shank tools such as boring bars and in-ternal threading tools on center with the spindle centerline.

The tool slot centerline of the active station and the spindle centerline are the same distance fromthe top surface of the machine ways. Therefore, if the tool nose is positioned on the tool slot centerline,it will be on center with the spindle centerline.

The tool setting gauge for main spindle operation mounts in the tool slot and provides aphysical projection of the tool slot centerline. Once the tool setting gauge is mounted on theturret, the tool is rotated to bring the tool nose against the gauge.

The tool setting gauge for sub-spindle operation is held against the side of the tool holderand provides a physical projection of the tool slot centerline. Once the tool setting gauge isproperly set up, the tool is rotated to bring the tool nose against the gauge.


INSTALLING ROUND SHANK TOOLS FOR MAIN SPINDLE OPERATION

1. If not already installed, loosely mount wedge clamp “A”, Figure 6.13, on the top plate in thecorrect orientation for the tool to be installed.

2. Mount the round shank tool holder on the turret.

3. If required, install the appropriate tool cartridge in the round shank tool holder.

4. Insert the tool in the holder or tool cartridge and adjust the tool to length. Align the flat on theHardinge Double-Angle Tool Holder Collet or the slot in Hardinge HDC-12 bushings and the flaton the tool shank with one of the groups of three set screws “C”, Figure 6.14.

- NOTE -

Orientation of the gauge for setting left-hand tools is shown in Figure 6.13.

5. Insert tool setting gauge “B”, Figures 6.13 and 6.14, in the turret tool slot with one of thechamfered edges toward the bottom of the slot.

6-10 M-489

Figure 6.13 - Tool Setting Gauge(Front View)

TI1908

A

B

Spindle Centerline

+X

+Y

Figure 6.14 - Tool Setting Gauge(Side View)

TI2410

B

C

6. Carefully position the tool setting gauge so the tool nose can be rotated to touch the inner faceof the gauge; then, tighten wedge clamp “A”, Figure 6.13.

- CAUTION -

Be careful not to damage the tool nose.

7. Rotate the tool until the tool nose touches the inner face of the tool setting gauge.

- CAUTION -

When the set screws are fully tightened there is the possibility that the toolmay rotate. This will damage the tool nose if it is against the tool settinggauge.

- NOTE -

To secure the tool, tighten the group of three set screws that align with the tool andtool holder as described in step 4.

8. Snug, but do not fully tighten any group of three set screws “C”, Figure 6.14, to hold the tool inplace.

9. Loosen wedge clamp “A”, Figure 6.13, swing the tool setting gauge out of the way, and tightenthe wedge clamp.

10. Fully tighten three set screws “C”, Figure 6.14, to secure the tool.

11. Loosen the wedge clamp and carefully position the tool setting gauge to check that the toolnose is still on center. If it has moved, repeat steps 6 through 10.

12. Remove the tool setting gauge from the turret and tighten the wedge clamp.

M-489 6-11

INSTALLING ROUND SHANK TOOLS FOR SUB-SPINDLE OPERATION

- CAUTION -

DO NOT use round shank tool holder adapter plates on machines equippedwith the sub-spindle option. Use of the adapter plates may result in interfer-ence between the round shank tool holders and the sub-spindle.

The operator must make certain that no interference exists between the turrettooling and the main spindle, workpiece, or sub-spindle before manually in-dexing the turret.

Operating Limits

- CAUTION -

When installing round shank tooling for sub-spindle operations, maximumtool extension is 7.25 inches [184.1 mm] from the surface of the tool holder.

When installing a drill or boring bar for sub-spindle operation, the following operating limits must beobserved:

• maximum tool extension is 7.25 inches [184.1 millimeters] from the surface of thetool holder. Refer to Figure 6.15.

• tool extension must provide a minimum of 1.25 inches [32 millimeters] clearancebetween the tool holder and the face of the sub-spindle at the end of the cut. Re-fer to Figure 6.16.

6-12 M-489


Inches[Millimeters]

MaximumTool Extension

TurretTop Plate

OptionalSub-Spindle

TI4740A

7.25[184.1]

M-489 6-13

Figure 6.16 - Minimum Tool Holder Clearancefor Round Shank Tool Holders

TI4926

1.25 [32.0]

Inches [millimeters]

OptionalSub-Spindle

TurretTop Plate

Tool Holder

Installation Procedure

1. Index the turret to the desired station.

2. Mount tool holder “E” on the turret, as shown in view #1 of Figure 6.17.

3. Refer to the illustration and complete steps 4 through 14.

4. Place setting bar “I” in the tool holder and tighten set screws “D” so that there is a slight drag onthe setting bar when it is rotated in the holder.

5. Loosen thumb screw “H” enough to allow locating bar “G” to slide.

6. Place the machined side of tool setter support “F” flat against the side of the tool holder.

7. Rotate setting bar “I” until the machined flat is in line with the flat surface of locating bar “G”, asshown in view #2.

8. Tighten thumb screw “H” when the following conditions are met:

A) The machined side of tool setter support “F” is flat against the side of the tool holder.

B) The flat on setting bar “I” is perpendicular to locating bar “G”. Refer to view #2.

9. Loosen set screws “D” and remove gauge “I”.

6-14 M-489

Figure 6.17 - Tool Setting Gauge for Sub-Spindle Tooling(Hardinge Turret Top Plate)

TI2773

D

E FG

H

IE

I

F

H

G

VIEW #1 VIEW #2

+X

+Z

- CAUTION -

Be sure that there is sufficient clearance between the sub-spindle tooling andthe turret.

10. Place the tool in the tool holder at the desired length.

11. Tighten set screws “D” just enough to apply a slight drag on the tool shank.

12. Place the machined side of tool setter support “F” against the side of tool holder.

13. Rotate the tool until the tool tip touches locating bar “G”.

14. Tighten set screws “D” to secure the setting.

15. Repeat steps 1 through 14 for additional tools as necessary.

M-489 6-15

- NOTES -

6-16 M-489

CHAPTER 7 - WORK SHIFT

INTRODUCTION

The work shift offset shifts the origin of the work coordinate system. Work Shift values (Z) arestored in the Work Shift file. The value stored in this file is active at all times.

- CAUTION -

The Work Shift file contains an X and a Z shift register. The X axis register inthe Work Shift file should be set to zero at all times.

The value entered into the Z axis Work Shift file must be a negative number.

The values stored in the Work Shift file are added to the Absolute Position registers, thus shiftingthe origin of the work coordinate system by the amount stored in the Work Shift file. For example, if theZ axis is at 14 inches and the operator stores Z-2.5 in the Work Shift file, the Absolute Position regis-ters would then display Z11.5 [14 +(- 2.5)].

Immediately after a Work Shift value is stored, the control adds it to the Absolute Position registers.The registers will remain modified until the Work Shift offset values are set to zero by the operator orfrom the part program.

Typically, the part length is stored as the Z Work Shift offset and the X Work Shift offset IS NOTUSED (set to zero). Since the Work Shift value is added to the Absolute Position registers, the partlength is stored as a negative Z value. With the part length stored in the Work Shift file, the origin of theAbsolute coordinate system is the intersection of the part face and the spindle centerline.

- NOTE -

Refer to the programmer’s manual (M-488) for information on storing a work shiftfrom the part program.

M-489 7-1

MANUALLY ESTABLISHING Z AXIS WORK SHIFT

VDI OR ESA TURRET TOP PLATE

- NOTE -

This procedure is used to set the work shift on RS and SR series lathes equippedwith a VDI or ESA turret top plate. Refer to page 7-6 for the procedure that applies toRS and SR series lathes equipped with a Hardinge turret top plate.

1. Load a workpiece into the collet or step chuck at the desired length.

2. Activate Jog mode.

3. Jog the turret to a safe position for indexing.

- CAUTION -

The machine operator must make certain that no interference exists betweenthe spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, orworkpiece before manually indexing the turret.

- NOTE -

If an square shank tool holder is not available, install a tool holder at any convenientstation.

4. Turn the Station switch to the number of a turret station equipped with a square shank toolholder.

5. Press the Turret Index push button to index the turret to the selected turret station.

6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jogfeedrate of approximately 37.5 in/min [952 mm/min].

7. Jog the tool holder to within 1 inch [25 mm] of the face of the workpiece.

8. Use the Manual Axis Movement switch to select the Z axis.

- NOTE -

Refer to page 1-11 for information on using the Rapid Override switch to selecthandwheel increments.

9. Use the Rapid Override switch to select the desired handwheel increment.

10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in theappropriate direction to move the turret toward the face of the workpiece until a slight drag is feltwhen moving the shim between the tool holder and workpiece. Refer to Figure 7.1, 7.2, 7.3, or7.4.

11. Press the Offset Setting key to display the offset pages.

12. Press the right hand soft key until the Work Shift soft key is displayed.

13. Press the Work Shift soft key to display the Work Shift registers.

7-2 M-489

M-489 7-3

Figure 7.1 - Establishing the Main Spindle Work Shift(VDI Turret Top Plate)

TI4682A

ShimThickness

Tool HolderOffset Value

Turret Position

Work Shift

MainSpindle

Figure 7.2 - Establishing the Sub-Spindle Work Shift(VDI Turret Top Plate)

TI4683B

Shim Thickness

Tool Holder Offset Value

Turret Position

Work Shift

MainSpindle

OptionalSub-Spindle

7-4 M-489

Figure 7.3 - Establishing the Main Spindle Work Shift(ESA Turret Top Plate)

TI5443

ShimThickness

Tool HolderOffset Value

Turret Position

Work Shift

MainSpindle

Figure 7.4 - Establishing the Sub-Spindle Work Shift(ESA Turret Top Plate)

TI5444

Shim Thickness

Tool Holder Offset Value

Turret Position

Work Shift

MainSpindle

OptionalSub-Spindle

14. If not already set to “0" (zero), set the X value under Shift Value to ”0" as follows:

A) Use the cursor keys to move the cursor to the X Data field under Shift Value.

B) At the Manual Data Input keyboard, key in the number “0" (zero).

C) Press the Input key.

15. Use the cursor keys to move the cursor to the Z Data field under Measurement.

- NOTE -

The tool holder offset value is the Z axis distance from the tool station centerline tothe tool holder surface used to set the work shift.

Refer to the appropriate tooling catalog for the tool holder offset value.

16. If setting work shift at the main spindle, key in:

+(Tool Holder Offset Value + shim thickness)

If setting work shift at the sub-spindle, key in:

-(Tool Holder Offset Value + shim thickness)

17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register.

18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm]from the face of the workpiece.


M-489 7-5

HARDINGE TURRET TOP PLATE

- NOTE -

This procedure is used to set the work shift on RS and SR series lathes equippedwith a Hardinge turret top plate. Refer to page 7-2 for the procedure that applies toRS and SR series lathes equipped with a VDI or ESA turret top plate.

1. Load a workpiece into the collet or step chuck at the desired length.



- CAUTION -

The machine operator must make certain that no interference exists betweenthe spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, orworkpiece before manually indexing the turret.

4. Turn the Station switch to the number of an empty turret station.

5. Press the Turret Index push button to index the turret to the selected turret station.

6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jogfeedrate of approximately 37.5 in/min [952 mm/min].

7. Jog the turret top plate to within 1 inch [25 mm] of the face of the workpiece.

8. Use the Manual Axis Movement switch to select the Z axis.

- NOTE -

Refer to page 1-11 for information on using the Rapid Override switch to selecthandwheel increments.

9. Use the Rapid Override switch to select the desired handwheel increment.

10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in theappropriate direction to move the turret toward the face of the workpiece until a slight drag is feltwhen moving the shim between the turret top plate and workpiece. Refer to Figure 7.5 or 7.6.


12. Press the right hand soft key until the Work Shift soft key is displayed.

13. Press the Work Shift soft key to display the Work Shift registers.

14. If not already set to “0" (zero), set the X value under Shift Value to ”0" as follows:

A) Use the cursor keys to move the cursor to the X Data field under Shift Value.

B) At the Manual Data Input keyboard, key in the number “0" (zero).

C) Press the Input key.

7-6 M-489

M-489 7-7

Figure 7.5 - Establishing the Main Spindle Work Shift(Hardinge Turret Top Plate)

TI4733

ShimThickness

Turret Position

Work Shift

MainSpindle

Figure 7.6 - Establishing the Sub-Spindle Work Shift(Hardinge Turret Top Plate)

TI4734A

Work Shift

MainSpindle

OptionalSub-Spindle

Turret Position

Shim Thickness

4.7875 inches[121.603 mm]

15. Use the cursor keys to move the cursor to the Z Data field under Measurement.

16. If setting work shift at the main spindle, key in the shim thickness as a positive (+) value.

If setting work shift at the sub-spindle, key in:

-(4.7875” [121.603 mm] + shim thickness)

17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register.

18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm]from the face of the workpiece.


7-8 M-489

- NOTES -

M-489 7-9

- NOTES -

7-10 M-489

CHAPTER 8 - TOOL OFFSETS

INTRODUCTION

The Tool Offset file is made up of two types of offsets: Tool Geometry Offsets and Tool Wear Off-sets. The control has the capacity to store 32 sets of each offset type (Offsets 01 through 32) in sepa-rate files.

- NOTE -

Information stored in the Geometry and Wear Offset files is automatically convertedinto the correct units when a programmed G20 or G21 command is used to switchbetween inch and metric mode.

Tool offsets are illustrated in Figures 8.1 through 8.12.

Machines equipped with an ESA turret top plate have the same X axis reference po-sition and travel specifications as a machine equipped with a VDI 30 turret top plate.As indicated in Figures 8.5 through 8.8, the diameter of the ESA turret top plate is1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.

Refer to the programmer’s manual (M-488) for:

• a description of turret reference point and the tool nose reference point.

• information on activating and canceling tool offsets

The following information is stored in the Tool Geometry Offset file:

X Tool Dimension

Diameter distance from the X axis tool touch-off point to the turret X axis referencepoint. Sign is determined by the direction from the tool nose reference point to the turretreference point.

Z Tool Dimension

Distance from the Z axis tool touch-off point to the turret Z axis reference point. Sign isdetermined by the direction from the tool nose reference point to the turret referencepoint.

Tool Orientation:

The orientation code describes the location of the center of the tool nose in relation tothe tool nose reference point.

Tool Nose Radius Value:

The distance from the cutting edge to the center of the tool nose radius.

M-489 8-1

8-2 M-489

Figure 8.1 - Square Shank Tool Offsetsfor Main Spindle Operation (VDI Top Plate)

TI4679A

Turret Z Axis Reference Position

Z Axis Tool Offset

Turret X Axis Reference Position

Main Spindle

+X Axis Tool Offset+Z Axis Tool Offset

This distance equals ½the X Axis Tool Offset

Figure 8.2 - Square Shank Tool Offsetsfor Sub-Spindle Operation (VDI Top Plate)


TI4687A

Z Axis Tool Offset


OptionalSub-Spindle

+X Axis Tool Offset-Z Axis Tool Offset


M-489 8-3

Figure 8.3 - Round Shank Tool Offsetsfor Main Spindle Operation (VDI Top Plate)

TI4680A


Z Axis Tool Offset



Main Spindle


Figure 8.4 - Round Shank Tool Offsetsfor Sub-Spindle Operation (VDI Top Plate)


Z Axis Tool Offset




TI4688A

8-4 M-489

Figure 8.5 - Square Shank Tool Offsetsfor Main Spindle Operation (ESA Top Plate)

TI5439A


Z Axis Tool Offset

Turret X Axis Reference Position(Refer to the note on page 8-1)

Main Spindle



1.378 [35.00]


Figure 8.6 - Square Shank Tool Offsetsfor Sub-Spindle Operation (ESA Top Plate)


TI5440A

Z AxisTool Offset

Turret X Axis Reference PositionRefer to the note on page 8-1)

OptionalSub-Spindle



1.378 [35.00]


M-489 8-5

Figure 8.7 - Round Shank Tool Offsetsfor Main Spindle Operation (ESA Top Plate)

TI5441A


Z Axis Tool Offset

Main Spindle




1.378 [35.00]


Figure 8.8 - Round Shank Tool Offsetsfor Sub-Spindle Operation (ESA Top Plate)


TI5442A

Z Axis Tool Offset

OptionalSub-Spindle




1.378 [35.00]


8-6 M-489

Figure 8.9 - Square Shank Tool Offsetsfor Main Spindle Operation (Hardinge Top Plate)

TI4736

Main Spindle




Z Axis Tool Offset


Figure 8.10 - Square Shank Tool Offsetsfor Sub-Spindle Operation (Hardinge Top Plate)

TI4737


Z Axis Tool Offset


OptionalSub-Spindle



M-489 8-7

Figure 8.11 - Round Shank Tool Offsetsfor Main Spindle Operation (Hardinge Top Plate)

TI4738


Z Axis Tool Offset



Main Spindle


Figure 8.12 - Round Shank Tool Offsetsfor Sub-Spindle Operation (Hardinge Top Plate)

TI4739


Z AxisTool Offset




The Tool Wear Offset file allows the operator to enter minor dimensional changes for each tool tocompensate for tool wear. The Tool Wear Offset files coincide with the Geometry Offset files. When atool offset is activated, the control looks at the corresponding Tool Wear offset and performs the nec-essary corrections to compensate for tool wear.

The Tool Offset files allow the operator to easily make corrections resulting from tool changes,eliminating the need for large-scale modifications to the part programs.

The data word format for the T word is T4. Tool Offsets are activated by the last two digits in the Tword. The first two digits specify the turret station

8-8 M-489

STORING TOOL GEOMETRY OFFSETS IN MEMORY

- NOTE -

Tool offset values can be entered using the following methods:

Manually from the keyboard.

Through the part program or a separate program. Refer to the programmer’smanual (M-488) for information on storing tool offsets from a program.

SETTING TOOL OFFSETS FOR NON-CENTER WORKING TOOLS ON THE TURRET

1. Load a workpiece of known diameter and length into the collet or chuck.

2. If it has not already been done, determine the Work Shift Offset following the procedurebeginning on page 7-2.

- NOTE -

The work shift value must be in the Z axis work shift register to accurately set thetool offsets.

3. Enter the work shift value into the Z axis work shift register.


5. Set the Feedrate Override switch to the desired setting.

- CAUTION -

The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before indexing aturret.


7. Index the turret to the selected station.

8. Mount the tool holder and tool onto the turret.

9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle.

10. Place a shim or scale against the face of the workpiece and use the handwheel to move theturret on the Z axis to gently touch the tool tip to the shim so that a slight drag is felt whenmoving the shim, as shown in Figure 8.13 or 8.14.


12. Press the Offset soft key to access the Tool Offset pages.

M-489 8-9

13. If not already displayed, press the Geometry soft key to display the Tool Geometry Offsetpages.

14. Use the page and cursor keys to position the cursor at the Z axis field for the desired offset.

15. If touching off on the main spindle, key in the letter Z and the thickness of the shim as a positivevalue.

If touching off on the optional sub-spindle, key in the letter Z and the thickness of the shimas a negative value.

8-10 M-489

Figure 8.13 - Tool Touch-Off Points at Main Spindle(VDI Turret Top Plate Shown)

TI4689A

Workpiece

Shim

O.D. Tool

Workpiece

Shim

I.D. Tool

Figure 8.14 - Tool Touch-Off Points at Optional Sub-Spindle(VDI Turret Top Plate Shown)

TI4690A

16. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under theappropriate offset number, as selected in step 14.

17. If touching off an O.D. working tool, jog the turret on the Z axis to clear the workpiece.

If touching off an I.D. working tool, use the handwheel to position the tool tip approximately.125 inch [3.2 mm] from the face of the workpiece.

18. Use the cursor keys to position the cursor at the X axis field for the desired offset.

19. If touching off an O.D. working tool, jog the turret on the X axis to place the tool tip beyond theO.D. of the part as shown in Figure 8.13 or 8.14.

20. If touching off an O.D. working tool, use the handwheel to move the turret on the Z axis until thetool tip is past the face of the workpiece.

21. Place the shim against the O.D. of the workpiece and turn the handwheel in the appropriatedirection until the tool tip gently makes contact with the shim, as shown in Figure 8.13 or 8.14.

22. Key in the diameter of the workpiece as a positive value.

Example: Diameter = 2.125

Input = X2.125

- NOTE -

Using the Measure soft key to set a tool geometry offset automatically resets thecorresponding wear offset to zero.

23. Press the Measure soft key. The X axis offset value for the tool will now be displayed under theappropriate offset number.

24. Compensate for shim thickness:

If touching off an O.D. working tool and the control is set for diameter programming, entertwice the shim thickness as a negative (-) value and press the Input+ soft key.

If touching off an O.D. working tool and the control is set for radius programming, enter theshim thickness as a negative (-) value and press the Input+ soft key.

If touching off an I.D. working tool, no shim compensation is needed.

25. Jog the turret in the +X direction to clear the diameter of the workpiece by at least 1 inch [25mm] in the +X direction.

26. Jog the turret in the +Z direction to clear the face of the workpiece by at least 1 inch [25 mm] inthe +Z direction.


28. Index the turret to the next tool station that is to be set.

29. Repeat steps 8 through 28 as required for other tools.

M-489 8-11

SETTING TOOL OFFSETS FOR CENTER-WORKING TOOLS ON THE TURRET

- CAUTION -

This procedure is to be used for center-working tools such as drills, taps, andreamers ONLY.

The X axis Wear Offset must always set to zero for center-working tools.

1. Load a workpiece of known diameter and length into the collet or chuck.


- NOTE -





- CAUTION -

The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before indexing aturret.



8. Mount the tool in the tool holder at the length desired.

9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle.

10. Place a shim against the face of the workpiece and use the handwheel to move the turret in theappropriate direction to gently touch the tool tip to the shim until a slight drag is felt when movingthe shim.



13. Press the Geometry soft key to access the Geometry Offset pages.

14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset.

8-12 M-489

- NOTE -

Refer to the appropriate tooling catalog for information on tool holder dimensions.

15. If the control is set for diameter programming, enter twice the tool holder dimension as apositive (+) value and press the Input key.

If the control is set for radius programming, enter the tool holder dimension as a positive(+) value and press the Input key.

16. Use the cursor keys to position the cursor at the Z axis field for the desired offset.

17. Key in the letter Z and the thickness of the shim as a positive value.

- NOTE -



19. Move the turret in the appropriate Z direction to clear the workpiece.

20. Repeat steps 6 through 19 as required for other center-working tools.


TOOL PROBE [Option]

INTRODUCTION

The tool probe allows the operator to set tool geometry offsets quickly and accurately. The toolprobe has been calibrated at the factory and is ready to use without further adjustment. Refer to “ToolProbe Calibration”, on page 8-21, for additional information.

The tool probe has three available operating modes:

• Manual Mode

• Semi-Automatic Mode

• Automatic Mode

MANUAL TOOL PROBE OPERATION

- NOTE -

The axis jog push buttons will not produce axis motion when the tool probe is acti-vated and deployed. Axis motion is obtained through the use of the manual pulsegenerator.

The optional sub-spindle must be at the E axis reference position before the toolprobe can be activated and deployed.

Once a tool has been probed, the X axis must be moved to the Reference Positionbefore the turret can be indexed.

This procedure assumes that all required turret tooling has been installed. Refer to:

Chapter 5 for information on installing tooling on a VDI turret top plate.

Chapter 4 for information on installing tooling on an ESA turret top plate.

Chapter 6 for information on installing tooling on a Hardinge turret top plate.

- CAUTION -

The machine operator must be sure that no interference exists between thespindle, spindle tooling, tool probe, turret, turret tooling, or workpiece beforeindexing the turret.

1. Activate Rapid Reference mode.

2. Set the Manual Axis Movement switch to “X”.

3. Press the Rapid Reference push button to move the turret to the X axis reference position.

8-14 M-489

4. If the machine is equipped with the sub-spindle option:

A) Set the Manual Axis Movement switch to “E”.

B) Press the Rapid Reference push button to move the sub-spindle to the reference position.


- CAUTION -

When the tool probe is turned ON, do not touch the probe with any objectother than the tool that is being set.

- NOTE -

Activating the tool probe will cause the control to automatically display the tool ge-ometry offset registers.

6. Press the Tool Probe push button to activate and deploy the tool probe.


8. Use the page and cursor keys to position the cursor at the desired offset number.

- CAUTION -

The machine operator must exercise care when approaching the tool probestylus with the tool. DO NOT impact the tool probe stylus with the tool.

9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe styluswith the tool.

10. Use the manual pulse generator to move the tool tip to a position near the appropriate side ofthe tool probe stylus.

11. Press the appropriate axis push button to choose which side of the tool probe stylus will beused. Refer to Figure 8.15.

12. Set the Rapid Override switch to the “1x” position for manual pulse generator control.

M-489 8-15

Figure 8.15 - Axis Push Buttons

TI4716

X/Z

X/Z

X/Z X/Z

+X

ToolProbeStylus

+Z

CL

13. Turn the manual pulse generator one increment at a time to move the tool tip carefully againstthe tool probe stylus until the probe is tripped. The offset will register on the display screen

14. Move the tool away from the tool probe stylus.

15. Repeat steps 8 through 14 if touching the tool off on another axis.





20. Repeat steps 7 through 19 if touching off additional tools.

21. Press the Tool Probe push button to deactivate and retract the tool probe.

SEMI-AUTOMATIC AND AUTOMATIC TOOL PROBE OPERATION

Datuming the Tool Probe

- CAUTION -

The tool probe must be correctly calibrated in manual mode before semi-auto-matic or automatic operation is performed.

All tools that are to be updated through semi-automatic or automatic toolprobe operation MUST have an offset value that is approximately equal to theactual tool offset data. This can be accomplished by either of the followingmethods:

• Manually touching off the tools

• Using the tool probe in manual mode

- NOTE -

It is recommended that a standard turning tool be used to datum the probe.

