FRYER MACHINE SYSTEMS MC P MECHANICAL MANUAL

Transcription

1 FRYER MACHINE SYSTEMS MC P MECHANICAL MANUAL FRYER MACHINE SYSTEMS, INC. 70 JON BARRETT ROAD ROBIN HILL CORPORATE PARK PATTERSON, NY PHONE: FAX: maintenance MC P series.doc 1 OF 19

2 MECHANICAL DRAWINGS...3 HEAD ASSEMBLY...4 CAROUSEL TOOL CHANGER...5 ARM TOOL CHANGER...6 Z AXIS COLUMN...8 X AXIS TABLE...9 BASE...10 MC SHEET METAL...11 RETENTION STUD...12 Leveling Procedure For VB or MC Machines...13 High Pressure Coolant System...16 maintenance MC P series.doc 2 OF 19

3 maintenance MC P series.doc 3 OF 19 MECHANICAL DRAWINGS

4 maintenance MC P series.doc 4 OF 19 HEAD ASSEMBLY

5 maintenance MC P series.doc 5 OF 19 CAROUSEL TOOL CHANGER

6 ARM TOOL CHANGER NOTE 1 OIL CUP NOTE 2 SOLENOID VALVE NOTE 1: OIL CUP SHOULD BE CHECKED MONTHLY FILL AS NEEDED WITH HYDRAULIC OIL FILL CUP HALF WAY NOTE 2: SOLENOID VALVE FUNCTIONS 1.POT UP 2.POT DOWN 3.ARM ORIGIN 4.ARM 60 5.ARM UP & DOWN maintenance MC P series.doc 6 OF 19

7 ARM TOOL CHANGER NO PART NO. DESCRIPTION SPECIFICATIONS QTY 1 Arm Assembly 1 2 Pot 24 3 Carousel Motor 220 VAC 200W 1 4 Soleniod 6 5 Limit Switch 1 6 Proximity Sensor 2 7 Air cylinder Arm up & down 1 8 Air cylinder Pot up & down 1 9 Proximity Switch on pot up/down cylinder 2 10 Air cylinder 60 deg.cylinder ass Air cylinder 180 deg. cylinder ass. 1 maintenance MC P series.doc 7 OF 19

8 Z AXIS COLUMN maintenance MC P series.doc 8 OF 19

9 X AXIS TABLE maintenance MC P series.doc 9 OF 19

10 maintenance MC P series.doc 10 OF 19 BASE

11 maintenance MC P series.doc 11 OF 19 MC SHEET METAL

12 FRYER PART NUMBERS CAT 40 TOL-5450 BT 40 TOL-5456 CAT 50 TOL-5454 NOTE: IF THRU COOLANT IS NEEDED, PLEASE CALL FOR PROPER PART NUMBER RETENTION STUD maintenance MC P series.doc 12 OF 19

13 Leveling Procedure For VB or MC Machines When leveling a machine with more than 6 leveling pads, care must be taken to not twist the base of the machine. This procedure will review the proper steps to level successfully. Tools required per foot level, & 32 mm (1.25) wrench Estimated time VB 1 to 2 hrs, MC 2 to 3 hrs Step 1 With the table centered, level the machine s four outside pads. Be sure that the center pads are not touching, and all four outside pads have load. Also check to make sure that the machine s casting is not touching the floor. Place level in center of table Adjust four pads Step 2 Bring four inside pads down till they are just touching. maintenance MC P series.doc 13 OF 19

14 Step 3 Move table to the front of the travel, and level the four front pads. The majority of adjustment should be on the two middle pads. Once level is achieved, verify all four pads have load. Two center pads Step 4 Now move the table to the rear and adjust the final two leveling pads. Once level is achieved, verify all eight pads have load Final pads maintenance MC P series.doc 14 OF 19

15 Step 5 Now that the machine should be level, jog the Y-axis back and forth to verify that level is consistent. If it is still out, slowly adjust pads to achieve level thru the travel of the machine. Jog machine Step 6 The final check to be performed is traming of the head. Over a 12 diameter circle you must be within.0005 total indicator reading TABLE SWEEP OVER 12 DIAMETER IN X-Y AXIS maintenance MC P series.doc 15 OF 19

