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Emcoturn 365

Modular CNC-Turning Center for Complete Machining

Machine Description
Emcoturn 365
Ref.-No. EN 4054

EMCO Maier Ges.m.b.H.


P.O. Box 131
A-5400 Hallein-Taxach/Austria
Phone ++43-(0)62 45-891-0
Fax ++43-(0)62 45-869 65
Internet: www.emco.at
E-Mail: service@emco.co.at

Edition F2002-04

Introduction
For more than five decades EMCO has been developing wood and metal working machines
and has been successfully on the market since 1980 with computer controlled machine tools
and systems for industry and training.
Our experience over decades and new customer requirements led to the development and
the construction of the EMCOTURN 365 lathe for complete machining from blank to
components ready for installation.
Due to an optimum distribution of machining sequences high production flexibility, half
processing time and, thus, double productivity are achieved.
Due to various accessories and special equipment such as integrated swivelling loader, bar
feed and loading magazine, tool holder, tool fracture control and an external measurement
station still a higher degree of automation can be achieved.
Due to the worldwide industrial use of our machines we dispose of a service network which
covers all world areas. Immediately available service engineers, telephone service as well
as a 100 % spare part supply exceeding the 10-year obligatory provision is something
natural for us.
One of our more than 100 general representatives worldwide will inform you on particular
new developments and their retrofitting possibilities.
The present user's manual for the EMCOTURN 365 comprises the description of the machine
and the accessories, instructions and procedures for handling and realization of cleaning
and maintenance work by the user as well as stipulations to be observed for the prevention
of accidents and machine damage.
We therefore ask all machine operators to read the subject user's manual prior to start-up
and also at a later point of time and to observe the guidlines attending it as exactly as
possible. Your machine will ofer you, on the other hand, permanent operatability and long
live.
For any inquiries or proposals for improvement with a view to the present operating
instructions please get directly in touch with
EMCO MAIER Gesellschaft m. b. H.
Abteilung Technische Dokumentation
A-5400 HALLEIN, Austria

EC conformity
The CE sign certifies together with the EC declaration of conformity that the
machine and the manual correspond to the EC guideline for machines 89/392/
EEC and its modifications 91/368/EEC and 93/68/EEC.
All rights reserved, duplication only upon authorization of Messrs. EMCO MAIER
EMCO MAIER Gesellschaft m. b. H. , Hallein/Taxach - Austria

Contents
Adequate Use ............................................................................ 9
Warranty conditions for new EMCO machines ......................... 9
Safety recommendations ......................................................... 10
Technical data of the machine - metric ................................... 13
Technical data of the machine - inch ....................................... 17
Declaration of conformity ......................................................... 21

A Installation of the machine

The Main Spindle 45 ........................................................... B10


Dimensions spindle connection ......................................... B10
Clamping cylinder with bore .............................................. B11
Clamping cylinder without bore ......................................... B11
Connection values for tensioning tubes ............................ B12
Machine with clamping cylinder with bore ..................... B12
Machine with clamping cylinder without bore ................ B12
Position of tensioning tube during the change
of clamping devices ....................................................... B13
Clamping devices - General hints ......................................... B13
Position of tensioning tube by changing clamping devices ..... B13

Machine acceptance ................................................................ A1


Machine number .................................................................. A1
Electrics number .................................................................. A1
Operation panel number ...................................................... A1
Scope of supply ....................................................................... A3
Basic machine ...................................................................... A3
Tool set ................................................................................ A3
Packing ................................................................................ A3
Modules ............................................................................... A3
Transport of machine ............................................................... A4
Transport with pallet ............................................................ A4
Transport without pallet ....................................................... A4
Transport with crane ............................................................ A5
Transport safety devices ...................................................... A6
Installation plan, dimensions of the machine .......................... A7
Basic machine ...................................................................... A7
Machine with bar loader and chip conveyor ........................ A8
Machine with gantry loader and chip conveyor ................... A8
Installation criteria .................................................................... A9
Requirements on installation surface .................................. A9
Installation possibilities ........................................................ A9
Anchoring on the ground ................................................. A9
Without anchorage on the ground ................................. A10
Additional criteria for installation ........................................ A10
Electrical connection - Machines with Sinumerik 810D/840D ..... A11
Mains connection data ....................................................... A12
Machine without counter spindle ................................... A12
Machine with counter spindle ........................................ A12
Electrical connection - Machines with Fanuc-Control ........... A13
Mains connection data ....................................................... A14
Pneumatic connection ........................................................... A14
Initial start-up ......................................................................... A15

B Description and operation


Reference points ...................................................................... B2
Machine zero point M .......................................................... B2
Tool fixture reference point T ............................................... B2
Measurement of the tools .................................................... B2
Coordinate system ............................................................... B2
Working area ........................................................................... B3
Tool turret ................................................................................ B4
Working area ........................................................................ B4
Tooling the tool turret ........................................................... B4
Weight counterbalance ........................................................ B5
The main spindle 65 .............................................................. B6
Dimensions spindle connection ........................................... B6
Clamping cylinder with bore ................................................ B7
Clamping cylinder without bore ........................................... B8
Connection values for tensioning tubes .............................. B9
Machine with clamping cylinder with bore ....................... B9
Machine without clamping cylinder with bore .................. B9

Clamping devices - spindle 65 ............................................ B14


Screwing the tensioning tube into the clamping cylinder .. B14
Spindle insert sleeves ........................................................ B14
Order numbers ............................................................... B14
Necessary hollow-out diameter ..................................... B14
Mounting the insert sleeves ........................................... B15
Dismounting the insert sleeves ...................................... B15
Three-jaw power chuck ...................................................... B16
Mounting the chuck ........................................................ B16
Adjusting the minimum value "X" ................................... B17
Dimensions of the chuck ................................................ B17
Dimensions of the jaws .................................................. B18
Clamping ranges of the chuck ....................................... B19
Clamping force diagram KFD-HS 175/3 ........................ B19
Clamping force diagram KFD-HS 200/3 ........................ B20
Clamping force diagram KFD-HS 250/3 ........................ B20
Collet chuck QUADRO-NC ................................................ B21
Technical data ................................................................ B21
Clamping possibilities - outline ...................................... B21
Clamping variant 1 (basic variant) ................................. B22
Clamping variant 2 ......................................................... B22
Clamping variant 3 ......................................................... B22
Mounting the collet chuck .............................................. B23
Changing the collets ...................................................... B23
Clamping force diagrams ............................................... B24
End face driver ................................................................... B25
Mounting the end face driver ......................................... B25
Dimensions of the carrier plates .................................... B25
Clamping force diagram for end face driver .................. B26
Clamping devices - spindle 45 ............................................ B27
Screwing the tensioning tube into the clamping cylinder .. B27
Spindle insert sleeves ........................................................ B27
Order numbers ............................................................... B27
Necessary hollow-out diameter ..................................... B27
Mounting the insert sleeves ........................................... B28
Dismounting the insert sleeves ...................................... B28
Three-jaw power chuck ...................................................... B29
Mounting the chuck ........................................................ B29
Dimensions of the chuck ................................................ B29
Dimensions of the jaws .................................................. B30
Clamping ranges of the chuck ....................................... B30
Clamping force diagram KFD-HS 160/3 ........................ B31
Rhm - Collet chuck .......................................................... B32
Technical data ................................................................ B32
Outline collets ................................................................ B32
Clamping principle ......................................................... B32
Mounting the collet chuck .............................................. B33
Dismounting the collet chuck ......................................... B33
Clamping force diagrams ............................................... B34
Changing the collets ...................................................... B34
Hainbuch - Collet chuck ..................................................... B35
Tecnical Data ................................................................. B35
Order numbers ............................................................... B35
Clamping principle ......................................................... B35
Clamping force diagrams ............................................... B35

End face driver ................................................................... B36


Mounting the end face driver ......................................... B36
Dimensions of the carrier plates .................................... B36
Clamping force diagram for end face driver .................. B37
Counter headstock ................................................................. B38
Traversing range ................................................................ B38
Tailstock ................................................................................. B39
Travelling range ................................................................. B39
Mounting the tailstock adapter ........................................... B39
Tailstock thrust ................................................................... B40
Removing the centre .......................................................... B40
Adjusting the detector of the tailstock stroke ..................... B41
Hydraulics .............................................................................. B42
Hydraulic unit equipment ................................................... B42
Oil level control .................................................................. B42
Hydraulic scheme .............................................................. B43
Setting work on hydraulics ................................................. B44
System main pressure ................................................... B44
Clamping device pressure and ...................................... B44
sleeve thrust ................................................................... B44
Minimum pressure for clamping devices ....................... B44
Pneumatics ............................................................................ B45
Compressed air supply ...................................................... B45
Pressure setting ................................................................. B45
Pneumatic scheme ............................................................ B45
Central lubrication .................................................................. B46
Function and monitoring .................................................... B46
Lubrication after longer standstill periods .......................... B47

C Programming and Operation


EMCO-specific - Sinumerik 810/840D
Survey M Commands machine .............................................. C1
Survey M Commands Gantry ................................................. C2
Survey Machine Configuration M99 ....................................... C2
Channel 1 (machine) ....................................................... C2
Channel 2 (Gantry) ......................................................... C2
Axes Description ..................................................................... C3
Machine Control Panel ........................................................... C4
Key Description ....................................................................... C5
Open Machine Door ............................................................. C15
Door Automatic ................................................................. C15
Clamping device control .......................................................
Purpose .............................................................................
Function ............................................................................
Condition displays of the clamping device .......................
Adjustment of the clamping device control .......................
Bridging the final position clamping device detectors ......
Switching off the final position detector ........................
Activate the final position detector ................................

C16
C16
C16
C16
C17
C18
C18
C18

Switch On/Off Sequence ......................................................


Switch On the Machine .....................................................
Approach Reference Point ............................................
Switch Off the Machine .....................................................

C19
C19
C19
C20

Chip Conveyor ...................................................................... C20

Workpiece collection device (option) ..................................... B48


Adjustment of the height of the collecting tray .................. B48
Adjusting the stroke of the collecting tray .......................... B49

Spindle Brake ....................................................................... C21

Workpiece ejector with flushing system (option) ................... B50


Mounting the ejector .......................................................... B51
Self-made ejector ............................................................... B51
Examples for self-made ejectors ................................... B52
Adjusting the stroke ........................................................... B53
Operating instructions ........................................................ B53

C Axes .................................................................................. C22

Y-Axis (option) ....................................................................... B54


Technical datas .................................................................. B54
Working Area ..................................................................... B54
Toolholders ............................................................................ B55
Single toolholders VDI-30 .................................................. B55
Double toolholders VDI-30 ................................................ B57
Driven toolholders VDI-30 .................................................. B58
Performance curve spindle 65 ............................................ B59
Performance curve spindle 45 ............................................ B59
Environmental Protection Notes ............................................ B60
Environmental burdens in machining production .............. B60
Lubricants ....................................................................... B60
Cooling lubricants .......................................................... B60
Solvents and cleaning agents ........................................ B61
Special problems with chips containing residual oil ...... B61
Problems with oil mists and oil vapours, dust etc. ......... B62
Further burdens ............................................................. B62
Measures of environmentally compatible design in
machining production ......................................................... B62
General hints .................................................................. B62
Hints for correct handling of utilities ............................... B62

Workpiece Collection Device (Option) .................................. C21


Tailstock ................................................................................ C21
Tool Turret ............................................................................ C22
Influencing the Tool Turret in
AUTOMATIC and JOG Mode ....................................... C22
Machine Configuration ..........................................................
Clamping Device Left ........................................................
Clamping Device Right .....................................................
Continuous Operation .......................................................
Programming ....................................................................

C23
C23
C23
C23
C23

R Parameter ......................................................................... C24


Workpiece Counter (R90, R91) ........................................ C24
Machining Time (R98, R99) .............................................. C24
Freeprogrammable Outputs ................................................. C25
Survey ............................................................................... C25
Standard Setting ............................................................... C25
Y-Axis .................................................................................... C26
Programming .................................................................... C26
Programming example for using the Y-axis ..................... C26
Cycle Programming ..............................................................
Roughing Cycle "CYCLE95" .............................................
Threading Cycle "CYCLE97" ............................................
Drilling Cycle "CYCLE83E" ...............................................
Tapping "CYCLE84E" .......................................................
Grooving Cycle "CYCLE93" ..............................................
TRANSMIT-Programming ................................................
Cylinderinterpolation .........................................................
Synchronization of two Spindles .......................................
Programming the automatic tailstock ...............................
Supporting on more length positions ............................
"TAKEOVER" - Cycle Mainspindle-Counterspindle .........
Bar Loading Cycles ...........................................................

C27
C27
C30
C33
C35
C37
C40
C42
C44
C45
C45
C46
C49

Bar Loader Interface ............................................................. C50


Serial Interface ......................................................................
Signal names ....................................................................
Maximum Cable Length ....................................................
Connection to PC ..............................................................

C53
C53
C53
C53

D Programming and Operation


EMCO-specific - Fanuc 21i-T
Machine Control Panel ........................................................... D1
Axes Description ..................................................................... D1
Description of Keys ................................................................. D2
Switch On/Off Sequence ......................................................
Switch ON the machine ....................................................
Approach reference point .............................................
Switch OFF the Machine ..................................................

D10
D10
D10
D11

Open Machine Door .............................................................


Door Automatic (Option) ...................................................
Open door automatically ...............................................
Close automatic door ....................................................
Automatic program start ...............................................

D11
D12
D12
D12
D12

Clamping Device Control ......................................................


Purpose .............................................................................
Function ............................................................................
Condition displays of the clamping device .......................
Adjustment of the clamping device control .......................
Bridging the final position clamping device detectors ......
Switching off the final position detector ........................
Activate the final position detector ................................

D13
D13
D13
D13
D14
D15
D15
D15

Standard Tailstock ................................................................ D16


Programming .................................................................... D16
Adjusting the detection of the tailstock quill ..................... D16
Automatic Tailstock .............................................................. D17
Programming .................................................................... D17
Adjustment of the tailstock stroke monitoring ................... D17

Cutter Radius Compensation ........................................... D33


G40 Cancel Cutter Radius Compensation ....................... D35
G41 Cutter Radius Compensation Left ............................ D35
G42 Cutter Radius Compensation Right .......................... D35
G52 Local Coordinate ....................................................... D36
G53 Selection of the Machine Coordinate System .......... D37
G54 to G59 Selection of a Workpiece Coordinate System D37
G70 Measuring in Inches .................................................. D39
G71 Metrical Measuring .................................................... D39
G72 Finishing Cycle .......................................................... D39
G73 Contour Roughing Cycle ........................................... D40
G74 Face Roughing Cycle ................................................ D42
G75 Pattern Repeating Cycle ........................................... D44
G76 Face Cut-in Cycle ..................................................... D45
G77 Side Cut-in Cycle (X Axis) ........................................ D46
G78 Multiple Threading Cycle (Thread cutting OD/ID) .... D47
Drilling cycles with driven tools ......................................... D48
G12.1/G13.1 Polar Coordinate Interpolation .................... D56
G7.1 Cylindrical interpolation ............................................ D59
G51.2 / G50.2 Polygonal Turning .................................... D61
G90 Absolute Programming ............................................. D64
G91 Incremental Programming ........................................ D64
G92 Adjustment for maximum Spindle Speed ................. D64
G92.1 Coordinate System Setting .................................... D64
G94 Feed Rate in Minutes ................................................ D65
G95 Feed Rate in Revolutions ......................................... D65
G96 Constant Cutting Speed ............................................ D65
G97 Constant Rotational Speed ....................................... D65
M-Commands - Survey ......................................................... D66
Bar Feed / Bar Loader Interface ........................................... D72

Spindle Brake ....................................................................... D18

Reversing Play Compensation ............................................. D77


Input of the reversing play ............................................ D77

C-axis .................................................................................... D18

Chip conveyor ....................................................................... D78

Workpiece Collection Device (Option) .................................. D19

Program interruption to open the door ................................. D78

Tool Turret ............................................................................


Manual operation ..........................................................
Influencing the Tool Turret in
AUTOMATIC and JOG Mode .......................................
Programming ................................................................

D19
D19

Macro Variables ....................................................................


Calling up Variables ..........................................................
Workpiece Counter ...........................................................
Machining Time ................................................................

D20
D20
D20
D21

D19
D20

Free Programmable Outputs ................................................ D21


Standard Setting ............................................................... D21
Survey Program Input, Administration ................................. D22

Tool Data Measuring with Scratching ................................... D79


Tool Data Measuring with the Optical Preset Device ........... D80
Serial Data Interface .............................................................
Signal names ....................................................................
Transmission cable ...........................................................
Settings for data transmission ..........................................
Transmission of NC-programs ..........................................

D81
D81
D81
D81
D81

E Maintenance of the machine


Maintenance survey ................................................................. E1
Filling quantities ................................................................... E2

G-Commands - Survey ......................................................... D23

Lubricant recommendations .................................................... E2

Short description G-Commands ...........................................


G00 Rapid Traverse ........................................................
G01 Linear Interpolation (Feed) ......................................
Einfgen von Fasen und Radien ......................................
Insertion of Chamfers and Radii .......................................
Direct Drawing Input .........................................................
G02 Circular Interpolation Clockwise ...............................
G03 Circular Interpolation Counterclockwise ...................
G04 Dwell .........................................................................
G10 Data Setting ..............................................................
Zero point shift G92 ......................................................
Zero point shift with workpiece
coordinate systems G54 to G59 ...................................
G20 Longitudinal Turning Cycle .......................................
(OD/ID Machining Cycle) ..............................................
G20 Longitudinal Turning Cycle .......................................
G21 Thread Cutting Cycle ................................................
G24 Face Turning Cycle ...................................................
G28 Reference Point Return ............................................
G33 Thread Cutting .........................................................

Cooling lubricants .................................................................... E3


Chlorin-free coolants ............................................................ E4

D24
D24
D25
D25
D25
D26
D28
D28
D28
D29
D29
D29
D30
D30
D30
D31
D31
D32
D32

Clamping pressure and clamping dev. function ...................... E5


Power chuck ............................................................................ E5
Collet chuck ............................................................................. E6
Bright parts .............................................................................. E6
Visula examination of all hoses ............................................... E6
Central lubrication .................................................................... E7
Oil level check ...................................................................... E7
Air inclusions ........................................................................ E7
Lubrication in case of major periods of standstill ................ E7
Installation of lines ............................................................... E8
Hydraulic unit ........................................................................... E8
Reduction of hydraulic pressure .......................................... E8
Additional regular checks ..................................................... E8
Cleanliness .......................................................................... E8
Hydraulic oil change ............................................................ E9

Coolant device ....................................................................... E10


Drawing out the cooling lubricant tank .............................. E10
Cooling lubricant level ........................................................ E11
Cleaning the cooling lubricant tank .................................... E11

F Additional instructions

Belt tension ............................................................................ E12

Bristol - Electrostatic Airfilter

Change of battery in the control Siemens 810 D/840 D ........ E13


Change of battery in the hard disk unit MMC .................... E13
Change of the battery ventilator insert of the
NC-CPU board (Sinumerik 840D) ..................................... E14
Change of the battery of the
CCU-board (Sinumerik 810D) ........................................... E14

Sauter - Tool Turret


Knoll - Chip Conveyor

G Spare Parts List

ADEQUATE USE / WARRANTY CONDITIONS

Adequate Use
The EMCOTURN 365 lathe is designed for complete machining by turning, drilling and
milling of machinable metals and plastics.
Machining of other materials is not admitted and may be carried out in particular cases only
after consultation with the machine manufacturer.
Adequate use also includes compliance with the operating, maintenance and repair
instructions indicated by the manufacturer.
The EMCOTURN 365 may excusively be operated by persons familiar with the operation,
maintenance and repair and who know the hazards.
All regulations for the prevention of accidents and safety instructions for work with machine
tools and CNC machine tools have to be complied with at any time.
In case of inadequate use of the EMCOTURN 365 the manufacturer renounces any liability
and the responsibility is transferred exclusively to the user.

Warranty conditions for new EMCO machines


1. The warranty period for new EMCO machines is, without limitation of operating hours, 12
months after initial shipment of the machine from EMCO or its authorized representative.
Should the installation be completed by EMCO or its authorized representative, the
warranty period begins with the completed installation of the machine.
If a delay of installation occurs which is not caused by EMCO or its representative, the
warranty period becomes invalid 12 months after scheduled installation date.
2. The warranty extends to the elimination of all defects in material or workmanship which
affect the regular function of the machine.
3. Occuring defects must be immediately reported to the EMCO respresentative or the next
EMCO service department with detailed description of the defect in written or oral form,
followed by a written verification.
4. Defects which are correctly reported and under warranty will be corrected by either
repair or replacement delivery to the original buyer free-of-charge; defective parts are to
be returned to EMCO or the EMCO authorized respresentative, freight prepaid, if
requested.
5. Warranty for spare parts: Emco guarantees to the original buyer that, only those parts
sold directly by Emco or through an authorized representative will be free from defects,
which render part commercially unacceptable in material and workmanship, for a period
according to applicable national law, at least three (3) months, but not to exceed six (6)
months from the date of initial shipment or installation by Emco or its representative.
In the case of repeated claims for the same part: Warranty replacement does not extend
the period of the original warranty.
6. There is no claim of warranty for defects which occured by:
Negligence of operating instruction manuals, safety and handling regulations or other
instructions regarding delivery, installation, set-up or usage of the machine, incorrect
set-up resp. installation, as well as, unauthorized, not expressed regulated or allowed
alternations or modifications of the machine by the original buyer or third parties, natural
wear, improper or negligent handling, chemical, electro-chemical or electrical influences,
inadequate energy supply or force majeure.
7. Any service performed by EMCO or its authorized representative beyond warranty will
be charged at EMCOs or its authorized representatives regular rates.

SAFETY

RECOMMENDATIONS

Safety recommendations
Personal protective equipment
Do not wear loose working clothes. Mind that the
working clothes are tight around the wrists and
hips.
Mind that your hair does not get caught in the
machine (in such a case wear hair protection).
Protect your eyes with safety-glasses.
When removing chips use a chip hook and gloves.

Read instructions
Read the instructions completely before you start
up the machine.
Prior to start of work get familiar with all functions
and operating elements. During the work it might
be too late.
Electrical connection
Electrical connection of the machine must only
carried out by an authorized electrics expert.
Local protection measures have always to be
borne in mind.

Setting, maintenance and adjusting work


All setting, maintenance and adjusting work must
only be carried out during standstill of machine
and EMERGENCY-OFF key actuated.
The inspection and maintenance instructions for
machine and accessories are to be observed. This
saves costs, excludes major standstills of the
machine, reduces hazards and saves the environment.

Observe local regulations


Observe your country's regulations for work
involving machine tools and CNC machine tools
Authorized operation
The machine may only be operated by authorized
persons.
Authorized persons are exclusively persons
familiar with operation, maintenance and repair
and who are instructed on hazards.

Tools, operating materials and spare parts


Only use tools, operating materials and original
spare parts recommended by EMCO.
For parts not supplied by EMCO, EMCO does not
assume liability.

Protect machine
Protect the machine (main switch can be locked)
during adjustment, maintenance and repair work
against unauthorized start-up.

Disposal of noxious materials


When handling auxiliary and operating materials
(cooling lubricants, cleaning solutions, lubricating
oils, etc.) observe the safety regulations for these
materials.
Take adequate measures for the appropriate
storage and disposal of noxious materials.

Start-up
Make sure that prior to each start-up the machine
is in perfect maintenance state and that no safety
features have been removed.

Claim
In the event of a collision or other instance of
damage contact immediately the representative
or manufacturer.
In case of complaints, damage, confusions and
spare part orders always indicate the machine
number, electric number and software version.

No modifications on machine
Modifications on your own on safety features,
bridgings of control features as well as any
interference with the electric/electronic part of the
machine are prohibited.
In case of hazards EMERGENCY-OFF
In case of hazards immediately stop machine with
EMERGENCY-OFF.

Machine supervision
Never leave running machine unattended.
Before leaving the working place switch off
machine and protect against unauthorized startup (lock main switch and remove key).

Tool change
Change machining tools only during standstill of
machine. Only use tools and sealing bolts with O
ring on the shaft, always close all stations
(otherwise danger of coolant and chip entry in the
internal area of the tool turret!). In case of tool
change always turn driven tool holder into locking
position.

10

SAFETY

RECOMMENDATIONS

Danger, Attention, Note


Please always mind the regulations for prevention
accidents and safety rules indicated in the
individual chapters and the additional instructions.
Important instructions concerning the technical
safety and the staff protection are emphasized
particularly:

Danger
refers to possible danger to persons during
working and operating procedures.