The semi-automatic and automatic tool probe functions require that a master tool be used to datumthe probe prior to use. A master tool is defined as a tool that has known offset values defined in the tooloffset file.

The process of datuming the tool probe for semi-automatic or automatic operation is not to be con-fused with calibrating the probe for manual operation.

When the probe is calibrated for manual operation, parameters 5015 through 5018 areused to record the position of the probe stylus. Refer to “Tool Probe Calibration”, on page8-21, for additional information.

When the probe is datumed for semi-automatic or automatic operation, macro variables522 through 531 are used to record the position of the probe stylus. Refer to “Tool ProbeDatum Procedure”, on the next page.

8-16 M-489

TOOL PROBE DATUM PROCEDURE

- NOTE -

Refer to “Entering a Program from the Keyboard”, page 3-10, for information on en-tering a program through the Manual Data Input keyboard.

1. Enter the following program into the control memory:

O____ (Datum Auto Tool Probe) ; Program Number (Operator Message)

#509=1 ; Specifies that Geometry and Wear Offsets are to be used

#530=.785 ;

#531=.3925 ;

G98 ; Inch/Millimeter per Minute Feedrate

M91 ; Enable Automatic Mode with Probe Extended

G65 P9011 K2. T_. H_. ; Call Macro Program 9011,K2. = Sets all Probe Faces for DatumT_. = Tool Station and Offset for Master Tool,H_. - Tool Quadrant (Tool Orientation Code)

M30 ; End of Program








7. Index the turret to the station with the master tool.


- CAUTION -



10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the cornerof the two sides of the probe stylus to be used for datuming.

11. Activate Automatic mode.

M-489 8-17

- NOTE -

Refer to “Activating a Stored Program”, page 3-10, for information on activating aprogram.

12. Verify the datum program entered in step 1 is active.

13. Press the Cycle Start push button to datum the probe. After datuming is complete, the tool willreturn to the position it was jogged to in step 10.




17. Press the Tool Probe push button to retract the tool probe.

8-18 M-489

Semi-Automatic Tool Probe Operation

- CAUTION -

The tool probe must be correctly calibrated before semi-automatic operation isperformed.

The probe must be datumed before semi-automatic operation is performed.Refer to “Datuming the Tool Probe”, page 8-16 for information on datumingthe probe for semi-automatic operation.

- NOTE -

Refer to “Entering a Program from the Keyboard”, page 3-10, for information on en-tering a program through the Manual Data Input keyboard.

1. Enter the following program into the control memory:

O____ (Semi-Automatic Tool Probe Cycle) ; Program Number (Operator Message)

#509=1 ; Specifies that Geometry and Wear Offsets are to be used

G98 ; Inch/Millimeter per Minute Feedrate

M91 ; Enable Automatic Mode with Probe Extended

G65 P9011 T_. H_. ; Call Macro Program 9011,T_. = Offset Location for Tool Data (1 - 32),H_. - Tool Quadrant (Tool Orientation Code)











- CAUTION -



10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the cornerof the two sides of the probe stylus to be used for datuming.

11. Activate Automatic mode.

M-489 8-19

- NOTE -


12. Verify the program entered in step 1 is active.

13. Press the Cycle Start push button to probe the tool. After probing is complete, the tool will returnto the position it was jogged to in step 10.




17. Press the Tool Probe push button to retract the tool probe.

- NOTE -

If probing additional tools, modify the values for the T and H words in programO3333 as needed for each tool to be probed.

18. Repeat steps 6 through 17, as needed, to probe additional tools.

Automatic Tool Probe Operation

- CAUTION -

The tool probe must be correctly calibrated before automatic operation is per-formed.

The probe must be datumed before automatic operation is performed. Refer to“Datuming the Tool Probe”, page 8-16 for information on datuming the probefor automatic operation.

Automatic tool probe operation can be performed by using either of the following methods:

• Execute automatic tool probe operation from within the part program

• Call a subprogram to execute automatic tool probe operation

Refer to the programmer’s manual (M-488) for information on programming automatic operation ofthe tool probe.

8-20 M-489

TOOL PROBE CALIBRATION

The tool probe parameters are set at the factory when the probe is calibrated. Normally, it is notnecessary to re-calibrate the probe unless one of the following occurs:

• The probe tip has been replaced.

• The turning center is operating at a temperature that is significantly different than thatwhich the tool probe was calibrated at.

- NOTE -

The values for parameters 5015 and 5016 are set as diameter values.

Parameters 5015 through 5018 define the locations of the stylus contact surfaces used to set tooloffsets. Refer to Figure 8.16.

CALIBRATION PROCEDURE

1. Mount sufficient tooling on each turret to be able to probe all 4 surfaces on each tool probestylus.

2. Set tool offsets for the tooling installed in step 1 using the procedure outlined under “SettingTool Offsets for Non-Center Working Tools on the Turret”, starting on page 8-9.

3. Probe one of the tools installed in step 1 and observe any difference between the tool offsetobtained in step 2 and the tool offset established by the tool probe.

- NOTE -

Refer to Chapter 3 for information on editing machine parameters.

4. Modify the associated parameters (5015 through 5018) as needed to produce the same offsetusing both steps 2 and 3.

5. Repeat steps 2 through 4 as needed until identical results are obtained when using both steps 2and 3.

M-489 8-21

Figure 8.16 - Tool Probe Parameter Definitions

TI4717A

Parameter 5018

+X

+Z

ProbeStylus

Parameter 5017

Parameter5015

Parameter5016

CL

ENTERING TOOL NOSE RADIUS VALUE AND ORIENTATION CODE

- NOTE -

If Tool Nose Radius Compensation is to be used, the tool nose radius value and thetool quadrant must be entered for each tool which uses Tool Nose Radius Compen-sation.



3. Press the Geometry soft key to display the tool geometry offsets.

4. Use the page and cursor keys to position the cursor at the R Data field for the desired offset.

5. Enter the tool nose radius value and press the Input key.

- NOTE-

The “T” value defines the orientation of the tool tip and has a range from 0 through 9.Refer to Figure 8.17.

6. Use the cursor keys to position the cursor at the T Data field for the desired offset.

7. Enter the tool orientation code number and press the Input key.

8. Repeat steps 4 through 7 for each tool, as required.

8-22 M-489

Figure 8.17 - Tool Orientation Codes

TI2376

8

6

5 7

4 3

21

+X

+Z

Main Spindle Tailstock / Sub-Spindle

TOOL WEAR OFFSETS

Tool wear offset adjustments are made by adding to or subtracting from an existing offset value us-ing positive or negative values and the Input+ soft key.

Tool Wear Offsets that are intended to adjust the position of the tool nose in the -X or -Z directionare entered as NEGATIVE values. Tool Wear Offsets that are intended to adjust the position of thetool nose in the +X or +Z direction are entered as POSITIVE values.

ADJUSTING X AND Z AXIS TOOL WEAR OFFSETS



3. Press the Wear soft key to display the Wear Offset page.


5. Enter the X axis wear value as follows:

If the control is set for Diameter Programming, enter the wear offset as a diameter value.

If the control is set for Radius Programming, enter one half the measured (diameter) wearoffset value.

6. Press the Input+ soft key.


8. Enter the Z axis wear value.

9. Press the Input+ soft key.

10. Repeat steps 4 through 9 for each tool as required.

RULES FOR ADJUSTING WEAR OFFSETS

1. Negative (-) offset values MUST be signed.

2. Wear Offset values may not exceed .5000 inch [12.700 mm].


- NOTES -

8-24 M-489

CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER

- WARNING -

Tighten all draw tube screws before beginning spindle operation.

- CAUTION -

Never operate the main spindle without a work-holding device if the draw tubeis in the spindle.

INTRODUCTION

The hydraulic collet closer can be programmed for bar feed operation or it can be operated manu-ally for machine setup and chucking operations. If repairs to the collet closer assembly are required,the ENTIRE ASSEMBLY must be removed and returned to the factory. Refer to the maintenancemanual (M-490) for information on removing or installing the collet closer assembly.

SPINDLE CAPACITIES

- CAUTION -

When machining bar stock that extends back into the spindle draw tube, spin-dle liners MUST be used when machining bar stock below the minimum sizelisted in the following table.

Refer to “Spindle Liners”, page 9-17, for additional information.

RS and SR series lathes have the following maximum through-spindle capacities:

MachineModel

Maximum Through-SpindleCapacity

Inch [Millimeter]

Minimum Bar StockDiameter for Operationwithout a Spindle Liner

RS 42 Lathe 1.625 [41.27] 1.500 [38.10]

RS 51 & SR 150 Lathes 2.000 [50.80] 1.875 [47.63]

RS 65 & SR 200 Lathes 2.500 [63.50] 2.375 [60.33]

SR 200 Big-Bore Lathes 3.070 [78.00] 2.945 [74.83]


FREE SPINDLE

A “Free Spindle” condition allows the main spindle to be turned by hand. To obtain a free spindle,proceed as follows:

- NOTE -

To obtain a free spindle, the control must be ON and the spindle must not be rotat-ing.

1. Power up the machine as described in Chapter 2.

2. Press the control Reset key.

3. Press the Main Spindle Free push button.

HYDRAULIC PRESSURE CONTROL

The collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic pressure con-trols are located at the right end of the machine.

Gauge “A”, Figure 9.1, registers the main spindle collet closer hydraulic pressure in psig and bars.

Knob “C”, Figure 9.2, is used to adjust the hydraulic pressure applied to the main spindle colletcloser draw bar.

Refer to Table 9.1, 9.2, or 9.3 to determine the approximate force that will be applied to the colletcloser draw bar for a given pressure.

A check valve system positively holds the closer open or closed, whichever is active, in the event ofan hydraulic pressure failure.

- CAUTION -

DO NOT exceed the maximum pressure setting, as shown in Tables 9.1, 9.2, or9.3.

The collet closer hydraulic pressure should be maintained at 500 psi [34.5 bar]when operating at spindle speeds above 4,200 rpm.

- NOTE -

It is the responsibility of the machine operator or set-up person to properly adjust thecollet closer hydraulic pressure, based on the type of material to be machined andthe configuration of the workpiece.

9-2 M-489

ADJUSTING THE MAIN SPINDLE HYDRAULIC PRESSURE

1. Remove cover "B", Figure 9.1.

2. Loosen the knurled lock nut behind adjustment knob “C”, Figure 9.2.

3. Turn the adjustment knob clockwise or counterclockwise to decrease or increase the colletcloser hydraulic pressure.

4. Tighten the knurled lock nut to secure the setting.

5. Replace the cover.

M-489 9-3

Figure 9.1 - Right Front Corner of Machine

TP7305

A

B

Figure 9.2 - Main Collet CloserPressure Adjustment

C

TP7304


English Metric

Gauge Pressure(psig)

Draw Bar Force(lbs)

Gauge Pressure(bar)

Draw Bar Force(daN)

100 1,206 6.9 538

200 2,412 13.8 1,076

300 3,619 20.7 1,615

400 4,826 27.6 2,152

500 6,000 34.5 2,678

Table 9.1 - Main Spindle Collet Closer Draw Bar Force(RS 42 Lathes)

English Metric


Draw Bar Force(lbs)

Gauge Pressure(bar)

Draw Bar Force(daN)

100 2,000 6.9 890

200 4,000 13.8 1,780

300 6,000 20.7 2,670

400 8,000 27.6 3,560

500 10,000 34.5 4,450

Table 9.2 - Main Spindle Collet Closer Draw Bar Force(RS 51 and SR 150 Lathes)

English Metric


Draw Bar Force(lbs)

Gauge Pressure(bar)

Draw Bar Force(daN)

100 2,533 6.9 1,127

200 5,066 13.8 2,253

300 7,599 20.7 3,380

400 10,132 27.6 4,507

500 12,665 34.5 5,634

Table 9.3 - Main Spindle Collet Closer Draw Bar Force(RS 65, SR 200, and SR 200 Big-Bore Lathes)

MAIN COLLET CLOSER OPERATION

AUTOMATIC OPERATION

For automatic operation, program M21 to open the collet and M22 to close the collet. The M21(Open Collet) command may be executed while the spindle is running. M21 will remain active until it iscanceled by an M22 (Close Collet) command. While M21 is active, the Main Open/Close push buttonwill not be active. A programmed M22 (Collet Close) command will remain active until it is canceled byan M21 (Open Collet) command.

MANUAL OPERATION

- NOTE -

Manual operation of the collet closer is not possible while Cycle Start is active.

When the bar feed option is turned OFF, the collet closer can be manually operated in any mode.When the bar feed option is turned ON, the machine must be in Jog mode to manually operate the col-let closer. Use the Main Open/Close push button to operate the collet closer manually.

CHUCKING MODES

There is no default chucking mode. The current chucking mode will remain active until canceled bythe appropriate command (M27 or M28).

External chucking mode permits the use of work-holding fixtures that grip the workpiece externally.Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally.

SWITCHING THE CHUCKING MODE

1. Check to be sure the Main Open/Close indicator light is ON. Place a workpiece in the collet andpress the Main Open/Close push button, if necessary.

2. Activate Manual Data Input mode.

3. Press the Program soft key.

4. At the Manual Data Input keyboard:

Key in “M28” for External Chucking

Key in “M27” for Internal Chucking




8. Close the machine guard door and press the Cycle Start push button.

9. Press the control Reset key. The selected chucking mode will be active

M-489 9-5

CLEANING THE SPINDLE

As a general rule, the spindle and spindle draw tube should be cleaned between setups or monthlyif a long-run job is on the machine. However, when the machine is run more than one shift per day orcertain types of materials are being machined, it may be necessary to clean the spindle and spindledraw tube more often. Use the spindle tooling removal and installation procedures that follow forcleaning the spindle and draw tube.

SPINDLE TOOLING

- CAUTION -

Read and follow all safety recommendations and operating limits for anywork-holding device installed in the spindle. DO NOT EXCEED the rated ca-pacity of the work-holding device.

The spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced toISO G2.5 or better.

All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limi-tations and balance specifications.

Hardinge Inc. offers chucks balanced to G2.5 or better.

RS 42, RS 51, SR 150, AND SR 200 LATHES

Removing Spindle Tooling

- CAUTION -

Do not operate the collet closer when a collet or step chuck is mounted inplace without gripping a piece of stock or a plug of the correct size.

- NOTE -

This procedure applies to RS 42, RS51, SR 150, and SR 200 lathes only.Refer to page 9-12 for information relat-ing to SR 200 BB (Big Bore) lathes.

1. Power the machine up using the procedureoutlined in Chapter 2.



4. If necessary, press the Main Open/Close pushbutton to open work-holding device in the colletcloser.

5. At the left end of the machine, remove accesscover “D”, Figure 9.3.

6. If present, remove the plug from the end of thespindle draw tube.


Figure 9.3 - Main Spindle Access Cover

D

TP7298

7. Completely loosen six screws “E”, Figure 9.4.

- NOTE -

Six screws “E”, Figure 9.4, must becompletely disengaged from the colletcloser liner before draw tube nut “F”can be rotated.

Removal of a jaw chuck or step chuckmay require the assistance of a secondperson.

8. Rotate draw tube nut “F”, Figure 9.4,counterclockwise to disengage the draw tubefrom the work-holding device.

- WARNING -

Be prepared to accept the weight ofthe work-holding device.

9. Remove the work-holding device from thespindle.

10. If the machine is equipped with the optional sub-spindle, cover the sub-spindle to protect it fromchips while the main spindle is being cleaned.

11. Close the main coolant guard door.

12. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of thespindle.

13. Completely remove the draw tube from the back of the spindle.

14. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of thespindle a second time.

15. Clean the spindle and draw tube.

16. Lightly lubricate the bearing surfaces of the draw tube with Molylube® Anti-Seize grease.

17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp® SHC 32 grease.

18. Carefully replace the draw tube in the spindle.

19. If spindle tooling is to be installed at this time, proceed to “Installing Spindle Tooling”, beginningon page 9-8.

If spindle tooling is not to be installed at this time:

A) Replace the draw tube plug.

B) Replace access cover “D”, Figure 9.3.

M-489 9-7

Figure 9.4 - Main Spindle Draw Tube Nut

TP7231

F

E

G

Installing Spindle Tooling

- NOTE -

For the best surface finish and part roundness, the main spindle and draw tube havebeen balanced together at the factory. Although the spindle and draw tube can berun in other positions, the best balance is when etched mark “G”, Figure 9.4, andspindle drive button “H”, Figure 9.5, are aligned.

Two procedures are outlined in this section. The first procedure, which begins below, covers the in-stallation of collets and step chucks. The second procedure, beginning on page 9-10, covers the in-stallation of jaw chucks.

COLLET OR STEP CHUCK

- NOTE -

SR 150 and SR 200 machines are designed for jaw chuck operation only. Refer topage 9-10 for information on installing jaw chucks on RS 42, RS 51, SR 150, and SR200 lathes.

Refer to page 9-14 for information on installing jaw chucks on SR 200 BB (Big Bore)lathes.

This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”,beginning on page 9-6.

If previously used spindle tooling has just been removed, proceed to step 6.

- CAUTION -


1. Power the machine up using the procedure outlined in Chapter 2.



4. Remove access cover “D”, Figure 9.3.

5. If present, remove the plug from the end of thespindle draw tube.

- NOTE -

The collet and spindle bore MUST beclean.

6. Clean the spindle bore and the collet or stepchuck and closer to be installed.

7. Press the Main Spindle Free push button torelease the spindle brake and allow the spindleto be rotated.

8. Manually position spindle drive button “H”,Figure 9.5, to the top dead center (12 o’clock)position.

9-8 M-489Revised: September 29, 2007

Figure 9.5 - Main Spindle Nose withDrive Button at Top Dead Center

H

TP4820

9. Press the Main Spindle Free push button again to have the brake secure the spindle drivebutton at 12 o’clock.

- WARNING -

To insure operator safety:- DO NOT use cast iron step chucks.- DO NOT use a step chuck without a step chuck closer.

- NOTE -

Installation of a step chuck may require the assistance of a second person.

10. If installing a step chuck in the spindle, place the step chuck closer against the spindle andinstall the mounting screws securely.

11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle untilit makes contact with the draw tube.

12. Carefully push the draw tube against the back of the collet while rotating the draw tubeclockwise to start the threads of the collet into the threads of the draw tube.

- NOTE -

Adjustment of the collet or step chuck may require the assistance of a second per-son.

13. Select the largest diameter workpiece which is to be chucked and position this part in the colletor step chuck.

14. Rotate draw tube nut “F”, Figure 9.4, clockwise until the workpiece is gripped tightly; then, backthe draw tube nut off ¼ to ½ turn.

15. Rotate the draw tube the shortest distance to locate etched mark “G” at top dead center (12o’clock) position.

16. Tighten six draw tube screws “E”.

17. Press the Main Open/Close push button to close the collet and test the gripping force on theworkpiece.

If the gripping force is satisfactory, go to step 18.

If the gripping force is more or less than desired, use the procedure on page 9-3 to adjustthe hydraulic pressure between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1,9.2, or 9.3.

- CAUTION -

If the machine will not be operated with a bar feed system, the draw tube plugshould be installed in the end of the spindle draw tube to prevent coolant andchips from entering the spindle drive motor compartment.

18. Install the plug in the end of the spindle draw tube if a bar feed system will not be used.

19. Replace access cover “D”, Figure 9.3.

M-489 9-9

JAW CHUCK

- NOTE -

This procedure applies to RS 42, RS 51, SR 150, and SR 200 lathes only. Refer topage 9-14 for information relating to SR 200 BB (Big Bore) lathes.

This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”,beginning on page 9-6.


- CAUTION -





4. Remove access cover “D”, Figure 9.3.

5. If present, remove the plug from the end of the spindle draw tube.

- NOTE -

The jaw chuck and spindle bore MUST be clean.

6. Clean the jaw chuck and spindle bore.

7. Press the Main Spindle Free push button to release the spindle brake and allow the spindle tobe rotated.

8. Manually position spindle drive button “H”, Figure 9.5, to the top dead center (12 o’clock)position.

9. Press Main Spindle Free push button again to have the brake secure the spindle drive button at12 o’clock.

10. Place the chuck in the spindle and install the mounting screws securely.

11. Carefully push the draw tube against the back of the chuck while rotating the draw tubeclockwise to start the threads of the chuck into the threads of the draw tube.

12. Thread the draw tube onto the 3 jaw chuck as far as possible.

13. Rotate the draw tube counterclockwise to locate etched mark “G”, Figure 9.4, at top deadcenter (12 o’clock) position.

14. Tighten six draw tube screws “E”.


15. Place a workpiece into the chuck and press the Main Open/Close push button to close thechuck and test the gripping force on the workpiece.



- CAUTION -




M-489 9-11

SR 200 BB (BIG BORE) LATHES

Removing the Chuck

- NOTE -

This procedure applies to SR 200 BB (Big Bore) lathes only. Refer to page 9-6 for in-formation relating to RS 42, RS 51, SR 150, and SR 200 lathes.




4. Remove the jaws from the chuck.

- NOTE -

Chuck draw tube nut “I”, Figure 9.6, alternately shifts to the left and right as the MainOpen/Close push button is pressed.

5. Press the Main Open/Close push button to shiftchuck draw tube nut “I”, Figure 9.6, to the right.

- WARNING -

DO NOT completely remove the sixchuck mounting screws until in-structed to do so.

- NOTE -

Heavy torque should only be applied tothe chuck mounting screws when theyare positioned toward the back of themachine.

6. Loosen, but DO NOT remove, the chuckmounting screws as follows:

A) Loosen the two chuck mounting screwspositioned toward the back of the machineapproximately 3 turns. Refer to Figure 9.7.

B) Press the Main Spindle Free push button torelease the spindle brake.

C) Rotate the main spindle to position the nextpair of chuck mounting screws toward theback of the machine.

D) Press the Main Spindle Free push button toengage the main spindle brake.

E) Repeat steps A through D to loosen all sixchuck mounting screws.


Figure 9.6 - Chuck Draw Tube Nut

TP7597

I

Figure 9.7 - Wrench Location

TP7600

7. Insert alignment plug “J”, Figure 9.8, into the spindle.

8. Using a dead-blow hammer, tap the side of the chuck to disengage the chuck from the taper onthe face of the spindle.

9. Mount offset lifting bracket “K”, Figure 9.9, with eye bolt, onto the chuck with the screwprovided.

- WARNING -

DO NOT attempt to manually remove the chuck from the spindle. A mechanicallifting device is required.

10. Attach a mechanical lifting device to the eye bolt on the offset lifting bracket.

11. Completely remove the six chuck mounting screws.

- NOTE -

Chuck draw tube nut “I”, Figure 9.6, isequipped with slots to engage the tabson draw tube nut wrench “L”, Figure9.10.

12. Using draw tube nut wrench “L” and rod “M”,Figure 9.10, rotate chuck draw tube nut “I”,Figure 9.6, counterclockwise to completelydisengage the spindle draw tube.

13. Slide the chuck, with alignment plug, awayfrom the spindle face and remove from themachine.


Figure 9.8 - Chuck Alignment Plugand Offset Lifting Bracket

J

TP7599

Figure 9.9 - Offset Lifting BracketMounted on the Chuck

K

TP7596

Figure 9.10 - Draw TubeNut Wrench and Rod

L

M

TP7598

14. At the left end of the machine, remove access cover “D”, Figure 9.3.


16. If the machine is equipped with the optional sub-spindle, cover the sub-spindle to protect it fromchips while the main spindle is being cleaned.


18. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of thespindle draw tube.

19. Clean the spindle draw tube and spindle face.

20. If a chuck is to be installed at this time, proceed to “Installing the Chuck”, below.



B) Replace access cover “D”, Figure 9.3.

Installing the Chuck

- NOTE -

This procedure applies to SR 200 BB (Big Bore) lathes only. Refer to page 9-10 forinformation relating to RS 42, RS 51, SR 150, and SR 200 lathes.

1. If necessary, clean the spindle draw tube and spindle face.

2. Clean the chuck to be installed.

3. Press the Main Spindle Free push button to release the spindle brake.

- NOTE -

The spindle draw tube alternately shifts to the left and right as the Main Open/Closepush button is pressed.

4. Press the Main Open/Close push button to shift the spindle draw tube to the right.

5. Insert alignment plug “L”, Figure 9.8, completely into the chuck.

6. Mount offset lifting bracket “M”, Figure 9.9, with eye bolt, onto the chuck with the screwprovided.

7. Coat the threads of the draw bar with Molylube® Anti-Seize grease.


- WARNING -

DO NOT attempt to manually install the chuck on the spindle. A mechanicallifting device is required.

8. Using a mechanical lifting device, align the chuck with the spindle draw bar.

9. Slide the chuck onto the spindle draw bar.

10. Rotate the spindle to align spindle drive button “N”, Figure 9.11, with one of the recesses in theback of the chuck.

11. Press the Main Spindle Free push button to engage the main spindle brake.

12. Using draw tube nut wrench “J” and rod “K”, Figure 9.10, rotate chuck draw tube nut “I”, Figure9.6, clockwise to completely engage the spindle draw tube.

13. Install the six chuck mounting screws hand tight. DO NOT torque the screws until instructed todo so.

14. Press the Main Open/Close push button to shift the spindle draw tube to the left.

15. Remove the lifting bracket.

16. Remove the alignment plug from the chuck.


Figure 9.11 - End View of Spindle(SR 200 BB Lathe)

TI5611

N

Figure 9.12 - Chuck MountingScrew Torque Sequence

TI5609

14

3 5

2 6

- NOTE -

Heavy torque should only be applied to the chuck mounting screws when they arepositioned toward the back of the machine, as shown in Figure 9.7.

