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ACE CNC LATHE

INSTRUCTION MANUAL

MACHINE : ACE CNC LATHE

MODEL : LT-20 CLASSIC MC

CONTROL SYSTEM : FANUC Oi-TC

IMPORTANT

Before operating the ACE CNC LATHE LT-20 CLASSIC MC this instruction

manual should be read carefully.

This instruction manual should be kept in a safe place where it is always easily

accessible during operation of ACE CNC LATHE.

While this manual has been compiled to give the general description and usage

of the machine, there may be changes owing to continuous design and develop-

ment. Also some options that have been custom built for your company may not

be included in this manual. Such options will be separately given as a supplement.

Suggestions for improvement are always welcome.

96-104 MC / IM-03 June ’06

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ACE CNC LATHE

INSTRUCTION MANUAL

MACHINE : ACE CNC LATHE

MODEL : LT-20 CLASSIC MC

CONTROL SYSTEM : FANUC Oi-TC

IMPORTANT

Before operating the ACE CNC LATHE LT-20 CLASSIC MC this instruction

manual should be read carefully.

This instruction manual should be kept in a safe place where it is always easily

accessible during operation of ACE CNC LATHE.

While this manual has been compiled to give the general description and usage

of the machine, there may be changes owing to continuous design and develop-

ment. Also some options that have been custom built for your company may not

be included in this manual. Such options will be separately given as a supplement.

Suggestions for improvement are always welcome.

96-104 MC / IM-03 June ’06

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Contents Page No.

INTRODUCTION1. Preface 1.1

2. Notes on safety 1.1

3. Basic points of safety 1.2

4. Clothing and personal safety 1.3

5. Safety aspects related to workpiece and tooling 1.5

6. Safety aspects related to maintenance 1.6

7. Safety aspects related to workplace 1.7

8. Safety equipment 1.7

PREPARATION

1. Preparation to be done by the customer 2.1

2. Foundation drawing for installation 2.2

3. Environmental conditions 2.3

4. Power source intake 2.4

INSTALLATION AND STARTUP

1. Lifting method using ropes 3.1

2. Installation check points 3.2

3. Grounding 3.3

4. Cautionary details concerning installation 3.3

5. Power on / power off check points 3.5

6. Manual operation check points 3.5

7. Manual / automatic operation check points 3.6

8. Automatic operation check points 3.8

9. Levelling 3.9

10. Installation and maintenance of inter-machine connection 3.10

MACHINE SPECIFICATION

1. Machine overall views 4.1

2. Machine specification 4.2

3. Power capacity chart 4.4

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Contents Page No.

4. Bed 4.5

5. Head stock 4.5

6. Spindle brake assembly 4.6

7. Spindle encoder assembly 4.7

8. Spindle speed characteristics : Alpha P22i, 50 - 3500 rpm 4.7

9. Spindle speed characteristics : Alpha P22i, 50 - 4000 rpm 4.8

10. Work holding 4.8

11. Z-axis assembly 4.9

12. X-axis assembly 4.10

13. Turret 4.10

14. Tailstock assembly 4.1115. Hydraulic system 4.13

16. Lubrication system 4.14

17. Coolant system 4.14

WORK HOLDING

1. Standard chucks and cylinders 5.1

2. Chuck installation - Standard chuck 5.1

3. Chuck installation - Hollow chuck 5.2

4. Standard chucking cylinder 5.3

5. Operation and adjustment of hydraulic chuck unit 5.4

6. Soft jaw boring 5.5

7. Spindle speed and chucking force 5.6

8. Sample drawing 5.7

9. Spindle details 5.8

APPLICATION - 12 STATION TURRET

1. Machine movable range 6.1

2. Interference diagram 6.7

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Contents Page No.

CONTROL SYSTEM

1. Fanuc Oi-TC specifications 7.1

2. G Code list 7.7

3. M Code list 7.10

4. Operator messages 7.11

MACHINE CONTROL PANEL

1. Operator control panel-1 diagram 8.1Operator control panel-1 details 8.2

Description of operator control panel-1 8.3

2. Operator control panel-2 diagram 8.7

Operator control panel-2 details 8.8

Description of operator control panel-2 8.9

MAINTENANCE

1. Daily maintenance 9.1

2. Periodic inspection 9.2

3. Lubrication 9.3

4. Head stock realignment 9.7

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1. PREFACE :

Proper operational techniques and safety procedures will be explained in detail by our

technical staff. The general principles for safe operation of Ace CNC lathe are outlined in

this manual.

All Ace lathes have been engineered for operational safety. You will note, for example, that

all rotating parts are protected by specially designed covers and shields. The entire machine

is covered to eliminate damage by metal chips and cuttings and to prevent an insecurely

clamped workpiece from being thrown out during cutting operations. If the Ace lathe is

operated in accordance with the manufacturer’s instructions, it will provide you with reliable

service. However, with machines of this nature, serious accidents may occur owing toimproper or careless operation. Do not attempt to operate this equipment without having first

read and thoroughly understood the contents of this instruction manual. Not every example

of improper operation or unauthorized usage which may lead to malfunction or an accident

can be anticipated. If a particular operation is not documented in the manual as authorized

usage of the equipment, it should be assumed that this is an unauthorized or improper usage

with potential danger and should be avoided.

2. NOTES ON SAFETY :

1. This machine is provided with various safety devices to protect the operator and the machine.

However, these cannot cover all aspects of safety, therefore the operator must thoroughly

read and understand this chapter before operating the machine. The operator should also take

into consideration other aspects of safety related to particular environmental conditions and

materials.

2. Three categories of safety guidelines have been used throughout this manual :

DANGER, WARNING and CAUTION.

Their meanings are as follows :

Failure to observe these instructions could result in loss of life.

Failure to observe these instructions could result in serious injury or substantial

damage to the machine.

Failure to observe these instructions could result in damage to the machine or

minor injuries.

1.1

DANGER :

WARNING :

CAUTION :

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3. Always observe the safety instructions inscribed on the safety nameplates fixed onto the

machine. Do not remove or damage these name plates.

4. Do not attempt to operate the machine until you have read the manuals supplied with the

machine and have understood each of the functions and operating methods.

3. BASIC POINTS OF SAFETY :

1. DANGER

There are high voltage terminals on the electrical control panel, transformer, motors, junction

boxes and other equipment.

DO NOT touch any of them under any circumstances, when the power supply is ON.Make sure that all doors and safety covers are fitted before switching on the power. If any

door or safety cover is to be removed, first switch off the main circuit breaker.

2. WARNING

Memorize the position of the EMERGENCY STOP button so that you can press it immedi-

ately from any position.

Take care not to touch any of the switches accidentally while the machine is in operation.

Take care not to catch your fingers in the chuck .Under no circumstances touch a rotating workpiece or the tool with your hands or any other

object.

To prevent incorrect operation of the machine, carefully check the position of the switches

before operation.

If in the slightest doubt about a procedure, ask the person in charge.

Always switch off the main circuit breaker before leaving the machine.

If more than one person is operating the machine, do not proceed to the next step without

indicating to the other operator(s) that you are about to do so.

Do not modify the machine in any way that will affect its safety.

1.2

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3. CAUTION

Do not subject the CNC unit, the operator panel, or the electrical control panel to strong voltage

fluctuations.

Do not change the parameter values, volume values, or other electrical setting values without

good reason. If it becomes necessary to change a value, first check that it is safe to do so,

then make a note of the original value so that it can be reset if necessary.

Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details

become illegible or if the name plate is lost, obtain a replacement from Ace and mount it in

the original position.

Do not open any doors or safety covers while the machine is in automatic operation.