Attention
is indicated in working and operating procedures which have to be observed exactly to
avoid possible damage of the machine and
slight danger of injury for operators.

Note
is indicated if something particular has to be
observed when an activity is carried out.

Enviromental Protection Notes


refer to the avoidance of special waste,
responsible handling of environmentally
noxious substances as well as possibilities
for saving auxiliary and operating materials.

11

12

TECHNICAL DATA

Technical data of the machine - metric


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Declaration of conformity

Product:

CNC Turning Centre

Machine data:

Model

Type

EMCO

ET 365

Address of manufactorer: Emco Maier Ges.m.b.H.


Salzachtal Bundesstrasse Nord 58
A-5400 Hallein

Bases of standards:

EN 292-1; EN 292-2; EN 294; EN 418; EN 60204-1; EN 954-1;


EN 1037; EN 1050; EN 1088

Regulations:

MSV (BGBl. Nr. 306/1994, 27.4.94)

Test certificates:

Particular notes,
enclosures:

Electrical documentation as applicable

We herewith declare that the above-mentioned product referring to the subject declaration is in conformity
with the currently valid stipulations of the directive of the Council dated June 22th, 1998 for the alignment
of the legal stipulations of the member states for machines (98/37/EEC), with the directive of the
Council dated May 3rd, 1989 for the alignment of the legal stipulations for electromagnetic compatibility
(89/336/EEC) and its modifications dated April 28th, 1992 (92/31/EEC) and July 22nd, 1993 (93/68/
EEC), and with the directive of the Council dated February 19th, 1973 concerning low voltage equipment
(73/23/EEC) and its modification dated July 22nd, 1993 (93/68/EEC).
Furthermore, the conformity of the subject product with the above-mentioned standard bases and
regulations is effective.

Place, date:

Hallein, 27.12.00

Authorized person: Head of quality department

EN

Peter Binggl

..............................................

A Installation of the machine


Machine acceptance
heck the machine for any transport damage and
completeness of the delivery.
If you find any defects, please contact the dealer
or the insurance company.
In case of complaints always specify the exact
designation of the machine and the machine
number and the electric number.

9
,
1 $

3(

Machine number

+]

,
PD[ $

The adhesive plate with the machine number (1)


is to be found laterally on the machine above the
lockable main switch.
The machine numer is also stamped into the
machine bed.

6

('RNX6HU1R 5$9%D
)DEU1R 5$1
%DXMDKU<HDURIFRQVWU 
0DGHE\(0&20$,(5*HVPE++DOOHLQ$8675,$

Electrics number

Machine number

The adhesive plate with the electrics number is


mounted on the left side of the machine on top at
the switch cabinet.
The electrics number consists of a 9-digit number
(2) followed by the version number (3).

R6A101000
SCHA. SCHR. MONT.

Example of a complete electrics number:

R6A 101 000 V1.30 (see illustration)


Verkabelung Maschine

Plan: 09 / 2

V 1.30

BAW.

Note:
The wiring diagrams valid for your machine
are to be found in the electrical documentation which is in the switch cabinet of the
machine.
An electrical documentation can also be
obtained under order number ZVP 674 150
and indicating the version number (e.g. V1.30)
from EMCO.

Electrics number

Operation panel number


R6A115000
BEDIENPULTMONT.

The adhesive plate with the operation panel


number is mounted on the rear side of the
operation panel.
The number consists of a nine-digit number (4)
and the version number (5).

Verkabelung Maschine

Plan: 09 / 2

V 1.00

BAW.

Example: R6A115000 V01.00

Operation panel number

A1

MACHINE ACCEPTANCE

INSTALLATION

Service

Diagnosis

displays

Software numbers

Version

For the full identification of the software of your


machine three numbers are necessary:

Siemens NC-software number (1)


Siemens MMC-software number (2)
EMCO software number (3)

Versiondates NCU
System

Versionstamp/date

Module-code

H0 kmpmain......

9001.34.07

34.07.00-NCU572
00000000000000000

Monitor Loader ....................................................................................................


Communic. Monitor .............................................................................................
Communic. System .............................................................................................
SIMATIC System .................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................

Siemens software numbers

1
Call-up of the Siemens NC-software number
Service

Diagnosis

displays

By pressing the respective softkeys you reach


the screen page on which the desired number is
to be found.

Version

Version

MMC

Siemens NC-number (1)


Diagnosis-menu/Service-displays/Version

Versiondates MMC

Siemens MMC-number (2)


File

Version

date

time

size

mmc0.exe

34.04

28.Jun.1996

13:32:14

162 133

File
File
File
File
File
File

...................
...................
...................
...................
...................
...................

...................
...................
...................
...................
...................
...................

.............
.............
.............
.............
.............
.............

.............
.............
.............
.............
.............
.............

Diagnosis-menu/Service-displays/Version/Version MMC

2
Call-up of the Siemens MMC-software number
Diagnosis

PLC-IBN

B W

PLC-Status-display
Operand
DB80.DBW0

Format

EMCO-software number

Value

0064

By pressing the opposite key combination the


page is called up on the screen of the control on
which the EMCO software number (3) is to be
seen (e.g. 0064).

3
Call-up of the EMCO-software number

A2

INSTALLATION

SCOPE OF SUPPLY

Enter machine and control specific numbers here!


Electrics number

Operation panel number

Siemens-NC-software number

Siemens-MMC-software number

EMCO-software number

Machine number

Numbers on the machine

Scope of supply
Basic machine

Modules

2-axes CNC lathe, incl. 12-fold tool turret with


direction logic, control, hydraulic unit, coolant
device, machine lamp, switch cabinet air conditioning device, interface for foot switch and
chip conveyor, workpiece counter, user's manual
and electrical documentaion.

Tool set

1
1
1
1
1
1
1
1
1

tailstock adapter (only tailstock machine)


ejection key for tailstock tools
tension tube spanner
spindleholder (for mounting the tension tube)
hook wrench
double-ended spanner 810
spanner 13
switchboard key SDB 3
Allan key SW 3, 4, 5, 6, 8, 10 each

Packing
The machine is delivered bolted to a wooden
pallet (4 saucer head screws M12). The outside
packaging depends on the country of destination
and the agreement made.
After unscrewing the hexagonal nuts M12/SW 19
the machine can be lifted off the pallet.

A3

SINUMERIK 810 D control


SINUMERIK 840 D control
spindle bore 45 mm
spindle bore 65 mm
clamping cylinder without bore
clamping cylinder with bore
12-fold TC tool turret
12-fold TCM tool turret
(driven tools)
tailstock
counter spindle 45 mm
counter spindle 65 mm
clamping cyl. without bore for counter spindle
clamping cyl. with bore for counter spindle
brake right side
gantry
automatic door mechanism
high-pressure pump
handwheel
signal lamp

TRANSPORT

INSTALLATION

Transport of machine
(119.96")

(76.417")

(60.079")

(5.079")

(37.598")

(6.575")

(45.079")

(42.402")

(14.567")
(42.717")
(127.953")

(85.827")

Position of stack forks(1) and of center of gravity of the machine with the transport

Transport with pallet


Caution:
The machine may only be transported on the
pallet if the machine is fixed on the pallet by
means of anchor bolts.

4 500 kg

Lifting capacity ............... min. 4 500 kg (9 920 lb)


Fork width ............................ min. 1 000 mm (40")
Fork length .......................... min. 1 800 mm (71")

transport with pallet

Transport without pallet


Attention:
The lifting points and the fork widths have
to be adhered to exactly so that there is no
deformation at the machine base.
The coolant tank must be removed during
transport.
Furthermore, the coolant pump(s) has
(have) to be lifted upward (see "transport
safety devices" in this chapter).

4 000 kg

Lifting capacity ............... min. 4 000 kg (8 820 lb)


Fork width ............................ min. 1 000 mm (40")
Fork length .......................... min. 1 800 mm (71")

transport without pallet

A4

INSTALLATION

TRANSPORT

Transport with crane

4 000 kg
8 820 lb

Transport with crane-rack

The crane-rack may be requested by EMCO if


needed.
Ref-No. .................................................... R60 007
Handle shackles (1) through the openings on
the top of the machine, and hang them into the
provided link plates on the machine-base.

Danger:
Pay attention to the safe load of the purchase!
The crane-rack may only be hanged in the
rails ans ears provided for, to avoid tipping
of the machine.

Hang in hoist arm (2) into the hooks in the chip


space.

A5

TRANSPORT

INSTALLATION

Transport safety devices


Mind:
Prior to start-up of the machine all transport
devices have to be removed.
Keep the transport safety devices and
remount them when transporting the machine again.

Transport safety device A


Securing of the control panel
Position:
on the upper side of the control
A

Transport safety device B

Front view of the machine - left side

Securing of the chip guard door


Position:
At the front side of the machine in the area of the
door handle

Transport safety device C


Securing of slide Z 2 (2 nd headstock)

Position:
Mounted between the spindle noses

Transport safety device D


Securing of the Z slide
Position:
Mounted at the pulley of the Z slide (slide for tool
turret)
The transport safety device D must be accessible
from the back side after opening the door (1).

Transport safety device E


E

Securing of the swivel device for the coolant


pumps (hexagon head screw M6 galvanized)

Position:
At the guide rail of the swivel device

Coolant pump
4

Detach pump bracket (4) with the mounted


coolant pump (5) by loosening the hexagon
socket screws (3).

Push bracket with pump (5) downward in the


long hole of the swivel device (2).
Hold pump min. 10 mm above the ground of the
coolant tank.

Lateral view of the machine - right side

Tighten hexagon socket screws (3).

A6

INSTALLATION

INSTALLATION

PLAN

Installation plan, dimensions of the machine

(73.701")

(37.795")

(43.228")

Basic machine

(20.866")

(14.646")
(119.961")

(24.094")
(67.245")

Hydraulic manometer
pressed air

(23.6")

(61")

(89")
(60")

(3.937")
(57.756")
(65.63")
(116.22")

(53.15")

(38.228")

(12.283")

(28.15") (12.008")

(38.78")

(25")

(25")

(23.6")

(76.417")

(24.67")

A Setting screws (8) resp. levelling elements (4)


(see "Installation criteria")

Space for operation

B Bores 18120 for anchor bolts


(0.709"4.724")

Space for maintenance

A7

INSTALLATION

INSTALLATION

PLAN

Machine with bar loader and


chip conveyor

Machine with gantry loader and


chip conveyor

A8

INSTALLATION

INSTALLATION CRITERIA

Installation criteria
Requirements on installation
surface
The machine is to be installed on a pavement as
horizontal as possible with adequate carrying
power and vibration stability.
When screwing down the machine bores for the
anchor bolts have to be mounted.

Installation possibilities

Note:
When using a gantry loader or a bar feed
magazine the machine has to be anchored
on the ground.

Aligning the machine

Anchoring on the ground


Required accessories (order no.):
1 set of setting angles (4 pcs.) ............... Q6Z 460
4 pcs. levelling elements ......................... 881 500
4 pcs. anchor bolts FHA 1860 B ............. 573 045

Drill 4 anchor bolts 18 120 in a distance of


1667 971 mm (see installation plan).

Place the machine above the bores.

Insert levelling elements (4) and align machine


horizontally.
80 Nm

Loosen setting angles (2) at the screws (1).

Thread in achor bolts (3) and push them into


the anchor bore until the distance between the
washer of the anchor bolt and the setting angle
(2) is approx. 5 mm (see sketch).
Retighten setting angle (2).

30 Nm

Pretension anchor bolts (3) with 80 Nm.


(anchorage in the ground)
Reloosen hexagon nuts of the anchor bolts and
attach insulating disk (5).

Tighten anchor bolts with 30 Nm (holding down


the machine).

Installation with levelling shoes and anchor bolts

A9

INSTALLATION CRITERIA

INSTALLATION

Without anchorage on the ground


Insert levelling elements (4) and align machine
horizontally.

Notes:
If the machine is not anchored, you can also
use setting screws M2080 DIN 933-8.8 (8)
with counter nuts (7) instead of levelling
elements.
Steel plates10020 (6) have to be placed
below the setting screws.
Mind: no vibration damping!

7 8

Installation without anchorage

Additional criteria for


installation
In addition to the required capacity and vibration
stability further requirements are to be met by
the installation surface and the installation site:

The specific noise load of a machine operator


is to be noted.
It has to be taken into account that in accordance with the operating situation a highly
qualified operator works on the lathes who
has to carry out exacting programming and
supervising activities.

The installation site has to comply with


building authority regulations so that in case
of possible leakage of cooling lubricant,
lubricating and hydraulic oil, the environment
is not burdened.

Sometimes the situation can be improved by


sound insulation walls.

An ideal situation would be provided if the


installtion site at the same time fulfilled the
function of a collecting tray.

From studies we know that the double distance to a nearby source of noise decreases
the sound level by 3 to 5 dB(A).

Vibration-proof features as favourable as


possible to avoid a transmission of vibrations
(particularly when working in the upper speed
range, with bar work, when machining heavily
unbalanced workpieces, with interrupted cut,
when using driven tools etc.) to nearby
objects.

When doubling the number of similar sources


of noise the level is increased by 3 dB(A).
Heat sources with inconstant temperature
near the machine as well as air drafts will
influence the quality of the place of work as
well as the operating position of the machine.
If necessary, adequate measures for protection are to be taken.

Good and sufficient lighting of the working


space facilitates operation of the machine and
increases the quality of work.
Unfavourable light and sun radiation may lead
to reflections on the control screen and, thus,
impair the visibility of information items.

A10

INSTALLATION

ELECTRICAL CONNECTION

Electrical connection - Machines with control


Sinumerik 810D/840D
Danger:
The electrical connection of the machine and
its accessories may only be established by
an electrics expert.
Feed cables must be idle during the connection.

Terminal strip
+1DL2-X1
   

Electrical connection of the


machine
Remove side wall (3).

/ / / 3(

Unscrew cover (2).


2

Thread feed cable (4) from below through the


cable screwed joint into the connecting box
under the cover (2).

Connect the three pases L1, L2 and L3 to the


terminal strip +1DL2-X1 (1) (connecting terminals 1, 2 and 3).
Connect earth contact (yellow/green core) to
the connecting terminal 4 of the terminal strip
(1).
Remount cover (2) and side wall (3).
Control of the correct connection
Control the connection by checking the rotary
direction of the hydraulic unit (5) or the switch
cabinet fan (6).
The rotary direction of the hydraulic unit (5) is
marked at the fan cover.
In case of wrong rotary direction switch off the
machine immediately and interchange two
phases of the main connection.

left side of the machine - E-connection

Caution:
Connecting this machine to a mains protected
by leakage current circuit breaker is admittable
only with using an all-current-sensitive
leakage current breaker.
Reason:
The drives used for this machine can cause
DC leakage currents which will impair the
protective function of the leakage current
breaker (no release).
Types of the all-current-sensitive leakage
current breaker tested by EMCO:

SIEMENS 5 SZ6 468 - OKG00


EMCO Order-no. ZME 280 720
ABB F804 - 63/0,3

back-side of the machine

A11

ELECTRICAL CONNECTION

INSTALLATION

Mains connection data

Attention:
A preliminary fuse is ordered forcible!
The specified value of the fuse has to be kept
strictly.

Machine without counter spindle


Power supply ................................... 3/PE 400V ~
Frequency ............................................... 50/60 Hz
Max. voltage fluctuations ........................ +5/-10%
Connected load ......................................... 20 kVA
Max. preliminary fuse ........................... 50 A/slow
Required short circuit power ................ 1100 kVA
Feed cross section .......... acc.to local regulations

Machine with counter spindle


Power supply .................................. 3//PE 400V ~
Frequency ............................................... 50/60 Hz
Max. voltage fluctuations ........................ +5/-10%
Connected load - spindle 45 .................. 25 kVA
Connected load - spindle 65 .................. 28 kVA
Max.preliminary fuse - spindle 45 ..... 50 A/slow
Max.preliminary fuse - spindle 65 ..... 63 A/slow
Required short circuit power ................ 1100 kVA
Feed cross section ......... acc. to local regulations

Note:
Further information about electrical connection is to be found in the electrical documentation of your machine.
In case of different specifications the data in
the electrical documentation are valid.

A12

INSTALLATION

ELECTRICAL CONNECTION

Electrical connection Machines with FanucControl


By machines with Fanuc-control the electrical
connection has to be established on the right side
of the machine, where the ballast transformer is
mounted.

Danger:
The electrical connection of the machine and
its accessories may only be established by
an electrics expert.
Feed cables must be idle during the connection. Follow also the local regulations!
1

Set main switch (2) to position "0".

Ballast transformer on the machine


terminal part B

Dismount transformer cover (1).


Thread feed cable (3) through the cable screwed
at the bottom of the transformer box.

terminal part A

Connect the three phases of the feed cable to


the fuse terminals.
(terminal part A - see illustration beside)

3( / / /

Connect earth contact to the earth terminal.




3
0

3(

              























































Caution:
The cable (4) is set to the standard connection,
the 400V-variant.
By using other voltage variants the cable
(4) has to be reconnected!
Be sure, that only the yellow cable (4) will
be reconnected.
The connections of all other cables in the
tronsformer may not be changed, otherwise
the electrical part of the machine could be
damaged.

Terminal strip of the transformer




(
3

3
0



/

  





/

          





/





/





/





/











/ / /

Reconnect cable (4) to the voltage variant you


need.
(terminal part B - see illustration beside)

Mount cover (1).


3230 VAC

3400 VAC
3480 VAC
(standard)

The machine will be switched ON with the main


switch (2).

Voltage variants, terminal part B

A13

ELECTRICAL CONNECTION / PNEUMATIC CONNECTION

INSTALLATION

Mains connection data


Attention:
A preliminary fuse is ordered forcible!
The specified value of the fuse has to be kept
strictly.
Power supply .................................. 3/PE ~ 400 V
3/PE ~ 230 V
3/PE ~ 480 V
Frequency ............................................... 50/60 Hz
Max. voltage fluctuations ........................ +5/-10%
Connected load ......................................... 20 kVA
Max. preliminary fuse:
400V-Version ........................................ 63 A/slow
230V-Version ........................................ 50 A/slow
480V-Version ........................................ 32 A/slow
Required short circuit power ................ 1100 kVA
Feed cross section .......... acc.to local regulations

Note:
Further information about electrical connection is to be found in the electrical documentation of your machine.
In case of different specifications the data in
the electrical documentation are valid.
1
p = 6 bar
p = 87 psi

Pneumatic connection
Supply pressure .............................. 6 bar (87 psi)
Supply quantity .............................. min. 300 l/min

Connect air supply at the connection piece (3)


of the pneumatic unit laterally at the machine
(compressed air supply 10 mm).

open

By pushing the manual slide (2) upward the


pneumatic maintenance unit is supplied with
compressed air.

close

The air pressure set is to be seen at the


manometer (1) of the machine.

Closing the air supply by pushing the manual


slide (2) downward.

Rear side of the machine - air supply

A14

INSTALLATION

INITIAL START-UP

Initial start-up
All bright parts are sprayed with oil-soluble
preservation agent and need not be treated prior
to initial start-up.
Check the oil level for the central lubrication on
the rear side of the machine on the tank (3), if
necessary refill oil.
Connect compressed air.
Check oil level of the hydraulics on the oil level
gauge (4) on the rear side of the machine, if
necessary refill oil.
Therefore open door (5).

Fill coolant into coolant tank (2) (filling capacity


230 l; also see coolant recommendations).
To draw out coolant lubricant tank see "Coolant
device" in chapter "E Maintenace".

Lateral view of the machine - main switch

Switch on machine at main switch (1).


Press "AUX-ON" key on the operation panel of
the control, thus the auxiliary units are switched
on.
After major standstills this key should be
subsequently pressed various times and in case
of initial start approx. 10 times.
Every time the key is pressed a lubricating
impulse is emitted to the slideways and ball
screws.
Further operation is described in chapter "C
operation and programming EMCO specific".

Notes:
Filling quantities, qualities and recommendations for lubricants, hydraulic oil and
cooling lubricant are to be found in the
chapter "Maintenance".
In case that no hydraulic pressure is built
up after switching on the auxiliary drives
(key "AUX ON"), the mains connection is
probably wrong (wrong rotary field).
Remedy: Clamp two phases interchanged
(see Electrical documentation).

Rear view of the machine - oils

A15

B Description and operation


1

1
2
3
4
5
6
7
8
9

B1

Sinumerik 810 D or 840 D control


Electric handwheel (option)
Main spindle
Tool turret (12-fold)
Counter spindle or tailstock
Main switch
Manometer fr spindle 1
Manometer for spindle 2/tailstock
Inspection glass for coolant level

REFERENCE POINTS

DESCRIPTION

Reference points
Machine zero point M
The machine zero point lies exactly in the rotating
axis of the machine at the plane face of the main
spindle nose (spindle 1).

Tool fixture reference point T


The tool fixture reference point T lies at the
surface area of the tool turret disc in the axis of
the tool station.

Reference points on the machine

Measurement of the tools


The tool fixture reference point T is described
from an incremental coordinate system whose
origin lies in the tool tip.

Note:
EMCO offers special devices for easy measurement of the tools.

Coordinate system

Measurements of the tools

Coordinate system

B2

DESCRIPTION

WORKING AREA

Working area

size 65

size 45

*)

Dimension 100 mm (3.94") with adapter (included in the additional pack of the basic machine)

B3

TOOL

DESCRIPTION

TURRET

Tool turret
The EMCOTURN 365 is equipped with a 12-fold
tool turret.
Depending on the type of the machine the tools
can also be driven.
Number of tool supports ................................... 12
Tool supports acc. to DIN69880 ............... VDI 30
driven tool stations (optional):
number of driven stations ................................. 12
torque (const. with 40% DC) .. 16 Nm (11.8 ftlbf)
speed range ....................................... 0-4000 rpm

Working area

Working area of the tool turret disk (metric)

Note:
The opposite figure is valid for all types of
tool turrets.
(Machines with and without driven tools.)

Tooling the tool turret


Working area of the tool turret disk (inch)
Danger:
Tooling the tool turret may only be carried out
during standstill of the machine.
Insert tool turret VDI (5) into support (2) of the
tool turret disc (1).
)

)

1
2the VDI
3 toolholder
4
Mounting

Turn hexagon socket screw (3) in the direction


of the arrow and tighten it.
The toothing of the eccentric (4) engages in the
toothing of the toolholder (5), pressing it against
the tool turret disc (force F 1) and upward at the
same time (force F 2).
In clamped condition the toolholder lies on the
clamping surface of the tool turret disc and is
fixed in the centre axis of the VDI mounting
bore.

B4

DESCRIPTION

TOOL

TURRET

Attention:
Tool supports not used have to be closed
with a VDI cover holder with O-ring.
Thus, the penetration of coolant and chips
is avoided.
Use indexable insert geometries which
guarantee short-chip material machining.
Long chips might jam tools, tool turrets and
clamping devices and also impair cutting
results. Long chips might also cause problems during clamping in the counter headstock.
Furthermore, the machine is cleaned easier
from short chips than from long ones.
Prior to refeeding the bar material move the
tool turret near (approx. 2-3 mm) the
clamping devices of the main headstock.
Only then refeed bar. Then move tool turret
together with bar material to the desired
length. Otherwise damage or dislocating of
the tool turret is possible.
Use an absorbing toolholder for the stop
(EMCO accessories).

Weight counterbalance
Attention:
To avoid unnecessary disturbances on the tool
turret during tooling of the tool turret you have
to pay attention to an adequate weight
counterbalance.

max. 32 Nm
(23.6 ftlbf)

Weight moment .......... max. 32 Nm (23.6 ftlbf)


Tool tool turret always in such a way that the tool
weights are distributed as evenly as possible on
the tool turret disc.
The maximum weight moment must on no account
be exceeded, otherwise disturbances on the tool
turret might occur.
The reason for this can be found in too high loads
during the switch-over of the tool turret drive
between swivel device and the driven tools.

even tooling of the tool turret

B5

MAIN SPINDLE 65

DESCRIPTION

The main spindle 65


Note:
The following data are valid for spindle 1 (left)
as well as for spindle 2 (right).

