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    AUGUST 2005SIEMENS OPERATOR MANUAL SIEMENS SINUMERIK 840D CONTROL OPERATOR MANUAL FADAL MACHINING CENT...

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    FADAL MACHINING CENTERS MAN_0124_R1

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    AUGUST 2005SIEMENS OPERATOR MANUAL

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    AUGUST 2005TABLE OF CONTENTSiSIEMENS OPERATOR MANUAL TABLE OF CONTENTSactionGoToR:1.0 POWER ON /OFF .......actionGoToR:...............................................................................................................................1actionGoToR:1.1 PRE-START actionGoToR:CHECKING STE...

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    FADAL MACHINING CENTERS iiTABLE OF CONTENTSMAN_0124_R14.2.4 actionGoToR:USING THE SET BASEactionGoToR: SOFT KEY TO actionGoToR:SET THE BASE OFFSET actionGoToR:.................................................................364.2.5 actionGoToR:USING THE MEASURE actionGoToR:WORKPIECE SOFTactionGoT...

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    AUGUST 2005POWER ON /OFF 1SIEMENS OPERATOR MANUAL 1.0 POWER ON /OFF

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    FADAL MACHINING CENTERS 2POWER ON /OFFMAN_0124_R11.1 PRE-START CHECKING STEPS 1.1.1 OIL RESERVOIRExamine the oil levels. Both should be filled before the levels are one inch from the bottom of the reservoir. The spindle oil reservoir may have oil in it for up to six months. The way lube oil reser...

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    AUGUST 2005POWER ON /OFF 3SIEMENS OPERATOR MANUAL 1.1.3 WATER RESERVOIRMost new VMC models release water collected in the water reservoir automatically. It is advisable to place an additional water trap in the air line going to the machine.1.1.4 FLOOD C...

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    FADAL MACHINING CENTERS 4POWER ON /OFFMAN_0124_R11.2 POWER ON/OFF1.2.1 POWER ONTo power on the machine, press the safety lock and turn the power switch in the clockwise direction. CNC will boot up and enter operating status.1.2.2 POWER OFFTo power off machine follow the next procedure:1. From the...

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    AUGUST 2005PENDANT LAYOUT / HHU5SIEMENS OPERATOR MANUAL 2.0 PENDANT LAYOUT / HHU

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    FADAL MACHINING CENTERS 6PENDANT LAYOUT / HHUMAN_0124_R1The table on the following pages shows the various buttons on the pendant. A brief description of the function of each button is given to assist the operator in becoming familiar with the control. Refer to the Siemens operator manuals for de...

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    AUGUST 2005PENDANT LAYOUT / HHU7SIEMENS OPERATOR MANUAL 2.1. PENDANT HARD KEYS FUNCTION GUIDE2.1.1 PENDANT KEYBOARDTable 2-1: Pendant Keyboard KeysKEYNAME FUNCTIONAlarm Displays alarms/messages screen. Alarm AcknowledgeResets CNC soft alarms.Cursor (left, right, up, down) Moves the cursor a...

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    FADAL MACHINING CENTERS 8PENDANT LAYOUT / HHUMAN_0124_R1Table 2-1: (Continued) Pendant Keyboard KeysKEYNAME FUNCTIONInput Used to accept entry of data.Insert Used to edit the existing data entry.Next Window Goes to the top of the next active display.Offset/Parameters Displays the offsets screen ...

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    AUGUST 2005PENDANT LAYOUT / HHU9SIEMENS OPERATOR MANUAL NOTE CHANNEL AND CUSTOM keys are not usable. ShiftAllows to use second character.BackspaceAllows to move the cursor back on space.DeleteDeletes character.ChannelThis button is not functional.CustomThis button is not functional.Table 2-1: (Co...

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    FADAL MACHINING CENTERS 10PENDANT LAYOUT / HHUMAN_0124_R12.1.2 UPPER MACHINE CONTROL PANEL (MCP)Table 2-2: Machine Control Panel KeysKEY NAME FUNCTIONAuto Initiates the automatic mode.Coolant 1 Toggles the flood coolant feature on and off. Works in combination with M7 (to turn it on) and M9 (t...