Stop all machine operations before cleaning the machine or any of the peripheral equipment.

After a job has been completed, set up each part of the machine so that it is ready to be used

for the next series of operation.

4. CLOTHING AND PERSONAL SAFETY :

1. DANGER

Tie back long hair which could become entangled in drive mechanisms.

Wear safety equipment (helmet, goggles, safety shoes, etc.) whenever possible.

Always wear a helmet if there are any overhead obstacles in the work area.

Always wear a protective mask when machining magnesium alloys.

Always use safety shoes with steel toecaps and oil-resistant soles.

Never wear loose or baggy clothes.

Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of

entanglement in drive mechanisms.

Do not operate the machine while under the influence of drugs with powerful effects,

unprescribed drugs or alcohol.

Do not operate the machine if you suffer from dizziness or fainting spells.

Always use gloves when loading or unloading workpieces or tools and when removing chips

from the work area to protect your hands from sharp edges and heat generated during

machining.

1.3

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2. WARNING

Close all doors and covers of the CNC unit, operation panel, electrical control panel and

junction boxes to prevent damage from water, chips and oil.

Check all electrical cables for damage to prevent accidents due to current leakage or electric

shock.

Do not handle coolant with bare hands since it is likely to cause irritation.

Operators with allergies should take special precautions.

Do not operate the machine during violent thunderstorms.

Check the safety covers regularly to make sure that they are properly fitted and that they are

not damaged. Repair or replace any damaged covers immediately.

Always obtain assistance in handling loads beyond your capacity.

Do not operate fork lifts or cranes or carry out slinging work unless you have undergone

officially approved training.

When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of

these machines.

Always use wire rope or slings as per standards, suitable for the load to be supported.

Do not adjust the coolant nozzles while the machine is in operation.

Do not remove or otherwise interfere with safety devices such as actuating dogs, limit switches

or interlocks in order to increase axis travel.

When loading workpiece blank onto or unloading the finished product from the machine,

make sure that the tools are as far away as possible from the work area and the spindle is not

rotating.

Do not wipe the workpiece or clear away chips with your hand or with a rag while the spindle

is rotating. Always stop the machine and use a brush.

Do not operate the machine with any of the safety covers removed.Always wear gloves and use a brush to clean chips off the tool tip. Never use bare hands.

Stop the machine before mounting or removing a tool.

Check slings, chains, hoists and other lifting gear for defects before use. Repair or replace

defective gear immediately.

1.4

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3. CAUTION

Do not allow chips to accumulate during heavy-duty cutting since they will be hot and could

start a fire.

Check that the belts have the correct tension before operating the machine.

Warm up the spindle and the axis motion mechanisms before operation.

Write the program for the warming-up operation so as to execute the functions of the full

range of the machine components.

Do not operate the operation panel switches while wearing gloves as this could lead to

incorrect operation or other mistakes.

Follow the sequence for switching off, press emergency switch off the power switch on the

CNC operation panel, switch off the machine circuit breaker, then switch off the factory power

supply.

5. SAFETY ASPECTS RELATED TO WORKPIECE

AND TOOLING :

1. WARNING

Always use tools suitable for the work and which conform to the machine specifications.

Replace the worn tools immediately, since badly worn tools are a cause of accidents or

damage.

Do not operate the spindle above the rated speed of the accessories mounted on it. Before

starting the spindle, check that any parts which are clamped onto it are properly secured.

If the centre hole on larger workpieces held between centres is too small, the work piece could

come off when cutting load is applied. Make sure that the hole is big enough and that is at

the correct angle.

Take care not to catch your fingers in the chuck.

Always use the correct lifting gear for heavy chucks and workpieces.

2. CAUTION

Make sure that the tool length is such that the tool will not interfere with fixtures or other

objects. Perform a test operation after mounting the tool.

After machining soft jaws, check if they grip the workpiece correctly and that the chuck

pressure is correct. 1.5

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6.SAFETY ASPECTS RELATED TO MAINTENANCE:

1. DANGER

Always switch off the main circuit breaker before carrying out any maintenance work. This

will eliminate the possibility of the machinery being started inadvertently by someone else.

After the power has been switched off for a short while, check the voltage with a multimeter

or similar instrument to make sure that there is no residual voltage.

2. WARNING

Always switch off the main circuit breaker before replacing bulbs or other electrical equipment

and use products with the same specifications as the original.

Maintenance of electrical equipment must be carried out by qualified licensed electrical

engineers only.

Do not remove or modify overtravel limit switches, interlock limit switches, proximity

switches, or other safety devices.

When carrying out maintenance in high places, always use a suitable ladder or a service

platform and always wear a helmet.

Keep your fingers clear of belts and pulleys.

Do not start the machine until all the covers removed for maintenance have been refitted.Wipe up any water or oil spills immediately and keep the maintenance area and the workplace

clean and tidy at all times.

3. CAUTION

Maintenance work should be carried out by qualified personnel in accordance with the

instructions of the person in charge.

Keep a stock of replacement parts.

Do not use compressed air to clean the machine or to remove chips.

Always use gloves when clearing away chips; never touch chips with bare hands.

Use only the specified grades of hydraulic oil, lubricating oil and grease or their equivalents.

When changing a fuse, check that the new fuse has the correct rating. (Using a fuse with too

high a rating could result in damage to the equipment).

Check the results of the maintenance work in the presence of the person in charge.

If one of the belts in a set has stretched beyond the prescribed limit, change the entire set.

Stop all machine operation before cleaning the machine or the surrounding area.

1.6

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7. SAFETY ASPECTS RELATED TO THE WORK

PLACE:

1. WARNING

Immediately remove all water and oil spills from the floor and dry the floor to prevent

accidents.

Use strong service platforms only and make sure that nothing can slip off them. Keep

combustible materials well away from the work area or any other place where there are hot

chips.

Always provide sufficient working space and clear access to the machine and peripheral

equipment and store tools and other potential obstacles in a prescribed place away from the

machine.

Never place tools or other potentially dangerous objects on top of the headstock, turret or

covers.

Make sure that the nominal cross-sectional area of the power supply cable between the factory

power supply switch and the machine main circuit breaker is sufficient to enable a stable

supply for operation at the maximum output.

Protect all cables which will run along the floor from being damaged by chips, since this could

cause short-circuiting.

8. SAFETY EQUIPMENT :

This machine is provided with various safety devices to protect the operator and the machine.

The safety devices include interlock devices and emergency stop switches as well as doors

and covers. However it is absolutely necessary that the operator familiarises himself with the

instruction manual of the machine. It is essential that all operations be carried out in

accordance with these instructions. The manufacturer emphasises that it is the sole respon-

sibility of the operator to ensure that all operations using the Ace CNC lathe are carried out

in complete safety.

Neither the manufacturer nor his representatives or dealers can assume responsibility

for any mishaps, damage or personal injury which may occur as a result of improper

operation or from failure to observe the safety precautions mentioned in this manual.

1.7

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PREPARATION TO BE DONE BY THE CUSTOMER

PRIOR TO INSTALLATION OF THE MACHINE :

1.Environment (Machine side)

While installing the machine tool, avoid installing the machine in such places as mentioned

below.

a. Places exposed to direct sunshine, close to heat sources and where temperature fluctuation is

considerable.

b. Places where it is extremely humid.

c. Places which are very dusty.

d. Places close to sources of vibration.e. Places where the floor is not firm.

While installing the machine tool, the foundation should be firm and stable in order to maintain

the machining accuracy of the machine in the best condition. One of the recommended examples

of installation is shown on next page. However, as the foundation construction much depends

upon the condition of soil stratum supporting the floor of your shop, general counter measures for

the foundation of the machine tool should be taken.