16 High Pressure Coolant System Component description and service procedures Low pressure tank - this component holds the coolant filter and supplies the hi pressure pump. Input feed from the coolant tank. Transfer pump supplies coolant to the low pressure tank, as well as the standard flood coolant system. This pump is not self-priming. Only prime if coolant tank is full High pressure pump supplies the high pressure thru spindle coolant only when turned on separate from flood coolant. MC max pressure 1000psi VB max pressure 300psi maintenance MC P series.doc 16 OF 19

17 High pressure pump adjuster this is preset from the factory, and do not recommend changing High pressure gauge will only display reading if there is sufficient backpressure. Tank pressure gauge will display 30 to 35psi with a new filter installed. You must replace the filter if pressure exceeds 50psi. Tank pressure relief valve use to bleed excess air out of the tank after replacing the coolant filter. maintenance MC P series.doc 17 OF 19

18 Do not open if drivers are powered on. Machine must be in E-stop. Filter replacement should be performed if the tank pressure gauge exceeds 50psi. You may also experience a high-pressure coolant fault on the cnc control. If this fault occurs check the pressure first. Filter replacement procedure 1. Place machine in e-stop 2. Open ball valve to insure the tank has no pressure. 3. Open top lid of the tank and remove the filter. 4. Discard filter (filter is not reusable) 5. Insert new filter and use installation tool to push the filter down until you feel it snap into place. 6. Close the tank lid and ball valve 7. Now turn on the drives and coolant option 8. You will need to bleed the tank with the ball valve while the high pressure thru spindle coolant is running 9. Now you should be able to continue machine operation. maintenance MC P series.doc 18 OF 19

19 Fill point for pump oil - Replace hydraulic oil once a year. If you are using the machine more than a typical 40 hr work week, change oil more frequently. Drain plug for pump oil maintenance MC P series.doc 19 OF 19

20 FRYER MACHINE SYSTEMS ELECTRICAL & PROCEDURES MANUAL ANILAM 6000i CONTROL FRYER MACHINE SYSTEMS, INC. 70 JON BARRETT ROAD ROBIN HILL CORPORATE PARK PATTERSON, NY PHONE: FAX: Electrical Manual Anilam 6000i.doc Page 1 of 25

21 Maintenance Manual Electrical and Procedure Section for Anilam 6000i control Table of Contents Safety Rules.Page 3 Startup Procedure.Page 4 Startup Report..Page 6 Electrical Panel Layout Page 8 External Transformer wiring Page 9 Pneumatic Arm ATC adjustment and repair Page 11 Carousel ATC details Page 16 Coolant system connections.page 21 Anilam 6000i M codes.page 22 Maintenance schedule...page 23 Renishaw tool probe installation..page 24 Optional Spindle chiller details Page 25 Electrical Schematics Page 26 Electrical Manual Anilam 6000i.doc Page 2 of 25

22 SAFETY RULES READ BEFORE OPERATING MACHINE 1. PREVENT LOOSE CLOTHING, HAIR, JEWELRY FROM CONTACTING SPINDLE 2. NEVER: CHANGE TOOLS, HANDLE SPINDLE, CHANGE PARTS OR PERFORM WORK ON MILL UNLESS CNC IS IN EMERGENCY STOP OR TOOL CHANGE MODES 3. ALWAYS WEAR EYE PROTECTION WHEN OPERATING MILL. 4. DO NOT OPERATE MILL WITHOUT AXIS MOTOR COVERS OR AXIS WAY COVERS IN PLACE. 5. DO NOT PLACE OBJECTS OR HANDS BETWEEN COLUMN AND TABLE/SADDLE ASSY, UNLESS CNC IS IN EMERGENCY STOP POSITION. 6. DO NOT MODIFY EQUIPMENT WITHOUT APPROVAL FROM FRYER MACHINE SYSTEMS. DOING SO MAY VOID YOUR WARRANTY. 7. ELECTRICAL ENCLOSURES CONTAIN HIGH VOLTAGE. DISCONNECT EQUIPMENT FROM POWER SOURCE BEFORE OPENING CABINETS. 8. CHECK LUBRICANT FILL LEVELS BEFORE OPERATING. 9. DO NOT OPERATE POWER DRAWBAR UNIT WHILE SPINDLE IS IN MOTION. 10. EMERGENCY STOP MILL WHEN NOT IN USE 11. KEEP VISES, CLAMPS, FIXTURE OR WORKPIECE FROM EXTENDING BEYOND BACK EDGE OF TABLE. 12. TURN OFF POWER IF: POWER PROBLEMS DEVELOP IN THE EVENT OF ELECTRICAL STORMS. AMBIENT TEMPERATURES EXCEED 105 DEGREES FARENHEIT. Electrical Manual Anilam 6000i.doc Page 3 of 25

