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FRYER MACHINE SYSTEMS MB-R SERIES

MECHANICAL MANUAL

FRYER MACHINE SYSTEMS, INC. 70 JON BARRETT ROAD

ROBIN HILL CORPORATE PARK PATTERSON, NY 12563 PHONE: 845-878-2500

FAX: 845-878-2525 WWW.FRYERMACHINE.COM

maintenance MB R SERIES 2 OF 14

MECHANICAL DRAWINGS....................................................................................................................................................3 HEAD ASSEMBLY..................................................................................................................................................................4 Z AXIS COLUMN ....................................................................................................................................................................5 Z AXIS RAM.............................................................................................................................................................................6 X AXIS TABLE ........................................................................................................................................................................7 X AXIS BALL SCREW ............................................................................................................................................................8 Y AXIS SADDLE .....................................................................................................................................................................9 Y AXIS BALL SCREW ..........................................................................................................................................................10 TOOL CHANGER ..................................................................................................................................................................11 BED AND COLUMN .............................................................................................................................................................12 COUNTER WEIGHT..............................................................................................................................................................13 RETENTION KNOBS ............................................................................................................................................................14


MECHANICAL DRAWINGS


HEAD ASSEMBLY


Z AXIS COLUMN


Z AXIS RAM


X AXIS TABLE


X AXIS BALL SCREW


Y AXIS SADDLE


Y AXIS BALL SCREW


TOOL CHANGER


BED AND COLUMN


COUNTER WEIGHT


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FRYER MACHINE SYSTEMS ELECTRICAL &

PROCEDURES MANUAL ANILAM 3000 CONTROL

FRYER MACHINE SYSTEMS, INC. 70 JON BARRETT ROAD

ROBIN HILL CORPORATE PARK PATTERSON, NY 12563 PHONE: 845-878-2500

FAX: 845-878-2525 WWW.FRYERMACHINE.COM

Electrical manual 3000.doc 1 OF 38 4/30/07

http://www.fryermachine.com/

SAFETY RULES.........................................................................................................................................................................3

STARTUP PROCEDURE FOR FRYER MB SERIES MILLS..............................................................................................4 UNPACK MACHINE .....................................................................................................................................................................4 LINE VOLTAGE CHECK................................................................................................................................................................4 MACHINE POWER-UP PROCEDURE ..............................................................................................................................................4 VOLTAGE CHECKS (ALL VOLTAGES +/- 10%): ...........................................................................................................................5 ADDITIONAL CHECKS:................................................................................................................................................................5

STARTUP REPORT - ANILAM 3000 CONTROL.................................................................................................................6 INITIAL START-UP QUALITY SURVEY.............................................................................................................................6

MB-R SERIES ELECTRICAL DRAWINGS...........................................................................................................................8 PANEL LAYOUT.....................................................................................................................................................................9 3000 OPTIONS .......................................................................................................................................................................10 3000 OPTIONS .......................................................................................................................................................................11 3000 OPTIONS .......................................................................................................................................................................12

MB Q SERIES ELECTRICAL DRAWINGS.........................................................................................................................13 PANEL LAYOUT...................................................................................................................................................................14 3000 OPTIONS .......................................................................................................................................................................16 3000 OPTIONS .......................................................................................................................................................................17

ANILAM ELECTRICAL DRAWINGS..................................................................................................................................18 3000 CABLE LAYOUT..........................................................................................................................................................19 CABINET WIRING DIAGRAM............................................................................................................................................20 CONSOLE WIRING DIAGRAM...........................................................................................................................................21

MB SERIES M CODES............................................................................................................................................................22

MAINTENANCE SCHEDULE................................................................................................................................................23

ADJUSTMENTS FOR ANILAM 3000 CONTROL ..............................................................................................................24 SETUP AND TESTING..........................................................................................................................................................25

YASKAWA GPD 315 SPINDLE DRIVE................................................................................................................................26

-BALDOR VECTOR SPINDLE DRIVE PARAMETERS-....................................ERROR! BOOKMARK NOT DEFINED.

INSTRUCTIONS FOR SETTING PARAMETERS...............................................ERROR! BOOKMARK NOT DEFINED.

ANILAM 3000 SOFTWARE UPDATE INSTRUCTIONS ...................................................................................................29

ANILAM 3000 SERVICE PROCEDURE FOR SAVING CONFIGURATION FILES.....................................................30 RENISHAW TOOL PROBE INSTALLATION ..................................................................................................................................31

DIAGNOSTICS OF ANILAM MB PLC.................................................................................................................................32

ANILAM HARD DRIVE INSTALLATION ..........................................................................................................................33

LOADING IPI FILE .................................................................................................................................................................35

USER SETUP FOR ANILAM NETWORKING....................................................................................................................36

FRYER OPTIONAL CHILLER INSTRUCTIONS...............................................................................................................38


SAFETY RULES READ BEFORE OPERATING MACHINE

1. PREVENT LOOSE CLOTHING, HAIR, JEWELRY FROM CONTACTING SPINDLE 2. NEVER: CHANGE TOOLS, HANDLE SPINDLE, CHANGE PARTS OR PERFORM WORK

ON MILL UNLESS CNC IS IN EMERGENCY STOP OR TOOL CHANGE MODES 3. ALWAYS WEAR EYE PROTECTION WHEN OPERATING MILL. 4. DO NOT OPERATE MILL WITHOUT AXIS MOTOR COVERS OR AXIS WAY COVERS IN

PLACE. 5. DO NOT PLACE OBJECTS OR HANDS BETWEEN COLUMN AND TABLE/SADDLE

ASSY, UNLESS CNC IS IN EMERGENCY STOP POSITION. 6. DO NOT MODIFY EQUIPMENT WITHOUT APPROVAL FROM FRYER MACHINE

SYSTEMS. DOING SO MAY VOID YOUR WARRANTY. 7. ELECTRICAL ENCLOSURES CONTAIN HIGH VOLTAGE. DISCONNECT EQUIPMENT

FROM POWER SOURCE BEFORE OPENING CABINETS. 8. CHECK LUBRICANT FILL LEVELS BEFORE OPERATING. 9. DO NOT OPERATE POWER DRAWBAR UNIT WHILE SPINDLE IS IN MOTION. 10. EMERGENCY STOP MILL WHEN NOT IN USE 11. KEEP VISES, CLAMPS, FIXTURE OR WORKPIECE FROM EXTENDING BEYOND BACK

EDGE OF TABLE. 12. TURN OFF POWER IF:

POWER PROBLEMS DEVELOP IN THE EVENT OF ELECTRICAL STORMS. AMBIENT TEMPERATURES EXCEED 105 DEGREES FARENHEIT.