When the floor of your shop is made of reinforced concrete having thickness of 300mm, it is

considered that the floor is firm enough to install this machine. The installing position should be

determined, considering the space around the machine so that the operator can remove the cover

for the maintenance of the machine, open and close the machine door and travel the carriage to

take out the cutting chips without contacting with other machines or bumping walls or the line.

Keep the environment around the machine clean at all times and do not install the machine where

it may be exposed to direct sunlight or heat source (heater).

FOUNDATION PROCEDURE FOR ISOLATING THE MACHINE

FROM SURROUNDING VIBRATIONS

In the case where the machine tool is installed out of necessity at a place close to vibration

sources, like hammers and presses, it is recommended to provide an isolated machine

foundation.

Please contact Ace Designers for further details.

2.1

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2. FOUNDATION DRAWING FOR INSTALLATION

2.2

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MACHINE INSTALLATION

1. Place the machine on 25 mm thick M.S. pads positioned so as to have the anchoring bolt holes

over the grouting pockets.2. Place the 150 x 150 x 20 mm plates in position and insert the anchor bolt into the pocket

through the gap of the opening of pocket beyond the plate. Assemble the jack bolt, levelling

pad and the anchor bolt.

3. Prepare the grout and pour into the pockets

4. After the specified time finish the floor around the pockets and remove the pads. (25 mm

thick M.S)

5. Level the machine

In case machine is to be installed at a place where the ground is not firm, reinforce it by piling

work to prevent the installation from settling.

3. ENVIRONMENTAL CONDITIONS (NC SIDE)

a. Ambient temperature :

During operation 00

to 450 C (32

0 to 113

0 F)

b. Humidity :Relative humidity in normal cases, 75% or below. High humidity will cause deterioration of

insulation, leading to accelerated parts deterioration. There is no particular necessity for

dehumidification. However, avoid installing NC equipment in a humid place.

c. Vibration

During operation: 0.5 G or less

During transportation: 3.5 G or less

2.3

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4. POWER SOURCE INTAKE : (in INDIA)

Total Power capacity : 27.11 KVA (For Alpha P22i Spindle motor)

Voltage : AC 415 V, +10%, -15%, 3 phaseFrequency : 50 Hz

Current : 42 A

Power cable connection : 10 mm2

POWER SOURCE INTAKE : (Export Machines)


Voltage : AC 380V, +10%, -15%, 3 phaseFrequency : 60 Hz

Current : 46 A





Current : 36 A





Current : 79 A


2.4

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1. LIFTING METHOD USING ROPES

The lifting arrangement of the machine is as shown in the figure. Remove the relevant covers

to sling the machine. Use a crane with capacity of at least 5 tons to lift the machine.

While lifting up, carefully check that the wire ropes do not touch the machine and provide

the portions where the ropes may touch with waste cloth or wooden pieces to prevent the

ropes from damaging the machine body.

NOTE : When lifting the machine, it is important to see that it is well balanced backwards

and forwards as well as to the right and left. Lift the machine a little above the floor and make

sure that it is well balanced before final lifting.

In case of lifting the machine by a group, proper co-ordination between the members of the

group has to be ensured.

3.1

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2. INSTALLATION - CHECK POINTS

INSTALLATION SITE

The CNC machine should be properly installed in a location not exposed to direct sunlight. Care

should be taken to locate the installation site such that any chips, water, oil, or vibrations from

other equipments do not affect the lathe. Failure to observe these installation precautions may

result in serious malfunction of the machine. Improper installation can cause both numerical

control (CNC) error and loss of precision in machining operations.

Proper ambient temperature : 00

- 450 C.

Proper humidity : Below 75% Relative Humidity.

POWER SOURCE

The power source to the lathe should be free from any electrical noise produced by other equipment

such as electric welders or electrical discharging machines. Voltage drops and insufficient input

current can result in improper functioning of the CNC. An independent power source should be

provided if possible.

ELECTRICAL WIRINGa. Connect the power line to the input terminals which are provided in the electrical cabinet of

the machine.

b. The power source should be AC 415V, +10%, -15%, 50 Hz, 3 phase supply.(In India)

c. Minimum gauge of the cable, from power source to the machine should be 10 mm2

. Separate

neutral and earth wires of 10 mm2

size are to be brought in.

Note : The machine should be earthed with an independent earth cable. We strongly insist

on the use of a 3Ø unbalanced voltage stabilizer at the incoming line.

3.2

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3. GROUNDING

To prevent personal injury due to any abnormal current surges which may result from electrical

malfunction in other equipments, it is absolutely essential that all Ace CNC Lathes be grounded

independent of other equipment. If welding machines, electrical discharging machines, or the

like, are grounded to the steel framework of the building at the installation site, in no case should

any Ace CNC Lathe be grounded to the same steel framework. Malfunctions in electrical

equipment grounded in common with the Ace CNC Lathe may have adverse effects on the CNC’s

performance. Grounding wires should be as short and as thick as possible (use a grounding wire

of at least 10 mm2).

4. CAUTIONARY DETAILS CONCERNING

INSTALLATION

Provide a proper maintenance area.

1. Make sure that all doors and panel coverings open and close freely without obstruction. Refer

to the appropriate installation diagram(s) in the manual provided with the Ace CNC Lathe.

2. Make sure that the installation foundation is of sufficient strength and sturdiness. Refer to

the appropriate installation foundation diagram(s) in the manual.

3. Ensure that the chip conveyor can be installed properly while accommodating the mainte-

nance space. Refer to the appropriate installation diagram in the manual.

4. All rust protective coatings on slideways which were applied for shipping should be

completely removed before beginning operations. Failure to do this can result in the actuation

of the servo-alarm when power is switched on.

5. Before turning on the power, be sure to remove all fasteners and stoppers attached to the

carriage and the cross-slide during shipping.

6. A number of internal cooling fans are fitted to each Ace CNC Lathe. It is imperative that the

installation site be located so as to prevent these fans from being clogged by dust or by mist

or spray from other equipment.

7. When lifting the lathe, be sure to use only properly-rated cables, shackles and pipes. Refer

to the appropriate hoisting diagrams in the manual.

3.3

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8. After the lathe has been properly installed, use the Accuracy Test Results Chart shipped with

the equipment to ensure that it has been accurately levelled and adjusted so as to function at

a level of accuracy specified as being within the proper operating tolerances. Failure to do

so will result in serious loss of precision in machining operations.

Check the following before switching the power ON for the first time :

1. Make sure that all bolts are properly tightened.

2. Make sure that all high-pressure feed hosing and piping are securely fastened.

All Ace CNC Lathes are inspected and tested at the factory before being shipped to our

customers. However, possible mishandling or carelessness during shipment to the installation

site may result in misalignment or damage to the equipment. If left unchecked, this could

result in serious malfunctions later, such as vibration, CNC error, or oil leaks. To prevent the

possibility of this, it is essential to make a complete pre-operation inspection of the Ace CNC

Lathe.

3. Power source:

Switch the power ON only after these points have been confirmed. At this time, once again,

check to make sure that all fastening and stoppers attached for shipping have been removed.

Do not begin operations immediately after switching the power ON. First operate the lub

pump manually to lubricate the slideways. Failure to provide proper lubrication can result in

seizing of the slideways.

After switching the power ON for the first time, check the following:

1. Inspect for oil leaks. Make sure that all meters and gauges are functioning properly. Confirm

that the main pressure gauge is reading normally.

2. Run the spindle, gradually increasing the RPM from low speed to maximum speed. This

should be separated into approximately five stages, operating at intermediate speeds at each

of the five stages for at least 20 minutes before eventually reaching the maximum allowable

RPM.