23 STARTUP PROCEDURE FOR FRYER VB/MC SERIES MILLS WITH ANILAM 6000i CONTROLLERS Unpack Machine: 1. Remove plastic wrap. Carefully inspect for any damage. 2. Install leveling pads and level machine. (This is usually the responsibility of the rigger or customer) Assistance will be necessary to perform the following steps: 3. Using a socket or suitable wrench (Pliers are not recommended) turn the Z ballscrew clockwise from the top of the screw enough to remove wooden shipping block on table. Be careful not to let the ratchet/wrench slip backwards. 4. Turn the ratchet/wrench counter clockwise until counterweight chains are taut, and counterweight bar is free 5. Remove counterweight bar. At this time you must remove the ratchet/wrench otherwise serious damage could occur. 6. Install the Z-Axis motor and drive belt, and any other items that may have been removed for shipping purposes. Make sure to align marks on direct drive coupling if equipped. Do not tighten motor locking bolts until motor is floated into center. 7. Check that front panel with swivel arm is clear of Z-Axis head motion. (If equipped) 8. Optional ATC: Remove the carousel support bolted to the table. Remove the locking orange bracket to prevent the carousel to slide back and fourth(mounted on rear of atc next to large air cylinder). Line voltage check: 1. Verify 230/460 vac. (+/- 10%) is wired to the main disconnect correctly. (460vac. Optional). The factory configuration is stamped on the serial number plack. The transformer equipped with all 6000i controls has multiple taps, that should be configured for 400VAC at the control amplifier input. See documentation included with this manual. 2. Check all wire connections, relays, contacts, and plugs to be sure nothing has come loose. If so, reseat or tighten before turning on main power. All voltage checks should be recorded on the STARTUP REPORT form. Machine power-up procedure: 1. Turn the 230/460VAC disconnect switch rod on the electrical cabinet with a pair of pliers a ¼ turn clockwise. 2. Boot-up the control. 3. Release the E-stop switch and press SERVO RESET to engage servo drives. Electrical Manual Anilam 6000i.doc Page 4 of 25

24 Voltage checks (All voltages +/- 10%): 1. Check for 110vac: terminal strip #1 AC hot #2 AC neutral 2. Check for 220 vac 3 phase: terminal strip #13- #14- #15 3. Check for 400 vac 3 phase: terminal strip #L1-#L2-#L3 4. Check for +24vdc: terminal strip #12=24 vdc #20=com Additional Checks: 1. Make sure way surfaces are receiving sufficient oil from pump. 2. Make sure air pressure to regulator-lubricator unit is set at 90 psi minimum. 3. Check the tool change height and orient position. 4. Check for proper phasing on all three phase motors. Especially arm style ATC carousel motor, flood pump, wash-down pump, chip auger, and spindle motor fan. All information should be recorded on a Fryer Machine Startup Form with any unusual conditions listed and returned to Fryer Machine Service Dept. If any problems are encountered or if you have any questions, please contact FRYER MACHINE SYSTEMS Service Department at (845) Electrical Manual Anilam 6000i.doc Page 5 of 25

25 70 Jon Barrett Road Robin Hill Corporate Park Patterson, N.Y Phone: (845) Fax: (845) STARTUP REPORT - ANILAM 6000i Control CUSTOMER DATE: MODEL #: SERIAL #: CONTROL SN#: DISTRIBUTOR: SERVICE TECH: SHOP CONTACT: TITLE: ATTENTION: ITEMS CAN BECOME LOOSE DURING SHIPPING CAUSING A LOSS OF CONNECTIONS. THIS MAY RESULT IN IMPROPER MACHINE FUNCTION AND/OR DAMAGE TO THE MACHINE OR COMPONENTS. BEFORE INITIAL POWER-UP: TIGHTEN ALL SCREWS AND ELECTRICAL CONNECTIONS IN THE ELECTRICAL CABINET. CHECK TO ENSURE THAT ALL ELECTRICAL COMPONENTS ARE PROPERLY SEATED AND SECURED. ELECTRICAL CONNECTIONS AND COMPONENTS CHECKED: ELECTRIAL CABINET 220/440vac: (MAIN DISCONNECT SWITCH) 110vac: (tb#1- tb#2) 400vac: (tb#l1-tb#l2-tb#l3) 24vdc: (tb#12-tb#20) AIR PRESSURE: WAYLUBE PRESENT AT X, Y & Z BOX WAY SURFACES. HOUR METER READING COUPLING ORIENTATION AND AXIS TRAVEL CHECKED INITIAL START-UP QUALITY SURVEY At Fryer Machine Systems, we strive to continuously improve the quality of our products and services. As a qualified machine tool technician, your feedback is an essential part of this ongoing process. Please take a moment to fill out the following information. It will be greatly appreciated. Please circle the appropriate response (1=worst, 5=best) for each question. Feel free to add any comments. Electrical Manual Anilam 6000i.doc Page 6 of 25

