operating manual fanuc 0i-tc gs 42 gs 51 gs 150 gs 200 … 000950004 e... · 2.15 alarm message 108...

Operating Manual

Fanuc 0i-TC

GS 42 GS 51 GS 150 GS 200 GS 250 GS 250 L

GS 200/66 GS 200/66 L

/ Fanuc SV

SV 150 SV 200 SV 200 L SV 250 SV 250 L

SV 200/66 SV 200/66 L

Original instructions

Document Number GS 000950004 Issue E

November 2009

CONTENTS

Page

1.1 INTENDED USE 3

1.2 IMPORTANT SAFETY NOTICE WARNING! 3

1.3 SAFETY LIST ALL COUNTRIES 5

1.4 GUARD VISION PANEL SAFETY 8

1.5 BEFORE SWITCHING ON 8

1.6 WARRANTY INFORMATION 9

1.7 ROUTINE INSPECTION 9

1.8 INTERRUPTING MACHINING 10

1.9 COMPLETING A JOB 10

1.10 SAFETY DEVICES 11

2.1 SERIAL NUMBER 12

2.2 OPERATOR PANEL 13

2.3 MACHINE FUNCTIONS 13

2.4 MACHINE POWER UP/DOWN AND CONTROL STATUS 30

2.5 OPERATIONAL MODES AND EDITING 37

2.6 M-FUNCTION CODES 49

2.7 WORK SHIFT AND TOOL OFFSETS 51

2.8 INSTALLING A TOOL ON THE TURRET 66

2.9 LIVE TOOLING [OPTION] 69

2.10 CHUCK CLOSER AND SPINDLE TOOLING 78

2.11 TAILSTOCK [OPTION] 84

2.12 INPUT/OUTPUT DEVICES 93

2.13 MISCELLANEOUS 101

2.14 TOOL LIFE MANAGMENT 104

2.15 ALARM MESSAGE 108

APPENDIX ONE 114

1.1 INTENDED USE Applicable Machines GS/SV Series Lathes. This lathe is a numerically controlled machine tool designed to shape cold metal by the application of rotating workpiece capable of performing two or more machining processes (e.g. turning, facing, grooving, boring) at one set-up of a workpiece and incorporating automatic facilities to:

Select and change tools from a turret Change the position of the turret relative to the spindle clamped workpiece Select and apply spindle speeds and axis feeds Control ancillary services (e.g. coolant flow)

Notice: Damage resulting from misuse, negligence, or accident is not covered by the

Hardinge Machine Warranty. Information in this manual is subject to change without notice. In no event will Hardinge be responsible for indirect or consequential damage resulting from the use or application of the information in this manual.

1.2 IMPORTANT SAFETY NOTICE WARNING! It is the user’s responsibility to be acquainted with the legal obligations and requirements in the safe use and application of the machine, particularly under the Health and Safety at Work Act 1974 and in the British Standard document PD 5304: 2005 Guidance on the Safe Use of Machinery, and other standards and safety codes applicable in the country of use. OPERATING MANUAL Read all the instructions contained in this manual carefully before operating the machine, the load/unload automation, or the bar feed system. When this manual was printed, the information given was current. However, since we are constantly improving the design of our machine tools, automation, and bar feed system, it is possible that the illustrations and descriptions may very from the machine, automation, or bar system you received. HQC (QUICK-CHANGE) COLLETS APPLICATIONS 1) Hardinge HQC (Quick-Change) collets MUST NOT be used in applications where the

spindle is rotating without a bar or workpiece in the collet. 2) Rotating the spindle without a bar or workpiece in the collet can result in the collet head

being expelled from the spindle. 3) Failure to comply with this warning can result in serious injury or death.

SAFE INSTALLATION It is the customer’s responsibility to ensure the machine is installed in a safe operating position, with all service pipes and cables clear of the operation area so as not to cause a hazard. Access must be allowed for safe maintenance, swarf and oil disposal including safe stacking of machined and un-machined components. MACHINE GUARDING The Hardinge CNC Lathe is fitted with completely enclosed guards as standard. In certain cases and tooling applications additional guarding may have to be provided by the user. The standard machine guarding has a special safety interlock on the guard door that complies with the Machinery Directive. Guards and interlocks must be kept fully maintained and tested by the customer and shall not be removed. The guards are made with clear observation windows having high impact resistance to provide operator safety and a clear unobstructed view of the operations in process. The opening of the guard door provides access to potential hazard areas. Opening of the front working area guard door is not allowed whilst the spindle is rotating, but it is still possible to manually initiate axis movements whilst the door is open (albeit at a reduced traverse rate). Extreme care must therefore be used at all times. SOFTWARE Unauthorized changing of machines software or control parameters is hazardous and is not permitted. Hardinge will not accept any liability whatsoever for unauthorized changes in this area. AUTHORISED PERSONNEL AND TRAINING Operating, service and maintenance engineers shall be authorized by the ‘User Company’ and properly trained in the use of the machine. SAFE WORKING PRACTICE The setting, operation and maintenance of workholding devices, lifting equipment, and tooling shall be the responsibility of the user. It is the user’s responsibility to protect against the hazards caused by swarf, leaking oil or coolant and their use. Use of proprietary oil or coolant is the responsibility of the user. Special instructions from the suppliers concerning their use should be carefully read and understood before use. To prevent bodily injury, safe working practices should be employed when operating or servicing the machine.

1.3 SAFETY LIST ALL COUNTRIES • It is the user’s responsibility to ensure all local regulations and safety instructions are

followed. • Users should consult with their own safety representative to ensure that all such

regulations are known and acted upon. • Additional safety notices may exist for certain specific countries for which Hardinge may

be able to advise. Please ask. • DON’T run the machine until you have made clear to your supervisor that you understand

the potential hazard of spindle rotation, the throwing of coolant and the removal of swarf from the cutting process.

• DON’T run the machine until you have read and understood all manuals provided with the machine.

• DON’T run the machine until you have read and understood all the machine and control keys.

• DON’T run the machine for the first time without a qualified instructor. Ask your supervisor for help when you need it.

• PROTECT your eyes. Wear safety glasses with side shields at all times. • DON’T get caught in moving parts. Remove watches, rings, jewelry, neckties and loose

fitting clothes. • PROTECT your head. Wear a safety helmet when working near overhead hazards. • KEEP your hair away from moving parts. • PROTECT your feet. Always wear safety shoes with steel toecaps and oil resistant soles. • Gloves are easily caught in moving parts. TAKE THEM OFF before you turn on the

machine. • Loose objects can become flying projectiles. REMOVE all loose items (wrenches, chuck

keys, rags etc.) from the machine before starting. • NEVER operate a machine tool after taking strong medication, using non-prescription

drugs, prescription drugs or consume alcohol which may impair concentration. • ALWAYS make sure the working and cutting zone is safeguarded. • PROTECT your hands. Make sure the spindle is stopped before manually changing a tool

or a workpiece. • PROTECT your hands. Make sure the spindle is stopped before manually clearing away

swarf or oil. Use a brush or chip scraper. NEVER use your hands. • PROTECT your hands. Make sure the spindle is stopped before manually adjusting the

work piece or fixture or coolant nozzle. • PROTECT your hands. Make sure the spindle is stopped before you take measurements. • PROTECT your hands. Make sure the spindle is stopped before you move a safeguard.

Never reach around a safeguard. • PROTECT your hands. Make sure the machine is switched off and electrically isolated

before making any mechanical adjustment. • PROTECT your hands. Beware sharp edges of cutting tools when changing and handling

tools. • PROTECT your hands. Beware of sharp edges on newly machined components. Wear

gloves when unloading. • PROTECT your eyes and the machine. Never use a compressed air hose to remove swarf

or to clean out air vents. • KEEP the work area well lighted. Ask for additional lighting if needed. • DON’T slip. Keep your work area clean and dry. Remove swarf, oil and obstacles. • NEVER lean on the machine. Stand away when machine is running. • DON’T get trapped. Avoid pinch points caused between other machines and the machine

you are working. • PREVENT tool and cutter breakage. Use correct cutting speeds and axis feed rate for the

job. Make manual over ride adjustments of axis feed rate or spindle speed if you notice unusual noise or vibration. Ask your supervisor for help if you need it.

SAFETY LIST ALL COUNTRIES (Cont.) • PREVENT work piece, tool and cutter damage. Never start the machine when the tool or

cutter is in contact with the work piece. • DON’T operate equipment if unusual or excessive heat, noise, smoke, or vibration occurs.

Report any excessive or unusual vibration, sounds, smoke, or heat as well as any damaged parts.

• REDUCE spindle speed if vibration occurs. Bar stock straightness will have an effect on vibration and balance of the spindle system.

• NEVER operate the machine spindle without a work-holding device if the draw tube is in the spindle.

• TIGHTEN all workholding mounting screws before beginning spindle operation. • KEEP chemical and flammable material away from electrical or operating equipment. • HAVE the correct type of fire extinguisher handy when machining combustible material

and keep chips clear of the work area. • DON’T use a toxic or flammable substance as a solvent cleaner or coolant. • TO remove or replace the chuck closer it is necessary to remove the guard door at the left

end of the machine. Make certain that the guard door is in place before starting the machine.

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

• ALWAYS check the machine and work area for loose tools and parts especially after work has been completed by maintenance personnel.

• REMOVE chuck wrenches before starting the machine. • KNOW where all stop push buttons are located in case of an emergency. • CHECK setup, tooling, and security of the workpiece if the machine has been OFF for any

length of time. • DON’T operate any equipment while any part of the body is in the proximity to a

potentially hazardous area. • 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. • USE caution around exposed mechanisms and tooling especially when setting up. Be

careful of sharp edges on tools. • DON’T use worn or defective hand tools. Use the proper size and type for the job being

performed. • 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

condition. Replace any defective chuck before operating the machine. Follow the manufacturer’s instructions on lubrication and maintenance.

• KEEP all lubrication reservoirs maintained at the correct level. Always keep to the maintenance schedule.

• CERTAIN materials such as magnesium are highly flammable in dust and chip form. See your supervisor before working these materials.

• PREVENT fire. Keep flammable liquids and materials away from the work area and from hot swarf.

• PREVENT the machine from moving unexpectedly. When leaving the machine unattended, not producing, leave switched in the MANUAL mode, with the EMERGENCY STOP button depressed.

• DON’T use the machine in a volatile atmosphere. Electrical devices fitted to the machine are for normal factory use and are not explosion proof.

• ALWAYS keep the machine clean and do not let swarf collect.

SAFETY LIST ALL COUNTRIES (Cont.) • ALWAYS keep the area around the machine clean and tidy. Opening the guards creates

the potential for residual coolant and swarf to fall to the swarf tray and possibly to the floor. Good housekeeping minimizes the potential for trips, slip or fall of all personnel.

• DON’T reach into any control or power case, unless electrical power is OFF. • DON’T touch electrical equipment when hands are wet or when standing on a wet surface. • ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before

restarting the machine. • INFORM all other personnel who approach the machine about the hazards described in

this safety list. • When making adjustments with spanners, always ensure that the required leverage is

safely applied. Always avoid slippage. Always apply the leverage by pulling, never by pushing. Always use the correct size spanner. Ensure the spanner is not damaged.

• Do not use organic chemical solvents to clean the machine guards or compressed air services equipment.

• This machine is intended for use in an industrial environment and must not be used in the residential, commercial and light industrial environment.

• Hardinge high speed spindles are balanced to an ISO G1.0 standard; high speed spindles require a work-holding device balanced to G2.5 or better.

• USE maximum allowable gripping pressure on the chuck. Consider weight, shape, and balance of the workpiece.

• USE lighter than normal feedrates and depth of cut when machining a workpiece diameter that is larger than the gripping diameter.

• DON’T exceed the rated capacity of the machine. • 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 chuck closer or machine spindle without

being adequately covered and properly supported. • FOLLOW each bar feed manufacturer’s guidelines. For performance and safe application,

size and 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 bar feed is a floor-mounted type, it must be securely bolted to the floor.

• ANY workholding device used in conjunction with this lathe must fit within the working envelope available. Under no circumstances must any such workholding device be used when it would require the need to override/defeat the safety interlocks fitted as standard to this machine.

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

1.4 GUARD VISION PANEL SAFETY The vision panels fitted to Hardinge Lathes comprise a sealed cartridge containing both glass and polycarbonate, and comply with Safety Standard EN12415. Check the panel daily for signs of cracking scratching or marring, and for signs of coolant penetration into the cartridge. Replace the cartridge immediately any imperfection is observed. Note that when a panel has been subject to a strong impact, its safety can no longer be guaranteed, even though it may appear to be unaffected, and it must be replaced. As a precaution, replace any cartridge which has been in service for over 5 years.

1.5 BEFORE SWITCHING ON Training on all aspects of this machine tool is available from Hardinge. Please contact your Hardinge representative for further details. Cables, cords or electric wires of which insulation is damaged can produce current leaks and electric shocks. Check their condition before connecting. A qualified electrician should only carry out connection of the power cable to the machine. Ensure the power cable to the machine main isolator has sufficient current carrying capacity to handle the electric power used. Cables which must be laid on the floor must be protected against chips, oil and coolants penetration, which might cause damage. In the event of power failure, turn off the main circuit breaker immediately. Fuses and circuit breakers should be replaced only with suitably rated alternatives. Safety devices should be replaced only with the machine manufacturers recommended parts. Protect the CNC unit, operating panel, and electric cabinet etc from shocks which could cause a failure of malfunction. Check the condition of the warning labels. If they are missing or become illegible, order replacements from Hardinge according to the part number on the label plate. Do not remove warning labels. After unpacking the machine clean all rust preventatives from the machine with a non-volatile cleaning fluid. Lightly lubricate each sliding part before trying to operate the machine. Use recommended oil brands and appropriate levels for all lubricating systems. See the instruction plate at the rear of the machine. The coolant system comprises of a separate tank at the front of the machine and a coolant pump toward the back (or right) of the machine, depending on the machine model.

1.6 WARRANTY INFORMATION Hardinge warrants to the original purchaser only that all products manufactured by it will be free from defects in materials or workmanship, such warranty to remain in effect if and only if such products are used in accordance with all instructions as to maintenance and operations set forth in manuals and instruction sheets furnished by Hardinge. The machine manufacturer is not responsible for any danger or damage arising from improper operation of the machine. Some examples of improper use are listed below.

1. Adding to or modifying the machine without consulting Hardinge. 2. Operating the machine outside the machining range. 3. Improper use of a tool or workpiece holding or peripheral device. 4. Using the machine with interlocks or protection covers removed. 5. Carrying out machine operation, programming or maintenance and inspection work

without thoroughly understanding the caution information, i.e. without having read the instruction manuals carefully.

1.7 ROUTINE INSPECTION The schedules below are based on single shift operations using coolant at all times. Daily

1. Check pressure gauge reading. Air pressure 5.5bar (80psi) 2. Check that there is sufficient oil in the air lubricator. 3. Check motors and other parts for abnormal noises. 4. Check the lubrication of sliding parts for evidence of proper lubrication. 5. Check safety covers and safety devices for proper operation. 6. Check coolant level and fill as necessary. 7. Clean dirt and chips from the axes and empty the swarf trays. 8. Check all polycarbonate vision panels for signs of damage – crazing, cracking etc. or

reduced visibility. Replace damaged vision panels immediately, and before continuing to use the machine. Contact your Hardinge representative for details.

Weekly (In addition to daily routine)

1. Clean chips and dirt from the entire machine and wipe down. 2. Check the air filter at the rear of the electrical cabinet. Replace the filter element if it

is contaminated.

1.8 INTERRUPTING MACHINING WARNING! When leaving the machine temporarily after completing a job, turn off the power on the operator panel with the Emergency Stop button and turn off the main isolator. Never turn off power during automatic operation or with the spindle or axes running unless an emergency occurs. It is better to interrupt the program by pressing the "Cycle Stop" push button.

1.9 COMPLETING A JOB. Always clean the machine and supporting equipment down after use. Remove and dispose of chips and clean the covers and windows etc. Return each machine component to its initial condition. Check wipers for damage and replace if necessary. Check coolants, hydraulic oils and lubricants for level & contamination. Change them if you suspect they are contaminated. Clean the filter on the top of the coolant tank. Turn off the power first on the control panel with the emergency stop button and then at the main isolator before leaving the machine at end of the shift.

1.10 SAFETY DEVICES Make yourself aware of the locations of the emergency stop push buttons, which should be well known so that they can be operated at any time without the need to look for them. Test the push buttons periodically for their correct operation. Further safety devices are located at the following points around the machine: The front door has safety interlock switches with guard door locking. Over travel limit switches are present at each end of each axis stroke. Stored stroke limit (Parameter setting): The control system will recognize when a move is requested that will take the motion beyond the end of the machine stroke. This move will not be allowed to start. Functional Explanation Emergency Stop Circuit A safety relay is fitted in the machine through which the Emergency Stop Buttons are wired. In addition to this are hard wired over travel switches on both ends of all 3 axes to check whether the axis has traveled beyond the allowed boundary. If any one of Emergency Stop buttons are pressed, the machine will stop immediately and go into an Emergency Stop condition. CAUTION! Once the emergency condition has been safely resolved, the emergency stop buttons are released in order to reset the safety relay into its normal condition. Firstly pressed the READY button, the machine should be power ON. The “RESET” button should then be pressed to clear any error messages within the control system. Servo & Spindle Power Disconnect Once the Emergency Stop button is pressed or any of the over travel limit switches have been operated, the machine will stop and the power supply to the drives is removed. Door Safety Circuit The main access door at the front of the machine is interlocked. During machine operation this door is shot bolted shut and can only be opened once the spindle is stationary and there is no program running (CE machines). Power On Safety Circuit (Allows the operator to execute certain tasks whilst the door is open) Limited machine functionality is available to the operator whilst the door is open. The handwheel and jog keys are able to move the machine axes at feed rates of 2m/min and less. Spindle operation is prohibited whilst the door is open as the spindle contactor is hard wired through the door interlock safety relay. Selection of automatic program running is prohibited until the door is shut. Rotation of the tool turret is also prohibited until the doors are shut. Door Interlock of Electrical Cabinet Safety Circuit When the door interlock switch is set to “0” and the cabinet doors are open, the machine power will remain ON. When door interlock switch is set to “1” and the cabinet doors are open, the machine power will be turned OFF.

2.1 SERIAL NUMBER CONTROL SERIAL NUMBER

Fanuc Control

The control serial number is located on tag “C”, Figure 1.2. This tag is located on the CNC control, which is located inside the control unit.

Include this serial number in all correspondence regarding the control.

Figure 1.2 - Control Serial Number

C

2.2 OPERATOR PANEL

2.3 MACHINE FUNCTION CONTROL DISPLAY SCREEN

Soft Keys The five unlabeled softkeys have various functions. The softkey functions are displayed at the bottom of the control display screen. Left-hand Softkey This key is used to return to the initial state after a function has been accessed by pressing a softkey.

Figure 2.1 - Control Display Panel and Manual Data Input Keyboard

Figure 2.2 – Operator Control Panel

READY

E D

F

G

H

I

Right-hand Softkey This key is used to display further softkey functions which are not currently displayed.