3.4

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5. POWER ON / POWER OFF - CHECKPOINTS

The following checkpoints should be observed at all times during daily operations :

When switching the power ON, make a careful inspection of all the moving parts of the machine,

ensure that no one is standing close and that there are no obstructions. After switching ON the

power, check to make sure that the pressure gauges, lube pump, cooling fans, and other auxiliary

equipments are functioning properly. After the power is switched ON, do not begin operations

immediately. First operate the lube pump manually to lubricate the slideways and ballscrews.

Then activate each of the axes. Run the spindle for a period of approximately 15 minutes.

When turning OFF the power, observe the following order of operations:1) Push the Emergency Stop Button

2) Turn OFF CNC

3) Shut OFF the machine power.

Do not leave the machine unattended with the power ON.

6. MANUAL OPERATIONS - CHECKPOINTS

The equipment should be operated only by one person at a time. It should never be operated by

anyone other than a trained operator who is familiar with the CNC Lathe.

If for example, one person is at the control panel operating the machine while another is replacing

the chuck jaws, the latter is liable to serious personal injury should the person at the control panel

inadvertently hit the wrong switch. If special circumstances make it unavoidable for two or more

persons to run the equipment, special care must be taken in co-ordinating activities to prevent

accidents.

Confirm that cutting tools and tool holders are securely fastened to the turret disc. Make sure that

these are fitted so as to be properly balanced and not to cause any interference or obstruction with

other parts of the equipment. Improper balance can have adverse effects on indexing cycle.

When performing set-up operations, be sure that the power is OFF. If it is absolutely necessary

to perform set-up operations with the power ON, take care before hand to set each switch located

on the control panel so as to prevent any accidents.

3.5

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When using a scroll chuck, be sure to remove the chuck handle after using it to tighten the jaws.

Even if the spindle is stopped, the spindle will rotate slightly. This movement is more pronounced

on larger equipment. Be prepared for this rotation.

Always start rotating the spindle from minimum speed.

If any axis has moved beyond software overtravel, move the axis in the opposite direction and

then press the System Reset key. If any axis movement has actuated the Emergency limit, the

power to the drives will be shut off. Then keeping the Emergency over ride push button switch

pressed, jog the axis in the opposite direction till the emergency limit switch is released. Then

the emergency over ride push button can be released.

Optimum spindle speed should be calculated with due consideration to the specifications of the

particular chuck and chucking cylinder being used for the operation, and to the specific cutting

conditions.

7. MANUAL / AUTOMATIC OPERATIONS -

CHECK POINTS

Do not remove the protective covers or shields. Never attempt to insert a bar into the bore through

the spindle while it is rotating. This is an extremely dangerous practice with a high likelihood of

personal injury should the operator or portions of his clothing come into contact with the moving

parts of equipment and be drawn into the lathe.

When machining a bar, be sure to use the bar feeder and the guide bush. When a short bar is to

be machined, it must be of such length as to not protrude beyond the end of the spindle and the

guide bush must be used without fail. If the bar is longer than the spindle, it will be whipped

around violently with severe vibration.

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Do not open the front guard or door while the spindle is rotating. Never open the front guard or

door to remove chips or cuttings or to gain access to the workpiece or the cutting tools while the

spindle is rotating.

Make sure that all rotating parts have come to a complete standstill before attempting to touch

them.

Never operate any Ace CNC Lathe with any of the safety devices removed. Be extremely careful

not to let loose clothing or hair get entangled in the moving parts of the machine. Be sure to wear

safety shoes or boots.

Be sure to keep the workpiece and cutting tools securely clamped at all times. Always begin

cutting operations at slow speeds and moderate cutting depths, gradually increase the feed and

depth of cut.

The operator should never stand in front of the spindle or other rotating parts. Particular care

should be taken during set-up operations or trial machining not to stand in front of the chuck since

there may be danger of the workpiece jumping out of the chuck jaws as a result of improper

clamping, and the cutting tool jumping out of the turret disc as a result of improper set-up.

During cutting operations, do not remove the chips by hand. Also, never attempt to touch the

chips directly with bare hands.

Never touch any of the switches or buttons with wet hands. This can cause short circuits or other

electrical malfunctions.

To prevent operational errors, operators should familiarize themselves thoroughly with the exact

positions of all the switches and push buttons.

3.7

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8. AUTOMATIC OPERATIONS - CHECKPOINTS

When initiating operations for the first time under a new program, do not attempt to begin

continuous automatic operations at once. Keep the equipment in Single Block Operation (SBL)

mode and use other manual backup devices as appropriate to stop operations in progress as

necessary to check the effects of the program and to eliminate any bugs or undesirable machining

conditions found during trial runs.

Before replacing the workpiece with a new one, check that the Program-End lamp has turned ON

(indicating that the cutting cycle has been completed), and machining operations are actually

completed.

Be careful not to touch any of the push buttons or switches unnecessarily during automatic

operation.

3.8

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9. LEVELLING

Before levelling, the machine base should rest on the levelling pads.

Fix the levelling bracket to the turret disc, as shown in the figure and place a spirit level onthe bracket.

Do a level check with the levelling bolts and foundation bolts tightened.

Level used

1 scale division = 0.02 mm per meter.

Face size = 150 x 55 mm

Keep the spirit level on the bracket.

Now, jog the Z-axis slide in both directions and adjust the levelling bolts so that the machine

is levelled both across and along the spindle axis. For levelling the machine across the spindle

axis keep the spirit level square to the spindle axis and repeat the same for different positions

of Z.

The bed should be levelled to get a reading within 2 divisions of the spirit level over the entire

axis length.

The level changes gradually depending on the condition of foundation, machine, etc. If the

above mentioned requirements are not satisfied the machining accuracy will be affected. So,

be sure to readjust the level atleast once every 6 months.

3.9

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10. INSTALLATION AND MAINTENANCE OF

INTER-MACHINE CONNECTION

In order to maintain precision of machine for a long period of time and to operate it always

in the best condition, it is necessary to properly maintain the machine. Giving careful attention

to the operating state, conducting periodic inspection and replacing worn-out parts in their

early stage will prevent unexpected accident from happening.

1. Maintenance immediately after installation

In the initial stage when the machine is installed, the machine is largely subject to change in

the bed level due to change in the foundation ground as well as to unstable solidification of the ground, all of which have a serious influence on machine accuracy and at the same time

the machine itself undergoes initial wear and other changes. These changes possibly could

eventually affect the machine adversely.

While operating the machine, therefore, it is necessary to pay particular attention. Mentioned

below are points of caution as to the initial maintenance.

i) Running in

After installation and when operating the machine for the first time, it is necessary to pay

particular attention to the machine before running in. Allow approximately 100 hours for the

running in. Avoid loading the machine heavily during the running in.

ii) Initial inspection of bed level

Check the bed level and the foundation for changes atleast once a month for a period of six

months after installation and, ensure correction of any disorder and always maintain the bed

level properly. After the six months, gradually extend the period between check as appropriate

depending on the changes observed, then carry out the check once or twice a year as it

stabilises.

3.10

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2. Inspection of inter-machine connection

Inspection of the state of electrical connections among respective units of the NC equipment,

the machine proper, the hydraulic unit, the control panel, etc.

i) Loosened connectors

Check each connecting portion for loosening and tighten if so.

ii) Loosened screws at each terminal

Check electrical terminals of machine relay regions and each operation panel for loosened

screws, and tighten them as required.

iii) Check terminal screws and mounting screws of micro-switches for loosening and tighten

them.