26 MISSING PARTS Were there any parts missing?...yes No If yes, what was missing? INITIAL IMPRESSIONS Was machine received in satisfactory condition?...yes No If no, what was lacking? Please rate the overall appearance of the machine: Comments: PERFORMANCE Please rate the mechanical systems of the machine: Please rate the electrical systems of the machine: Comments: SERVICE Were there any problems with the machine during start-up?...yes No If yes, please list: What issues, if any, are still outstanding? Was our Service Dept. helpful during the start-up? Please rate us: ADDITIONAL COMMENTS: Electrical Manual Anilam 6000i.doc Page 7 of 25

27 PANEL LAYOUT Electrical Manual Anilam 6000i.doc Page 8 of 25

28 Fryer Mill with Anilam 6000 and 20KVA Transformer Setup The Anilam 6000 control requires special secondary voltage of 400 vac. This requires a special transformer to be installed on all mills equipped with this control. The 20KVA transformer is used on all mills except ones with the 30 Horsepower spindle option. The transformer is pre-wired at the factory for the primary voltage specified at time of order and the machine serial number tag. Main input power must ONLY be connected to the line side (TOP) of the disconnect switch located inside the electrical cabinet. NEVER connect main power directly to the Transformer. Following is an explanation of how to configure the transformer (all wiring changes are done inside the transformer) for the two most common incoming primary voltage ranges. Refer to the specifications on the front cover of the transformer for other possible inputs ( V). For VAC input (Voltage must be within this range or warranty will be void.), connect the internal tap wires from H1-H2-H3 to each corresponding tap (4=250, 5=230, 6=210) respectively (one wire per phase). The 3-12 AWG black wires labeled as should be connected to H1, H2, H3 respectively alongside with the input AC wires ONLY when volt primary is used. For VAC input (Voltage must be within this range or warranty will be void), connect the internal tap wires from H1-H2-H3 to each corresponding tap (1=483, 2=460, 3=437) respectively (one wire per phase). The 3-12 AWG black wires labeled as should be connected to X1-13, X2-14, X3-15 Electrical Manual Anilam 6000i.doc Page 9 of 25

29 Fryer Mill with Anilam 6000i Controls and 25KVA Transformer Setup The Anilam 6000 control requires special voltage of 400 volts AC. This requires a special transformer to be installed on all mills equipped with this control. The 25 KVA transformer is only used on mills equipped with the 30 HP spindle motor. The transformer is pre-wired at the factory for the primary voltage specified on the order and the machine serial number tag. Main input power is ALWAYS connected to the line side of the disconnect switch located inside the electrical cabinet. NEVER connect main power directly to Transformer wires. Following is an explanation of how to configure the transformer ( all wiring changes are done inside the transformer) for the two possible incoming voltage ranges. For VAC input (Voltage must be within this range or warranty will be void.), connect the wires with white insulation from H1-H2-H3 to corresponding taps #2 on the transformer phase columns. The 12 AWG black wires labeled as should be connected to H1, H2, H3 respectively along with the input AC wires. For VAC input (Voltage must be within this range or warranty will be void), connect the wires with white insulation from H1-H2-H3 to corresponding taps #1 on the transformer phase columns. The 12 AWG black wires labeled as should be connected to Y1, Y2, Y3 respect.. Electrical Manual Anilam 6000i.doc Page 10 of 25