Spindle connection .......... acc. to DIN 55 026-A6


Chuck size spindle 1/2 ............. max. 9.8"/7.8"
Speed ......................................... max. 4 200 min-1
Torque spindle 1/2 ................... max. 114/94 ftlbf
Clamping system:
Cylinder with bore ....................... hole max. 2.6"
Cyl. without bore ............. chuck parts max. 7.8"

Spindle connection .......... acc. to DIN 55 026-A6


Chuck size spindle 1/2 ....... max. 250/200 mm
Speed ......................................... max. 4 200 min-1
Torque spindle 1/2 ................... max. 155/128 Nm
Clamping system:
Cylinder with bore ............... hole max. 66.5 mm
Cyl. without bore ...... chuck parts max. 200 mm

Dimensions spindle connection

Section AA:

Connection dimensions of the main spindle 65

B6

DESCRIPTION

MAIN SPINDLE 65

Clamping cylinder with bore


Hydraulic clamping cylinder with bore
Rhm SZS-E 66/120
Type ............................. 459-109 with safety valve
Piston stroke .................................. 35 mm (1.38")
Piston area A ..................................... 105.8 cm
B ..................................... 120.0 cm
Working pressure ............... max. 50 bar (725 psi)
Speed ......................................... max. 5 000 min-1
dyn. balanced .................. Q 6.3 acc. to VDI 2060

Clamping cylinder with bore for spindle 65

B7

MAIN SPINDLE 65

DESCRIPTION

Clamping cylinder without bore


Hydraulic cylinder without bore
Rhm OVS 115
with safety valve
Piston stroke .................................. 32 mm (1.26")
Piston area A ....................................... 87,9 cm
B ....................................... 91,3 cm
Working pressure ............... max. 50 bar (725 psi)
Speed ......................................... max. 6 500 min-1
dyn. balanced .................. Q 6,3 acc. to VDI 2060

Clamping cylinder without bore for spindle 65 and 45

B8

DESCRIPTION

MAIN SPINDLE 65

Connection values for tensioning tubes


Machine with clamping cylinder with bore

stroke 35

connection values for tensioning tubes 65, clamping cylinder with bore

Machine without clamping cylinder with bore

stroke 32

Clamping cylinder for tensioning tubes 65, clamping cylinder without bore

B9

MAIN SPINDLE 45

DESCRIPTION

The Main Spindle 45


Note:
The following data are valid for spindle 1 (left)
as well as for spindle 2 (right).

Spindle connection .......... acc. to DIN 55 026-A5


Chuck size spindle 1/2 ....................... max. 6.3"
Speed ......................................... max. 6 300 min-1
Torque spindle 1/2 ............................ max. 86 Nm
Clamping system:
Cylinder with bore ..................... hole max. 1.79"
Cyl. without bore ............. chuck parts max. 6.3"

Spindle connection .......... acc. to DIN 55 026-A5


Chuck size spindle 1/2 ................ max. 160 mm
Speed ......................................... max. 6 300 min-1
Torque spindle 1/2 ............................ max. 86 Nm
Clamping system:
Cylinder with bore ............... hole max. 45,5 mm
Cyl. without bore ...... chuck parts max. 160 mm

Dimensions spindle connection

Section AA:

Connection dimensions of the main spindle 45

B10

DESCRIPTION

MAIN SPINDLE 45

Clamping cylinder with bore


Hydraulischer Hohlspannzylinder
Rhm SZS-E 45/102
Typ ......................... 459-109 mit Sicherheitsventil
Kolbenhub ........................................ 25 mm (.98")
Kolbenflche A ....................................... 92,0 cm
B ..................................... 102,5 cm
Betriebsdruck ..................... max. 50 bar (725 psi)
Drehzahl ..................................... max. 6 300 min-1
dyn. gewuchtet ................... Q 6,3 nach VDI 2060

Clamping cylinder with bore for spindle 45

Clamping cylinder without bore


The clamping cylinder without bore for the spindle
45 is identical with that of spindle 65.
Data and connection values are to be seen at the
beginning of this chapter under "Spindle 65 /
clamping cylinder without bore".

B11

MAIN SPINDLE 45

DESCRIPTION

Connection values for


tensioning tubes
Machine with clamping cylinder
with bore

stroke 25

connection values for tensioning tubes 45, clamping cylinder with bore

Machine with clamping cylinder


without bore

stroke 32

Clamping cylinder for tensioning tubes 45, clamping cylinder without bore

B12

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 65

Clamping devices General hints


The position of the tensioning tube during
mounting and changing the collets has to be
observed.
The following table is valid for machines with
clamping cylinder without bore and with bore.

Position of tensioning tube during the change of clamping devices


Chuck (jaw chuck)
Dismounting

Pull collet chuck


(Hainbuch collet chuck)
Dismounting
Mounting
Collet changing

spindle 1

Mounting

Pressure collet chuck


(Rhm chuck)
Dismounting
Mounting
Collet changing

chuck closed
Dismounting

Mounting

Dismounting
Collet changing

collet open
Mounting

Dismounting
Collet changing

spindle 2

Mounting

collet open

chuck closed

collet open

collet open

With using own clamping devices, they have to


be balanced exactly.
When working with the bar feed you have to
take care that the diameters of the guide tube
and the spindle insert sleeves are exactly in
conformity.

Notes:
The switch-over of the control from condition
"chuck" to "collet" is described in chapter "C
Operation and Programming EMCO-specific"
under "Machine configuration".
For setting the clamping device control see
chapter "C/D Programming and Operation".
For setting the clamping pressure see
"Hydraulics" further below in this chapter.

The delivered tensening tube fits to the power


chuck and the collet chuck.
Mind that clamping devices are maintained and
serviced according to the manufacturer's
regulations.
Safe clamping and a long durability can only be
guaranteed observing this item.

B13

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Clamping devices - spindle 65


Screwing the tensioning tube
into the clamping cylinder
Hazard:
Screwing in the tensioning tube into the
clamping cylinder may only be carried out
during machine standstill.
The procedure described in the following is valid
for cylinders with bore and without bore.
Screwing in is carried out with dismounted
clamping device.
Insert tube (1) from the front into the main
spindle (2) until stop and turn it into the support
of the clamping cylinder.
1

Tighten tensioning tube (1) with the tensioning


tube key (4) supplied.
The main spindle is held tight with the key (3).

Mounting the tensioning tube

Spindle insert sleeves


The insert sleeves are necessary for work with
the bar feed facility and with workpieces protruding far into the main spindle.
10 insert sleeves for each case are necessary.
These insert sleeves have to be hollowed out by
the customer to the necessary internal diameter.

Caution:
Without the adequate insert sleeves problems
during machining may occur (unbalanced
mass, bad workpiece quality).
5

5
6
7
8

workpiece
insert sleeves
tensioning tube
clamping device

Order numbers
Adapter set consisting of fixing flange,
clamping nut, counter sleeve and various fixation
material .................................................... R6Z 260
1 insert sleeve ......................................... R6Z 270

Clamping principle with insert sleeves

Necessary hollow-out diameter


D nec = D W+1
D nec [mm] ..... necessary hollow-out diameter
D W [mm] ..... workpiece diameter

B14

DESCRIPTION

1 2

CLAMPING DEVICES FOR SPINDLE 65

5 6 7

Mounting the insert sleeves

Hazard:
Mounting the spindle insert tube may only be
carried out during machine standstill.
Raise cover (1) after loosening the clamping
screw.
Loosen fastening screw (2) and take off second
cover (3) upwards.
Screw fixing flange (7) onto the clamping
cylinder with bore (9) by means of the enclosed
three hexagon socket screws M58 (8).
Insert counter sleeve (11) into the tensioning
tube (10) and mount clamping device (12) (see
specific clamping device).
Insert insert sleeves (6) from behind through
the clamping cylinder with bore and the
tensioning tube.
You need 10 insert sleeves which have to be
hollowed out to the diameter corresponding to
the bar material.
Screw clamping nut (5) onto the fixing flange
(7) to fix the insert sleeves.
Fasten clamping nut (5) with moderate manual
force.
Fixation of the clamping nut (5) by tightening
the hexagon socket screws M625 (4).
Remount cover (3) and close and clamp cover
(1).

Mounting the insert sleeves - figure 1

Dismounting the insert sleeves


After unscrewing the clamping nut (5) the insert
sleeves can be pushed out backward by means
of a suitable tube (13 ) (collect insert sleeves).
The diameter of the tube (13) must be larger than
the internal diameter of the insert sleeve.
10 6

11

12

The insert sleeves can also be pushed out forward


after removing the chuck (insert sleeves fall into
the chip room).

Mounting the insert sleeves - figure 2

Notes:
At least every second insert sleeve must
have the necessary hollow-out diameter,
each first insert sleeve may have a larger
internal diameter.
The fixation flange (7) need not be dismounted any more after taking off the insert
sleeves.

13

Dismounting the insert sleeves

B15

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Three-jaw power chuck


The following three power clamping chucks are
available for spindle 65:
Chuck
Power chuck KFD-HS 175/3
Power chuck KFD-HS 200/3
Power chuck KFD-HS 250/3

Ord.-nr.
438 060
571 200
586 160

Attention:
To guarantee faultless function and disturbance-free operation of the chuck please also
observe the manufacturer's instruction enclosed with the respective chuck.

Mounting the chuck


Screw in tensioning tube and traverse into
foremost position (tensioning tube projects from
spindle).
3

Clean carefully chuck support of the main


spindle and thread connection of the tensioning
tube.

Mounting chuck KFD-HS 175/3 and 200/3

KFD-HS 175/3 and 200/3:


Pull clamping cylinder (2) in chuck (1) in
maximum rear position (jaws in max. internal
position).

KFD-HS 250/3:
Push clamping cylinder (6) in chuck (5) in front
position (jaws in outermost position).
Remove screw plugs (4) and press fastening
screws (3) of the chuck to the inside.

Turn chuck until stop onto the tensioning tube.


Take care that the threads of chuck and
tensioning tube are not damaged.

Turn back chuck until the carrier of the main


spindle can be inserted into the chuck support.
In this position press chuck against main spindle
and tighten fastening screws (3) reciprocally.
Check minimum size "X" and correct it if
necessary (see next page).
Check function and jaw stroke of the chuck.
Mount screw plugs (4).
3

Check chuck regarding facing accuracy and true


running.

Mounting chuck KFD-HS 250/3

B16

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 65

Adjusting the minimum value "X"


To be able to guarantee faultless function of the
chuck, the minimum value "X" has to be in
accordance with the following table.
Min. value X

Chuck

+1

KFD-HS 175/3

25,5 0,5

KFD-HS 200/3

24,5 0,5

KFD-HS 250/3

32,3 0,5

+1
+1

Chuck KFD-HS 175/3 and 200/3:


Loosen fastening screws (3).
Adjust minimum value X by turning the chuck
against the main spindle.
Refix chuck on the main spindle.
3
Chuck KFD-HS 250/3:
The minimum value X is adjusted by turning the
insert nut (7) against the tensioning tube.

Adjusting the minimum value X (KFD-HS 250/3)

Dimensions of the chuck

Note:
Single chuck dimensions may deviate from
the dimensions indicated in the instruction
enclosed with the chuck.

Dimensions of the chuck


Chuck
KFD-HS 175/3
KFD-HS 200/3
KFD-HS 250/3

amin bmin
c
amax bmax
29

33

24,5

35

8,5

40

32,5

43,8

50

47,5

d A C D* E

L M N

15

55 175 108

16

133,4 M12 19,45 2,5

56

68

19

60 200 110

16

133,4 M12 19,45 2,5

66

80

19

75 250 130

15

133,4 M12 19,45 2,5

66

80

*) short cone size acc. to DIN 55 026

B17

Omin
Omax
16
31
16,5
35
2
25

M721,5 108 M8
M721,5 112 M12
M721,5 132 M12

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Dimensions of the jaws


Reversible interchangeable jaws UB, hardened
The jaws enclosed with the chucks are already
ground at the chuck.

$
*

A
B
C
DH7
E
F
G
H
J
K
L
M
N
O
P
Q
R
Weight
Ord.-nr.

&

2
-

1
.


4 +
'

hardened reversible interchangeable jaws UB

KFD-HS
175/3
56
26
37,5
12
3,5
14
15
29
8,4
13,5
20
10
4
4
5
5
1/16"90
0,17 kg
574 675

KFD-HS
200/3
68
34,7
45
17
5
17
19
33,5
13
19
20
10
5
7
10
5
1/16"90
0,35 kg
571 220

KFD-HS
250/3
75
36
19
17
5
21,5
19
37,5
13
19
24
12
6
7,5
18
7
1/16"90
0,46 kg
586 175

Soft top jaws AB


For high-accuracy clamping.
The jaws are to be turned under clamping force
to the desired diameter.
Jaws hardened subsequently have to be ground.

&
-

A
B
C
D+0,05
E
F
G
H
J
K
R
Weight
Ord.-nr.

(
' 

%
$

soft top jaws AB

B18

KFD-HS
175/3
55
26,5
38
12
3,5
31
15
28
8,4
13,5
1/16"90
0,32 kg
R3Y 230

KFD-HS
200/3
66,7
36,5
53
17
5
36
19
43
13
19
1/16"90
0,7 kg
R3Y 410

KFD-HS
250/3
75
36,5
53
17
5
44
19
43
13
19
1/16"90
0,88 kg
586 165

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Clamping ranges of the chuck


The clamping ranges are valid for chuck KFD-HS
with reversible interchangeable jaws UB.

KFD-HS 175/3
KFD-HS 200/3
KFD-HS 250/3

A1
6 - 82
12 - 98
22 - 144

A2

26 - 112
40 - 156

A3
54 - 133
82 - 165
94 - 210

A4
90 - 180
132 - 218
146 - 262

J1
36 - 114
61 - 144
76 - 192

J2
71 - 149
110 - 198
128 - 244

J3
116 - 196
162 - 248
182 - 298

Clamping force diagram KFD-HS 175/3


clamping cylinder without bore
Clamping force [daN]

Clamping force [daN]

clamping cylinder with bore

hydraulic pressure [bar]


max. pressure

Clamping force of the jaws

Actuating force at the tensioning tube

Total clamping force [daN]

hydraulic pressure [bar]


max. pressure

Reduction of clamping force with


high speeds

A
B

Minimum centrifugal force of the


top jaw;

Maximum centrifugal force of the


top jaw;
Speed [min-1]

B19

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Clamping force diagram KFD-HS 200/3


clamping cylinder with bore
Clamping force [daN]

Clamping force [daN]

clamping cylinder with bore

1
2

hydraulic pressure [bar]

hydraulic pressure [bar]

Total clamping force [daN]

A
B

Minimum centrifugal force of the


top jaw;

Grte Fliehkraft der Aufsatzbacke;


Speed [min-1]

Clamping force of the jaws

Actuating force at the tensioning tube

Clamping force diagram KFD-HS 250/3


clamping cylinder with bore
Clamping force [daN]

Clamping force [daN]

clamping cylinder with bore

hydraulic pressure [bar]

hydraulic pressure [bar]

Total clamping force [daN]

Minimum centrifugal force of the


top jaw;

A
B

Maximum centrifugal force of the


top jaw;
Speed [min-1]

B20

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 65

Collet chuck QUADRO-NC


Technical data
Clamping range:
acc. to clamping variant ................ 3 to 65 mm
Suitable collets ....................... 185E, RF52, 173E
max. actuating force ........... 3 000 daN (6700 lbf)
max. speed .......................................... 4 000 min-1

Clamping possibilities - outline

185E, 4-60 mm

variant 1

union
nut 1
RF52,
35-61 mm
body

61-65 mm

variant 2

2 RF52, 35-61 mm

61-65 mm
variant 3

173E, 3-42 mm

Outline of clamping possibilities (order numbers see variants)

B21

union
nut 2

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Clamping variant 1 (basic variant)


The basic variant comprises the following components:
body (1)
pressure sleeve (2)
union nut 1 (3)

order no. 586 390

Suitable collets
Steel collets
E 185 .................................................... 4-60 mm
E 185 .. SW8-17, 19, 22, 24, 27, 30, 32, 36 mm
E 185 .............. SW7-16, 18, 20, 22, 25, 40 mm

Rubberflex collets
RF 52 .................................................. 35-61 mm
Steel collets ........................................ 61-65 mm

Clamping variant 1

Clamping variant 2
In contrast to variant 1, a double clamping
pressure sleeve (5) is mounted here.
Union nut (3) and body (1) are used from the
basic variant.
Double clamping pressure sleeve
order no. ................................................... 586 120

Note:
When clamping with the double clamping
pressure sleeve (5) a spacer is put between
the collets.
Suitable spacers are available with EMCO.

Clamping variant 2

Clamping variant 3
In this variant a pressure sleeve (6) for collets of
series 173 E is mounted into the body (1) of variant 1.
A particular union nut (7) is necessary.
Pressure sleeve with union nut
order no. ................................................... 586 395
Collets
173 E .................................................... 3-42 mm
6

Clamping variant 3

B22

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 65

Mounting the collet chuck


Screw in tensioning tube and traverse it into
foremost position (tensioning tube protrudes
spindle).
1

Remove dirt from spindle nose and tensioning


tube connection.

Insert pressure sleeve (5) into the body (3)


according to the collets to be used and fix with
screw (4).
Insert collet (6).
If the double clamping pressure sleeve (clamping variant 2) is used insert the 1st collet after
securing the 1 st pressure sleeve, introduce
spacer, then insert the 2 nd pressure sleeve with
the second collet.
Screw on union nut (8) by means of the doubleended wrench supplied and secure with screw
(7).
Screw preassembled unit onto the tensioning
tube; observe position of the driver (2).
Reduce clamping pressure to approx. 4.5 bar
and traverse tensioning tube into rear position
(open collet).

Mounting the collet chuck

Screw collet chuck tight onto spindle nose with


tensioning screws M12 (1).
Functional test:
It must be possible to open and close the collet
with a clamping pressure of 4.5 bar.
Dismounting the chuck is carried out according
to mounting in reverse sequence.

Changing the collets


Traverse clamping cylinder into rear position
(clamping cylinder open).
Caution:
If the union nut is screwed off with closed
collet, the screw (4) is damaged, a faultless
function of the chuck cannot be guaranteed
any more.

Screw off union nut (8) after loosening the


securing screw (7) by means of the doubleended wrench.
Exchange collet (6).
Screw on union nut (8) again and secure with
the screw (7).
Note:
For changing the collets with clamping variant 2 (double clamping pressure sleeve) the
entire chuck has to be dismounted from the
spindle.
For changing the pressure sleeves the
complete collet chuck has to be dismounted.

B23

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Clamping force diagrams

Caution:
To avoid damages at the collet chuck the
maximum actuating force of 3 000 daN (6700 lbf)
must not be exceeded.

Clamping cylinder without bore

cl

am

pi

ng

fo

rc

Clamping force [daN]

Clamping fore [daN]

Clamping cylinder with bore

force
ating
actu

hydraulic pressure [bar]

cla

pi

ng

fo

rc

t
actua

orce
ing f

hydraulic pressure [bar]

B24

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 65

End face driver


Order no. ................................................. 586 140

Spannkreis-

The basic equipment comprises the end face


driver including lathe center and carrier plates for
turning work in anticlockwise rotation.
Clamping circle diameter ................ 13100 mm

Mounting the end face driver

Danger:
Mounting the end face driver may only be
carried out during standstill of the machine.
Dismount the tensioning tube.
1

Carefully clean the spindle bore.

Put end face driver (3) on the spindle nose and


fix it with the screws M12 (1).
In doing so, observe the position of the recess
(2) for the driver on the main spindle.

Mounting the end face driver

Put the respective carrier plate (5) onto the end


face driver; (4) mind driver.

Dimensions of the carrier plates


Carrier plates - toothed
Clamping circle
Rotation
diameter
range [mm]
S [mm]

Carrier plates - toothed

12
20
32

Rotation
direction

left
left
left

7
13
22

36
30
30

4
4
10

13 - 24
21 - 40
33 - 64

Carrier plates with interchangeable


HM-driving chucks 9.53.2
(4-sided usable)
Clamping circle
diameter
S [mm]

Rotation range
[mm]

50

51 - 100

25

24

If during work with end face drivers straight or


right tools are used, you have to use a special
toolholder so that the tool can be machined across
the entire length.

Carrier plates with HM driving chucks

B25

CLAMPING DEVICES FOR SPINDLE 65

DESCRIPTION

Clamping force diagram for end face


driver
Clamping ratio [1]
Rotation diam./Clamping circle diam.

Ftail [daN]
Standard
values for
tailstock

Chip section [mm]


(chip depth feed)

Workpiece strength
[daN/mm]

Example:

tail

Chip section ............................... 30.3 = 0.9 mm


Workpiece strength ........................... 63 daN/mm
Clamping ratio ..................................... 60/50 = 1.2

Rotation
diam.50

Clamping circle
diam. 50

Machining A (turning against headstock):

Tailstock force acc. to diagram:


Ftail = 160 daN
Machining B (radial cut):
Conversion factor: .................................. 1,5 F tail
Machining C (turning against tailstock):
Conversion factor: ......................................2 F tail

B26

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 45

Clamping devices - spindle 45


Screwing the tensioning tube
into the clamping cylinder
Hazard:
Screwing in the tensioning tube into the
clamping cylinder may only be carried out
during machine standstill.
The procedure described in the following is valid
for cylinders with bore and without bore.
Screwing in is carried out with dismounted
clamping device.
Insert tube (1) from the front into the main
spindle (2) until stop and turn it into the support
of the clamping cylinder.
1

Tighten tensioning tube (1) with the tensioning


tube key (4) supplied.
The main spindle is held tight with the key (3).

Mounting the tensioning tube

Spindle insert sleeves


The insert sleeves are necessary for work with
the bar feed facility and with workpieces protruding far into the main spindle.
11 insert sleeves for each case are necessary.
These insert sleeves have to be hollowed out by
the customer to the necessary internal diameter.

Caution:
Without the adequate insert sleeves problems
during machining may occur (unbalanced
mass, bad workpiece quality).
5

5
6
7
8

workpiece
insert sleeves
tensioning tube
clamping device

Order numbers
Adapter set consisting of fixing flange,
clamping nut, counter sleeve and various fixation
material .................................................... R6Z 210
1 insert sleeve ......................................... R6Z 220

Clamping principle with insert sleeves

Necessary hollow-out diameter


D nec = D W+1
D nec [mm] ..... necessary hollow-out diameter
D W [mm] ..... workpiece diameter

B27

CLAMPING DEVICES FOR SPINDLE 45

1 2

5 6 7

DESCRIPTION

Mounting the insert sleeves

Hazard:
Mounting the spindle insert tube may only be
carried out during machine standstill.
Raise cover (1) after loosening the clamping
screw.
Loosen fastening screw (2) and take off second
cover (3) upwards.
Screw fixing flange (7) onto the clamping
cylinder with bore (9) by means of the enclosed
three hexagon socket screws M58 (8).
Insert counter sleeve (11) into the tensioning
tube (10) and mount clamping device (12) (see
specific clamping device).
Insert insert sleeves (6) from behind through
the clamping cylinder with bore and the tensioning tube.
You need 10 insert sleeves which have to be
hollowed out to the diameter corresponding to
the bar material.
Screw clamping nut (5) onto the fixing flange
(7) to fix the insert sleeves.
Fasten clamping nut (5) with moderate manual
force.
Fixation of the clamping nut (5) by tightening
the hexagon socket screws M625 (4).
Remount cover (3) and close and clamp cover
(1).

Mounting the insert sleeves - figure 1

Dismounting the insert sleeves

10 6

11

After unscrewing the clamping nut (5) the insert


sleeves can be pushed out backward by means
of a suitable tube (13 ) (collect insert sleeves).
The diameter of the tube (13) must be larger than
the internal diameter of the insert sleeve.

12

The insert sleeves can also be pushed out forward


after removing the chuck (insert sleeves fall into
the chip room).

Mounting the insert sleeves - figure 2

Notes:
At least every second insert sleeve must
have the necessary hollow-out diameter,
each first insert sleeve may have a larger
internal diameter.
The fixation flange (7) need not be dismounted any more after taking off the insert
sleeves.

13

Dismounting the insert sleeves

B28

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 45

Three-jaw power chuck


Ref-No. KFD-HS 160/3 ............................ 574 670

Attention:
To guarantee faultless function and disturbance-free operation of the chuck please also
observe the manufacturer's instruction enclosed with the respective chuck.

Mounting the chuck


Screw in tensioning tube and traverse into
foremost position (tensioning tube projects from
spindle).

Clean carefully chuck support of the main


spindle and thread connection of the tensioning
tube.
2

Pull clamping cylinder (2) in chuck (1) in


maximum rear position (jaws in max. internal
position).

X=25,5

Remove screw plugs (4) and press fastening


screws (3) of the chuck to the inside.
Turn chuck until stop onto the tensioning tube.
Take care that the threads of chuck and
tensioning tube are not damaged.

Turn back chuck until the carrier of the main


spindle can be inserted into the chuck support.
In this position press chuck against main spindle
and tighten fastening screws (3) reciprocally.

Mounting the chuck

Check minimum size "X" and correct it if


necessary:
Loosen fastening screws.
Adjust minimum value X by turning the chuck
against the main spindle.
Refix chuck on the main spindle.
Check function and jaw stroke of the chuck.
Mount screw plugs (4).
Check chuck regarding facing accuracy and true
running.