3. Inspection of electrical control panel

When inspecting the electrical control panel, be sure to turn off the main circuit breaker before

performing each check.

i) Terminal screws and soldered portions

Check terminal screws of each electrical component for loosening and tighten them if

loosened. Lightly pull soldered portions of relay panel to check soldering strength.

ii) Cleaning

Dust and chips in the electrical control panel will lead to accidents. So vacuum clean them

with care.

3.11

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1. ACE LT-20 CLASSIC MC - OVERALL VIEWS

4.1

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2. MACHINE SPECIFICATIONS

Description Standard Optional

Swing over bed Ø550 mm

Swing over carriage Ø290 mm

Capacity Distance between centres 650 mm

Maximum machining diameter Ø250 mm

Maximum longitudinal travel (Z) 600 mm

Maximum transverse travel (X) 193 mm

Maximum power requirement 27 KVA

Approximate weight 4500 Kg

Spindle centre height from floor 1050 mm

Spindle nose A2 - 6 A2-8

Bore through spindle Ø63 mm Ø86 mm

Maximum bar capacity Ø51 mm Ø75 mm

Spindle Front bearing I.D. Ø100 mm Ø120 mm

Spindle speed 50 - 4000 rpm 3500 rpm

Spindle motor (A.C. Motor)cont./30min Fanuc Alpha P22i, 11/15 kW

Tailstock quill diameter Ø80 mm

Tailstock taper in quill MT - 4

Tailstock Tailstock quill stroke 120 mm

Tailstock base travel 425 mm

Thrust (Maximum recommended) 500 kg @ 20 kg/cm2

Cross slide inclination 300

Number of turret stations 12

X & Z Standard cutting tools 25 x 25 mm

Axes Ball screw diameter X-axis Ø32 mm; Pitch=10 mm

Ball screw diameter Z-axis Ø40 mm; Pitch=10 mm

Feed motor X-axis Fanuc AC12Bi, 12 Nm

Feed motor Z-axis Fanuc AC12Bi, 12 Nm 4.2

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Turret specification : Duplomatic BSVN-200

Driven tool System : ODTN 20

Type of Tooling : VDI 40

Rotary tool motor power cont. / 30 min : 3.7 kW / 5.5 kW

Motor Specification : Fanuc Alpha 3i

TURNMILL SPECIFICATIONS

4.3

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3. MACHINE POWER CAPACITY CHART

MACHINE : LT-20 CLASSIC MC

CNC System : FANUC 0i-TC

CNC Package : Alpha C12Bi (Feed motor - 2 Nos.), Alpha P22i (Spindle) with PSM26i.

Elements used Power required (KVA)

Spindle & Servo drives 22.42

Electrical control unit 1.00

Hydraulic pump motor 1.40

Coolant pump motor 0.94

Lubricant pump motor 0.15

Chip conveyor 0.20

Cooling unit 1.00

Total 27.11 KVA

4.4

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4. BED :

The Bed is of box type construction made of cast iron grade 25. It is designed for high

rigidity with suitable cross section and ribs. The bed undergoes natural seasoning and stress

relieving before assembly.

5. HEAD STOCK ASSEMBLY (A2-8) :

The head stock aasembly features cartridge type construction. The spindle assembly consists

of three angular contact ball bearings of P4 class accuracyin the front of 2TB construction

and double row cylindrical roller bearing with taper bore NN30K (Super precision class) in

the rear. The bearings are grease lubricated for life. The spindle drive is thro’ a set of SPA

series wedge belts.

4.5

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The spindle brake mounting assembly is as shown in figure. The brake is actuated hydraulically

and it locks the spindle in the oriented position.

6. SPINDLE BRAKE ASSEMBLY :

4.6

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7. SPINDLE ENCODER ASSEMBLY :

The spindle speed feed back is through an incremental rotary optical encoder which is driven

by a timing belt.

8. SPINDLE SPEED CHARACTERSTICS :

4.7

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9. SPINDLE SPEED CHARACTERSTICS :

10. WORK HOLDING :

The work holding mounted on the spindle front end and the chucking cylinder at the rear are

connected by a drawbar. The clamping and declamping is achieved by the actuation of the

draw bar.

Any standard work holding and chucking cylinder can be mounted on the spindle with suitable

adaptors.

4.8

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11. Z-AXIS ASSEMBLY :

The Z-axis slide moves over a pair of hardened & ground guide strips. The sliding surfaces

are lined with Turcite for anti stick slip properties. An AC servo motor drives the ball screw

through a timing belt. The pretensioned ball screw arrangement takes care of the expansion

effect due to temperature variation.

The axis system is provided with overload safety clutch to protect the machine against

application of excessive motor torque on to the elements in case of accidents.

The feedback for the Z-axis motion is through the encoder built into the motor.

For setting the machine co-ordinates in the Z-axis a set of actuating dogs and limit switches

are provided. Machine reference and emergency positions can be set with these limit switches.

4.9

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12. X-AXIS ASSEMBLY :

The X-axis slide moves over a pair of hardened & ground guide strips. The sliding surfaces

are lined with Turcite for anti stick slip properties. An AC servo motor drives the ball screw

through a timing belt. The pretensioned ball screw arrangement takes care of the expansion

effect due to temperature variation.

The axis system is provided with overload safety clutch to protect the machine against

application of excessive motor torque on to the elements in case of accidents. An electro-

magnetic brake is provided on the axis for added safety. The feedback for the X-axis motion

is through the encoder built into the motor.

For setting the machine co-ordinates in the X-axis a set of actuating dogs and limit switches

are provided. Machine reference and emergency positions can be set with these limit switches.

13. TURRET

Refer to Duplomatic Rotary Tool Turret Manuals.

4.10

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14. TAILSTOCK ASSEMBLY :

The tailstock assembly consists of hardened quill sliding in a honed cast iron housing. The

housing which is adjustable crosswise is mounted on a cast iron base which moves on V and

flat guide ways. The tail stock quill can be advanced and retracted hydraulically using the

foot switch. The whole tailstock body can be moved after loosening the clamp bolts. The

bullet can be removed from the centre assembly by a wedge.

The quill is provided with MT-4 taper in the front to facilitate mounting of add-on revolving

centre, with MT-2 bullet.

The tailstock is also offered with built-in revolving centre with MT-2 bullet as an option. 4.11

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Example : Admissible load of centre at 1000 rpm

Axial load = 480 Kgf and Radial load = 320 Kg workpiece

Tailstock revolving centre - Load diagram

4.12

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15. HYDRAULIC SYSTEM :

The power pack is mounted at the rear side of the bed. A variable displacement vane pump

supplies oil to the manifold block mounted at the front of the machine. The various control

elements are mounted on the manifold block and the settings of these can be done from the

front of the machine. A gauge isolator with pressure gauge is provided to read the different

pressure settings. From the manifold blocks A & B lines of the actuators are connected

through flexible hoses. The leakage line from the chucking cylinder is connected back to the

power pack through a PVC wire braided hose. Pressure switches provided in the circuit enable

interlocking features to ensure clamping. The spindle locking in oriented position is achieved

by a hydraulic actuated brake. 4.13

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16. LUBRICATION SYSTEM

The machine is built with an automatic centralized lubrication system which supplies a

metered quantity of lubricant at a set regular interval to the guide ways and the ball screw

nuts. The quantity of the lubricant is regulated by metering cartridges and the time interval

through a PLC timer. The lubrication system monitors the build up of pressure and oil level

and gives suitable signals to the operator. An oil collector collects the spent lubricant which

is to be disposed off at regular intervals. For lubricant system details refer to the annexure.

17. COOLANT SYSTEM :

The machine has got a coolant tank of 130 litres capacity. The coolant pump mounted on the

tank delivers the coolant to the tool tip through each of the turret station and tool disc assembly.