MANUAL DATA INPUT KEYBOARD

Alter This key permits changes to an existing entry in an active program while in Edit mode. CAN (Cancel) This key cancels or deletes the last character or symbol which has been entered into the input buffer. It is also used, together with the appropriate function key, to clear the data displayed on the screen. Cursor Control Keys These keys will shift the cursor forward or backward through the program or parameters. Custom No function. Data Input Keys 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, EOB, and Cancel keys are active. Data entered with the data input keys is indicated at the bottom of the display screen. Each alphabetic data input key is capable of inputting two distinct characters. The input is switched by pressing the Shift key. The Rapid Traverse symbol on the 5 key has no function. Delete This key causes the data word directly above the cursor to be deleted. EOB This key is used to input an End of Block (;) character. Graph (Graphics) Pressing this key allows the operator to set graphic display parameters and display the tool path or a solid model of the workpiece. This key also provides access to the Manual Guide function. Refer to the Fanuc documentation for information on Manual Guide. Help The Help key allows the operator to gain access to an on-line help system. Input This key is used to set data, which has been entered into the input buffer area, into the

appropriate area in the control memory. Insert This key allows additional commands to be inserted in a program line while in Edit mode.

Message This key allows the operator to display alarm messages, operator messages, or the alarm message history.

Offset / Setting This key allows the setting and display of offset values.

Page Up / Page Down The Page keys are used to display information which requires more than one display page. Pressing Page UP or Page DOWN 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 softkey. 2. In the relative coordinate system by pressing the Relative softkey. 3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to

go, by pressing the ALL softkey. Use the Page keys to switch between the various position display screens.

PROG (Program) This key allows the operator to perform the following: 1. In Edit mode - edit and display program memory. 2. In Manual Data Input mode - Input and display Manual Data Input data. 3. In Memory mode - display the active part program. Reset This key can be activated any time while a part program is being executed. When the Reset key is pressed, axis and spindle motion are stopped. The M and G codes are reset to the power-up default status. The Reset key is also used to clear an alarm state after a fault has been corrected.

Shift Each of the data input keys has one large and one small character. By pressing the shift

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

key, the user can switch between the two characters on the data input key. Pressing the Shift key will alternate the screen cursor between “_” and “^”. The “_” cursor indicates that the large character in the center of the data input key will be input. The “^” cursor indicates that the small character in the lower right corner of the data input key will be input. System

The System key allows access to the following information. 1. The Parameter softkey allows display and setting of machine parameters. 2. The Diagnostic softkey allows display of machine diagnostic information. 3. The PMC soft key allows display of the following PMC information:

Ladder Diagnostics Parameters

The System softkey allows display of the control hardware and software configuration. The Operator softkey provides the capability of searching, editing, uploading, or downloading machine parameters.

CONTROL POWER AND EMERGENCY STOP PUSH BUTTONS Control Power ON Push Button Press Control ON push button “A”, Figure 2.3, to apply power to the machine control. Control Power OFF Push Button Press Control OFF push button “B” to remove power from the machine control.

Main Power ON Indicator Light This indicator light turns ON when the main disconnect switch is turned ON.

Manual/Auto Mode Switch The switch limits the operator under manual mode or in auto mode. CE mark version only. Program Protect Key Switch The function of the switch, Figure 2.2, is explained on page 39. Emergency Stop

Exercise caution when accessing control functions that allow parameter editing. Making incorrect changes in the parameter tables may disable the machine or cause undesirable machine behavior.

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

I

0 E11

Emergency Stop push button “C” 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 up. 3. Release the Emergency Stop push button.

OPERATOR CONTROL PANEL Selector Switches Rapid Override Switch This switch can modify the machine rapid traverse rate on the X and Z axes in steps from 0% ~ 100%. It is active in Positioning Mode (G00). It is also active during return passes for machining cycles.

Feedrate / Jog Override Switch In Memory or Manual Data Input mode, this switch allows the operator to modify programmed feedrates from 0% ~ 150%. A setting of “0" will stop G01, G02, & G03 motion. In Jog mode, this switch establishes the rate of motion when manually jogging the machine axes. A setting of “0" will inhibit axis motion.

Spindle Override Switch This switch allows the operator to modify programmed spindle speeds from 50% ~ 120%. Edit Mode This switch setting activates Edit mode. Edit mode allows the operator or programmer to enter a new program or edit a stored program. To deactivate Edit mode, select another operating mode.

Memory Mode

Figure 2.3a - Emergency Stop Push Button for GS series

Figure 2.3b - Emergency Stop Push Button for SV series

This switch setting activates Memory mode, which allows execution of a part program stored in control memory and modification of part programs using the Back Edit function.

Manual Data Input Mode This switch setting activates Manual Data Input mode. Manual Data Input mode allows manual input of a temporary program block.

Direct Numerical Control (DNC) Mode This switch setting activates Direct Numerical Control mode. Direct Numerical Control mode allows execution of a part program read directly from an input device connected to the machine control.

Jog Mode This switch setting activates Jog mode. Jog mode allows:

Non-programmed movement of the X and Z axes through the use of the axis direction push buttons.

Non-programmed rotation of the spindle on machines equipped with the C axis option. Non-programmed rotation of the live tooling attachment at the active turret station on

machines equipped with the live tooling option.

Handwheel (Manual Pulse Generator) Mode This switch setting activates Handwheel mode. Refer to Manual Pulse Generator for additional information.

Reference Mode This switch setting activates Reference mode. Reference mode allows the selected axis to be moved to the “Home” position.

MANUAL TURRET CONTROL Push button “D” allows the machine operator to index the turret to the station selected with switch “E” when Jog mode is active. INDEXING THE TURRET 1. Close the main guard door. 2. Set the Mode Select switch to Jog mode. 3. Set Turret Station selector switch “E” to the turret station to be indexed to the active

position. 4. Press Turret Index push button “D” to index the selected turret station to the active

position. Tailstock Jog Switch

The work-holding device mounted in the spindle and the main guard door must be closed. Skip step 3 if the control panel is without the selector switch.

Switch “I”, Figure 2.2, is a return-to-center switch that allows the operator to manually position the optional tailstock when Jog mode is active. Tailstock motion will stop when the switch is released. The indicator light will turn ON when the tailstock is at the Home position.

PROGRAM CYCLE PUSH BUTTONS

Cycle Start This push button initiates program execution when the control is in Memory mode or Single mode. An additional function of this switch is to execute Manual Data Input commands. This push button is illuminated when Cycle Start is active.

Feed Hold The Feed Hold push button allows the operator to stop all programmed slide motion. However, the active spindle speed is not affected. Feed Hold can be activated while in Memory, Single Block, Dry Run, or Machine Lock modes. Cycle Start turns OFF when Feed Hold is activated. Press Cycle Start to resume normal operation after a feed hold. This push button is illuminated when Feed Hold is active.

MANUAL PULSE GENERATOR

Manual pulse generator “H”, Figure 2.2, allows the operator to jog the selected axis by specific increments. The Mode Select switch must be set to Handwheel mode for the manual pulse generator to function. The axis velocity (rate of travel) is determined by the rate at which the manual pulse generator dial is rotated. Be aware that the X or Z axis velocity will not be allowed to exceed the maximum velocity of 1181 inches [30,000 millimeters] per minute. Any pulses produced by the manual pulse generator that would cause the velocity to exceed this maximum value will be ignored by the machine control. Accurate position data will be maintained by the machine control. Axis Select Switch Axis select switch “G” determines which machine axis will move when the manual pulse generator dial is turned while the control is in Handwheel mode. Increment Select Switch Increment select switch “F” allows the operator to select the increment jog rate when Handwheel mode is active. X1 The incremental jog rate per division on the dial is .0001 inches in English

mode or .001 millimeters in Metric mode for the X and Z axes.

When jogging the machine axes, be sure no interference exists between fixtures, tooling, or workpiece.

The incremental jog rate per division on the dial is .001 degrees for the optional C axis.

X10 The incremental jog rate per division on the dial is .001 inches in English mode

or .01 millimeters in Metric mode.


X100 The incremental jog rate per division on the dial is .01 inches in English mode

or .1 millimeters in Metric mode.


Manual Pulse Generator Dial After Handwheel mode has been activated and the desired axis and increment have been selected, rotate the manual pulse generator dial as follows:

Clockwise: Positive Axis Motion Counterclockwise: Negative Axis Motion

AXIS DIRECTION PUSH BUTTONS AND INDICATOR LIGHTS

NOTE: If the Rapid push button is NOT pressed, the maximum jog feedrate is 50 inches

[1,270 millimeters] per minute. If the Rapid push button is pressed, the maximum jog feedrate is 590 inches [15,000 millimeters] per minute.

The axis push buttons are used to allow manual axis movement in Jog mode. The Feedrate/Jog override switch is used to control the rate of axis motion.

X Axis Linear motion is parallel to the spindle face and parallel to the machine bed. Pressing one of the X directional push buttons causes the turret to move in the corresponding direction. The +X axis push buttons are also used to home the machines axes. Refer to Figure 1.4.

Z Axis Linear motion is parallel to the spindle centerline and parallel to the machine bed. Pressing one of the Z directional push buttons causes the turret to move in the corresponding direction. The +Z axis push buttons are also used to home the machines axes. Refer to Figure 2.4.

When jogging the machine axes, be sure no interference exists between fixtures, spindle, tooling, or workpiece.

C Axis (Option) Rotary motion of the spindle on machines equipped with the C axis option. Pressing one of the C directional push buttons causes the spindle to rotate in the corresponding direction. The +C push button can be used to rotate the machine spindle to the zero degree reference angle on machines equipped with the C axis option. Refer to Figure 2.4. Manual Jog Move

When the Auto mode is selected and the front door is open. Press this button and one of the Axis Direction button simultaneously to move an axis.

Rapid This push button allows the machine operator to activate manual rapid traverse mode. Pressing this push button and an axis directional push button causes the selected axis to move at the rapid jog rate. The Rapid Override switch can be used to adjust the rapid traverse rate. NOTE: If the Rapid push button is NOT pressed, the maximum jog feedrate is 50

inches [1,270 millimeters] per minute. If the Rapid push button is pressed, the maximum jog feedrate is 590 inches [15,000 millimeters] per minute. The axis push buttons are used to allow manual axis movement in Jog mode. The Feedrate/Jog Override switch is used to control the rate of axis motion.

Indicator Lights The +X indicator light will turn ON when the X axis is at the Home position. The +Z indicator light will turn ON when the Z axis is at the Home position. The +C indicator light will turn ON when the C axis is at the zero degree reference angle. Figure 2.4 – C, X, and Z Axis Definitions

MANUAL SPINDLE CONTROL

NOTE: Jog or Handwheel mode must be active to enable the spindle jog

function.

M/S Spindle Control This push button allows the machine operator to select the main spindle or live tooling on machines equipped with the live tooling option.

Spindle Orient

The Spindle Orientation operating description is based on the front door being closed. This push button allows the operator to orient the spindle to the zero degree position and lock the spindle when Jog mode is active. Press this push button a second time to unlock the spindle. The indicator light will be ON when the spindle is locked. (Note: The spindle brake must be off prior to using the spindle orient feature.)

Note: If want to lock the spindle whilst the front door is open, please follow the procedure as below – (THIS ONLY APPLIES TO A GS PRODUCT WITH Cs SPINDLE) 1. Close the front operator door of machine. 2. The spindle must be in “Spindle” mode, otherwise change by command M124 or

press Cs key as required. 3. Command M117 to lock the spindle. 4. The spindle will now be locked while the front operator door is open.

Manual Spindle Jog This push button allows the operator to manually jog the machine spindle in the forward (M03) direction at 40 rpm. The spindle will stop when this push button is released.

Spindle Jog Speed Control This variable switch allows the operator to adjust the spindle speed when using continuous spindle jog.

Counterclockwise Continuous Spindle Jog This push button allows the operator to jog the machine spindle in the counterclockwise direction when Jog mode is active and the guard doors are closed. Spindle speed will be determined by the Spindle Jog Speed Control switch.

Spindle Stop This push button allows the machine operator to cancel continuous spindle jog.

Clockwise Continuous Spindle Jog This push button allows the machine operator to jog the machine spindle in the clockwise direction when Jog mode is active and the guard doors are closed. Spindle speed will be determined by the Spindle Jog Speed Control switch.

MISCELLANEOUS PUSH BUTTON FUNCTIONS

M01 (Option Stop) This push button allows the operator to alternately activate and deactivate Option Stop. This function causes the control to stop execution of the part program AFTER executing an active block that contains an M01 code.

This function may be activated before or during execution of the block containing the M01 code. The indicator light is illuminated when Option Stop is active. When a block containing 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.

To resume program execution, press the Cycle Start push button. The Feed Hold push button light will turn OFF.

BDT (Block Skip) This push button allows the operator to alternately activate and deactivate Block Skip. When Block Skip is active, the control will ignore any program data block preceded by a slash (/) code. The indicator light is illuminated when Block Skip is active.

SBK (Single Block) This push button allows the operator to activate Single Block. The indicator light is illuminated when Single Block is active. Single Block provides the operator with the ability to execute one block of data each time the Cycle Start push button is pressed.

DRN (Dry Run)

NOTE: This mode must be OFF for normal machine operation. This push button allows the machine operator to alternately activate and deactivate Dry Run mode. When this mode is active, programmed feedrates are ignored and cutting moves are performed at a Jog feedrate of 50 inches [1260 millimeters] per minute. The indicator light is illuminated when Dry Run is active. MLK (Machine Lock)

NOTE: This mode must be OFF for normal machine operation. This push button allows the operator to alternately activate and deactivate Machine Lock mode. When this mode is active, all X and Z axes motion are inhibited. The indicator light is illuminated when Machine Lock is active. Reference machine slides after using machine lock function.

It is the responsibility of the part programmer to program M03, M04, M13, or M14 to restart the spindle and coolant when program execution is resumed after an Option Stop.

Probe This push button allows the operator to alternately deploy and stow the optional tool probe when the machine is in Jog mode. Coolant ON / OFF This push button controls standard coolant operation. If coolant flow has been activated by a programmed M08 (Coolant ON), M13 (Spindle Forward/Coolant ON), or M14 (Spindle Reverse/Coolant ON), pressing this push button will stop the coolant flow. If coolant flow has not been activated by the program, pressing this push button will start coolant flow even though an M08, M13 or M14 has not been programmed. However, if the program is repeated the push button will not be active. The indicator light is illuminated when this function is active. Chip Conveyor ON/OFF This push button allows the machine operator to turn the chip conveyor ON or OFF. The user can also use M68 to turn ON and M69 to turn OFF the chip conveyor.

Chip Conveyor Direction When the chip conveyor is turned ON, press and hold this push button to reverse the direction of chip conveyor motion. Forward motion will resume when this push button is released. This push button is illuminated when the chip conveyor is running in the reverse direction. Work Light This push button allows the operator to alternately turn the work light ON and OFF.

Alarm Cancel NOTE: Deactivating the audible alarm does not correct the condition that caused the alarm. This push button allows the operator to cancel an audible alarm, which is activated when an alarm is issued by the machine control. Emergency Stop Reset NOTE: The condition that caused the machine to go into emergency stop MUST be corrected before Emergency Stop can be cleared. The Emergency Stop Reset push button, when pressed and held, also allows the machine operator to jog the axes out of an over-travel condition. The Emergency Stop Reset push button is used to reset the control once the Emergency Stop push button has been released or the problem that caused the Emergency Stop condition has been corrected. To return the control to normal operation: 1. Correct the problem that caused the Emergency Stop condition. 2. If necessary, release the Emergency Stop push button by pulling it OUT. 3. Press the Emergency Stop Reset push button.

4. Move all axes to a safe program restart position.

READY (for EM Released Confirm) After pull the Emergency Stop button to released and pressed the Emergency Stop Reset button for axis movement, the circuit of Emergency will not be reset. Need to pressed the READY button firstly, then pressed the RESET button in order that the circuit of Emergency is actually reset.

Electrical Cabinet Door Interlocks

When the electrical cabinet door interlock is set to “0” (only allowed for the qualified and competent engineers with door-key), power can be turned ON while the electrical cabinet door is open. When the electrical cabinet door interlock is set to “1” (normal operating condition), power cannot be turned ON while the electrical cabinet door is open. (CE machine only)

Manual Door Open/Close Button

When spindle is stopped, press “Door Open” to open the optional auto door. In Manual or Auto mode, press the “Door Close” and “Feed Hold” buttons simultaneously to close the auto door. In auto mode, M38 is for door open. For safety, there is no M code for door close.

MISCELLANEOUS INDICATOR LIGHTS

Hydraulic Pressure Fault This light will turn ON when the hydraulic pressure drops below the minimum pressure allowed. Machine operation will stop. Correct the problem before attempting to resume machine operation. Chuck Open/Close This light will turn ON when the work-holding device in the spindle clamps the workpiece and turn OFF when the workpiece is released. Stack Lights Assembled on top of the machine, this optional stack light is used for alarm and machine status indication. Each light indicates the following: RED indicates that EM button is pressed or an alarm is issued from the control. YELLOW indicates a finish of the program. GREEN indicates the machine is running a program.

1

0

DOORINTERLOCK

READY

J

Figure 2.5 - Chuck Closer Foot Switch

CHUCK OPEN/CLOSE FOOT SWITCH GS/SV 150, 200 Series and GS 41, 52 Series Lathes Pressing Chuck Open/Close foot switch “J”, Figure 2.5, when bar feeder setting is ON (refer to Figure 2.7) then only Jog mode is active will cause the work-holding device in the spindle to alternately open and close. Otherwise when bar feeder setting is OFF (refer to Figure 2.7) then will be able to open/closing the work holding device in any mode. The Chuck Open/Close indicator light, located near the right end of the operator control panel, will be ON when the work-holding device is closed and will be OFF when the work-holding device is open.

GS/SV 200/66 Series and GS/SV 250 Series Lathes

Chuck Open/Close foot switch “K”, Figure 2.6, will cause the work-holding device in the spindle to alternately open and close when bar feeder setting is ON (refer to Figure 2.7) then only Jog mode is active. Otherwise when bar feeder setting is OFF (refer to Figure 2.7) then will be able to open/closing the work holding device in any mode. NOTE: Tailstock foot switch “L”, Figure 2.6, allows the machine operator to extend or

retract the tailstock quill when Jog mode is active.

SOFTWARE OPERATOR PANEL The software operator panel, shown in Figure 2.7, provides the operator with the following control functions: Accessing the Software Operator Panel 1. Press the Offset/Setting Function key. 2. Press the Far Right softkey. 3. Press the OPR softkey. 4. Press the Page Down key to access the operator software screen.

Figure 2.6 - Collet Closer and Tailstock Quill Foot Switches

K

L

Function Descriptions Key Switch

The Key Switch softkey is intended to prevent accidental changes to programs. To Change the Setting:

1. Access the software operator panel. 2. Move the cursor to the “Key Switch” line on the screen. 3. Set the cursor to ON to allow changes to programs or set the cursor to OFF to lock

out changes. SRN

Program restart function: If the automatic operation is stopped because of a broken tool or turn off power, then you want to restart the program at a block by specifying the sequence number of the block, you should change SRN to ON, call the program number in EDIT mode, change mode to MEM and input the sequence number of the block, press the softkey “+” to choose P TYPE (restart after a tool is broken down) or Q TYPE (restart after turn off power), then the tool is moved back to the machining restart point at dry run speed along the axes one by one in the sequence specified in parameter No. 7310. When the tool is set to the restart point, change SRN to OFF and press cycle start button, machining restarts. MST Lock Set this function to OFF to allow the execution of M codes, spindle commands (S word), and turret commands (T word). Set this function to ON to inhibit the execution of M codes, spindle commands (S word), and turret commands (T word). The Machine Lock push button allows the machine operator to inhibit X and Z axis motion. X, Z INT X and Z axis manual handle interruption function. Rotating the manual pulse generator during automatic operation can increase the distance traveled by the amount corresponding to the handle feed. The axis to which the handle interrupt is applied is selected using the manual handle interrupt axis select signal. Bar Feed

Figure 2.7 - Software Operator Panel

DO NOT turn this function ON if the machine is not equipped with a bar feed. Machine operation will be disabled, if this condition occurs, set the Bar Feed function to OFF to enable Machine operation.