Dimensions of the chuck


Note:
Single chuck dimensions may deviate from
the dimensions indicated in the instruction
enclosed with the chuck.

Dimensions of the chuck

B29

CLAMPING DEVICES FOR SPINDLE 45

DESCRIPTION

Dimensions of the jaws


Reversible interchangeable jaws UB, hardened

Soft top jaws AB

The jaws enclosed with the chucks are already


ground at the chuck.

For high-accuracy clamping.


The jaws are to be turned under clamping force
to the desired diameter.
Jaws hardened subsequently have to be ground.



































[




[




+
















hardened reversible interchangeable jaws UB

soft top jaws AB

Clamping ranges of the chuck


The clamping ranges are valid for chuck KFD-HS
with reversible interchangeable jaws UB.

Clamping ranges for KFD-HS 160/3 with jaws "UB"

B30

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 45

Clamping force diagram KFD-HS 160/3

clamping cylinder without bore


Clamping force [daN]

Clamping force [daN]

clamping cylinder with bore

hydraulic pressure [bar]


Max. Druck

Spannkraft der Backen

Bettigungskraft am Zugrohr

hydraulic pressure [bar]


Max. Druck

Total clamping force [daN]

Reduction of clamping force with


high speeds

Minimum centrifugal force of the


top jaw;

A
B

Maximum centrifugal force of the


top jaw;
Speed [min-1]

B31

CLAMPING DEVICES FOR SPINDLE 45

DESCRIPTION

Rhm - Collet chuck


The collet chuck is available as accessory from
EMCO.
Order no. .................................................. 575 001

Technical data
Type ........................................... Rhm KZF 40/5
Clamping range:
acc. to clamping variant ......................... 2-42 mm
Collets .................................. 173E, Rubberflex 36
Work. pressure-clamp.cyl. with bore max. 27 bar
Work.press.-clamp.cyl.without bore max. 29 bar
Actuating force ............................ max. 2 500 daN
Speed ......................................... max. 6 000 min-1

Outline collets
Collets
173E acc. to DIN 6343
Clamp. range Clamp.
toler.

Collets Rubber Flex


series 36
Clamp.
Clamp.
range
tolerance

2-42 6-36 6-29


h13
8-42
Grading of the colets: 1 mm

2 0,3

Danger:
Workpieces with diameters deviating from the
tolerance of the inserted collets must not be
clamped since concentric running accuracy
and clamping force are not sufficient.
During work with bar feed use adequate
guide tubes.
With longer bar material use spindle insert
sleeves.
Mind machine configuration (chuck/collet).

Collet chuck for spindle diam.45 - clamping


principle

Clamping principle
During clamping the tensioning tube (1) is pressed
forward by the clamping cyinder with (without)
bore.
The cone of the pressure sleeve (2) presses the
collet (3) together, the workpiece is clamped.
By drawing back the tensioning tube (1) the
workpiece is relieved.

B32

DESCRIPTION

CLAMPING DEVICES FOR SPINDLE 45

Mounting the collet chuck


Screw in tensioning tube and traverse it into
foremost position (tensioning tube protrudes
from spindle).

Slightly oil pressure sleeve (7) with slideway


oil, insert it into the body (2) and fix it with the
screw (6).

Screw preassembled unit until stop onto the


tensioning tube.
Turn unit back again 2-3 rotations.
In doing so, observe position of the driver bolt,
which is thread into the recess (1) of the body.
Fix collet by means of 4 hexagon socket screws
M10 (5) on the spindle nose.
Insert collets (8).
Screw on union nut (4), tighten by means of the
double-ended wrench supplied and secure with
the screw (3).
Functional test:
Actuate collet chuck at max. 5 bar.
It must be possible to open and close the collet
perfectly.
5

8
Adjust the desired clamping pressure (see
following diagrams).

Mounting the collet chuck

Dismounting the collet chuck


Dismounting the collet chuck is carried out
according to mounting in reverse order.
During this procedure the tensioning tube is in
backmost position (collet open).

B33

CLAMPING DEVICES FOR SPINDLE 45

DESCRIPTION

Changing the collets


1

Traverse clamping cylinder with bore into


backmost position (collet open).

Unscrew securing screw (1).


Unscrew union nut (2).
Pull out union nut (4) and replace by new one.
Remount union nut (2), tighten and secure with
screw (1).

Attention:
If the union nut is screwed off with closed
clamping device condition, the screw can be
(3) damaged.
The function of the chuck is impaired by this,
thus, the chuck must no longer be used.
3

Changing the collets

Clamping force diagrams


Attention:
To avoid damage at the collet chuck the
maximum actuating force of 2 500 daN must
not be exceeded.

Clamping cylinder without bore

cl

am

n
pi

actua

fo

rc

Spannkraft [daN]

clamping force [daN]

Clamping cylinder with bore

ting

force

m
cla

pi

ng

fo

actua

hydraulic pressure [bar]

rc

et

ting

force

hydraulic pressure [bar]

B34

CLAMPING DEVICES FOR SPINDLE 45

DESCRIPTION

Hainbuch - Collet chuck


Tecnical Data
Type ....... Hainbuch Axzug 65/KK5 with stopper
Clamping range ................................. max. 65 mm
Collets ................................................... SK 65 BZI
Work. pressure-clamp.cyl. with bore .... max. 43 bar
Work.press.-clamp.cyl.without bore ..... max. 49 bar
Actuating force ............................ max. 4 500 daN
Speed ......................................... max. 6 000 min-1

Order numbers
Collet chuck .............................................. 440 700
Collets ................................................. auf Anfrage
Special attachments
pneumatic changing device PP 65 .......... 440 710
manual changing device MV 65 .............. 440 720
1

Dimensions - clamping principle


Danger:
Workpieces with diameters deviating from the
tolerance of the inserted collets must not be
clamped since concentric running accuracy
and clamping force are not sufficient.
During work with bar feed use adequate
guide tubes.
With longer bar material use spindle insert
sleeves.
Mind machine configuration (chuck/collet).

Clamping force [daN]

Clamping cylinder with bore

cl

am

pi

ng

at
ctu

fo

rc

ing

forc

Clamping principle
During clamping the tensioning tube is pressed
back by the clamping cyinder with (without) bore.
The cone of the pressure sleeve (1) presses the
collet (2) together, the workpiece is clamped.
By drawing frontward the tensioning tube the
workpiece is relieved.

hydraulic pressure [bar]

Clamping force [daN]

Clamping cylinder without bore

cl

am

pi

ng

fo

ati
actu

rc

Clamping force diagrams


orc
ng f

Attention:
To avoid damage at the collet chuck the
maximum actuating force of 4 500 daN must
not be exceeded.

hydraulic pressure [bar]

B35

CLAMPING DEVICES FOR SPINDLE 45

DESCRIPTION

End face driver


Order no. ................................................. 573 090
The basic equipment comprises the end face
driver including lathe center and carrier plates for
turning work in anticlockwise rotation.
Spannkreis-

Clamping circle diameter ................ 12100 mm

Mounting the end face driver

Danger:
Mounting the end face driver may only be
carried out during standstill of the machine.
Dismount the tensioning tube.
1

Carefully clean the spindle bore.

Put end face driver (3) on the spindle nose and


fix it with the screws M12 (1).
In doing so, observe the position of the recess
(2) for the driver on the main spindle.

Mounting the end face driver

Put the respective carrier plate (5) onto the end


face driver; (4) mind driver.

Dimensions of the carrier plates


Carrier plates - toothed
Clamping circle
Rotation
diameter
range [mm]
S [mm]

Carrier plates - toothed

12
20
32

Rotation
direction

left
left
left

7
13
22

36
30
30

4
4
10

13 - 24
21 - 40
33 - 64

Carrier plates with interchangeable


HM-driving chucks 9.53.2
(4-sided usable)
Clamping circle
diameter
S [mm]

Rotation range
[mm]

50

51 - 100

25

24

If during work with end face drivers straight or


right tools are used, you have to use a special
toolholder so that the tool can be machined across
the entire length.

Carrier plates with HM driving chucks

B36

CLAMPING

DESCRIPTION

DEVICES FOR

SPINDLE 45

Clamping force diagram for end face


driver
Clamping ratio [1]
Rotation diam./Clamping circle diam.

Ftail [daN]
Standard
values for
tailstock

Chip section [mm]


(chip depth feed)

Workpiece strength
[daN/mm]

Example:

tail

Chip section ............................... 30.3 = 0.9 mm


Workpiece strength ........................... 63 daN/mm
Clamping ratio ..................................... 60/50 = 1.2

Rotation
diam.50

Clamping circle
diam. 50

Machining A (turning against headstock):

Tailstock force acc. to diagram:


Ftail = 160 daN
Machining B (radial cut):
Conversion factor: .................................. 1,5 F tail
Machining C (turning against tailstock):
Conversion factor: ......................................2 F tail

B37

COUNTER

DESCRIPTION

HEADSTOCK

Counter headstock
The counter headstock (spindle 2) can be designed
according to the machine type as follows:
Spindles:
spindle size 65
spindle size 45
Clamping cylinders:
clamping cylinder with bore
clamping cylinder without bore

Machine with counter headstock


Note:
The designs of the spindles and clamping
cylinders are identical with those of the main
spindle (spindle 1).
For all data, connection dimensions and
clamping devices refer to this chapter above
"spindle diam. 65" and "spindle diam. 45".

Traversing range
spindle 1

spindle 2

The counter spindle can be traversed exactly to


position via the control Siemens 840D (axis Z2).
The slide drive is carried out via a separate ACmotor.
Traverse path .................................. max. 510 mm

Traverse path of spindle 2

B38

DESCRIPTION

TAILSTOCK

Tailstock
Cone of tool support ..................................... MK 4
Tailstock stroke ............................... max. 500 mm
Tailstock extension (adapter) .................. 100 mm
Tailstock thrust .............................. 1000 8100 N

Travelling range

Travelling range of the tailstock, with and without adapter

Attention:
Prior to mounting tools carefully clean the
support flange and the tailstock cone.
Unless the adapter is used, the protection
ring (5) must be mounted with the O-rings
(4) and (7) to prevent dirt and corrosion on
the tailstock support.

A
4

Unless the tailstock is needed, mount


protection ring and unclamp tools from the
tailstock to avoid collisions.

5
6

7
8

I
I

View A:

Mounting the tailstock adapter


Unscrew protection ring (5) by loosening the 3
socket head screws M6 (6).
Take care that you do not lose the O-rings (4)
and (7).

1
2

Screw adapter (1) with the 5 socket head screws


(2) on the support (3).
Mount adapter in such a way that the markings
(8) of tailstock and adapter are opposite each
other so that the position of the tailstock axis is
not dislocated.

5
6

Tool support on the tailstock (with and without


adapter)

B39

TAILSTOCK

DESCRIPTION

Tailstock thrust
tailstock thrust [N]

Attention:
During adjustment of the tailstock thrust mind:
workpiece material
clamping device used and adjusted clamping
force
For adjusting the tailstock clamping force refer
to "Hydraulics" further below in this chapter.

hydraulic pressure [bar]

Tailstock clamping force

Removing the centre


The centre (7) and other tailstock tools can be
removed from the tailstock cone by means of the
ejection key (6) included in the scope of supply.

Tailstock with centre punch and ejection key

B40

DESCRIPTION

TAILSTOCK

Adjusting the detector of the


tailstock stroke
Diagnosis

PLC-IBN
The position of the tailstock is controlled by the
proximity detectors (5) and (6).
The adjustment of the detector is carried out by
regulating the switching mechanism (4).

Set "JOG" mode.

PLC-Status-Display
Operand

Format
Z10

Call up PLC-status control via the softkeys


"Diagnosis/PLC-IBN".

Value

0011

Call up counter Z10.


Enter "Z10" and confirm by means of the Enter
key.
A table with the operand "Z10" in format "B"
and a value (1) is displayed on the screen.
1
Call-up of the "counter 10" on the screen

Jump into the column "format" by means of the


cursor keys and overwrite the format "B" with
"H".
Loosen counternut (3).

Detail X:

Adjust setting screw (2) by means of an Allan


key flush with the counternut (3).
Clamp workpiece and approach tailstock against
the workpiece.
(For adjustment of the tailstock thrust refer to
"Hydraulics" further below in this chapter).
2
2

3
Turn setting screw (2) from the tailstock, until
the value (1) of the counter 10 on the screen
indicates more by a number of 1 (e.g. change
of the value from "0011" to "0012").

View A:

3
Turn setting screw back until the value (1)
counts back again by "1" (from "0012" to
"0011").

Turn in screw (2) by another rotation into the


tailstock.

5
6

Secure setting screw (2) by means of the


counternut (3) in this position.

Detail view - tailstock, adjusting the stroke

B41

HYDRAULICS

DESCRIPTION

Hydraulics
Power .......................................................... 1.5 kW
Speed hydraulic drive .......................... 1425 min-1
Conveying capacity ............................... 10.7 l/min
System pressure ...................................7080 bar
Tank capacity .................................................. 10 l

Hydraulic unit equipment


1

The operation part of the hydraulics is accessible


below the control after opening the cover (1).
The system pressure is set by the manufacturer
and cannot be changed.

Hydraulics of the machine


3

Operation part

Manometerno.

pressure
control no.

2
3
4
5
6

7
8
9
10

System pressure
Clamping device 1
Gantry - blank gripper
Gantry - finished part gr.
Clamp. dev. 2 / tailstock

Note:
Unless an extension step exists on your
machine, the following extension steps move
up (no gaps on the mounting plate).
The position of the manometer, however,
remains unchanged.

10

Detail X - Operation part of the hydraulics

Oil level control


Attention:
The oil level of the hydraulic system,
however, has to be controlled prior to each
switch-on of the machine.
The system-pressure has to be 0 bar by filling
in oil (pressureless - see Maintenance)!
Pay attention to the positions of the cylinders
with refilling hydraulic ol - see "Maintenance"
Open machine door (11) on the rear side of the
machine.
The oil level (12) can be read at the oil level
gauge and must be between the upper and the
lower mark.
2

11

12

Close machine door again.

Oil level control at hydraulics

B42

V0 =34 l
p0=55 bar

Tool turret
Q max=16 l/min
Qeff =0,84 l/min
V=35 cm

Clamping cyl.
left
(105/80/35)
QL =4 l/min
Q=15 l/min
V=195 cm

Indexation
left
(25/16/20)
Q=0,7 l/min
V=5,8 cm

Clamping cyl.
right
(105/30/32)
QL=0,5 l/min
Q=15 l/min
V=120 cm

Indexation
right
(25/16/20)
Q=0,7 l/min
V=5,8 cm

Automatic door
(25/18/730)
Q=11,8 l/min
V=393 cm
V=204 cm (diff.)

Portal
Portal
blank part gripper finish part gripper
(2220)
(2220)
Q=0,85 l/min
Q=0,85 l/min
V=7 cm
V=7 cm

Portal gripperreversing cyl..


(18/165)
Q=0,75 l/min
V=12 cm

Tailstock
(40/28)
Q S=1,5 l/min - slow feed
QE=12 l/min - rapid feed

Portal gripper
swivelling head
(2233)
Q=0,75 l/min
V=12 cm

DESCRIPTION
HYDRAULICS

Hydraulic scheme

Hydraulic scheme fully equipped (all options and accessories)

B43

HYDRAULICS

DESCRIPTION

Setting work on hydraulics


System main pressure
The system main pressure set can be read on the
manometer (2) on the rear side of the machine
after switching on the machine and the auxiliary
drives.
System pressure ...................................7080 bar

Caution:
The hydraulic pressure is set by the manufacturer.
A change of the system pressure may only be
carried out by EMCO service engineers.

Hydraulics of the machine

Clamping device pressure and


sleeve thrust
The clamping device pressure and/or sleeve
thrust is set at the valves (6) and/or (7).
Left spindle .................... pressure control unit (6)
Right spindle/tailstock ........ press. control unit (7)
The pressure set can be read on the manometers.
Left spindle .................................... manometer (3)
Right spindle/tailstock ................... manometer (8)

Setting procedure
3

Open flap (1) beneath the control.

Setting the pressures (detail X)

Loosen fixation screw (4) at the respective


valve.
Carry out pressure setting at handle (5)
(see table and corresponding chuck):
Pressure increase ............... clockwise direction
Pressure reduction ........anticlockwise direction

max. press. [bar]


Clamping device

clamp. cyl.
with bore

Spindle 65
Chuck KFD-HS 175/3
Chuck KFD-HS 200/3
Chuck KFD-HS 250/3
Collet chuck - Quadro NC
Spindle 45
Chuck KFD-HS 160/3
Collet chuck - Rhm
Collet chuck - Hainbuch
Tailstock
Sleeve thrust

clamp. cyl.
without
bore

34
40
50
29

44
50
50
34

34
27
43

38
29
49

Retighten fixation screw (4).


Close flap (1).

Minimum pressure for clamping


devices
The minimum pressure for clamping devices is
set by the hydraulic system and is approx. 20%
below the clamping device pressure.
If the pressure falls below the minimum clamping
device pressure and with running main spindle
an EMERGENY-OFF condition is caused and an
alarm is displayed.

65

max. clamp. dev. pressure/sleeve thrust

B44

PNEUMATICS

DESCRIPTION

Pneumatics

The pneumatics is needed for the options workpiece collection device and workpiece ejector
spindle 45.
Due to the the installed automatic condensate
diverter (1) the pneumatic unit is maintenancefree.

Compressed air supply


Supply pressure ....................................min. 6 bar
Supply quantity .............................. min. 300 l/min
By opening the manual slide (4) the pneumatic
unit is supplied with compressed air.

Pressure setting
The pneumatic pressure is set by the manufacturer and should not be changed.
The pressure set can be controlled at the
manometer (3) of the pressure control (2).
Pressure set .................................................. 6 bar

Rear side of the machine - pneumatic unit

Pneumatic scheme
collecting tray
swivel movement
50 50 mm

collecting tray
stroke movement
25 1450 mm

Pneumatic scheme

B45

workpiece ejector
16 160 mm

CENTRAL

DESCRIPTION

LUBRICATION

Central lubrication
Lubrication pulse (after slide path) 150 m (490 ft)
Lubricant per lubrication point ................ 0,06 cm
Pump flow .......................................... 100 cm/min
adm. operational viscosity ................ 20-1500 cSt
Tank capacity .................................. 2,7 l (0.7 gal)
The central lubrication automatically supplies the
slideways (4 roller slideways per slide) and the
recirculating ball spindles with slideway oil.
The lubrication pump (1) will be activated automatically after a traversed slide path of 150 m.
This value is set at works and may not be
changed.
Addiational a lubrication pulse is given by
pressing the key "AUX ON".

Position of the lubrication pump

Function and monitoring

After activation the lubrication pump (1) by the


control, the dosing elements (7) will be filled with
slideway oil.
After a renewed activation of the lubrication pump
the filled dosing elements will be evacuated into
the lubrication points and already refilled.
This sequence lasts for approx. 4 sec.

This function is supervised by the pressure switch


(4) in the lubrication pump:
If the pressure switch (4) doesn't react after
approx. 20 sec., alarm "510 301-Low pressure
central lubrication" appears.
If the oil level drops below the "Min." indicator
the float switch (3) reacts and alarm "510 300Float switch central lubrication" appears.
In both cases the program will be continued for
approx. 150 sec., a new program start is not
possible.
After this time the program stops and alarm
"510 104-Low pressure central lubrication" appears.
Check the oil level at the lubrication pump and
check pump and lubrication pipes for damages.

1 ...
2 ...
3 ...
4 ...
5 ...
6 ...

lubrication pump
oil tank with "min.-"/"max.-" indicator
float switch
pressure switch
filler neck
dosing element

B46

CENTRAL

DESCRIPTION

LUBRICATION

Lubrication after longer


standstill periods
If the machine is not used for a longer period
preceed a manual lubrication before and after
the standstill period.
Therfore press the "AUX ON"-key 2 or 3 times
with an interval of 5 sec..
Each press triggers a lubricating pulse.

$8;

Note:
Informations about maintenance and oil
quality se chapter "D Maintenance".

Note:
The central lubrication is an open lubrication
system, that means that the slideway oil is
"lost" after use.
It gets into the coolant (see coolant treatment)
or flows down the machine.
A sparingly use of the central lubrication is
recommended and will be reached by the
presettings at works.

B47

WORKPIECE COLLECTION DEVICE

DESCRIPTION

Workpiece collection
device (option)

Y
X

Front view of the machine - workpiece collection device


The workpiece collection device is mounted by
the manufacturer.
The workpieces can be deposited in the collecting
tray (4) by spindle-1 as well as by spindle-2.
Swivelling in the swivel arm (3) is controlled by
the pneumatic cylinder.
After collecting the workpiece the collecting tray
(4) is traversed via the pneumatic cylinder (5) to
the unloading station and unloaded by a rocking
motion into the collecting tray (6).
The collecting tray (6) can be unlocked from the
anchorage by slight lifting and thus be removed
from the machine.

Adjustment of the height of the


collecting tray
The collecting tray (4) can be adjusted in its height
according to the workpiece.
Loosen locking screws M6 (7).
Shift collecting tray (4) into desired height.
Retighten locking screws (7).

Detail X - height adjustment of the collecting tray

B48

W ORKPIECE COLLECTION DEVICE

DESCRIPTION

Adjusting the stroke of the


collecting tray
The limit switch (1) is actuated during approaching
the swivel arm (3) with the guiding unit (11)
against the control cam (10).
The stroke movement of the cylinder (5) is thus
stopped.
The adjustment of the stroke is carried out by
regulating the control cam (10) via the clamping
jaw (9).
Interrupt air supply (close manual slide valve of
the pneumatics).
Draw swivel arm (3) by hand into the desired
position, in which the workpiece should be
collected.
8

10

Loosen both hexagon screws SW13 (8) and


push clamping part (9) against the guiding unit
(11) of the swivel arm.

11

Detail Y - Adjusting the stroke of the collecting


tray (positions 17 see front view)

Fix clamping part (9) in this position by


tightening both screws (8).
Close machine door.
Reestablish air supply on the manual slide valve
of the pneumatics.
The swivel arm (3) returns to its initial position.

B49

WORKPIECE

DESCRIPTION

EJECTOR

Workpiece ejector with flushing system (option)


Upon order the workpiece ejector with integrated
rinsing system is installed in the spindle system
of spindle 2.
The operation of the ejector is carried out via a
pneumatic cylinder.
Ejector and integrated rinsing system are triggered via the control.

As standard 2 ejector variants are supplied with


the consignment:
Variant 1:
for ejecting workpieces without bore
Variant 2:
for ejecting workpieces with bore (with mounted
driving device)
The ejector should be engaged on the rotating
workpiece. Thus, chips cannot get behind the
clamping device (sector B) to destroy sealings.

Stroke of the ejector


minimal stroke ............................................ 70 mm
maximal stroke ......................................... 160 mm

() .. Measures in brackets for spindle


65

Workpiece ejector - variant 1 (solid shaft ejector)

() .. Measures in brackets for spindle


65

Workpiece ejector - variant 2 (hollow shaft ejector)

B50

DESCRIPTION

WORKPIECE

EJECTOR

Mounting the ejector

Danger:
Mounting and dismounting of the ejector may
only be carried out during standstill of the
machine.
1

2
Swivel out ejector.
Screw desired ejector (1) onto ejector bar (2).
Tigthen ejector (1) with fork wrench SW17 or
SW19.
Counterhold ejector bar with a fork wrench
SW11.

Mounting the ejector

Self-made ejector
Self-made ejectors can be mounted instead of or
on the ejectors supplied with the standard
equipment.
You have to observe the following items if you
make your own ejector:
Determine precisely the dimensions of the
ejector in accordance with the workpiece and
the inserted clamping device.

Connection dimensions for self-made ejectors


(variant 1, connection dimension of the ejector bar)

Provide bores for the rinsing system.


Minimum diameter of the bore 3,5 mm.
If the workpiece will be opened by boring or is
hollow, provide free running bores resp. free
running hollow-outs (A), with it the ejector
won't be damaged by the tool.
The ejector variant 2 supplied can be reworked
according to application (smaller external
diameter, free-running hollow-out A).