The coolant which flows out through the turret, drains back to the tank. The machine guarding

is designed to protect the drive elements from coolant splash and chips and to facilitate easy

maintenance. A sight glass with safety grill is provided for viewing the machining

operation with the front doors closed. 4.14

Pump

Motor

Relief valve

Pressure gauge dampner

Pressure gauge

Pressure switch

Float switch

Oil filler cum breather

Suction strainer

Pressure reducing valve

Feed valve

Reservoir

7.

8.

9.

10.

11.

12.

1.

2.

3.

4.

5.

6.

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1. STANDARD CHUCKS AND CYLINDERS

Standard 3 jaw / 2 jaw chucks (GMT)

Hollow 3 jaw / 2 jaw chucks (GMT)

Standard chucking cylinders (PRAGATI)

2. STANDARD CHUCK

DISMOUNTING AND INSTALLING PROCEDURE

If the machine is supplied with a standard chuck (GMT 3B/2B x 200), follow the procedure

given below to dismount the chuck.

a. Put the chuck in clamping condition.

b. Remove the jaws.

c. Remove the centre piece.

d. Remove the chuck mounting screw.

e. Actuate the draw bar in out position. The chuck slides out from mounting flange.

f. Hold the chuck firmly.

g. Use the special Allen (or box spanner) supplied along with the chuck to loosen the draw bolt

completely. The chuck will slide out. Avoid hammer blows on the Allen key.

While following the above procedure it is suggested that the hydraulics be put OFF.

HOLLOW CHUCK : Insert a suitable rod inside the draw bar and unscrew the draw nut of

the chuck

FOR REINSTALLING FOLLOW THE STEPS GIVEN BELOW:

a. Clean the chuck mounting surfaces with lint free cloth.

b. If the chuck to be installed is a new one, it has to be dismantled, cleaned and greased as per

the recommended instructions of the manufacturer. Then the chuck assembly without the

hard/soft jaws and centre piece is to be mounted on the face plate.

c. It is assumed that the relevant chucking cylinder and the corresponding drawbar is already

installed on the machine. If it is not done, the appropriate chucking cylinder flange and the

drawbar are to be fitted on to the chucking cylinder after cleaning the mounting surfaces.

5.1

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Provisions for mounting the chucking cylinder flange exists on the face of the pulley on the

spindle. Clean the surface well and mount the chucking cylinder together with the flange

and the drawbar onto this surface. Check the alignment of mounting by dialling the reference

surface at the rear of the chucking cylinder. The total indicated reading (TIR) should be

preferably less than 0.04 mm to keep the spindle vibrations to the minimum.

Connect hoses to the input lines. The drain line should be directed downward and held in

that position to avoid tilting, thereby preventing overflow of oil from the drain chamber.

d. Switch on the hydraulics and actuate the chuck clamp, the draw bar will be drawn in. Mount

the chuck in this condition. Engage the draw bar bolt into the draw bar and rotate the draw

bolt till the chuck is seated on the face plate. Insert the mounting bolts and tighten them

uniformly.

To set the clamping stroke, operate the foot pedal to release the chuck. Loosen the draw bar

till it just meets the resistance. This is the fully opened position of the jaws. Now tighten

the draw bolt by half a turn. Now the full stroke of the master jaws is available for clamping.

Operate the clamp/declamp switch/foot pedal to ensure the above. Then insert the centre

piece and fix it. Mount the hard/soft jaws suitably.

3. HOLLOW CHUCK INSTALLING PROCEDURE

This is almost similar to the mounting and dismounting of a standard chuck.

Following are the differences:

The draw bar is hollow and threaded to the piston of the chucking cylinder, and is prevented

from loosening by applying suitable thread locking compounds, which also prevents coolant

seeping through the threads.

The chuck being hollow, a draw nut is provided in it to fasten the draw bar. The draw nut

needs a special tool to rotate it (supplied by chuck manufacturer).

The chucking cylinder is provided at the rear with a coolant collector, (connected to the

housing) and a face seal is provided to seal coolant entry in to the chucking cylinder.

The chuck flange is not the same as that of a standard solid chuck.

5.2

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4. STANDARD CHUCKING CYLINDERS(PRAGATI)

The hydraulic cylinders are suitable for operation of power chucks or collets. The cylinder

is mounted on the rear of the lathe spindle, and operates the job holding device through a

draw bar.

These cylinders have been designed with a hole through the entire assembly. The through

hole can be used to supply air or coolant to the work holding fixture. It is also possible to

use a length stop rod fitted from the rear of the cylinder to provide axial location for the

workpiece. This rod rotates with the spindle, but always remains axially stationary with

respect to the spindle, thus providing a positive reference point for job location.

The cylinders incorporate a non-contacting type of rotary joint, which is virtually free from

maintenance problems. This type of rotary joint gives a certain amount of leakage. The

leakage return tube should be of generous size and should be connected directly to the tank.

Cylinders should be mounted in the HORIZONTAL position, with leakage oil connection

pointing downward.

5.3

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5. OPERATION AND ADJUSTMENT OF

HYDRAULIC CHUCK UNIT

The hydraulic chuck is opened by depressing the foot pedal and closed by depressing it again.

a. If reduced jaw opening is desired then the draw bolt has to be adjusted after removing the

centre piece. The centre piece should be put back again after adjustment. For large

adjustments, the jaws have to be shifted on the serration on the master jaw.

b. Jaw change :

For jaw change, clean the serration of the master jaw and jaws, and the jaw nut fitting part

carefully, and then install with the same serration engagement as at the time of jaw

boring/turning.

c. Adjustment of the clamping force :

Adjustment is done with the pressure reducing valve on the hydraulic power pack. Adjust

while observing the pressure gauge. After the adjustment, it must be locked with the lock

nut. The chuck pressure adjustment range is from 5 to 30 kg/cm2.

d. Change between Chuck Clamp / Declamp (by M codes).

To be used in MDI mode only and spindle should be OFF.

1. Select MDI mode

2. Enter M11 for chuck clamping

3. Enter M10 for chuck declamping

4. Press cycle start. The selected mode will be retained even after power OFF.

NOTE :

1. For execution of M03 and M04 ensure that chuck is clamped properly before starting the

cycle.

2. Change over from internal to external clamping should be done through I.D./O.D. selection

M codes i.e M16 for I.D. and M18 for O.D.

5.4

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6. SOFT JAW BORING SEQUENCE FOR

EXTERNAL CLAMPING

1. Install the soft jaws on the chuck.

2. Set the hydraulic chuck internal clamping by parameter (M11).

3. Use an inner diameter cutting tool to cut a hole (d) about 8 mm smaller than the workpiece

clamping diameter (D) into the soft jaws installed in the chuck.

4. Set the hydraulic chuck external clamping by parameter (M10).

5. Clamp a blank (outer diameter d-1 mm, length about 6 mm) in the hole (d) of the machined

soft jaws.

6. Bore the soft jaws according to the clamping diameter (D) of the workpiece and remove the

blank after boring.

7. Remove burrs.

NOTE : For detailed explanations regarding the hydraulic chuck, refer to the instructions

issued by the chuck manufacturer. 5.5

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Drg. No. 97-108 / 74-0-38. SAMPLE DRAWING

5.7

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3. MACHINING RANGE

6.3

96-104 / M373

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4. MACHINING RANGE

6.4

96-104 / M375

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SPECIFICATIONS Oi-TC

CONTROLLED AXIS

Controlled path 1 path @

2 axes @

4 axes (Including Cs axis) #

Simultaneous controlled axes Max. 4 axes @

Axis control by PMCMax. simultaneous 4 axes,

(Not available on Cs axis)@

Cs contouring control 1 axis @

In case of G code system A, basic 2

axes are X and Z, Additional axes are

optional from Y, A, B, and C.