1. Verify the machine spindle and slides are stationary. 2. Press the Emergency Stop push button. 3. Set Bar Feed to OFF to run the machine in slug mode or set Bar Feed to ON to run the

machine in bar mode. PW OFF Automatic power OFF function: If you have option “AUTOMATIC POWER OFF” and set this function to ON, when the program executes the block “M30” or “M80”, the machine will power off automatically. If set this function to OFF, the machine will not power off when executing block “M30” or “M80”. W/GOQSM Relates to the tool probe: Change this function to ON to choose the workpiece origin offset measurement mode; Change this function to OFF to choose the tool offset measurement mode.

AXIS AND SPINDLE MONITOR DISPLAY Introduction The monitor display provides access to the following data: X and Z axis load meters Display the percentage of recommended maximum full load current being drawn by the specified axis drive. Each asterisk displayed to the right of the axis designation represents 10% of the recommended maximum full load current. Spindle load meter (S1) Displays the percentage of recommended maximum full load current being drawn by the spindle drive. Each asterisk displayed to the right of the “S1" designation represents 20% of the recommended maximum full load current. Speed Meter (Spindle RPM) Display the speed of the spindle in rpm. Each asterisk displayed to the right of the axis designation represents 10% of the maximum spindle speed. Accessing the Monitor Display 1. Press the Position key. 2. Press the right-hand softkey. 3. Press the Monitor softkey.

ON-LINE HELP SYSTEM Introduction The on-line help system provides information and instructions relating to P/S alarms, methods of operation, and parameter tables. P/S Alarms

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 Screens”, the help system will

display two numbers in the upper right-hand corner of the screen; for example 1/4. The upper number indicates the current page number and the lower number indicates the total number of pages for that particular topic.

Alarm Detail 1. Press the 1 ALAM softkey. 2. Key in the alarm number and press the Select softkey. The alarm number and a

detailed explanation will be displayed. 3. Exit the on-line help system. Refer to “Exiting the On-Line Help system”, on the next

page. Operation Method 1. Press the 2 OPR softkey. 2. Key in the topic number and press the Select softkey. The selected topic and a

detailed explanation will be displayed. 3. Exit the on-line help system. Refer to “Exiting the On-Line Help system”, on the next

page. Parameter Table 1. Press the 3 PARA softkey. Page 1 of 4 will be displayed. 2. Use the Page keys to view the various pages, as needed. 3. Exit the on-line help system.

Only the more difficult to understand P/S alarms are supported by the on-line help system. Information and remedies concerning specific P/S alarms are supplied.

EXITING THE ON-LINE HELP SYSTEM Press the Help key again or press one of the following function keys to exit the on-line help system:

- GRAPH - MESSAGE - OFFSET/SETTING - POS - PROG - SYSTEM

2.4 MACHINE POWER UP/DOWN AND CONTROL STATUS POWER-UP PROCEDURE

1. Close the main guard door. 2. Turn main disconnect switch “A”, Figure 2.8, ON. 3. If the machine is equipped with the optional parts catcher, turn main air valve “B”,

Figure 2.9, ON. 4. Check the coolant and hydraulic oil levels. Refill as needed.

NOTE: Skip step 5 when operating the SV type lathes. 5. Press the Control ON push button and wait until the control display screen is ON. 6. Pull the Emergency Stop push button out. 7. Open and close the coolant guard door to perform the guard door switch verification

and clear the verification alarm.

REFERENCE HOME PROCEDURE

1. Set the Mode Select switch to Jog mode. 2. If the lathe is equipped with the optional tailstock, check the indicator light next to the

Tailstock switch.

A

Figure 2.8 - Main Disconnect Switch Figure 2.9 – Air Filter Regulator for Optional Parts Catcher

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

When zeroing the axes, be sure that no interference exists between the workpiece, spindle tooling, or turret tooling.

The X and Z axes must both be jogged approximately 1inch [25 millimeters] in the minus direction before a Reference Home can be performed. The optional tailstock must be at Home position before the X and Z axes can be homed.

If the light is ON, proceed to step 3. If the light is not ON, turn the Tailstock Jog switch to the right to move the

tailstock to the Home position. The light will turn ON when the tailstock is at the Home position.

3. Set the Feedrate switch to any setting above 0 (zero). 4. Press and hold the -X push button to jog the turret approximately 1 inch [25

millimeters] in the minus direction. 5. Press and hold the -Z push button to jog the turret approximately 1 inch [25

millimeters] in the minus direction. 6. Set the Mode Select switch to Reference mode. NOTE: The X axis must be “homed” before the Z axis is “homed” on machines equipped

with a tailstock. 7. Press the +X push button. The X axis will move to the X Home position and the X

Home indicator light will turn ON. 8. Press the +Z push button. The Z axis will move to the X Home position and the X

Home indicator light will turn ON. 9. If the machine is equipped with the live tooling option, reference the turret as follows:

A) Set the Turret Station selector switch to any station not at the active position. B) Press the Turret Index push button.

POWER-DOWN PROCEDURE 1. Be sure “Cycle Start” is not active. 2. Be sure the program has been completed and that the spindle and slides are

stationary. 3. Verify the control is NOT in edit mode. If necessary, switch to any mode except Edit

mode.

4. Press the Emergency Stop push button.

NOTE: Skip step 5 when operating the SV type lathes. 5. Press the Control OFF push button. 6. Turn main air valve “B”, Figure 2.9, OFF. 7. Turn main disconnect switch “A”, Figure 2.8, OFF.

REVIEWING CONTROL STATUS The following descriptions refer to the control status displays. POS (Position) KEY

The Position key provides access to the following data:

DO NOT power down the machine while the control is in Edit mode. Loss of control data may result.

When the Position key is pressed, the display page that was last active will appear on the control display screen.

1. ALL (Overall Position Display): The active program number and block number are displayed in the upper right-hand corner of the control display screen if the control is in Memory mode. A) Relative: The axis position on the Relative Coordinate System. Position is

displayed as U and W coordinates. B) Absolute: Axis position on the Work Coordinate System. After power-up, the origin

of the Work Coordinate System is the intersection of the spindle face and the spindle centerline. Position is displayed as X and Z coordinates. This origin can be relocated by any one of the following:

Active set of tool offsets Position Reset operation Work Shift offset

C) Machine: Displays the axis position in relation to the Reference Zero position. D) Distance to Go: This is the distance between current axis position and the

programmed axis position. This register is displayed only while the control is in Memory or Manual 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)”. 4. Axis and Spindle Monitor Display: The display provides access to the following data:

A) X & Z axis load meters: Displays the percentage of recommended maximum full load current being drawn by the specified axis. Each asterisk displayed to the right of the axis represents 10% of the recommended maximum full load current.

B) Spindle load meter: Displays the percentages of recommended maximum full load current being drawn by the spindle drive. Each asterisk displayed to the right of the “S1” represents 20% of the recommended maximum full load current.

C) Speed meter: Displays of the spindle in rpm. Each asterisk displayed to the right of the axis represents 10% of the maximum spindle speed.

Figure 2.10 - Machine and Absolute Positions (X and Z Axis Tool Offsets Active)

PROG (Program) KEY Press the Program function key to display the active program number, and active block sequence number and eleven blocks of the active program on the control display screen. To display other pages of the program, select Edit mode and use the page keys to read through the program. During execution of the active part program, the cursor will be positioned under the sequence number of the active block. To return to the start of the program, press the Reset key. Offset Setting Key When the Offset Setting function key is pressed, the Offset and Setting softkeys are displayed. From the first Offset Setting screen, press the soft key expansion key once to display the Macro and Operator softkeys. From the first Offset Setting screen, press the softkey expansion key twice to display the Work Shift softkey. Offset Softkey Press the Offset soft key to access the geometry and wear softkeys.

Geometry: Accesses the Geometry offset pages. Wear: Accesses the Wear offset pages.

One of the two chapters will be displayed on the control display screen. The displayed page will be the page which was active when the Offset display was last deactivated. To display the other chapter, press the corresponding softkey. Use the page keys to view other pages within a chapter. The tool geometry and wear offset chapters display the following information:

Figure 2.11 - Machine and Absolute Positions (Work Shift, X and Z Axis Tool Offsets Active)

X and Z Tool Offsets (64 pair) Tool nose radius values Tool nose orientation numbers

Setting Softkey Press the Setting softkey to access the system variables page, which allows the operator or programmer to assign the system variables listed below. To modify these variables, move the cursor to the variable which is to be modified, enter the desired 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 = _(0-1:CHANNEL NO.) SEQUENCE number = _(0:OFF 1:ON)

Parameter Write When set to “0", parameter editing is disabled. When set to ”1", parameter editing is enabled. TV Check When set to “1", parity checking is from the beginning of each block to the beginning of the next block. When set to “0", parity checking is disabled. Punch Code 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 When it set to “0", the operating mode is Metric. When it set to “1", the operating mode is set to Inch. I/O Channel The valid selections for the I/O port assignments are 0 or 4. 0 represents the RS-232 C port and 4 represents the PCMCIA card slot. Sequence No. When active, sequence numbers will be automatically inserted into a program which is entered into memory from the manual data input keyboard. When set to “0", automatic sequence number insertion is inactive. When it set to “1", automatic sequence number insertion is active. Macro Softkey Press the Macro softkey to display the macro variable registers. Operator Softkey

Press the Operator softkey to access the software operator panel. Work Shift Softkey Press the Work Shift softkey to display the work shift offset registers. System Key Press the System function 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 the page which was active when the key was last deactivated. If necessary, press the softkey to display the desired chapter. Use the page keys to view other pages within a chapter. Parameter Softkey Press the Parameter softkey to display machine parameters. These parameters establish many of the characteristics, specifications, and functions of the machine tool. The page that was active when the parameter chapter was last exited will be displayed. To view other pages within the chapter, press the page keys to move to the desired page. Diagnostic Softkey Press the Diagnostic softkey to display the machine diagnostics chapter. The page that was active when the diagnostics chapter was last exited will be displayed. Use the page keys to view other pages within the chapter. PMC Softkey Press the PMC softkey to display the PMC information screen. The purpose of this screen is to view the PMC ladder, parameters, and diagnostics. System Softkey Press the System softkey to display the control system information screen. Message Key If “ALM” is displayed at the bottom right-hand corner of the control display screen during machine operation, press the Message key. When the Message key is pressed, one of the three chapters will be displayed. To display one of the other chapters, press the appropriate softkey. Alarm Softkey Alarm Message chapter. This chapter displays alarms that create a feed hold condition. The display is formatted to indicate which problem has generated the alarm. Descriptions of each alarm are given in the alarm list in Appendix 2. Message Softkey Operator messages do not initiate a feed hold condition. They call the operator’s attention to a specific machine condition.

History Softkey The Fanuc control is capable of storing the last 25 alarms generated by the machine control. There are a maximum of five pages, with up to five alarms per page. Press the page keys to display the next or previous page.

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

2.5 OPERATIONAL MODES AND EDITING JOG MODE

NOTE: Jog mode permits non-programmed movement of the axes. X and Z Axes While in Jog mode, press and hold the axis direction push buttons to obtain the desired X or Z continuous axis movement at a selected feed rate. The Feedrate/Jog Override switch determines the X and Z axis jog speeds. The maximum feed rate for the X and Z axis is 50 inches [1,270 millimeters] per minute. The Traverse push button will increase the normal jog speed. When the Traverse push button is pressed along with one of the axis push buttons, the Feedrate/Jog Override switch is ignored and the selected axis moves at 590 inches [15,000 millimeters] per minute. Machine Spindle Continuous Spindle Jog 1. Set the Mode Select switch to Jog mode. 2. Press the M/S Spindle Select push button to activate “M”. 3. Close the main guard door. 4. Press the Clockwise or Counterclockwise Continuous Spindle Jog push button to obtain

spindle motion. 5. Use the Spindle Jog Speed Control switch to obtain the desired spindle rpm. 6. Press the Spindle Stop push button to stop spindle motion. Manual Spindle Jog NOTE: Manual spindle rotation is always in the Forward (M03) direction at 40 rpm. 1. Set the Mode Select switch to Jog mode. 2. Press the M/S Spindle Select push button to activate “M”. 3. Press the Manual Spindle Jog push button to obtain spindle motion. 4. Release the Manual Spindle Jog push button to stop spindle motion. Live Tooling [Option] Continuous Spindle Jog 1. Set the Mode Select switch to Jog mode. 2. Press the M/S Spindle Select push button to activate “S”. 3. Close the main guard door. 4. Press the Clockwise or Counterclockwise Continuous Spindle Jog push button to obtain

live tool motion. 5. Use the Spindle Jog Speed Control switch to obtain the desired live tool rpm. 6. Press the Spindle Stop push button to stop live tool motion. Manual Spindle Jog NOTE: Manual live tool rotation is always in the Forward (M03) direction at 40 rpm. 1. Set the Mode Select switch to Jog mode. 2. Press the M/S Spindle Select push button to activate “S”. 3. Press and hold the Manual Spindle Jog push button to obtain live tool motion.

4. Release the Manual Spindle Jog push button to stop live tool motion. HANDWHEEL MODE The handwheel (manual pulse generator) permits the X, Z, or optional C axis to be moved incrementally. The axis to be moved is selected by using the selector switch on the operator control panel. The movement increment is selected with the Increment Select switch. The direction and distance is determined by the direction and amount of rotation of the handwheel. 1. Set the mode selector switch to Handwheel mode. 2. In the Manual Axis Movement section of the operator control panel, use the selector to

select the desired axis. 3. Set the Increment Select switch to the desired increment. 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 to determine 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 the cross slide away from the spindle centerline and turn the handwheel in the minus direction to move the cross slide toward the spindle centerline. If the Z axis was selected in step 2, turn the handwheel in the plus direction to move the carriage away from the face of the spindle and turn the handwheel in the minus direction to move the carriage toward the face of the spindle. If the optional C axis was selected in step 2, turn the handwheel in the plus direction to rotate the spindle in the Forward direction (M03) and turn the handwheel in the minus direction to rotate the spindle in the Reverse direction (M04). MANUAL DATA INPUT MODE Manual Data Input mode allows the operator to input up to 10 blocks of non-stored Data into the Manual Data Input memory. The Data can then be executed by pressing the Cycle Start push button. Once the 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. 2. Press the Program key. 3. Press the Reset key. 4. Enter the Data into the Manual Data Input buffer using the Data input keys. Each Data

block must end with a valid End of Block character.

The machine is configured to operate in diameter mode. When moving the X axis, physical axis motion will be one half the selected increments.

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

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

Data. EDIT MODE Edit mode allows creation of new part programs or modification of existing part programs held in memory. 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 at a time.

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

1. Use the cursor left and right keys to move the cursor word by word on the screen. 2. Use the cursor up and down 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 up or Page down keys to display the preceding or following pages and

search for the first word of that page. Word Search Word Search permits a specified word to be searched for from the current cursor position using the following procedure: 1. Key in the Data word to be searched for. 2. Press the cursor up key to search forward or cursor down to search backward. If the

Data word entered in step 1 is located, the cursor will be displayed below the first character in the Data word.

Program Protect Key Switch

Setting the program protect key switch to “0” enables editing of programs, offsets and

To alter Data after it has been entered into the Manual Data Input memory, place the cursor on the word, key in the correct Data, and press the Alter key. If it is necessary to delete a word, place the cursor on the word and press the Delete key. The chuck closer must be in the closed position before a Manual Data Input command can be executed.

Be sure to set the program protect key switch to “1” when program or parameter editing is completed.

parameters. Setting the program protect key switch to “1” disables editing of programs, offsets and parameters. Setting the program protect key switch to “E1” disables editing of programs and parameters without offsets. 1. Press the Offset Setting key until the Setting softkey is displayed. 2. Press the right hand softkey until the Operator softkey is displayed. 3. Press the Operator softkey to display the software operator panel. 4. Use the page keys to display the page containing the Key Switch function. 5. Use the cursor keys to position the cursor on the Key Switch function. 6. Press the cursor left or right key to select the desired setting. Editing a Program 1. Set the mode selector switch to Edit mode. 2. Set the Program Protect Key Switch to “0”. 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 down 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.

7. Press the Reset key to “rewind” the part program back to the beginning. 8. Set the Program Protect Key Switch to “1”. Altering a Word

NOTE: The cursor will highlight the 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 will highlight the word immediately preceding the location of the new Data word.

1. Use the Word Scan or Word Search function to find the Data word or End of Block

immediately preceding 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.

The program protect key switch MUST be set to “0” to allow creating, editing, or deleting of part programs. Refer to Program Protect Key Switch.

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

Deleting a Word

CAUTION: The cursor will highlight the 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. Deleting Data Blocks 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. PROGRAMS Entering a Program from the Keyboard

NOTE: The program protect key switch MUST be set to “0” to allow creating, editing, or deleting of part programs.

1. Set the mode selector switch to Edit mode. 2. Set the Program Protect Key Switch to “1”. 3. Press the Program key. 4. Key in the letter and the program number at the Manual Data Input panel.

Example: O1111 5. Press the Insert key. 6. Press the EOB (End of Block) key. 7. Press the Insert 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. Set the Program Protect Key Switch to “1”.

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.

In the procedure which follows, all Data from the cursor to, and including, the block specified by the sequence number will be deleted. The cursor will move to the next sequence number in the program.

Activating a Stored Program 1. Set the mode selector switch to Memory mode. 2. Press the Reset key. 3. Press the Program key. 4. Key in the letter “O” followed by the number for the desired program.

Example: O100 5. Press the cursor down key. Running a Part Program for the First Time

1. Press the Reset key. 2. Press the Program key. 3. Activate the desired program. 4. Set the mode selector switch to Memory mode.

NOTE: Single mode is used for first part set up (Block-by-Block execution). 5. Press the Single Block push button. 6. Close the guard door. 7. Press the Check softkey.

NOTE: Program Check displays the Absolute Position and Distance to Go to complete the move.

8. Press the Option Stop push button. 9. Turn the Rapid Override switch to LOW. 10. Turn the Feedrate/Jog Override switch to 10% for program dry run. 11. Press the Cycle Start push button to execute each block of Data.

Before executing any part program, be sure that all offsets are correct and that no interference exists in the working area of the machine tool. When Cut-off and Feed Stock are the first operations on bar work, the operator must make certain that the stock face is placed flush with the collet face to ensure that the turret tooling will not come in contact with workpiece before starting the cycle. When testing an operation that uses a self-releasing tap or die holder, activate Memory 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, activate Single mode to test the remainder of the program.

Setting the Rapid Override switch to LOW causes non-cutting linear moves (G00) to be made at 39 inches/minute [990 millimeters/minute]. Turning Feedrate/Jog Override switch to “0" stops X and Z axes motion. When the switch is turned to another setting axis motion will resume.

Stopping a Program Running in Memory Mode

There are several ways to stop a program running in Memory mode: Program a stop command in the part program where it is to be stopped. Press the Feed Hold push button.