STARTUP PROCEDURE FOR FRYER MB SERIES MILLS WITH ANILAM 3000 MK CONTROLLERS

Unpack Machine

1. Remove plastic wrap. Carefully inspect for any damage. 2. Install leveling pads and level machine. (This is usually the responsibility of the rigger or customer) 3. Remove Wooden counterweight SPIKE at top of machine. Assistance will be necessary to perform the following steps: 4. Using a socket or suitable wrench (Pliers are not recommended) turn the Z

ballscrew clockwise from the top of the screw enough to remove wooden shipping block on table. Be careful not to let the ratchet/wrench slip backwards.

5. Turn the ratchet/wrench counter clockwise until counterweight chains are taut, and counterweight bar is free.

6. Remove counterweight bar. At this time you must remove the ratchet/wrench otherwise serious damage could occur.

7. Install the Z-Axis motor and drive belt, and any other items that may have been removed for shipping purposes. 8. Check that front panel with swivel arm is clear of Z-Axis head motion.

Line voltage check

1. Verify 220/440vac. (+/- 10%) is wired to the main disconnect correctly. 2. Verify 110vac plug is in a 20 amp minimum dedicated receptacle, or the warranty will be voided.

3. The breaker for the 110vac must be a high magnetic breaker. An example is a Square D PN:Q0BHM-20

4. Check all wire connections, relays, contacts and plugs to be sure nothing has become loose. If so, reseat or

tighten before turning on main power. 5. All voltage checks should be recorded on the STARTUP REPORT form.

Machine power-up procedure

1. The electrical cabinet door should remain open until this startup is completed. The switch on the back of the console (MANUAL/AUTO) should be in the AUTO position.

2. Turn on the main disconnect switch on the electrical cabinet to power up 220/440vac. A pair of pliers may be used to turn the disconnect rod ¼ turn CW.

3. On the side of the electrical cabinet, the switch marked CONTROL POWER (0/1) should be in the 1 position to power up 110vac.

4. Press F10 to continue, press ENTER to boot into software. 5. Rotate the E-stop button CW, then press SERVO RESET to engage servo drives.


Voltage checks (All voltages +/- 10%):

1. Check for +160VDC at the large blue capacitor in the electrical cabinet. 2. Check for 110VAC at the Corcom EMI line filter in the electrical cabinet. 3. Check for +5VDC between pins 1 & 4 (common) on the P2 connector of the power supply in the console. 4. Check for +12VDC between pins 8 & 4 (common) on the P2 connector of the power supply in the console. 5. Check for –12VDC between pins 11 & 4 (common) on the P2 connector of the power supply in the console. 6. Check for +5VDC between pins 1 & 3 (common) on the P2 connector of the power supply in the electrical

cabinet. Refer to the Panel Layout drawing for more detail. 7. Check for +15VDC between pins 6 & 3 (common) on the P2 connector of the power supply in the electrical

cabinet. Refer to the Panel Layout drawing for more detail. 8. Check for –15VDC between pins 5 & 3 (common) on the P2 connector of the power supply in the electrical

cabinet. Refer to the Panel Layout drawing for more detail. 9. Check for +24VDC at the 24volt power supply (blue & yellow wires). Refer to the Panel Layout drawing for

more detail.

Additional Checks: 1. Make sure way surfaces are receiving sufficient oil from pump. 2. Make sure air pressure to power drawbar unit (if so equipped) is set at 85psi minimum.

All information should be recorded on a Fryer Machine Startup Form with any unusual conditions listed and returned to Fryer Machine Service Dept. If any problems are encountered or if you have any questions, please contact FRYER MACHINE SYSTEMS Service Department at (845) 878-2500.


STARTUP REPORT - ANILAM 3000 Control CUSTOMER: ____________________________________________DATE:____________________ MODEL #: ____________________ SERIAL #: _________________ CONTROL SN#: ____________________ DISTRIBUTOR: _______________________________ SERVICE TECH: _________________________________ SHOPCONTACT:___________________________TITLE:__________________________________

ATTENTION: ITEMS CAN BECOME LOOSE DURING SHIPPING CAUSING A LOSS OF CONNECTIONS. THIS MAY RESULT IN IMPROPER MACHINE FUNCTION AND/OR DAMAGE TO THE MACHINE OR COMPONENTS. BEFORE INITIAL POWER-UP: TIGHTEN ALL SCREWS AND ELECTRICAL CONNECTIONS IN THE ELECTRICAL CABINET . CHECK TO ENSURE THAT ALL ELECTRICAL COMPONENTS ARE PROPERLY SEATED AND SECURED.

70 Jon Barrett RoadRobin Hill Corporate Park

Patterson, N.Y. 12563Phone: (845) 878-2500

Fax: (845) 878-2525

E-mail: [email protected]

ELECTRICAL CONNECTIONS AND COMPONENTS CHECKED: _________ COMPUTER POWER SUPPLY (+5, +/- 12 VDC) (in consol) SERVO POWER SUPPLY (+5, +/-15 VDC)

+5 VDC: ________ P2-1 +5 VDC: ___________ P2-1 +12 VDC: ________ P2-8 +15 VDC: ___________ P2-6 • -12 VDC: ________ P2-11 -15 VDC: ___________ P2-5 (COMMON P2-4) (COMMON P2-3) 24VDC POWER SUPPLY- 24VDC: ________ 220/440 VAC (MAIN DISCONNECT)