@

In case of G code system B/C, basic

2 axes are X and Z, Additional axes

are optional from Y, U, V, W, A, B,

and C.

@

2 units @

@

0.001mm, 0.001deg, 0.0001inch @

0.0001mm, 0.0001deg,

0.00001inch@

Optional DMR @

@

HRV3 @

@

All axes / each axis / each direction /block start / cutting block start.

@

All axes / each axis @

@

@

@

@

Chuck & Tailstock barrier @

Each axis @

@

@@

@

@

@

@

@

7.1

1. FANUC Oi-TC SPECIFICATIONS

Axis name

Increment system 1/10

Spindle

ITEM

Mirror image

Stored stroke check 2, 3

Follow-up

Emergency stop

Overtravel

Stored stroke check 1

Flexible feed gear

Fine Acc & Dec control

M a c h i n e

c o n t r o l l e d

a x e s

Controlled axis

Simple synchronous control

Least input increment

Backlash compensation

Stored pitch error compensation

Servo off

Backlash compensation for each rapid traverse and

cutting feed

Unexpected disturbance torque detection function

Servo HRV control

Inch / Metric conversion

Machine lock

Interlock

Chamfering on/off

Position switch

' @ ' = Standard, ' # ' = Optional

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2. G CODES

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M00 Program stop M50M01 Optional stop M51M02 End of program M52 Turret Zero cycle ONM03 Spindle rotation CW M53M04 Spindle rotation CCW M54 T.S. quill override ON

M05 Spindle stop M55 Chuck signal override ONM06 M56 T.S. quill interlock ONM07 Coolant ON M57 T.S. quill interlock OFFM08 M58M09 Coolant OFF M59M10 Chuck declamp M60M11 Chuck clamp M61M12 M62M13 Live tool rotation cw M63 Cs contour mode ONM14 Live tool rotation ccw M64 Cs contour mode OFFM15 Live tool stop M65M16 Chuck clamp on I.D. M66 Spindle brake ONM17 M67M18 Chuck clamp on O.D. M68M19 M69M20 M70M21 M71M22 M72M23 M73M24 M74M25 M75M26 M76M27 M77

M28 M78M29 M79M30 End of main program M80M31 M81M32 T.S. quill forward M82 T.S. body forwardM33 T.S. quill retract M83 T.S. body retractM34 Parts catcher fwd M84 T.P. arm forwardM35 Parts catcher ret M85 T.P. arm retractM36 M86M37 M87M38 M88

M39 M89M40 M90M41 M91M42 M92M43 M93M44 M94M45 M95M46 M96M47 M97M48 M98 Sub program callM49 M99 Sub program end

7.9

M-code list for Classic MC

7/22/2019 Classic MC IM 03 20 Jun 06


M00 Program stop M50

M01 Optional stop M51

M02 End of program M52 Turret Zero cycle ON

M03 Spindle rotation CW M53

M04 Spindle rotation CCW M54 T.S. quill override ON

M05 Spindle stop M55 Chuck signal override ONM06 M56 T.S. quill interlock ON

M07 Coolant ON M57 T.S. quill interlock OFF

M08 M58

M09 Coolant OFF M59

M10 Chuck declamp M60

M11 Chuck clamp M61

M12 M62

M13 Live tool rotation cw M63 Cs contour mode ON

M14 Live tool rotation ccw M64 Cs contour mode OFF

M15 Live tool stop M65

M16 Chuck clamp on I.D. M66 Spindle brake ON

M17 M67

M18 Chuck clamp on O.D. M68

M19 M69

M20 M70

M21 M71

M22 M72

M23 M73

M24 M74

M25 M75

M26 M76

M27 M77

M28 M78M29 M79

M30 End of main program M80

M31 M81

M32 T.S. quill forward M82 T.S. body forward

M33 T.S. quill retract M83 T.S. body retract

M34 Parts catcher fwd M84 T.P. arm forward

M35 Parts catcher ret M85 T.P. arm retract

M36 M86

M37 M87

M38 M88

M39 M89M40 M90

M41 M91

M42 M92

M43 M93

M44 M94

M45 M95

M46 M96

M47 M97

M48 M98 Sub program call

M49 M99 Sub program end

7.9

M-code list for Classic MC

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1. OPERATOR CONTROL PANEL

8.1

The above operator panel is only for the user reference. For exact description of operator

panel for the machine supplied refer to the relevant operator panel drawing supplied with

the machine interface manual.

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OPERATOR CONTROL PANEL-1 DETAILS

Emergency stop push button

CNC OFF/ON push buttonEmergency override push button

+X jog push button

-X jog push button

+Z jog push button

-Z jog push button

Rapid override push button

Cycle start push button

Feed hold push button

Spindle CW/CCW push button

Spindle stop push button

Feed override rotary switch

Rapid override rotary switch

Handle/Step feed rotary switch

Mode selection rotary switch

Spindle speed override rotary switch

Optional stop switch

Block delete switch

Dry run switch

Machine lock switch

Program check switch

Program protect OFF/ON key switch

RS 232C port

8.2

1.

2.3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

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DESCRIPTION OF OPERATOR CONTROL PANEL-1

1. EMERGENCY STOP PUSH BUTTONMachine will be in emergency state if this push button is pressed. After pressing the CNC

ON push button, if the emergency push button is released hydraulic gets ON and machine

will reset, automatically. In emergency state, power to the drives and hydraulics are

removed and not ready message is displayed on the screen.

2. CNC ON/OFF PUSH BUTTON

After the main supply is switched ON, CNC system can be switched ON by pressing CNC

ON push button. After a few seconds delay the CRT display will come ON showing

software version number and PMC number. The CNC can be switched OFF by pressing

CNC OFF push button.

3. EMERGENCY OVERRIDE PUSH BUTTON

During machine operation if any slide actuates the end limit switch, the machine will come

to emergency stop state. Jog keys become ineffective unless the emergency override push button is pressed. Keeping emergency override push button pressed jog the axis in opposite

direction till the end limit switch is released. Then emergency override push button should

be released. After this jog switches will remain effective.

4. +X JOG PUSH BUTTON

If this key is pressed in jog mode then X-slide will move in positive direction at a feed rate

depending upon the feed override selected. When in reference mode, this key can be used

for X-axis homing.

5. -X JOG PUSH BUTTON

If this key is pressed, in jog mode then X-slide will move in negative direction at a feed

rate depending upon the feed override selected.

8.3

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6. +Z JOG PUSH BUTTON

If this key is pressed in jog mode then Z-slide will move in positive direction at a feed rate

depending upon the feed override selected. When in reference mode and X-axis reference

is completed then with this key Z-axis homing is possible.

7. -Z JOG PUSH BUTTON

If this key is pressed in jog mode then Z-slide will move in negative direction at a feed rate

depending upon the feed override selected.

8. RAPID OVERRIDE PUSH BUTTON

When this push button is pressed along with any of the jog push buttons, the respective

slide moves in rapid rate set for that slide. This push button is effective only after axes are

referenced. Rapid rate can be set using the rapid override rotary switch.

9. CYCLE START PUSH BUTTON

This push button is effective in Auto single and MDI modes of operation

10. FEED HOLD PUSH BUTTON

Auto cycle is interrupted when this push button is pressed.

11. SPINDLE CW/CCW PUSH BUTTON

In jog mode spindle direction of rotation can be selected using these two push buttons.

The spindle speed can be selected using S command in MDI mode.