NOTE: Memory operation can be restarted by pressing the Cycle Start

push button when the Feed Hold push button has been used. Press the Reset key. 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 through 4. If the program was stopped by pressing the Reset key, perform steps 3 and 4. 1. Pull the Emergency Stop push button out and hold until the hydraulic pump starts. 2. Press the Reset key. The control will go to the beginning of the part program. 3. If it is necessary to restart the program at a point other than the beginning:

A) Key in the letter “N” and the block number for the restart point. For example, “N5". B) Press the cursor down key. The control will search the program for the block

specified in the previous step. 4. Press the Cycle Start push button. Program execution will resume. DRY RUN AND MACHINE LOCK MODES

Pressing either the Reset key or the Emergency Stop push button while a program is running in Memory mode will leave the tool against the workpiece if performed at the wrong time. DO NOT stop the program with a tool against the workpiece unless absolutely necessary. Damage to the workpiece and/or tooling may result.

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

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

Feedrate Override has a direct effect on the Dry Run feedrate. When Dry Run mode is active, axis motion will occur at a feedrate of 100 inches/minute [2540 millimeters/minute] when the Feedrate Override is set to 100%. When the Feedrate Override is set to zero, axis motion and program execution are inhibited.

Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. Activating Dry Run and Machine Lock modes together allows the operator to execute part programs without X and Z axis motion. MST LOCK must also be activated if spindle and turret motion is to be inhibited. ACTIVATING DRY RUN AND MACHINE LOCK 1. Set the mode selector switch to Memory 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, press the Single Block push button.

NOTE: If Single Block mode is active, the Cycle Start push button must be pressed for each program 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

and Machine Lock modes. 2. If necessary, deactivate MST LOCK. 3. Home the X and Z axes. BACKGROUND EDIT The Background Edit function enables the operator or programmer to edit or create a part program while a second program is being executed by the machine tool. Edit mode does not affect the program being executed in the foreground or vice-versa.

NOTE: The program protect key switch MUST be set to “0” to allow

creating, editing, or deleting of part programs. Activating Background Edit Mode 1. Set the Program Protect Key Switch to “0”. 2. Press the Program key.

If the Reset key is pressed while Background Edit is active, the part program that is being executed will stop and the offset will be canceled. The operator must escape Background Edit (Press the Background End softkey) to return to the main program. With the main program displayed, the operator must jog the turret to a safe area and restart the program at the beginning of the tool operation.

Dry Run and Machine Lock cannot be activated when the program is running.

3. Press the Operator softkey. 4. Press the Background Edit softkey.

NOTE: The editing functions which may be performed in Background Edit mode are the same as the foreground editing functions.

Editing an Existing Program 1. Activate Background Edit mode. 2. Key in the letter “O” and the desired program number. 3. Press the cursor down key. Creating a New Program from the Keyboard 1. Activate Background Edit mode. 2. Key in the letter “O” and the desired program number. 3. Press the Insert key. 4. Press the EOB (End of Block) key. 5. Press the Insert key. Ending Background Editing 1. Press the Background End softkey. 2. Set the Program Protect Key Switch to “1”. EXTENDED PART PROGRAM EDITING 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/Move Part of a Program


1. Set the mode switch to Edit mode. 2. Set the Program Protect Key Switch to “0”. 3. Press the Reset key. 4. If necessary, activate the source program as follows:


Example: O1111 C) Press the Cursor down key.

5. Press the Operator softkey. 6. Press the right-hand softkey. 7. Press the Extended Edit softkey. 8. Press the Copy/Move softkey. 9. Select the beginning of the range to be copied/moved by moving the cursor to the

beginning of the range and pressing the CRSL~ softkey. 10. Select the end of the range to be copied/moved by moving the cursor to the end of the

range and pressing the ~CRSL or the ~BTTM soft key to indicate the end of the program as the end of the range to be copied/moved.

11. Key in only the number for the new program. DO NOT key in the letter “O”. 12. Press the Input key.

13. Press the Execute softkey. 14. When editing is complete, set the Program Protect Key Switch to “1”. Merge a Program


1. Set the mode selector switch to Edit mode. 2. Set the Program Protect Key Switch to “0”. 3. Press the Reset key. 4. If necessary, activate the source program as follows:



5. Press the Operator softkey. 6. Press the right hand softkey. 7. Press the Extended Edit softkey. 8. Press the Merge softkey. 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 or the ~BTTM soft key to indicate the end of the program as the position where the program is to be inserted.

10. Key in only the number for the program to be inserted. DO NOT key in the letter “O”. 11. Press the Input key. 12. Press the Execute softkey. 13. If editing is complete, set the Program Protect Key Switch to “1”. Search and Replace

NOTE: The program protect key switch MUST be set to “0” to allow creating, editing, or deleting of part programs. Refer to Program Protect Key Switch.

1. Set the mode selector switch to Edit mode. 2. Set the Program Protect Key Switch to “0”. 3. Press the Reset key. 4. If necessary, activate the program as follows:



5. Press the Operator softkey. 6. Press the right hand softkey. 7. Press the Extended Edit softkey.

8. Move the cursor to the desired position in the program. 9. Press the Change softkey.

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.

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

10. Key in the Data word to be replaced. 11. Press the Before softkey. 12. Key in the new Data word. 13. Press the After softkey. 14. Press the Execute softkey to replace all occurrences of the specified Data word or press

the Execute Single softkey to individually replace each occurrence the specified Data word or press the Skip softkey to search for the first occurrence of the specified Data word.

15. When editing is complete, set the Program Protect Key Switch to “1”. EDITING MACHINE PARAMETERS

1. Press the Offset Setting key. 2. Press the Setting softkey. 3. If necessary, use the page up/down keys to display the Setting page that contains the

Parameter 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. 6. Press the Operator softkey. 7. Press the ON:1 softkey.

NOTE: The control is placed in P/S alarm No. 100. 8. Press the System key. 9. Press the Parameter softkey. 10. Use the page and/or cursor keys to position the cursor on the parameter to be modified. 11. Key in the new parameter value. 12. Press the Input key. 13. Repeat steps 10 through 12 as needed. 14. Press the Offset Setting key. The Setting page that contains the Parameter Write field

will be displayed. 15. Press the Operator softkey. 16. Press the OFF: 0 softkey. 17. Press the Reset key to cancel P/S alarm No. 100.

Use extreme caution when editing machine parameters. Making incorrect changes in the parameter table may disable the machine or cause undesirable machine behavior.

Depending on which parameters have been modified, the control may output P/S alarm No. 000. If this alarm message is displayed, it will be necessary to re-initialize the 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.

ACCESSING THE MACRO VARIABLE FILE Macro variables are used to store data that is used repeatedly within a part program, such as safe index positions and work shifts.

The 500 series macros variables (#500 ~ #999) are permanent until changed and are not canceled by Emergency Stop, control reset, or power down. When the power is turned off, variables (#100 ~#199) are initialized to null. ACCESSING THE MACRO VARIABLE REGISTERS 1. Press the Offset Setting key to display the offset pages. 2. Press the right hand softkey until the Macro softkey is displayed. 3. Press the Macro softkey to display the Macro Variable registers. 4. Press the Operator softkey. 5. Key in the number of the macro variable to be viewed. 6. Press the Number Search softkey. INPUTTING A VALUE 7. Key in the desired value. 8. Press the Input key. DISPLAYING THE PROGRAM DIRECTORY Use the following procedure to display the programs stored in the control memory: 1. Set the mode switch to Edit mode. 2. Press the Program key. 3. Press the Directory softkey. The program directory will be displayed.

2.6 M-FUNCTION CODES

M Code Definition

M00 Program Stop

M01 Option Stop

M03 Spindle Forward Rotation

M04 Spindle Reverse Rotation

M05 Spindle Stop

M08 Coolant ON

M09 Coolant OFF

M10 High Pressure Coolant ON

M11 High Pressure Coolant OFF

M13 Spindle Forward Rotation / Coolant ON

M14 Spindle Reverse Rotation / Coolant ON

M15 Spindle Stop / Coolant OFF

M19 Spindle Orientation ON

M20 Spindle Orientation OFF

M21 Chuck Open

M22 Chuck Close

M25 Part Catcher Retract

M26 Part Catcher Extend

M27 Internal Chucking Mode

M28 External Chucking Mode

M29 Rigid Tapping Mode

M30 Program End

M33 Work Light ON

M34 Work Light OFF

M36 Air Blast ON

M37 Air Blast OFF

M38 Door Open

M40 Spindle Low Speed Range

M41 Spindle High Speed Range

M42 No Corner Rounding -Exact Stop

M43 Corner Rounding

M46 Free Purpose Counter Start

M47 Free Purpose Counter Stop

M48 Enable Spindle and Feedrate Override

M49 Disable Spindle and Feedrate Override

M61 Load New Bar

M66 Spindle Constant Speed in Chuck Open Valid

M67 Spindle Constant Speed in Chuck Open Invalid

M68 Chip Conveyor ON

M69 Chip Conveyor OFF

M72 Chamfering OFF

M73 Chamfering ON

M80 Auto Power OFF

M82 Tailstock Body Advance (GS 200/66 & 250 Lathes)

M83 Tailstock Body Home (GS 200/66 & 250 Lathes)

M84 Tailstock Forward (GS 150 & 200 Lathes) Tailstock Quill Forward (GS 200/66 & 250 Lathes)

M85 Tailstock Retract (GS 150 & 200 Lathes) Tailstock Quill Retract (GS 200/66 & 250 Lathes)

M86 Tailstock Home (GS 150 & 200 Lathes) Tailstock Quill Home (GS 200/66 & 250 Lathes)

M92 Tool Probe Arm Down

M93 Tool Probe Arm Up

M97 Part Counter

M98 Subprogram Call

M99 Subprogram End, Return to Main Program

M106 Mist Collector ON

M107 Mist Collector OFF

M111 Main spindle and live tool motions in operation

M112 Main spindle and live tool stop

M113 Live tool rotates CW

M114 Live tool rotates CCW

M115 Live tool stops

M117 Spindle Brake ON

M118 Spindle Brake OFF

M123 Contouring Mode ON, Spindle Commands to Live Tool

M124 Contouring Mode OFF, Spindle Commands to Main Spindle

2.7 WORK SHIFT AND TOOL OFFSETS WORK SHIFT (Zero Offset) Introduction

The work shift offset shifts the origin of the work coordinate system. Work Shift values (Z) are stored in the Work Shift file. The value stored in this file is active at all times.

The values stored in the Work Shift file are added to the Absolute Position registers, thus shifting the origin of the work coordinate system by the amount stored in the Work Shift file. For example, if the Z axis is at 14 inches and the operator stores Z-2.5 in the Work Shift file, the Absolute Position registers 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 or from the part program.

Typically, the part length is stored as the Z Work Shift offset and the X Work Shift offset IS NOT USED (set to zero). Since the Work Shift value is added to the Absolute Position registers, the part length is stored as a negative Z value. With the part length stored in the Work Shift file, the origin of the Absolute coordinate system is the intersection of the part face and the spindle centerline. Manually Establishing the Z Axis Work Shift 1. Load a workpiece into the collet or step chuck at the desired length. 2. Set the mode switch to Jog mode. 3. Jog the turret to a safe index area.

4. Index the turret to position an empty turret station in the active position.

NOTE: If an empty station is not available, remove the tooling from any convenient station.

The Work Shift file contains an X and a Z shift register. The X axis register in the 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 machine operator must make certain that no interference exists between the spindle, spindle tooling, turret, turret tooling, tailstock, or workpiece before manually indexing the turret.

5. Set the Feedrate Override switch to an appropriate setting to safely control turret jog rate.

6. Jog the turret to within 1 inch [25 millimeters] of the face of the workpiece. 7. Place a shim against the face of the workpiece. 8. Set the mode selector switch to Handwheel mode. 9. Set the Increment Select and Axis Select switches to the appropriate settings. 10. Use the handwheel to incrementally jog the turret toward the face of the workpiece until

a slight drag is felt when moving the shim between the turret face and the face of the workpiece.

11. Press the Offset Setting key to display the offset pages. 12. Press the right hand softkey until the Work Shift softkey is displayed. 13. Press the Work Shift softkey 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.

15. Use the cursor keys to move the cursor to the Z data field under Measurement. 16. At the Manual Data Input keyboard, key in the thickness of the shim as a positive value. 17. Press the Input softkey. The Z axis Work Shift will be recorded in the Z Shift Value

register as a negative value.

18. Set the mode switch to Jog mode. 19. Use the handwheel to move the turret at least 1 inch [25 millimeters] from the face of

the workpiece. 20. Jog the turret to a safe position for indexing. Adjusting the Z Axis Work Shift

1. Press the Offset Setting key to display the offset pages. 2. Press the right hand softkey until the Work Shift softkey is displayed. 3. Press the Work Shift softkey to display the Work Shift registers. 4. Use the cursor keys to move the cursor to the Z shift data field. 5. Key in the amount of change. Refer to the note above. 6. Press the +Input softkey. The Z axis work shift value will be updated.

The W value at the bottom of the screen will register the distance between the face of the workpiece and the face of the turret. Work Shift Example: Assume that the X and Z Axes Work Shift offsets are both set to zero and that the Absolute Position registers display X0. Z6. Shim thickness is .020 inches. When step 17 is performed, Z-5.98 is entered into the Work Shift file and the Absolute Position registers will display X0. Z0.02

To make the work shift value smaller (move the part face closer to the spindle face), key in the amount of change as a positive value. To make the work shift value larger (move the part face farther from the spindle face), key in the amount of change as a negative value.

The value stored in the Z axis Work Shift file must always be a negative number.

TOOL OFFSETS Introduction The Tool Offset file is made up of two types of offsets: Tool Geometry Offsets and Tool Wear Offsets.

The following information is stored in the Tool Geometry Offset file:

NOTE: Tool offset are illustrated in figures 2.12 and 2.13. X TOOL DIMENSION

Diameter distance from the X-axis tool touch-off point to the turret reference point. Sign is determined by the direction from the tool nose reference point to the turret reference point.

Z TOOL DIMENSION Distance from the Z axis tool touch-off point to the turret reference point. Sign is determined by the direction from the tool nose reference point to the turret reference point. TOOL ORIENTATION The orientation code describes the location of the center of the tool nose in relation to the tool nose reference point. TOOL NOSE RADIUS VALUE This distance is from the cutting edge to the center of the tool nose radius. The Tool Wear Offset file allows the operator to enter minor dimensional changes for each tool to compensate for tool wear. The Tool Wear Offset files coincide with the Geometry Offset files. When a tool offset is activated, the control looks at the corresponding Tool Wear offset and performs the necessary corrections to compensate for tool wear.

If the part program is using a macro variable statement to establish the work shift value, it will be necessary to edit the part program to update the value being loaded into the macro variable from the part program.

Information stored in the Geometry and Wear Offset files is NOT automatically converted into the correct units when G20 or G21 command switches programming resolution from inch to metric or vice versa. Offsets in the desired unit of measure should be entered after the control has been set to the proper mode, inch (G20) vs. metric (G21). If a G20 or G21 is programmed after the tool offsets are entered, the decimal point will be shifted one place to the left or right. If start-up mode is G20 (inch) and the program switches to G21 (metric), the offset decimal point will shift one place to the right. If start-up mode is G21 (metric) and the program switches to G20 (inch), the offset decimal point will shift one place to the left.

The Tool Offset files allow the operator to easily make corrections resulting from tool changes, thus large-scale modifications to the part programs are eliminated.

Tool Offsets are activated by the last two digits in the T word. The first two digits specify the turret station. The data word format for the T word is T4.

A suggested method for numbering the offsets that will assign a number related to the turret station is as follows:

Turret Station: 1 2 3 4 5 6 7 8 9 10 11 12

Offset Number: 01 02 03 04 05 06 07 08 09 10 11 12

Figure 2.13 - Round Shank Tool Holder (Shown with Left-Hand Boring Bar)

Figure 2.12 - Square Shank Tool Holder (Shown with Left-Hand Turning Tool)

Storing Tool Geometry Offsets in Memory Setting Tool Offsets for Non-Center Working Tools on the Turret - (Square Shank Tools, Boring Bars, etc.) 1. Load a workpiece of known diameter and length into the collet or chuck. 2. If it has not already been done, perform the Work Shift Offset procedure. 3. Set the mode selector switch to Jog mode. 4. Set the Feedrate/Jog Override switch to the desired setting.

5. Jog the turret to a safe position for indexing. (Depends on K bit setting steps 5 and 6) 6. Index the turret to the selected station. 7. Mount the tool holder and tool onto the turret. 8. Jog the tool tip to within 1 inch [25 millimeters] of the face of the workpiece held in the

spindle. 9. Place a shim or scale against the face of the workpiece and use the handwheel to move

the turret in the -Z direction to gently touch the tool tip to the shim so that a slight drag is felt when moving the shim.

10. Press the Offset Setting key. 11. Press the Offset soft key to access the Tool Offset pages. 12. If not already displayed, press the Geometry soft key to display the Tool Geometry

Offset pages. 13. Use the page and cursor keys to position the cursor at the Z axis field for the desired

offset. 14. At the Manual Data Input keyboard, key in the letter Z and the thickness of the shim as

a positive value. 15. Press the Measure soft key. The Z axis offset value for the tool will now be displayed

under the appropriate offset number, as selected in step 13. 16. If touching off an O.D. working tool, jog the turret in the +Z direction 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 millimeters] from the face of the workpiece.

17. Use the cursor keys to position the cursor at the X axis field for the desired offset. 18. If touching off an O.D. working tool, jog the turret in the +X direction to place the tool

tip beyond the O.D. of the part as shown in Figure 2.14. 19. If touching off an O.D. working tool, use the handwheel to move the turret in the -Z

direction until the tool tip is beyond the face of the workpiece in the -Z direction. 20. Place the shim against the O.D. of the workpiece and turn the handwheel in the

appropriate direction until the tool tip gently makes contact with the shim, as shown in Figure 2.14.

21. Key in X and the diameter of the workpiece as a positive value. Example: Diameter = 2.125 Input = X2.125

22. Press the Measure softkey. The X axis offset value for the tool will now be displayed under the appropriate offset number.

23. Compensate for shim thickness: If touching off an O.D. working tool and the control is set for diameter programming, enter twice the shim thickness as a negative (-) value and press the Input+ softkey.

The machine operator must be sure that no interference exists between the spindle, spindle tooling, tailstock, turret, turret tooling, or workpiece before indexing the turret.

If touching off an O.D. working tool and the control is set for radius programming, enter the shim thickness as a negative (-) value and press the Input+ soft key. If touching off an I.D. working tool, no shim compensation is needed.

24. Jog the turret in the +X direction to clear the diameter of the workpiece by at least 1

inch [25 millimeters] in the +X direction. 25. Jog the turret in the +Z direction to clear the face of the workpiece by at least 1 inch

[25 millimeters] in the +Z direction. 26. Jog the turret to a safe position for indexing. (Depends on K bit setting steps 26 and 27) 27. Index the turret to the next tool station which is to be set. 28. Repeat steps 7 through 27 as required for other tools.

Setting Tool Offsets for Center-Working Tools on the Turret

1. If it has not already been done, perform the Work Shift Offset procedure 2. Set the mode switch to Jog mode. 3. Set the Feedrate/Jog Override switch to the desired setting.

4. Jog the turret to a safe position for indexing. (Depends on K bit setting steps 4 and 5) 5. Index the turret to the selected station. 6. Mount the tool in the tool holder at the length desired. 7. Jog the tool tip to within 1 inch [25 millimeters] of the face of the workpiece held in the

spindle. 8. Place a shim against the face of the workpiece and use the handwheel to move the

turret in the -Z direction to gently touch the tool tip to the shim until a slight drag is felt when moving the shim.