L1-L2 _________ L2-L3 _________ L1-L3 _________ L1-GND _________ L2-GND _________ L3-GND _________ 110 VAC (CORCOM LINE FILTER) 110VAC _________ 160 VDC (DRIVE BUS CAPACITOR) 160VDC_________ WAYLUBE: PRESENT AT X, Y & Z BOX WAY SURFACES: __________ AIR PRESSURE: _________PSI

HOUR METER READING ______________

INITIAL START-UP QUALITY SURVEY At Fryer Machine Systems, we strive to continuously improve the quality of our products and services. As a qualified machine tool technician, your feedback is an essential part of this ongoing process. Please take a moment to fill out the following information. It will be greatly appreciated. Please circle the appropriate response (1=worst, 5=best) for each question. Feel free to add any comments. INITIAL IMPRESSIONS Was machine received in satisfactory condition? ................................................................Yes No If no, what was lacking? ____________________________________________________________________________


MACHINE SERIAL NO.______________________ DATE ____________ Please rate the overall appearance of the machine: ...........................................................1 2 3 4 5 Comments: ____________________________________________________________________________ ____________________________________________________________________________ PERFORMANCE Please rate the mechanical systems of the machine: ..........................................................1 2 3 4 5 ____________________________________________________________________________ ____________________________________________________________________________ Please rate the electrical systems of the machine: ..............................................................1 2 3 4 5 Comments: ____________________________________________________________________________ ____________________________________________________________________________ SERVICE Were there any problems with the machine during start-up? ...............................................Yes No If yes, please list: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ What issues, if any, are still outstanding? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Was our Service Dept. helpful during the start-up? Please rate us:.....................................1 2 3 4 5 GENERAL Would you recommend this machine to others?................................................................... Yes No Why? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ADDITIONAL COMMENTS: ________________________________________________________________________________________________________________________________________________________________________________________________________________________


MB-R SERIES ELECTRICAL DRAWINGS


PANEL LAYOUT


Ω−

3000 OPTIONS


3000 OPTIONS


MB Q SERIES ELECTRICAL DRAWINGS


PANEL LAYOUT


FRYER MB PART LIST SERIES B DRAWING REF. – PANEL LAYOUT

ITEM PART NO. PART NAME QTY SPECIFICATION 1 DRV-1010 SPINDLE DRIVE 1 2 CMB-2320 SERVO CONTROL BOARD 1 3 MSE-1930 24VDC POWER SUPPLY 1 4 MSE-1950 5/15VDC POWER SUPPLY 1 5 DRV-1185 SERVO DRIVE BOARD 3 6 SWT-5190 DISCONECT SWITCH 1 7 MSE-1016 CORCOM FILTER 1 8 MSE-1185 OMRON RELAY 24VDC 2 9 MSE-1954 BRIDGE RECTIFIER 1

MISC. ITEMS NOT IN DRAWING SCA-1010 COUPLED QUILL SCALE 1 SWT-5014 MICRO SWITCH 4 MSE-1460 AIR FILTER 1 MTR-3050 AXIS MOTOR W/ CABLE 3 SWT-5180 OVERRIDE SWITCH 2 SWT-5200 E-STOP BUTTON 1 SWT-5170 E-STOP BLOCK 1 CMB-2168 FLOPPY DRIVE 1 CMD-2164 HARD DRIVE (PART STORAGE) 1 CMB-2290 F-KEY STRIP 1 CMB-2280 MAIN KEY BOARD (3000 CONTROL) 1 CMB-2286 MAIN KEY BOARD (5000 CONTROL) 1


3000 OPTIONS


ANILAM ELECTRICAL DRAWINGS


DWG REF.#302008516

3000 CABLE LAYOUT


DWG REF.#302008517

CABINET WIRING DIAGRAM


DWG REF. #D000775

CONSOLE WIRING DIAGRAM


MB SERIES M CODES M00 Program stop M01 Optional stop(Optional hardware is required) M02 End of program and rewind M03 Spindle clockwise (an “s” code must also be present to specify RPM) M04 Spindle counter-clockwise (an “s” code must also be present to specify RPM) M05 Spindle stop M06 Turn off spindle and does tool change( a “T” number must be present to specify tool requested) M07 Mist coolant on(optional) M08 Flood coolant on(optional) M09 Mist and flood coolant off M10 Optional indexer interface, will cause cycle start on indexer and wait for finish pulse M11 Spare “M” function turns on output bit 0 M12 Spare “M” function turns off output bit 0 M9293x1 will display following error on screen ATC M-CODES M12 MISC MCODE OFF (CHIP AUGER OR BRAKE ETC) M13 U BRAKE ON M14 U BRAKE OFF M15 W BRAKE ON M16 W BRAKE OFF M50 SPINDLE ORIENT M51 ORIENT OFF M52 ATC CAROUSEL IN M53 ATC CAROUSEL OUT M54 DRAWEAR ON M55 DRAWEAR OFF M58 ATC INDEX FWD M59 ATC INDEX REV M61 HOME ATC


MAINTENANCE SCHEDULE FRYER MB SERIES MILLING MACHINES

daily weekly monthly 3 months 6 months yearly as req’d.

fill oil cups1 X fill lube pump2 X

fill drawbar lube3 X grease head4 X

grease drawbar5 X check coolant level X

change coolant6 X check head tram X

check machine level X check gibs X

check backlash X check belt tension X

check servo cabinet and console fans,

clean filters

X

replace servo cabinet and console filters7 X

1 -Mobil Velocite #10 (ISO VG 22) or equivalent 2 -Mobil Vactra #2 (ISO 68) or equivalent 3 -Break-Free Synthetic Air Tool Oil (5W) or equivalent 4 -Mobil 1 Universal Synthetic Grease (ISO VG 220) or equivalent 5 -Mobil XHP 220 Special Moly Grease or equivalent 6 -Valenite Turn Tech Blue Metalworking Fluid or equivalent 7 -See Anilam Manual


ADJUSTMENTS FOR ANILAM 3000 CONTROL FOR MB MACHINES

PART 1 GLENTEK SMA 7215-2 DRIVE CARD PRESETS 1. E-stop machine in the middle of its travel X-Y-Z. Make sure parameters for DSP motion are as follows:

DSP Motion Gain Tables: (All axis) FEED RAPID NO MOTION Kp 10 7 10 Ki 0 0 5 Kd 10 10 10 Kf 0 0 0 Il 0 0 10 Ds 5 2 5

2. Turn power off. 3. Disconnect the J1 connector on all drive cards. 4. Set DVM to thousand OHMs scale. Connect black lead to the J2-1 common test lead on drive card. This

is the common to set all potentiometers. 5. Adjust as follows: (NOTE: Look at diagram on side of drive card for correct position)

TEST POINT ADJUST POTOTENTIOMETER OHM VALUE J2-1 (Common) J2-2 (Signal Input) J2-3 (Tach Input) J2-4 (Diff Sig Gain) (1) Diff Gain 0 or Full CCW J2-5 (Signal Gain) (2) Sig Gain 2.18K J2-6 (Tach Gain) (4) Tach 4.60K J2-7 (Comp) (5) Comp 3.40K (6) Fldbk Full CW (20 turn pot) (7) ILIM Full CW (20 turn pot)

LOOP GAIN Full CW ( 1 turn pot)

6. For your reference, DIP switch settings should be:

ON (Towards circuit board) 1-5-6-7-9 OFF(Away form circuit board) 2-3-4-8-10

7. Reconnect all J1 connectors.


PART II ADJUSTMENTS FOR ANILAM 3000/5000 CONTROL ON MB MACHINES – MOTION

SETUP AND TESTING

8. Once the drives are pre-adjusted, turn on power to machine, make sure all axis are in the middle of their travel. Go to machine setup and disable home requirement.

9. Go to motion setup and testing. 10. Leave drives off. 11. Press axis you wish to test (X or Y or Z). 12. Press balance, this will cause the DSP board to output 0 mV and START. 13. Inside the CRT box is the DSP board. Set your DVM to mV scale, connect the black lead to the Glentek

drive card you are setting at the J2-1 test point (common) and the red lead to J2-2 test point (Signal Input). Adjust the appropriate POT on the DSP board (labeled on card) to obtain 0 mV.

14. Now you can remove the DVM leads. Press manual and then turn on the drives , then go to balance. On

the screen under the “X-Y-Z” readout is an “F”. Adjust the balance POT (3) on the Glentek drive card for 0 feed rate. This will stop the axis from drifting.

15. Now press manual to cancel the balance test. 16. Press signal gain to activate the signal gain test. It will ask for a time period = 2, and press start. This will

cause the control to output .9 VDC and the axis will move positive and negative. 17. Adjust the signal gain POT on the appropriate Glentek drive card to obtain 10% of the rapid feed rate

(usually 20 IPM). 18. Press manual and you are done with the test. Repeat steps 11 through 18 until all axis are adjusted.


YASKAWA GPD 315 SPINDLE DRIVE PARAMETERS FOR MILLS

TO RUN MACHINE IN LOCAL MODE:

1. Turn servos on. 2. Make sure the spindle is off 3. The run light should be blinking on the PC7 drive 4. Press the “ DSPL “ key 5 times so the “ LO/RE “ is illuminated in red. 5. Use the “ ∧ ” or “ ∨ ” arrow buttons to display “ Lo “ 6. Press the “DSPL “ key to illuminate “F/R”, use the “ ∧ ” or “ ∨ ” arrows to select forward or reverse spindle rotation. 7. Press the “ DSPL “ key to illuminate “FREF” 8. Press the “RUN” button and adjust the min/max knob to desired frequency (RPM)

PROCEDURE TO PROGRAM PC7 PARAMETERS: 1. Turn the drives on 2. Make sure the spindle is off 3. The run light should be blinking on the PC7 drive 4. Press the “ DSPL “ key 6 times until “PRGM” is illuminated in red 5. Use the “ ∧ ” or “ ∨ ” arrow buttons to select the parameter that must be edited 6. Press “ DATA/ENTER “ key to view the value of the parameter 7. This parameter can now be changed with the “ ∧ ” or “ ∨ ” arrow buttons 8. Once the change has been made press the “ DATA/ENTER “ key. The display will change to display the parameter

number (ex. “ N001 “ ) 9. Repeat this procedure for all parameters that must be modified.

TO INITIALIZE ALL PARAMETERS: (Warning this will reset all parameters in the PC7) 1. Follow the above procedure to set parameter N001=10 2. Once N001 is set recheck the value it should equal 1, this confirms that all parameters have been reset to factory default 3. Change the parameters specified below: (Warning do not change any other values!) N001=4 N002=1 (Vector control mode) N011=Depends on the machine. Standard machines settings MB15=150 , MB14=121 This sets the maximum frequency to limit the RPM of the machine. To accurately set this: Follow the procedure above to run the machine in Local mode. Press the “ DSPL “ button once to move the green light to “ FOUT “

Adjust the Min/Max knob to make the display reads 60 HZ ±.5 Use a tachometer and record the RPM Use this formula to calculate the RPM / HZ= recorded rpm / 60 HZ

Now divide the maximum RPM desired by the RPM/HZ this is the value that should be entered for N011. N019=3 (Accel time may have to be increased if fault occurs during accel to max speed.) N020=3 (Decel time may have to be increased if fault occurs during decel from max speed to stop) N022=2 (Emergency stop decel time) N036=(motor rated current-read motor tag) MB15/16=20 MB11/14=14 *440 VAC use ½ values N037=1 N052=19 N058=3 ( ZERO SPEED ) NO59=1 (DURING RUNNING) N092=1 N096=2 N106=2.7 N107=( 220VAC=.235) (440VAC= .924) N110=(MB15/16=59) (MB11/14=39) 4. When complete make sure unit is in “rE” (remote mode) press “DSPL” until “FREF”is illuminated.

Dip switch settings: SW1=NPN SW2= 1=off 2=off Refer to manual for any further information.


BALDOR H2 VECTOR SPINDLE DRIVE PARAMETERS

MB-10 Instructions for setting parameters and tuning drive.