Connection dimensions for self-made ejectors


(variant 2)

B51

WORKPIECE

DESCRIPTION

EJECTOR

Examples for self-made ejectors

1 ......
2 ......
3 ......
4 ......

workpiece
collet
self-made ejector
standard ejector

L ...... according to clamping device

Example of a self-made ejector for workpieces with an external diameter of < 20 mm

1 ...... workpiece
2 ...... collet
3 ...... self-made ejector
1 2

d ...... larger than workpiece bore


D ...... smaller than external workpiece diameter
L ...... according to clamping device

Example of a self-made ejector for workpieces with an external diameter < 35 mm

B52

DESCRIPTION

WORKPIECE

EJECTOR

Adjusting the stroke


The stroke of the pneumatic cylinder for the
ejector is supervised over the contact cam (2)
from the limit switch (3).
By reaching the limit switch position the forward
movement of the cylinder stops, and the ejector
moves back to the rear final position.
By adjusting the position of the limit switch the
stroke can regulated individually.
maximal stroke ............................... 90 mm (3.54")

Open cover (1) lateral on the machine.


By turning the pinion (4) with a scredriver the
position of the limit switch can be adjusted
1 turnround = 4 mm (.157") stroke
1

Check the adjusted stroke by moving the ejector


forwards (M-funktion M22).

Lateral side of the machine - right side

Close cover (1).

Operating instructions
To guarantee an error-free operation, the
following notes have to be observed!
2

The connecting tube may not be dismounted,


otherwise the ejector bar has no bearing!
With ejector - variant 1 - never traverse against
rotating parts!
Take care that the ejector is not damaged during
machining the workpiece on spindle 2 (e.g.
boring open the workpiece - drill moves against
ejector).
Never approach ejector - variant 2 with rotating
spindle!
1. clamp workpiece
2. set ejector
3. switch on spindle
The flushing of the spindle may only carried out
if:
- ther is no workpiece in the clamping device
- the pressure of the coolant device is max.
3.5 bar (no high-pressure coolant pump)
Otherwise the sealings of the ejector will be
damaged.

Adjusting the stroke of the ejector

B53

Y-AXIS

DESCRIPTION

Y-Axis (option)
Because of the mounting of a Y-slide on the XZslides and the using of driven tools it is possible
to program classic milling works on a CNC-lathe.
You can use axial and radial tools.

: ;<

Technical datas
stroke of Y-slide ................. +40 / 40 mm (1.57")
feed force ................................... 4000 N (900 lbf)
speed range ...................................... 04000 rpm
Torque ...................... constant 16 Nm (11.8 ftlbf)
rapid traverse ................... 7,5 m/min (24.6 ft/min)

Coordinate system of Y-axis

Working Area
Danger:
To avoid crashes, the tool turret may only be
swiveled in Y-position "0"!

Working area - tool turret with Y-axis

B54

DESCRIPTION

TOOLHOLDERS

Toolholders
Single toolholders VDI-30
Radial holder

Radial holder "over head"

for left hand rotation (M4)


shaft ...................................................... 20 mm

for right hand rotation (M3)


shaft ...................................................... 20 mm

Order-No. R4Z 410

Order-No. R4Z 420

Axial holder

Axial holder "over head"

for left hand rotation (M4)


shaft ...................................................... 20 mm

for right hand rotation (M3)


shaft ...................................................... 20 mm

Order-No. R4Z 430

Order-No. R4Z 440

Set of support plates

Cut-off holder

for shaft ......................................................... "

for left hand rotation (M4)


shaft height for cut-off blades ................... 26 mm

Order-No. R4Z 490

Order-No. R4Z 450

B55

TOOLHOLDERS

DESCRIPTION

Internal toolholder "long" 25

Internal toolholder "short" 25

for internal facing up to 3 mm below rot. centre

Order-No. R4Z 310


Order-No. R4Z 330

Collet support ESX 25

Floating holder ESX 16

for internal toolholder 25


Clamping range ...................................... 216 mm

for internal toolholder "short" 25


Clamping range ...................................... 110 mm

Order-No. R4Z 320

Order-No. R4Z 410

Internal toolholder "short"

Internal toolholder "short" 32

without bore, for hollowing out by customer

Order-No. R4Z 340

Order-No. R4Z 320

B56

DESCRIPTION

TOOLHOLDERS

Double toolholders VDI-30


Double toolholder

Double toolholder "over head"

Order-No. R6Z 410

Order-No. R6Z 420

Double internal toolholder "long" 25

Double internal toolholder "short" 25

Order-No. R6Z 330

Order-No. R6Z 310

Double internal toolholder "short" 32

Order-No. R6Z 320

B57

TOOLHOLDERS

DESCRIPTION

Driven toolholders VDI-30

Double milling holder ER 25

Milling holder axial ER 25

Clamping range ...................................... 116 mm


Speed .......................................... max. 4000 min-1
Torque ............................................... max. 30 Nm

Clamping range ...................................... 116 mm


Speed .......................................... max. 4000 min-1
Torque ............................................... max. 30 Nm

Ref-No. 440 400

Ref-No. 440 410

Milling holder radial ER 25


Clamping range ...................................... 116 mm
Speed ....................................... max. 10 000 min-1
Torque ............................................... max. 16 Nm

Ref-No. 440 420

B58

DESCRIPTION

PERFORMANCE CURVES

Performance curve spindle 65


M left

M right
P right

Performance P [kW]

Torque M [Nm]

P left

speed n [min -1]


Characteristic curves for machine with spindle 65 (left and right spindle)

Performance curve spindle 45


P left

Performance P [kW]

Torque M [Nm]

P right
M left
M right

speed n [min-1]
Characteristic curve for machine with spindle 45 (left and right spindle)

B59

E NVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Environmental Protection Notes


For a better comprehension of the solutions
offered a short outline on the environmental
problems occurring in machining production is
provided prior to the hints proper.

In addition to the constantly increasing requirements of productivity and flexibility of working


processes the demand for environmental compatibility has become of utmost importance.
Avoiding environmental damage in the past years
has become a central issue of society. We can
no longer shift the blame on others according to
the principle dont hit me but hit the others. Rather, everybody has to contribute in his sphere of
responsibility.
Machining production, too, contains many areas
that may represent a burden to environment.

Environmental burdens in
machining production

The main burdens are:


chips contaminated with cooling lubricant
auxiliary materials and utilities (cooling lubricants, cutting oils, lubricating oils etc.)
special waste (oily cleaning clothes, used
emulsions etc.)
formation of oil mist
annoyance caused by noise; vibrations
waste heat, etc.

Lubricants
The use of lubricants in machining production is
indispensable. Frequently the lubricants are not
used with optimum efficiency out of ignorance.
Particularly when storing the lubricants the
materials are handled in a careless way which is
why the lubricants reach the soil and add to
burdening the ground water.

Based on the necessity of the protection of our


environment, laws and stipulations were created
the observation of which aims at the improvement
of the present situation. Additionally, the control
of the compliance with these regulations has
become stricter recently. Increasingly, also small
companies are subjected to this trend and have
to guarantee an environmental compatibility as
high as possible of their production. Thus, reacting
in time a to a changed situation turns out to be of
utmost importance for the business.

Leakages, damaged barrels, carelessness when


handling oils, lacking or poorly serviced oil
separators, empty barrels being washed out by
the rain in the open air are just a few examples
for the situation to be found too often in the
companies.
Nor does the existence of oil barrels in the most
out-of-place corner of production represent a
desirable solution. Oil-contaminated bay floors
and dirty machines - as a result of incorrect
handling of lubricating oils - represent an essential impairment of the quality of the place of work
and, thus, indirectly also of the quality of the
results achieved.

It is EMCOs aim to contribute to an improvement


of the present environmental and waste disposal
situation in machining production.
The following important hints are to be intended
as a contribution.
By observing these hints you will render a direct
service for the protection of our environment in
general and also for the quality improvement of
your own working area.
The hints are described in such a way that their
observation will not cause additional costs and in
most cases even a reduction of costs is possible
in the short-term perspective.

Cooling lubricants
Just like greases, cooling lubricants, too, are an
indispensable factor in machining production.
Cooling lubricants are highly developed chemical
products that require careful handling.
Wrong handling may lead to serious damage of
health.

B60

ENVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Finely sprayed emulsions (open working space)


reach the lung and are not eliminated any more.
Similarly, the wrong handling of emulsions may
lead to skin diseases (oil acne, oil eczema etc.)
and via injuries of the skin also to infections.

Solvents and cleaning agents


Cleaning agents are amply used in machining
production for washing of machined workpieces
as well as in repairs and for cleaning utilities.
But the chlorinated hydrocarbons (e.g. trichloroethylene, trichloroethane, perchloroethylene etc.)
are amply used.

By adequate hygienic measures of the company


these dangers can be avoided.

For the user these substances represent a source


of danger that is not evident. Particularly due to
the seemingly non-problematic use of these
substances (inflammable, very good liposolubility,
little odour etc.) these substances obscure the
fact that they are serious poisons of the liver and
the nerves.

Emulsions are highly dangerous to ground water


and must in no case be spilled away carelessly.
Biodegradable cooling lubricants do not represent
a solution in this respect since these emulsions
are innocuous for the environment when being
supplied but during operation, due to the contaminations occurring (leakage oils from lost oil
lubrication, frictions etc.) loose their biological
innocuousness and thus cannot be disposed of
any more via sewage system.

Therefore, it is necessary to handle these


substances adequately. Additionally, these substances are able, due to their little density, to
penetrate without problems through concrete
floors (even very thick ones) and thus contaminate
the ground water. Due to their low boiling point
these substances evaporate from open plants
(e.g. open cleaning tray).
A very unfavourable feature is the fact that these
substances are not decomposed biologically and
thus represent a serious environmental hazard.

A particular source of danger are the residual


emulsions that adhere to the chips. When storing
the chips in the open air or under roofs permeable to water the residual emulsion may be washed
out by the rain and thus reaches the sewage
system or the ground water.
The durability of cooling lubricants is limited.
Since cooling lubricants contain organic substances they are prone to infestation by microorganisms. If their number increases too much
the emulsion tilts over and has to be renewed. If
the growth of these microorganisms is avoided
the service life can be prolonged.

In the past this has led to environmental burdens


which today lead to a contamination of the ground
water reservoir.

1 kg of chlorinated hydrocarbons may


render forever unusable 40 millions litres
of drinking water!

By service measures and careful handling of


emulsions the durability can be prolonged considerably.
Essentially, these microorganisms reach the
emulsion:

Special problems with chips


containing residual oil

via the air


via dirty water
via leakage oils
via waste getting in touch directly or indirectly
with the emulsion (cigarette ends, empty tins of
drinks etc.)
via the workpiece machined
via operating staff
via lacking hygienic conditions in the company

With the chips considerable quantities of lubricants and emulsions are discharged by the
machine.
By drop-off of the chips a part of these substances
can be recovered (as valuable auxiliary materials). The remaining quantities are lost during
transport and storage until further use and thus
also contribute to ground water contamination.

Observing the following hints of care you can


contribute considerably to an improvement of the
situation and to cost savings.

Chips are not waste but represent valuable


raw materials!

B61

E NVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Therefore, it is necessary:

Measures of environmentally
compatible design in machining
production

that the chip containers are not used as waste


baskets (cigarette ends, plastic cups etc. are
not to be thrown into the chip container)
that the chips are collected in accordance with
grades
that the chips reach their further use without oil,
if possible, since otherwise they burn more
when charged into the steel furnace.

General hints
The best way to remove waste is to not cause it
at all!
Thus, avoid as much as possible any special
waste!

Problems with oil mists and oil


vapours, dust etc.

Handle substances noxious to the environment


with great efficiency!

Oil mists are caused by evaporation and mixing


of lubricants or emulsions by draughts in the
working space. An essential factor in the formation of oil mist is also represented by the user
of compressed air when cleaning workpieces,
machines and devices. The same holds also true
for dust development during dry machining.

Mind correct operation when handling dangerous substances!


Carefree handling of problematic substances
is not a simple offence, it damages your health
and increases the burden on environment and
on costs!
Use the right dosages!

In addition to representing a burden to the working


environment (machines and devices become oily),
oil mists and vapours contribute to health hazards
of the operating staff.

Observe the instructions of the manufacturer!


Avoid any unnecessary waste!

Hints for correct handling of utilities

Further burdens

Lubricant oils

In addition to the burdens illustrated particularly


annoyance by excessive noise, problems with
accumulating waste heat and the use of other
problem substances connected indirectly with
machining production (e.g. cold cleaning agents,
pour-in resins, packaging materials etc.) represent further burdens for the machine operating
staff and the environment.

Storage of lubricant oils:


Avoid any kind of loss of lubricant; during
storage, use (leaking lines, sealings), during
refilling and transport etc. Accordingly.
This also applies to used oil.
Pay attention that the storage is on solid ground
and that the oil containers cannot tilt.
Drop trays must be able to collect the residual
oil.
Prevent empty oil barrels stored in the open air
against wash-out by rain.
Used lubricant oils are special waste and have
to be disposed of as such.
Identify clearly those containers which are
available for the collection of different disposal
substances (e.g. used oil, barrel for used oil
filters, oily cleaning rags etc.).

B62

ENVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Check regularly the concentration of the emulsion


(too fat emulsions lead to a major health hazard
and also attack machine parts).

Use of lubricant oils:


Only use adequate lubricants (wrong lubricants
are consumed faster, lead to formation of fumes
and to unnecessary disposal quantities).

Check daily the filling level of the emulsion; too


little emulsion quantities are warmed up excessively and thus promote bacterial growth.

When using lubricant oils mind the compatibility


with other auxiliary materials (e.g. emulsions);
instructions are provided by the manufacturer
of the products.

Avoid unnecessary splashing of emulsions (e.g.


by skinning geometries).

In case of doubt try to get information since the


wrong use of the product may lead to considerable costs.

With major standstill times of the machines


repump the emulsion quantity at least once daily
(oxygen activation!).

Take care of the lubricants! Regular cleaning or


change of filters will increase service life.

Remove the chips after operation from the


machine (short after-running of the chip conveyor will be sufficient in most cases).

Close carefully the filling outlets.

Mind during change of emulsion:


The used emulsions are to be pumped into
containers designated clearly for that purpose
(independently of persons; to be understood by
everybody as a prevention against emergencies) to avoid confusion!

Cooling lubricants
Only use cooling lubricants that are compatible
with the lubricants used. (Incompatibility among
each other will result in shorter life time of the
cooling lubricant used.)

Do not mix carelessly the emulsions to be


disposed of with other substances since the
disposal costs might increase considerably.

If possible, use cooling lubricant without halogens


(these are considerably cheaper for disposal).

Clean the entire coolant circuits very carefully


(contaminations particularly in corners of
difficult access are a source for bacteria which
will attack again immediately the freshly prepared emulsion).
Mind: When using system cleaning agents
the costs of the disposal of the emulsion
may be increased!

Observe the storage conditions for the concentrate containers (no frost, no excessive heat
etc.).
Multi-use containers help to reduce disposal
quantities and are therefore to be preferred.

Mind the correct mixing ratio during fresh


preparation!

Take particular care of your cooling lubricants!


Due to thorough care the service life is at least
doubled.
Mind the following hints for care:

Emulsions should not be mixed for storage and


then stocked.

Avoid any contamination of the emulsion.


The cooling lubricant container is not a waste
basket.
Avoid mixing of residual oils in the emulsion
(used oils are lighter than the emulsion and
remain on top. They cover the emulsion and
prevent oxygen supply. Thus, there is an ideal
source for anaerobic microorganisms).
Regularly eliminate the used oils on top (daily
prior to operation start), or simply by skimming
off.
Avoid contamination of the emulsion by leaking
oils (e.g. leaky pneumatic system etc.).

B63

E NVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Hints for the correct handling of dangerous


substances

Hints for correct handling of chips


Basical hints:

Try to resort to alternative substances; use


dangerous substances only if it is indispensable
to use them!

Chips represent a valuable raw material! They


are not to be treated as waste.
When handled incorrectly, chips may contaminate
the ground water and the soil (if adhered with
emulsions and lubricants).

The cost argument can frequently not be supported with a view to increasing disposal costs
and often also because of the incorporation of
the disposal costs in the overhead costs.

Chips are to be stored in the state as they leave


the machine tool in an oil-proof container which
makes it possible to drop off the residual
emulsion (used oils).

Avoid the use of dangerous substances whenever


it is possible by:
Quantitative avoidance:
by renouncing problem substances and/or
change to products that can be recycled or
decompose

On the bottom of the container a collecting tray


has to be placed where the dropped-off emulsion
may collect without mixing with the chips. An
outlet valve should facilitate emptying of the
dropped-off lubricant.

Qualitative avoidance:
by saving measures and optimization in use

A sufficiently long drop-off period is to be


provided as well as an adequately high temperature (in winter not in unheated environments) so
that the residual materials show a viscosity which
favours a complete drop-off.

If dangerous substances cannot be avoided only


such substances should be used that can be
recycled by:
material reutilization (recycling)
biochemical reutilization (composting)
energetic reutilization (burning)

The collection of emulsions (oils) has to be


according to grades so that during refilling into
the cooling lubricant circuit necessary contamination items will not reach the circuit.

Waste that cannot be avoided nor recycled has


to be disposed of as innocuously as possible
(disposal after adequate pretreatment).

The chips should also be collected and stored


according to the grades since a mix-up will lead
to an impairment of the quality of the raw
material.

So-called special waste requires particularly


careful handling.
A list of these special wastes is to be found on
the following pages. This outline forms an extract
of NORM S 2101 in which special wastes are
indicated that need supervision.

The chip container must not represent the waste


basket in production; waste must not be mixed
with valuable raw materials.
After drop-off the chips - also classified according
to grades - are to be stored intermediately until
being carried away by the scrap dealer.

For all these substances the following applies:


information and notification required
records required
innocuous disposal required
declaration required (accompanying certificate)

The collection of the residual oil dropping down


has to be guaranteed so that in this phase there
is no hazard to soil and ground water.
In any case the storage in the open air or under
inadequately fixed roofs is to be avoided since
here the residual oils may be washed out by
rain.

B64

ENVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Designation

Keynumber

Properties

State

1) note
2) Origin (examples)

oil-contaminated soil
(excavated material)

31 423

hazard to water

solid
(also pasty)

1) during collection, transport and storage


is protected against heat
2) oil accidance, mineral oil extraction, old
charges

used filter ans absorption


masses if charged with other
special waste that needs
supervision

31 434

hazard to water
see 1)

solid

1) classification with a view to properties


ist to be carried out according to the
filtered material
2) water preperation, production of foods
and luxury foods, chemical industry,
laundries, adsorptive gas and liquid
cleaning process

METALL WASTES

35

dust containing nonferrous


metals

35 321

toxic
hazard to water
explosive

solid

1) may contain lead, cadmium, arsenic,


beryllium. Particular measures avoid
dust explosions required.
2) Production of processing of prongs.
Production of aluminium, Foundries,
production of lead, magnesium, ignition
stones and pyrotechnical products,
electrical engeneering.

mercury batteries

35 324

toxic
hazard to water

solid

2) production of batteries, trade, application

dry batteries, containing mercury


and silver

35 325

toxic
hazard to water

solid

2) production of batteries, trade, application

2) textile industry

WASTE PRODUCED BY
MINERAL OIL PRODUCTS

54

oils, acid

54 101

hazard to water
caustic with pH<3
may form explosive
gases with air

liquid

used oils

54 102

hazard to water
residues from used oil
treatmentmay be toxic
may form explosive
gases with air

liquid to
solid

drilling cutting and grinding oils

54 109

hazard to water
may form explosive
gases with air

liquid

2) metal machining

synthetic coolants and


lubricants

54 401

hazard to water

liquid

2) metal machining

drilling and grinding oil


emulsions and emulsions mixes

54 402

hazard to water

liquid

2) metal machining

oil-water mixes

54 408

hazard to water

liquid

B65

1) also hydraulic oils and brake liquids


2) trade and industry, filling stations
car repair workshops

E NVIRONMENTAL PROTECTION NOTES

DESCRIPTION

Designation

Keynumber

Properties

State

contents of oil seperators and


of petrol seperators

54 702

hazard to water

liquid to
solid

sludge from oil seperating


plants

54 703

hazard to water

liquid to
solid

sludge from container cleaning


and barrel cleaning

54 704

hazard to water

liquid to
solid

paraffine oil sludge

54 706

hazard to water

liquid to
solid

2) petrol chemistry, comercial trade

grinding sludges, oil containing

54 710

hazard to water

liquid to
solid

2) metal, glass and rock machining

used oil binding materials

54 926

hazard to water

used oil and air filters


(containing mineral oil)

54 928

hazard to water

perchlorethylene (per)

55 209

hazard to water

liquid

2) chemical industry, textile industry,


laundries, degreasing, production of
coating agents

trichlorethane

55 212

hazard to water
toxic only the 1.1.2
trichlorethane,
detrimental to health

liquid

2) chemical industry, textile industry,


laundries, degreasing, production of
coating agents

trichlorethylene (tri)

55 213

hazard to water
detrimental to health

liquid

2) chemical industry, textile industry,


laundries, degreasing, production of
coating agents

cold cleaning agents

55 214

hazard to water

liquid

2) industry and trade

solvent mixes,
halogen-containing

55 220

hazard to water,
may be toxic

liquid

2) industry and trade

diluent for cellulose lacqers

55 359

hazard to water, kann


mit Luft explosive Gase
bilden

liquid

2) cleaning and degreasing of metallic


surfaces, production of coating agents,
textile industry, plastics processing,
chemical industry

paraffine oil

55 360

hazard to water, kann


mit Luft explosive Gase
bilden

liquid

2) cleaning and degreasing of metallic


surfaces

solvent mixes, halogen-free

55 370

hazard to water,
may be toxic,
may form explosive
gases with air

liquid

2) industry and trade

lsemittelhaltige Schlmme,
halogenhaltig

55 401

hazard to water,
may be toxic

liquid to
pasty

2) industry and trade, concentration

lsemittelhaltige Schlmme,
halogenfrei

55 402

hazard to water,
may be toxic

liquid to
pasty

2) industry and trade, concentration

B66

1) note
2) Origin (examples)

C Programming and Operation


EMCO-specific - Sinumerik 810/840D
Survey M Commands machine
(Channel 1)

M0
M1

Programmed stop
Optional stop

M3
M4
M5

Main spindle on clockwise


Main spindle on counterclockwise
Main spindle stop

M2=3
M2=4
M2=5

Counter spindle on clockwise


Counter spindle on counterclockwise
Counter spindle stop

M3=3
M3=4
M3=5

Driven tool on clockwise


Driven tool on counterclockwise
Driven tool stop

M7
M8
M9

Coolant 2 on (high pressure coolant)


Coolant 1 on (standard coolant)
coolant off

M 10
M 11
M2=10
M2=11

Spindle
Spindle
Spindle
Spindle

M 17

Subprogram end

M 20
M 21

Tailstock back (Hxxx back end position)


Tailstock forward (Hxxx front end position)

M 22
M1=22
M2=22

Eject part
Part ejector forward
Part ejector backward

M 23
M 24
M 1=24

Collection tray back


Collection tray forward
Collection tray forward in wait position

M 29

Collect part from counter spindle

M 25
M 26
M2=25
M2=26

Open clamping device left


Close clamping device left
Open clamping device right
Close clamping device right

M 30

Program end

M 31

Release open gantry door

brake
brake
brake
brake

spindle
spindle
spindle
spindle

1 on
1 off
2 on
2 off

M 50

Deselect direction logic

M 57
M 58

Main spindle oscillation on


Main spindle oscillation off

M 59

Chip conveyor interval time (in connection


with H word)

M 65
M 66

Feed hold / read-in lock KUPA/EMCO bar


loader
Release feed KUPA/EMCO bar loader

M 71
M 72

Rinse on
Rinse off

M 73
M 74

Runtime measuring on
Runtime measuring off

M 81

Channel 1 waits until M30 in channel 2

M 89
M 90

Release spindle rotation with open clamping device


Reset M89

M 96

Set nominal workpiece number reached

M 99

Machine configuration (in connection with


H word)

M 103 Read lockout, until spindle speed (S1/S2)


is reached
M 105 Read lockout, until spindle (S1/S2) stands
M 150
M 160
M 151
M 161
M 152
M 162
M 153
M 163
M 154
M 164
M 155
M 165
M 156
M 166
M 157
M 167

M30 M32 Program end with restart (depending on


1x key)

Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free

programmable output (A57.0) on


programmable output (A57.0) off
programmable output (A57.1) on
programmable output (A57.1) off
programmable output (A57.2) on
programmable output (A57.2) off
programmable output (A57.3) on
programmable output (A57.3) off
programmable output (A57.4) on
programmable output (A57.4) off
programmable output (A57.5) on
programmable output (A57.5) off
programmable output (A57.6) on
programmable output (A57.6) off
programmable output (A57.7) on
programmable output (A57.7) off

M 158 Warning lamp red on


M 168 Warning lamp red off

SW5 - 10/01

C1

M COMMANDS, MACHINE CONFIGURATION

PROGRAMMING AND OPERATION - SINUMERIK

Survey M Commands Gantry


(Channel 2)
M 17

Subprogram end

M 25
M 26
M2=25
M2=26

Open clamping device left


Close clamping device left
Open clamping device right
Close clamping device right

M 67 Open finished part grip


M 68 Close finished part grip
M 71 Rinse on
M 72 Rinse off
M 83 Pallet magazine step 1 position

M 30
Program end
M30 M32 Program end with restart (depending on
1x key)

M 89 Release spindle rotation with open clamping device


M 90 Reset M89

M 60
M 61

Close gantry door


Open gantry door

M 65
M 66

Open raw part grip


Close raw part grip

H1
H2
H3
H4

Raw part grip left, finished part grip right


Raw part grip bottom, finished part grip top
Raw part grip right, finished part grip left
Raw part grip top, finished part grip bottom

Survey Machine Configuration M99


Channel 1 (machine)

Channel 2 (Gantry)

H0

M99

H1
H2

H1
H2

M99
M99

manual chuck / end face driver


clamping device left
jaw chuck / pull collets left
pressure collets left

H3

M99

Clamping device control left off

H4
H5

M99
M99

bar feed / loading magazine on


bar feed / loading magazine off

H10 M99
H11 M99
H12 M99

manual chuck / end face driver


clamping device right
jaw chuck / pull collets right
pressure collets right

H13 M99

Clamping device control right off

M99
M99

H11 M99
H12 M99

C2

raw part gripper outside clamping


raw part gripper inside clamping
finished part gripper outside clamping
finished part gripper intside clamping

PROGRAMMING AND OPERATION - SINUMERIK

AXES DESCRIPTION

Axes Description

Axes description of machine with tailstock

Axes description of machine with counter spindle (spindle 2)

Axes description of machine with gantry loader (option)

C3

MACHINE CONTROL PANEL

PROGRAMMING AND OPERATION - SINUMERIK

Machine Control Panel


6.,3 '5<
581

& ; &

237
[ 6723

=

=

6%/

&

; &

357

=

=

4

57

)7





 



4 4 4







 

$8;








$8;




Machines with tailstock (option) are equipped with

Machines with gantry loader (option) are equipped


with the key

the keys tailstock forward

Handling Start instead of the

backward

additional NC Start key (2).

instead of the free key and the key

clamping device right (3).