Figure 2.14 - O.D. and I.D. Tool Touch-Off Points

This procedure is to be used for center-working tools such as drills, taps, and reamers ONLY. The X axis Wear Offset must always set to zero for center-working tools.

The machine operator must be sure that no interference exists between the spindle, spindle tooling, tailstock, turret, turret tooling, or workpiece before manually indexing the turret.

9. Press the Offset Setting key. 10. Press the Offset softkey to access the Tool Offset pages. 11. Press the Geometry softkey to access the Geometry Offset pages. 12. Use the page and cursor keys to position the cursor at the X axis field for the desired

offset. 13. Enter zero and press the Input softkey. 14. If using a double round shank tool holder, enter TWICE the qualified tool holder

dimension as a positive (+) value and press the Input soft key. Refer to Figure 2.15. 15. Use the cursor keys to position the cursor at the Z axis field for the desired offset. 16. At the Manual Data Input keyboard, key in the thickness of the shim as a positive value. 17. Press the Measure softkey. The Z axis offset value for the tool will now be displayed

under the appropriate offset number, as selected in step 15. 18. Move the turret in the +Z direction to clear the workpiece. 19. Repeat steps 4 through 18 as required for other center-working tools. Resetting Wear Offsets

20. Press the left-hand softkey to return to the offset selection softkeys. 21. Press the Wear softkey to access the Wear Offset pages. 22. Reset the X Wear offset for each tool that was just installed:

A) Use the page and cursor keys to position the cursor at the X axis field for the desired offset.

B) Key in “0" (zero) and press the Input softkey. TOOL PROBE [Option] Introduction The tool probe allows the operator to set tool geometry offsets quickly and accurately. The tool probe must be calibrated before it is ready to use for the first time. The tool probe has three available operating modes: • Manual Mode • Semi-Automatic Mode • Automatic Mode

Figure 2.15 - Sample Qualified Tool Holder Dimensions

Manual Tool Probe Operation

1. Set the Mode Select switch to Reference mode. 2. Press the +X push button. The X axis will move to the X Home position and the X Home

indicator light will turn ON. 3. Set the Mode Select switch to Jog mode.

NOTE: Activating the tool probe will cause the control to automatically display

the tool geometry offset registers. 4. Press the Tool Probe push button to activate and deploy the tool probe. 5. Index the turret to the selected station. 6. Use the page and cursor keys to position the cursor at the desired offset number.

7. Set the Feedrate/Jog Override switch to an appropriate value to safely approach the tool

probe stylus with the tool. Refer to Figure 2.16. 8. Use the axis push buttons to move the tool tip to a position near the appropriate side of

the tool probe stylus. 9. Set the Feedrate/Jog Override switch to the lowest setting available that allows axis

motion. 10. Use the appropriate axis push button to move the tool tip carefully against the tool

probe stylus until the probe is tripped. The offset will register on the display screen. 11. Move the tool away from the tool probe stylus. 12. Repeat steps 6 through 12 if touching the tool off on another axis. 13. Set the Mode Select switch to Reference mode. 14. Press the +X push button. The X axis will move to the X Home position and the X

Home indicator light will turn ON. 15. Set the Mode Select switch to Jog mode.

Axis motion is obtained through the use of the manual pulse generator or jog push buttons when the tool probe is activated and deployed. Once a tool has been probed, the X axis must be moved to the Reference Position before the turret can be indexed. (Depends on K bit setting) This procedure assumes that all required turret tooling has been installed.

The machine operator must be sure that no interference exists between the spindle, spindle tooling, tool probe, turret, turret tooling, or workpiece before indexing the turret.

When the tool probe is turned ON, do not touch the probe with any object other than the tool that is being set.

The machine operator must exercise care when approaching the tool probe stylus with the tool. DO NOT impact the tool probe stylus with the tool.

Figure 2.16 - Axis Push Buttons

16. Repeat steps 5 through 16 if touching off additional tools. 17. Press the Tool Probe push button to deactivate and retract the tool probe.

Note: Current GS machines require both X and Z axis to be at reference position to index turret or deploy probe.

Semi-Automatic and Automatic Tool Probe Operation Datuming the Tool Probe

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 datum the probe prior to use. A master tool is defined as a tool that has known offset values defined in the tool offset file. The process of datuming the tool probe for semi-automatic or automatic operation is not to be confused with calibrating the probe for manual operation. When the probe is calibrated for manual operation, parameters 5015 through 5018 are used to record the position of the probe stylus. When the probe is datumed for semi-automatic or automatic operation, macro variables 522 through 531 are used to record the position of the probe stylus.

The tool probe must be correctly calibrated in manual mode before semi-automatic or automatic operation is performed. All tools that are to be updated through semi-automatic or automatic tool probe operation MUST have an offset value that is approximately equal to the actual tool offset Data. This can be accomplished by either of the following methods: • Manually touching off the tools. • Using the tool probe in manual mode.

Tool Probe Datum Procedure

NOTE: Refer to “Entering a Program from the Keyboard” for information on entering 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 Tool offset type setting: =0; Combined geometry and wear tool offset register. =1; Separate geometry and wear tool offset registers. #530=.5905; X direction stylus size #531=.2953; Z direction stylus size G65P9011K2.T_.H_.; Call Macro Program 9011 T_. = Tool Offset Number H_. = Tool nose vector M30; End of Program

2. Set the Mode Select switch to Reference mode. 3. Press the +X push button. The X axis will move to the X Home position and the X Home

indicator light will turn ON. 4. Set the Mode Select switch to Jog mode. 5. Index the turret to the station with the master tool. 6. Press the Tool Probe push button to activate and deploy the tool probe.

7. Set the Feedrate/Jog Override switch to an appropriate value to safely approach the tool probe stylus with the tool. Refer to Figure 2.16.

8. Use the manual pulse generator to move the tool tip within 0.1 inch [2.54 millimeters] of the corner of the two sides of the probe stylus to be used for datuming.

9. Set the Mode Select switch to Memory mode.

NOTE: Refer to “Activating a Stored Program” for information on activating a program.

10. Verify the datum program entered in step 1 is active. 11. Press the Cycle Start push button to datum the probe. After datuming is complete, the

tool will return to the position it was jogged to in step 8. 12. Set the Mode Select switch to Reference mode. 13. Press the +X push button. The X axis will move to the X Home position and the X Home

indicator light will turn ON. 14. Press the Tool Probe push button to retract the tool probe. Semi-Automatic Tool Probe Operation


The tool probe must be correctly calibrated before semi-automatic operation is performed. The probe must be datumed before semi-automatic operation is performed. Refer to “Datuming the Tool Probe” for information on datuming the probe for semi-automatic operation.

NOTE: Refer to “Entering a Program from the Keyboard” for information on

entering 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 Tool offset type setting: =0; Combined geometry and wear tool offset register. =1; Separate geometry and wear tool offset registers. G65P9011T_.H_.; Call Macro Program 9011

T_.=Tool Offset Number H_.=Tool nose vector

M30; End of Program 2. Set switch to Reference mode. 3. Press the +X push button. The X axis will move to the X Home position and the X Home

indicator light will turn ON. 4. Set the Mode Select switch to Jog mode. 5. Index the turret to the selected station. 6. Press the Tool Probe push button to activate and deploy the tool probe.

7. Set the Feedrate/Jog Override switch to an appropriate value to safely approach the tool

probe stylus with the tool. Refer to Figure 2.16. 8. Use the manual pulse generator to move the tool tip within 0.1 inch [2.54 millimeters]

of the corner of the two sides of the probe stylus to be used for datuming. 9. Set the Mode Select switch to Memory mode.

NOTE: Refer to “Activating a Stored Program” for information on activating a program.

10. Verify the program entered in step 1 is active. 11. Press the Cycle Start push button to probe the tool. After probing is complete, the tool

will return to the position it was jogged to in step 8. 12. Set the Mode Select switch to Reference mode. 13. Press the +X push button. The X axis will move to the X Home position and the X Home

indicator light will turn ON. 14. 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 program as needed for each tool to be probed.

15. Repeat steps 4 through 14, as needed, to probe additional tools.


Automatic Tool Probe 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 For Example: O____ (Automatic Tool Probe Cycle); Program Number (Operator Message) #509 Tool offset type setting: =0; Combined geometry and wear tool offset register. =1; Separate geometry and wear tool offset registers. M50; Allow tool probe deploy in mem mode. G28U0.; Make X axis move to X Home position. G28W0.; Make Z axis move to Z Home position. M92; Make Tool probe deploy. T0101; Turret station 1 will be indexed and the tool offsets stored on line 1 in the tool geometry and wear offset tables will be activated

G65P9012H_.; Call Macro Program 9012 H_.=Tool Nose Vector M93; Make Tool probe retract. M30; End of Program Tool Probe Calibration The tool probe must be calibrated before the probe can be used for the first time. It will also be necessary to re-calibrate the probe if one of the following occurs: The probe tip has been replaced. The machine is operating at a temperature that is significantly different than that which

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 tool offsets. Refer to Figure 2.17. CALIBRATION PROCEDURE 1. Mount sufficient tooling on the turret to be able to probe all 4 surfaces on the tool probe

stylus. 2. Set tool offsets for the tooling installed in step 1 using the procedure outlined under

“Setting Tool Offsets for Non-Center Working Tools on the Turret”. 3. Probe one of the tools installed in step 1 and observe any difference between the tool

offset obtained in step 2 and the tool offset established by the tool probe.

NOTE: Refer to Page 47 for information on editing machine parameters.

4. Modify the associated parameters (5015 through 5018) as needed to produce the same offset using both steps 2 and 3.

The tool probe must be correctly calibrated before automatic operation is performed. The probe must be datumed before automatic operation is performed. Refer to “Datuming the Tool Probe” for information on datuming the probe for automatic operation.

5. Repeat steps 2 through 4 as needed until identical results are obtained when using both steps 2 and 3.

Figure 2.17 - Tool Probe Parameter Definitions ENTERING TOOL NOSE RADIUS VALUE AND ORIENTATION Entering Tool Nose Radius Value and Orientation Code

1. Press the Offset Setting function key. 2. Press the Offset softkey to access the Tool Offset pages. 3. Press the Geometry softkey 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 softkey.

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 softkey. 8. Repeat steps 4 through 7 for each tool, as required.

Figure 2.18 - Tool Orientation Codes

If Tool Nose Radius Compensation is to be used, the tool nose radius value and the tool quadrant must be entered for each tool which uses Tool Nose Radius Compensation.

The “T” value defines the orientation of the tool tip and has a range from 0 through 9. Refer to Figure 2.18. The “R” value should be placed in only one file, either Geometry or wear not both.

Adjusting Tool Wear Offsets Tool wear offset adjustments are made by adding to or subtracting from an existing offset value using positive or negative values and the Input+ softkey. Tool Wear Offsets that are intended to adjust the position of the tool nose in the -X or -Z direction are entered as NEGATIVE values. Tool Wear Offsets that are intended to adjust the position of the tool nose in the +X or +Z direction are entered as POSITIVE values.

NOTE: Negative (-) offset values MUST be signed. Adjusting X and Z Axes Tool Wear Offsets 1. Press the Offset Setting key to display the offset pages. 2. Press the Offset softkey to access the Tool Offset pages. 3. Press the Wear softkey to display the Wear Offset page. 4. Use the page and cursor keys to position the cursor at the X axis field for the desired

offset. 5. Enter the X axis wear value as a diameter value. 6. Press the +Input softkey. 7. Use the cursor keys to position the cursor at the Z axis field for the desired offset. 8. Enter the Z axis wear value. 9. Press the +Input softkey. 10. Repeat steps 4 through 9 for each tool as required. Activating and Canceling Tool Offsets ACTIVATING TOOL OFFSETS Tool offsets are activated by a T word having the format T4. The first two numbers select the turret station that is to be indexed to the cutting position. The last two numbers specify which tool offsets in the tool geometry and wear offset tables are to be used with the selected turret position.

Example: N0120 T0616; In data block N0120, turret station 6 will be indexed to the cutting position and the tool offsets stored on line 16 in the tool geometry and wear offset tables will be activated. The leading zero in the T word may be omitted:

T0101 = T101

When a T word with a tool offset is programmed in a block containing axis motion, the tool offset motion is computed with the programmed axis position, causing the slide(s) to move directly to the corrected axis position at the programmed feedrate. Use caution as slide may move before the turret is indexed. When a T word with a tool offset is programmed in a block without axis motion, the tool offset move will occur in the next block containing axis motion. The tool offset motion is

If tool offsets are not to be called up with a turret index, the last two numbers in the T word MUST be “00" (Example: T0100). If no numbers are programmed in the last two places, the control will use the numbers programmed in the first two places as the tool offset and the turret will not index (Example: T01 will be interpreted by the control as T0001).

computed with the programmed axis position, causing the turret reference point to move directly to the corrected axis position at the programmed feedrate. Canceling Tool Offsets Tool offsets are canceled when a T0 is commanded. Tool offset cancellation (T0) will occur in the next programmed axis movement for the X and Z axes. The next programmed X axis movement will cancel the X axis offset and move the turret reference point to the programmed X axis position. The next programmed Z axis movement will cancel the Z axis offset and move the turret reference point to the programmed Z axis position. Tool offsets are also canceled when the machine is first powered up or when the Reset key is pressed.

Figure 2.19 - Tool Holder with Tool (Viewed from Spindle)

2.8 INSTALLING A TOOL ON THE TURRET

VDI TOP PLATE Square Shank Tools Qualified Tooling For optimum performance, GS/SV lathes are designed to use qualified square shank tools. Since these tools are length, width, and height qualified, both set-up time and downtime due to tool replacement are greatly reduced. Refer to the appropriate tooling catalog for tooling dimensions. Installing Square Shank Tools on the Turret 1. Thoroughly clean the top plate, tool holders,

and tooling. 2. Aligning the locating pin on the tool holder

with the locating hole in the turret top plate, mount tool holder “B”, Figure 2.19, onto the top plate.

NOTE: Clamp screw “C” is accessed from the

side of the turret top plate. 3. Torque clamp screw “C”, Figure 2.19, as

following:

VDI 30: 18.5 lb-ft [25 N•m] VDI 40: 29.5 lb-ft [40 N•m]

4. Mount the tool in the tool holder and tighten three clamp screws “A”.

When using square shank tooling, the exclusive use of left-hand tools is recommended. This insures that all cutting forces will be directed into the machine base, resulting in maximum tool life.

Be sure the tool sits squarely in the tool holder slot and is against the front edge of tool holder “B”.

F

G

Figure 2.22 – Turning Tool

E

Figure 2.20 - Single Tool Holder

Figure 2.21 - Double Tool Holder

Round Shank Tool Holders Tool Holder Capacity Refer to the appropriate tooling catalog for information on tool holders used on machines equipped with VDI top plates. Installing Round Shank Tools on the Turret 1. Thoroughly clean the turret top plate, tool

holders, and tooling. 2. Aligning the locating pin on the tool holder with

the locating hole in the turret top plate, mount tool holder onto the top plate. Refer to Figures 2.20 and 2.21.

NOTE: Clamp screw “D” is accessed from the side

of the turret top plate. 3. Torque clamp screw “D”, Figure 2.20, as

following:

VDI 30: 18.5 lb-ft [25 N•m] VDI 40: 29.5 lb-ft [40 N•m]

4. If required, install the appropriate tool cartridge

in the round shank tool holder. 5. Insert the tool in the holder or tool cartridge. 6. Adjust the tool for length and properly align the

tool shank and tool cartridge, if used, with the set screws in the tool holder.

7. Tighten the set screws to hold the tool in place. 8. Move the turret to a safe index position. VERTICAL TOP PLATE Installing Turning Tool on the Turret 1. Thoroughly clean the turret top plate, tool

holder, tool retainers and tooling. 2. Use tool retainers “F” and “G” to fix the turning

tool onto the turret top plate, as shown in Figure 2.22.

3. Tighten the set screws to hold the tool in place. CAUTION: Be sure the maximum extension from the rim of the turret top plate to the tool tip is within 0.98 inch [25millimeters].

H

JI

Figure 2.23 – Boring Bar Tool

Figure 2.24 – Facing Tool

K M

L

Installing Boring Bar Tool on the Turret 1. Thoroughly clean the turret top plate, tool

holder, tool sleeve and tooling. 2. Install the tool holder “H” onto the periphery of

the turret top plate, as shown in Figure 2.23. 3. Insert the boring bar tool “I” into the tool

sleeve “J’ and set to length. 4. Mount the boring bar tool and the tool sleeve in

the tool holder and tighten with the clamp screws.

CAUTION: Be sure the tool sleeve sits squarely in the tool holder. Installing Facing Tool on the Turret 1. Thoroughly clean the turret top plate, tool

holder, tool retainer and tooling. 2. Install the tool holder “K” onto the periphery of

the turret top plate, as shown in Figure 2.24. 3. Adjust the facing tool “L” for length and

position with the tool retainer “M” in the tool holder.

4. Tighten the set screws to hold the tool in place. CAUTION: Be sure the retainer sits within the tool holder.

2.9 LIVE TOOLING [Option] INTRODUCTION

This live tooling option only opens to lathes equipped with VDI top plates. VDI 30 live tooling attachments have a maximum spindle speed of 5000 rpm, as measured at the tool tip, and can be operated at 30 percent of the total duty cycle at 5000 rpm. VDI 40 live tooling attachments have a maximum spindle speed of 4000 rpm, as measured at the tool tip, and can be operated at 30 percent of the total duty cycle at 4000 rpm. TYPES OF ATTACHMENTS

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. VDI 40 live tooling attachments are designed to use ER 32 collets to grip the tools. Cross-Working Attachment: This attachment locates the center of the drill or milling tool 2.126 inches [54 millimeters] from the face of the turret. The spindle of the attachment is aligned with the X axis. End-Working Attachment: This attachment locates the center of the drill or milling tool on the centerline of the tool station, with the spindle of the attachment aligned with the Z axis. LIVE TOOLING COLLETS AND CAPACITIES

NOTE: ER 25 and ER32 collets conform to DIN 6499. VDI 30 Live Tooling ER 25 collets are capable of employing English tools with a shank size from 0.02 inches up to and including 0.63 inches. ER 25 collets are capable of employing Metric tools with a shank size from 0.5 millimeters up to and including 16 millimeters. VDI 40 Live Tooling ER 32 collets are capable of employing English tools with a shank size from 0.04 inches up to and including 0.79 inches.

Live tooling attachments are available with or without through-tool coolant capability. Live tooling attachments without through-tool coolant capability can be run with or without coolant, as the machining process requires. Live tooling attachments with through-tool coolant capability MUST be run with coolant turned ON.