1. Make sure the software version is 1.06 or newer. If it is not update to the latest software version. 2. Make sure motor is securely bolted down, as the auto tuning will cause the motor to rotate. 3. In order to set the parameters press the program button, use the up-down arrow keys to cursor to the correct parameter

level. Once the correct parameter is selected press enter this will enter into this parameter. Use the right arrow key to go to the next parameter. Press enter to modify the parameter, use the left and right arrow key to select the digit and the up and down key to change the value. Once the correct value is displayed press enter to save the change. Press status to exit the parameter edit field.

4. Set the following parameters: LEVEL 2 BLOCKS →DRIVE CONFIGURE →FACTORY SETTINGS=1-YES LEVEL 2 BLOCKS→DRIVE CONFIGURE→SPEED UNITS=1-RPM LEVEL 2 BLOCKS→DRIVE CONFIGURE→POWER INPUT=2-THREE PHASE (Note: use single phase only if ordered.) =0-SINGLE PHASE LEVEL 2 BLOCKS →DRIVE PROTECT→OVERLOAD=0-FAULT LEVEL 2 BLOCKS→MISCELLANEOUS→HOMING SPEED=200RPM. SPEEDS 2-15=0 LEVEL 2 BLOCKS→MISCELLANEOUS→HOMING OFFSET=1024 (Note: change this value to adjust spindle orient position) LEVEL 2 BLOCKS→MOTOR CONTROL→CONTROL TYPE=2-CLOSED VECTOR LEVEL 2 BLOCKS→MOTOR DATA→MOTOR RATED VOLT=220(see motor tag) LEVEL 2 BLOCKS→MOTOR DATA→MOTOR RATED AMP=22(see motor tag) LEVEL 2 BLOCKS→MOTOR DATA→MOTOR RATED SPEED=1750(see motor tag) LEVEL 2 BLOCKS→MOTOR DATA→MOTOR RATED FREQ=60(see motor tag) LEVEL 2 BLOCKS→MOTOR DATA→ENCODER COUNTS=1024(see encoder) LEVEL 2 BLOCKS→BRAKE ADJUST→RESISTOR OHMS=15(check resistor) LEVEL 2 BLOCKS→BRAKE ADJUST→RESISTOR WATTS=1000(check resistor) LEVEL 1 BLOCKS→INPUT SETUP→OPERATING MODE=14-BIPOLAR LEVEL 1 BLOCKS→INPUT SETUP→COMMAND SOURCE=2-ANALOG IN2 LEVEL 1 BLOCKS→OUTPUT SETUP→DIGITAL OUTPUT1=8-AT ZERO SPEED LEVEL 1 BLOCKS→OUTPUT SETUP→DIGITAL OUTPUT2=25-AT POSITION LEVEL 1 BLOCKS→OUTPUT SETUP→RELAY OUTPUT1=17-FAULT LEVEL 1 BLOCKS→OUTPUT SETUP→ZERO SPEED SET POINT=50 LEVEL 1 BLOCKS→PRESET SPEED 1=200RPM LEVEL 1 BLOCKS→RAMP RATES→ACCEL TIME 1=5 SEC LEVEL 1 BLOCKS→RAMP RATES→DECEL TIME 1=7 SEC

5. Once these values are set enable the drive by either commanding a M50 on the Anilam control or placing a jumper wire on the Baldor terminal strip between J2-8 and J3-21. Then put the drive in local mode.

LEVEL 2 BLOCKS→AUTOTUNE→ONE STEP TUNING=1-YES. Follow the directions on the BALDOR screen. This will go through the auto tuning procedure which will run the motor and set parameters automatically.

6. Once the auto tuning is complete set : LEVEL 2 BLOCKS→DRIVE LIMITS→MAXIMUM OUTPUT SPEED=6000 ( if this requires a higher spindle speed change this parameter)

7. Remove temporary jumper and put drive in remote mode, install all covers.


NOTES NOTE 1: The drive must be programmed for maximum RPM through the control. Cycle the drive forward and reverse allowing the spindle to obtain the extreme RPM ranges, if an error occurs during accel or decel the appropriate value should be enlarged. NOTE 2: The homing offset (LEVEL 2 BLOCKS→MISCELLANEOUS→HOMING OFFSET) is used only on machines equipped with Automatic Tool Changers. This will be adjusted from its original factory set value of 1024. After doing an M50 (orient spindle) command, adjust accordingly to correct the spindle home position. NOTE 3: Auto-tune values are set by following the instructions above. No manual entry is required.


Anilam 3000 software update instructions 1. Press E-stop and plug in an external keyboard 2. Press F10 exit 3. Press clear then type password “Z48” ↵ (enter) 4. Now you are in DOS at the C:\P3M prompt * 5. Type “cd..” ↵ You will now be in the root directory c:\ 6. Type “md old”↵ This will create an old directory 7. Type “cd P3M” (*) This will return you to the P3M directory 8. Type “copy *.* c:\old”↵ This will copy all files to the old directory for backup purposes. If there is a

problem with the software installation you can get your machine back to original operating software by copying all the files in the old directory back to the P3M directory. To do this type “cd..”↵ - “cd old” - “copy *.* c:\P3M” say yes to overwrite files. Power down to restore when completed copying files.

9. Now you can install the software update disk . (If you received the software via E-mail please copy all attached files to a clean 3.5” disk ) Type “a:”↵

10. Type “install”↵ this will start the installation process follow the directions on the screen. 11. Once you have completed the installation process and your machine is functioning properly you must

backup your configuration file onto the floppy disk in the electrical cabinet (usually mounted on the door). See the Anilam manual for directions.

* When updating a 5000 control the directory is c:\P5M


ANILAM 3000 Service Procedure for Saving Configuration files.

Copy Configuration

This feature enables the user to make copies of the configuration and save the copies to a floppy diskette. NOTE: FRYER MACHINE recommends that you copy your Configuration file before any changes are made to the system. Such as, software updates, backlash adjustments, console swap etc. (↵ = ENTER) 1. Go to the Software Options Menu. 2. #2 Setup Utility ↵ 3. #3 Utilities ↵ 4. #2 Copy Configuration ↵ 5. Enter the password Z48 ↵ 6. Highlight A: to copy the configuration to a floppy diskette. The configuration will be saved as

A:\P3MCFG.CFG ( 3000 ) OR A:\P5MCFG.CFG ( 5300 )

Restore from Copy

Use this feature to restore a copy of the configuration from the A drive (A:\P3MCFG.CFG) and save it as the new configuration file. NOTE: If you restore your configuration file from a copy or a backup you will need to reboot when the system prompts to do so. You will prompt for an automatic reboot.