12. SPINDLE STOP PUSH BUTTON

In jog mode spindle is disabled using this push button.

13. FEED OVERRIDE ROTARY SWITCH

Feed can be varied from 0-150% of the set feed rate.

14. RAPID OVERRIDE ROTARY SWITCH

Rapid rate can be varied from 0-100% in steps of 25%.8.4

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7/22/2019 Classic MC IM 03 20 Jun 06


21. MACHINE LOCK SWITCH

The slide movement will only be effective with this switch OFF. This switch is not

effective with auto cycle ON in auto continuous mode. If this switch is selected during

the execution of auto cycle in single block then system indicates the error alarm "PRGM

CONT SW OPERATED, RST & HOME".

22. PROGRAM CHECK SWITCH

Program check switch in combination with the machine lock switch can be used to check

the part program using graphic option. (Graphic simulation)

23. PROGRAM PROTECT OFF/ON KEY SWITCH

Program protection is possible only when this switch is in ON position. In order to edit

the part program in edit mode this switch must be in OFF position.

24. RS 232C PORT

This port can be used to upload or download the PLC program, part program or machine

parameters from CNC system to the computer or other Fanuc system compatible peripheral

devices.

8.6

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2. OPERATOR CONTROL PANEL-2

The above operator panel is only for the user reference. For exact description of operator

panel for the machine supplied refer to the relevant operator panel drawing supplied with

the machine interface manual.

8.7

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7/22/2019 Classic MC IM 03 20 Jun 06


DESCRIPTION OF OPERATOR CONTROL PANEL-2

1. CYCLE START PUSH BUTTON

This push button is effective in Auto continuous/Auto single and MDI modes of operation

2. COOLANT ON/OFF SELECTOR SWITCH

Coolant can be switched ON and OFF using coolant ON and OFF selector switch in jog

mode. In auto mode, for coolant ON, M07 to be commanded along with coolant ON

selection. Coolant can be made OFF by M09 or machine reset or coolant OFF selection.

3. TURRET INDEX ON PUSH BUTTONIn the jog mode the turret can be indexed forward direction by pressing this push button

provided turret is in safe zone and turret clamp signal is present.

4. TURRET UNCLAMP OVERRIDE PUSH BUTTON

If the turret is unclamped the axes can’t be moved. This can be overridden by pressing

this switch.

5. MACHINE RESET PUSH BUTTON

This push button can be used to reset M, S or T functions when in execution. This push

button can also be used to reset PLC messages and spindle alarm.

6. LUB INCH PUSH BUTTON

Once this push button is inched lub motor will be ON for three seconds. Lubrication

inching is possible only when the machine is not under emergency and sufficient oil is

present in the lubrication tank.

7. CHIP CONVEYOR FORWARD/REVERSE SPRING RETURN

SELECTOR SWITCH

In jog mode chip conveyor can be run forward/reverse, by using spring return selector

switch. In auto mode chip conveyor works in forward direction.

8.9

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7/22/2019 Classic MC IM 03 20 Jun 06


1. DAILY MAINTENANCE

1. Lubrication system Check for oil level, pressure At the start of the work

(Alarm signal) build up & film on sliding

surfaces

2. Chuck Greasing the master jaws At the start of the work

through grease nipples.

Tighten the jaws

3. Cutting tools Tighten the tool blocks, At the start of the work

tools and inserts

4. Hydraulic oil level Check for level Replenish if needed

5. Pressure gauge Check system pressure 30 Kg/cm2

Check for chuck pressure As per requirement

6. Coolant level Check for level Replenish if needed

7. Tubing and machine Check for leakage and

surroundings cleanliness

8. External wiring and Check for disconnections and

cables damage to sheath

9. Cleaning Clean the work holding, turret At the end of the work

and sliding guards to remove

chips and coolant

9.1

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2. PERIODIC INSPECTION

Coolant Check for condition Replace as required

Hydraulic system Return line filter replacement 6 months

Check condition of oil and replace 1 year

Clean power pack and surroundings 1 year

Clean suction strainer 1 year

Check proper working of 6 months

accumulator

Lubricating system Check for proper working 1 month

Check for oil lubrication lines 1 month

V belts and timing belts Check for condition and tension 1 month

Motors Check for rigid (proper) mounting 6 months

Chuck Overhaul the chuck 1 month

Chucking cylinder Check for leakage across the piston 3 months

Electrical cabinet Vacuum clean the CNC and the 3 months

electrical cabinets

Electrical contacts Check for discolouration in the 3 months

contacts

Electrical elements Check for proper working of push 3 months

button switches

Limit switches Check for proper signals 3 months

Axes backlash Check and compensate 6 months

Foundation Check for level and relevel 6 months

Headstock Clean labrynth holes 1 month

Turret Check for alignment and correct As required

9.2

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3. LUBRICATION

Lubrication is very important for machine tools since it greatly affects machine life. Use

only recommended lubrication oils which can clean and free foreign matter. Periodically

clean the tank and filter, inspect equipment or piping for damages to ensure optimum machine

operation.

a. SPINDLE

The headstock houses the spindle in bearings which are lubricated for life with high grade

grease (KLUBER ISOFLEX NBU-15). This grease can withstand low and high tempera-

tures (-60o C to +130o C).

Spindle should be warmed up for approximately one hour when the machine has been

stopped for a long period (e.g. five days or more on account of holidays etc.).

See Cautionary details concerning Installation

b. TAILSTOCK

The tailstock quill is connected to the central lubrication system. If the tailstock contains a

built-in live centre, then it is lubricated for life with KLUBER ISOFLEX NBU-15 grease.

It needs to be changed when the bearings are to be changed. If the machine is with add-on

revolving centre there is no lubrication required.

3.1 COOLANT

A tank serving both as a coolant tank and a chip tray (or optional chip conveyor) is installed

in the front side of the bed. It can be removed from the front side of the machine. Therefore,

it is easy to clean the inner part of the tank and to dispose chips. (Capacity 130 litres)

9.3

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7/22/2019 Classic MC IM 03 20 Jun 06


3.5 OIL GUIDE TABLE

Lubrication point Lubrication system Recomm. oil grade Quantity

Head stock Grease KLUBER ISOFLEX NBU-15

Ball screws,

Guideways, Centralised lubrication ISO VG-68 3 Litres

Tailstock

Hydraulic ISO VG-68 45 Litres

Coolant 130 Litres

NOTE : Do not use oil other than the above mentioned.

Also, do not use the mixture of oils of different makes.

9.5

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3.6 STARTING CHECK TABLE

Check item

9.6

1. Lubrication oil level

Check

a. Centralised lubrication unit tank

2. Grease injection

a. Check master jaw (Once every day)3. Oil flow

Check

a. Slideway

4. Oil leak from each part

a. Hydraulic unit

b. Chucking cylinder

c. Peripheral area of machine

5. Abnormal noise from spindle drive system

a. Head stock

b. Motors

6. Electrical system

a. Check for each indication

b. Check for each switch function

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4. HEAD STOCK REALIGNMENT

In case of axis misalignment of the spindle with respect to the Z-axis, follow the method given

below for resetting:

1. Remove the chuck, chucking cylinder etc.

2. Mount the inspection mandrel.

3. Open the left hand guard covering the head stock.

4. Loosen the mounting bolts of the head stock slightly and use the screws provided to align

the axis with respect to the Z-axis.

5. Tighten the clamping bolts and recheck the alignment in both primary and secondary planesof the Z-axis.

6. Shift the tailstock also if necessary in the appropriate direction (use a mandrel between

centres for this task).

7. Refix the covers.

9.7

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classic mc im 03 20 jun 06

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