ER 32 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to and including 20 millimeters. DRIVE SHAFT ORIENTATION The drive shaft on the live tooling attachment is equipped with a detent to ensure proper orientation of the drive shaft spline with the drive gear in the turret top plate. Check detent engagement before installing the live tooling attachment on the turret top plate by attempting to rotate the spindle of the live tooling attachment by hand: If the spindle of the live tooling attachment rotates freely, the detent is not engaged. Rotate the spindle of the live tooling attachment until the detent engages, locking the drive shaft. If the spindle of the live tooling attachment will not rotate, the detent is engaged. If necessary, it is possible to manually overcome the drive shaft detent as follows: Apply a wrench to the hexagonal spindle face and rotate the spindle.

or Press the drive shaft collar inward to release the detent, as shown in Figure 2.25, and rotate the drive shaft. ADJUSTABLE DEAD STOP Each live tooling attachment is equipped with an adjustable dead stop. The dead stop can be adjusted against the end of the tool to prevent the tool from sliding in the tool holder during high-thrust machining operations. The adjustable dead stop is threaded and can be adjusted using a small common-blade

Figure 10.1 - Releasing the Drive Shaft Detent

Figure 2.25 - Releasing the Drive Shaft Detent

screwdriver. The adjustable dead stop for all end-working live tooling attachments is accessed through the front of the tool holder. Refer to Figure 2.26. The adjustable dead stop for cross-working live tooling attachments equipped with internal coolant is accessed through the front of the tool holder. The adjustable dead stop for cross-working live tooling attachments NOT equipped with internal coolant is accessed through the back of the tool holder. Refer to Figure 2.27.

Figure 2.26 - End-Working Live Tooling Attachment

Figure 2.27 - Cross-Working Live Tooling Attachment

LIVE TOOLING ATTACHMENT INSTALLATION

NOTE: All turret tool stations can be used for live tooling applications. Mounting the Attachment 1. Power-up the machine. 2. Press the control Reset key. 3. Activate Jog mode.

4. Move the turret to a safe position for indexing.

5. Close the main guard door. 6. 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.

7. Open the main guard door. 8. Thoroughly clean the turret top plate and the live tooling attachment. 9. Clean and check the O-ring on the live tooling attachment to be sure the O-ring is in

good condition. 10. Clean the spline shaft carefully and lightly coat with Molylube® Anti-Seize grease. 11. Verify the drive shaft detent is engaged. Refer to “Drive Shaft Orientation”.

12. Aligning live tooling attachment “A” with coolant button “C”, mount the live tooling

attachment on the turret top plate, as shown in Figure 2.28 or 2.29.

NOTE: VDI 30: Maximum torque for the clamp screw is 12.9 lb-ft [17.5 N•m]. VDI 40: Maximum torque for the clamp screw is 20.7 lb-ft [28 N•m].

13. Tighten clamp screw “B”. 14. If necessary, remove cap “E”, Figure 2.31, and install the proper collet for the tool to be

used. Replace the cap, but DO NOT TIGHTEN.

The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before manually indexing the turret.

Stay clear of the turret and turret tooling when indexing the turret. Physical injury can result.

NEVER force the live tooling attachment into the turret top plate. Be sure the live tooling attachment is mounted flush against the face of the turret top plate.

Figure 2.29 - Mounting an End-Working Live Tooling Attachment: (Side View)

Figure 2.28 - Mounting a Cross-Working Live Tooling Attachment (Side View)

INSTALLING / REMOVING TOOLS Maximum Tool Extension

NOTE: All dimensions are shown in inches [millimeters].

Cross-working live tooling attachments have a maximum tool extension from the center of the live tool attachment. Refer to the following table and Figure 2.30.

Type of Attachment Maximum Tool

Extension Inches [Millimeters]

VDI 30 3.45 [87.5]

VDI 40 3.94 [100.0]

Figure 2.30 - Maximum Tool Extension for Cross-Working Attachments

DO NOT exceed the maximum tool extension value. Personal injury and damage to the tooling and machine can result.

INSTALLATION / REMOVAL PROCEDURE 1. Insert the tool into the attachment and set to length. 2. Mount a wrench on spindle “F”, Figure 2.31, and use a spanner wrench to turn cap “E”

in the clockwise direction to tighten. Reverse the procedure to remove the tooling.

LIVE TOOLING ATTACHMENT REMOVAL

1. Loosen clamp screw “B”, Figure 2.28 or 2.29. 2. Remove the tool holder from the turret top plate. 3. Repeat steps 1 and 2 for additional tool holders, as necessary. LIVE TOOLING ALIGNMENT Cross-working live tooling attachments are factory set to be on center and should require no further adjustment. If adjustment becomes necessary, use two alignment adjustment screws “G”, Figure 2.32, to bring the attachment back to center.

Figure 2.31 - Tool in End-Working Attachment

When removing a live tooling attachment from the top plate, have a firm grip on the attachment body while loosening the clamp screw in the top plate. DO NOT hold the attachment by the cutting tool.

LIVE TOOLING MAINTENANCE

1. Move the turret to a safe index position. 2. Index the turret top plate to a convenient position for removing the live tooling

attachment. 3. Open the main coolant guard door. 4. Press the Emergency Stop push button. 5. Wipe coolant, chips, and other contaminants from the live tool attachment and turret

top plate.

6. Unthread the clamp screw just enough to be able to remove the live tooling attachment

and pull the live tooling attachment straight out from the top plate. 7. Inspect the live tooling attachment for wear and the amount of grease on spline “H”,

Figure 2.33. 8. Lightly coat spline “H” with Molylube® Anti-Seize grease. 9. Check O-ring “I” to be sure that it is in good condition. 10. Mount the live tooling attachment on the turret top plate.

NOTE: VDI 30: Maximum torque for the clamp screw is 12.9 lb-ft [17.5 N•m]. VDI 40: Maximum torque for the clamp screw is 20.7 lb-ft [28 N•m].

Figure 2.32 - Alignment Screws for Cross-Working Attachment

Each live tooling attachment must be removed from the turret top plate at least once per month to be inspected and lubricated.

When removing a live tooling attachment from the top plate, have a firm grip on the attachment body while loosening the clamp screw in the top plate. DO NOT hold the attachment by the cutting tool.

11. Tighten the clamp screw. 12. Close the main coolant guard door. 13. Pull the Emergency Stop push button out and release. 14. Repeat steps 1 through 13, as needed, for additional live tooling attachments.

Figure 2.33 – Drive Spline and O-Ring (End-Working Attachment Shown)

2.10 CHUCK CLOSER AND SPINDLE TOOLING

GS/SV Series lathes are equipped with hydraulically actuated chuck closers. The chuck closer can be programmed for bar feed operation or be operated manually for machine setup and chucking operations. If repairs to the chuck closer assembly are required, the ENTIRE ASSEMBLY must be removed and returned to the factory.

FREE SPINDLE A “Free Spindle” condition allows the spindle to be turned by hand. “Free Spindle” is active whenever the spindle drive system is not running.

CHUCK CLOSER OPERATION Automatic Operation For automatic operation, program M21 to open the chuck and M22 to close the chuck. The M21 (Open Chuck) command may be executed while the spindle is running. M21 will remain active until it is canceled by an M22 (Close Chuck) command. A programmed M22 (Chuck Close) command will remain active until it is canceled by an M21 (Open Chuck) command. Manual Operation The machine must be in Jog mode with the main guard door open to manually operate the chuck closer. Use the Chuck Open/Close foot switch to alternately open and close the chuck closer manually.

ADJUSTING CHUCK CLOSER PRESSURE The chuck closer chucking force is controlled by hydraulic pressure and can be adjusted by the machine operator. The chuck closer hydraulic pressure control is located at the left end of the machine, behind access door “A”, Figure 2.34. Knob “B”, Figure 2.35, is used to adjust the hydraulic pressure applied to the chuck closer draw bar and Knob “D” is for the C-axis brake. The hydraulic pressure switch “E”, “F” and “G” is used for the main pressure, internal chucking mode and external chucking mode individually. Gauge “C”, Figure 2.36, registers the hydraulic pressure applied to the chuck closer draw bar in psi and bars. A check valve system positively holds the chuck closer in the open or closed position, whichever is active, in the event of a hydraulic pressure failure.

Figure 2.34 - Access Door for Chuck Closer Hydraulic Control

The chuck closer maximum working pressure must be set correctly according to the manufactures instructions: For Tonfou 3-Jaw power chucks GS/SV 150 Series (Tonfou 3B-6A5) --- below 28 bar GS/SV 200 Series (Tonfou 3B-8A6) --- below 27 bar GS/SV 200, 200/66 & 200/66 L Series (Tonfou 3X-8A6) --- below 26 bar GS/SV 250, 250 L Series (Tonfou 3X-10A8) --- below 27 bar For Hardinge power operated collet chucks GS 42 Series (Hardinge 16C) --- below 20 bar GS 51 Series (Hardinge 16C) --- below 15 bar

Adjusting the Hydraulic Pressure 1. Open access door “A”, Figure 2.34. 2. Loosen the knurled lock nut behind knob “B”, Figure 2.35. 3. Turn knob “B” clockwise or counterclockwise to decrease or increase the hydraulic

pressure applied to the chuck closer draw bar. 4. Close the access door. 5. Press the Reset key.

CHUCKING MODES There is no default chucking mode. The current chucking mode will remain active until canceled by the 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 and press the Main Open/Close push button, if necessary. 2. Set the mode selector switch to Manual Data Input mode. 3. Press the Program softkey. 4. At the manual Data input keyboard:

Key in “M28” for Internal Chucking Key in “M27” for External Chucking

It is the responsibility of the machine operator or set-up person to properly adjust the chuck closer hydraulic pressure, based on the type of material to be machined and the configuration of the workpiece. Always follow the safe operating instructions supplied by the workholding system manufacturer. If in doubt contact your local Hardinge distributor.

The chuck pressure switch is set at 8 bar in the factory. If this setting pressure needs to be altered, for safety reasons, please contact your local Hardinge distributor.

Figure 2.36 - Chuck Closer Hydraulic Pressure Gauge

C

Figure 2.35 - Chuck Closer Hydraulic Control

BD

FE

G

5. Press the Insert key. 6. Press the EOB (End of Block) key. 7. Press the Insert key. 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.

CLEANING THE SPINDLE As a general rule, the spindle and spindle draw tube should be cleaned between setups or monthly if a long-run job is on the machine. However, when the machine is run more than one shift per day or certain types of materials are being machined, it may be necessary to clean the spindle and spindle draw tube more often.

SPINDLE TOOLING Removing Spindle Tooling 1. Power the machine up. 2. Press the Reset key. 3. Set the mode selector switch to Jog mode. 4. Press the Spindle Orient push button. NOTE: Use of the optional spindle wrench is recommended when loosening the

mounting screws for chucks and chuck jaws. 5. Remove mounting screws “D”, Figure 2.37, to release the jaws from the chuck. 6. Remove mounting screws “E” to release the chuck from the face of the spindle. 7. If necessary, press the Chuck Open/Close foot switch to open the chuck. 8. Remove center cover “F”. 9. Using the wrench supplied with the chuck, disengage the chuck draw nut from the

spindle draw tube. 10. Remove the chuck from the spindle. 11. Clean the chuck and chuck jaws. 12. Mount center cover “F” on the chuck. 13. Close the main coolant guard door. 14. At the left end of the machine, remove cover “G”, Figure 2.38, to gain access to the

chuck closer draw tube. 15. From the chuck close end, use an air line to blow chips and other contaminants out of

the spindle. 16. Replace cover “G”.

When a bar feed is being used, it must be disabled before removing or installing spindle tooling. Refer to the instructions supplied with the bar feed system.

Be prepared to accept the weight of the work-holding device.

17. If spindle tooling is to be installed at this time, proceed to the next section, “Installing Spindle Tooling”.

Installing Spindle Tooling This procedure assumes that any previously used spindle tooling has already been removed. If there is spindle tooling to be removed, perform the steps outlined under “Removing Spindle Tooling”, If previously used spindle tooling has just been removed, proceed to step 6. 1. Power the machine up. 2. Press the Reset key. 3. Set the mode selector switch to Jog mode. 4. If necessary, press the Chuck Open/Close foot switch to extend the spindle draw bar. 5. Press the Spindle Orient push button. 6. If necessary, remove the jaws and center cover from the chuck before installing the

chuck. NOTE: All components MUST be clean before installation. 7. Clean the chuck, chuck jaws, center cover, and machine spindle. 8. Aligning the chuck draw nut with the spindle draw tube, place the chuck on the

spindle. 9. Using the wrench supplied with the chuck, thread the chuck draw nut onto the spindle

draw tube.

10. Rotate the chuck to align one of the drive holes in the backing plate with the spindle drive pin.

D

E

F

Figure 2.37 - Chuck Mounted on Spindle

G

Figure 2.38 - Spindle Draw Tube Access Cove

When a bar feed system is being used, it must be disabled before removing or installing spindle tooling. Refer to the instructions supplied with the bar feed system.

Pressing the chuck toward the spindle will make the operator feel the alignment of one of the drive holes in the backing plate with the spindle drive pin.

11. Press the Chuck Open/Close foot switch to close the chuck. NOTE: Use of the optional spindle wrench is recommended when tightening the

mounting screws for chucks and chuck jaws. Refer to Figure 2.39 for the installation sequence and torque specification for mounting screws “E”, Figure 2.37.

12. Install mounting screws “E”, Figure 2.37. 13. Mount center cover “F” on the chuck. 14. Mount the jaws on the chuck and secure with screws “D”. 15. Place a workpiece into the chuck and press the Chuck Open/Close foot switch to close

the chuck and test the gripping force on the workpiece.

If the gripping force is more or less than desired, use the procedure outlined earlier in this chapter to adjust the chuck closer draw bar force as needed.

16. If necessary, replace spindle draw tube access cover

If the machine will not be operated with a bar feed system, the spindle draw tube access cover must be installed.

Spindle tooling and workholding used on the machine must be operated, maintained and lubricated in accordance with the manufacturer’s instructions

Figure 2.39 - Installation Sequence and Torque Specification for Chuck Mounting Screws

SPINDLE WRENCH [Option] The optional spindle wrench is designed to aid in the installation or removal of:

● the chuck closer ● the chuck closer jaws

1 Adjust the length of bolts “D”, Figure 2.40, to fit the socket holes in the chuck and

tighten locking nut “E”. 2 Position the spindle wrench as shown in Figure 2.41 or 2.42. 3 Hold the wrench to prevent the spindle from rotating while the mounting bolts are

loosened or tightened.

Figure 2.40 -Spindle Wrench: Side View

Figure 2.41 - Spindle Wrench Positioned for Chuck Removal

Figure 2.42 - Spindle Wrench Positioned for Chuck Jaw Removal

2.11 TAILSTOCK [OPTION] INTRODUCTION GS/SV Series lathes are available with an optional programmable tailstock. The tailstock gives added support when machining long parts and reduces part deflection. This provides closer tolerances, better surface finishes, and higher speeds and feeds than would otherwise be possible. Tailstock motion can be controlled: • Automatically from the part program • Manually using the Tailstock Jog switch on the operator control panel. (GS/SV 150 & 200

and GS 42 & 51 series lathes) • Manually using the Tailstock Jog switch on the operator control panel and the tailstock

foot switches. (GS/SV 200/66 & 250 series lathes)

There are two rates of tailstock motion on GS/SV 150 & 200 and GS 42 & 51 series lathes: • Normal traverse rate. • Preset feedrate. There is one rate of tailstock motion on GS/SV 200/66 & 250 series lathes: • Normal traverse rate. LIVE CENTERS The tailstock on GS/SV 150 & 200 and GS 42 & 51 series lathes accepts a live center with a #4 Morse taper. The tailstock on GS/SV 200/66 & 250 series lathes accepts a live center with a #5 Morse taper. TAILSTOCK POSITIONS GS/SV 150 & 200 and GS 42 & 51 Series Lathes There are three tailstock positions recognized by the control. Tailstock Forward Position The machine operator establishes the forward position by locating the feed limit switch dog as needed. Refer to information on setting the forward position. Refer to “Tailstock Movement” for information on moving the tailstock to this position. Tailstock Retract Position The retract position can be located anywhere between the forward position and the home position. This position is intended to minimize tailstock motion, resulting in lower cycle times. The machine operator establishes the retract position by setting a retract timer.

Check and, if necessary, adjust the tailstock force before using the tailstock for machining operations. Refer to “Checking and Adjusting Tailstock Force”. Always make certain the turret is in a safe index position before moving the tailstock toward the spindle.

Refer to “Tailstock Movement” for information on moving the tailstock to the retract position. Setting the Retract Timer 1. Press the Manual push button. 2. Press the control panel Auxiliary Data softkey. 3. Move the cursor to Retract Time.

NOTE: The Retract Timer has a valid range of 0 to 10 seconds. 4. Enter the desired value and press the Input key. 5. Press the Exit softkey to leave the timer screen. Tailstock Home Position This position is NOT adjustable. See Appendix one for the home position. The indicator light will be ON when the tailstock is at the home position. Refer to “Tailstock Movement”, for information on moving the tailstock to the retract position. GS/SV 200/66 & 250 Series Lathes There are five tailstock positions recognized by the control. Tailstock Forward Position The machine operator establishes the forward position by locating the tailstock trip dog as needed. Refer to information on setting the forward position. Refer to “Tailstock Movement” for information on moving the tailstock to this position. Tailstock Home Position This position is NOT adjustable. See Appendix one for the home position .The indicator light will be ON when the tailstock is at the home position. Refer to “Tailstock Movement” on the next page for information on moving the tailstock to this position. Tailstock Quill Forward Position The tailstock quill is in the forward position when it is extended. Tailstock Quill Retract Position The retract position can be located anywhere between the quill forward position and the quill home position. This position is intended to minimize quill motion, resulting in lower cycle times. The machine operator establishes the retract position by setting a retract timer. Refer to “Programmed Movement” for information on moving the tailstock quill to the retract position. Refer to “Setting the Retract Timer” as above, for information on establishing the retract position. Tailstock Quill Home Position

The tailstock quill is at the home position when it is fully retracted. This position is NOT adjustable. Refer to “Tailstock Movement” below for information on moving the tailstock to this position. TAILSTOCK MOVEMENT Manual Movement The machine control must be in Jog or Handwheel mode to manually control tailstock motion.

NOTE: Tailstock motion will stop when the Tailstock Jog switch is released. GS/SV 150 & 200 and GS 42 & 51 Series Lathes Turning the Tailstock Jog switch to the left will move the tailstock toward the spindle at the normal traverse rate until the feed switch is tripped. At that point the tailstock will move at the preset federate and feed onto the workpiece. Turning the Tailstock Jog switch to the right will move the tailstock away from the spindle (toward the home position). Manual tailstock motion will stop when the Tailstock Jog switch is released. GS/SV 200/66 & 250 Series Lathes Turning the Tailstock Jog switch to the left will move the tailstock toward the spindle. Turning the Tailstock Jog switch to the right will move the tailstock away from the spindle (toward the home position). Manual tailstock motion will stop when the Tailstock Jog switch is released. The Tailstock Quill foot switches are used to extend or retract the quill. PROGRAMMED MOVEMENT GS/SV 150 & 200 and GS 42 & 51 Series Lathes The machine control must be in Memory or Manual Data Input mode to command tailstock motion using M codes. M84 Tailstock Forward The tailstock will move forward (toward the machine spindle) until the feed switch is tripped. At that point, the tailstock will slow to the preset feedrate and feed onto the workpiece. M85 Tailstock Retract When the tailstock is in the forward position and M85 is read by the control, the tailstock will move to the retract position as established by the tailstock retract timer. Refer for information on setting the tailstock retract timer, as above. M86 Tailstock Home

When an M86 is read by the control, the tailstock will move to the home position. GS/SV 200/66 & 250 Series Lathes The machine control must be in Memory or Manual Data Input mode to command tailstock motion using M codes. M82 Tailstock Body Forward The tailstock will move forward (toward the machine spindle) until the limit switch dog engages the limit switch on the tailstock. At that point, tailstock motion will stop. M83 Tailstock Body Home When an M83 is read by the control, the tailstock will move to the home position. M84 Tailstock Quill Forward The tailstock quill will extend, making contact with the workpiece. M85 Tailstock Quill Retract When the tailstock quill is in the forward position and M85 is read by the control, the quill will move to the retract position as established by the tailstock retract timer. Refer to “Setting the Retract Timer” as above, for information on setting the tailstock retract timer. M86 Tailstock Quill Home M86 commands the tailstock quill to fully retract. GS/SV 200/66 L & GS 250 L Lathes The machine control must be in Memory or Manual Data Input mode to command tailstock motion using M codes.