1. Go to the software Options Menu. 2. #2 Setup Utility ↵ 3. #3 Utility ↵ 4. #3 Restore From Copy ↵ 5. Enter the password Z48 ↵ 6. Highlight A: to restore the configuration from a floppy diskette. The configuration will be

restored from A:\P3MCFG.CFG ( 3000 ) OR A:\P5MCFG.CFG ( 5300 ) Print configuration

Use this feature to save a copy of the configuration to diskette as a text file. P3CFG.TXT ( 3000 ) OR P5CFG.TXT ( 5300 ) may then be taken to desktop P.C. and printed as a readable text file. 1. Go to the Software Options Menu. 2. #2 Setup Utility ↵ 3. #3 Utility ↵ 4. #6 Printer Configuration ↵ 5. #2 Text File (A:) ↵ 6. F1 Yes Print Anilam 3000 M/MK CNC VER.XXX to A:\P3MCFG.TXT? OR 5300 M/MK CNC

VER. XXX TO A:\ P5MCFG.TXT?


Renishaw Tool Probe Installation This will assist you in setting up and installing your Renishaw TS-27R tool probe on your Fryer milling machine with Anilam control. Make sure you read the instruction manual that came with the Renishaw probe and the Anilam manual pertaining to probing cycles. The probe has been pre-wired and tested on the Fryer machine at the factory. The manuals also can be downloaded in PDF format from either Renishaw.com or Anilam.com Installation should be completed at the customer’s facility. Follow these basic instructions referring to the manufacturers manuals for further details:

1. Find a suitable mounting location for the probe ( most common is the far right hand corner of the table ) The probe should be mounted with the stylus pointing up and towards the left, this will exit the cable to the right. The Stylus should be approximately ½ the largest tool diameter used from the positive limit in x axis and at the rearmost t-slot(as long as it is a couple inches from the y limit). A t-nut can be used to mount the probe base with a ½-13 socket head cap screw. Make sure the cable will not interfere with anything during machine operation.

2. Once the probe is securely mounted tram the probe within .0002” perpendicular and parallel to the machine slides. See Renishaw installation manual for further details.

3. Follow the Anilam instructions to set the parameters according to your installation. 4. Now you will need a tool with a known diameter to preset the tool presetter. You should use the Anilam G150 or tool

probe calibration cycle. See the Anilam manual for further details. 5. Once the G150 cycle is accomplished a G53 fixture offset should be activated and set to the top of the part so that all

other tool to be set with the G151 cycle will be referenced to the top of the part.


Diagnostics of Anilam MB PLC

Refer to the Anilam Manual-Integral Programmable Intelligence User’s Guide for more information, included is the page on “Viewing the IPI Monitor” for your reference. An example of the input and output bits:

Can 0 input bit 0 X axis Home Switch 0=on trip dog 1=off trip dog (nc switch) Can 0 input bit 1 Spindle drive fault 0=drive ok 1=spindle drive fault Can 0 input bit 2 Y axis Home Switch 0= on trip dog 1=off trip dog (nc switch) Can 0 input bit 3 Low Way Lube 0=low lube level 1=good oil level (no float switch) Can 0 input bit 4 Z axis Home Switch 0=on trip dog 1=off trip dog (nc switch) Can 0 input bit 6 Index complete cycle Can 0 input bit 7 Spindle zero speed 0=spindle on 1=spindle not running Can 0 input bit 8 Spindle in orient position 0=not orient 1=spindle in orient position Can 0 output bit 0 Spare M-code M11=on M12=off Can 0 output bit 1 Indexer start command (enables wait state) Can 0 output bit 2 Mist coolant 1=on M7 0=off M9 Can 0 output bit 3 Spindle Enable 1=run the spindle or orient (power to spindle motor) Can 0 output bit 4 Spindle Orient 1=orient the spindle for tool changeM50 0=off M51 Can 0 output bit 5 Flood coolant 0=off M9 1=on M8 Can 1 input bit 0 Drawbar off switch 0=tool not clamped 1=tool clamped (no sw on dbar air cyl) Can 1 input bit 1 Drawbar on switch 0=tool locked 1=tool released (no switch on dbar air cyl) Can 1 input bit 2 Low air pressure switch 0=low air pressure 1=good air pressure (no switch) Can 1 input bit 3 ATC carousel in under spindle 0=not in 1=under spindle (no prox switch) Can 1 input bit 4 ATC carousel out 0=not out 1=normal position (no prox switch) Can 1 input bit 5 ATC Geneva drive prox 0=at pocket 1=not at pocket (no prox switch) Can 1 input bit 6 ATC home prox 0=not at home pocket 1=at pocket 1 (no prox switch) Can 1 input bit 7 Manual Tool in/out button on head 0=not pressed 1=pressed(no momentary sw) Can 1 output bit 0 ATC index direction Can 1 output bit 1 ATC index 1=spin the ATC geneva drive motor M58 or M59 Can 1 output bit 3 ATC carousel in under head M52=1 move under head 0=retract M53 Can 1 output bit 4 Drawbar on 1=drawbar on to release the tool (also airblast on)M54=off M55


ANILAM HARD DRIVE INSTALLATION

MATERIALS REQUIRED: -Hard Drive -Machine Parameter Disk -Blank, Formatted 3.5” Floppy Disk PROCEDURE:

1. Install the hard drive into the control. Depending on the machine model, the hard drive will be located either in the operator console or the computer chassis in the electrical cabinet.

2. If you received a DSP and/or keyboard chip with your new software, please install it following the directions provided with the chip(s).