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    AUGUST 2005PENDANT LAYOUT / HHU11SIEMENS OPERATOR MANUAL Table 2-2: (Continued) Machine Control Panel KeysKEY NAME FUNCTIONIncrement Jog Activates Incremental sub-mode of Manual Mode. Allows incremental JOG by JOG keys or MPG (hand wheel). Jog Initiates Manual Mode. Note: Reference, Incre-mental...

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    FADAL MACHINING CENTERS 12PENDANT LAYOUT / HHUMAN_0124_R1Turret CW Rotates the turret in the clockwise direction. This button is active only in the Manual Mode.Work Light Toggles the machine work lights ON and OFF.ConveyorAllows to toggle the conveyor ON and OFF.Reset Resets the currently active ...

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    AUGUST 2005PENDANT LAYOUT / HHU13SIEMENS OPERATOR MANUAL 2.1.3 LOWER MACHINE CONTROL PANEL (MCP)Emergency StopEmergency Push button will cut the power to all axis motors, spindle drives and the tool changer. To cancel Emergency Stop first press READY pushbutton, then Reset hard key. The program ...

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    FADAL MACHINING CENTERS 14PENDANT LAYOUT / HHUMAN_0124_R1Table 2-3: Machine Control Panel KeysKEYNAME FUNCTIONRapid Rate OverrideAllows to override programmed rapid rate. (G0)ResolutionAllows to select increment.Axis Selector To select the axis, use Axis Selector switch.Override Override push bu...

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    AUGUST 2005PENDANT LAYOUT / HHU15SIEMENS OPERATOR MANUAL 2.2. HAND HELD UNIT (HHU)Table 2-4: Hand Held Unit hard keysKEYNAME FUNCTIONRapidAllows to select rapid jog axis when pressed together with + or -.Position directionAllows to jog in the positive direction. Negative directionAllows to jog ...

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    FADAL MACHINING CENTERS 16PENDANT LAYOUT / HHUMAN_0124_R1Table 2-4: (Continued) Hand Held Unit hard keysKEYNAME FUNCTIONTool IN/OUTTo manually load or unload a tool into the spindle press F1 key.Jog/MPGTo switch from Jog mode into MPG and vice verse, press F2 key on the HHU.To check if MPG is ac...

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    AUGUST 2005PENDANT LAYOUT / HHU17SIEMENS OPERATOR MANUAL Override Override push button is used to override the door interlock when using the MPG. (Excep-tion, if the feedrate is at 0% then MPG will stop the motion)It allows to jog machine with open doors.Override push button can be either in acti...

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    FADAL MACHINING CENTERS 18PENDANT LAYOUT / HHUMAN_0124_R1

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    AUGUST 2005MANUAL OPERATION19SIEMENS OPERATOR MANUAL 3.0 MANUAL OPERATION

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    FADAL MACHINING CENTERS 20MANUAL OPERATIONMAN_0124_R13.1 MANUAL DATA AUTOMATIC (MDA)To display MDI screen follow next steps:•Press the MDA hard key.MDI display

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    AUGUST 2005MANUAL OPERATION21SIEMENS OPERATOR MANUAL 3.2 JOG MODETo display Jog mode position readout display follow the next step:•Press the JOG hard key.3.2.1 SETTING INCREMENTIncremental jog using JOG hard key1. Press JOG hard key.2. Press VAR hard key.(On the upper left corner of the displ...

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    FADAL MACHINING CENTERS 22MANUAL OPERATIONMAN_0124_R1Incremental jog using HHU1. Select REMOTE on axis selector switch that is located on the lower MCP panel.2. Press JOG hard key3. Press F2 on HHU (LED above MPG should turn on)4. Press F3 to toggle increment between x1, x10, x100 and VAR.5. Indi...

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    AUGUST 2005MANUAL OPERATION23SIEMENS OPERATOR MANUAL If axis selector is set on VAR, set jog increment value manually following the next steps:1. Press menu extention key “>”.2. Press ShopM. Sett. soft key3. With the blue cursor keypad arrow, cursor down to the variable increment box.4. Ty...

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    FADAL MACHINING CENTERS 24MANUAL OPERATIONMAN_0124_R13.2.2 RAPID JOG 1. Press the JOG hard key and select the axis to be jogged from the axis selector switch located on the lower MCP panel.2. Select the direction of the tool by pressing the “+” or “–” hard key. 3. Pressing the RAPID har...