In this case the NC Start key (1) operates the
machine (channel 1) and the Handling Start key
(2) operates the gantry loader (channel 2).

C4

and tailstock

PROGRAMMING AND OPERATION - SINUMERIK

KEY DESCRIPTION

Key Description
Skip
In skip operation the program blocks that are
marked with a slash "/" before the block number,
will not be executed in program run (e.g.: /N100).

6.,3

Dryrun
In dryrun operation the traversing movements will
be executed with the feed set in setting data
"dryrun-feed" .
The dryrun feed works instead of the programmed
feed.

'5<
581

Single Piece Mode


With this key you can select single piece mode or
continuous operation in connection with an
automatic loading device.
Power-on status is single piece operation.
The additional key Single Piece Mode shows the
active status by light.

[

Optional Stop
At active function (key was pressed) the program
run will be stopped at blocks that contain the
command M01.
The screen shows "Halt: M00/M01 active". Continue the program with the key NC Start.
When the function is not active, M01 (in the part
program) will be ignored.

237
6723

Reset Key
Actuating Reset causes:
Stop of working off the actual part program.
Alarms and messages are cleared with the exception of Power On or Recall alarms.
The channel will be set to the reset status, that
means:
- The NC control stays synchronous to the machine.
- All intermediate and working memory is cleared
(the contents of the part program memory stays
resident).
- The control is in basic setting and ready for
program run.

C5

KEY DESCRIPTION

PROGRAMMING AND OPERATION - SINUMERIK

Single Block
This function allows to work off a part program
block by block.
The function single block can be activated in AUTOMATIC mode.

6%/

Active single block mode causes:


Display SBL1 or SBL2 at the screen (in the line
channel).
Display of "Halt: Single block mode" in the
message line (in interruption status).
The actual block of the part program will be
worked off after pressing NC Start.
Working off will be stopped after each block.
The following block will be worked off after
pressing NC Start.
Deselect the function by pressing again on the
single block key.
SBL1
Single block mode with stop after every block
with machine functions.
Machining stop after every block that releases a
machine function (no stop with calculation blocks).
SBL2
Single block mode with stop after every block.
With active function the blocks will be worked off
as following:
Every block will be decoded one by one, at every
block occurs a stop.
Exceptions are only threading blocks without
DRYRUN. Here occurs the stop at the end of the
thread.
SBL2 can be selected only in Reset status.

Note
You can select either SBL1 or SBL2 .
Select SBL1 or SBL2 in AUTOMATIC or MDA
mode or with the softkey "program influence".

Program Test
Use this key for program test run without axes
movements. This test run is used to recognize
programming errors.

357

C6

PROGRAMMING AND OPERATION - SINUMERIK

KEY DESCRIPTION

NC Stop
After pressing the NC Stop key and takeover of
the function by the control, working off of the
running part program will be stopped.
You can continue working off by pressing NC
Start.

NC Start
After pressing the NC Start key the selected part
program will be started with the actual block.

Direction Keys

& ; &
=

=

&

; &

=

=

Use this keys to traverse the axes in the JOG


mode.

Rapid
If this key is pressed simultaneous to a direction
key the responding axis traverses in rapid feed.

Reference Point
Pressing this key causes approaching the reference point in all axes..

Feed Stop
This key stops slide movements in AUTOMATIC
mode (not for threads).

Feed Start
This key continues programmed, interrupted slide
movements.
When spindle run was interrupted additionally first
the spindle run must be continued.

Direction Keys Gantry Loader


(Option)

4

Use this keys to traverse the axes of the gantry


loader in the JOG mode.
See chapter F Gantry Loader.

4 4 4
C7

KEY DESCRIPTION

PROGRAMMING AND OPERATION - SINUMERIK

Spindle Override
The actual spindle speed S is shown at the screen
as absolute value and in percent.
Valid for main spindle, counter spindle and driven
tools.



Setting range:
Step width:
100% spindle speed:

50 - 120 % of the programmed spindle speed


5 % per key touch
100% key.

Spindle Stop
This key stops the running of the main and counter spindle and driven tools. Before stopping the
spindle you must stop the slides.

Spindle Start
This key continues the programmed run of the
main and counter spindle and driven tools.
Programming
M3
Main spindle on clockwise
M2=3 Counter spindle on clockwise
M3=3 Driven tool on clockwise.
M4
M2=4
M3=4

Main spindle on counterclockwise


Counter spindle on counterclockwise
Driven tool on counterclockwise.

M5
M2=5
M3=5

Main spindle stop


Counter spindle stop
Driven tool stop

Raw Part Grip OPEN - CLOSE


(Option)

57

M 65
M 66

Open raw part grip


Close raw part grip

Swivel Grip Head (Option)


H1
H2
H3
H4

Raw part grip left, finished part grip right


Raw part grip bottom, finished part grip top
Raw part grip right, finished part grip left
Raw part grip top, finished part grip bottom

Finished Part Grip OPEN - CLOSE


(Option)
M 67
Open finished part grip
M 68
Close finished part grip

)7

C8

PROGRAMMING AND OPERATION - SINUMERIK

KEY DESCRIPTION

Gantry Door Open/Close (Option)


M 60
M 61

Close gantry door


Open Gantry door

With M60 or key closed gantry door:


The gantry door will open and close together with
the machine door.
With M61 or key opened gantry door:
The gantry door keeps open, irrespective of the
movement of the machine door.

Magazine Step (Option)


See chapter F Gantry Loader.
The raw part magazine steps for one position.
M 83
Pallet magazine step 1 position

Clamping Device Left


This key actuates the clamping device on the left
side.
Switchover chuck/collet see "Machine configuration".
Via NC program
M25 ........ Open clamping device left
M26 ........ Close clamping device left

Clamping Device Right (Option)


This key actuates the clamping device on the right
side (counter spindle).
Switchover chuck/collet see "Machine configuration".
Via NC program
M2=25 .... Open clamping device right
M2=26 .... Close clamping device right

Tailstock Forward, Backward


These keys move the tailstock forward and backward.
Actuating the tailstock in the program
M20
M21

M20 H...
M21 H...

C9

Tailstock back (back end position)


Tailstock forward
The tailstock goes to the last manual
clamping position in JOG
Tailstock back
Tailstock forward
The tailstock goes to the Z-position
determined by H

KEY DESCRIPTION

PROGRAMMING AND OPERATION - SINUMERIK

Coolant
This key switches the coolant device on or off.
The last with M07 or M08 activated coolant device will be switched on or off.
M7
M8
M9

High pressure coolant device


Standard coolant device
Coolant off

The additional coolant key shows the actual status.

Chip Conveyor (Option)


Switch on chip conveyor:
Forward: Press key shorter than 1 second.
Backward: Press key longer than 1 second
The chip conveyor will be switched off after
approx. 35 seconds.
This value is set at works.

Tool Turret
In JOG mode this key swivels the tool turret for
one position.

Auxiliary OFF
This key switches off the auxiliary drives of the
machine. Effective only at spindle and program
stop.

$8;

Auxiliary ON
This key switches the auxiliary drives of the machine to ready status (hydraulics, feed drives,
spindle drives, lubrication, chip conveyor, coolant).
The key must be pressed for approx. 1 second.
Short pressing the AUX ON key is a quit function
and effects a lubrication impulse.

$8;

C10

PROGRAMMING AND OPERATION - SINUMERIK



KEY DESCRIPTION

Mode Selection Switch



Teach In
Creating programs in dialogue with the machine
in MDA mode.
MDA
Manual Data Automatic
Control of the machine by working off one block
or a sentence of blocks. The input of the blocks
occurs via operation panel.
Jog
Manual traverse
Conventional traversing of the machine by continuous moving of the axes via direction keys or
via incremental moving of the axes via direction
keys or via handwheel.
Inc Var
Incremental Feed variable
Traverse incremental value with variable increment width (setting data)



Inc 10
Incremental Feed
Traverse incremental value with fix step width of
10 increments.



Inc 100
Incremental Feed
Traverse incremental value with fix step width of
100 increments.
Repos
Repositioning, approach back to contour in JOG
mode.
Automatic
Control of the machine by automatic working off
of programs.
Ref
Approaching the reference point (Ref) in JOG
mode.

 









Feed Override Switch



The rotary switch with 23 positions allows to alter


the programmed feed F (meets 100 %).
The selected feed value F in % is displayed at
the screen.




Setting range:
0 % to 120 % of the programmed feed.
In rapid feed 100 % will not be exceeded.



C11

KEY DESCRIPTION

PROGRAMMING AND OPERATION - SINUMERIK

EMERGENCY OFF
Actuate the red button only in emergency situations.
Effects:
Normally all drives are stopped with maximum
deceleration by EMERGENCY OFF.
Unlock: Turn button
To continue press the following keys:
RESET, AUX ON, OPEN and CLOSE door.

Key Switch Special Operation


The key switch can be set to "AUTOMATIC" or
"SETUP" (manual) position.
Only by pressing the consent key the respective
function of the key switch will be released (see
consent key).
This key switch allows some dangerous movements with open door in tipping operation (with
consent key).

DANGER
Active special operation increases the danger of accidents.
The key must be used only by authorized
persons, who have the knowledge about the
dangers and are careful in operation.
Keep the chip guard door closed also during
setup operation.
Take off key always after working in special
operation (danger of accidents).
Observe the local safety regulations (e.g.:
SUVA, BG, UVV ....).

Key Switch Data Protection

Position 0
Part program input is locked.
Tool wear can be compensated.

Position 1
Part program input is released.
Possible further inputs:
Zero offsets, tool geometry, setting data.
With active single piece key the limit proximity
switches of the clamping device are not active
(for test run without workpiece).

C12

PROGRAMMING AND OPERATION - SINUMERIK

KEY DESCRIPTION

Additional NC Start Key


Same function as NC START key at the machine
control panel (Siemens).
(Double equipment for better comfort).

Handling Start (Option)


Machines with gantry loader are equipped with
the key Handling Start instead of the second NC
Start key.
For Gantry loader machines the NC Start key (Siemens keyboard) is effective for the machine
(channel 1), the Handling Start key is effective
for the gantry loader (channel 2).

Additional Key Single Piece


mode
Key light on: single piece mode is active

Additional Key Clamping Device


Left
Key light on: Part clamped

Additional Key Coolant


Key light on: Coolant runs
Key flashes: Coolant on was programmed but
coolant does not run (Dryrun or switched off
manually)

Additional Key Clamping Device


Right
Key light on: Part clamped
The additional keys have the same function as
on the machine control panel (Siemens).
(Double equipment for better comfort).

Consent Key
Axis movements via direction keys and tool turret
movements at open door are allowed by pressing
the consent key (precondition: key switch in
position setup).

C13

MAIN SWITCH, SIGNAL LAMP

PROGRAMMING AND OPERATION - SINUMERIK

Main Switch
Function:
0 - OFF
1 - ON
The main switch has no emergency off function,
that means the drives run out (unbreaked).
The programs in the NC core will be lost with
switching off.
The main switch can be locked (unauthorized
operation of the machine).

Signal Lamp (Option)


The signal lamp is divided in three indication fields
(white, green, red) which indicate the operating
status of the machine.

Operating statii:
WHITE
Flashing ...................................... lack of raw parts
Permanent light .............................. loading active

GREEN
Flashing ................. automatic operation selected
Permanent light ......... automatic operation active

RED
Permanent light ........ Alarm / EMERGENCY OFF

C14

PROGRAMMING AND OPERATION - SINUMERIK

OPEN MACHINE DOOR

Open Machine Door


Danger:
Do not remove or bypass control or safety
devices of the machine.
These devices are installed for your own
safety and in case of elimination will increase
the risk of accidents.
For reasons of safety door safety switches are
used for supervising.
Note:
After the machine has been switched on the
door must be opened and closed once as
otherwise message "door open" is emitted.
This measure serves to check whether the
door safety switch is operating.

Door safety switch

If NC START-key is pressed with open door, message "door open" appears. The NC START command will not be executed.
To open the chip guard door the consent key must
be pressed.
Thus the door lock bolt will be released and the
door can be opened.
Therefore the following conditions must be met:
1. All spindle drives must stand still.
2. No part program must be active.

Door Automatic
By machines with the attachment "Door Automatic" the door lock bolt will be released and the
door opened automatically by pressing the
consent key.
The machine door will also be opened automatically, if the bar feed / loading magazine or
handling is active.
Key "Close Door"
Machines with the door automatic have a "close
door"-key instead of the additional NC-Start key.
By pressing this key simultaneous with the
consent key, the machine door will be closed (in
the JOG-mode).
If there is no bar feed / loading magazine or
handlig active, the program will be started
automatically, when the machine door is closed.

C15

CLAMPING DEVICE CONTROL

PROGRAMMING AND OPERATION - SINUMERIK

Clamping device control


Purpose
1

With automatic workpiece loading for safety


reasons prior to switching on the main spindle, it
is automatically asked if the clamping device is
within the permitted clamping area.
For this purpose the control must know certain
data of each clamping device.

2
b1

Function

(Example jaw chuck)


b2

With opened jaw chuck (1) the clamping cylinder


with bore is in front (right) position.
The sensor (2) measures the distance (b1) and
thus the condition "chuck open" is defined.
When closing the jaw chuck the piston (1) moves
backwards with the tensioning tube (traversing
movement a), thus the measurable distance
changes (b).
The new distance (b2) defines the condition
"chuck closed and workpiece clamped".

Sensors for the clamping device control

If the chuck is closed without workpiece, the


piston (1) moves until stop to the left. The distance
b is bigger than b2 and thus the control knows
that no workpiece is clamped and emits an alarm.

Condition displays of the


clamping device
The condition of the clamping device is indicated
at the additional clamping device keys:
Clamping device key dark
Clamping device open
Clamping device key clear
Clamping device closed, workpiece clamped;
the clamping device pressure is achieved, the
final position of the clamping device has not been
reached.
Clamping device key blinks
Clamping device closed, no workpiece clamped;
the clamping pressure is achieved, the final
position of the clamping device has been reached.

C16

PROGRAMMING AND OPERATION - SINUMERIK

CLAMPING DEVICE CONTROL

Adjustment of the clamping


device control
During this procedure the final positions of the
clamping device for the clamping condition open
and closed are adjusted (see "clamping device
key dark" and/or "clamping device key blinks").

permitted clamping area


(clamping device closed,
workpiece clamped)

Clamping
device closed

Clamping
device open

maximum clamping area

Furthermore, the permitted clamping area is


defined (see "clamping device key lights").
Note:
The adjustment of the clamping device control
must be carried out:
after each clamping device change
in case of the emission of the alarms
510 100, 510 108, 520 108 - "clamping
device 1/2 open missing"

Safety area

Clamping and safety areas

Procedure
Note:
Prior to the adjustment check the machine
configuration for the clamping device (chuck/
collet)!

Set operating mode selector to "JOG".

$8;

Delete actual datas


Delete the actually stored values by actuating
simultaneously the key "AUX ON" and the
clamping device key.

Open clamping device


Release key "AUX ON" and actuate clamping
device key once; the clamping device is opened.
Close clamping device
Actuate clamping device key once; the clamping
device is closed.
The control computes and stores the permitted
clamping area with the help of the identified
final positions.

C17

CLAMPING DEVICE CONTROL

PROGRAMMING AND OPERATION - SINUMERIK

Bridging the final position


clamping device detectors
With "Key switch data protection"

Key switch - position "1"


With active single piece key the final position
sensors of the clamping devices are not active.

Application
test run without workpiece

Programming with H-word


If clamping is to be carried out in an area
exceeding the limits of the permitted clamping
area, the final position control must be switched
off (clamping in the safety area).

maximum clamping area


permitted clamping area
(clamping device closed,
workpiece clamped)

Caution:
Consider that with this possibility the survey
function is permanently switched off.
For this reason it may only be used if this
clamping state (clamping in the safety area)
cannot be changed by other measures (e.g.
collet change, chuck change, etc.).

Safety area
required clamping
area

Clamping area outside of the permitted area

Switching off the final position


detector
Spindle 1
Spindle 2

H3 M99
H13 M99

Activate the final position detector


Spindle 1
Spindle 2

C18

H1/H2 M99
H11/H12 M99

PROGRAMMING AND OPERATION - SINUMERIK

SWITCH ON/OFF SEQUENCE

Switch On/Off Sequence


Switch On the Machine
(machines with one tool turret)
Switch on main switch at the electrical cabinet
(cabinet fan runs).

$8;

Open and close the chip guard door once for


checking the door safety switch.

Press key AUX ON for at least 1 second (main


drive fan runs, axes active).

Approach Reference Point


Possibility A:
Referencing axis by axis

=

Press the +Z key


The slide traverses to the reference point in Z.

;

Press the +X key


The slide traverses to the reference point in X.
(Only after the collision-free area was reached in
Z)

=

Press the Z2 key


The slide traverses to the reference point in Z2.
Press the tool turret key to reference the tool
turret.

Note:
After reaching the reference points the
software limit switches are active.

Possibility B:
Automatic referencing
Press the key "reference". The axes traverse to
the reference point one after the other.

C19

SWITCH ON/OFF SEQUENCE, CHIP CONVEYOR

PROGRAMMING AND OPERATION - SINUMERIK

Switch Off the Machine


$8;

Press AUX OFF.

Switch off main switch

Notes:
Switching off the machine occurs with the
main switch.
We recommend to switch off the machine
only at ready position of the tool turret.
Interruptions of operating are done with the
RESET key.
RESET stops all running machine functions.

Chip Conveyor
Example

Programming:

%1
N10 M59 H180
N20 ...

M 59 H ....
While program run the chip conveyor is switched
on in certain intervals, runs approx. 35 s and is
switched off again. The time from switch on to
switch on is programmed with H (max. 4 digits) in
seconds. By it for every part program the interval
time can be programmed depending on the
amount of chips.
This interval time stays resident until the next
M59 is programmed, also after machine off - on.
Overstore in MDA mode is possible.

The chip conveyor is switched on all 180 seconds, runs for approx. 35 s and is switched off.

Note:
To avoid contamination of the emulsion the
chips should be removed out of the machine
before end of working.
A short run out of the chip conveyor is recommended.

Manual Operation:
Forward: Press key shorter than 1 second.
Backward: Press key longer than 1 second

C20

PROGRAMMING AND OPERATION - SINUMERIK

SPINDLE BRAKE, WORKPIECE COLLECTION, TAILSTOCK

Spindle Brake
Programming
M10
M11
M2=10
M2=11

Note:
The brake force is set at works (hydraulics)
and must be altered by a service technician
only.

Main spindle brake on


Main spindle brake off
Counter spindle brake on
Counter spindle brake off

Manual operation
JOG mode
Brake on:

AUX ON

Brake off:

Reset

$8;

+ Spindle Stop

Workpiece Collection
Device (Option)
The swivelling operation can only be carried out
via CNC program. Swivelling in and out is possible only with closed door.
Programming
M1=22
M2=22
M22
M 23
M 24
M 1=24
M 29

Ejector forward
Ejector backward
Eject (forward and backward)
Collecting tray backward
Collecting tray forward
Collecting tray forward in waiting position
Collect part from counter spindle

Tailstock
Programming
M20
M21

M20 H...
M21 H...

Tailstock back (back end position)


Tailstock forward
The tailstock goes to the last manual
clamping position in JOG
Tailstock back
Tailstock forward
The tailstock goes to the Z-position
determined by H

The tailstock goes up to 20 mm before end position with rapid feed, then with reduced feed.
When the tailstock overtravels the determined
position (JOG or H...) an alarm occurs.
Manual operation
Tailstock forward / backward

C21

C AXES, TOOL TURRET

PROGRAMMING AND OPERATION - SINUMERIK

C Axes
For milling planes (square, hexagon, etc.) the C
axis and the tool slide must be moved together in
a certain relation (= hob milling).

JOG operation of the C axes


The following program must be executed in MDA
before operating the C axes in JOG mode:
Main spindle
SPOS[1]=0
G0 C0
M30

(switch on C axis)
(C axis movement)

Counter spindle
SPOS[2]=0
G0 C2=0
M30

(switch on C axis)
(C axis movement)

The software accessory "Transmit" allows simple


programming of such planes.
Description with programming example see
"Transmit".
Switch on the C axes
SPOS=0..360
SPOS[1]=
SPOS[2]=

(angle in degree)
Main spindle
Counter spindle

Deselection of the C axes


M3, M4, M5

Tool Turret
Manual operation
JOG mode, the tool turret swivels on key tip for
one position.

 








Influencing the Tool Turret in AUTOMATIC and JOG Mode






Altering swivel speed



The swivel speed can be altered with the feed


override switch.



Interruption of the swivel sequence

$8;

To avoid a collision while swivelling you can interrupt swivelling with the key AUX ON.
Keep the key AUX ON pressed!
(otherwise swivelling will be continued) traverse
out of the danger area with the direction keys X,
Z (the override switch must not be at 0).
Aborting the swivel sequence
When aborting with EMERGENCY OFF or RESET, the tool turret looses its reference point.
Remedy:
Unlock EMERGENCY OFF, RESET, AUX ON,
chip guard door open-close, Traverse tool turret
with AUX ON and X, Z key out of the danger
area, referencing with tool turret key.

C22

PROGRAMMING AND OPERATION - SINUMERIK

MACHINE CONFIGURATION

Machine Configuration
Clamping Device Left
H0
H1
H2
H3

M99
M99
M99
M99

manual chuck / end face driver


jaw chuck (outside clamping)
collet chuck (inside clamping)
Clamping device control left off

Clamping Device Right


H10
H11
H12
H13

M99
M99
M99
M99

manual chuck / end face driver


jaw chuck (outside clamping)
collet chuck (inside clamping)
Clamping device control right off

Continuous Operation
H4

M99

Release continuous operation (select continuous/single piece mode


with key [ )

H5

M99

Single piece mode

Programming
H.. and M99 must be programmed in the same
program block.
The machine configuration can be written in a
part program or can be entered in MDA - overstore.
The machine configuration stays resident also
with switch off and on the machine until it will be
overwritten by a new H.. M99 command.

C23

R-PARAMETER

PROGRAMMING AND OPERATION - SINUMERIK

R Parameter
The control Sinumerik 840 D offers 100 calculating variables (= R parameter) of type REAL as
standard.
The array from R0 to R89 is free available for the
user, the array R90 to R99 is reserved for EMCO.

Workpiece Counter (R90, R91)


Actual workpiece number
The actual workpiece number is shown in parameter R90.
Nominal workpiece number
The nominal workpiece number is shown as parameter R91.

Example
250 pieces are to be machined.