Refer to Figure 9.12 for the chuck mounting screw torque sequence.

Torque the chuck mounting screws to 200 lb-ft [270 N•m].

17. Torque the chuck mounting screws as follows:

A) Torque one of the chuck mounting screws positioned toward the back of the machine, asshown in Figure 9.7.

B) Press the Main Spindle Free push button to release the spindle brake.

C) Rotate the main spindle to position the next chuck mounting screw to be torqued toward theback of the machine.

D) Press the Main Spindle Free push button to engage the main spindle brake.

E) Repeat steps A through D to torque all six chuck mounting screws.

18. Install the jaws on the chuck.

19. Place a workpiece into the chuck and press the Main Open/Close push button to close thechuck and test the gripping force on the workpiece.



- CAUTION -





SPINDLE LINERS

INTRODUCTION

- CAUTION -

When machining bar stock that extends back into the spindle draw tube, spin-dle liners MUST be used when machining bar stock below the minimum sizelisted in the table shown on page 9-1.

The spindle liner supports and aligns the bar stock in the spindle draw tube. Each spindle liner con-sists of four nylon spindle liner bushings, three spindle liner spacers, and one spindle liner nut.

The spindle liner bushings must be bored to the appropriate size before the spindle liner compo-nents are installed in the spindle draw tube.

SPINDLE LINER COMPONENTS

RS 42 Lathe:

• Four nylon spindle liner bushings

• Three spindle liner spacers

• One spindle liner extension

• One spindle liner nut

RS 51, RS 65, SR 150, SR 200, and SR 200 BB (Big Bore) Lathes:

• Four nylon spindle liner bushings

• Three spindle liner spacers

• One spindle liner nut


SPINDLE LINER BUSHING

- NOTE -

A spindle liner requires four spindle liner bushings bored to the same size.

A round capacity hole will always be used in the spindle liner bushing, regardless ofthe profile of the bar stock to be machined (round, square, hex, ...).

Referring to Figure 9.13, the dimensions of the spindle liner bushings are as follows:

MachineModel

Dimension “A”Inch [Millimeter]

Dimension “B”Inch [Millimeter]

Dimension “C”Inch [Millimeter]

RS 42 Lathe 1.673 2.677 .250

RS 51 & SR 150 Lathes 2.080 3.203 .250

RS 65 & SR 200 Lathes 2.628 4.816 .468

SR 200 BB Lathes 3.128 4.816 .468

Boring a Bushing to Size

1. Install a 3 jaw chuck or step check in the machine spindle that will accommodate the O.D. of thespindle liner bushing.

2. Insert the spindle liner bushing into the selected work-holding device and press the MainOpen/Close push button to close the work-holding device.

- CAUTION -

If drilling the capacity hole for clearance purposes, be sure to drill the capacityhole undersize.

3. If necessary, use a drill to open up the capacity hole to accommodate the boring bar.

4. Bore the capacity hole in the spindle liner bushing to a diameter that is .020 inch [.5 millimeter]larger than the bar stock to be machined.


Figure 9.13 - Spindle Liner Bushing(Cross Section View)

TP4838

A

B

C

INSTALLING OR REMOVING THE SPINDLE LINER

- NOTE -

The spindle, draw tube, and spindle liner components must be cleaned beforeinstallation.



3. If the collet closer is in the closed position, press the Main Open/Close push button to set thecollet closer to the open position.

4. On the machine, press the Emergency Stop push button.

5. On the bar feed unit or bar loader, press the Emergency Stop push button.

6. If necessary, move the bar feed unit or bar loader away from the machine.

7. Remove access cover “C”, Figure 9.3.

8. Install or remove the spindle liner bushings components. Refer to Figure 9.14, 9.15, or 9.16.

Installation:

- NOTE -

Before installing the spindle liner extension on a 42 millimeter spindle, remove anyburrs from the rear face of the draw bar.

A) If installing spindle liners in a 42 millimeter spindle, install the spindle liner extension usingthree M5 screws provided.

B) Install the spindle liner bushings and spacers.

C) Install the spindle liner nut using three M5 screws provided.

- NOTE -

Total indicator run-out must less than 0.005 inches [0.127 millimeters].

D) If using the extended configuration, check the run-out on the outer diameter of the spindleliner extension. Refer to Figure 9.14 for the location to check the run-out.

To adjust the run-out:

1. Loosen the three M5 screws.

2. Gently tap the spindle liner extension with a soft-faced hammer to obtain an acceptableamount of run-out.

3. Tighten the three M5 screws.

4. Check the run-out again.

Removal:

A) Loosen the three screws and remove the spindle liner nut.

B) Remove the spindle liner bushings and spacers.

C) If installed, remove the spindle liner extension.


9. Replace access cover “C”, Figure 9.3.

10. Position the bar feed unit or bar loader in operating position.

11. Clear the Emergency Stop on the bar feed unit or bar loader.

12. Clear the Emergency Stop on the machine.



Figure 9.14 - Spindle Liner Components Installed in Spindle Draw Tube(RS 42 Lathe)

TI4806

Spindle Liner Spacers

Spindle Liner BushingsSpindle Liner Nut

Location for CheckingSpindle Run-Out


Figure 9.15 - Spindle Liner Components Installed in Spindle Draw Tube(RS 51, RS 65, SR 150, and SR 200 Lathes)

TI4806

Spindle Liner SpacersSpindle Liner Nut

Spindle Liner Bushings

Figure 9.16 - Spindle Liner Components Installed in Spindle Draw Tube(SR 200 BB Lathes)

TI5610

Spindle Liner NutSpindle Liner Spacers

Spindle Liner Bushings

Power Chuck

- NOTES -

9-22 M-489

CHAPTER 10 - TAILSTOCK

INTRODUCTION

RS and SR series lathes feature a hydraulically operated, programmable tailstock. The hydraulicsystem is located at the rear of the machine. The tailstock gives added support when machining longparts and reduces part deflection. This allows for closer tolerances, better surface finishes, and higherspeeds and feeds than would otherwise be possible.

- WARNING -

Be sure all personnel are clear of the tailstock before initiating tailstock mo-tion.

- CAUTION -

Always make certain the turret is in a safe index position before moving thetailstock toward the machine spindle.

Check and, if necessary, adjust the tailstock feedrate before using thetailstock for machining operations. Refer to “Checking and AdjustingTailstock Feedrate”, page 10-7.

Check and, if necessary, adjust the tailstock force before using the tailstockfor machining operations. Refer to “Checking and Adjusting Tailstock Force”,page 10-8.

- NOTE -

Refer to Appendix One for tailstock travel specifications.

The tailstock assembly is advanced and retracted by means of a hydraulic cylinder. Tailstock mo-tion can be controlled automatically from the part program or manually using push buttons on the op-erator control panel.

There are two rates of motion:

• The rapid traverse rate (approximately 300 in/min [7620 mm/min])

• The adjustable feedrate.

The tailstock incorporates a “safety shear” feature to prevent damage to the tooling, turret,tailstock, and linear ways in the event that the turret contacts the tailstock. If contact is made betweenthe tailstock and turret, the “safety shear” feature allows the tailstock to be pivoted away from the tur-ret. Refer to the maintenance manual (M-490) for instructions on aligning the tailstock.

Tailstock overtravel protection in the forward direction is provided by macro program 9130. If thetailstock reaches the overtravel coordinate programmed in macro program 9130, tailstock motion willstop and the machine is put into a feed hold condition.

M-489 10-1

TAILSTOCK POSITIONS

Four tailstock positions are recognized by the control:

• Fixed Home Position

• Adjustable Home Position (Retract)

• Rapid-To-Feed Position

• Overtravel Position

- NOTE -

The programmer establishes the adjustable home, rapid-to-feed, and overtravel po-sitions, as needed, through macro program 9130. When the tailstock is commandedto one of these positions, the tip of the tailstock center will be moved to the com-manded position.

Refer to the programmer’s manual (M-488) for information on setting the adjustablehome, rapid-to-feed, and overtravel positions through macro program 9130.

FIXED HOME POSITION

The fixed home position is at the maximum tailstock travel away from the machine spindle. Refer to“Tailstock Movement”, page 10-4, for information on moving the tailstock to this position. This positionis NOT adjustable.

ADJUSTABLE HOME POSITION (RETRACT)

The adjustable home position is located between the rapid-to-feed position and the fixed home po-sition. This position is intended to minimize tailstock motion, resulting in lower cycle times.

When the tailstock is commanded to the adjustable home position, the tip of the live center is posi-tioned at the adjustable home position.

RAPID-TO-FEED POSITION

The rapid-to-feed position is the coordinate at which the rapid forward motion of the tailstock is re-duced to provide acceptable contact with the workpiece.

OVERTRAVEL POSITION

The overtravel position is the coordinate at which the forward motion of the tailstock is stopped andthe machine is put into a feed hold condition.

10-2 M-489

TAILSTOCK SAFETY INTERLOCKS

There are two safety interlocks associated with the tailstock. These interlocks are designed to re-duce the possibility of crashes that result from incorrect tailstock positioning.

CYCLE START INTERLOCK

To activate Cycle Start while in Automatic, Manual Data Input, or Single mode, the tailstock MUSTbe in one of the following positions:

• Fixed Home position

• Adjustable Home Position (Retract)

• Forward Position (Any coordinate between the rapid-to-feed and the overtravel posi-tions)

If the tailstock is not in one of these three positions, an alarm will be generated by the control whenthe Cycle Start push button is pressed.

To clear the alarm, move the tailstock to the fixed home position. Refer to “Tailstock Movement”,page 10-4, for information on moving the tailstock.

OVERTRAVEL INTERLOCK

While in Automatic, Manual Data Input, or Single mode, M84 commands RAPID tailstock motiontoward the machine spindle. Macro program 9130 MUST be executed to set the rapid-to-feed positionso that the tailstock center will FEED onto the workpiece. If no workpiece is present, the tailstock willcontinue to move toward the machine spindle, resulting in an overtravel condition.

Tailstock overtravel protection in the forward direction is provided by the overtravel coordinate pro-grammed in macro program 9130. If the tailstock reaches the overtravel coordinate, an alarm will begenerated and the machine will be put into a feed hold condition.

To clear the alarm:


2. Press the right-hand Z/E push button to move the tailstock to the fixed home position at therapid traverse rate.

M-489 10-3

TAILSTOCK MOVEMENT

Generally, the machine control must be in Jog mode to manually control tailstock motion. The nota-ble exception is during “between-center” work. If M30 (End of Program) is active while in Automaticmode, it is possible to manually jog the tailstock without switching to Jog mode. Be aware that activat-ing Jog mode will cancel this feature until another M30 is read by the control while in Automatic mode.

The Z/E push buttons are used to jog the tailstock in the indicated direction.

While in manual mode, the tailstock will always FEED toward the machine spindle and RAPIDaway from the machine spindle.

MANUAL MOVEMENT

Initiating Manual Movement


2. Use the Manual Axis Movement switch to select the E axis.

3. Move the tailstock as follows:

TOWARD THE MACHINE SPINDLE

When the tailstock is to the right of the rapid-to-feed position:

Press the left-hand Z/E push button to FEED the tailstock toward the machine spindle(-Z direction).

Press the left-hand Z/E push button and the Rapid Traverse push button to RAPID thetailstock toward the machine spindle (-Z direction).

TOWARD THE FIXED HOME POSITION

Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.

Stopping Manual Movement

Manual tailstock motion can be stopped by pressing the Emergency Stop push button, Hold pushbutton, or control Reset key.

EMERGENCY STOP

To initiate tailstock motion after an Emergency Stop:




4. Press a Z/E push button to move the tailstock in the desired direction.

HOLD or RESET

To initiate tailstock motion after a Hold or control Reset, press a Z/E push button to movethe tailstock in the desired direction.


PROGRAMMED MOVEMENT

Initiating Programmed Movement

- NOTE -

The machine control MUST be in Automatic, Manual Data Input, or Single mode tocommand tailstock motion using M codes.

Refer to the programmer’s manual (M-488) for information on programming tailstockoperation.

M84 Tailstock Forward

When an M84 is read by the control, the tailstock will RAPID forward (toward the machinespindle) until the rapid-to-feed position is reached. At that point, the tailstock will slow tothe preset feedrate and feed onto the workpiece.

M85 Tailstock Retract

When an M85 is read by the control, the tailstock will move to the first home position en-countered at RAPID TRAVERSE rate.

M86 Tailstock Home

When an M86 is read by the control, the tailstock will move to the fixed home position atthe RAPID TRAVERSE rate.

Stopping Programmed Movement

Programmed tailstock motion can be stopped by pressing the Emergency Stop push button, FeedHold push button, or control Reset key.

EMERGENCY STOP

To initiate programmed tailstock motion after an Emergency Stop:





5. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.

6. Reset the program to the beginning of the current operation.

7. Activate Automatic mode and press the Cycle Start push button.


FEED HOLD

To initiate programmed tailstock motion after a Feed Hold, press the Cycle Start push but-ton.

RESET

To initiate programmed tailstock motion after a control Reset:



3. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position.

4. Reset the program to the beginning of the current operation.

5. Activate Automatic mode and press the Cycle Start push button.

10-6 M-489

CHECKING AND ADJUSTING TAILSTOCK FEEDRATE



3. Press the right-hand Z/E push button to Home the tailstock.

4. Press the left-hand Z/E push button to move the tailstock toward the machine spindle andobserve the current tailstock feedrate. The tailstock will move toward the machine spindle at theadjustable feedrate.

5. If the tailstock feedrate needs to be changed:

A) Remove cover "B", Figure 10.1.

B) Loosen the knurled lock nut behind adjustment knob “D”, Figure 10.2.

C) Turn knob “D” in the required direction to increase or decrease the feedrate as desired.

D) Use the Z/E push buttons to check the tailstock feedrate and adjust as needed.

E) Tighten the knurled lock nut to secure the setting.


7. If necessary, press the right-hand Z/E push button to move the tailstock to the fixed homeposition.

M-489 10-7

Figure 10.1 - Right FrontCorner of Machine

TP7233

B

A

Figure 10.2 - Tailstock Forceand Feedrate Adjustment

C D

TP7303

CHECKING AND ADJUSTING TAILSTOCK FORCE

The force applied to the workpiece is controlled by hydraulic oil pressure which is regulated byvalve “C”, Figure 10.2. Gauge “A”, Figure 10.1, indicates the hydraulic pressure in pounds per squareinch and bars. Tables 10.1 and 10.2 list the approximate force in pounds and dekanewtons which willbe applied to the workpiece for a given hydraulic pressure.



3. Use the left-hand Z/E push button to engage the tailstock with the workpiece.

4. Check the tailstock hydraulic pressure on gauge “A”, Figure 10.1.

If the tailstock hydraulic pressure needs to be adjusted, go to step 4.

If the tailstock hydraulic pressure does not need to be adjusted, go to step 6.


English Metric


Applied Force(lbs)

Gauge Pressure(bar)

Applied Force(daN)

200 290 13.8 129

300 430 20.7 191

400 570 27.6 254

500 720 34.5 320

Table 10.1 - Applied Tailstock Force(RS 42 Lathes)

English Metric


Applied Force(lbs)

Gauge Pressure(bar)

Applied Force(daN)

200 630 13.8 280

300 940 20.7 420

400 1,260 27.6 560

500 1,570 34.5 700

Table 10.2 - Applied Tailstock Force(RS 51, RS 65, SR 150, SR 200, & SR 200 BB Lathes)

- CAUTION -

Recommended tailstock pressure is 350 psig (24 bars). For maximum operat-ing safety and to ensure that the hydraulic tailstock functions correctly, neverset the tailstock pressure below 200 psig [13.8 bars].

5. Loosen the knurled lock nut on valve “C”, Figure 10.2, and turn the adjusting nut in the requireddirection until the desired pressure registers on gauge “A”, Figure 10.1. Refer to Tables 10.1and 10.2.

6. Tighten the lock nut on valve “C”.

7. Press the right-hand Z/E push button to move the tailstock to the fixed home position.

REMOVING AND INSTALLING A LIVE CENTER

- NOTE -

The tailstock is designed for a #5 morse taper.

REMOVING A LIVE CENTER

Release nut "F", Figure 10.3, requires a 2 inch wrench, which is supplied with the machine. Thewrench part number is QC 0009189.

Remove the live center by rotating release nut "F", Figure 10.3, outward to push live center "E" fromthe tailstock bushing.

INSTALLING A LIVE CENTER

1. Rotate the release nut inward before installing a live center.

2. Insert the live center into the tailstock bushing.

The live center will be seated in the bushing the first time it contacts a workpiece.

M-489 10-9

Figure 10.3 - Live Centerand Release Nut

TI5362

E

F

- NOTES -

10-10 M-489

CHAPTER 11 - SUB-SPINDLE ANDCOLLET CLOSER [Option]

INTRODUCTION

- WARNING -

Tighten all draw tube screws before beginning spindle operation.

- CAUTION -

Never operate the sub-spindle without a work-holding device if the draw tubeis in the spindle.

- NOTE -

Refer to Appendix One for sub-spindle travel specifications.

The sub-spindle allows parts to be machined at both ends without stopping the machine toend-for-end the workpiece. This reduces cycle times by eliminating part handling by the operator.Drilling, boring, turning and facing operations can be performed on parts that are chucked in thesub-spindle.

Depending on the machining sequence which is selected, the first side of the workpiece is ma-chined in either the main spindle or the sub-spindle. The workpiece is then transferred to the otherspindle to complete machining of the second side.

CYCLE START SAFETY INTERLOCK

Cycle Start is inhibited when the main spindle and sub-spindle work-holding devices are both open.At least one work-holding device must be closed before Cycle Start can be activated.

FREE SPINDLE

A “Free Spindle” condition allows the sub-spindle to be turned by hand. To obtain a free spindle,proceed as follows:

- NOTE -

To obtain a free spindle, the control must be ON and the sub-spindle must not be ro-tating.

1. Power up the machine as described in Chapter 2.


3. Press the Sub Spindle Free push button.

M-489 11-1

CONTROLLING SUB-SPINDLE MOVEMENT

AUTOMATIC, MANUAL DATA INPUT, OR SINGLE MODE

- NOTE -

When E axis motion is programmed by itself, the sub-spindle moves at the pro-grammed feedrate. When E axis motion is programmed with X and/or Z axis motion,the sub-spindle moves at a compensated feedrate to cause the sub-spindle to com-plete the move at the same time as the other axes.

Linear motion of the sub-spindle assembly, designated the E axis, is performed by a servo drivesystem that is controlled by the CNC control. The E data word is used to command direction and dis-tance when moving the ball screw driven sub-spindle in Automatic, Manual Data Input, or Singlemode. The face of the sub-spindle is the sub-spindle reference point.

The maximum programmable feedrate (G01 active) is 394 in/min [10,000 mm/min].

The machine is forced into a Feed Hold condition when Automatic, Manual Data Input, or Singlemode is active and any interlocked door is opened or cover removed. The Feed Hold condition is re-leased when the door is closed or cover replaced. Press the Cycle Start push button to resume pro-gram execution.

E Data Word

The E data word commands an absolute move referenced against the Z0 (zero) position of the ma-chine coordinate position. Positive E coordinates are to the right of Z0 and negative E coordinates areto the left of Z0. The Z0 position will be equal to the face of the main spindle unless modified throughthe Work Shift offset. Refer to Chapter 4 for information on the Work Shift offset.

Feedrate Override Switch

The Feedrate Override switch allows the machine operator to adjust the programmed feedrate ofthe sub-spindle from 0% to 150%, up to a maximum feedrate of 394 in/min [10,000 mm/min].

11-2 M-489

JOG MODE

Axis Direction Keys

When a Z/E push button is pressed while Jog mode is active and the Manual Axis Movement switchis set to the E axis, the servo drive system causes the sub-spindle to move in the selected direction ata jog feedrate of 25 in/min [635 mm/min] when the Feedrate Override switch is set to 100%. Refer to“Feedrate Override Switch”, below.

FEEDRATE OVERRIDE SWITCH

The Feedrate Override switch allows the machine operator to adjust the jog feedrate ofthe sub-spindle from 0 to 37.5 in/min [952 mm/min].

RAPID TRAVERSE

The Traverse push button allows the machine operator to jog the sub-spindle on the Eaxis at approximately 150 in/min [3810 mm/min], regardless of the setting of the FeedrateOverride switch.

MOVING THE SUB-SPINDLE




4. Press the appropriate Z/E push button to jog the sub-spindle in the desired direction.

Handwheel Control

The handwheel can be used to move the sub-spindle incrementally on the E axis whenever CycleStart is not active. The E axis is selected with the Manual Axis Movement switch. The movement in-crement is selected by with the Rapid Override switch. The sub-spindle will move incrementally whenthe handwheel is rotated. The direction and distance is determined by the direction and amount of ro-tation of the handwheel.

MOVING THE SUB-SPINDLE



3. Use the Rapid Override switch to select the desired increment.

4. To view axis position on the control display:

A) Press the Position key.

B) Press the Page key until the desired position display appears on the control display.

5. Turn the handwheel in the desired direction (+ or -). Observe the axis position display todetermine when the axis has been moved the required distance.

• Turn the handwheel in the plus (+) direction to move the sub-spindle away fromthe face of the main spindle.

• Turn the handwheel in the minus (-) direction to move the sub-spindle toward theface of the main spindle.

M-489 11-3

SUB-SPINDLE TOOLING

This section covers the removal and installation of spindle tooling; such as collets, step chucks, andjaw chucks.

- CAUTION -

Read and follow all safety recommendations and operating limits for anywork-holding device installed in the spindle. DO NOT EXCEED the rated ca-pacity of the work-holding device.

The spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced toISO G2.5 or better.

All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limi-tations and balance specifications.

Hardinge Inc. offers chucks balanced to G2.5 or better.

REMOVING SUB-SPINDLE TOOLING

- CAUTION -





4. If necessary, press the Sub Open/Close push button to open work-holding device in the colletcloser.

5. At the right end of the machine, remove draw tube access cover “C”, Figure 11.1.


11-4 M-489

Figure 11.1 - Draw Tube AccessCover at Right End of Machine

TP7233

AC

B

7. Completely loosen six screws “D”, Figure 11.2.

- NOTE -

Six screws “D”, Figure 11.2, must becompletely disengaged from the colletcloser liner before draw tube nut “E”can be rotated.

Removal of a jaw chuck or step chuckmay require the assistance of a secondperson.

8. Rotate draw tube nut “E” counterclockwise todisengage the draw tube from the work-holdingdevice.

- WARNING -

Be prepared to accept the weight ofthe work-holding device.

9. Remove the work-holding device from the spindle.

10. Cover the main spindle to protect it from chips while the sub-spindle is being cleaned.


12. From the collet closer end of the draw tube, use an air line to blow any contaminants present outof the spindle.

13. Completely remove the draw tube from the back of the spindle.

14. From the collet closer end of the draw tube, use an air line to blow any contaminants present outof the spindle a second time.

15. Clean the spindle and draw tube.

16. Lightly lubricate the bearing surfaces of the draw tube with Molylube® Anti-Seize grease.

17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp® SHC 32 grease.

18. Carefully replace the draw tube in the spindle.

19. If spindle tooling is to be installed at this time, proceed to “Installing Spindle Tooling”, beginningon page 11-6.



B) Replace draw tube access cover “C”, Figure 11.1.

M-489 11-5

Figure 11.2 - Spindle Draw Tube

TP4133A

D

F

E

INSTALLING SUB-SPINDLE TOOLING

- NOTE -

For the best surface finish and part roundness, the sub-spindle and draw tube havebeen balanced together at the factory. Although the spindle and draw tube can berun in other positions, the best balance is when etched mark “F”, Figure 11.2, andspindle drive button “G”, Figure 11.3, are aligned.

Two procedures are outlined in this section. The first procedure, which begins below, covers the in-stallation of collets and step chucks. The second procedure, beginning on page 11-8, covers the in-stallation of jaw chucks.

Collet or Step Chuck

This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Sub-SpindleTooling”, beginning on page 11-4.


- CAUTION -





4. Remove draw tube access cover “C”, Figure 11.1.


- NOTE -

The collet and spindle bore MUST be clean.

6. Clean the spindle bore and the collet or stepchuck and closer to be installed.

7. Press the Sub-Spindle Free push button torelease the spindle brake and allow the spindleto be rotated.

8. Manually position spindle drive button “G”,Figure 11.3, to the top dead center (12 o’clock)position.

9. Press the Sub-Spindle Free push button againto have the brake secure the spindle drivebutton at 12 o’clock.

11-6 M-489

Figure 11.3 - Sub-Spindle Nose withDrive Button at Top Dead Center

G

TP5785

- WARNING -

To insure operator safety:- DO NOT use cast iron step chucks.- DO NOT use a step chuck without a step chuck closer.

- NOTE -

Installation of a step chuck may require the assistance of a second person.

10. If installing a step chuck in the spindle, place the step chuck closer against the spindle andinstall the mounting screws securely.

11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle untilit makes contact with the draw tube.

12. Carefully push the draw tube against the back of the collet while rotating the draw tubeclockwise to start the threads of the collet into the threads of the draw tube.

- NOTE -

Adjustment of the collet or step chuck may require the assistance of a second per-son.

13. Select the largest diameter workpiece which is to be chucked and position this part in the colletor step chuck.

14. Rotate the draw tube nut “E”, Figure 11.2, clockwise until the workpiece is gripped tightly; then,back the draw tube off ¼ to ½ turn.

15. Rotate the draw tube the shortest distance to locate etched mark “F” at top dead center (12o’clock) position.

16. Tighten six draw tube screws “D”.

17. Press the Sub Open/Close push button to close the collet and test the gripping force on theworkpiece.

If the gripping force is satisfactory, then go to step 18.