M84 Tailstock Quill Forward The tailstock quill will extend, making contact with the workpiece. M85 Tailstock Quill Retract When the tailstock quill is in the forward position and M85 is read by the control, the quill will move to the retract position as established by the tailstock retract timer. Refer to “Setting the Retract Timer” as above, for information on setting the tailstock retract timer. M86 Tailstock Quill Home M86 commands the tailstock quill to fully retract. Stopping Programmed Movement Programmed tailstock motion can be stopped by pressing Emergency Stop, Feed Hold, or Reset. EMERGENCY STOP

To initiate programmed tailstock motion after an Emergency Stop: 1. Release the Emergency Stop push button. 2. Press the Emergency Stop Reset push button. 3. Press the control Reset key. 4. Select Jog mode and move the tailstock to the home position. 5. Reset the program to the beginning of the current operation. 6. Select Memory mode and press the Cycle Start push button. FEED HOLD To initiate programmed tailstock motion after a Feed Hold, press the Cycle Start push button. RESET To initiate programmed tailstock motion after a control Reset: 1. Select Jog mode and move the tailstock to the home position. 2. Reset the program to the beginning of the current operation. 3. Select Memory mode and press the Cycle Start push button. SETTING THE TAILSTOCK FORWARD POSITION GS/SV 150 & 200 and GS 42 & 51 Series Lathes 1. Power-up the machine. 2. Set the Mode Select switch to Jog mode. 3. Place a workpiece in the work-holding device and press the Chuck Open/Close foot

switch. 4. Loosen the nut on feed limit switch “A”, Figure 2.43, move the limit switch to the

extreme right position, and secure the nut. 5. Close the main guard door. 6. Turn the Tailstock Jog switch to the left. The tailstock assembly will move toward the

spindle and slow to the preset feedrate after the feed switch is tripped. Release the Tailstock Jog switch when the tailstock slows to the preset feedrate.

7. Open the main guard door and measure the distance from the tailstock live center to the workpiece.

8. Calculate the adjustment value by subtracting 1 inch [25 millimeters] from the distance measured in step 7.

9. Adjust the feed position: A) Loosen the wing nuts on feed limit switch “A”. B) Move the limit switch to the left a distance equal to the adjustment value calculated

in step 8. C) Secure the wing nuts.

10. Close the main guard door. 11. Turn the Tailstock Jog switch to the right to move the tailstock assembly away from the

workpiece. 12. Turn the Tailstock Jog switch to the left. The tailstock assembly will move toward the

spindle and slow to the preset feedrate after the feed switch is tripped. Observe the distance from the feed position and workpiece engagement.

13. Turn the Tailstock Jog switch to the right to move the tailstock assembly to the home position.

14. Adjust the position of the feed limit switch as needed.

Figure 2.43 - Tailstock Feed Limit Switch Adjustment

GS/SV 200/66 & 250 Series Lathes 1. Power-up the machine. 2. Set the Mode Select switch to Jog mode. 3. If necessary, turn the Tailstock Jog switch to the right to move the tailstock away from

the spindle. 4. Loosen the nut on limit switch dog "B", Figure 2.44, and move the dog to the far left. 5. Place a workpiece in the work-holding device and press the Chuck Open/Close foot

switch. 6. Turn the Tailstock Jog switch to the left to move the tailstock to a convenient position to

access cover “C”, Figure 2.45, and adjust tailstock quill switch dog “E”, Figure 2.46. 7. Remove cover “C”.

NOTE: It may be necessary to move the tailstock quill to gain access to both screws

in switch dog “E”, Figure 2.46. 8. Loosen the two screws in switch dog "E". 9. Use the Tailstock Quill Extend and Retract foot switches to achieve the desired amount

of quill extension.

An alarm will be issued by the control if the quill goes into an overtravel condition. If an alarm occurs, retract the quill a short distance and press the Reset key to clear the alarm.

Figure 2.46 - Tailstock Quill Switch Dog and Limit Switches

10. Position the center of surface “E” on limit switch

“D” and tighten the screw on the switch dog that is accessible.

11. Turn the Tailstock Jog switch to the left to move the tailstock toward the spindle, engaging the tailstock quill with the workpiece.

12. Move limit switch dog “B”, Figure 2.44, to the right until it engages the tailstock limit switch.

13. Tighten the nut on limit switch dog “B”. 14. Press the Tailstock Quill Retract foot switch

until the second screw in switch dog “E”, Figure 2.46, is accessible.

15. Tighten the second screw in switch dog “E”.

16. Check the tailstock position:

A) Use the Tailstock Quill foot switch to retract the quill. B) Turn the Tailstock Jog switch to the right to move the tailstock away from the

spindle. C) Turn the Tailstock Jog switch to the left until tailstock motion stops. D) Use the Tailstock Quill foot switch to extend the quill and contact the workpiece. E) Adjust the tailstock limit switch dogs as needed for desired tailstock positioning.

CHECKING AND ADJUSTING TAILSTOCK FORCE 1. Set the tailstock forward position as described in the preceding instructions. 2. Set the Mode Select switch to Jog mode. 3. Turn the Tailstock Jog switch to the left to engage the tailstock with the workpiece. 4. Check the tailstock hydraulic pressure on gauge “G”, Figure 2.47. If the tailstock hydraulic pressure needs to be adjusted, go to step 5.

Figure 2.45 - Tailstock Cover Figure 2.44 - Tailstock Limit Switch Dog Adjustment

Leave sufficient space between the chuck and tailstock quill to allow insertion and removal of the workpiece when the quill is retracted.

If the tailstock hydraulic pressure does not need to be adjusted, go to step 8. 5. Open access door “H”, Figure 2.48. 6. Loosen the lock nut on adjustment knob “I”, Figure 2.49 or 2.50, and turn the

adjustment knob in the required direction until the desired pressure registers on gauge “G”.

7. Tighten the lock nut. 8. Turn the Tailstock Jog switch to the right to Home the tailstock.

Figure 2.49 - Tailstock Hydraulic Manifold (GS/SV 150 & 200 and GS

42 & 51 series lathes)

Figure 2.50 - Tailstock Hydraulic Manifold (GS/SV 200/66 & 250 series lathes)

Figure 2.47 - Tailstock Pressure Gauge

G

Figure 2.48 - Access Door for Tailstock Hydraulic Manifold

H

TAILSTOCK CENTER REMOVAL 1. Move the tailstock to a convenient position to access knock-out “J”, Figure 2.51 or “K”,

Figure 2.52. 2. On GS 150/200 and GS 42/51 series lathes, tap knock-out “J” with a soft face hammer

until the tailstock center can be removed from the tailstock.

On GS 200/66 or GS 250 series lathes: A) Rotate knock-out “K” counterclockwise. B) Tap knock-out “K” with a soft face hammer until the tailstock center can be removed

from the tailstock. C) Tighten knock-out “K”.

CLAMPING LIMIT ON TAILSTOCK QUILL The clamping limit is indicated on the tailstock quill and at the end of the quill stroke is indicated by a red coloured ring “A”, Figure 2.53. The maximum stroke of quill is 120mm and this red coloured ring is located at 100mm to 120mm of quill stroke.

Figure 2.51 - Tailstock Center Knock-Out (GS/SV 150/200 & GS 42/51 series lathes)

Figure 2.52 - Tailstock Center Knock-Out (GS/SV 200/66 & 250 series lathes)

Figure 2.53 – Clamping limit on the tailstock quill

A

2.12 INPUT/OUTPUT DEVICES DATA COMMUNICATIONS PROTOCOL Data communications protocol consists of three basic types of information: parity, baud rate, and stop bits. The baud rate and stop bits are controlled by parameters, which may be modified as required. Tape Parity Check Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in each character and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number of holes in each character. This characteristic of having an odd or even number of holes punched in every character is called parity. The control accepts tape punched in either code, but each tape must be programmed in only one of the accepted codes. The control automatically determines the particular type of coding by decoding the first End of Block (;) character on the tape. Each character is checked for parity as it is read by the tape reader or computer. Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired parity. Baud Rate Baud rate is the speed at which data is transmitted from one device to another. To successfully transmit 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 input/output port is active. Refer to the I/O setting on Setting Page 1 to determine which input/output port is active. Refer to “Input/Output Port Assignment” on the next page. Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired baud rate. Stop Bits The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The number of stop bits active in the machine control is controlled by three different parameters, depending on which input/output port is active. These parameters may be modified as required. Refer to “Input/Output Port Assignment” on the next page. CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS Use the following procedure to check communications protocol parameters: 1. Press the System function key. 2. Press the Parameter softkey. 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: 1. Press the Offset Setting function key. 2. Press the Setting softkey. 3. If necessary, use the Page keys to display the Setting page. 4. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 5. Set the mode selector switch to Manual Data Input mode. 6. Press the Operator softkey. 7. Press the ON: 1 softkey. Parameter editing will be enabled.

NOTE: The control is placed in P/S alarm number 100. 8. Press the System function key. 9. Press the Parameter softkey. 10. Use the Cursor and Page keys to position the cursor on the parameter to be modified. 11. Key in the new parameter value. 12. Press the Input key. 13. Repeat steps 10 through 12, as needed. 14. Press the Offset Setting key. The Setting page that contains the Parameter Write field

will be displayed. 15. Press the Operator softkey. 16. Press the OFF: 0 softkey. Parameter editing will be disabled. 17. Press the Reset key to cancel P/S alarm number 100. INPUT/OUTPUT PORT ASSIGNMENT GS/SV Series lathes are equipped with one physical RS-232 port. Three independent port assignments are available to allow the operator or programmer to establish three different input/output port configurations for the same physical input/output port. These three configurations are designated as channels “0", "1" and ”2". Instead of changing the associated parameters to reassign the baud rate and stop bits, it is possible to select a different input/output port assignment and have the changes implemented by the control automatically. Refer to “Input/Output Port Parameter Settings”, for a listing of the parameter settings for the input/output port assignments. INPUT/OUTPUT PORT PARAMETER SETTINGS Refer to “Checking and Modifying Communications Parameters” for information on modifying the parameter settings for the three input/output ports. These parameters may be modified as required. Baud Rate Parameter Settings

Input/Output Port Parameter Number

0 103

1 113

2 123

The valid parameter settings are as follows:

Setting Number 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

Input/Output 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 (0 or 1). The bits are read “0" to “7”, from right to left.

DATA TRANSFER TO THE CONTROL Up-loading Control Parameters into Memory

1. Verify the machine control communications protocol as outlined under “Checking and Modifying Communication Protocol”.

2. Refer to the appropriate manual to set the tape reader or computer to the desired communications protocol.

3. Remove magnetic access cover and connect the interface cable from the tape reader or computer to serial port “A”, Figure 2.54.

4. Press the Offset Setting function key. 5. Press the Setting softkey. 6. If necessary, use the Page keys to display the Setting page. 7. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 8. Set the mode selector switch to Manual Data Input mode. 9. Key in the number 1 (one). 10. Press the Input key. Parameter editing will be enabled. 11. Press the System key. 12. Press the Parameter softkey. 13. Press the Operator softkey. 14. Set the mode selector switch to Edit mode. 15. Press the soft key expansion key until the Read soft

key is displayed. 16. Press the Read softkey. 17. Press the Execute softkey. 18. Set the tape reader or computer to transmit data to

the machine control. 19. After the control parameters have been uploaded, set

the mode selector switch to Manual Data Input mode. 20. Press the Offset Setting function key. 21. Key in the number 0. 22. Press the Input key. Parameter editing will be disabled. 23. Remove power from the external device; then,

disconnect the RS-232 cable from the machine control. 24. Replace the magnetic access cover. 25. Turn the control OFF and wait approximately 10 seconds. 26. Turn the control ON. Up-loading Part Programs into Memory

Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable.


Figure 2.54 - RS-232 Serial Port

A

1. Verify the machine control communications protocol as outlined “Checking and Modifying Communication Protocol”.

2. Refer to the appropriate manual to set the tape reader or computer to the desired communications protocol.


4. Set the mode selector switch to Edit mode.

NOTE: The program protect key switch MUST be set to ON to allow uploading part programs. Refer to Program Protect Key Switch, page 39.

5. Set the Program Protect Key Switch to ON. 6. Press the Program key. 7. Press the soft key expansion key until the Read softkey is displayed.

NOTE: If the program has no program number or if the program number is to be altered, key in the letter “O” and the desired program number.

8. Key in the letter “O” and the program number. Example: O1111 9. Press the Read softkey. 10. Press the Execute softkey. 11. Set the tape reader or computer to transmit data to the machine control.

- NOTE - When the program has been completely loaded into the control, it will appear as the active program on the control display screen.

12. After the part programs have been uploaded, set the program protect key switch to OFF. 13. Remove power from the external device; then, disconnect the RS-232 cable from the

machine control. 14. Replace the magnetic access cover. Up-loading Tool Offsets into Memory


2. Refer to the appropriate manual to set the tape reader, or computer to the desired communications protocol.


4. Set the mode selector switch to Edit mode.

NOTE: The program protect key switch MUST be set to ON to allow uploading tool offsets. Refer to Program Protect Key Switch, page 39.

5. Turn the program protect key switch to ON. 6. Press the Program key. 7. Press the soft key expansion key until the Read soft key is displayed.


8. Key in the letter “O” and the desired program number. 9. Press the Read softkey. 10. Press the Execute softkey. 11. Set the tape reader or computer to transmit data to the machine control.

NOTE: When the offset program has been completely loaded into the control, it will appear as the active program on the control display screen.

12. After the tool offsets have been uploaded, press the Reset key. 13. Set the mode selector switch to Auto mode. 14. Close the main guard door. 15. Press the Cycle Start push button. 16. Turn program protect key switch to OFF. 17. Remove power from the external device; then, disconnect the RS-232 cable from the

machine control. 18. Replace the magnetic access cover. DATA TRANSFER FROM THE CONTROL Down-loading Control Parameters from Memory

1. Verify the machine control communications protocol as outlined earlier under “Checking and Modifying Communication Protocol”.

2. Refer to the appropriate manual to set the tape punch or computer to the desired communications 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. 6. Set the mode selector switch to Edit mode. 7. Press the System key. 8. Press the Parameter softkey. 9. Press the Operator softkey. 10. Press the Punch softkey. 11. Press the Execute softkey.

Offsets loaded through the RS-232 serial port are loaded as a separate program. Once loaded, this program is executed to enter the offset values into the offset files. Be sure this program number does not match a program number already present in the control memory.


To stop the parameters from downloading, press the Reset key. Once the Reset key has been pressed, it is not possible to download the rest of the parameters without starting this procedure from the beginning.

12. After the control parameters have been downloaded, remove power from the external device and disconnect the RS-232 cable from the machine control.

13. Replace the magnetic access cover. Down-loading Part Programs from Memory




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. 6. Set the mode selector switch to Edit mode. 7. Press the Program key. 8. Key in the letter “O” and the program number. Example: O1111 9. Press the soft key expansion key until the Punch softkey is displayed. 10. Press the Punch key. 11. Press the Execute softkey.

12. After the part programs have been downloaded, remove power from the external device

and disconnect the RS-232 cable from the machine control. 13. Replace the magnetic access cover. Down-loading Tool Offsets from Memory



3. Remove magnetic access cover and connect the interface cable from the tape reader or


When outputting to a tape punch, the control will automatically output 3 feet of leader and trailer tape. To shorten the leader or trailer length, press the Cancel key while the leader or trailer is being punched, respectively. To stop the part program from downloading, press the Reset key. Once the Reset key has been pressed, it is not possible to download the rest of the part program without starting this procedure from the beginning.


computer to serial port “A”, Figure 2.54. 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. 6. Set the mode selector switch to Edit mode. 7. Press the Offset Setting key. 8. Press the Offset softkey. 9. Press the Geometry softkey to display the Geometry offset page. 10. Press the Operator softkey. 11. Press the soft key expansion key until the Punch soft key is displayed. 12. Press the Punch key. 13. Press the Execute softkey.

14. After the tool offsets have been downloaded, remove power from the external device

and disconnect the RS-232 cable from the machine control. 15. Replace the magnetic access cover.

To stop the tool offsets from downloading, press the Reset key. Once the Reset key has been pressed, it is not possible to download the rest of the tool offsets without starting this procedure from the beginning.

2.13 MISCELLANEOUS CONTROL TIMERS The control is equipped with timers that allow the machine operator to control the following machine functions: • Tailstock Retract Position • Part Catcher Extend Delay • Chip Conveyor ON and OFF

NOTE: Timer values are input in milliseconds. TIMER DESCRIPTIONS Tailstock Retract Timer This timer is used to establish a retract point between the forward position and the fixed home position. When M85 is executed, the tailstock will begin moving toward the fixed home position and the retract timer will begin counting. Tailstock motion will stop when the time set has expired. Part Catcher Extend Delay This timer is used to specify a time delay for the part catcher extend command. When M26 (Part Catcher Extend) is commanded and this timer is set to a non-zero value, the part catcher will not extend until the time set has expired. Chip Conveyor ON and OFF The chip conveyor ON and OFF timers are used to cycle the chip conveyor ON and OFF when continuous chip conveyor operation is not desired. Set the desired values in the chip conveyor timers and command M68 (Chip Conveyor ON) from the part program. The chip conveyor will turn ON and OFF according to the time values specified. Refer to “Setting a Timer” for timer identification and the procedure for setting a timer. Setting a Timer 1. Press the Offset Setting key. 2. Press the Setting softkey. 3. If necessary, use the page up/down keys to display the Setting page that contains the

Parameter 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. 6. Press the Operator softkey. 7. Press the ON: 1 softkey.

NOTE: The control is placed in P/S alarm No. 100. 8. Press the System key. 9. Press the PMC softkey. 10. Press the PMCPRM softkey. 11. Press the Timer softkey. 12. Move the cursor to the appropriate timer:

Timer Number Timer Function

03 Tailstock Retract Timer

05 Part Catcher Extend Delay

12 Part Conveyor OFF Delay

NOTE: Timer values are input in milliseconds.

13. Key in the desired value. 14. Press the Input key. 15. Press the Offset Setting key. The Setting page that contains the Parameter Write field

will be displayed. 16. Press the Operator softkey. 17. Press the OFF:0 softkey. 18. Press the Reset key to cancel P/S alarm No. 100. PART COUNTER The Part Counter shows the total number of times a program has been run during automatic operation. The Part Counter is increased by one (1) each time an M97 command is read by the control.

NOTE: The Parts Required register is located on the same display screen as the Part Count register.

There are three data registers associated with the Part Counter. Refer to “Setting the Part Counter Data” for information on setting values in these data registers. PARTS TOTAL This register displays the total number of times the program has been run since this register was reset to zero. Resetting the Parts Count register WILL NOT reset this counter. PARTS REQUIRED When this register is set to any non-zero number and M99 is programmed at the end of the program instead of the M30 command, program execution will continue until the number in the Parts Count register is equal to the number in the Parts Required register. PARTS COUNT This register contains the number of times the program was executed since this register was reset to zero. Program execution will stop when the value in this register equals the value in the Parts Required register. ACCESSING THE PART COUNTER DISPLAY 1. Press the Position key. The Part Counter is displayed at the bottom of the page. Setting the Part Counter Data 1. Press the Offset Setting key. 2. If the Setting (Timer) page is not displayed: A) Press the Setting softkey.