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    AUGUST 2005MANUAL OPERATION25SIEMENS OPERATOR MANUAL 3.3 TOOL OPERATION3.3.1 MANUAL TOOL LOADING AND UNLOADINGA tool can be manually loaded or unloaded into the spindle by using the TOOL IN/OUT hard key. 1. The tool holder must be held in the left hand with the thumb and the first finger grasping...

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    FADAL MACHINING CENTERS 26MANUAL OPERATIONMAN_0124_R13.3.2 LOADING AND UNLOADING A TOOL FROM TOOL CHANGER (ATC)NOTE When tool holders are in the ATC (Automatic Tool Changer), they can be loaded into the spindle by using the T,S,M mode.1. Press the T,S,M soft key. 2. Type T# (where # is the turre...

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    AUGUST 2005MANUAL OPERATION27SIEMENS OPERATOR MANUAL 3.4 MANUALLY JOGGING THE DATCNOTE Machine must be in JOG mode. Multiple key combinations are required to move the dual tool armchanger.•Press and hold the SPINDLE STOP (d), FEED STOP (e), and CYCLE STOP (f) red hard keys and the RAPID OVR (a...

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    FADAL MACHINING CENTERS 28MANUAL OPERATIONMAN_0124_R13.5 SPINDLE OPERATION3.5.1 ESTABLISHING SPINDLE RPMNOTE Use the spindle OVERRIDE switch to vary the RPM manually from 50% to 120% of the programmed value. M3 = CW SPINDLE ONM4 = CCW SPINDLE ONM5 = SPINDLE OFFM40 = AUTO BELT RANGEM41 = LOW B...

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    AUGUST 2005MANUAL OPERATION29SIEMENS OPERATOR MANUAL 3.5.2 SPINDLE STARTAfter establishing the RPM from T,S,M Mode, or at any time in any mode of operation, the spindle can be turned on manually by using the green SPINDLE START hard key button.•Press the SPINDLE START hard key. The spindle will...

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    FADAL MACHINING CENTERS 30MANUAL OPERATIONMAN_0124_R1

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    AUGUST 2005OFFSETS31SIEMENS OPERATOR MANUAL 4.0 OFFSETS

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    FADAL MACHINING CENTERS 32OFFSETSMAN_0124_R14.1 COORDINATE SYSTEMSMachine coordinate system (MCS)The machine coordinate system is based on the machine axes that are designated X1, Y1, Z1, A1 and B1 in the actual value display. At the reference point (alignment position) all machine axes = 0. Tool...

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    AUGUST 2005OFFSETS33SIEMENS OPERATOR MANUAL The Work Coordinate System (WCS)The workpiece coordinate system is based on the MCS with offsets to shift the workpiece to zero. Workpiece programming is done in WCS using the workpiece axes designations X, Y, Z, A and B. The WCS includes all active off...

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    FADAL MACHINING CENTERS 34OFFSETSMAN_0124_R14.2 OFFSETSThe most commonly used offsets are the Base Offset, Zero (Work) Offset, and Tool Offset. These offsets are combined together to define the WCS relative to the MCS Machine Zero (Cold Start) position.4.2.1 BASE OFFSETThe Base Offset is always a...

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    AUGUST 2005OFFSETS35SIEMENS OPERATOR MANUAL The figure below is a two dimensional diagram illustrating the various coordinate systems and their relationship.Offset screenWork ZeroWCS)Work offsetBase OffsetHomeMachine ZeroMCS)(Cold start)

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    FADAL MACHINING CENTERS 36OFFSETSMAN_0124_R14.2.4 USING THE SET BASE SOFT KEY TO SET THE BASE OFFSETNOTE Only the X, Y and Z Axes can be set with this method. The Base Offset for the A and B axes must be set directly in the Zero Offset screen.1. Press JOG hard key.2. Press Set WO soft key. The X...

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    AUGUST 2005OFFSETS37SIEMENS OPERATOR MANUAL 7. Press the X=0 soft key to set the X-Axis base position for the WCS. The WCS posi-tion for the X-Axis will reset to Zero. 8. Press Machine Position soft key. MCS screen displays.

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    FADAL MACHINING CENTERS 38OFFSETSMAN_0124_R19. Toggle to the MCS display. The WCS base position for the machine will be dis-played. In the example below the X-Axis was jogged to +3.0314”. The MCS display for the X-Axis now shows the Machine Zero (Cold Start) position is -1.00 inches away from t...