3. Plug a standard keyboard into the control. Start the computer. If the computer boots into the Anilam software, proceed to Step 3. Otherwise, proceed as follows: During the initial boot sequence, enter the BIOS setup menu by pressing the key specified by the message “press __ to enter setup” (usually <F2> or <Del>). You will need to enter the “Main” or “Standard CMOS Setup” menu. Now you must auto-detect the hard drive. Due to variations in the BIOS versions used by Anilam, it is difficult to provide one exact procedure to cover all controls. Call for assistance if you run into any problems. NOTE: For non-Pentium computers using large hard drives, check the auto-detected information for “no. of heads”. If this field says 16, it needs to be changed to 15. Highlight the field with the cursor and use the <-> minus key to change. Now proceed to the “Exit” menu. Choose “Save changes and exit”- if prompted, answer “Y” <Enter>.

4. The computer should reboot and start the Anilam software. Press <F10> until you get to the Software Options menu. Press <Alt>+<C>. When prompted for the password, type the password corresponding to your control from the list below, followed by <Enter>. -“Y10” for 1100 controls -“SERVICE” for 1400 controls -“Z48” for 3X00 5X00 controls

5. You should see a black screen with the DOS prompt: -S1100\> for 1100 controls -S1400\> for 1400 controls -P3M\> for 3X00 controls -P5M\> for 5X00 controls

6. Insert the machine’s original parameter disk into the floppy drive. 7. Type “cd\” <Enter>. Then, type “A:” <Enter>. Then, type:

“COPY *.* C:\_____” <Enter>, inserting the directory name that corresponds to your control from the list below:

S1100 for 1100 controls S1400 for 1400 controls P3M for 3X00 controls P5M for 1100 controls This will copy your original parameter file and machine files into the control software. If you are asked, “File exists, replace?” Press <Y> <Enter>. You should get a “_ file(s) copied” message.

8. Now you will need to re-install the Anilam software onto the hard drive in order to update the parameter file. To do this, insert the Anilam software disk into the floppy drive and reboot the computer. The Anilam software installation utility should start automatically (If it does not, type “A:\install”). Follow the prompts on the screen, performing a normal software installation.

9. At the end of the software installation, remove the floppy disk and press <F10> to reboot the computer. It should boot from the hard drive and automatically start the Anilam software. The machine should be ready to run. Test the machine to ensure that it is functioning properly.


Once you are satisfied with the machine’s operation, you will need to make a new parameter disk. To do this, perform the following procedure:

For 3X00 and 5X00 Controls:

Press in the E-stop button and exit the CNC software <F10>. Use the cursor to highlight #2, Setup Utility, press <Enter>. Go to #3, Utilities, press <Enter>. Go to #2, Copy Configuration, press <Enter>. Enter the password “Z48”, <Enter>. Go to A:, press <Enter>. When copying is complete, remove the floppy disk and store it in a safe place. Press <F10> until you get back to the Software Options menu. Go to Control Software, press <Enter>.

10. You are done! If you need help, please call our Service Department at (845) 878-2500.


Loading IPI file Anilam 3000 Control

This procedure goes through a step by step process to put a new PLC program into the hard drive of the machine in the P3M directory. Then you must compile the file through the IPI interface section. The “particular plc file.DBO” is________________________ the file made for your machine on the floppy disk with the .DBO extension. Do the following steps from the main screen (Manual) with the drives off: (F2) program (F8) display keep pressing (F8) until ..\ is in the upper left of the screen move cursor to (..\) (enter) cursor to (p3m\) or (p5m) (enter) (F7) log cursor to (A:) (enter) (make sure the floppy is in the drive) move cursor to (particular plc file .DBO) (MBMENG.TXT) (enter) this is the message file (optional) (F9) utilities cursor to (copy) (enter) cursor to (c:) (enter) *this will copy file to machines hard drive (F7) log cursor to (c:) (enter) (F10) exit get back to the main screen (manual) (F10) exit *this will exit out of the cnc software cursor to (2.setup utility) (enter) cursor to (1.builder setup) (enter) cursor to (3.prog. I/O interface) enter password (IPI) (enter) cursor to (2.select program) (enter) cursor to (particular plc file .DBO) (enter) *this is the program loaded from the disk cursor to (4.load) (enter) *this will compile file (F10) exit two times. you are now done with the installation so keep exiting back to the cnc software saving the changes. If you get an error of block 90 not found during a tool change, you must power down to eliminate this error, this may take more than one reboot cycle. Make sure you put the floppy disk in a safe place.


User Setup For Anilam Networking

Upon receiving your Fryer machine networking will be setup for TCPIP protocol. We only support this method of networking. If you need to use a different protocol, like Novel, the system will need to be reconfigured. For those using TCPIP you will only need to edit two files to configure to your network. The proticol.ini and system.ini files are located in the c:\net directory. Below are examples of these files.

You will first boot up your machine and get to the control software menu. At this point, you will need to plug in an external keyboard and press the escape key. A password box will now be displayed. The password is Z48. Once you type in the password press enter and you will be in Dos. To edit the files you can use XTG utility that is installed in your machine. Once you are exited the Anilam software and at the c:\> prompt, type XTG and then press enter. This will get you into the XTG dos utility. To use this software the cursor keys will move the highlighted box. The enter key will access the highlighted box which must be a directory. Once you are in the proper directory select the file you wish to edit and press the letter “E” then enter to edit the file. Once you finished editing press the “ESC” key and then select “save file and quit”.

Proticol.ini – in the C:\net directory [network.setup] version=0x3110 netcard=smc9000,1,SMC9000,1 transport=tcpip,TCPIP lana0=smc9000,1,tcpip [TCPIP] NBSessions=6 SubNetMask0=255 255 255 0 defined by the network tech. IPAddress0=100 100 100 2 defined by the network tech. DisableDHCP=1 DriverName=TCPIP$ BINDINGS=SMC9000 LANABASE=0 [protman] DriverName=PROTMAN$ PRIORITY=MS$NDISHLP [SMC9000] DriverName=SMC9X$ Interrupt=9 IOBase=0x300 MaxTransmits=1

System.ini – in the C:\net directory [network] sizworkbuf=1498 filesharing=yes printsharing=yes autologon=yes computername=MINIMILL defined by network tech. lanroot=C:\NET username=MINIMILL defined by network tech. workgroup=CNC defined by network tech. reconnect=yes dospophotkey=N lmlogon=1 logondomain=CNC defined by network tech. preferredredir=full autostart=full maxconnections=8 [Password Lists] *Shares=C:\NET\Shares.PWL MACHINE=C:\NET\MACHINE.PWL___________delete this line, the next boot-up will allow you to store a new network password.