If the gripping force is more or less than desired, use the procedure on page 11-11 to ad-just the hydraulic pressure between 60 and 500 psig (4.14 and 34.5 bars). Refer to Table11.1.

- CAUTION -



19. Replace draw tube access cover “C”, Figure 11.1.

M-489 11-7

Jaw Chuck

This procedure assumes that any previously used spindle tooling has already been removed. Ifthere is spindle tooling to be removed, perform the steps outlined under “Removing Sub-SpindleTooling”, beginning on page 11-4.


- CAUTION -





4. Remove draw tube access cover “C”, Figure 11.1.


- NOTE -

The jaw chuck and spindle bore MUST be clean.

6. Clean the jaw chuck and spindle bore.

7. Press the Sub-Spindle Free push button to release the spindle brake and allow the spindle tobe rotated.

8. Manually position spindle drive button “G”, Figure 11.3, to the top dead center (12 o’clock)position.

9. Press the Sub-Spindle Free push button again to have the brake secure the spindle drivebutton at 12 o’clock.

10. Place the chuck in the spindle and install the mounting screws securely.

11. Carefully push the draw tube against the back of the chuck while rotating the draw tubeclockwise to start the threads of the chuck into the threads of the draw tube.

12. Rotate draw tube nut “E”, Figure 11.2, to thread the draw tube onto the 3 jaw chuck as far aspossible.

13. Rotate the draw tube counterclockwise to locate etched mark “F” at top dead center (12 o’clock)position.

14. Tighten six draw tube screws “D”.

11-8 M-489

15. Place a workpiece into the chuck and press the Sub Open/Close push button to close the chuckand test the gripping force on the workpiece.

If the gripping force is satisfactory, then go to step 16.

If the gripping force is more or less than desired, use the procedure on page 11-11 to ad-just the hydraulic pressure between 60 and 500 psig (4.14 and 34.5 bars). Refer to Table11.1.

- CAUTION -



17. Replace draw tube access cover “C”, Figure 11.1.

M-489 11-9

SUB-SPINDLE COLLET CLOSER

The sub-spindle is equipped with a .5 inch [12.7 mm] stroke, hydraulically actuated collet closer. Ifrepairs to the collet closer assembly are required, the ENTIRE ASSEMBLY must be removed and re-turned to the factory. Refer to the maintenance manual (M-490) for information on removing or install-ing the sub-spindle collet closer assembly.

HYDRAULIC PRESSURE CONTROL

- NOTE -

The sub-spindle collet closer has an operational pressure range of 60 psig [4.14bars] to 500 psig [34.5 bars].

The collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic pressure con-trols are located at the right end of the machine.

Gauge “A”, Figure 11.1, registers the main spindle collet closer hydraulic pressure in psig and bars.

Knob “H”, Figure 11.4, is used to adjust the hydraulic pressure applied to the main spindle colletcloser draw bar.

Refer to Table 11.1, to determine the force that will be applied to the collet closer draw bar for agiven pressure.

A check valve system positively holds the closer open or closed, whichever is active, in the event ofa hydraulic pressure failure.

- CAUTION -

DO NOT exceed the maximum pressure setting, as shown in Table 11.1.

- NOTE -

It is the responsibility of the machine operator or set-up person to properly adjust thecollet closer hydraulic pressure, based on the type of material to be machined andthe configuration of the workpiece.

11-10 M-489

Figure 11.4 - Sub-Spindle Collet CloserPressure Adjustment

TP7234

H

Adjusting the Hydraulic Pressure

1. Remove cover "B", Figure 11.1.

2. Loosen the knurled lock nut behind adjustment knob “H”, Figure 11.4.

3. Turn the adjustment knob clockwise or counterclockwise to decrease or increase the colletcloser hydraulic pressure.

4. Tighten the knurled lock nut to secure the setting.


M-489 11-11

English Metric


Draw Bar Force(lbs)

Gauge Pressure(bar)

Draw Bar Force(daN)

100 1,206 6.9 538

200 2,412 13.8 1,076

300 3,619 20.7 1,615

400 4,826 27.6 2,152

500 6,000 34.5 2,678

Table 11.1 - Sub-Spindle Collet Closer Draw Bar Force

SUB-SPINDLE COLLET CLOSER OPERATION

- CAUTION -

Do not operate the sub-spindle collet closer when a collet or step chuck ismounted in place without gripping a piece of stock or a plug of the correctsize.

Automatic Operation

For automatic operation, program M56 to open the collet and M57 to close the collet. The M56(Open Collet) and M57 (Collet Close) commands may be executed while the spindle is running. M56will remain active until it is canceled by an M57 (Close Collet) command. A programmed M57 (ColletClose) command will remain active until it is canceled by an M56 (Open Collet) command.

Manual Operation

The collet closer can be manually operated whenever the machine is in a Reset or program stop(M00, M01, or M30) condition. Use the Sub Open/Close push button to operate the sub-spindle colletcloser manually.

Chucking Modes

There is no default chucking mode. The current chucking mode will remain active until canceled bythe appropriate command (M68 or M69).

External chucking mode permits the use of work-holding fixtures that grip the workpiece externally.Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally.

SWITCHING THE CHUCKING MODE

1. Check to be sure the Sub Open/Close indicator light is ON. Place a workpiece in the collet andpress the Sub Open/Close push button, if necessary.


3. Press the Program soft key.

4. At the Manual Data Input keyboard:

Key in “M68” for External Chucking

Key in “M69” for Internal Chucking




8. Close the machine guard door and press the Cycle Start push button.

9. Press the control Reset key. The selected chucking mode will be active

11-12 M-489

MAIN AND SUB-SPINDLE MACHINING SET-UP AND OPERATION

Main and sub-spindle machining involves the following procedures:

• Set offsets and machine the first side.

• Set offsets and machine the second side.

- CAUTION -

WORK SHIFT When machining operations involving both spindles are per-formed, two work shifts must be called out through the part pro-gram. Both the main and sub-spindle work shifts must be recordedfor insertion into the part program.

Z AXIS VALUES For sub-spindle machining, negative Z values will be clearingmoves outside the workpiece face. Positive Z values will be insidethe workpiece face.

SAFE START ANDSAFE ENDPROGRAMS

The operator should be aware that programs O1 and O2 are usedfor the main spindle ONLY. To avoid crash situations, programsO3 and O4 must be used for the sub-spindle.O3 must be used to start all sub-spindle tool operations and to endall outside diameter work.O4 must be used to end all sub-spindle inside diameter work.

SAFE INDEXPROGRAMS

The operator should be aware that program O999 is used for themain spindle ONLY. To avoid crash situations, program O998must be used for the sub-spindle.

Prerequisites:

Control is turned ON and part program is loaded and active. Refer to Chapters 3 and 7.

Safe Start and Safe End Programs O1, O2, O3, and O4 are loaded into the control andare called out in the part program.

Safe Index Programs O998 and O999 are entered into the control.

Operator knows how to edit part programs. Refer to Chapter 3.

Work-holding device is installed on the main spindle and adjusted to grip the workpieceproperly. Refer to Chapter 9.

Work-holding device is installed on the sub-spindle and adjusted to grip the workpieceproperly. Refer to page 11-6.

Tools are mounted on the turret top plate at the correct stations. Refer to Chapter 7.

Operator knows how to establish the work shift offset and tool offsets for the main spindle.Refer to Chapter 7.

Operator knows how to establish the work shift offset and tool offsets for the sub-spindle.Refer to Chapter 7.

M-489 11-13

SAMPLE MACHINE SET-UP

The sample machine set-up on pages 11-14 through 11-16 illustrates how a machine could be setup for main spindle machining, followed by sub-spindle machining.

- CAUTION -

If the machine is to be operated in Metric mode, the Z pull back value in pro-gram O4 must be converted to the metric value.

When a bar feed is being used, the face of the bar should be flush with the col-let face since the program begins with a feed stock operation.

Set Up and Machine Main Spindle Operation

1. Place a workpiece of the correct size in the main spindle work-holding device at the desiredlength.

2. Press the Main Open/Close push button to close the work-holding device.

3. Establish the work shift offset for the main spindle. Record this dimension.

4. Find the tool geometry offsets for the turret tooling used for the main spindle.

5. Subtract the shim thickness and face stock to be removed from the value recorded in step 3 andrecord this dimension for insertion into the part program.

- CAUTION -

The X Safe Index coordinate defined in subprogram O999 should be equal theX Home position. The Z Safe Index coordinate should equal the LONGEST toolplus 1.000 inch [25.4 mm] minimum. Refer to Chapter 4 for additional informa-tion.

The Z Safe Index coordinate defined in subprogram O999 MUST be pro-grammed as a POSITIVE number.

6. Check the coordinates in Safe Index Sub-Program O999 to be sure that they are adequate.

If Then

Adequate Go to step 7.

Inadequate Edit sub-program O999 to provide extra clearance.Refer to Chapter 3.

7. If necessary, select the part program that is to be executed.

8. If a bar job is being run, press the Repeat Mode push button.

If a bar job is not being run, go to step 9.

11-14 M-489

- CAUTION -

For safe operation, the main spindle work shift must be programmed at thestart of each main spindle operation.

9. Enter the work shift in the program at the start of each main spindle operation.

- NOTE -

The work shift is entered in the G10 P0 Z-____ block.

10. Press the control Reset key and make certain the program is at the beginning.


- NOTE -

This will cause the active program to be displayed as well as the Distance To Go tocomplete the move.

12. Set the Rapid Override switch to LOW.

13. Adjust the Feedrate Override switch to the desired percentage.

- CAUTION -

Do not use Single Block for a releasing Tap and Die Holder Operation.

14. Activate Single mode.



17. Press the Cycle Start push button for each block and machine the first side.

Set Up and Machine Sub-Spindle Operation

18. Execute the part transfer operation.

19. Establish the work shift offset for the sub-spindle. Record this dimension.

20. Establish the X and Z tool geometry offsets for the sub-spindle tooling on the turret.

- CAUTION -

To insure safe operation, the work shift for the sub-spindle must be entered atthe start of each Sub-Spindle operation.

The Z SHIFT VALUE defined in subprogram O998 must be programmed as aNEGATIVE value.

21. Subtract the shim or scale thickness and face stock from the value recorded in step 19.Program this dimension as the Z axis work shift at the beginning of each sub-spindle operation.

The work shift is entered in the G10 P0 Z-____ block.

M-489 11-15

- CAUTION -

The X Safe Index coordinate defined in subprogram O998 should be equal theX Home position. The Z Safe Index coordinate should equal the LONGEST toolplus 1.000 inch [25.4 mm] minimum. Refer to Chapter 4 for additional informa-tion.

The Z Safe Index coordinate defined in subprogram O998 MUST be pro-grammed as a NEGATIVE number.

22. Check the Sub-Spindle Safe Index coordinates in subprogram O998.

They should read X19.5 Z-____ . Refer to page 3-7 for information on calculating the Zsafe index coordinate.

If the coordinates are: Then:

Correct Go to step 23.

Incorrect Edit the program to enter the correct values.


24. Activate the main workpiece program.



27. Activate Edit mode.

28. Key in the letter N and the sequence number of the first sub-spindle machining operation.

29. Press Cursor �.

30. Activate Single mode.


32. Set the Feedrate Override switch to the desired percentage.

33. Set the Rapid Override switch to LOW.


35. Press the Cycle Start push button to execute each block of data.

11-16 M-489

- NOTES -

M-489 11-17

- NOTES -

11-18 M-489

CHAPTER 12 - VDI LIVE TOOLING [Option]

INTRODUCTION

A live tooling option is available on RS and SR series lathes equipped with a VDI top plate. The livetooling attachments are not included with the machine tool and must be purchased separately.

VDI 30 live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at thetool tip, and can be operated at 30 percent of the total duty cycle at 8000 rpm.

TYPES OF ATTACHMENTS

- CAUTION -

Live tooling attachments are available with or without through-tool coolant ca-pability.Live tooling attachments without through-tool coolant capability can be runwith or without coolant, as the machining process requires.Live tooling attachments with through-tool coolant capability MUST be runwith coolant turned ON.

Refer to page 12-3 for information on live tooling RPM limits for through-toolcoolant attachments, based on coolant pressure.

The live tooling attachments are identified by axis of operation and if they have internal (thru-tool)coolant.

VDI 30 live tooling attachments are designed to use ER 25 collets to grip the tools.

Cross-Working Attachment:

This attachment aligns the centerline of the tool with the X axis.

End-Working Attachment:

This attachment aligns the centerline of the tool with the Z axis.

M-489 12-1

ADJUSTABLE DEAD STOP

Each live tooling attachment is equipped with an adjustable dead stop. The dead stop can be ad-justed against the end of the tool to prevent the tool from sliding in the tool holder during high-thrustmachining operations.

The adjustable dead stop is threaded and can be adjusted using a small common-blade screw-driver.

The adjustable dead stop for all cross-working live tooling attachments is accessed through thefront of the tool holder. Refer to Figure 12.1.

The adjustable dead stop for end-working live tooling attachments equipped with internal coolant isaccessed through the front of the tool holder. The adjustable dead stop for end-working live tooling at-tachments NOT equipped with internal coolant is accessed through the back of the tool holder. Referto Figure 12.2.

12-2 M-489

Figure 12.1 - Cross-Working Live Tooling Attachment

TI4811

Access toDead Stop

Figure 12.2 - End-Working Live Tooling Attachment

TI4812

Access to Dead Stop(Attachment without internal coolant)

Access to Dead Stop(Attachment with internal coolant)

LIVE TOOLING COLLETS AND CAPACITIES

- NOTE -

ER 25 collets conform to DIN 6499.

ER 25 collets are capable of employing English tools with a shank size from 0.039 inches up to andincluding 0.629 inches.

ER 25 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to andincluding 16 millimeters.

LIVE TOOLING RPM LIMIT

- CAUTION -

DO NOT exceed the RPM limits for through-tool coolant live tooling attach-ments, as indicated in graphs 12.1 and 12.2.

- NOTE -

The RPM limits DO NOT apply to live tooling attachments without through-tool cool-ant capability

Live tooling attachments with through-tool coolant capability are subject to an RPM limit, based onthe pressure of the coolant supplied to the attachment. The coolant pump delivers approximately 187psi [12.9 bar].

Refer to graphs 12.1 and 12.2 for RPM limits.

M-489 12-3

12-4 M-489

End-Working Toolholder

Internal Coolant

0

50

100

150

200

250

300

350

400

3000 4000 5000 6000 7000 8000

Spindle Speed, (RPM)

Ma

xim

um

Co

ola

nt

Pre

ss

ure

,

(PS

I)

Graph 12.1 - End-Working Attachments

TI4750A

Cross-Working Toolholder

Internal Coolant

050

100

150

200

250

300

350

400

1000 3000 5000 7000

Spindle Speed, (RPM)

Maxim

um

Co

ola

nt

Pre

ssu

re,(P

SI)

Graph 12.2 - Cross-Working Attachments

TI4751A

LIVE TOOLING ATTACHMENT INSTALLATION

- CAUTION -

Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool. Refer to page 5-3 forinformation on VDI tool station plugs.

- NOTE -

All turret tool stations can be used for live tooling applications.

MOUNTING THE ATTACHMENT

1. Power-up the machine according to the procedure outlined in Chapter 2.



- CAUTION -

The machine operator must be sure that no interference exists between thespindle, spindle tooling, turret, turret tooling, or workpiece before manually in-dexing the turret.

4. Move the turret to a safe position for indexing.

- WARNING -

Stay clear of the turret and turret tooling when indexing the turret. Physical in-jury can result.

5. Manually index the turret to position the desired tool station:

A) Set the Turret Station switch to the tool station to be indexed to the active position.

B) Press the Index push button.

6. Thoroughly clean the turret top plate and the live tooling attachment.

7. Clean and check the O-ring on the live tooling attachment to be sure the O-ring is in goodcondition.

8. If mounting an end-working attachment, loosen two screws “D”, Figure 12.4.

M-489 12-5

- CAUTION -

NEVER force the live tooling attachment into the turret top plate.

Be sure the live tooling attachment is mounted flush against the side of theturret top plate, as shown in Figure 12.3 or 12.4.

9. Aligning live tooling attachment “A” with coolant button “C”, mount the live tooling attachmenton the turret top plate, as shown in Figure 12.3 or 12.4.

10. If mounting an end-working attachment, press the tool holder against the turret top plate andtighten two screws “D”, Figure 12.4.

- NOTE -


11. Tighten clamp screw “B”.

12. If necessary, remove cap “E”, Figure 12.7, or cap “F”, Figure 12.8, and install the proper colletfor the tool to be used. Replace the cap, but DO NOT TIGHTEN.


M-489 12-7

1

2

10

3

4

65

7

8

9

Figure 12.3 - Mounting a VDI 30 Cross-Working Live Tooling Attachment

TI4714A

C

A

B

1

2

10

3

4

65

7

8

9

Figure 12.4 - Mounting a VDI 30 End-Working Live Tooling Attachment

TI4872

A

B

D

C

INSTALLING / REMOVING TOOLS


- WARNING -

DO NOT exceed these maximum tool extension values. Personal injury anddamage to the tooling and machine can result.

- NOTE -

All dimensions are shown in inches [millimeters].

Cross-working live tooling attachments have the following maximum tool extension from the edgeof the turret top plates:

VDI 30 Turret: 6.985 [177.4]

VDI 30 Turret with Y-Axis Option: 5.605 [142.4]


End-working live tooling attachments oriented for sub-spindle operation have a maximum tool ex-tension of 8.375 inches [212.73 mm] from the centerline of the turret top plate tool mounting location.



Figure 12.5 - Maximum Tool Extensionfor Cross-Working Attachments

(Oriented for Main Spindle Operation)

TI4715

Inch [Millimeter]

Standard Turret: 6.985 [177.4]Y-Axis Turret: 5.605 [142.4]

Figure 12.6 - Maximum Tool Extensionfor End-Working Attachments

(Oriented for Sub-Spindle Operation)

TI4704

Inch [Millimeter]

8.375[212.73]

2.756[70.00]

6.997[177.73]

Procedure

- NOTE -

Wrenches are supplied with the live tooling attachments.

1. Insert the tool into the attachment and set to length.

2. Secure the tool:

On cross-working attachments, mount a wrench on spindle “E”, Figure 12.7, and use asecond wrench to turn cap “F” in the clockwise direction to tighten.

On end-working attachments, mount a wrench on spindle “H”, Figure 12.8, and use aspanner wrench to turn cap “G” in the clockwise direction to tighten.


Figure 12.7 - Cross-Working Attachment

TI4209

EF

Figure 12.8 - End-Working Attachment

TI4210

H

G

LIVE TOOLING OFFSETS

Live tooling offsets are set in the same manner as standard tooling. However, there are some con-siderations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling at-tachments. These considerations are outlined below.

Refer to page 12-11 for information on setting live tooling offsets.

CROSS-WORKING ATTACHMENTS

Cross-working attachments are qualified on the Z axis. The centerline of the spindle in thecross-working attachment will always be located at the Z axis reference position of the turret topplates. Therefore, the Z axis tool offset will always be “0".

Figures 12.5 illustrates a cross-working drill/mill attachment mounted on the turret top plate.

END-WORKING ATTACHMENTS

End-working attachments are qualified on the X axis.

Figures 12.6 illustrates an end-working drill/mill attachment mounted on the turret top plate.

The centerline of the spindle in the VDI 30 end-working attachment will be located 2.756 inches[70.0 mm] from the side of the turret top plate.

On machines set for diameter programming, this will result in an X tool geometry offset of 5.512inches [140.00 mm]. On machines set for radius programming, this will result in an X tool geometry off-set of 2.756 inches [70.00 mm].


SETTING TOOL OFFSETS FOR LIVE TOOLING

The live tooling feature allows milling, drilling, and tapping operations to be performed on either thediameter or face of the workpiece. The method used to establish the tool offset values for live toolingare similar to the method used for standard tooling. Live tooling attachments can be mounted at anytool station on the turret top plate.

Setting Offsets for End-Working Tools

- NOTE-

VDI 30 end-working live tooling attachments place the tool centerline 2.756 inches[70.0 mm] from the X axis turret face. When establishing tool offsets, this dimensionmust be doubled for machines that have been set for Diameter Programming.

This procedure assumes that the live tooling attachment has already been mountedon the turret top plate and the tooling has been installed in the attachment. Refer topage 12-5 for information on installing live tooling attachments.

1. Load a workpiece of known diameter and length into the collet closer or chuck.


- NOTE -





- CAUTION -



7. Select the desired turret station using the Turret Station switch.

8. Press the Index push button to index the turret to the selected station.

9. Jog the tool to within 1 inch [25 mm] of the workpiece being held in the spindle.

10. Place a shim against the part face and use the handwheel to move the turret on the Z axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.


11. Press the Offset Setting function key.


13. Press the Geometry soft key to display the Tool Geometry Offset pages.


15. Key in the appropriate value from the following table:

Programming Mode Programming Unit Value to Enter as Offset

DiameterInch 5.512

Millimeter 140.00

RadiusInch 2.756

Millimeter 70.00


17. Use cursor keys to position the cursor at the Z axis field for the desired offset.


19. Key in the letter Z and the thickness of the shim as a negative value.

- NOTE -



21. Turn the handwheel in the appropriate direction to clear the workpiece.



Setting Offsets for Cross-Working Tools

- NOTE -

Cross-working live tool attachments place the tool centerline at the Z axis turret ref-erence position. Therefore, the Z axis tool offset will be equal to “0” (zero).




- NOTE -





- CAUTION -





9. Jog the tool until it is positioned over the workpiece O.D.

10. Press the X push button.

11. Press the desired handwheel increment push button.

12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.








Input = X2.125

- NOTE -


18. Press the Measure soft key.


If the control is set for diameter programming, enter twice the shim thickness as a negative(-) value.

If the control is set for radius programming, enter the shim thickness as a negative (-)value.

20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step 19.


22. Key in “0" (zero).




TOOL NOSE RADIUS COMPENSATION

For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool NoseRadius Compensation may be required for live tooling during C-Axis operations. Refer to the pro-grammer’s manual (M-488) for information on Tool Nose Radius Compensation or C-Axis.

LIVE TOOLING MAINTENANCE

Refer to the maintenance manual (M-490) for information on live tooling maintenance.

LIVE TOOLING ALIGNMENT

Live tooling alignment is set at the factory and should require no further adjustment.


- NOTES -

M-489 12-15

- NOTES -

12-16 M-489

CHAPTER 13 - ESA LIVE TOOLING [Option]

INTRODUCTION

A live tooling option is available on RS and SR series lathes equipped with an ESA top plate. Thelive tooling attachments are not included with the machine tool and must be purchased separately.

ESA live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at the tooltip, and can be operated at 30 percent of the total duty cycle at 8000 rpm.

LIVE TOOL ATTACHMENT OR PLUG REMOVAL

- WARNING -

When removing a live tooling attachment or plug from a top plate, have a firmgrip on the attachment or plug when releasing it from the top plate.

- NOTE -

Button "B", Figure 13.2, must be pressed to release a tool holder or plug from theturret top plate.

The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The airpressure in the turret may cause the tool holder or plug to begin moving out of the top plate when it isreleased from the top plate.

M-489 13-1Revised: June 4, 2008

TYPES OF ATTACHMENTS

- CAUTION -

Live tooling attachments are available with or without through-tool coolant ca-pability.Live tooling attachments without through-tool coolant capability can be runwith or without coolant, as the machining process requires.Live tooling attachments with through-tool coolant capability MUST be runwith coolant turned ON.

The live tooling attachments are identified by axis of operation and if they have internal (thru-tool)coolant.

Cross-Working Attachment:

This attachment aligns the centerline of the tool with the X axis.

End-Working Attachment:

This attachment aligns the centerline of the tool with the Z axis.

LIVE TOOLING COLLETS AND CAPACITIES

- NOTE -

ER 25 collets conform to DIN 6499.

ESA live tooling attachments are designed to use ER 25 collets to grip the tools.

ER 25 collets are capable of employing English tools with a shank size from 0.039 inches up to andincluding 0.629 inches.

ER 25 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to andincluding 16 millimeters.

13-2 M-489Revised: June 4, 2008

LIVE TOOLING ATTACHMENT INSTALLATION

- CAUTION -

Failure to install tool station plugs at turret tool stations not equipped withtooling can result in damage to the machine tool. Refer to page 4-3 for infor-mation on ESA tool station plugs.

Turret top plate cleaning plugs must to be used to protect empty turret sta-tions when cleaning the turret top plate during the process of removing or in-stalling turret tooling. Refer to page 4-2 for information on cleaning plugs.

- NOTE -

All turret tool stations can be used for live tooling applications.

MOUNTING THE ATTACHMENT

1. Thoroughly clean the top plate, live tooling attachments, and tooling.

2. Clean and check the O-ring on each live tooling attachment to be sure the O-ring is in goodcondition.




4. Move the turret to a convenient position for installing tools.


6. Loosen rear clamp screw "A", Figure 13.1.


8. Verify release button "B", Figure 13.2, snaps out the same distance as the other releasebuttons.

M-489 13-3Revised: June 4, 2008

Figure 13.1 - Rear Clamping Screw

A

TP7130

9. Carefully pull on the live tooling attachment to be sure it is totally engaged with the top plate.

10. Inspect face mounting screws “C" and associated washers to be sure they are not warped ordamaged. Replace hardware as needed.

11. Install washers and face screws “C” until the screws are approximately ¼ inch from the face ofthe tool holder.

- CAUTION -

DO NOT overtighten clamp screw "A", Figure 13.1.

12. Tighten rear clamp screw "A", Figure 13.1, until it stops turning.

13. Incrementally tighten four face screws “C”, Figure 13.2, in a cross pattern as follows:





E) Repeat steps A through D until the live tooling attachment is fully seated in the slot.