30 ATC Pneumatic Arm Operation and Repair with Anilam 6000i control ATC Operation Guidelines Due to the complexity and timing of the ATC, it should only be operated with the M6 command. Never interrupt the tool changer in the middle of cycle, wait for it to complete the tool change. If a low air alarm sets and the tool gets stuck in the spindle, then go to the recovery section on page 3 of this document. This is a random access tool changer to reduce tool change time. The machine will always keep track of the correct tool even though it may not agree with the bin #. You can have the carousel move to the next tool requested with a T# command on a line by itself. When a tool change is specified (M6) this tool # will be loaded into the spindle. If the t code is programmed on the same line as the M6 command make sure the M6 is before the T code (example: M6T4). Most tools have a deeper notch on one side of the tools v-flange. The ATC carousel will only allow this deeper notch to fit into the carousel key. Make sure when installing tools in spindle this orientation is verified. After spindle orientation the key slot on the v-flange of the tool furthest from the operator will align with the key on the carousel. The carousel motor is a 3 phase motor and must be phased correctly for proper direction. M58 will increase carousel position to next higher tool number. The machine is phased properly at the factory before shipment, so if carousel rotates wrong direction switch any two incoming power wires at disconnect. Make sure main power breaker is off! Manual operation of tool change solenoid valves If the tool changer gets hung up the solenoid valves can be operated manually to reset the tool changer. Here is a description of the operation of the valves. Access the air solenoid valves for the tool changer behind the door on the front of the ATC. There is a diagram of the operation of each solenoid. These can be run manually by depressing the blue manual override buttons. Make sure you push the buttons in sequence otherwise damage could be done to the ATC. There are three two way solenoid valves mounted horizontally. The top solenoid valve controls the carousel tool pot; left button returns tool pot to up position, right button drops pot down. The middle solenoid controls the arm movement 60 under the spindle and to normal rest position. The right button moves the arm under the spindle nose to grab a tool, left button moves the arm back to its normal clearance position. The bottom solenoid controls the arm down and 180 and arm up. The right button moves the arm down and then 180, the left button returns the arm up. The proper sequence of a tool change and the respective M-codes is as follows: (Note that you will have to press the cycle start button twice to execute these commands) 1. T-code to move carousel to pending tool 2. M52 tool pot down 3. M68 moves z axis to tool change position 4. M60 spindle orient 5. M62 Arm moves under spindle to grab tool and carousel pot 6. M54 turns drawbar on 7. M64 Arm removes tool from spindle and carousel tool pot and swaps them 8. M65 arm up to install pending tool in spindle and old tool into carousel pot. 9. M55 Drawbar off to grab tool in spindle. 10. M63 Arm origin 11. M53 carousel tool pot up Electrical Manual Anilam 6000i.doc Page 11 of 25

31 Tool Change Height Adjustment The proper tool change height must be set for the ATC to perform correctly. The tool change height (machine coordinates from home position) is stored in parameter NP_DG_TC_pos_Z_put_in. This will have to be checked if the home position is different due to removing the z motor or home switch or dog. Here is a procedure to set this height correctly: There is some allowance ( play ) allowed for the tool change height (about.03 ) This is the difference between the v flange groove of the tool and the v location of the arm. You will see this vertical play if you install a tool into the arm when the machine is in e-stop. Make sure you do not leave the tool there! 1. Home the machine. 2. Move the z-axis to the tool change height with an M68 command in manual mode. The number is derived from the distance from home position (machine zero) to the proper height for tool change. To get to this parameter from manual mode: -Press shift -(F3) config -Password= 222 (may not be necessary if you already typed in the password) -(F6) config data -Now you will have to follow the directory tree by opening up each folder and edvancing into the proper subfolders. The path is a follows: System-PLC-cfgoemposition The parameter for tool change height is: NP_DG_TC_pos_z_put_in. That number is in MM (millimeters) and is a negative value. Change display to read in MM to get a direct read out in the Machine Coordinates box in Z =(ex MM) 3. Orient the spindle with an M60 command. 4. Install a tool in the spindle. 5. Press the middle right solenoid manual button to grab the tool, see the description of manual solenoid operation. 6. Look to see if the position of the z axis will cause the v flange groove of the tool is in the center of the arm v notch. Return the arm manually back out of way with the middle left button on the solenoid valve. Adjust the tool change height parameter outlined in step 2 and repeat until correct alignment is achieved. 7. At this time you can alternate the middle left and middle right button to check for smooth engagement of the arm into and away from the tool. If the arm doesn t respond smoothly then further z axis height adjustment may be required. Spindle Orient Adjustment 1. With z axis at maximum positive limit and ATC arm under spindle nose (manual solenoid button 2 nd on right). Make sure spindle can be spun without spindle keys hitting ATC arm. 2. Orient spindle with M60 3. Look to see if spindle keys are in alignment with notch in the arm. 4. In manual follow the steps below to get to the orient postion parameter: -Press shift -Password=222 (may not be necessary if you already typed in the password) -(F6) config data -Now you will have to follow the directory tree by opening up each folder and edvancing into the proper subfolders. The path is a follows: System-PLC-cfgoemposition The parameter for spindle orient position is: NP_DG_TC_pos_spindle 5. Command M5 cycle start. This will turn off the orient command. 6. Repeat steps 2 and 5 and adjust parameter until correct. Recovering From Tool Change Failure If the tool changer fails you may get an alarm timeout in spindle sequence, this means that after 30 seconds of waiting a function did not get it s proper finish signal. You must look to see what function did not complete. It most likely had to do with movement of the arm. Look at the solenoid valves, the solenoid valve that is illuminated is the operation that failed. Press emergency stop. If the arm did not complete grabbing the tool, make sure the pot is down and then press the arm return manual button. Refer to manual operation of tool changer pneumatic solenoid valves. After the arm is returned to normal resting position, tool is removed from the spindle and carousel pot returned manually, the carousel pots may have to be reset. If the carousel does not rotate check the fuses in the electrical cabinet. Refer to electrical schematics in maintenance manual. Electrical Manual Anilam 6000i.doc Page 12 of 25