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    AUGUST 2005OFFSETS39SIEMENS OPERATOR MANUAL 4.2.5 USING THE MEASURE WORKPIECE SOFT KEY TO SET THE BASE AND ZERO OFFSETSNOTE Only the X, Y and Z Axes can be set with this method, the Base Offset for the A and B axes must beset directly in the Zero Offset screen.1. Press JOG hard key.2. Press the ...

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    FADAL MACHINING CENTERS 40OFFSETSMAN_0124_R14. Select the Edge soft key when using the X, Y and Z WCS position to determine the base setting by using an edge finder or touch probe on the part from each WCS axis.

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    AUGUST 2005OFFSETS41SIEMENS OPERATOR MANUAL

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    FADAL MACHINING CENTERS 42OFFSETSMAN_0124_R1NOTE An edge finder or probe can be used for these procedures.

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    AUGUST 2005OFFSETS43SIEMENS OPERATOR MANUAL 5. Select the Corner soft key when setting the WCS base position by determining the orientation of the workpiece to a selected corner.

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    FADAL MACHINING CENTERS 44OFFSETSMAN_0124_R16. Select the Hole soft key when setting the WCS base position by determining the center of a hole at four positions.

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    AUGUST 2005OFFSETS45SIEMENS OPERATOR MANUAL 7. Select the Spigot soft key when setting the WCS base position by determining the center of a cylinder at four positions.

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    FADAL MACHINING CENTERS 46OFFSETSMAN_0124_R18. Select the Calibrate Probe soft key when checking the accuracy of the probe against standards for length or radius.

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    AUGUST 2005OFFSETS47SIEMENS OPERATOR MANUAL 4.2.6 USING THE MEASURE TOOL SOFT KEY TO SET THE TOOL OFFSET1. Press JOG hard key.2. Press the MEASURE TOOL soft key. The operator has six options to choose from: Length Manual, Diameter Manual, Length Auto, Diameter Auto, Calibrate probe and Calibrate ...

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    FADAL MACHINING CENTERS 48OFFSETSMAN_0124_R13. Select the Length Manual soft key when manually setting the tool length offset by jogging the tool to a reference block or part.

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    AUGUST 2005OFFSETS49SIEMENS OPERATOR MANUAL 4. Select the Diameter Manual soft key when manually setting the tool diameter offset by jogging the tool to a reference block or part.

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    FADAL MACHINING CENTERS 50OFFSETSMAN_0124_R15. Select the Length Auto soft key when setting the tool length offset with a touch probe.

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    AUGUST 2005OFFSETS51SIEMENS OPERATOR MANUAL 6. Select the Diameter Auto soft key when setting the tool diameter offset with a touch probe.

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    FADAL MACHINING CENTERS 52OFFSETSMAN_0124_R17. Select the Calibrate Probe soft key when checking the accuracy of the probe against standards for length or radius.

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    AUGUST 2005OFFSETS53SIEMENS OPERATOR MANUAL 8. Select the Calibrate Fixed point soft key.

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    FADAL MACHINING CENTERS 54OFFSETSMAN_0124_R14.2.7 USING THE ZERO OFFSET SOFT KEY TO SET THE BASE AND ZERO OFFSETS1. Press OFFSET soft key to display the main manual display.2. Press WORK OFFSET soft key. The zero offsets table displays.3. Use the cursor key pad arrows to move to the desired field...

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    AUGUST 2005OFFSETS55SIEMENS OPERATOR MANUAL 4.2.8 USING THE TOOL SOFT KEY TO SET THE TOOL OFFSETS1. The TOOL soft key is accessed from the main manual display. To get to the main manual display press the OFFSETS hard key.2. Press the Tool List soft key. The Tool List table is displayed.3. Use th...

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    FADAL MACHINING CENTERS 56OFFSETSMAN_0124_R14. Use the ALTERNATE soft key to toggle between options available in the Tool List variable fields. In the example below the ALTERNATE soft key was used to change the tool type for tool number 1 (compare with previous screen display).

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    AUGUST 2005OFFSETS57SIEMENS OPERATOR MANUAL 5. The default setting of the tool list shows the 1st cutting edge. To set offsets for tools with two cutting edges press the Cutting Edges soft key.Use the Cutting Edges soft key to toggle between the displays. The CNC command D2 is used to activate of...