13-4 M-489Revised: June 4, 2008

Figure 13.2 - Live Tooling Attachment Installation(Cross-Working Attachment Shown)

B

TI5451

C

VIEW ALive Tool AttachmentAligned for Installation

VIEW BLive Tool AttachmentInstalled on Top Plate

14. Using the pattern outlined in step 13, torque the face screws to within the range shown below.

MinimumTorque Value

MaximumTorque Value



15. If necessary, remove cap “D”, Figure 13.3, and install the proper collet for the tool to be used.Replace the cap, but DO NOT TIGHTEN.

16. Repeat as needed for additional tooling.

M-489 13-5Revised: June 4, 2008

Figure 13.3 - Collet Caps on Live Tool Attachments

D

D

TI5452

Cross-WorkingLive Tooling Attachment

End-WorkingLive Tooling Attachment

INSTALLING TOOLS


- WARNING -

DO NOT exceed these maximum tool extension values. Personal injury anddamage to the tooling and machine can result.

- NOTE -

All dimensions are shown in inches [millimeters].

Cross-working live tooling attachments have the following maximum tool extension from the edgeof the turret top plates:

Standard Turret: 8.363 [212.42]

Turret with Y-Axis Option: 6.983 [177.37]

End-working live tooling attachments oriented for sub-spindle operation have a maximum tool ex-tension of 8.375 inches [212.73 millimeters] from the centerline of the turret top plate tool mounting lo-cation.


13-6 M-489Revised: June 4, 2008

Figure 13.4 - Maximum Tool Extensions

Standard Turret: 8.363 [212.42]

Y-Axis Turret: 6.983 [177.37]

5.481[139.22]

8.375[212.73]Inch [Millimeter]

TI5453

Cross-Working Live Tooling Attachment End-Working Live Tooling AttachmentOriented for Sub-Spindle Operation

Tool Installation Procedure

- NOTE -

Wrenches are supplied with the live tooling attachments.

1. Insert the tool into the attachment and set to length.

2. Mount a spanner wrench on spindle “E”, Figure 13.5.

3. Use a wrench to tighten cap “F”.

M-489 13-7Revised: June 4, 2008

Figure 13.5 - Tools Installed in Live Tool Attachments

TI5454

Cross-WorkingLive Tooling Attachment

End-WorkingLive Tooling Attachment

F

E

F

E

LIVE TOOLING OFFSETS

Live tooling offsets are set in the same manner as standard tooling. However, there are some con-siderations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling at-tachments. These considerations are outlined below.

Refer to page 13-9 for information on setting live tooling offsets.

CROSS-WORKING ATTACHMENTS

Cross-working attachments are qualified on the Z axis. The centerline of the spindle in thecross-working attachment will always be located at the Z axis reference position of the turret topplates. The Z axis tool offset will always be “0".

END-WORKING ATTACHMENTS

- NOTE -

Machines equipped with an ESA turret top plate have the same X axis turret refer-ence position and travel specifications as a machine equipped with a VDI 30 turrettop plate. As indicated in Figure 13.6, the diameter of the ESA turret top plate is1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.

End-working attachments are qualified on the X axis. The centerline of the spindle in the end-work-ing attachment will be located 2.7559 inches [70.00 millimeters] from the X axis turret reference posi-tion.

On machines set for radius programming, the X tool geometry offset will be 2.7559 inches[70.00 millimeters].

On machines set for diameter programming, the X tool geometry offset will be 5.5118 inches[140.00 millimeters].

13-8 M-489Revised: June 4, 2008

Figure 13.6 - X Axis Tool Offset forEnd-Working Live Tooling Attachments

2.7559[70.0]

TI5455A

Inch [Millimeter]

1.378[35.00]

Turret X Axis Reference Position(Refer to the note on this page)

SETTING TOOL OFFSETS FOR LIVE TOOLING

The live tooling feature allows milling, drilling, and tapping operations to be performed on either thediameter or face of the workpiece. The method used to establish the tool offset values for live toolingare similar to the method used for standard tooling. Live tooling attachments can be mounted at anytool station on the turret top plate.

Setting Offsets for End-Working Tools

- NOTE-

ESA end-working live tooling attachments place the tool centerline 2.7559 inches[70.00 millimeters] from the X axis turret reference position. When establishing tooloffsets, this dimension must be doubled for machines that have been set for Diame-ter Programming.



2. If it has not already been done, determine the Work Shift Offset following the procedurebeginning on page 7-2 .

- NOTE -





- CAUTION -





9. Jog the tool to within 1 inch [25 millimeters] of the workpiece being held in the spindle.

M-489 13-9Revised: June 4, 2008

10. Place a shim against the part face and use the handwheel to move the turret on the Z axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.





15. Key in the appropriate value from the following table:

ProgrammingMode

ProgrammingUnit

Value to Enteras Offset

DiameterInch 5.5118

Millimeter 140.00

RadiusInch 2.7559

Millimeter 70.00


17. Use cursor keys to position the cursor at the Z axis field for the desired offset.


19. Key in the letter Z and the thickness of the shim as a negative value.

- NOTE -





13-10 M-489Revised: June 4, 2008

Setting Offsets for Cross-Working Tools

- NOTE -

Cross-working live tool attachments place the tool centerline at the Z axis turret ref-erence position. Therefore, the Z axis tool offset will be equal to “0” (zero).



2. If it has not already been done, determine the Work Shift Offset following the procedurebeginning on page 7-2 .

- NOTE -





- CAUTION -





9. Jog the tool until it is positioned over the workpiece O.D.

10. Press the X push button.

11. Press the desired handwheel increment push button.

12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis togently touch the tool tip to the shim so that a slight drag is felt when moving the shim.




M-489 13-11Revised: June 4, 2008




Input = X2.125

- NOTE -


18. Press the Measure soft key.


If the control is set for diameter programming, enter twice the shim thickness as a negative(-) value.

If the control is set for radius programming, enter the shim thickness as a negative (-)value.

20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step 19.


22. Key in “0" (zero).




TOOL NOSE RADIUS COMPENSATION

For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool NoseRadius Compensation may be required for live tooling during C-Axis operations. Refer to the pro-grammer’s manual (M-488) for information on Tool Nose Radius Compensation or C-Axis.

LIVE TOOLING MAINTENANCE

Refer to the maintenance manual (M-490) for information on live tooling maintenance.

LIVE TOOLING ALIGNMENT

Live tooling alignment is set at the factory and should require no further adjustment.

13-12 M-489Revised: June 4, 2008

- NOTES -

M-489 13-13

- NOTES -

13-14 M-489

CHAPTER 14 - TOOL LIFE MANAGEMENT

INTRODUCTION

The basic concept of Tool Life Management is that after a specific number of parts or a specificamount of machining time, the control will automatically begin using another tool in place of the cur-rent tool being used for a particular operation.

Tools are assigned to specific groups, as designated by the programmer. The control will monitorthe measurement value assigned to each tool group and automatically switch to the next tool in thegroup when the counter for that tool group reaches the measurement value specified by the program-mer.

TOOL LIFE MEASUREMENT UNITS

Tool life can be measured using one of the two following methods:

• Number of parts (machined by the tool)

• Amount of machining time (on the tool)

Only one of these methods may be used at a time. “Number of parts” will be the active measure-ment unit when the machine is shipped from the factory. Refer to Determining the Measurement Unit,page 14-5, for information on verifying or switching the active measurement unit.

An alarm message will be displayed when any tool group has reached its programmed tool life andan “M30" (End of Program) is read by the control. At that point, the machine operator will replace thetooling and reset the counter relating to the affected tool group. Refer to Resetting a Tool Group Coun-ter, page 14-6.

NUMBER OF PARTS

When this type of measurement is used, the control will increment the tool group counter for the ac-tive tool each time the tool group is called by the part program.

AMOUNT OF MACHINING TIME

When this type of measurement is used, the control will run the tool group counter for the currenttool whenever G01, G02, or G03 is active.

M-489 14-1

TOOL LIFE MANAGEMENT PROGRAM

When using Tool Life Management, tools and offsets are assigned to specific groups. Thesegroups are established by the programmer through the use of a Tool Life Management program,which is independent of the part program. The Tool Life Management program will define the parame-ters required for Tool Life Management.

The Tool Life Management program defines the following parameters:

• Group numbers.

• Tool life value for each group.

• Tool stations and offsets for each group.

- CAUTION -

When the Tool Life Management program is executed, all Tool Life Manage-ment counters will be reset to 0 (zero).

When using Tool Life Management, the machine operator MUST load and execute the Tool LifeManagement program BEFORE executing the part program for the first time.

Refer to the programmer’s manual (M-488) for information on the Tool Life Management programand how to incorporate Tool Life Management information in the part program.

BAR FEED OPERATION

There are no special considerations for running bar jobs. When running a bar job and using ToolLife Management, the programmer will program an M30 at the end of the part program and the ma-chine operator will activate Repeat mode to cause the part program to loop.

Refer to page 1-8 for information on Repeat mode.

14-2 M-489

OPERATION

DETERMINING MAXIMUM GROUPS AND GROUP SIZES

The maximum number of tool groups and maximum number of tools per group are established byparameter 6800, bits 0 and 1. Be sure that bits 0 and 1 are set to appropriate values to allow for thenecessary number of tool groups and tools per group to be programmed in the Tool Life ManagementProgram.

The bits in parameter 6800 are numbered as follows:

7 6 5 4 3 2 1 0

Set bits 0 and 1 according to the following chart:

Bit 1 Bit 0 Max No. of Groups Max Tools per Group

0 0 16 16

0 1 32 8

1 0 64 4

1 1 16 16

When the machine is shipped from the factory, the maximum number of groups and maximum toolsper group will be set to 16.

Verifying Maximum Groups and Group Sizes



3. Use the Page keys to display the page that contains parameter 6800.

4. Compare bits 0 and 1 to chart above to determine the maximum groups and group sizes.

Setting Maximum Groups and Group Sizes



3. If necessary, use the Page keys to display the Setting page that contains the Parameter Writefield.

4. If necessary, use the cursor keys to position the cursor at the Parameter Write field.


6. Key in the number 1 (one).

M-489 14-3

7. Press the Input key. Parameter editing will be enabled.



10. Use the Page and Cursor keys to position the cursor at parameter 6800.

11. Record the current number in parameter 6800.

12. Key in the entire parameter value with bits 0 and 1 set to the appropriate values.





17. Key in the number 0 (zero).

18. Press the Input key. Parameter editing will be disabled.

14-4 M-489

DETERMINING THE MEASUREMENT UNIT

The two types of measurement units available are “Number of Parts” and “Amount of MachiningTime”. To verify which measurement unit is active, it is necessary to view parameter 6800, bit 2. Toswitch the type of measurement unit to be used with Tool Life Management, it is necessary to modifyparameter 6800, bit 2.

The bits in parameter 6800 are numbered as follows:

7 6 5 4 3 2 1 0

Verifying the Measurement Unit



3. Use the Page keys to display the page that contains parameter 6800.

If parameter 6800, bit 2 is set to 0, “Number of Parts” is active.If parameter 6800, bit 2 is set to 1, “Amount of Machining Time” is active.

Switching the Measurement Unit










10. Use the Page and Cursor keys to position the cursor at parameter 6800.

11. Record the current number in parameter 6800.

12. Key in the entire parameter value with bit 2 set to the appropriate value.







M-489 14-5

RESETTING A TOOL GROUP COUNTER

Resetting the control or turning the control OFF will have NO AFFECT on the tool group counters.When all of the tools in a tool group have reached the tool life specified in the Tool Life Managementprogram and an M30 “End of Program” is read, the following alarm message will be displayed:

1006 TOOL GROUP LIFE END

The expired tool groups will be listed near the bottom of the Tool Life Management screen on thecontrol display. The control can display more than one tool group number at a time, when applicable.Resetting the counter for the expired tool group(s) will clear the alarm and allow machine operation.

- NOTE -

It is not necessary to change machine modes to reset tool group counters.

Use the following procedure to reset the tool group counter(s):



3. Press the Tool Life soft key.

- NOTE -

Each time a cursor control key is pressed, the cursor will move to the next tool groupin the corresponding direction.

4. Use the cursor control keys to move the cursor to the desired tool group.


6. Press the Clear soft key.

7. Press the Execute soft key. The tool group counter at the cursor position will be reset to 0(zero).

8. Repeat steps 4 through 7 to reset additional tool group counters, as needed.

14-6 M-489

- NOTES -

M-489 14-7

- NOTES -

14-8 M-489

CHAPTER 15 - INPUT/OUTPUT DEVICES

INTRODUCTION

The purpose of this chapter is to explain the transfer of data between the input/output devices andthe CNC control.

INPUT/OUTPUT DEVICE LOCATIONS

The control interface is equipped with 3 data input/output ports:

• ATA Flash Card Port, Figure 15.1

• RS-232 Serial Port (25 pin), Figure 15.2

• Ethernet Port, Figure 15.2

Contact your network administrator for information on using the Ethernet port.

M-489 15-1

Figure 15.1 - ATA Flash Card Port

TP7290

ATA FlashCard Port

Figure 15.2 - RS-232 and Ethernet Ports

RS-232Serial Port

TP7289

EthernetPort

INPUT/OUTPUT DEVICE SELECTION

The input/output device to be used is selected through the I/O Channel setting, which is discussedon page 2-6. The valid settings for the I/O Channel are 0, 1, 2, and 4.

I/O CHANNEL 0, 1, OR 2

Three independent port assignments are available to allow the operator or programmer to estab-lish three different I/O port configurations for the same physical RS-232 port. These three configura-tions are designated as channels 0, 1, and 2.

Instead of changing the associated parameters to reassign the baud rate and stop bits, it is possibleto select a different I/O port configuration and have the changes implemented by the control automati-cally.

Setting the I/O Channel to 0, 1, or 2 selects the RS-232 port and selects which configuration will beactive.

Refer to page 15-3 for information on the RS-232 port.

Refer to page 15-5 for information on the RS-232 port parameter settings.

I/O CHANNEL 4

Setting the I/O Channel to 4 selects the ATA Flash Card port. Refer to page 15-12 for information onusing the ATA Flash Card port.

15-2 M-489

RS-232 SERIAL PORT (NC DATA)

DATA COMMUNICATIONS PROTOCOL

Data communications protocol consists of three basic types of information: parity, baud rate, andstop bits. The baud rate and stop bits are controlled by parameters, which may be modified as re-quired.

Tape Parity Check

Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in eachcharacter and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number ofholes in each character. This characteristic of having an odd or even number of holes punched in ev-ery character is called parity.

The control accepts tape punched in either code, but each tape must be programmed in only one ofthe accepted codes.

The control automatically determines the particular type of coding by decoding the first End ofBlock (;) character on the tape. Each character is checked for parity as it is read by the tape reader orcomputer.

Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired par-ity.

Baud Rate

Baud rate is the speed at which data is transmitted from one device to another. To successfullytransmit data between two devices, it is necessary to have both devices set to the same baud rate.

The baud rate is set by three different parameters, depending on which I/O port is active. Refer tothe I/O setting on Setting Page #1 to determine which I/O port is active. Refer to ”Input/Output DeviceSelection”, page 15-2.

Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired baudrate.

Stop Bits

The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The numberof stop bits active in the machine control is controlled by three different parameters, depending onwhich I/O port is active. These parameters may be modified as required. Refer to ”Input/Output De-vice Selection”, page 15-2.

Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desirednumber of stop bits.

M-489 15-3

CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS

Use the following procedure to check communications protocol parameters:



3. Use the Page keys to display the parameter page to be viewed.

Use the following procedure to check and modify communications protocol parameters as needed:










10. Use the Cursor and Page keys to position the cursor on the parameter to be modified.

11. Key in the new parameter value.


13. Repeat steps 10 through 12, as needed.






15-4 M-489

RS-232 PORT PARAMETER SETTINGS

Refer to “Checking and Modifying Communications Parameters”, starting on page 15-4, for infor-mation on modifying the parameter settings for the three I/O ports. These parameters may be modi-fied as required.

Baud Rate Parameter Settings

I/O Port Parameter Number

0 103

1 113

2 123

The valid parameter settings are as follows:

Setting Baud Rate

1 50

2 100

3 110

4 150

5 200

6 300

7 600

8 1200

9 2400

10 4800

11 9600

12 19200

Stop Bit Parameter Settings

I/O Port Parameter Number Bit Number

0 101 0

1 111 0

2 121 0

The valid parameter settings are “0" for 1 Stop Bit and ”1" for 2 Stop Bits.

- NOTE -

The Stop Bit parameter settings are displayed as one bit in an 8 bit binary number (0or 1). The bits are read “0" to ”7", from right to left.

M-489 15-5

DATA TRANSFER

RS-232 SERIAL PORT (NC DATA)

Uploading Data through the RS-232 Port

UPLOADING CONTROL PARAMETERS INTO CONTROL MEMORY

- CAUTION -

Always connect the RS-232 cable before applying power to the external deviceand always remove power from the external device before disconnecting theRS-232 cable.

1. Verify the machine control communications protocol as outlined under “Checking andModifying Communications Parameters”, page 15-4.

2. Refer to the appropriate manual to set the tape reader or computer to the desiredcommunications protocol.

3. Connect the interface cable from the tape reader or computer to the serial port.












15. Press the soft key expansion key until the Read soft key is displayed.

16. Press the Read soft key.


18. Set the tape reader or computer to transmit data to the machine control.

19. After the control parameters have been uploaded, activate Manual Data Input mode.

20. Press the Offset Setting soft key.



15-6 M-489

23. Remove power from the external device; then, disconnect the RS-232 cable from the machinecontrol.

24. Close the serial port cover.

25. Turn the control OFF and wait approximately 10 seconds.

26. Turn the control ON.

UPLOADING PART PROGRAMS INTO CONTROL MEMORY

- CAUTION -



2. Refer to the appropriate manual to set the tape reader or computer to the desiredcommunications protocol.






- NOTE -

If the program has no program number or if the program number is to be altered, keyin the letter “O” and the desired program number.

8. Key in the letter “O” and the program number. Example: O1111




- NOTE -

When the program has been completely loaded into the control, it will appear as theactive program on the control display screen.

12. After the part programs have been uploaded, turn the Program Protect key to ON.



M-489 15-7

UPLOADING TOOL OFFSETS INTO CONTROL MEMORY

- CAUTION -



2. Refer to the appropriate manual to set the tape reader, or computer to the desiredcommunications protocol.




6. Press the Offset soft key.





- NOTE -

The offset data will load directly into the offset registers.




15-8 M-489

Downloading Data through the RS-232 Port

DOWNLOADING CONTROL PARAMETERS FROM CONTROL MEMORY

- CAUTION -



2. Refer to the appropriate manual to set the tape punch or computer to the desiredcommunications protocol.


4. Connect the interface cable to the output device and the serial port on the control.

5. Set the tape punch or computer to receive data.





10. Press the soft key expansion key until the Punch soft key is displayed.

11. Press the Punch soft key.

12. Press the ALL soft key to download all parameters

- or -

Press the NON ZERO soft key to download only parameters with non-zero values.


- NOTE -

To stop the parameters from downloading, press the Reset key. Once the Reset keyhas been pressed, it is not possible to download the remaining parameters. It will benecessary to download all of the parameters.

14. After the control parameters have been downloaded, remove power from the external deviceand disconnect the RS-232 cable from the machine control.


M-489 15-9

DOWNLOADING PART PROGRAMS FROM CONTROL MEMORY

- CAUTION -









8. Key in the letter “O” and the program number. Example: O1111


10. Press the Punch key.


- NOTE -

When outputting to a tape punch, the control will automatically output 3 feet of leaderand trailer tape. To shorten the leader or trailer length, press the Cancel push buttonwhile the leader or trailer is being punched, respectively.

To stop the part program from downloading, press the Reset key. Once the Resetkey has been pressed, it is not possible to download the rest of the part program. Itwill be necessary to download the entire part program.

12. After the part programs have been downloaded, remove power from the external device anddisconnect the RS-232 cable from the machine control.


15-10 M-489

DOWNLOADING TOOL OFFSETS FROM CONTROL MEMORY

- CAUTION -









8. Press the Offset soft key.

9. Press the Geometry soft key to display the Geometry offset page.



12. Press the Punch key.


- NOTE -

To stop the tool offsets from downloading, press the Reset key. Once the Reset keyhas been pressed, it is not possible to download the remaining tool offsets. It will benecessary to download all of the tool offsets.

14. After the tool offsets have been downloaded, remove power from the external device anddisconnect the RS-232 cable from the machine control.


M-489 15-11

ATA FLASH CARD PORT

- NOTE -

Any flash card used must be an ATA Flash Card.

I/O Channel 4 must be selected. Refer to page 15-2 for information on selecting I/OChannel 4.

FILE MANAGEMENT

1. Insert the ATA flash card into the flash card port.

2. Set the I/O Channel to 4.

3. If copying a program to the machine control, turn the Program Protect key to OFF.

4. If copying parameters to the machine control:

A) Press the Offset Setting key.

B) Press the Setting soft key.

C) If necessary, use the Page keys to display the Setting page that contains the ParameterWrite field.

D) If necessary, use the cursor keys to position the cursor at the Parameter Write field.

E) Activate Manual Data Input mode.

F) Key in the number 1 (one).

G) Press the Input key. Parameter editing will be enabled.



7. Press the soft key expansion key until the ALL IO soft key is displayed.

8. Press the ALL IO soft key.

9. Press the appropriate soft key, based on the type of file to be copied to the control memory:

Program: This function is used to transfer a program between the I/O device and controlmemory.

Parameter: This function is used to transfer a parameter file between the I/O device andcontrol memory.

Offset: This function is used to transfer an offset file between the I/O device and con-trol memory.

15-12 M-489

10. Press the Operator soft key. The following soft key functions will be displayed:

FILESEARCH

This function is used to search the selected input/output device for a specificfile name.

A) Press the File Search soft key.

B) Key in the number of the file, NOT a program name.

C) Press the File Set soft key.

D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of thefile listing.

FILEREAD

This function is used to copy the selected file from the input/output device tothe machine control.

A) Press the File Read soft key.



D) Press the Execute soft key. The selected file will be copied to the control memory.

PUNCH This function is used to copy the machine parameters, offset register data, orthe active program from the machine control to the input/output device

A) If necessary, activate the program to be copied. Refer to Chapter 3 for information onactivating programs.

B) Press the Punch soft key.

C) If a file name is to be assigned, key in the file name and press the File Name soft key.

D) If a program name is to be changed, key in the new program name and press the O Set softkey.

E) Press the Execute soft key. The selected file will be copied from the control memory to theinput/output device.

DELETE This function is used to delete a selected file from the input/output device.

A) Press the Delete soft key.



D) Press the Execute soft key. The specified file will be deleted from the input/output device.

11. If a program was copied to the machine control, turn the Program Protect key to ON.

M-489 15-13

12. If control parameters were copied to the machine control:

A) Activate Manual Data Input mode.

B) Press the Offset Setting soft key.

C) Key in the number 0 (zero).

D) Press the Input key. Parameter editing will be disabled.


14. Remove the ATA flash card and close the cover.

15-14 M-489

- NOTES -

M-489 15-15

- NOTES -

15-16 M-489

CHAPTER 16 - OPTIONS AND MISCELLANEOUS FEATURES

MACHINE RUN TIME COUNTER

The machine Run Time counter shows the total run time during automatic operation. The Run Timecounter does not count during a feed hold or programmed stop condition.

ACCESSING THE RUN TIME DISPLAY

Press the Position function key. The Run Time is displayed at the bottom of the page.

RESETTING THE RUN TIME COUNTER TO ZERO


2. If the Setting (Timer) page is not displayed:

A) Press the Setting soft key.

B) Use the page keys to display the Setting (Timer) page.


4. Turn the Program Protect key switch to the OFF position.


6. Move the cursor to the number to be reset.

7. Key in “0" (zero) and press the Input key.

8. Repeat steps 6 and 7 as needed.

9. Turn the Program Protect key switch to the ON position.

MACHINE CYCLE TIME COUNTER

The machine Cycle Time counter shows the time of one automatic operation. The Cycle Timecounter starts counting when Cycle Start is pressed and stops counting when an End of Program(M02/M30) is encountered. The Cycle Time counter does not count during a feed hold or programmedstop condition.

The Cycle Time counter is automatically reset to zero when the Cycle Start push button is pressed,or when the control is turned OFF.

ACCESSING THE CYCLE TIME DISPLAY

Press the Position key. The Cycle Time is displayed at the bottom of the page.

M-489 16-1

CLOCK FUNCTION

The clock function is displayed in the lower right corner of all screens. The clock function is dis-played as a 24 hour clock.

RESETTING THE CLOCK DISPLAY








6. Move the cursor to the number to be corrected.

- NOTE -

The display will not be updated if an invalid value is entered. Negative numbers areconsidered invalid values.

7. Enter the correct value and press the Input key. Refer to the following chart.

ITEM MAXIMUM VALUE

Year 2085

Month 12

Day 31

Hour 23

Minute 59

Second 59



16-2 M-489

PARTS COUNTER

The Parts Counter shows the total number of times a program has been run during automatic oper-ation. The Parts Counter is increased by one (1) each time an M97 command is read by the control.

- NOTE -

The Part Required register is located on the same display screen as the Parts Coun-ter register.

When Part Required is set to any non-zero number and the machine is running in Repeat mode,program execution will stop when the number in the Part Counter register is equal to the number in thePart Required register.

ACCESSING THE PARTS COUNTER DISPLAY

Press the Position key. The Parts Counter is displayed at the bottom of the page.

RESETTING THE PARTS COUNTER TO ZERO








6. Move the cursor to the number to be reset.

7. Key in “0" (zero) and press the Input key.



- NOTE -

Part Required must be set to zero for continuous cycling of bar work.