32 Tool Carousel Reset To reset all the tool bin locations follow this procedure. 1. Remove tool from spindle 2. In MDI command : M6T0 cycle start 3. Remove any tool from spindle 4. In MDI command : M61 cycle start ( this will index carousel to bin #1 ) 5. Go to tool table, soft key F9, and then press soft key F4 BIN. The bin numbers on the left hand side will be 0-#pots in carousel, set the tool number to the same as the bin number leaving bin 0 blank. 6. Remove all tools from carousel and reinstall. Arm Alignment If the arm no longer moves in the proper angular alignment then an adjustment may be required. The arm is held in place on the arm shaft with a compression clamp. 1. Install tool in spindle 2. Orient spindle M60 3. Install tool in carousel pot 4. Drop carousel pot down with manual button(top right) 5. Move z axis to tool change height M68 6. Move arm to grab tools with manual button.(middle right) 7. Loosen socket head cap screws at bottom center of arm and align arm to grab tools fully. Once completed adjustment tighten screws. 8. Move arm back to origin location with manual button (middle left) 9. Remove tools 10. Reset carousel pot back up with manual button. (top left) 11. Turn off orient with M5 command Electrical Manual Anilam 6000i.doc Page 13 of 25

33 Arm Up/Down Ram 6 control solenoids (6) (1) (5) (2) (4) (3) Home and In Position at spindle indicators. Figure 1: Pneumatic ATC unit with covers off (front view). Tool Pot up/down ram w/ position sensors mounted on it. Electrical Manual Anilam 6000i.doc Page 14 of 25

34 6 control solenoids (6) (1) (5) (2) (4) (3) Note the blue button on each for manual activation. Home and In Position at spindle indicators. Oiler cup with oil at proper level for operation. Oil should always be visible In the glass bowl with a minimum level at the disk in the lower portion of the bowl. Figure 2: Pneumatic ATC unit with covers off. A typical recovery sequence for an out of position ATC arm is as follows: Be sure that Z-axis is up at home position (if possible) and all tool holders are removed from arm and spindle first. Push the blue buttons on the solenoid controls shown in Figure 1 and 2 above in the following order. 1. Push blue button on #3 2. Push blue button on #2 3. Push blue button on #4 4. Push blue button on #5 5. Push blue button on #6 Electrical Manual Anilam 6000i.doc Page 15 of 25