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    FADAL MACHINING CENTERS 58OFFSETSMAN_0124_R14. Press the MPG button and use the Manual Pulse Generator to jog the Z axis until the tip of the tool is just above the top of the gauge block. Select smaller increments for jog, and jog the tool down until the tip of the tool is close enough to the ga...

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    AUGUST 2005OFFSETS59SIEMENS OPERATOR MANUAL This inputs the tool length based on the current Z axis location into the tool table:

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    FADAL MACHINING CENTERS 60OFFSETSMAN_0124_R1

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    AUGUST 2005GENERAL INFORMATION61SIEMENS OPERATOR MANUAL 5.0 GENERAL INFORMATION

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    FADAL MACHINING CENTERS 62GENERAL INFORMATIONMAN_0124_R15.1 FINDING MACHINE REFERENCE (COLD START)The FADAL machine tool has software limits and does not contain position limit switches. Therefore, the machine tool must be physically located at set alignment marks. The Siemens control automatical...

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    AUGUST 2005GENERAL INFORMATION63SIEMENS OPERATOR MANUAL 5.2 TOOL DIAMETER INPUTTo enter tool diameter offsets follow the next steps:1. Press the OFFSET hard key.2. Press the Tool List soft key.3. Use the cursor keypad arrows, cursor down and over to highlight the diameter (Ø symbol) for the des...

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    FADAL MACHINING CENTERS 64GENERAL INFORMATIONMAN_0124_R15.3 TOOL WEAR TABLEThe operator has the option to adjust the tool length or the tool diameter by an incremental value.1. Press the OFFSET hard key.2. Press the Tool wear soft key.3. Use the cursor keypad arrows, cursor down and over to highl...

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    AUGUST 2005GENERAL INFORMATION65SIEMENS OPERATOR MANUAL 5.4 MAGAZINE TABLE•Press OFFSET hard key. MAGAZINE soft key displays active tool and turret loca-tion.

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    FADAL MACHINING CENTERS 66GENERAL INFORMATIONMAN_0124_R15.5 R VARIABLE TABLE•Press OFFSET hard key. R vari. soft key displays the user defined R parameters that can be activated by the program.

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    AUGUST 2005GENERAL INFORMATION67SIEMENS OPERATOR MANUAL 5.6 A NEW PROGRAM FOR AUTOTo create a new program for AUTO follow the next steps:1. Press the PROGRAM MANAGER hard key.2. Press the Program soft key.3. Press the New soft key. 4. The operator has the option of using Shop Mill or G-code progr...

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    FADAL MACHINING CENTERS 68GENERAL INFORMATIONMAN_0124_R15. Type in the new program name. 6. Press the INPUT hard key.

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    AUGUST 2005GENERAL INFORMATION69SIEMENS OPERATOR MANUAL 5.7 EDITING AN EXISTING PROGRAMFollow the next steps:1. Press the Program manager hard key.2. Use the cursor keypad arrows, cursor down and over to highlight the program name. 3. Press INPUT hard key.4. If the program is in the Shop Mill for...

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    FADAL MACHINING CENTERS 70GENERAL INFORMATIONMAN_0124_R15.8 CHOOSING A PROGRAM TO RUN IN AUTONOTE To choose a program to run in AUTO it must first be active.1. Press the PROGRAM MANAGER hard key.2. Use the cursor keypad arrows, cursor down and over to highlight the program name.3. Press the Exec...

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    AUGUST 2005GENERAL INFORMATION71SIEMENS OPERATOR MANUAL 5.9 AUTO, RUNNING A PROGRAMThe AUTO button will only execute the currently active program. To run the currently active program: 1. Press the AUTO hard key.2. Press the NC Cycle Start hard key to begin automatic operation.NOTE NC Cycle Start...

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    FADAL MACHINING CENTERS 72GENERAL INFORMATIONMAN_0124_R15.10 MID-TAPE (PROGRAM) STARTUsing the mid-tape start option of the auto command, the program can be started from any block. The options are available from the BLOCK SEARCH soft keys on the auto display.

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    AUGUST 2005GENERAL INFORMATION73SIEMENS OPERATOR MANUAL 5.11 OEM ALARM (V050805)Table 5-1: Alarm ListALARM NO.DEFINITIONREACTIONREMEDYSOLLUTION66500Spindle Orientation FailedThe spindle failed to orient properlyDisplay alarm.Axis movement disable.NC start disable.Check the spindle for proper posi...