M-489 16-3

THREAD CUTTING CYCLE RETRACT

- NOTE -

Thread Cutting Cycle Retract is NOT functional during G32 Threadcutting.

This feature allows the operator to retract the tool from the workpiece during a threading pass. Thetool retracts to an X coordinate equal to the X coordinate of the start point of the threading cycle andmoves to the start point. The tool will follow the same basic retract movement that it would follow at theend of the thread.

To retract the tool, press the Feed Hold push button. The tool will be retracted from the workpiecewhen the current lead is completed. The tool will NOT finish the threading pass.

To restart the threading cycle, press the Cycle Start push button. The control will execute thethreading cycle as programmed. The tool will re-execute the pass which was interrupted by FeedHold.

The CNC control will synchronize the re-entry of the tool with the thread on the workpiece. This willassure the thread will be properly formed when the threading cycle is completed.

HIGH PRESSURE COOLANT SYSTEM

The High Pressure coolant system option is used when special coolant-fed tools are mounted onthe turret. When the High Pressure coolant system is operating, the standard machine coolant systemis disabled. The pump unit is located externally from the machine and draws coolant from the ma-chine’s coolant reservoir. The coolant is then pumped to the special tools when they are in the cuttingposition.

The spindle must be running before activating High Pressure coolant. When the option turned ON,the High Pressure coolant can be controlled manually by pressing the HP Coolant ON/OFF push but-ton. The High Pressure coolant can also be activated and deactivated from the part program using theM10 and M11 commands, respectively.

BAR FEED INTERFACE

- NOTE -

The bar feed interface must be activated for bar work and deactivated for slug work.

1. Press the Emergency Stop push button.

- NOTE -

The Block Skip push button indicator light will be ON when the bar feed interface isactivated.

2. Press and hold the Spindle Increase and Spindle Decrease push buttons.

3. Press the Block Skip push button to activate or deactivate the bar feed interface.

4. Release the Spindle Increase and Spindle Decrease push buttons.



ENGLISH / METRIC MODE

One of the purposes of the Setting page is used to establish whether the control is to power-up andoperate in English mode or Metric mode. This section outlines the procedure for selecting the desiredoperating mode.

Through the use of the G20 (Inch Mode) and G21 (Metric Mode) commands, It is possible to oper-ate in either mode regardless of which mode has been selected on the Setting page. However, the useof these two G codes will not automatically adjust the position registers to display the position valuesin the proper units (inches vs millimeters).

- CAUTION -

Part programs should usually be written in the same format as selected on theSetting page. Programs not written in the same format as established on theSetting page MUST contain the appropriate English / Metric G code, G20/G21respectively. When required, this G code must be programmed by itself in thefirst data block following the program number.

The work shift values are NOT automatically changed to the appropriate unitswhen the operating mode is changed.

- NOTE -

The tool offsets are automatically changed to the appropriate units when the operat-ing mode is changed.

ESTABLISHING ENGLISH / METRIC MODE



3. If necessary, use the Page keys to display the Setting page that contains the Input Unit field.

4. If necessary, use the cursor keys to position the cursor at the Input Unit field.


6. Key in the appropriate number (0:MM 1:INCH).


8. Turn the Control ON / OFF switch to OFF.

9. Wait a few seconds; then, turn the Control ON / OFF switch to ON and wait until the controldisplay screen is ON. The machine will power up in the desired operating mode.

M-489 16-5

AXIS THRUST LIMITATION

INTRODUCTION

The E and Z axis servo drives are capable of delivering levels of thrust that exceed the limits of themachine tool. Therefore, axis thrust must be limited or machine life may be reduced. There is refer-ence material available for the programmer that provides approximate thrust values based on drill di-ameter, spindle speed, feedrate, and the type of material being machined. Hardinge Inc.recommends the MACHINING DATA HANDBOOK from Metcut Research Associates, Inc.

- NOTE -

Thrust limits are not easily exceeded unless large diameter twist drills are being runwith aggressive feedrates.

Axis thrust is limited to the following:

AXISTHRUST LIMIT

English (Pounds-Force) Metric (Newtons)

E 1,500 6,670

Z 2,250 10,000

MONITORING AXIS THRUST

It is possible to monitor axis thrust as a percentage of how much current the E or Z axis servo motoris drawing compared to the maximum amount of current that the motor should draw.

- CAUTION -

The percentage of maximum current must not exceed the following limits:

AXIS LIMIT VALUE

E 107

Z 132

If the percentage of maximum current on the E or Z axis exceeds the limit value, an alarmmessage will be displayed.

The percentage of maximum current is displayed under “CURRENT (%)” on the associated axisServo Tune page. Refer to the position indicator shown in Figure 16.1.

16-6 M-489

Accessing the Axis Servo Tune Page

- CAUTION -

DO NOT modify any of the parameters displayed on the “Servo Setting” and“Servo Motor Tuning” screens. If any of the parameters are modified, reloadthe machine parameters from the diskette supplied with the machine tool. Re-fer to Chapter 6 for information on loading machine parameters.



3. If necessary, press the right hand soft key to display the Servo Parameter soft key.

4. Press the Servo Parameter soft key.

5. Press the Servo Tune soft key.

6. If necessary, use the Page keys to access the appropriate “Servo Motor Tuning” screen.

7. Observe the value shown to the right of “CURRENT (%)”. Refer to the position indicator shownin Figure 16.1.

M-489 16-7

S E RVO MOT OR T U NINGZ AXIS

O____ N____

FU NC. B ITL OOP GAINT U NING S TS E T P E R IODINT GAINP R OP. GAINF ILT E RVE L OC. GAIN

NU M.

(S V. S E T )

(PAR AME T E R )~~~~~~~~

AL AR M 1AL AR M 2AL AR M 3AL AR M 4AL AR M 5L OOP GAINP OS E R R ORCU R R E NT %

(MONIT OR )~~~~~~~

~S P E E D (R P M)AU T O

( )(S V. T U N) ( ) ( )

Figure 16.1 - Servo Tune Screen(Z axis page shown)

TI4179

ADJUSTING AXIS THRUST

- NOTE -

This procedure is to be performed during the operation that causes the axis over-load.

When performing machining operations where axis thrust is a concern, it is possibleto minimize cycle time by adjusting the programmed feedrate to bring the value un-der “CURRENT (%)” as close to the limit without exceeding the limit.

If the value displayed under “CURRENT (%)” on the appropriate axis Servo Tune page exceedsthe limit, reduce axis thrust according to the following procedure:

1. Turn the Feedrate Override switch down by 10%.

2. Run the operation that caused the axis overload and observe the value displayed under“CURRENT (%)” on the axis Servo Tune page.

If the value displayed under “CURRENT (%)” on the Servo Tune page still exceeds thelimit, repeat steps 1 and 2.

If the value displayed under “CURRENT (%)” on the Servo Tune page is under the limit,adjust the programmed feedrate in the part program according to the setting of the Feed-rate Override switch.

EXAMPLE

Assuming that the Feedrate Override switch had to be set to 80% to allow the operation to be per-formed:

1. Multiply the programmed feedrate by “.8".

2. Modify the programmed feedrate for the operation to match the number calculated in step 1.

16-8 M-489

PARTS CATCHERS

MAIN SPINDLE PARTS CATCHER [Option]

Introduction

The main spindle parts catcher is controlled from the operator panel through the use of the PartsCatcher push button when the machine is in Jog mode.

The main spindle parts catcher is controlled from the part program through the use of the followingM codes:

M25 - MAIN SPINDLE PARTS CATCHER RETRACT

The M25 command rotates the parts catcher arm toward the front of the machine.

M26 - MAIN SPINDLE PARTS CATCHER EXTEND

The M26 command rotates the parts catcher arm to the spindle centerline for part pickup andopens the part conveyor cover.

Parts Catcher Interlocks

1. The parts catcher cannot be extended unless the optional tool probe is stowed.

2. Automatic machine operation cannot be started when the parts catcher is extended.

Typical Part Unload Sequence

1. The parts catcher arm rotates inward to aposition under the spindle (M26) and the partconveyor cover opens.

2. The collet/chuck opens, ejecting the part ontothe arm (M21).

3. The arm rotates outward (M25).

4. The part falls from the arm onto the conveyor.

5. The part conveyor cover closes.

6. The part is carried by the conveyor to unloadramp "A", Figure 16.2.

- NOTE -

Provide a suitable container or surfaceto receive the finished workpiece whenit leaves the unload ramp.

M-489 16-9

Figure 16.2 - Parts Catcher UnloadRamp at Left End of Machine

TP7361

A

Adjusting the Parts Catcher for Part Length

1. Loosen the screw in locking collar “B”, Figure 16.3.

2. Slide the parts catcher toward or away from the machine headwall to adjust the position, asneeded.

3. Tighten the screw in locking collar “B”.

16-10 M-489

Figure 16.3 - Position AdjustmentLocking Collar

B

TP7353

Adjusting the Parts Catcher Extend / Retract Speeds

The parts catcher extend and retract speeds are controlled by separate flow control valves and canbe adjusted independently.

Remove cover “C”, Figure 16.4, from the left end of the machine to gain access to the partscatcher flow control valves.

- NOTE -

The flow control valves are located be-hind main spindle coolant catcher "D",Figure 16.5.

Flow control valve “E”, Figure 16.6, is used toadjust the speed at which the parts catcher ex-tends (moves toward the spindle centerline).

Flow control valve “F” is used to adjust thespeed at which the parts catcher retracts (movestoward the front of the machine).

Rotate the knob on a flow control valve clock-wise to reduce speed.

Rotate the knob on a flow control valve coun-terclockwise to increase speed.

M-489 16-11

Figure 16.4 - Left End Cover

C

TP7298

Figure 16.5 - Main Spindle Coolant Catcher

D

TP7354

Figure 16.6 - Parts CatcherExtend/Retract Adjustments

F

E

TP7355

SUB-SPINDLE PARTS CATCHER [Option]

Introduction

The sub-spindle parts catcher is designed to remove a workpiece from the sub-spindle and depositthe workpiece on the conveyor, which will carry the workpiece to unload ramp "A", Figure 16.2.

- NOTE -

Provide a suitable container or surface to receive the finished workpiece when itleaves the unload ramp.

Parts Catcher M Codes

The sub-spindle parts catcher is controlled through the use of the following six M codes:

M221 PARTS CATCHER SLIDE EXTEND

M221 commands the parts catcher to slide OUT from the sub-spindle headwall to thefixed part pick-up position.


M222 PARTS CATCHER SLIDE RETRACT

M222 commands the parts catcher to slide IN to the part drop-off position over the partconveyor.

M225 PARTS CATCHER ARM ROTATE DOWN

M225 commands the parts catcher arm to swing down to allow the parts catcher to be re-tracted.

M226 PARTS CATCHER ARM ROTATE UP

M226 commands the parts catcher arm to swing up to the part retrieve position at thespindle centerline.


M227 PARTS CATCHER GRIPPER CLOSE

M227 commands the parts catcher gripper to close and grip the workpiece.

M228 PARTS CATCHER GRIPPER OPEN

M228 commands the parts catcher gripper to open and release the workpiece.

16-12 M-489

M-489 16-13

Figure 16.7 - Parts Catcher Extended,Arm Rotated to Down Position

TP4654

Figure 16.8 - Parts Catcher Extended,Arm Rotated to Up Position

TP4655

Interlocks

1. M221 must be active (Parts Catcher Slide Extend) before M226 (Parts Catcher Arm Rotate Up)can be commanded.

2. The sub-spindle must be at the reference position before M225 (Parts Catcher Arm RotateDown) can be commanded.

3. M225 (Parts Catcher Arm Rotate Down) must be active before M222 (Parts Catcher SlideRetract) can be commanded.

Capacity

The parts catcher has the following workpiece capacity:

Category English Units Metric Units

Maximum Length 6 inches 152.4 millimeters

Maximum Diameter 2.5 inches 63.5 millimeters

Maximum Weight 7 lb 3.18 Kg

16-14 M-489

Parts Catcher Gripper Pads

The parts catcher grippers are designed to be equipped with nylon pads. The nylon pads are boredto the outer diameter of the workpiece to be machined.

BORING THE GRIPPER PADS

The gripper pad fixture, shown in Figure 16.9, is used to hold the gripper pads when they are boredto the required size.

1. Install a work-holding device capable of holding a 3½ inch workpiece in the machine spindle.

2. Insert blank gripper pads into the fixture and secure with four M3 x .5 x 10mm screws, suppliedwith the fixture.

3. Insert the gripper pad fixture into the spindle and close the work-holding device.

4. Bore the gripper pads to the required diameter.

5. Remove the gripper pad fixture from the spindle.

6. Remove the gripper pads from the gripper pad fixture.

7. Install the gripper pads on the parts catcher gripper. Refer to “Changing the Gripper Pads”,page 16-16.

M-489 16-15

Figure 16.9 - Gripper Pad Fixturewith Blank Gripper Pads

TI4745

Gripper PadFixture

Gripper Pads

CHANGING THE GRIPPER PADS

1. If necessary, bore the gripper pads as outlined in the preceding section.





6. Set the Manual Axis Movement switch to “E”.

7. Press the Rapid Reference push button to move the sub-spindle to the reference position.

- NOTE -

Refer to Chapter 3 for information on using Manual Data Input mode.

The guard door must be closed to execute commands in Manual Data Input mode.

8. Use Manual Data Input mode to:

A) Extend the parts catcher slide (M221).

B) Rotate the parts catcher arm to the up position (M226).

9. Open the guard door.

10. If necessary, loosen screws “G”, Figure 16.10,to remove the gripper pads currently installedon the grippers.

11. Clean the parts catcher grippers.

12. Thoroughly clean the replacement gripperpads.

13. Install the replacement gripper pads.


15. Use Manual Data Input mode to:

A) Rotate the parts catcher arm to the downposition (M225).

B) Retract the parts catcher slide (M222).

16-16 M-489

Figure 16.10 - Gripper PadMounting Screws

TP4656

G

PART PROBE [Option]

INTRODUCTION

- CAUTION -

Although overtravel protection is built into the probe, the probing velocitymust not exceed 18 inches/minute to insure that the machine stopping dis-tance does not exceed the probe overtravel.

The optional part probe extends the versatility of the machines by providing automatic size check-ing and updating of tool offsets. Outside diameters, inside diameters, and lengths can be checkedwhen a cutting operation is not active.

The system consists of a measuring probe which is datumed in reference to a known surface. Theprobe is a multi-directional switch that is programmed to contact the workpiece at the desired inspec-tion point. Contact can be made from any direction. When the probe stylus makes contact, a signal isgenerated which is relayed to the interface where it is converted into a form the machine control willaccept. The control compares the inspection point to the calibration point and offsets are automati-cally corrected when required. The slide then backs off and a second signal is relayed to the interface,indicating the stylus has reseated and the probe is ready for the next measurement.

SET-UP PROCEDURE

- NOTE -

The probe holder installs in the same manner as a standard round shank tool holder.Refer to Chapter 8 for information on installing tool holders.

1. Mount probe holder “F”, Figure 16.11 or 16.12, on the turret at the desired station.

2. Place OMP unit “E” in the probe holder and tighten mounting screws “G” just enough to hold theprobe in position.

3. Screw probe “A” into OMP unit “E” and tighten at “D” using the spanner wrench provided withthe probe.

M-489 16-17

Figure 16.11 - Part Probe Mountedon a Hardinge Top Plate

TP4688

B

C D E FG

A

Figure 16.12 - Part Probe Mountedon a VDI Top Plate

TP4693A

F

G

4. Position the turret midway between the reference position and the spindle face and spindlecenterline.

5. Adjust OMP unit “E”, Figure 16.11, and OMM unit “I”, Figure 16.13, so that the optical windowon the OMP unit and the window on the OMM unit are aligned.

6. Tighten mounting screws “G”, Figure 16.11 or 16.12.

7. Tighten screw “H”, Figure 16.13.

- NOTE -

The probe stylus has a 360 degree rotational capability. However, it is important thatthe center of the stylus ball coincides with the X axis centerline of the turret.

8. Mount probe stylus “C”, Figure 16.11, on the probe with screw “B” so that the center of thestylus ball is approximately on line with the X axis center line of the turret top plate.

9. Index the turret to the station with the probe mounted on it.

10. Place a center in the spindle work-holding device.

11. Jog the turret to position the center of the stylus ball on center with the spindle centerline.

12. Adjust the probe stylus until the center of the ball is on the spindle centerline. This will place thecenter of the ball on the X axis centerline of the turret.

13. Tighten screw “B” using the wrench provided.

14. Datum the part probe, as outlined on the next page.

16-18 M-489

Figure 16.13 - Part Probe OMM Uniton the Main Spindle Headwall

TP4689

H

I

DATUM THE PART PROBE

- CAUTION -

The part probe must be correctly datumed before automatic operation is per-formed.

When the probe is datumed for automatic operation, macro variables 500 and 501 are used to re-cord the position of the probe stylus.

Datuming the Part Probe on the X Axis

- NOTE -

The program in step 1 is only an example to illustrate program structure. Turret sta-tion, tool offset, and coordinate data may vary, depending on workpiece geometryand probe location on the turret top plate.

If necessary, refer to “Entering a Program from the Keyboard”, page 3-10, for infor-mation on entering a program through the Manual Data Input keyboard.

In this example, a piece of bar stock has been turned to a diameter of 1.7500 inches for the purposeof datuming the probe on the X axis.

1. Enter a program similar to the following into the control memory:

O____ (Radial Datum X Axis Part Probe) ; Program Number (Operator Message)

G10 P0 Z___ ; Set Work Shift, if Required

G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation,Inch/Millimeter per Minute Feedrate,Move Turret to Safe Index Position,Cancel Tool Offset

T0800 ; Index to Probe Station, No Tool Offset Active

X3. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset

M90 ; Part Probe ON

G4 X1. ; Dwell to Allow Probe ON

X1.76 Z-.375 ; Position Probe for X Axis Datuming as Required

G65 P9013 X1.75 ; Call Macro Program 9013,X1.75 = Known Diameter of the Bar stock

G0 X3. Z.5 ; Move to Clear Bar stock in Spindle

X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset


2. Activate Automatic Mode.

- NOTE -



4. Press the Cycle Start push button to datum the probe on the X axis.

5. Proceed to “Datuming on the Z Axis”, on the next page.

M-489 16-19

Datuming the Part Probe on the Z Axis

- NOTE -

The program in step 1 is only an example to illustrate program structure. Turret sta-tion, tool offset, and coordinate data may vary, depending on the Z axis surface tobe used for datuming and probe location on the turret top plate.

If necessary, refer to “Entering a Program from the Keyboard”, page 3-10, for infor-mation on entering a program through the Manual Data Input keyboard.

In this example, the spindle face will be used for datuming the probe on the Z axis.

1. Enter a program similar to the following into the control memory:

O____ (Datum Z Axis Part Probe) ; Program Number (Operator Message)

G10 P0 Z___ ; Set Work Shift, if Required

G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation,Inch/Millimeter per Minute Feedrate,Move Turret to Safe Index Position,Cancel Tool Offset

T0800 ; Index to Probe Station, No Tool Offset Active

X5. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset

M90 ; Part Probe ON

G4 X1. ; Dwell to Allow Probe ON

X3.625 Z.05 ; Position Probe for Z Axis Datuming as Required

G65 P9017 Z0. T8. ; Call Macro Program 9017,Z0. = Known Z Position,T8. = Offset Location for Part Probe

G0 X5. Z.5 ; Move to Clear Spindle

X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset


2. Activate Automatic Mode.

- NOTE -



4. Press the Cycle Start push button to datum the probe on the Z axis.

The probe is now datumed and is ready for automatic operation. Refer to the programmer’s manual(M-488) for information on programming automatic operation of the part probe.

16-20 M-489

MAINTENANCE

- CAUTION -

Only a minimum amount of maintenance can be done by user. Dismantling ofRenishaw equipment is a highly specialized operation and must be carried outby an authorized service center. Equipment requiring repair that is still underwarranty should be returned to Hardinge Inc.

Adjustment to the stylus spring pressure may affect probe repeatability. Referto the Renishaw LP2 Probe document supplied with the probe.

Do not use sharp cleaning tools.

Do not use a degreasing agent when washing the probe cavity.

The probe system requires minimum maintenance. Approximately once a month the cavity be-tween front cap “K”, Figure 16.14, and inner seal “Q”, Figure 16.15, should be checked for contami-nants. A build-up of dirt or fine chips could eventually cause the probe to malfunction.

1. Use the hex pin wrench supplied with probe to remove screw “L” and stylus “J”, Figure 16.14.

2. Remove cap “K”, using spanner wrench supplied with the probe.

3. Remove seal “N”, Figure 16.15, and compression spring “O”.

4. Wash out cavity “P” and all parts with a jet of coolant.

M-489 16-21

Figure 16.14 - Probe and Stylus Assembly

TP754

J K

L

Figure 16.15 - Probe Disassembled

TP751

MN O

P

Q

5. Check rear O-ring “R”, Figure 16.16, for damage or wear and replace if necessary.

6. If inner seal “Q”, Figure 16.15, is pierced or damaged, return the probe to Hardinge Inc.

7. Reverse the procedure to reassemble. Front cap “K”, Figure 16.14, need only be finger tight.

CLEANING THE PROBE AND OMM UNIT WINDOWS

The optical windows on the probe and OMM units should be checked several times during eachwork shift for any accumulation of dirt or chips which might interfere with probe operation. Use glasscleaner and a rag to clean the windows at least once per shift. More frequent cleaning may be requireddepending on the material being machined.

16-22 M-489

Figure 16.16 - Rear O-Ring

TP755

R

CHANGING THE PROBE BATTERIES

- NOTE -

The probe unit is supplied with four 3 volt lithium batteries. Two 3 volt lithium batter-ies are required for probe operation.

1. Loosen screws “G”, Figure 16.11 or 16.12, and remove the probe assembly from probe holder“F”.

2. Remove cap “S”, Figure 16.17, using a coin or screwdriver.

3. Remove battery retractor “T” and the old batteries.

4. Install the battery retractor and two fresh batteries in the probe, positive end first. Refer toFigure 16.18 for the correct position of the battery retractor.

5. Install cap “S”.

6. Re-install the probe assembly on the top plate. Refer to page 16-17.

7. Re-calibrate the probe.

M-489 16-23

Figure 16.17 - Battery Orientation

TP4694

S

T

Figure 16.18 - Battery Retractor Position

TP4695

Battery Retractor

SUB-SPINDLE PART PRESENT DETECTOR [Option]

- CAUTION -

Refer to page 5-2 for information concerning turret tooling for RS 42 lathesequipped with the following options:



INTRODUCTION

Sub-spindle part present detector "U", Figure 16.19, is commanded from the part program to checkthe sub-spindle for a part. Refer to the programmer’s manual (M-488) for an explanation of the Mcodes used to command the sub-spindle part present detector.

16-24 M-489

Figure 16.19 - Part Present Detector

U

TP6968

EXTENDING THE PART PRESENT DETECTOR

An extension is provided in the event an application requires positioning the part present detectorarm further from the face of the sub-spindle.

- CAUTION -

Care must be used to avoid an impact between the part present detector andthe main machine headwall when the part present detector extension is in-stalled.

1. Note the radial position of part present detector arm "V", Figure 16.20.

2. Loosen two screws "W".

3. Remove the part present detector arm from main shaft "Z".

4. Thread extension "X" into the main shaft.

5. Tighten set screw "Y".

6. Install the part present detector arm and position radially as noted in step 1.

7. Tighten two screws "W".

RANGE OF MOTION

The range of motion for the part present detector is 120. Refer to View "B", Figure 16.20.

M-489 16-25

16-26 M-489

Figure 16.20 - Part Present Detector Extension and Range of Motion

TP5349

VIEW "A"

VIEW "B"

Extension Not Installed Extension Installed

V

X Y

120°

W Z

- NOTES -

M-489 16-27

- NOTES -

16-28 M-489

CHAPTER 17 - OPERATOR MAINTENANCE

INTRODUCTION

Operator maintenance is normally confined to cleaning the machine and maintaining the hydraulicfluid and coolant levels. It is a good practice to check all fluid levels at the beginning of each shift. Theoperator should also check the cooling fans periodically to see that they are free of obstructions andfunctioning properly. Refer to the maintenance manual (M-490) for more extensive maintenance pro-cedures.

MACHINE AIR SYSTEM

The machine is equipped with a regulator and two-stage filter system to regulate and filter the in-coming air supply. The filter/regulator assembly is located at the back of the machine.

- CAUTION -

The air filter bowl should be drained at least once a day. If more frequentdraining is required, it may be necessary to install an air dryer in the air line.

DRAINING THE AIR FILTER BOWLS

1. Turn the main air valve on regulator “B”, Figure 17.1, ON.

2. Unscrew drain valve “C” only enough to drain the bowl of the standard air filter. Close the valvewhen the air filter bowl has finished draining.

3. Unscrew drain valve “D” only enough to drain the bowl of the coalescing air filter. Close thevalve when the air filter bowl has finished draining.


Figure 17.1 - Air Filter/Regulator

TP4101

B

CD

A

ADJUSTING THE MACHINE AIR PRESSURE

Regulator “B”, Figure 17.1, is equipped with a pressure gauge that indicates the air pressure deliv-ered to the machine. The recommended range for machine air pressure is 70 psig [4.8 bars] to 90 psig[6.2 bars]. If necessary, adjust the regulator to set the machine air pressure to within the recom-mended range.

- NOTE -

The machine is equipped with an air pressure sensor that will force the machine intoEmergency Stop if the air pressure falls below 60 psig [4.1 bars].