35 CAROUSEL TOOL CHANGER Electrical Manual Anilam 6000i.doc Page 16 of 25

36 SERIES SPECIFICATIONS Carousel Tool Changer Maintenance Electrical Manual Anilam 6000i.doc Page 17 of 25

37 Electrical Manual Anilam 6000i.doc Page 18 of 25

38 Electrical Manual Anilam 6000i.doc Page 19 of 25

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40 COOLANT SYSTEM HOOK-UP PROCEDURE THE COOLANT PUMP HAS 2 PORTS LOCATED ON EITHER SIDE OF THE PUMP. THE (IN) PORTS WHICH ARE A ¾ SIZE MUST BE HOOKED UP TO THE COOLANT PAN OUT PORTS. THESE ARE LOCATED ON THE LOWER REAR CORNERS OF THE MACHINE. SECURE THE HOSE USING HOSE CLAMPS, THE (OUT) SIDE OF THE PUMP HAS 3 PORTS, ONE IS A ½ HOSE AND TWO ARE A ¾ HOSE. THE ½ HOSE GETS HOOKED UP TO THE COOLANT FEED LINE AND THE ¾ HOSE GETS HOOKED UP TO THE WASHDOWN PORTS LOCATED ON BOTH SIDES OF THE MACHINE. THE WASH DOWN PORT IS EQUIPPED WITH A BALL VALVE ENABELING THE OPERATOR TO SHUT DOWN THE WASHDOWN COMPLETELY OR JUST ONE SIDE SECURE ALL LINES USING HOSE CLAMPS. Electrical Manual Anilam 6000i.doc Page 21 of 25

41 ANILAM 6000i M Codes This document is information pertaining to operation and maintenance of all Fryer machining centers and vertical bed machines with Anilam 6000i controls. LIST OF M-CODES *M00 PROGRAM STOP *M01 OPTIONAL PROGRAM STOP *M02 END OF PROGRAM *M03 SPINDLE CLOCKWISE *M04 SPINDLE COUNTERCLOCKWISE *M05 SPINDLE STOP *M06 TOOL CHANGE REQUESTED *M07 MIST COOLANT OUTPUT(SPINDLE MAY HAVE TO BE ON) / OPTIONAL AIR BLAST *M08 FLOOD COOLANT (SPINDLE MAY HAVE TO BE ON) *M09 COOLANT (FLOOD AND MIST) OFF *M10 INDEXER CYCLE START WAIT FOR COMPLETION *M11 MISC. MCODE M11=ON *M12 MISC. MCODE M12=OFF *M13 U AXIS BRAKE ON *M14 U AXIS BRAKE OFF *M15 W AXIS BRAKE ON *M16 W AXIS BRAKE OFF *M17 HIGH PRESSURE THRU SPINDLE COOLANT ON *M18 HIGH PRESSURE THRU SPINDLE COOLANT OFF *M19 SPINDLE POSITION AND LOCK *M20 CHIP AUGER ON (CHIP WASHDOWN. PRIME PUMP FIRST) *M21 CHIP AUGER REVERSE *M22 CHIP AUGER OFF *M40 SHIFT GEARBOX INTO LOW RANGE *M41 SHIFT GEARBOX INTO HIGH RANGE *M50 DISABLE SPINDLE DRIVE FOR INDICATING PURPOSES *M51 ENABLE SPINDLE DRIVE FOR OPERATION *M52 ATC CAROUSEL IN (ARM ATC POT DOWN) *M53 ATC CAROUSEL OUT (ARM ATC POT UP) *M54 DRAWBAR ON *M55 DRAWBAR OFF *M58 ATC CAROUSEL CW 1 POSITION *M59 ATC CAROUSEL CCW 1 POSITION *M60 SPINDLE ORIENT FOR TOOL CHANGE *M61 HOME ATC CAROUSEL TO POCKET 1, ASUMES TOOL 0 IN SPINDLE *M62 ARM ATC GRAB TOOL(ON ELECTRIC ATC ALSO SWAPS TOOLS AND GOES UP) *M63 ARM ATC ARM ORIGIN *M64 PNEUMATIC ARM ATC ARM DOWN AND SWAP TOOLS *M65 PNEUMATIC ARM ATC ARM UP Electrical Manual Anilam 6000i.doc Page 22 of 25

42 MAINTENANCE SCHEDULE fill lube pump 1 fill drawbar lube 2 check coolant level change coolant 3 check machine level check gibs check backlash check belt tension check servo cabinet and console fans, clean filters daily weekly monthly 3 months 6 months yearly as req d. replace servo cabinet and console filters 4 X X X X X X X X X X 1 -Mobil Vactra #2 (ISO 68) or equivalent 2 -Break-Free Synthetic Air Tool Oil (5W) or equivalent 3 -Valenite Turn Tech Blue Metalworking Fluid or equivalent 4 -See Anilam Manual Electrical Manual Anilam 6000i.doc Page 23 of 25