B) Use the page keys to display the Setting (Timer) page. 3. Activate Manual Data Input mode.

NOTE: The program protect key switch MUST be set to ON to allow altering the data in the Part Counter registers. Refer to Program Protect Key Switch, page 39.

4. Set the Program Protect Key Switch to ON. 5. Press the Operator softkey. 6. Move the cursor to the part counter data field to be set. 7. Key in the desired value and press the Input key. 8. Repeat steps 6 and 7 as needed. 9. Set the Program Protect Key Switch to OFF.

NOTE: Parts required must be set to zero for continuous cycling of bar work. Resetting the Part Count Register 1. Press the Position key. The Parts Counter is displayed at the bottom of the page. 2. Press the Operator softkey. 3. Press the PTSPRE (Parts Preset) soft key. “Part Count” will blink. 4. Press the Execute softkey to set the Parts Count register to zero. FREE PURPOSE COUNTER The Free Purpose counter shows the elapsed time between an M46 and M47 command. The Free Purpose counter starts counting when M46 is read by the control and stops counting when an M47 or M30 (End of Program) is read by the control. The Free Purpose counter will continue to count during a feed hold or programmed stop condition. The Free Purpose counter is an increment counter that does not automatically reset to zero. Each time the control reads an M46 command, the value in Free Purpose counter increases until an M47 or M30 (End of Program) is read by the control. The Free Purpose counter can be used as many times as needed within a program. When necessary, the Free Purpose counter must be manually reset to zero. ACCESSING THE FREE PURPOSE COUNTER 1. Press the Offset Setting key. 2. Press the Setting softkey. 3. Press the Page keys to display the Setting Timer page. RESETTING THE FREE PURPOSE TIMER 1. Access the Free Purpose counter, as described above. 2. Set the mode selector switch to Manual Data Input mode. 3. Move the cursor to the Free Purpose data field to the reset. 4. Key in “0” and press the Input key to reset the value. 5. Repeat steps 3 and 4 as needed.

2.14 TOOL LIFE MANAGEMENT INTRODUCTION The basic concept of Tool Life Management is that after a specific number of parts or a specific amount of machining time, the control will automatically begin using another tool in place of the current tool being used for a particular operation. Tools are assigned to specific groups, as designated by the programmer. The control will monitor the measurement value assigned to each tool group and automatically switch to the next tool in the group when the counter for that tool group reaches the measurement value specified by the programmer. TOOL LIFE MEASUREMENT UNITS Tool life can be measured using one of the two following methods: 1. Number of parts (machined by the tool) 2. 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 measurement unit when the machine is shipped from the factory. Refer to Determining the Measurement Unit 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 and an “M30” (End of Program) is read by the control. At that point, the machine operator will replace the tooling and reset the counter relating to the affected tool group. Refer to Resetting a Tool Group Counter. Number of Parts When this type of measurement is used, the tool group counter for the active tool is increased 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 current tool whenever G01, G02, or G03 is active. TOOL LIFE MANAGEMENT PROGRAM DESCRIPTION When using Tool Life Management, tools and offsets are assigned to specific groups. These groups 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 parameters required for Tool Life Management. The Tool Life Management program defines the following parameters: 1. Group numbers. 2. Tool life value for each group. 3. Tool stations and offsets for each group.

When using Tool Life Management, the machine operator MUST load and execute the Tool Life Management program BEFORE executing the part program for the first time.

When the Tool Life Management program is executed, all Tool Life Management counters will be reset to 0 (zero).

BAR FEED OPERATION There are no special considerations for running bar jobs. When running a bar job and using Tool Life Management, the programmer will program an M99 at the end of the part program instead of M30 to loop the part program. OPERATION Determining Maximum Groups and Group Sizes The maximum number of tool groups and maximum number of tools per group are established by parameter 6800, bits 0 and 1. Be sure that bits 0 and 1 are set to appropriate values to allow for the necessary number of tool groups and tools per group to be programmed in the Tool Life Management Program. 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 tools per group will be set to 16. VERIFYING MAXIMUM GROUPS AND GROUP SIZES 1. Press the System key. 2. Press the Parameter softkey. 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 1. Press the Offset Setting key. 2. Press the Setting softkey. 3. If necessary, use the Page keys to display the Setting page that contains the Parameter

Write field. 4. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 5. Activate Manual Data Input mode. 6. Key in the number 1. 7. Press the Input key. Parameter editing will be enabled. 8. Press the System key. 9. Press the Parameter softkey. 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. 13. Press the Input key. 14. Press the Offset Setting key. 15. Press the Setting softkey. 16. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 17. Key in the number 0. 18. Press the Input key. Parameter editing will be disabled. Determining the Measurement Unit The two types of measurement units available are “Number of Parts” and “Amount of Machining Time”. To verify which measurement unit is active, it is necessary to view parameter 6800, bit 2. To switch the type of measurement unit to be used with Tool Life Management, it is necessary to modify parameter 6800, bit 2. The bits in parameter 6800 are numbered as follows:

7 6 5 4 3 2 1 0

VERIFYING THE MEASUREMENT UNIT 1. Press the System key. 2. Press the Parameter softkey. 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 1. Press the Offset Setting key. 2. Press the Setting softkey. 3. If necessary, use the Page keys to display the Setting page that contains the Parameter

Write field. 4. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 5. Activate Manual Data Input mode. 6. Key in the number 1 (one). 7. Press the Input key. Parameter editing will be enabled. 8. Press the System key. 9. Press the Parameter softkey. 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. 13. Press the Input key. 14. Press the Offset Setting key. 15. Press the Setting softkey. 16. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 17. Key in the number 0 (zero). 18. Press the Input key. Parameter editing will be disabled. Resetting a Tool Group Counter Resetting the control or turning the control OFF will have NO EFFECT on the tool group counters. When all of the tools in a tool group have reached the tool life specified in the Tool Life Management program 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 the control 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): 1. Press the Offset Setting key. 2. Press the right-hand softkey. 3. Press the Tool Life softkey.

NOTE: Each time a cursor control key is pressed, the cursor will move to the next tool group in the corresponding direction.

4. Use the cursor control keys to move the cursor to the desired tool group. 5. Press the Operator softkey. 6. Press the Clear softkey. 7. Press the Execute softkey. The tool group counter at the cursor position will be reset

to 0. 8. Repeat steps 4 through 7 to reset additional tool group counters, as needed.

2.15 Alarm messages 1000 X AXIS NOT IN POSITION

The machine operator tried to home the Z axis before the X axis was homed or before the X axis completed the move to the Home position.

1001 TURRET SERVO ALARM

Turret drives unit failure. Check the alarm code displayed by the turret drive in the power case. Refer to the maintenance manual and identify the turret drive unit. The alarm code definitions are:

Alarm Code

Definition Alarm Code

Definition

A.10 Undervoltage A.37 Parameter Error

A.11 Board Error 1 A.46 Servo Motor Overheat

A.12 Memory Error 1 A.50 Overload 1

A.13 Clock Error A.51 Overload 2

A.15 Memory Error 2 A.52 Error Excessive

A.16 Encoder Error 1 A.8E RS-232C Communication Error

A.17 Board Error 2 8888 Watchdog

A.18 Board Error 3 A.90 Zero Point Return Incomplete Warning

A.20 Encoder Error 2 A.92 Open Battery Cable Warning

A.24 Main Circuit Error A.96 Servo Point Setting Error

A.25 Absolute Position Erase A.97 Feed Step Position Warning

A.30 Regenerative Error A.9F Battery Warning

A.31 Over Speed A.E3 Absolute Position Counter Warning

A.32 Over Current A.E6 Servo Emergency Stop

A.33 Over Voltage A.E9 Main Circuit OFF Warning

1002 TURRET FEEDBACK NOT EQUAL TO T COMMAND

The turret station in the active position is not equal to the turret station commanded.

1003 T CODE OVER RANGE The T word exceeds the maximum number of turret stations on the top plate.

1004 T REACH OVER TIME Turret index time has exceeded 4½ seconds.

1005 PART COUNTER REACHED The part count specified has been completed. Set the part counter to "0"; then,

press Reset to clear this message.

1006 TOOL MEASURE ARM OUT/HOME OVER TIME The tool probe arm remained in between the active and stowed positions for more than ten seconds. Clear any obstruction. Select Jog mode. Move the probe arm to one position or the other using the probe push button. Press Reset to clear this message.

1007 X/Z AXIS/TAILSTOCK NOT HOME The tool probe is commanded to deploy and the X axis, Z axis, or tailstock is not at the reference position. Be sure the X axis, Z axis, and tailstock are at the reference position before deploying the tool probe.

1008 HYD./COOLANT MOTOR OVERLOAD The overload on the contactor for the coolant pump motor or the hydraulic pump motor has tripped. Reset the overload to restart the motor and press Reset to clear this message.

1009 CHUCK NOT ENOUGH PRESSURE The hydraulic pressure for the chuck closer is below the minimum pressure allowed during spindle operation. The control is put in an alarm condition and the machine in Emergency Stop. Increase the chuck closer hydraulic pressure to within the recommended range and press Reset to clear the alarm. Check / replace the chuck closer pressure switch.

1010 CHUCK ACTIVE OVER TIME The chuck closer open/close has exceeded 8 seconds.

1011 TAILSTOCK BODY NO PRESSURE A low tailstock pressure condition has been detected during spindle operation. Correct the low pressure condition and resume machine operation.

1012 TAILSTOCK BODY NO PRESSURE NOT ENOUGH A low tailstock pressure condition exists and spindle operation has been attempted. Correct the low pressure condition to allow machine operation.

1013 TAILSTOCK BODY ACTIVE OVER TIME The tailstock motion has exceeded 20 seconds.

1014 TAILSTOCK M85/M86 OVER TIME The tailstock retract motion has exceeded 10 seconds.

1015 TURRET NOT CLAMPED The turret top plate is not clamped. Turret proximity switch may be faulty. The control is put in an alarm condition.

1016 PARTS CATCHER RETURN OVER TIME

Parts catcher retracts has been commanded, but not detected.

1017 BAR FEED ALARM Bar feed signals a fault. The control is put in an alarm condition. Consult the bar feed system documentation to identify the fault condition. Remedy the fault condition and press Reset to clear the alarm.

1018 BAR FEED DISABLE ALARM Bar feed signals a fault. The control is put in an alarm condition. Consult the bar feed system documentation to identify the fault condition. Remedy the fault condition and press Reset to clear the alarm.

1019 TORQUE OVER SETTING ALARM Main spindle torque exceeds the set value. Check the tooling or set value.

1021 TAILSTOCK / TAILSTOCK QUILL FORWARD POSITION END On GS 150 or 200 lathes, tailstock moving toward the spindle goes into an over-travel condition and has touched the feed limit switch. On GS 200/66 or 250 lathes, tailstock quills moving toward the spindle goes into an over-travel condition and has touched the feed limit switch.

1022 SPINDLE IN CS AXIS M40 / M41 is commanded when spindle rotation is active.

1023 SENSOR ARM SIGNAL ERROR Tool probe arm is down during spindle operation. Part catcher not retracted.

1024 TAILSTOCK BODY FOR/RET OVER TIME M82 / M83 executed, but exceed the time allowed.

1025 TAILSTOCK BODY / SENSOR ARM NOT HOME The tailstock is moving forward and the tool probe arm was not retracted. The tool probe is commanded to deploy and the tailstock is not at the home position.

1029 SPINDLE RUNNING CAN’T BREAK ON M117 is executed during spindle operation.

1030 TWICE SPINDLES CONDITION DISAGREEMENT M111 is executed during spindle operation.

1999 CALL SERVICE

Contact the Hardinge Taiwan Inc. Service Department.

2000 LUB. TIME OVER The lubricator counter register equals the lubricator preset register. The control forces Single Block mode. Apply grease lubrication according to the information provided in the maintenance manual. Press Reset and Feed Hold simultaneously to clear this message.

2001 DOOR OPEN The main guard door is open. Cycle Start is inhibited.

2002 TURRET SETTING STATION K0.6 ON Diagnostic bit K0.6 is set to “1”. K0.6 must be set to “0” to allow normal machine operation. Refer to the maintenance manual for information on setting Diagnostic bit K0.6 to "0".

2003 CHIP CONVEYOR OVERLOAD The chip conveyor overload in the power case has tripped. Determine and correct the cause of the overload. Reset the overload in the power case.

2004 TURRET UNCLAMP/CLAMP IN TEST MODE Diagnostic bit K1.6 is set to “1”. K1.6 must be set to "0" to allow normal machine operation. Refer to the maintenance manual (M-448) for information on setting Diagnostic bit K1.6 to "0".

2005 PLEASE OPEN THE DOOR The main guard door is closed when the chuck foot switch is pressed. Open the main guard door before pressing the chuck foot switch.

2006 CHUCK NOT CHUCKING Cycle Start was attempted and the chuck is not in the clamped position. The chuck must be in the clamped position to initiate Cycle Start.

2007 CHUCK OF FOOT SWITCH ALWAYS ON The main spindle is running and the chuck foot switch input is ON. Stop the spindle. Check the chuck foot switch and input point.

2008 X AXIS NO REFERENCE The X axis must be referenced before the Z axis.

2009 TOOL MEASURE I/O ERROR A tool measure input error has occurred.

2010 SPINDLE 1 OR 2 NO ZERO SPEED The main spindle must be stopped to initiate live tool motion. Live tooling must be stopped to initiate main spindle motion.

2014 MANUAL/AUTO SWITCH IS NOT ON The mode selector switch is in the wrong position. Press the Reset key and set the mode selector switch to the correct mode.

2015 SPINDLE NOT IN 1ST SPINDLE A spindle orient command (B word) is programmed during a live tooling (2nd spindle) operation. Spindle orient commands are only allowed when the main spindle (1st) spindle is active.

2016 TURRET REFERENCE X AXIS NOT REFERENCED The X axis must be referenced before the turret top plate is referenced.

2017 TURRET NOT REFERENCED The turret needs to be referenced. Press the Reset key and reference the turret top plate. Refer to the Reference Home procedure in Chapter 2 for information on referencing the turret top plate.

2018 TURRET NEEDS REFERENCE This is a power up message to remind the machine operator to reference the turret top plate. This message is only on live tooling machines.

2022 TURRET TYPE SETTING ERROR Tool setting fault

2023 TOOL LIFE END All of the tools in one or more tool groups have reached the tool life specified in the Tool Life Management program and an M30 “End of Program” has been read by the control.

2024 DUPLOMATIC ALARM NUMBER 1 Supply fault.

2025 DUPLOMATIC ALARM NUMBER 2 Over-voltage alarm.

2026 DUPLOMATIC ALARM NUMBER 3 Fault due to an over-current condition, servo error, or a thermal overload has tripped.

2027 DUPLOMATIC ALARM NUMBER 4

Turret top plate unclamp fault. Check for a switch fault, improper setting, or low hydraulic pressure.

2028 DUPLOMATIC ALARM NUMBER 5 Turret top plate unclamp fault. Check for a switch fault, improper setting, or low hydraulic pressure.

2029 DUPLOMATIC ALARM NUMBER 6 Turret zero return failure. Check for a switch fault or improper setting.

2030 DUPLOMATIC ALARM NUMBER 7 Fault due to a turret zero return failure, position code error, cycle time-out, or turret start signal time-out.

2031 CHECK TURRET LUBRICATION OIL Apply grease lubrication according to the information provided in the maintenance manual. Press Reset and Feed Hold simultaneously to clear this message.

APPENDIX ONE WORK ENVELOPE

6":182.5 6":93.5

406 Z AXIS REFERENCE POSITION

416 +Z SOFTWARE LIMIT

341

162.5

8":207.5 8":93.5

25

47

107.5

228

+X S

OFT

WA

RE

LIM

IT

218

X AX

IS R

EFE

RE

NC

E P

OS

ITIO

N

7614

2

10

10

Figure A1.1 – Work Envelope (GS/SV 150 series & 200 series equipped with VDI top plate)

NOTE: Dimensions are shown in millimeters

6":182.5

8":207.5

6":43

406 Z AXIS REFERENCE POSITION

416 +Z SOFTWARE LIMIT

341

162.5

8":43

107.5

25

5

163

+X S

OFT

WA

RE

LIM

IT

153

X A

XIS

RE

FER

EN

CE

PO

SIT

ION

142

11

10

10

Figure A1.2 – Work Envelope (GS 150 series & 200 series equipped with vertical plate)


600 Z AXIS REFERENCE POSITION610 +Z SOFTWARE LIMIT

625

8":749.5

186.5

8":4.5

8":223

No 5 Centre

120

8":34.5

216.

5 X

AXI

SR

EFE

RE

NC

E P

OSI

TIO

N

226.

5+X

SO

FTW

ARE

LIM

IT

200.

516

10

21

7

No 5 Centre

10

10":43

10":741

10":-4

10"231.5

Figure A1.3 – Work Envelope (GS 200/66, SV 200/66, GS 250 & SV 250 equipped with vertical top plate)


610 +Z SOFTWARE LIMIT600 Z AXIS REFERENCE POSITION

625

8":749.58":223

8":4.5 120

No 5 Centre

179.5

8":41.5

281.

5+X

SO

FTW

ARE

LIM

IT

271.

5 X

AX

ISR

EFE

RE

NC

E P

OS

ITIO

N

178

93.5

21

No 5 Centre

10

10

10":50

10":-4

10":231.5 10":741

Figure A1.4 – Work Envelope (GS 200/66, SV 200/66, GS 250 & SV 250 equipped with VDI plate)


TAILSTOCK STROKE

QUILL

Z-STROKE

X-S

TRO

KE

NO 5 CENTER

Figure A1.5 – Work Envelope (GS 200/66 L equipped with vertical top plate)


Z-STROKE

TAILSTOCK STROKE

QUILL

X-S

TRO

KE

NO 5 CENTER

Figure A1.6 – Work Envelope (GS 200/66 L equipped with VDI plate)


Figure A1.7 – Work Envelope (GS/SV 250 L equipped with vertical top plate)


TAILSTOCKQUILL


Figure A1.8 – Work Envelope (GS/SV 250 L equipped with VDI plate)

L0137

Figure A1.9 – Work Envelope (GS/SV 200/66 L equipped with vertical top plate)


Figure A1.10 – Work Envelope (GS/SV 200/66 L equipped with VDI plate)


L0136

GS

42

wit

h 16

C c

olle

t sp

indl

eG

S 5

1 w

ith

20C

col

let

spin

dle

unit:mm

Figure A1.11 – Work Envelope

(GS 42 & 51 series equipped with Block Type Turret)

unit:mm

X ho

me

Z stroke

GS

42

wit

h 16

C c

olle

t sp

indl

eG

S 5

1 w

ith

20C

col

let

spin

dle


(GS 42 & 51 series equipped with Live Tooling Turret)

unit:mm

X ho

me

Z stroke

GS

42

wit

h 16

C c

olle

t sp

indl

eG

S 5

1 w

ith

20C

col

let

spin

dle


(GS 42 & 51 series equipped with Servo VDI Turret)

operating manual fanuc 0i-tc gs 42 gs 51 gs 150 gs 200 … 000950004 e... · 2.15 alarm message 108...

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