1. Turn main air valve on regulator “B”, Figure 17.1, ON.

2. Lift knob “A”, then turn the knob clockwise or counterclockwise to increase or decreasemachine air pressure, respectively.

3. Press knob “A” down to lock the setting.

17-2 M-489

HYDRAULIC SYSTEM

STANDARD HYDRAULIC UNIT

- NOTE -

Use only Mobil® DTE-13M® hydraulic fluid in the standard hydraulic unit.

The standard hydraulic unit provides hydraulic oil under pressure to operate the collet closer, spin-dle brake, and turret. The reservoir should be filled whenever the hydraulic fluid level drops belowsight gauge “F”, Figure 17.3.

Filling the Oil Reservoir

- NOTE -

It is recommended that the machine not be powered up for at least 10 minutes afteroil has been added to the hydraulic tank. This will allow any air bubbles present inthe oil to dissipate.

It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particlesize before being added to the hydraulic tank.

1. Power down the machine as outlined in Chapter 2.

2. Remove access cover "E", Figure 17.2.

3. Remove cap “G”, Figure 17.3, and SLOWLY fill the reservoir with Mobil DTE-13M hydraulicfluid until sight gauge ”F” is filled.

4. Replace the cap.

5. Replace the access cover.

M-489 17-3

Figure 17.2 - Rear Access Covers

TP7384

E

Figure 17.3 - Standard Hydraulic Unit

TP7394

G

F

HYDROSTATIC HYDRAULIC UNIT

- NOTE -

The hydrostatic hydraulic unit is only used on machines equipped with theHydroGlide® hydrostatic linear guideway option.

Use only Mobil® DTE-18M® hydraulic fluid in the hydrostatic hydraulic unit.

The hydrostatic hydraulic unit provides hydraulic oil under pressure to the linear guideway trucks.The reservoir should be filled whenever the hydraulic fluid level drops below sight gauge “I”, Figure17.4.

Filling the Oil Reservoir

- NOTE -

It is recommended that the machine not be powered up for at least 10 minutes afteroil has been added to the hydraulic tank. This will allow any air bubbles present inthe oil to dissipate.

It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particlesize before being added to the hydraulic tank.


2. Remove access cover "E", Figure 17.2.

3. Remove cap “H”, Figure 17.4, and SLOWLY fill the reservoir with Mobil DTE-18M hydraulicfluid until sight gauge ”I” is filled.

4. Replace the cap.

5. Replace the access cover.

17-4 M-489

Figure 17.4 - Hydrostatic Hydraulic Unit

H

I

TP5765

COOLANT SYSTEM

- NOTE -

Water-based or oil-based coolant can be used.

Hardinge machine tools are designed using the latest technology and highest quality materialsavailable. However, due to the ever-increasing number of coolant selections available, it is importantto test material compatibility with each and every coolant. Refer to the maintenance manual (M-490)for additional information regarding coolant selection, coolant maintenance, and the coolant systemon this machine.

- CAUTION -

Whenever water-soluble coolants are used, it is important to use the manufac-turer’s recommended mix ratio (concentration). It is also important to maintainthe coolant by keeping the proper concentration level when coolant is addedto compensate for evaporation. Another important factor is coolant pH (acid-ity). Typically, the coolant pH should be in the range of 8.5 to 9. When the pHdrops below 8.5 the rust inhibitors in the coolant start depleting, which can re-sult in corrosion of machine components. Also, the quality of the water shouldbe tested by the coolant manufacturer so that the proper coolant additives canbe administered. Failure to follow these recommendations could result in dam-age to the machine, seals, and paint.

If the coolant you have selected starts to react (cause material to rust, pit,swell, soften, crack, blister, etc.) with any portion of the machine tool,Hardinge suggests that you discontinue use and contact your coolant repre-sentative for alternative coolants.

It should also be noted that certain chemicals react with different metals.Hardinge recommends that you consult with your coolant representative to as-sure that the material you are cutting does not react with the coolant you haveselected.

The coolant tank should be drained and cleaned at least every six months or whenever the type orbrand of coolant is changed. More frequent cleaning may be required if the material being machinedcontaminates the coolant. Refer to the maintenance manual (M-490) for instructions on draining andcleaning the coolant system.

To fill the coolant tank, open the front coolant guard door and pour the required amount of coolantdirectly into the chip pan. Fill the coolant tank to the covers.

The coolant tank capacity is approximately 50 U.S. gallons [189 liters].

M-489 17-5Revised: March 7, 2008

TRAMP OIL PAN

- WARNING -

Dispose of waste oil in accordance with all applicable government guidelines.DO NOT introduce the waste oil into the hydraulic system.

- NOTE -

The tramp oil pan is only used on machines equipped with the HydroGlide® hydro-static linear guideway option.

The machine has been designed to keep contamination of the coolant by the oil used for the hydro-static linear guideways to a minimum. The oil drains from the machine and is collected in the tramp oilpan. The pan should be removed and emptied once a day. Empty the pan and place it back into posi-tion.

1. Slide the tramp oil pan under the hydraulic platform. Refer to Figure 17.5.

2. Insert the end of the tramp oil return line into the pan.

17-6 M-489

Figure 17.5 - Tramp Oil Pan Location

Pan LocationTP7395

CHIP REMOVAL(Machines Without an Optional Chip Conveyor)


2. If coolant was ON, wait a few minutes to allow any coolant that was in use to drain back into thetank.

3. Move the coolant tank as needed to gain access to the chips.

- WARNING -

Do not remove chips with your bare hands.

4. Rake or shovel the chips into a suitable container.

5. Return the coolant tank to its opening under the front of the machine.

6. Check inside the work area to make certain that coolant will drain back into the coolant tankproperly.

M-489 17-7

- NOTES -

17-8 M-489

APPENDIX ONE

M-489 A1-1

Figure A1.1 - Turret Travel Specifications: X and Z Axes(Lathes equipped with an ESA Turret Top Plate)

TI5430A

0.500 [12.70] -Z Software Limit

25.630 [651.00] +Z Software Limit

25.380 [644.65] Z Axis Reference Position

Z0

+Z

+X

19.500 [495.30]X Axis

Reference Position

19.770 [502.15]+X Software Limit4.870 [123.70]

-X Software Limit

5.000 [127.00]Turret Top Plate

MainSpindle

Ma

inS

pin

dle

He

ad

wa

ll

CL

NOTES:

1. All dimensions are shown in inches [millimeters].

2. All X axis travel specifications are diameter values measured from the spindle centerline.

3. All Z axis travel specifications are measured from the face of the main spindle.

4. Full programmable travel on the X axis is 14.900 [378.46], measured on the diameter.

5. Full programmable travel on the Z axis is 25.130 [638.30].

6. Machines equipped with an ESA turret top plate have the same X axis reference position and travel specifica-tions as a machine equipped with a VDI 30 turret top plate. As indicated above, the diameter of the ESA turrettop plate is 1.378 inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate.

1.378 [35.00](Refer to Note 6)

X and Z Axis Reference Position(Refer to Note 6)

A1-2 M-489

Figure A1.2 - Turret Travel Specifications: X and Z Axes(Lathes equipped with a VDI 30 Turret Top Plate)

TI4649B




Z0

+Z

+X

19.500 [495.30]X Axis

Reference Position

19.770 [502.15]+X Software Limit

4.870 [123.70]-X Software Limit

5.000 [127.00]

1.378 [35.00]

Turret Top Plate

MainSpindle

Ma

inS

pin

dle

He

ad

wa

ll

CL

NOTES:






M-489 A1-3

Figure A1.3 - Turret Travel Specifications: X and Z Axes(Lathes equipped with a Hardinge Turret Top Plate)

TI4735




Z0

+Z

+X

17.330 [440.18]X Axis

Reference Position

17.362 [441.00]+X Software Limit

2.316 [58.83]-X Software Limit

5.000 [127.00]

Turret Top Plate

MainSpindle

Ma

inS

pin

dle

He

ad

wa

ll

CL

NOTES:






A1-4 M-489

Figure A1.4 - Turret Travel Specifications: Y Axis Option(VDI or ESA Turret Top Plate)

(Viewed from the Tailstock/Sub-Spindle End of the Machine)

TI4643

0.126[3.18]

2.879 [73.13]

2.854 [72.50]

14.000[355.60]

SpindleCenterline

2.435[61.85]

7.450[189.23]

1.377[34.98]

2.000 [50.80]

NOTE: All dimensions are shown in inches [millimeters].

+X

-X

+Y

-Y13.780

[350.00]

M-489 A1-5

Figure A1.5 - Tailstock Travel Specifications


TI4651A

28.75 [730.3]

CL

MainSpindle

7.25[184.2]

Dependent on Tailstock Center used

Tailstock at FixedHome Position

Tailstock atForward Position

+X

+Z

Z0

Figure A1.6 - Sub-Spindle Travel Specifications


23.25 [590.55] Reference Position

Z0

NOTE: All dimensions are shown in inches [millimeters].TI4650B

0.500 [12.70] Software Limit

CL

MainSpindle

+X

+Z

23.500 [596.90] Software Limit

23.25 [590.55] Reference Position

A1-6 M-489

Figure A1.7 - Work Envelope for Turning:Machine Equipped with Tailstock and ESA Turret Top Plate

TI5431A

NOTES:


2. All measurements for X are radius values.

3. The turret is shown at the +X and +Z software limits.

4. The tailstock is shown at the fixed Home position.

25.130 [638.30](Z Axis Travel)

CL

7.450[189.23]

(X Axis Travel)

23.054 [585.57](Maximum Turn Length)

5.275[133.99]

1.250[31.75]

5.70[144.8]

Maximum Turn Diameter = 10.55 [267.9]

M-489 A1-7

Figure A1.8 - Work Envelope for Turning:Machine Equipped with Tailstock and VDI 30 Turret Top Plate

TI4719A

NOTES:





25.130 [638.30](Z Axis Travel)

CL

7.450[189.23]

(X Axis Travel)


6.076[154.33]

1.250[31.75]

5.02[127.5]


A1-8 M-489

Figure A1.9 - Work Envelope for Turning:Machine Equipped with Tailstock and Hardinge Turret Top Plate

TI4741A

22.660 [575.56](Z Axis Travel)

CL

6.155[156.34]

7.523[191.08]

(X Axis Travel)


NOTES:





7.431[188.75]

1.250[31.75]Maximum Turn Diameter = 14.86 [377.5]

M-489 A1-9

Figure A1.10 - Work Envelope for Turning:Machine Equipped with Sub-Spindle and ESA Turret Top Plate

TI5432A

CL

25.130 [638.30](Z Axis Travel)

7.450[189.23]

(X Axis Travel)

3.006 [76.34]

5.275[133.99]

1.250[31.75]


0.196 [4.98]

NOTES:




4. The sub-spindle is shown at the Reference position.


A1-10 M-489

Figure A1.11 - Work Envelope for Turning:Machine Equipped with Sub-Spindle and VDI 30 Turret Top Plate

TI4718C

CL

25.130 [638.30](Z Axis Travel)

7.450[189.23]

(X Axis Travel)

1.705 [43.31]

6.076[34.90]

1.250[31.75]


0.476 [12.09]

NOTES:






M-489 A1-11Revised: May 7, 2007

Figure A1.12 - Work Envelope for Turning:Machine Equipped with Sub-Spindle and Hardinge Turret Top Plate

TI4742A

CL

7.523[191.08]

(X Axis Travel)

22.660 [575.56](Z Axis Travel)

3.655[92.84]


NOTES:





7.431[188.75]

1.250[31.75]

0.655[16.64]


A1-12 M-489

Figure A1.13 - Sample Tooling Layout:12 Station ESA Turret Top Plate

TI5433

Ø 8.88 [225.6]

Ø 8.96 [227.6]

Ø 9.57 [243.1]

Ø 11.02[280.0]

Ø 9.48 [240.8]

Ø 9.48 [240.8]

Ø 9.14 [232.2]

Ø 9.06 [230.1]

0.88 [22.4]

Ø 8.85 [224.8]

Ø 8.85 [224.8]

Ø 9.46 [240.3]Ø 9.46 [240.3]

Ø 9.46 [240.3]

Ø 20.7087 [526.0]

Cut-OffTool Holder

0.75 TurningTool

1.25 [31.8]

Ø 1.25 Drill

Ø 1.25Boring Bar

Ø 0.63 Drill in ER Collet

NOTES:

1. All single dimensions are shown in inches.2. All dual dimensions are shown in inches [millimeters].

M-489 A1-13

Figure A1.14 - Sample Tooling Layout:12 Station ESA Turret Top Plate with Live Tooling

TI5434

Ø 20.7087 [526.0]

Ø 19.2915 [490.0]

0.75 TurningTool

Ø 8.96 [227.6]

Ø 1.25 Boring Bar

0.88 [22.4]

Ø 9.49 [241.0]

Cut-Off Tool Holder

Ø 11.19 [284.2]

End-Working Mill/Drill Attachment

Cross-Working Mill/Drill Attachment



Ø 0.63 Drill in ER Collet

Ø 1.25Drill

Ø 9.46 [240.3]

Ø 9.48[240.8]

Ø 9.48[240.8]

Ø 9.47[240.5]

Ø 9.25 [235.0]

Ø 9.27 [235.5]

Ø 9.26 [235.2]

Ø 8.86 [225.0]

Ø 9.10 [231.1]

Ø 9.11 [231.4]

NOTES:


A1-14 M-489

Figure A1.15 - Sample Tooling Layout:10 Station VDI 30 Turret Top Plate

TI4710

Ø10.66[270.76]

Ø 11.17[283.72]

Ø 11.10 [281.94]

Centerline at 88 mm

Centerline at 70 mm

Centerline at 70 mm

Centerline at 88 mmCenterline at 88 mm

Centerlineat 88 mm

Centerline at 70 mm

Centerlineat 70 mm

1.25

.88

Ø 11.17 [283.72]

Ø 11.17 [283.72]

Ø 11.17[283.72]

Ø 11.17 [283.72]

Ø 11.17 [283.72]Ø 11.17 [283.72]

Ø 11.53[292.86]

Ø 11.53 [292.86]

Ø 10.66[270.76]

Ø 9.84 [249.94]

Ø 11.47[291.34]

Ø 11.76[298.70]

Cut-Off Tool Holder

.750” ToolHolder

NOTES:


M-489 A1-15

Figure A1.16 - Sample Tooling Layout:10 Station VDI 30 Turret Top Plate with Live Tooling

Ø 11.10 [281.94]

Centerline at 88 mm

Centerline at 70 mm

Centerline at 70 mm

Centerlineat 88 mm

1.25

.88

Ø 10.25 [260.35]

Ø 11.17 [283.72]

Ø 9.82 [249.43]

Ø 11.47[291.34]

Ø 11.76[298.70]

Cut-Off Tool Holder

.750” ToolHolder

NOTES:


TI4711

Centerlineat 70 mm

Ø 11.17 [283.72]

Ø 10.66 [270.76]

Ø 10.63[270.00]

Ø 9.99[253.75]

Ø 11.17[283.72]

End Mill/Drill Attachment

Cross Mill/Drill Attachment

End Mill/DrillDouble SpindleAttachment

A1-16 M-489


Ø 9.36 [237.74]

Centerline at 88 mm

Centerline at 70 mm

1.25

.88

Ø 8.71 [221.23]Ø 8.71

[221.23]

9.18 [233.17] Dia.

Ø 9.39[238.51]

Ø 9.18[233.17]

Cut-Off Tool Holder

.750” ToolHolder

NOTES:


TI4712

Ø 9.46 [240.28]

Ø 9.18 [233.17]

Centerline at 70 mm

Centerline at 70 mm

Centerline at 88 mm

Ø 9.46 [240.28]

Ø 9.18 [233.17]

Centerline at 70 mm

Centerlineat 88 mm

Ø 9.18[233.17]

Centerlineat 70 mm

Ø 9.18[233.17]

Centerlineat 88 mm

Centerline at 88 mm

Ø 9.18 [233.17]

M-489 A1-17


Ø 9.36 [237.74]

Centerlineat 88 mm

Centerline at 70 mm

1.25

.88

Ø 8.70 [220.98]

Ø 8.06[204.72]

Ø 8.13 [206.50]

Ø 9.41[239.01]

Ø 9.18[233.17]

Cut-Off Tool Holder

.750” ToolHolder

NOTES:


TI4713

Ø 8.72 [221.49]

Centerline at 70 mm

Centerline at 88 mm

Ø 9.18 [233.17]

Ø 9.18 [233.17]

End Mill/Drill Attachment

Cross Mill/Drill Attachment

End Mill/DrillDouble SpindleAttachment

Ø 9.18[233.17]

Ø 8.53[216.66]

Centerlineat 70 mm

Ø 8.32 [211.33]

Ø 9.66[245.36]

Centerlineat 88 mm

Ø 9.18[233.17]

End Mill/Drill Double Spindle Attachment

Ø 7.90 [200.66]

A1-18 M-489


NOTES:


TI4832

Ø6.63[168.40]

Ø 6.61[167.89]

Ø 8.19[208.03]

Ø 6.46[164.08]

Ø 6.76[171.70]

Ø 6.29[159.77]

Ø 8.29[210.57]

Ø 6.95[176.53]

Ø 6.69[169.93]

1.25[31.75]

¾” SquareTurning Tool

1-1/4” Boring Bar

40mm Boring Bar

1” SquareTurning Tool

M-489 A1-19


NOTES:


TI4833

Ø 6.55[166.37]

Ø 6.67[169.42]

Ø 7.82[198.63]

Ø 6.46 [164.08]

Ø 27.80 [706.12]Swing-Over Way CoverNon-Y Axis

Ø 6.41[162.81]

Ø 7.70[195.58]

Ø 6.68[169.67]

Ø 6.69 [169.93]

1.79 [45.47]

End-WorkingLive Tool

1-1/4” Boring Bar

¾” SquareTurning Tool

Ø 6.69 [169.93]

40mm Boring Bar

Ø 6.68[169.67]

Cross-WorkingLive Tool

3.19 [81.03]

Ø 25.00 [635.00]Swing-Over Way CoverY Axis

A1-20 M-489

Figure A1.21 - Sample Tooling Layout:12 Station Hardinge Turret Top Plate

1.438

1.125

Ø 8.859 [225.02]

Ø 9.510[241.55]

Ø 9.514[241.66]

Ø 9.510[241.55]

.060Past Center

NOTES:


TI4732

Ø 9.510 [241.55]

Ø 8.530 [216.66]

Centerline at 1.500

Ø 8.530 [216.66]

Centerlineat 2.813

Ø 9.046 [229.77]

Ø 9.510[241.55]

Ø 9.510[241.55]

Ø 9.510 [241.55]

F = 1.250(Worst Case)

Ø 8.567[217.60]

M-489 A1-21

Continuous

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

012

85

1653

2020

2387

2754

3122

3489

3856

4223

4591

4958

5325

5692

6001

Speed (rpm)

To

rqu

e(N

m)

0

1

2

3

4

5

6

7

8

Po

wer

(kW

)

Torque Power

Figure A1.22 - Main Spindle Torque/Horsepower Curves, Continuous Rating(RS 42 Lathe)

TI5505

30 minute

0.00

20.00

40.00

60.00

80.00

100.00

120.00

012

85

1653

2020

2387

2754

3122

3489

3856

4223

4591

4958

5325

5692

6001

Speed (rpm)

To

rqu

e(N

m)

0.0

2.0

4.0

6.0

8.0

10.0

12.0

Po

wer

(kW

)

Torque Power

Figure A1.23 - Main Spindle Torque/Horsepower Curves, 30 Minute Rating(RS 42 Lathe)

TI5506

A1-22 M-489

High Winding - Continuous

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

075

0

1000

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

6000

Speed (rpm)

To

rqu

e(N

m)

0

2

4

6

8

10

12

Po

wer

(kW

)

Torque Power

Figure A1.24 - Main Spindle Torque/Horsepower Curves,High Speed Range, Continuous Rating (RS 51 and SR 150 Lathes)

TI5501

High Winding - 30 minute

0.00

50.00

100.00

150.00

200.00

250.00

075

0

1000

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

6000

Speed (rpm)

To

rqu

e(N

m)

0

2

4

6

8

10

12

14

16

Po

wer

(kW

)

Torque Power

Figure A1.25 - Main Spindle Torque/Horsepower Curves,High Speed Range, 30 Minute Rating (RS 51 and SR 150 Lathes)

TI5502

M-489 A1-23

Low Winding - Continuous

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

0 500 600 700 800 900 1000 1100 1200 1300 1400 1500

Speed (rpm)

To

rqu

e(N

m)

0

1

2

3

4

5

6

7

8

Po

wer

(kW

)

Torque Power

Figure A1.26 - Main Spindle Torque/Horsepower Curves,Low Speed Range, Continuous Rating (RS 51 and SR 150 Lathes)

TI5503

Low Winding - 15 minute

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

0 500 600 700 800 900 1000 1100 1200 1300 1400 1500

Speed (rpm)

To

rqu

e(N

m)

0

2

4

6

8

10

12

14

16

Po

wer

(kW

)

Torque Power

Figure A1.27 - Main Spindle Torque/Horsepower Curves,Low Speed Range, 15 Minute Rating (RS 51 and SR 150 Lathes)

TI5504

A1-24 M-489

Continuous

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

0 575 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3450 4500

Speed (rpm)

To

rqu

e(N

m)

0

2

4

6

8

10

12

14

16

18

20

Po

wer

(kW

)

Torque Power

Figure A1.28 - Main Spindle Torque/Horsepower Curves, Continuous Rating(RS 65 and SR 200 Lathes)

TI5507

30 minute

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

0 575 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3450 4500

Speed (rpm)

To

rqu

e(N

m)

0

5

10

15

20

25

Po

wer

(kW

)

Torque Power

Figure A1.29 - Main Spindle Torque/Horsepower Curves, 30 Minute Rating(RS 65 and SR 200 Lathes)

TI5508

M-489 A1-25Revised: February 5, 2008

Continuous

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

0 518 900 1125 1350 1575 1800 2025 2250 2475 2700 2925 3105 4000

Speed (rpm)

To

rqu

e(N

m)

0

2

4

6

8

10

12

14

16

18

20

Po

wer

(kW

)

Torque Power

Figure A1.30 - Main Spindle Torque/Horsepower Curves, Continuous Rating(SR 200 BB Lathes)

TI5615

30 minute

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

450.00

0 518 900 1125 1350 1575 1800 2025 2250 2475 2700 2925 3105 4000

Speed (rpm)

To

rqu

e(N

m)

0

5

10

15

20

25

Po

wer

(kW

)

Torque Power

Figure A1.31 - Main Spindle Torque/Horsepower Curves, 30 Minute Rating(SR 200 BB Lathes)

TI5616

A1-26 M-489Revised: February 5, 2008

Sub-Spindle (cont.)

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

0

40

0

80

0

12

00

16

00

21

00

25

00

29

00

33

00

37

00

41

00

45

00

49

00

53

00

57

00

61

00

65

00

69

00

73

00

77

00

Speed (RPM)

Ho

rsep

ow

er

(HP

)

0.0

5.0

10.0

15.0

20.0

25.0

30.0

To

rqu

e(f

tlb

s)

HP (cont)

Torque (cont)

Figure A1.32 - Sub-Spindle Torque/Horsepower Curves, Continuous Rating

TI4758A

Sub-spindle (30 min.)

0.0

2.0

4.0

6.0

8.0

10.0

12.0

052

5

1000

1500

2100

2600

3100

3600

4100

4600

5100

5600

6100

6600

7100

7600

Speed

Ho

rsep

ow

er

(HP

)

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

To

rqu

e(f

tlb

s)

HP (30 min.)

Torque (30 min)

Figure A1.33 - Sub-Spindle Torque/Horsepower Curves, 30 Minute Rating

TI4759A


Continuous

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

0 300

600

900

1200

1500

1800

2200

2500

2800

3100

3400

3700

4000

Speed (rpm)

Ho

rse

po

we

r(H

P)

0.0

2.0

4.0

6.0

8.0

10.0

12.0

To

rqu

e(f

tlb

s)

HP (cont)

Torque (cont)

Figure A1.34 - Live Tooling Torque/Horsepower Curves,Continuous Rating (VDI 30 and ESA Turret Top Plates)

TI4766B

30 minute

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0 300

600

900

1200

1500

1800

2200

2500

2800

3100

3400

3700

4000

Speed (rpm)

Ho

rse

po

we

r(H

P)

0.0

5.0

10.0

15.0

20.0

To

rqu

e(f

tlb

s)

HP (30 min.)