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    FADAL MACHINING CENTERS 74GENERAL INFORMATIONMAN_0124_R1Table 5-1: (Continued) Alarm ListALARM NO.DEFINITIONREACTIONREMEDYSOLLUTION510012Dual Arm ActiveThe dual arm gripper in the tool changer in movement. Display alarm.Axis movement disable.Spindle rotation disable.Normal during tool change.Chec...

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    AUGUST 2005GENERAL INFORMATION75SIEMENS OPERATOR MANUAL ALARM NO.DEFINITIONREACTIONREMEDYSOLLUTION510105 Spindle Draw Bar Arm Time-outDraw bar mechanism failed to close/open in time allowed.Display alarm.Axis movement disable.Program interrupted.Check draw bar for mechanical problems, lack of com...

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    FADAL MACHINING CENTERS 76GENERAL INFORMATIONMAN_0124_R1ALARM NO.DEFINITIONREACTIONREMEDYSOLLUTION510216 Oiler level too lowWay-lube oiler level too low.Display alarm.Program interrupted (read-in disabled).Fill up way-lube oiler reservoir. Program will continue automatically.Program will continue...

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    AUGUST 2005GENERAL INFORMATION77SIEMENS OPERATOR MANUAL ALARM NO.DEFINITIONREACTIONREMEDYSOLLUTION700035 A Axis Needs ReferencingThe ìAî axis has not been referenced (cold started).Display alarm.NC-start disableD until all axes are referenced.Reference (cold start) the axis.Reference (cold star...

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    FADAL MACHINING CENTERS 78GENERAL INFORMATIONMAN_0124_R1ALARM NO.DEFINITIONREACTIONREMEDYSOLLUTION700056 Air Pressure FailureThe spindle air-oil air pressure is too low.Display alarm. Machine continues to run.Check incoming air pres-sure. Check spindle air-oil air pressure sensor.Press the RESET ...

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    AUGUST 2005GENERAL INFORMATION79SIEMENS OPERATOR MANUAL 5.12 M CODESTable 5-2: M code listCODEFUNCTIONNOTESM0Unconditional NC stopM1Conditional NC stopM2NC program endM3Spindle CWM4Spindle CCWM5Spindle StopM6Execute tool changeM7Activate Coolant 1M8Activate Coolant 2M9Stop all coolantM11Set curre...

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    FADAL MACHINING CENTERS 80GENERAL INFORMATIONMAN_0124_R1Table 5-2: (Continued) M code listCODEFUNCTIONNOTESM68Set M68/M69 outputMisc. M FunctionM69Reset M68/M69 outputMisc. M FunctionM83Spindle set-upM84Spindle belt measurementM85Activate A axisM86Deactivate A axisUsed to remove rotary tableM87Ac...

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    AUGUST 2005INDEX81SIEMENS OPERATOR MANUAL INDEXA(ATC) 26A NEW PROGRAM FOR AUTO 67AIR PRESSURE 2AUTO, RUNNING A PROGRAM 71BBASE OFFSET 34CCHOOSING A PROGRAM TO RUN IN AUTO 70COORDINATE SYSTEMS 32EEDITING AN EXISTING PROGRAM 69ESTABLISHING SPINDLE RPM 28FFINDING MACHINE REFERENCE (COLD START) 62FLO...

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    FADAL MACHINING CENTERS 82INDEXMAN_0124_R1MAGAZINE TABLE 65MANUAL DATA AUTOMATIC (MDA) 20MANUAL OPERATION 19MANUAL TOOL LOADING AND UNLOADING 25MANUALLY JOGGING THE DATC 27MID-TAPE (PROGRAM) START 72OOEM ALARM (V050805) 73OFFSETS 31OFFSETS 34OIL RESERVOIR 2PPENDANT HARD KEYS FUNCTION GUIDE 7PENDA...

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    AUGUST 2005INDEX83SIEMENS OPERATOR MANUAL USING THE SET BASE SOFT KEY TO SET THE BASE OFFSET 36USING THE TOOL SOFT KEY TO SET THE TOOL OFFSETS 55USING THE ZERO OFFSET SOFT KEY TO SET THE BASE AND ZERO OFFSETS 54WWATER RESERVOIR 3ZZERO OFFSET 34

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