43 Renishaw Tool Probe Installation This will assist you in setting up and installing your Renishaw TS-27R tool probe on your Fryer milling machine with Anilam control. Make sure you read the instruction manual that came with the Renishaw probe and the Anilam manual pertaining to probing cycles. The probe has been pre-wired and tested on the Fryer machine at the factory. The manuals also can be downloaded in PDF format from either Renishaw.com or Anilam.com Installation should be completed at the customer s facility. Follow these basic instructions referring to the manufacturers manuals for further details: 1. Find a suitable mounting location for the probe ( most common is the far right hand corner of the table ) The probe should be mounted with the stylus pointing up and towards the left, this will exit the cable to the right. The Stylus should be approximately ½ the largest tool diameter used from the positive limit in x axis and at the rearmost t-slot(as long as it is a couple inches from the y limit). A t-nut can be used to mount the probe base with a ½-13 socket head cap screw. Make sure the cable will not interfere with anything during machine operation. 2. Once the probe is securely mounted tram the probe within.0002 perpendicular and parallel to the machine slides. See Renishaw installation manual for further details. 3. Follow the Anilam instructions to set the parameters according to your installation. 4. Now you will need a tool with a known diameter to preset the tool presetter. You should use the Anilam G150 or tool probe calibration cycle. See the Anilam manual for further details. 5. Once the G150 cycle is accomplished a G53 fixture offset should be activated and set to the top of the part so that all other tool to be set with the G151 cycle will be referenced to the top of the part. Electrical Manual Anilam 6000i.doc Page 24 of 25

44 Fryer Optional Chiller Instructions Used on all optional high speed spindles and automatic gearbox INSTALLATION: The chiller has been wired and tested at the factory. The reservoir is filled with ISO#32 spindle oil. At installation check the level at the tank sight glass and top off as necessary. The ambient temperature to run the chiller must be between Fahrenheit (5-40 Celsius). The working range of the chiller is between Fahrenheit (25-35 Celsius). The factory preset is to run at 77 F. This is the optimal setting for most applications. The chiller must be located in a clean dry area with good ventilation and level. WIRING: The chiller is pre-wired at the factory. Incoming 3 phase power is applied at terminals R-S-T. Ground is connected to E. Terminals 93 and 95 are fault contacts going back to the CNC control. Terminals 224 and 225 are the remote start inputs. Do not turn the chiller off or on with the on switch on the chiller operator panel. This will bypass the remote on from the CNC and cause an alarm on the CNC. ADJUSTMENT: The display on the chiller normally shows the oil temperature. To adjust the preset temperature when the refrigeration will cycle on press the left arrow button. The display will now show the preset value. This should be set at 25 Celsius (77 Fahrenheit). Use the right and left arrow keys to adjust. Wait for 5 seconds and the display should revert back to displaying the liquid temperature. TROUBLESHOOTING: 1. Alarm on CNC control Spindle chiller alarm : Look at the chiller for any alarms. If the display is blank press the ON button on the chiller. If there still is no display check the fuses in the CNC electrical cabinet (normally fuses D1- D2_D3). 2. If there is an alarm displayed on the chiller,here is a brief listing: AL-1 REV: Phase failure or out of phase, The is not three phase present or line is out of phase. Switch any two lines at the terminal strip in the chiller R-S or T. Check the fuses in the CNC cabinet. AL-2 PUMP: The pump motor is not functioning properly. -Check that there is no obstruction in lines -Reverse red and white wire of thermal relay 51P in chiller -Replace pump -Add recirculating oil to the reservoir -Adjsut the oil pressure switch to.3kgf/cm2 under.5-.8cmhg -Reset the thermal overload AL-3 COMP: The compressor motor is not functioning properly. -Reset the thermal overload -Replace the compressor AL-4 RA: Temperature probe of the room is not functioning properly -Replace the RA room temperature probe AL-5 RO: Temperature probe of oil is abnormal -Replace the RO liquid temperature sensor AL-6 OT: The cooling oil is overheating -Shut down the coller and wait until the temperature drops to acceptable levels. -Recharge Freon. -Check level of oil MAINTENANCE: -Clean the filter net periodically as required. -Replace oil as required and make sure there is no blockage in the lines. Electrical Manual Anilam 6000i.doc Page 25 of 25

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