FURTHER INSTRUCTIONS

Once the two files are edited and stored turn off the main disconnect switch wait 30 seconds and turn back on to reboot the system.

1. Watch closely the boot process once you see “starting MS-DOS” hold down F8 key on keyboard. This will ask you yes or no for each line of the autoexec file. You will answer yes (type the letter “y” and ↵) to each question until the line that asks you to type your username.

2. Type “network administrator supplied user name” for username and when asked for the password enter “network administrator supplied user password” press the enter key. When prompted to create a password list for this username type “y↵” and when asked to confirm password re-enter “network administrator supplied user password” press the enter key.

3. When prompted for a domain password enter “domain password supplied by the network administrator” and press the enter key. This will create a stored password file in the system.ini

4. Continue to enter “y” (type the letter “y” and ↵) for each line of the Autoexec file until the line that states “c:\touch\elodev ####,#,…” type “n↵” for the rest of the questions. You will then be at the c:\>_ (c prompt).

5. At the C:\>_ type “netshare.exe↵” This will bring up a blue window, instructions how to maneuver the cursor are on the bottom of the screen.

6. Type in the SHARE NAME as “network administrator supplied sharename” this is the name of the CNC control. 7. Type in the PATH as “c:\user” 8. Move cursor to SHARE and press↵. This should put the name and path in the current share window if everything

is done correctly. 9. Exit Netshare 10. Type “cd net↵” 11. Type “net↵” This will bring up a blue window, instructions on how to maneuver the cursor are on the bottom of

the screen. Sometimes you will not see where the cursor is, so just keep using the tab button until you can change the value you desire.

12. DRIVE should be already set at G: if not type it in. 13. Type in the PATH as “network administrator supplied path” 14. Make sure the box for reconnect on startup is “x” ed. 15. Move the cursor to connect and press↵ 16. Repeat steps 12-16 to map additional drives. Now you can exit net.exe and reboot the machine 17. You now should be completed with the installation. Verify that you can see the machine on the network and

make sure that you have drive G and any other mapped drive listed when you are in Program and log (use the shift key ) If you cannot see drive G you may have to repeat step 12 through 16.

Notes on NT systems 1. Limits of Microsoft DOS client 3.0 do not allow for digital signatures. 2. Using windows XP the network neighborhood GUI (Graphic User Interface) will not allow explorer to access a

DOS shared drive. The workaround is done by using the command prompt (under start-programs-accessories-command prompt) type: “net use (drive letter): \\ (computer name) \ (share name) “ then enter . Example: net use M: \\machine\test. On DOS systems it may take some time to map.

3. Microsoft 2003 server requires all machines on the network to have digital signing. In order for the CNC to function with this, the digital signing must be turned off, which would cause a security issue. In order to work around this problem the machine can be mapped to a intermediary that has an XP operating system. This can be done by using the command prompt (under start-programs-accessories-command prompt) type: “net use (drive letter): \\ (computer name) \ (share name) “ then enter . Example: net use M: \\machine\test. On DOS systems it may take some time to map.


Fryer Optional Chiller Instructions Used on all optional high speed spindles and automatic gearbox

INSTALLATION: The chiller has been wired and tested at the factory. The reservoir is filled with ISO#32 spindle oil. At installation check the level at the tank sight glass and top off as necessary. The ambient temperature to run the chiller must be between 41°-104° Fahrenheit (5-40°Celsius). The working range of the chiller is between 77°-95° Fahrenheit (25-35° Celsius). The factory preset is to run at 77° F. This is the optimal setting for most applications. The chiller must be located in a clean dry area with good ventilation and level. WIRING: The chiller is pre-wired at the factory. Incoming 3 phase power is applied at terminals R-S-T. Ground is connected to E. Terminals 93 and 95 are fault contacts going back to the CNC control. Terminals 224 and 225 are the remote start inputs. Do not turn the chiller off or on with the on switch on the chiller operator panel. This will bypass the remote on from the CNC and cause an alarm on the CNC. ADJUSTMENT: The display on the chiller normally shows the oil temperature. To adjust the preset temperature when the refrigeration will cycle on press the left arrow button. The display will now show the preset value. This should be set at 25° Celsius (77°Fahrenheit). Use the right and left arrow keys to adjust. Wait for 5 seconds and the display should revert back to displaying the liquid temperature. TROUBLESHOOTING:

1. Alarm on CNC control “Spindle chiller alarm”: Look at the chiller for any alarms. If the display is blank press the ON button on the chiller. If there still is no display check the fuses in the CNC electrical cabinet (normally fuses D1-D2_D3).

2. If there is an alarm displayed on the chiller,here is a brief listing: AL-1 REV: Phase failure or out of phase, The is not three phase present or line is out of phase. Switch any two lines at the terminal strip in the chiller R-S or T. Check the fuses in the CNC cabinet. AL-2 PUMP: The pump motor is not functioning properly. -Check that there is no obstruction in lines

-Reverse red and white wire of thermal relay 51P in chiller -Replace pump -Add recirculating oil to the reservoir -Adjsut the oil pressure switch to .3kgf/cm2 under .5-.8cmHg -Reset the thermal overload

AL-3 COMP: The compressor motor is not functioning properly.

-Reset the thermal overload -Replace the compressor

AL-4 RA: Temperature probe of the room is not functioning properly

-Replace the RA room temperature probe

AL-5 RO: Temperature probe of oil is abnormal -Replace the RO liquid temperature sensor

AL-6 OT: The cooling oil is overheating -Shut down the coller and wait until the temperature drops to acceptable levels.

-Recharge Freon. -Check level of oil

MAINTENANCE: -Clean the filter net periodically as required. -Replace oil as required and make sure there is no blockage in the lines.


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