Function
If a nominal workpiece number is entered in
parameter in R91, parameter R90 will count
from the nominal workpiece number down to 0.
When the nominal workpiece number is worked
off, the control shows the message "nominal
workpiece number reached".
When nominal workpiece number R91 and actual workpiece number R90 are set to 0, parameter R90 counts from 0 upward.

Set nominal workpiece number R91 = 250


The workpiece counter counts down from 250
to 0 and emits the message "nominal workpiece
number reached".
Set nominal workpiece number R91 = 0
Set actual workpiece number R90 = 0
The workpiece counter counts from 0 up to 250
and emits no message.

Programming
The call-up of the workpiece counter in the program is carried out just before the M30 command
with L700 P1.

Machining Time (R98, R99)


Example
%1
.
.
.
T6D7
M6
M3 S4000 F...
M73
.
.
R99
.
M74
T7D1
.
M2

The actual machining time of the whole part program is stored in R98.
Runtime measuring R99
Runtime is the machining time for a single machining sequence (e.g. finishing).
M73 Runtime measuring start
M74 Runtime measuring stop

R98

The measured runtime is stored in R99.

Format for parameter R98 and R99


Example: 6347.387
= 63 min, 47 s, 387 ms

C24

PROGRAMMING AND OPERATION - SINUMERIK

FREEPROGRAMMABLE OUTPUTS

Freeprogrammable Outputs
Survey
M-fuction
Output signal
A57.0
A57.1
A57.2
A57.3
A57.4
A57.5
A57.6
A57.7

on

off

M 150
M 151
M 152
M 153
M 154
M 155
M 156
M 157

M 160
M 161
M 162
M 163
M 164
M 165
M 166
M 167

Input signal

Query in part-program

E44.0
E44.1
E44.2
E44.3
E44.4
E44.5
E44.6
E44.7

$A_IN[9]
$A_IN[10]
$A_IN[11]
$A_IN[12]
$A_IN[13]
$A_IN[14]
$A_IN[15]
$A_IN[16]

You have the possibility to set several functions


for the freeprogrammable outputs with machine
datas.
The output won't be resetted with M30/reset,
but only with the M-function.
The output will be resetted after a time, adjusted
with machine datas.
By setting the output a feed hold will be triggered
in this channel, in which the M-function wa
pragrammed, until the belonging input will be
"one".
By setting the output a read lockout will be
triggered in this channel, in which the M-function
wa pragrammed, until the belonging input will
be "one".

Standard Setting
The output will be resetted with the Reset-key
or with M30
(or with the M-function)
Feed hold and read lockout won't be triggerd.
For other settings please contact EMCO-Service
Department.

C25

Y-AXIS

PROGRAMMING AND OPERATION - SINUMERIK

Y-Axis
Programming
DIAMOF .... diameter programming off
DIAMON ... diameter programming on

G19 ........... choose working plane (YZ) for lateral


area-working, in-feed coordinate is X
G17 ........... choose working plane (XY) for facing,
in-feed coordinate is Z
G18 ........... Resetting for lathing

M10 ........... spindle clamping on


M11 ........... spindle clamping off

Programming example for using the Y-axis


(lateral area-working - areas 1 and 2)

milling area 2

To avoid crashes, the Y-axis should be traversed


to position 0 after every use.

Working areas

N1750
N1760
N1770
N1775
N1780
N1800
N1810
N1820
N1830

N2010
N2020
N2030
N2050

C26

...

Programming notes

milling area 1

Drawing for example part

N2060
N2070
N2080
N2090
N2100
N2110
N2120
N2125
N2160
N2170

T5 D1 .............. milling diameter = 10


G95 ................. belongs to SPOS
SPOS[1]=0 ..... activate C-axis
M10 ................. spindle clamping on
SETMS(3) ....... driven tool = master spindle
G95 S2700 M3
G0 X76 Y-25 Z-13
G1 Y25 F0.2
G0 Z-23
G0 X100 Y0 Z-30.5
G19 ................. choose working plane (YZ)
T5 D2 .............. milling diameter = 10
POCKET2(100,72,0,64,8,20,0,-30.5,
0.05,0.2,8,3,0.2,1,0,0.1,2700)
G0 Z-33.5 Y0
G0 X73
G1 X64 F0.1
G1 Y20 Z-30.5 G41
G3 Y20 Z-30.5 J-20
G0 G40 Y0 Z-30.5 X90
X120 M5
M11 ................. spindle clamping off
M9
M30

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE95"

Cycle Programming
Roughing Cycle "CYCLE95"
This cycle can be used for external or internal,
longitudinal or transversal roughing or finishing
operations. The largest diameter for external
roughing and the smallest diameter for internal
roughing sets the start point for the roughing
cycle.
The last position in your program must be out of
the roughing area made by the cycle, otherwise
an alarm "wrong startpoint" appears.

Machining type

ORQJLWH[WHUQDO

ORQJLWLQWHUQDO

9DUL

9DUL



IDFLQJH[WHUQDO
9DUL 

longitud. outside /
kind of machining
/ facing
inside

1
l
o
roughing
2
f
o
roughing
3
l
i
roughing
4
f
i
roughing 1)
5
l
o
finishing
6
f
o
finishing
7
l
i
finishing
8
f
i
finishing 1)
9
l
o
compl. machining
10
f
o
compl. machining
11
l
i
compl. machining
12
f
i
compl. machining 1)
1) Only used for the machining behind a
shoulder

value



IDFLQJLQWHUQDO
9DUL 

roughing cycles

Notes:
It is important to choose the right cutting
edge position, because G41/G42 is activated automatically!
Further informations see Siemens-book
"Cycles"_4-18

C27

CYKLES / "CYCLE95"

PROGRAMMING AND OPERATION - SINUMERIK

Example
external contour longit. turning
Name of contour subprogram ..................................................
Depth of cut ...............................................................................
Finishing allowance in Z ..........................................................
Finishing allowance in X ..........................................................
Finishing allowance contour paralel ........................................
Roughing feedrate ....................................................................
Undercut feedrate .....................................................................
Finishing feedrate .....................................................................
Type of machining ....................................................................
Dwell time for chip breaking ....................................................
Chip breaking length ................................................................

G54
G53 G0 X610 Z350 Z2=760
N1 T1 D1 G96 S250 M4 G0 X65 Z0
G1 F0,18 X-1,6
G0 X65 Z5
CYCLE95("CONT1",3,0.05,0.3,0,0.3,0.1,0.12,9,0,0)
G0 X200 Z100
M30

&RQWRXU&217






SCHRUPP1
3
0,05
0,3
0
0,3
0,1
0,12
9
0
0



Subroutine for contour: CONT1:

G1 X35 Z2
Z0
X40 Z-1
Z-5
X50
X58 Z-10
Z-25
X38 Z-45
Z-50
X60 CHR=0,3
Z-50,4
M17






external contour logitudinal turning

[

G54
G53 G0 X610 Z350 Z2=760
N1 T1 D1 G96 S250 M4 G0 X65 Z0 ;roughing tool
G1 F0,18 X-1,6
G0 X65 Z5
CYCLE95("CONT",1,0.02,0.05,0,0.3,0.1,0.12,10,0,0)
G0 X200 Z100
M30





Example - external contour facing

[

Subroutine: CONT
G1 X100 Z-12
Z-10 CHR=1
X25
Z0 CHR=1
X22
M17



external contour facing

C28

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE95"

Example
internal contour longit. turning
G54
G53 G0 X610 Z350 Z2=760
N5 T5 D1 G96 S250 M4 ; boring bar
CYCLE95("CONTI1",3,0.05,0.3,0,0.3,0.1,0.12,11,0,0)
G0 X200 Z100
M30

&RQWRXU&217,

5



ERUH







[



[
 
 


 0


Subroutine: CONTI1
G1 X40 Z0 F0,12
X38 Z-2,5
Z-10
X40 Z-12,5
Z-20
X30 CHR=0,3
Z-30 F0,1
X20 RND=0,3
Z-40
X17
M17










internal contour longitudinal turning

G54
G53 G0 X610 Z350 Z2=760
....
N1 T1 D1 G96 S250 M4 G0 X65 Z0 ; boring bar
CYCLE95("CONT",1,0.02,0.05,0,0.3,0.1,0.12,10,0,0)
G0 X200 Z100
M30





Example - internal contour facing

[

Subroutine: CONT



G1 X25 Z-12
Z-10 CHR=1
X100
Z0 CHR=1
X103
M17

[

internal contour facing

C29

CYKLES / "CYCLE97"

PROGRAMMING AND OPERATION - SINUMERIK

Threading Cycle "CYCLE97"


It is possible to make cylindrical or tapered,
external or internal threads with constant pitch,
longitudinal or transversal. The threads can be a
single start or a multiple start thread.

constant chip-load
VARI=3/4
= = = = =

constant feed-in depth


VARI=1/2

radial infeed
"0"

You can choose between two different ways of


feed-in: constant feed-in depth or constant chipload.

angular infeed
e.g. "26"

alternating side
cuting "-29"

value
1
2
3
4

thread
outside
inside
outside
inside

infeed
constant infeed
constant infeed
constant chip section
constant chip section

infeed possibilities for "CYCLE97"


Note:
Further informations see Siemens-book
"Cycles"_4-33

Numer of roughing passes insteel accoring


to Sandvik
external / internal (metric. threads 60)
pitch
0,5
0,75
1
1,25
1,5
1,75
2
2,5

C30

number of
cuts
4
4
5
6
6
8
8
10

pitch
3
3,5
4
4,5
5
5,5
6

number of
cuts
12
12
14
14
14
16
16

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE97"

Example - external thread


Thread pitch .........................................................................................2
Thread size .......................................................................................... 0
Start point in Z-axis .............................................................................0
Start point in Z-axis ......................................................................... -10
Diameter at start point ...................................................................... 30
Diameter at end point ....................................................................... 30
Approach length ...................................................................................5
Run out length ..................................................................................... 2
Depth of thread (radial/no sign) ......................................................... 1,227
Finishcut allowance .............................................................................0,1
Infeed angle (+/-) .............................................................................. 26
Degree of rotation of thread start ....................................................... 0
Number of roughing passes ................................................................ 8
Number of idle passes ........................................................................ 1
Type of cycle ........................................................................................ 3
Number of starts .................................................................................. 1

G54
G53 G0 X610 Z350 Z2=760
N2 T2 D1 G95 S2000 M3 ; Threading tool pitch 2mm
CYCLE97(2,0,0,-10,30,30,5,2,1.227,0.1,26,0,8,1,3,1)
G0 X200 Z100
N3 T3 D1 G95 S1500 M3 ;Threading tool pitch 3mm
CYCLE97(3,0,-25,-40,50,50,5,3,1.84,0,-29,0,12,2,3,1)
G0 X200 Z100
M30

WKUHDG0[

Calculation of radial depth of thread


"external thread - 60"

WKUHDG0[

t = 0,6134 x p
t ................................................. thread depth
p .............................................................. pitch





external thread

C31

CYKLES / "CYCLE97"

PROGRAMMING AND OPERATION - SINUMERIK

Example - internal thread


Thread pitch .........................................................................................4
Thread size .......................................................................................... 0
Start point in Z-axis .............................................................................0
Start point in Z-axis ......................................................................... -20
Diameter at start point ...................................................................... 35,67
Diameter at end point ....................................................................... 35,67
Approach length ...................................................................................5
Run out length ..................................................................................... 2
Depth of thread (radial/no sign) ......................................................... 2,165
Finishcut allowance .............................................................................0
Infeed angle (+/-) ............................................................................. -29
Degree of rotation of thread start ....................................................... 0
Number of roughing passes ............................................................. 14
Number of idle passes ........................................................................ 0
Type of cycle ........................................................................................ 4
Number of starts .................................................................................. 1

G54
G53 G0 X610 Z350 Z2=760
N4 T4 D1 G95 S1000 M3 ; Threading bar pitch 4mm
CYCLE97(4,0,0,-20,35.67,35.67,5,1,2.165,0,-29,0,14,0,4,1)
G0 X200 Z100
N5 T5 D1 G95 S3000 M3 ; Threading bar pitch 1,5mm
CYCLE97(1.5,0,-30,-40,18.37,18.37,5,0,0.812,0,29,0,6,0,4,1)
G0 X200 Z100
M30







 
[

0

Calculation of radial depth of thread


"internal thread - 60"

[

0

t = 0,5413 x p
t ................................................. thread depth
p .............................................................. pitch




C32

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE83E"

Drilling Cycle "CYCLE83E"


This cycle is used for drilling of deep holes, either
in X-axis or z-axis direction.
Also you can choose between CHIP-BREAKING
or SWARF-REMOVAL.

Note:
Further informations see Siemens-book
"Cycles"_2-13

Example drilling on the main spindle

 





Absolut start point ............................................... 1


Absolut end point ............................................. -75
First drill depth (absolut) ................................. -30
Depth reduction ................................................ 10
Dwell at start point .............................................. 0
Dwell at end point ............................................... 0
Type:
0 = Chip breaking; 1 = Swarf removal .............. 1
Drilling axis:
0 = X - axis; 1 = Z - axis ..................................... 1








G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 G95 S1000 M3 F0,12; drill diam. 10
G0 X0 Z2
CYCLE83E(1,-75,-30,10,0,0,1,1)
G0 X200 Z10
M30

C33

CYKLES / "CYCLE83E"

PROGRAMMING AND OPERATION - SINUMERIK

Example
drilling with driven tools (axial):

Example
drilling with driven tools (radial):

Absolut start point ............................................... 1


Absolut end point ............................................. -30
First drill depth (absolut) ................................. -15
Depth reduction .................................................. 3
Dwell at start point .............................................. 0
Dwell at end point ............................................... 0
Type:
0 = Chip breaking; 1 = Swarf removal .............. 1
Drilling axis:
0 = X - axis; 1 = Z - axis ..................................... 1

Absolut start point ............................................. 62


Absolut end point ............................................... -5
First drill depth (absolut) .................................. 40
Depth reduction .................................................. 5
Dwell at start point .............................................. 0
Dwell at end point ............................................... 0
Type:
0 = Chip breaking; 1 = Swarf removal .............. 1
Drilling axis:
0 = X - axis; 1 = Z - axis ..................................... 0



















axial drilling with driven tools

radial drilling with driven tools

G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 ;
drill diam. 6mm - driven
STOPRE ;
Stop read
SETMS(3) ;
set driven tools as MASTERSPINDLE
G95 S1000 M4 G0 X20 Z2 F0,12
SPOS[1]=0 ;
turn on C-axis and position at
0
CYCLE83E(1,-30,-15,3,0,0,1,1)
G0 X200 Z10 M5
STOPRE ; Stop read
SETMS(1) ;
set main spindle as MASTERSPINDLE
M5
M30

G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 ;
drill diam. 6mm - driven
STOPRE ;
Stop read
SETMS(3) ;
set driven tools as MASTERSPINDLE
G95 S1000 M3 G0 X70 Z-20 F0,12
SPOS[1]=0 ;
turn on C-axis and position at
0
CYCLE83E(62,5,40,-5,0,0,1,0)
G0 X200 Z10 M5
STOPRE ;
Stop read
SETMS(1) ;
set main spindle as MASTERSPINDLE
M5
M30

C34

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE84E"

Tapping "CYCLE84E"
Note:
Further informations see Siemens-book
"Cycles"_2-17

Axial at the Main spindle or Counter


spindle without Floating holder
At the mainspindle
Absolut start point ............................................... 3
Absolut end point ............................................. -25
Thread pitch (+ M3 / M4) .................. -2,5
Tapping speed (rpm) ...................................... 600
Retract speed (rpm) ....................................... 800
Tapping axis:
0 = X - axis; 1 = Z - axis ..................................... 1

tap M202,5



STOPRE ;
Stop read
SETMS(1)
G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 M5 ;
tap M20 x 2,5
G0 X0 Z5
CYCLE84E(3,-25,-2.5,600,800,1)
""spindle direction
G0 X200 Z10
M30

axial tapping on main- or counterspindle

At the counter spindle


STOPRE ;
Stop read
SETMS(2)
G55
MIRROR Z0
G53 G0 X610 Z350 Z2=760
N8 T8 D1 M5 ;
tap M20 x 2,5
G0 X0 Z5
CYCLE84E(3,-25,-2.5,600,800,1)
"" spindle direction
G0 X200 Z10
M30

C35

CYKLES / "CYCLE84E"

PROGRAMMING AND OPERATION - SINUMERIK

Axial with driven tools without


floating holder

Radial with driven tools without


floating holder

Es kann mit herkmmlichen Bohr- und Frshaltern axial oder radial Gewinde gebohrt werden.
tap M101,5





tap M61






axial tapping with driven tools (without floating


holder)

radial tapping with driven tools (without floating


holder)

Absolut start point ............................................... 2


Absolut end point ............................................. -20
Thread pitch (+ M3 / M4) ..................... -1
Tapping speed (rpm) .................................... 1000
Retract speed (rpm) ..................................... 2000
Tapping axis:
0 = X - axis; 1 = Z - axis ..................................... 1

Absolut start point ............................................. 65


Absolut end point .............................................. 40
Thread pitch (+ M3 / M4) ................... 1,5
Tapping speed (rpm) .................................... 1000
Retract speed (rpm) ..................................... 2000
Tapping axis:
0 = X - axis; 1 = Z - axis ..................................... 0

G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1 ;
tap M6 x1 - driven tool
STOPRE ;
Stop read
SETMS(3)
G0 X20 Z2
SPOS[1]=0
CYCLE84E(2,-20,-1,1000,2000,1)
"" poss. turning direction reverse for angle holder
G0 X200 Z10 M5
STOPRE ;
Stop read
SETMS(1)
M5
M30

G54
G53 G0 X610 Z350 Z2=760
N8 T8 D1
STOPRE ;
Stop read
SETMS(3) ;
tap M10 x1,5 - driven
G0 X70 Z-20
SPOS[1]=0
CYCLE84E(65,40,1.5,1000,2000,0)
G0 X200 Z10 M5
STOPRE ;
Stop read
SETMS(1)
M5
M30

C36

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE93"

Grooving Cycle "CYCLE93"


With this cycle it is possible to make symmetric
or asymmetric grooves at the OD, ID and at the
face.
Via the parameter VARI you can define the
location of the groove and the start point.
If you use two digits, you can program the
chamfer according to the drawing and you dont
have to calculate the length of the chamfer.

9$5, 

9$5, 

9$5, 

9$5, 

9$5, 

9$5, 

=
;

9$5, 
=

=
;

9$5, 

9$5, 

9$5, 

9$5, 

=
;

9$5, 

9$5, 

=
;

9$5, 
=

=
9$5, 

9$5, 
=

startpoint and situation of the grooves

Notes:
Keep in mind that the next higher tool-offset
number is called up automatically for the
other side cutting edge!
Example:
IKeep in mind that the next higher tool-offset
number is called up automatically for the
other side cutting edge.
Further informations see Siemens-book
"Cycles"_4-5

C37

CYKLES / "CYCLE93"

PROGRAMMING AND OPERATION - SINUMERIK

Example - grooving cycle


1.
2.
3.
4.
5.
6.
7.
8.

Start point in X-axis .................................... 40


Start point in Z-axis ..................................... -5
Width of groove (no sign) ............................ 5
Depth of groove (radial) ............................. 10
Angle of surface at sart of groove ............... 0
Angle of the flank at start point side ......... 30
Angle of the flank at opposite side .............. 5
Radius/chamfer:
external at start point side ....................... -0,8
( for chamfer)
9. Radius/chamfer:
external at opposite side .......................... -0,8
( for chamfer)
10. Radius/chamfer:
at bottom at start point .............................. 0,5
(+ for radius)
11. Radius/Fase:
at bottom at opposite side ........................ 0,5
(+ for radius)
12. Finish cut allowance at bottom ................. 0,2
13. Finish cut allowance at flanks .................. 0,1
14. Feed in depth without sign ......................... 10
15. Dwell at bottom ............................................. 0
16. Type of cycle ............................................... 15





 










grooving cycle

G54
G53 G0 X610 Z350 Z2=760
N1 T1 D1 G96 S250 M4 G0 X65 Z0
G1 F0,18 X-1,6 G0 X65 Z5
CYCLE95("ROUGH5",4,0.05,1,0,0.35,0.1,0.15,9)
G0 X200 Z100
N9 T9 D1 G96 S180 M4 F0,12 ;
(grooving tool 3,5 mm / D1 - rh cutting)
CYCLE93(40,-5,5,10,0,30,5,-0.8,-0.8,0.5,0.5,0.2,
0.1,10,0,15) ;
(D2 - lh cutting edge)
G0 X200 Z100
M30





5

[



[





Subprogram for contour

example for groove

ROUGH5:
G1 X36 Z2
Z0
X40 CHR=2
Z-45
X60
M17

C38

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYCLE93"

Example - face-groove
1.
2.
3.
4.
5.
6.
7.
8.

Start point in X-axis .................................... 40


Start point in Z-axis ...................................... 0
Width of groove (no sign) ............................ 6
Depth of groove (radial) ............................... 5
Angle of surface at sart of groove ............. 90
Angle of the flank at start point side ......... 30
Angle of the flank at opposite side ............ 15
Radius/chamfer:
external at start point side ........................ 0,5
(+/ -radius/chamfer)
9. Radius/chamfer:
external at opposite side ........................... 0,5
(+/ -radius/chamfer)
10. Radius/chamfer:
at bottom at start point side ...................... 0,5
(+/ -radius/chamfer)
11. Radius/Fase:
at bottom at opposite side ........................ 0,5
(+/ -radius/chamfer)
12. Finish cut allowance at bottom ................. 0,2
13. Finish cut allowance at flanks .................. 0,1
14. Feed in depth without sign ........................... 5
15. Dwell at bottom ............................................. 0
16. Type of cycle ............................................... 16







face-groove

G54
G53 G0 X610 Z350 Z2=760
... ;machining
G0 X200 Z100
N9 T9 D1 G96 S180 M4 F0,12 ;
(grooving tool 3,5mm (D1 - upper cutting edge)
CYCLE93(40,0,6,5,90,30,15,0.5,0.5,0.5,0.5,0.2,
0.1,5,0,16) ;
(D2-lower cutting edge)
G0 X200 Z100
M30

C39

CYKLES / "TRANSMIT"

PROGRAMMING AND OPERATION - SINUMERIK

TRANSMIT-Programming
TRANSMIT

TRANSform - Milling Into Turning

With Transmit you can programm any contours


at the face of the part.
Activation:
main spindle ............................................. TMCON
counter spindle ...................................... TMC2ON
Deactivation:
general .................................................... TMCOFF

Note:
Further informations see Siemens-book
"Cycles"_11-36

Example - Hexagon A/F30

<


&


6

WDUWSRLQW


(


point
S
1
2
3
4
5
6
7
E

G54
G53 G0 X610 Z350 Z2=760
STOPRE ;
Stop read
TMCON
N1 T1 D1 ;
axial and mill DM 10 - tool
type 100
G95 S950 M4 F0,1 ; offset: L1...Z-length, L3...Xlength, R...radius e.g. 5
G0 X17,32 Y10 G41 Z-2
G1 Y0 F0,12
X8,66 Y-15
X-8,66
X-17,32 Y0
X-8,66 Y15
X8,66
X17,32 Y0
Y-10
G0 Z10 X150 G40 M5
TMCOFF
M30

;

&

QGSRLQW


X
17,32
17,32
8,66
-8,66
-17,32
-8,66
8,66
17,32
17,32

Y
10
0
-15
-15
0
15
15
0
-10

C40

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "TRANSMIT"

Subprogram macro for hexagon


milling works with Transmit
EXTERN HEXAGON (REAL,REAL) ;
has to programmed at the beginning!
....
M5 Z20 X100
STOPRE ;
Stop read
TMCON
N8 T8 G95 ;
AXIAL ENDMILL DIA14
G95 S900 M4 F0.12
Z-11.5
HEXAGON(17,5) ; A/F 17, radius of mill - 5
G0 X100 Y0 M5
TMCOFF
.....
%_N_HEXAGON_SPF
;$PATH=/_N_WKS_DIR/_N_IMTS98_WPD
PROC HEXAGON (REAL SW,REAL RAD) SAVE
R1=SW/2
R2=COS(30)
R3=TAN(30)
R4=R1/R2
R5=R1*R3
G0 X=R4+RAD+2 Y0
G1 G42 F0.2 X=R4 Y0
X=R5 Y=R1
X=-R5 Y=R1
X=-R4 Y0
X=-R5 Y=-R1
X=R5 Y=-R1
X=R4 Y=0
Y3
G40 G0 X=R4+RAD+2 Y0
RET ;
end of subprogram (M17)

Example - key-flats A/F 30

<
(

QGS

WDUWS

;

&


point
S
1
2
E

G54
G53 G0 X610 Z350 Z2=760
STOPRE ;
(Stop read)
TMCON ;
end mill cutter dia 10, - tool
type 100
N1 T1 D1 ;
offset: L1...Z-length, L3...Xlength, R cutter radius e.g. 5)
G95 S950 M4 F0,1
G0 X15 Y15 G41 Z-4
G1 Y10 F0,14
F0,12 Y-15
G2 X-15 Y-15 CR=21,21 F1
G1 X-15 Y15 F0,12
G0 Z10 X-100 Y-100 G40 M5
TMCOFF
M30

&

X
15
15
-15
-15

Y
15
-15
-15
15

C41

CYKLES / "CYLINDERINTERPOLATION"

PROGRAMMING AND OPERATION - SINUMERIK

Example 1

Cylinderinterpolation

G54
G0 D0 G53 X600 Z400 Z2=760
.....
N1 T1 D1 ; radial end mill 5
STOPRE
SETMS(3)
G95 S1000 M3
G0 X26 Z-9,5
SPOS[1]=0
TRACYL(24)
G54
G19
ATRANS Z-8
G1 X22 F0,06
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
G0 X26
X150 Z150 M5
TRAFOOF
G54
G18
....