Torque (30 min)

Figure A1.35 - Live Tooling Torque/Horsepower Curves,30 Minute Rating (VDI 30 and ESA Turret Top Plates)

TI4767B

- NOTES -

A1-28 M-489

APPENDIX TWO

G CODES

G Code Group Definition

G00 1 Rapid Traverse Positioning Mode

G01 1 Linear Interpolation

G02 1 Clockwise Circular Interpolation

G03 1 Counterclockwise Circular Interpolation

G04 0 Dwell

G10 0 Offset Value Setting

G17 16 X,C Work Plane Selection

G18 16 X,Z Work Plane Selection

G19 16 Z,C Work Plane Selection

G20 6 Inch Data Input

G21 6 Metric Data Input

G22 9 Stored Stroke Limits ON

G23 9 Stored Stroke Limits OFF

G28 0 Return to Reference Position

G31 0 Skip Function

G32 1 Threadcutting Routine (Constant Lead)

G34 1 Threadcutting Routine (Variable Lead)

G40 7 Cancel Tool Nose Radius Compensation

G41 7 Tool Nose Radius Compensation (Part Right)

G42 7 Tool Nose Radius Compensation (Part Left)

G50 0 Maximum RPM Limit for Constant Surface Speed

G65 0 User Macro Call

G70 0 Automatic Finishing Cycle

G71 0 Automatic Rough Turning Cycle

G72 0 Automatic Rough Facing Cycle

M-489 A2-1

G Code Group Definition

G73 0 Automatic Rough Pattern Repeat Cycle

G74 0 Automatic Drilling Cycle

G76 0 Automatic Threading Cycle

G80 10 Cancel G80 Series Cycle

G83 10 Z Axis Drilling Cycle

G84 10 Z Axis Tapping Cycle

G85 10 Z Axis Boring Cycle

G87 10 X Axis Drilling Cycle

G88 10 X Axis Tapping Cycle

G89 10 X Axis Boring Cycle

G90 1 Canned Turning Cycle

G92 1 Canned Threading Cycle

G94 1 Canned Facing Cycle

G96 2 Constant Surface Speed

G97 2 Direct RPM Programming

G98 5 Inches/mm per Minute Feedrate

G99 5 Inches/mm per Revolution Feedrate

G107 0 Activate Cylindrical Interpolation

G112 21 Activate Polar Interpolation

G113 21 Cancel Polar Interpolation

A2-2 M-489

M CODES

M Code Definition Standard / Option

M00 Program Stop Standard

M01 Option Stop Standard

M03 Main Spindle Forward Rotation Standard

M04 Main Spindle Reverse Rotation Standard

M05 Main Spindle Stop / Coolant OFF Standard

M07 Spindle Phase Synchronization Option

M08 Coolant ON Standard

M09 Coolant OFF Standard

M10 High Pressure Coolant ON Option

M11 High Pressure Coolant OFF Option

M12 Parts Catcher Conveyor Cover Open Option

M13 Main Spindle Forward Rotation / Coolant ON Standard

M14 Main Spindle Reverse Rotation / Coolant ON Standard

M15 Thru-Spindle Coolant ON, Main Spindle Option

M16 Thru-Spindle Coolant OFF, Main Spindle Option

M20 Speed Arrival Check ON Standard

M21 Main Spindle Collet / Chuck Open Standard

M22 Main Spindle Collet / Chuck Close Standard

M23 Main Spindle Contouring Mode ON Option

M24 Main Spindle Contouring Mode OFF Option

M25 Main Spindle Parts Catcher Retract Option

M26 Main Spindle Parts Catcher Extend Option

M27 Main Spindle Internal Chucking Mode Standard

M28 Main Spindle External Chucking Mode Standard

M29 Rigid Tapping Mode Standard

M30 Program End, Optional Auto Door Open Standard

M32 Spindle Synchronization Option

M-489 A2-3


M33 Sub-Spindle Forward Rotation Option

M34 Sub-Spindle Reverse Rotation Option

M35 Sub-Spindle Stop Option

M36 Main Spindle Air Blast ON Option

M37 Main Spindle Air Blast OFF Option

M38 Auto Door Open Option

M40 Low Speed Range Option

M41 High Speed Range Option

M42 No Corner Rounding - Exact Stop Standard

M43 Corner Rounding Standard

M44 Enable Turret Bi-Directional Index Standard

M45 Disable Turret Bi-Directional Index Standard

M46 Sub-Spindle Air Blast ON Option

M47 Sub-Spindle Air Blast OFF Option

M48 Enable Feedrate and Spindle Override Standard

M49 Disable Feedrate and Spindle Override Standard

M51 Live Tooling Rotation Option

M52 Live Tooling Rotation Option

M53 Live Tooling Rotation / Coolant ON Option

M54 Live Tooling Rotation / Coolant ON Option

M55 Live Tooling Stop / Coolant OFF Option

M56 Sub-Spindle Collet / Chuck Open Option

M57 Sub-Spindle Collet / Chuck Close Option

M58 Feed Bar Stock Option

M59 Cancel Feed Bar Stock Option

M60 Speed Arrival Check OFF Standard

M61 Bar Change Option

M62 Activate C Axis Spindle Synchronization Option

A2-4 M-489


M63 Cancel C Axis Spindle Synchronization Option

M64 Spindle Feedback from Main Spindle (Default) Standard

M65 Spindle Feedback from Sub-Spindle Option

M66 Spindle Feedback from Live Tool Spindle Option

M68 Sub-Spindle External Chucking Mode Option

M69 Sub-Spindle Internal Chucking Mode Option

M70 Spindle Orient Commands to Sub-Spindle Option

M71 Spindle Orient Commands to Main Spindle Option

M72 Chamfering OFF Standard

M73 Chamfering ON Standard

M76 Sub-Spindle Drive OFF Option

M77 Sub-Spindle Drive Low Torque Option

M78 Sub-Spindle Drive Normal Torque Option

M80 Check Part Missing Option

M81 Check Part Present Option

M84 Tailstock Advance Standard

M85 Tailstock Retract Standard

M86 Tailstock Retract to Fixed Home Position Standard

M90 Part Probe ON Option

M91 Tool Probe Enable Option

M92 Tool Probe Deploy Option

M93 Tool Probe Stow Option

M97 Increment Part Counter Standard

M98 Sub-Program Call Standard

M99 Return from Sub-Program Standard

M200 Main Spindle Brake ON Option

M201 Main Spindle Brake OFF Option

M202 Sub-Spindle Brake ON Option



M203 Sub-Spindle Brake OFF Option

M215 Thru-Spindle Coolant ON, Sub-Spindle Option

M216 Thru-Spindle Coolant OFF, Sub-Spindle Option

M221 Sub-Spindle Parts Catcher Slide Extend Option

M222 Sub-Spindle Parts Catcher Slide Retract Option

M223 Sub-Spindle Contouring Mode ON Option

M224 Sub-Spindle Contouring Mode OFF Option

M225 Sub-Spindle Parts Catcher Arm Rotate Down Option

M226 Sub-Spindle Parts Catcher Arm Rotate Up Option

M227 Sub-Spindle Parts Catcher Gripper Close Option

M228 Sub-Spindle Parts Catcher Gripper Open Option

A2-6 M-489Revised: February 5, 2008

ALARM MESSAGES

1000 Air Pressure Low

Low air pressure to machine. The control is put in an alarm condition and the machine inE-stop.

Increase the air pressure to within the recommended range and press Reset to clear thealarm.

1002 Verify Operator Door Switch

Machine Power-Up Message. Open and close the main guard door to verify interlock switchoperation.

1006 Tool Group Life End

All of the tools in one or more tool groups have reached the tool life specified in the Tool LifeManagement program and an M30 “End of Program” has been read by the control.

Refer to Chapter 14 for information on resetting a tool group counter.

1007 Barfeed Fault Powerdown

The automatic power down feature of the machine has been selected and the conditions forshutdown have been met.

1013 Tool Probe Arm Timeout

The tool probe arm remained in between the active and stowed positions for more than tenseconds. Clear any obstruction. Select Jog mode. Move the probe arm to one position or theother using the probe push button. Press Reset to clear the alarm.

1014 Tool Probe Not Enabled

Program M91 to enable the tool probe when it is deployed for use with the machine inAutomatic mode. Failing to enable the probe with M91 causes this alarm to be displayed whenthe machine moves. Press Reset to clear the alarm.

1015 Tool Probe Switch Fault

Both the probe stowed and probe active limit switches are activated. This may indicate that aswitch has failed. When the problem is fixed, press Reset to clear the alarm.

1016 Spindle Fault

The spindle coolant chiller temperature is too high or too low, spindle coolant chiller flow istoo low, or the collet drain overflow sensor indicates the collet drain pump has failed. When oneof these conditions has been true for four minutes or more, the machine will stop. When theproblem is fixed, press Reset to clear the alarm.

M-489 A2-7

1026 Hydraulic Pressure Too Low

The hydraulic pressure switch indicated that the pressure was too low for machine operation.To restart, press the Emergency Stop push button to put the machine in emergency stop state.After a few seconds, clear the Emergency Stop. If the pump starts and stays ON, press Reset toclear the alarm.

1035 Hydraulic Pump Overload

The hydraulic pump motor overload has tripped. Reset the overload to restart the motor andclear this message.

1036 Hydraulic Fan Overload

The hydraulic fan motor overload has tripped. Reset the overload to restart the motor andclear this message.

1050 X1 Torque Limiter Fault

The X axis torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.

1051 Z1 Torque Limiter Fault

The Z axis torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.

1053 E Torque Limiter Fault

The E axis torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.

1056 Live Tool Torque Limit

The live tool torque limiter has tripped. The control is put into an alarm condition and themachine in Emergency Stop.

1057 Live Tool Fault

The live tooling disengaged proximity switch does not give the expected signal. The livetooling spline may have failed to engage or the live tooling disengaged proximity switch may befaulty. Press Reset to clear the alarm.

A2-8 M-489

1060 Turret Fault

Turret index was interrupted by Reset or Emergency Stop.

To clear the fault:

1. Reset Emergency Stop.

2. Select Jog mode.

3. Select a station and press the Turret Index push button.

4. The turret will index to the selected station.

1061 Turret Unclamped

The turret top plate is not properly seated. Turret index time exceeds two seconds. Turretproximity switch may be faulty. The control is put in an alarm condition.

1062 Please Press Reset

Turret index is not allowed when the live tool drive is engaged. Press Reset to disengage thelive tool drive. Try to index the turret.

1063 Turret Unclamped Switch

The turret unclamp solenoid is energized but the turret unclamped switch has not beenactivated. Either the turret has failed to unclamp or the unclamped switch has failed.

1067 Turret Station Switch Fault

The turret station selector switch indicates an invalid station. The control is put into an alarmcondition.

1072 Please Turn Off Power

After operating the machine with the Machine lock feature active, power down is required toreset the machine position. Power OFF the machine, wait a few seconds, and then restart themachine.

1075 Bar Feed Fault

Bar feed signals a fault. The control is put in an alarm condition.

Adjust the bar feed and press Reset to clear the alarm.

1076 End of Bar

End of bar condition exists. The control is put in an alarm condition.

Press Reset to clear the alarm.

M-489 A2-9

1082 T Code Invalid

The T word exceeds the maximum number of turret stations on the top plate.

T word format error.

1083 M Code Invalid

M word is programmed for an option not available/enabled on the machine.

M word is not defined in the control.

M word format error.


1085 B Code Invalid

B word orient angle is invalid.

B word is programmed for an option not available/enabled on the machine.

B word format error.


1100 Parts Catcher Must be Retracted

The main spindle parts catcher must be retracted before starting a program in Automaticmode or deploying the optional tool probe in any mode.


1110 Left Collet Access Door

The main spindle collet access door is open. Automatic mode is inhibited. Close the door andpress Reset to allow machine operation.

1111 Right Collet Access Door

The sub-spindle collet access door is open. Automatic mode is inhibited. Close the door andpress Reset to allow machine operation.

1113 Main Collet Limit Switch

One or both of the main collet Open/Close pressure switches are faulty. Both switchesindicate the same state. The control is put into an alarm condition.

1114 Main Spindle Orient Fault

Spindle orient failed to complete in five seconds. Press Reset to clear the alarm.

1115 Main Spindle Brake Fault

Main spindle brake switch input contradicts the state of the solenoid valve.

A2-10 M-489

1120 Tailstock Past Limit Position

The tailstock has traveled past the position defined by the A word in macro program 9130.

Refer to the programmer’s manual (M-488) for information on macro program 9130.

1121 Move Tailstock to Mid or Home

The tailstock is out of position. Move the tailstock to either the mid-point or the fixed Homeposition. Cycle Start is inhibited.

1123 Please Home Tailstock

Power Up Message. Home the tailstock.

Refer to Chapter 10 for information on homing the tailstock.

1140 Parts Catcher, See Messages

The sub-spindle parts catcher slide has a fault. Refer to the message display page fordetailed information.

1170 Hydraulic Temperature Too High

- NOTE -

This alarm applies only to machines equipped with HydroGlide® hydrostatic linearguideways.

The fluid temperature in the hydraulic unit for the HydroGlide hydrostatic linear guidewaysexceeds the high limit. Possible causes for hydraulic fluid high temperature are:

• Ambient temperature is in excess of the recommended maximum operatingtemperature, which is 95°F [35°C]

• Hydraulic unit pump motor is running hot

• Hydraulic unit heat exchanger fan has malfunctioned

• Hydraulic unit heat exchanger coils need to be cleaned

M-489 A2-11

1174 Hydrostatic Pressure Fault

Hydrostatic pressure is too low to support the slides. Emergency stop is applied. Determinethe cause of the problem. Restart the machine and Press Reset to clear this message.

1180 CH1 Temperature Out of Range

This message applies to Super-Precision® machines only.

Temperature sensor channel 1 indicates an improbable value. The temperature monitoringsystem needs to be checked. Refer to Appendix Three of the maintenance manual (M-490) fortemperature sensor locations.


This message applies to Super-Precision machines only.


1187 Temperature Compensation Out of Range


The temperature compensation calculated by the control is too large. Temperaturecompensation is disabled.







1210 Part Missing

The sub-spindle part detector did not find a part in the sub-spindle.

1211 Part Present

The sub-spindle part detector found a part in the sub-spindle.

A2-12 M-489

1212 Part Detector Failed to Retract

The sub-spindle part detector is actuating the extended switch or not actuating the homeswitch.

1213 Opposite Collet Limit Switch

One or both of the sub-spindle collet Open/Close pressure switches are faulty. Both switchesindicate the same state. The control is put into an alarm condition.

1214 Opposite Spindle Orient Fault

Sub-spindle orient failed to complete in five seconds. Press Reset to clear the alarm.

1215 Opposite Spindle Brake Fault

Sub-spindle brake switch input contradicts the state of the solenoid valve.

1244 Door Failed to Lock

The main guard door failed to lock when the part program was started.

M-489 A2-13

OPERATOR MESSAGES

2001 1000 Hour Lube Required

Machine lubrication is required every 1000 hours of machine ON time. Cycle Start is inhibitedwhile this message is displayed.

Refer to the maintenance manual (M-490) for information on machine lubrication.

After lubricating the machine, press the Reset and Feed Hold push buttons at the same timeto clear this message.

2004 Live Tool Lube Oil Level Low. Refill with Mobil DTE 24.

The oil level in the reservoir is low. Cycle Start is inhibited. Refill the reservoir with MobilDTE® 24 oil.

Press Reset to clear this message.

2005 New Tool Used on this Part

A tool in the currently active tool group has reached the tool life specified in the Tool LifeManagement program. The next tool in the active tool group has been selected.

Press Cycle Start or Reset to clear this message.

2021 Lamp Output Disconnected

An output module driving the panel lamps is overloaded. Turn the machine OFF to clear thismessage.

2022 Operator Door Open

The coolant guard door is open. Cycle Start is inhibited until the guard door is closed.

2023 Control Battery Low

Low voltage condition on control memory battery back-up. DO NOT POWER DOWN THEMACHINE!

Refer to the maintenance manual (M-490) for instructions to replace the battery.

2024 Part Probe Battery Low

The part probe battery is nearly discharged.

Refer to Chapter 16 for instructions to replace the battery. After the battery is replaced, pressReset to clear this message.

A2-14 M-489

2030 Coolant Pump Overload

The coolant pump motor overload on the coolant pump contactor in the machine power casehas tripped. Repeat mode is canceled.

Correct the cause of the overload. Locate the coolant pump contactor in the power case andreset the overload. When the overload is reset, press Reset to clear this message.

2031 Coolant Chiller Flow

The flow switch in the coolant chiller unit has opened, indicating low coolant flow. This maybe due to a clogged coolant filter.

After proper coolant flow is restored, press Reset to clear this message.

2034 X Scale Air Purge Pressure Fault


The scale air purge pressure switch indicates a loss of pressure. Repeat mode is canceled.Cycle Start is inhibited.

Correct the cause of the pressure loss and press Reset to clear this message.

2054 E Axis Thrust Limit Exceeded, Please Adjust Feedrate

The E axis thrust limit has been exceeded. The machine is put into a feed hold condition.

Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until themessage clears. Adjust the feedrate in the part program by the percentage that was required toclear the message.

2055 Turret Thrust Limit Exceeded, Please Adjust Feedrate

The Z axis thrust limit has been exceeded. The machine is put into a feed hold condition.

Turn the Feedrate Override switch down by 10% and press Cycle Start. Repeat until themessage clears. Adjust the feedrate in the part program by the percentage that was required toclear the message.

2071 Y Too Low to Jog E1 or Z1

The turret is positioned below Y0. Move the turret to Y0 before attempting to move the E1 orZ1 axis.

2077 Open Collet Only in Jog Mode

For machines equipped with the bar feed option and the option is turned ON, the control mustbe in Jog mode to manually open the collet or chuck. Press Reset or select Jog mode to clearthis message.

M-489 A2-15

2086 Part Count Satisfied

The part count specified has been completed. Repeat mode is canceled. Press Cycle Startor Reset to clear this message.

2090 Turret Must be at X Axis Home Position

The tool probe was commanded to deploy and the turret is not at the X axis referenceposition. Move the turret to the X axis reference position before deploying the tool probe.

When the tool probe is deployed, the turret can only be indexed when it is positioned at the Xaxis reference position.

2091 Opposite Spindle Must be at Home Position

The tool probe was commanded to deploy and the sub-spindle is not at the referenceposition. Move the sub-spindle to the reference position before deploying the tool probe.

2092 Tailstock Must be at Home Position

The tool probe was commanded to deploy and the tailstock is not at the reference position.Move the tailstock to the reference position before deploying the tool probe.

2093 Tool Probe Must be Stowed

The tool probe is not stowed and Cycle Start was pressed with Automatic mode active. Thetool probe must be stowed to start a part program in Automatic mode.

The tool probe is not stowed and the parts catcher was commanded to extend. The toolprobe must be stowed before the parts catcher can be extended in any mode.

2096 Spindle Chiller Temperature

The spindle chiller temperature is too high or low or the spindle coolant chiller flow is too lowon machines equipped with built-in spindle motors. This fault cancels Repeat mode. Themachine will stop with alarm 1016 after four minutes. Press Reset to clear this message.

2097 Collet Drain Pump Fault

The collet drain reservoir overflow sensor indicates the main or sub-spindle collet drain pumphas failed. Repeat mode is canceled. The machine will stop with alarm message 1016 after fourminutes. Press reset to clear this message.

2101 Parts Catcher Timeout

The main spindle parts catcher took too much time to complete the commanded motion. Thearm may be stuck or obstructed. Press Reset to clear this message.

A2-16 M-489

2102 Parts Catcher Limit Switch Fault

One of the following conditions exists:

• The main spindle parts catcher arm extended and retracted limit switches areboth activated.

• This may indicate that one of the limit switches has failed.

2103 Please Close Parts Catcher Cover

The main spindle parts catcher cover is open. Program execution is inhibited. Close thecover to allow program execution.

2133 Main Collet Open

The main spindle collet/chuck is open. Cycle Start and manual spindle operation areinhibited. Close the Collet/chuck to allow Cycle Start and manual spindle operation.

Press Reset to clear this message

2134 Main Spindle Contouring Mode

The manual axis movement selector switch is set to C1 and the operator is attempting tomanually operate the main spindle through the use of the spindle control functions on theoperator panel.

Set the manual axis movement selector switch to another setting.

2141 Opposite Spindle Parts Catcher Timeout

The sub-spindle parts catcher took too long to complete the commanded motion. The slide,arm, or gripper may be stuck. Correct the problem and press Reset to clear the alarm.

2142 Opposite Spindle Parts Catcher Limit Switch Fault

The sub-spindle parts catcher slide, arm, or gripper limit switches indicate the same state.This may indicate that one of the switches has failed. Correct the problem and press Reset toclear the alarm.

2143 Opposite Spindle Parts Catcher Slide Must be Extended

The sub-spindle parts catcher slide must be extended before the arm can be rotated up to thespindle centerline.

M-489 A2-17

2144 Opposite Spindle Must be Home

The sub-spindle must be at the reference position before the sub-spindle parts catcher armcan be rotated up or down.

2145 Opposite Spindle Parts Catcher Arm Must be Down

The sub-spindle parts catcher arm must be rotated down before the parts catcher slide canbe retracted.

2146 Opposite Spindle Parts Catcher Gripper Fault

The parts catcher grippers are closed without gripping a part.

2147 Part Conveyor Motor Overload

The part conveyor motor overload in the machine power case has tripped.

Correct the cause of the overload. Reset the overload in the power case. When the overloadis reset, press Reset to clear this message.

2150 High Pressure Coolant Filter Clogged

The high pressure coolant filter pressure drop is too high. This message cancels Repeatmode, but allows machine operation. Check the condition of the filter.

Press the Reset key to clear this message from the screen.

2151 High Pressure Coolant Motor Overload

The high pressure coolant motor is overloaded. Correct the cause of the problem.

Press the Reset button on the high pressure coolant unit to reset the alarm.

Press the control Reset key to clear this message from the screen.

2152 High Pressure Coolant Level Low

The level switch in the high pressure coolant tank indicates that the coolant level is too low.Check the operation of the pump. Find and correct the cause of the problem.

Press the Reset button on the high pressure coolant unit to reset the alarm.

Press the control Reset key to clear this message from the screen.

2153 One Spindle Must be Running

The active spindle must be running before the high pressure coolant pump can be started.The active spindle is selected by M64 or M65. The main spindle is the default.

Revise the part program is necessary.


A2-18 M-489

2154 High Pressure Coolant Not Ready

The high pressure coolant unit is not ready.

Verify the high pressure coolant unit is ON.

Check the fuses in the machine power case.

Find and correct the cause of the problem.


2155 Lower Axis Thrust Limit

The lower axis thrust limit has been exceeded. The machine is put into a feed hold condition.

Press Cycle Start or Reset to clear this message.

2170 Hydrostatic Fluid Level too Low

The hydrostatic fluid level is below the full mark. The machine goes into Emergency Stop. Fillthe tank and restart the machine. Press Reset to clear this message.

2171 Hydrostatic Fluid Level Low, Refill

The hydrostatic fluid level is below the full mark. The tank should be filled soon. Filling thetank clears this message.

2172 Hydrostatic Pump Overload

Hydrostatic pump circuit breaker tripped. Determine the cause of the problem. Reset thecircuit breaker and press Reset to clear this message.

2173 Hydrostatic Fan Overload

Hydrostatic cooling fan circuit breaker tripped. Determine the cause of the problem. Resetthe circuit breaker and press Reset to clear this message.

2175 Hydrostatic Temperature Fault

Hydrostatic temperature is too high. Determine the cause of the problem and correct it. PressReset to clear this message.

2176 Excessive Flow

Hydrostatic fluid flow is excessive. Determine the cause of the problem and correct it. PressReset to clear this message.

2200 Parameter Write Fault 1: Please Turn Off Power and Restart Machine

The control has failed to write a parameter correctly. Restarting the machine may clear theproblem. Contact the Hardinge Service Department if necessary.

M-489 A2-19

2201 Parameter Write Fault 2: Please Turn Off Power and Restart Machine

The control has failed to write a parameter correctly. Restarting the machine may clear theproblem. Contact the Hardinge Service Department if necessary.

2220 Axis Thrust Limit X Axis

The optional programmable X axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.

2221 Axis Thrust Limit Y Axis

The optional programmable Y axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.

2222 Axis Thrust Limit Z Axis

The optional programmable Z axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.

2223 Axis Thrust Limit E Axis

The optional programmable E axis thrust limit has been exceeded. Refer to theprogrammable thrust limit documentation.

2233 Opposite Collet Open

The sub-spindle collet/chuck is open. Cycle Start and manual spindle operation are inhibited.Close the Collet/chuck to allow Cycle Start and manual spindle operation.

Press Reset to clear this message

2234 Opposite Spindle Contouring Mode

The manual axis movement selector switch is set to C2 and the operator is attempting tomanually operate the sub-spindle through the use of the spindle control functions on theoperator panel.

Set the manual axis movement selector switch to another setting.

2240 Door Closed Switch Fault — Shorted

One of the two door closed switch contacts is ON all the time or the two contacts are shortedtogether. Cycle Start is inhibited. Check the switch wiring.

When the problem is corrected, press Reset to clear this message.

2241 Door Closed Switch Fault — Open

One of the two door closed switch contacts is disconnected. Cycle Start is inhibited. Checkthe switch wiring.


A2-20 M-489

2242 Door Locked Switch Fault — Shorted

One of the two door locked switch contacts is ON all the time or the two contacts are shortedtogether. Cycle Start is inhibited. Check the switch wiring.


2243 Door Locked Switch Fault — Open

One of the two door locked switch contacts is disconnected. Cycle Start is inhibited. Checkthe switch wiring.


2246 Please contact Hardinge at 800/635-0192 extension 2227, or [email protected], and provide the key code shown below.You will be given a four digit password. You have 45 Days Toobtain your password. Key Code: [Xxxx]

Contact Hardinge Inc. as instructed.

2247 Your warning period has expired. Please contact Hardinge at800/635-0192 extension 2227, or at [email protected], and providethe key code shown below.Key Code: [Xxxx]

Contact Hardinge Inc. as instructed.

5305 Illegal Spindle Number

A spindle command (S word) was issued without an active P word. Program P1, P2, or P3 tospecify the active spindle.

Refer to programmer’s manual (M-488) for information on programming the P word forspindle selection.

M-489 A2-21

- NOTES -

A2-22 M-489

- NOTES -

M-489 A2-23

Hardinge Inc.

Elmira, New York 14902-1507 USAPhone: 607-734-2281 Fax: 607-734-8819

www.hardinge.com

RS 42, RS 51, RS 65, SR 150, and SR 200 -0009500-0489.pdf · OPERATOR’S MANUAL RS 42, RS 51, RS...

Documents

Transcript of RS 42, RS 51, RS 65, SR 150, and SR 200 -0009500-0489.pdf · OPERATOR’S MANUAL RS 42, RS 51, RS...