To be used for milling contours at the circumferance.


Therfore it is necessary to make a "developed
view".

5
5











S











 [
 
 

<
=
developed view - example 1

C42

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "CYLINDERINTERPOLATION"

Example 2
G54
G0 D0 G53 X600 Z400 Z2=760
.....
N1 T1 D1 ; radial end mill 5
STOPRE
SETMS(3)
G95 S1000 M3
G0 X20 Z2
SPOS[1]=0
TRACYL(24)
G54
G19
G0 Z1 Y0
G1 Z0 F0,06
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
ATRANS Y12,566
G2 Z-0,987 Y2,224 CR=3
G1 Z-3,013 Y4,059
G3 Z-3,013 Y6,283 CR=3
G1 Z-0,987 Y8,507
G2 Z0 Y12,566 CR=3
G0 Z10
X150 Z150 M5
TRAFOOF
G54
G18
....

5
5




 [
 






S










<
=
developed view - example 2

C43

CYKLES / "SPINDLESYNCHRONIZATION"

PROGRAMMING AND OPERATION - SINUMERIK

Synchronization of two Spindles


Polygonalturning
Workpiece and driven tool are synchronized.

To be used for machining hexagons, Squares,...in


soft materials like brass, Aluminium, plastic and
similar materials.
Advantage:
Hexagons,.Squares,... with open tolerances can
be machined quickly.



....
N10 T10 D1 S1800 M4 G95 ; mill diam. 10 mm
G0 X22 Z1
COUPDEF(S3,S1,-2,1,CO,DV ;
(Folgespindel,Leitspindel, -direction of rotation
with spidle ratio S3:S1=2:1 )
SPCON(1)
SPCON(3)
COUPON(S3,S1,0) ;
(couple function
ON)
G1 Z-15 F0,1
X26
G0 X100 Z100
COUPOF(S3,S1) ;
(couple function
OFF)
SPCOF(1)
SPCOF(3)
M5
...

+(;VL]H

polygonalturning (hexagon)

Note:
Every spindle can be synchonized with each
other according to machine setup.

C44

PROGRAMMING AND OPERATION - SINUMERIK

CYCLES / "AUTOM. TAILSTOCK"

Programming the automatic


tailstock
here you will find two different cases of applications.
tailstock suports the shaft at one length position
tailstock suports the shaft at two or more different length position (used for multiple bar feed
out)

Supporting on one length position

Supporting on more length positions

Clamp the shaft into the mainspindle just as


you would machine it.
Move tailstock towards the part in JOG mode.
Then the preasure builds up and the machine
memorizes this position.
Move tailstock back into home-position

Clamp the shaft into the mainspindle just as


you would machine it.
Move tailstock towards the part in JOG mode
until preasure builds up.
Press Softkey Diagnosis
Press Softkey PLC
Press Softkey "Read in Operand"
Set cursor to "TAILSTOCK.PLC" an press
Softkey "OK".
The listened value in the table is the position to
be programmed.

in program:
....
M5
M21 ; Tailstock forward
N2 T2 D1 G96 S200 M4
....
; machining
M5
M20 ; tailstock back to home position
M30

1 unit = 5 mm = 1u
PP

PP

X

Home
position

    PP
X

in program:
....
M5
M21 H425
; Tailstock forward
N2 T2 D1 G96 S200 M4
....
; machining
M5
M20 H220
; retract tailstock 200 mm (to
the right)
... bar feed out 100 mm
M21 H325
; Tailstock forward 100 mm
(to the left)
.... machining
M20
; tailstock back to home
position
M30

C45

CYKLES / "TAKEOVER"

PROGRAMMING AND OPERATION - SINUMERIK

"TAKEOVER" - Cycle
Mainspindle-Counterspindle
This cycle is used for part transfer from main- to
counterspindle at bar- or swing loader machines.

Example for bar machine, without


pulling out the bar stock via the
counterspindle
= 
WRJJOHSRLQW*WR* = 
WDNHRYHUSRVLWLRQ = 

takeover with bar machine


name of cut-off subprogram .................. CUTOFF
position in Z2 to switch from G0 to G1 ......... 360
G1 feedrate in mm/min ................................. 6000
takeover position Z2 ....................................... 330
spindle orientation S2 to S1 in degree ............. 0
shoulder location 0=NO; 1= YES ..................... 1

....
G0 X300 Z20 M5 M9
N12 T12 D1 ; parting off tool 3mm
STOPRE
SETMS(1)
G95 S100 M3 ; if takeover at the fly is required
G0 X250 Z-50,25 (e.g. for part length 50mm)
TAKEOVER(CUTOFF,360,6000,330,0,1)
STOPRE
SETMS(2)
G55
MIRROR Z0
N100 T1 D2 ....
Subprogram: Cutoff
G0 X49 Z-50,25
G96 S150 M3
G1 F0,1 M8 X-1
G91 G0 Z1 Z2=2
G53 G90 G0 X600 Z400 Z2=760 M5 M9 D0
M17

C46

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "TAKEOVER"

Takover for bar machine, with pulling


out via counterspindle

Takover for bar machine with pulling


out via counterspindle and grip
closer cut off length

name of cut-off subprogram ................ CUTOFF1


position in Z2 to switch from G0 to G1 ......... 360
G1 feedrate in mm/min ................................. 6000
takeover position Z2 ....................................... 330
spindle orientation S2 to S1 in degree ............. 0
shoulder location 0=NO; 1= YES ..................... 1

name of cut-off subprogram ................ CUTOFF2


position in Z2 to switch from G0 to G1 ......... 395
G1 feedrate in mm/min ................................. 6000
takeover position Z2 ....................................... 292
spindle orientation S2 to S1 in degree ............. 0
shoulder location 0=NO; 1= YES ..................... 0

....
G0 X300 Z20 M5 M9
N12 T12 D1 ; parting off tool 3mm
STOPRE
SETMS(1)
G95 S100 M ; if takeover at the fly is required
G0 X250 Z3,25
TAKEOVER(CUTOFF1,360,6000,330,0,1)
STOPRE
SETMS(2)
G55
MIRROR Z0
N100 T1 D2 ....

....
G0 X300 Z20 M5 M9
N12 T12 D1 ; parting off tool 3mm
STOPRE
SETMS(1)
M5 ;
if there is no spindle rotation
wanted
G0 X250 Z3,25
TAKEOVER(CUTOFF2,395,6000,292,0,0)
STOPRE
SETMS(2)
G55
MIRROR Z0
N100 T1 D2 ....

Subprogram: Cutoff1
Subprogram: Cutoff2

M25
G91 Z2=103,5 G9
M26
G90 G0 X49 Z3,25
G96 S150 M3
G1 F0,1 X-1 M8
G91 G0 Z1 Z2=2
G53 G90 G0 X600 Z400 Z2=760 M5 M9 D0
M17

M25
G91 Z2=246,6 G9
M26
G4 F0,3
M2=25
G9 Z2=-158
M2=26
G90 G0 Z3,25 X32
G96 S150 M4
G1 F0,1 X-1 M8
G91 G0 Z1 Z2=2
G53 G90 G0 X600 Z400 Z2=760 M5 M9 D0
M17

C47

CYKLES / "TAKEOVER"

PROGRAMMING AND OPERATION - SINUMERIK

Takeover for chucking parts


(manual or loaded by swing loader)
name of cut-off subprogram ................ CUTOFF3
position in Z2 to switch from G0 to G1 ......... 400
G1 feedrate in mm/min ................................. 1000
takeover position Z2 ....................................... 390
spindle orientation S2 to S1 in degree ............. 0
shoulder location 0=NO; 1= YES ..................... 1
....
G53 G0 X600 Z400 D0 M5 M9
STOPRE
SETMS(1)
M5 ; if there is no spindle rotation wanted
TAKEOVER(CUTOFF3,395,6000,292,0,1)
STOPRE
SETMS(2)
G55
MIRROR Z0
N100 T1 D2 ....
Subprogram "Cutoff3"
M25
Z2=760
M17

C48

PROGRAMMING AND OPERATION - SINUMERIK

CYKLES / "EMCOLADER",
KUPA", "IRCO_FMB"

Bar Loading Cycles


There are three different bar loading cycles
LOADER, KUPA and IRCO_FMB. Those
cycles can be found in support - usere cycles
and filled out via an input mask.




)LQPPPLQ






loading cycle

"KUPA":

"EMCOLADER"

G54
G0 G53 D0 X600 Z400 Z2=760
N12 T12 D1 ; damped bar stop
KUPA(,,-78,0,0.25,100,0.5,4000,3,2,1,1)
G0 Z40
X50
N1 T1 D1 G96 S250 M4 ; roughing tool
.... ; machining

(1) name for program after bar change ........... __


(2) name for program to machine remnant ..... __
(3) pick-up position in Z ................................... -78
(4) pick-up position in X ..................................... 0
(5) bar stop position in Z ............................... 0,25
(6) safety position in Z .................................... 100
(7) bar stop position in Z (for new bar) .......... 0,5
(8) feedrate in mm/min ................................. 4000
(9) dwell time partschatcher forward ................. 3
(10) dwell time for remnant drop down ............. 2
(11) spindle oscilating 0=OFF 1=ON ................. 1
(12)0=parts catcher
1=chip conveyor
2=remnant machining ................................... 1

"IRCO_FMB":
G54
G0 G53 D0 X600 Z400 Z2=760
N12 T12 D1 ; damped bar stop
IRCO_FMB(NEWBAR,,-50,0,0.25,100,0.5,
4000, 3,2,1,1)
G0 Z40
X50
N1 T1 D1 G96 S250 M4 ; roughing tool
.... ; machining

in program:
G54
G0 G53 D0 X600 Z400 Z2=760
N12 T12 D1 ; damped bar stop
EMCOLADER(,,-78,0,0.25, 100,0.5,4000,
3,2,1,1)
G0 Z40
X50
N1 T1 D1 G96 S250 M4 ; roughing tool
.... ; machining

Subprogram "NEWBAR":
T10 D1 G95 S2000 M4
G0 X52 Z3,25
G1 F0,1 X-1 M8
G0 Z0,2
X250 Z150
M17
C49

BAR LOADER INTERFACE

PROGRAMMING AND OPERATION - SINUMERIK

Bar Loader Interface


(stored programmable)
This kind of programming is used in the cycles "EMCOLOADER", "KUPA"
and "IRCO_FMB".

M-functions
M57
M58
M67
M68
M69
M32

main spindle oscillation ON


main spindle oscillation OFF
feed ON (automatic mode)
feed OFF
bar changing
restart machine after M30 (dependent from the status of the "1key").

Signals
(connection load see Electrical Documentation of the machine/wiring
diagram=1DX1.D1/page 1)

EMCO bar feed / bar loading magazine


EMERGENCY OFF
machine door closed
bar changing
feed command
SPM open

contact of the Emergency Off switch


door safety board
A52.7
A52.6
A52.2

bar feed / bar loading magazine EMCO


NOT-AUS
bar end
start after bar changing
failure
loading magazine has feeded

embedment in Emergency Off-line


E37.5
E37.6
E37.7
E37.2

Signal-transfer PLC to NC
bar end
loader has feeded
start after bar changing

$A_IN[6] (status like inverted E37.5).


$A_IN[8] (status like E37.2).
$A_IN[7] (setted with M69 "bar
changing" and resetted with E37.6
"start after bar changing").

Examples
Query "bar end"

Query "start after bar changing"

If $A_IN[6]==0 GOTOF KSTE


MSG("bar end")
;This program part will only be passed through
by bar end.
MSG("");delete message
KSTE:
...

M69 ; bar changing A52.7 is setted.


STOPRE
STNW:MSG("waiting for start after changing")
If $A_IN[7]==1 GOTOB STNW
MSG("");delete message
...

C50

PROGRAMMING AND OPERATION - SINUMERIK

BAR LOADER INTERFACE

Example for machining with bar feed


M25 ; open clamping device
M67 ; feed ON
IF $A_IN[6]==0 GOTOF NOEND ; Query singal end of bar
MSG("END OF BAR")
M158 ; signal lamp on
M0
M168 ; signal lamp off
NOEND:M26
M68 ; feed hold
...... ; machining
M30 M32

Example for machining with bar loading magazine


M25 ; open clamping device
M67 ; feed ON
IF $A_IN[6]==0 GOTOF NOEND ; Query singal end of bar
MSG("END OF BAR")
;bar changing program:
M57 ; main spindle oscillating ON
M69 ; bar changing
AAA:
MSG("CHANGE OF BAR")
IF $A_IN[7]==0 GOTOF ENDWE ; waiting for E37.6, start after bar
changing
GOTOB AAA
ENDWE:M58 ; main spindle oscillating OFF
MSG(" ")
;bar beginning program:
NOEND:M26
M68 ; feed hold
...... ;machining
M30 M32

C51

C52

PROGRAMMING AND OPERATION - SINUMERIK

SERIAL INTERFACE

Serial Interface
The 25-pin sub-D-jack ist mounted laterally on
the operatiom panel.
Pin occupation: identical with system Sinumerik
800

SH
TXD
RXD

Signal names

RTS

SH
TXD
RXD
RTS
CTS
DSR
GND
CD
DTR
RI

CTS
DSR
GND

DTR

CD
RI

Schielding
Transmit data
Receive data
Request to send
Clear to send
Data send ready
Ground
Carier identification
Data terminal ready
Ring indicator

Maximum Cable Length


Serial interface - occupation

The maximum cable length depends the bit rate.

Standard Values
machine side

PC-side

9 600 bd ................................................ max. 10 m


19 200 bd ................................................ max. 7 m
38 400 bd ................................................ max. 5 m

Attention:
Don't overshoot maximum cable length!
Don`t use schield for signal ground GDN!

female connection,
9 poles

Connection to PC
The plug load you see in the plot beside.

plug connection
25-poles

Cable connection machine-PC

C53

C54

D Programming and Operation


EMCO-specific - Fanuc 21i-T
Machine Control Panel
6.,3 '5<
581

*5$3+

; &

237
6723

=

[

&




=



;
 

$8;










$8;




*)

*) By machines with door automatic instead of the external cycle-start-key

Axes Description

Axes description of machine

D2003-03

D1



 








KEY DESCRIPTION

PROGRAMMING, OPERATION EMCO-SPECIFIC

Description of Keys
Reset Key
Actuating Reset causes:
Stop of working off the actual part program.
Alarms and messages are cleared with the exception of Power On or Recall alarms.
The channel will be set to the reset status, that
means:
- The NC control stays synchronous to the machine.
- All intermediate and working memory is
cleared (the contents of the part program
memory stays resident).
- The control is in basic setting and ready for
program run.

5(6(7

Skip (skip block)


In skip operation program blocks marked before
the block number with a slash "/", are skipped
during program run (e.g.: /N100).
Active with illuminated LED.

6.,3

Dryrun (Test run feed)


In dryrun operation traversing motions are
executed with the feed value preset in the setting
date "test run-feed".
The test run feed is effective instead of the
programmed motion commands.
Spindle commands are not executed.
Active with illuminated LED.

'5<
581

Caution:
The test run feed normally is higher than the
programmed feedrate.
Be sure, that no workpiece is clamped before
starting the Dry Run.
By machining parts pay attention, that the Dry
Run mode is switched off (LED of the key is
off), before starting the machine.

Single Piece Operation


With this key the single piece operation or
continuous operation in connection with automatic
loading facilities are available.
The switch-on state is single piece operation.
The active single piece operation is indicated by
the illumination of the respective LED at the
machine control panel.

[

D2

PROGRAMMING, OPERATION EMCO-SPECIFIC

KEY DESCRIPTION

Graphic Simulation
With this key you can execute a program test run
without axis movement. The programmed tool
path is displayed on the screen. This test run
serves for testing and recognizing program errors.
Active with illuminated LED.
After leaving the graphic simulation the reference
point is to be approached again.

*5$3+

Remark:
To display the programmed path during the
program test in Graphic Mode press *5$3+ and
softkey "GRAPH".
The workpiece dimensions (Length=W and
Diameter=D) are to be set in [m] in the screen
"G.PRM".

Single Block
This function allows to work off a part program
block by block.
The function single block can be activated in AUTOMATIC mode.
Active single block mode causes:
The actual block of the part program will be
worked off after pressing NC Start.
Working off will be stopped after each block.
The following block will be worked off after
pressing NC Start.
Deselect the function by pressing again on the
single block key.
The Mode is active, when the LED is lightening.

Optional STOP
At active function (key was pressed) the program
run will be stopped at blocks that contain the
command M01.
Continue the program with the key NC Start.
When the function is not active, M01 (in the part
program) will be ignored.

237
6723

NC STOP
After pressing the NC Stop key and takeover of
the function by the control, working off of the
running part program will be stopped.
You can continue working off by pressing NC
Start.

NC START
After pressing the NC Start key the selected part
program will be started with the actual block.

D3

KEY DESCRIPTION

PROGRAMMING, OPERATION EMCO-SPECIFIC

; &
=
&

Direction Keys
With these keys the NC axes can be traversed in
operating mode JOG.

=

Unless the machine is referenced, you must


simultaneously press the key AUX ON to move
the axes (release).

;

Rapid
If this key is pressed simultaneous to a direction
key the responding axis traverses in rapid feed.

Feed STOP
This key stops slide movements in AUTOMATIC
mode (not for threads).

Feed START
This key continues programmed, interrupted slide
movements.
When spindle run was interrupted additionally first
the spindle run must be continued.

Clamping Device
The clamping device is operated using this key.
Clamping direction see M90-M92.
Via NC program
M25 ........ open clamping device
M26 ........ close clamping device

Tailstock forward, tailstock


backward
With these keys the tailstock is moved forward or
backward.
Via NC program
M20 ........ tailstock backward (rear final position)
M21 ........ tailstock forward (clamping position)

Tool Turret
In JOG mode this key swivels the tool turret for
one position.

D4

PROGRAMMING, OPERATION EMCO-SPECIFIC

KEY DESCRIPTION

Spindle Speed Override


The set spindle speed value S can be changed
manually.



Setting range:
Step width:
100% spindle speed:

50 - 120 % of the programmed spindle speed


10% per key pressure
100% key

Spindle STOP
This key stops the running of the main and counter spindle and driven tools. Before stopping the
spindle you must stop the slides.

Spindle START
This key continues the programmed run of the
main and counter spindle and driven tools.
Programming
see "M-functions" forwards in this chapter
Rotation directions
see "Axes description" forwards in this chapter

Coolant
With this key the coolant device is switched on
and/or off.
The LED indicates the running of the coolant
pump.
With open chip guard door the coolant pump runs
only as long as the key is pressed.
If this key is pressed in operating mode AUTOMATIC after the coolant has been switched on in
the program with M8, the coolant pump is switched
off and the LED flashes. Switch on again by
pressing the key again.
Programming:
M8 Coolant on
M9 Coolant off

D5

KEY DESCRIPTION

PROGRAMMING, OPERATION EMCO-SPECIFIC

Chip Conveyor (option)


Switch on chip conveyor:
Forward: press key less than 1 second, forward
run for about 35 s (LED illuminates).
Backward: press key less than 1 second, backward run as long as key is pressed (LED flashes
slowly), then forward run for about 35s.
The running time of the chip conveyor is set in
the counter C8 (by the manufacturer, approx. 35
seconds).
The intermission time is set in the counter C12
(by the manufacturer 300 seconds).
Interrupt chip conveyor:
For emptying etc. simultaneously press AUX ON
and chip conveyor key (LED flashes quickly).
Switch on again with chip conveyor key.

Reference Point
By pressing this key in operating mode REFERENCE approaching the reference points in all axes
is carried out.

Auxiliary OFF
This key switches off the auxiliary drives of the
machine. Effective only at spindle and program
stop.

$8;

Auxiliary ON
With this key the auxiliary units of the machine
are made ready for operation (hydraulics, feed
drives, spindle drives, lubrication chip conveyor,
coolant).
The key must be pressed for about 1 second.
Short pressing of the AUX ON key is a quit
function and effects a lubricating impulse of the
central lubrication.

$8;

Release prior to referencing


If the slide must be released prior to referencing
(e.g. from a collision exposed position), press

$8;

and the respective direction key simultaneously.

Swivelling free the tool turret


If, in case of an accruing alarm, the tool turret
must be swivelled free, press the keys
simultaneously.

D6

$8;

and

PROGRAMMING, OPERATION EMCO-SPECIFIC

KEY DESCRIPTION

Mode Selection Switch




Automatic
Control of the machine by automatic working off
of programs




Edit
Edit part programs



MDI
Manual Data Input
Control of the machine by working off of blocks or
sequences of blocks. Input of blocks via operation
panel.
Manual operation
Conventional traversing of the machine by
continuous movement of the axes via direction
keys or incremental movement of the axes via
direction keys or handwheel.

Incremental feed 1 - 1000


See manual operation, traverse increments with
fix step width from 1 to 1000 increments (m or
inch/10000).



Ref
Manual approaching the reference point (Ref)












 



Feed Override Switch



The rotary switch with 20 positions allows to alter


the programmed feed F (meets 100 %).
The selected feed value F in % is displayed at the
screen.




Setting range:
0 % to 120 % of the programmed feed.
In rapid feed 100 % will not be exceeded.



D7

KEY DESCRIPTION

PROGRAMMING, OPERATION EMCO-SPECIFIC

EMERGENCY OFF
Actuate the red button only in emergency situations.
Effects:
Normally all drives are stopped with maximum
deceleration by EMERGENCY OFF.
Unlock: Turn button
To continue press the following keys:
RESET, AUX ON, OPEN and CLOSE door.

Key Switch Special Operation


The key switch can be set to "AUTOMATIC" or
"SETUP" (manual) position.
Only by pressing the consent key the respective
function of the key switch will be released (see
consent key).
This key switch allows some dangerous movements with open door in tipping operation (with
consent key).

Danger:
Active special operation increases the danger
of accidents.
The key must be used only by authorized
persons, who have the knowledge about the
dangers and are careful in operation.
Keep the chip guard door closed also during
setup operation.
Take off key always after working in special
operation (danger of accidents).
Observe the local safety regulations (e.g.:
SUVA, BG, UVV ....).

Key Switch Data Protection


Position 0
Part program input is locked
Tool wear can be compensated

Position 1
Part program input is released
Possible further inputs:
Zero offsets, tool geometry, setting data
With active single piece key the limit proximity
switches of the clamping device are not active
(for test run without workpiece)!

D8

PROGRAMMING, OPERATION EMCO-SPECIFIC

KEY DESCRIPTION

Additional NC START Key


Additional Key Clamping Device
The additional keys have the same function as on
the machine control panel (Siemens).
(Double equipment for better comfort).

Key "Close Door " with Door


Automatic
Notes see "Open Machine door"

Consent Key
Axis movements via direction keys and tool turret
movements with open door are admitted by
pressing the consent key (prerequisite key switch
in position SET UP).
To open the chip guard door the consent key must
be pressed, too.

Main Switch
Function:
0 - OFF
1 - ON
The main switch has no emergency off function,
that means the drives run out (unbreaked).
The main switch can be locked (unauthorized
operation of the machine).

Signal Lamp (Option)


The signal lamp is divided in three indication fields
(white, green, red) which indicate the operating
status of the machine.
Operating statii:
WHITE
Flashing ...................................... lack of raw parts
Permanent light .............................. loading active

GREEN
Flashing ................. automatic operation selected
Permanent light ......... automatic operation active

RED
Flashing .................... Alarm / EMERGENCY OFF

D9

SWITCH ON SEQUENCE

PROGRAMMING, OPERATION EMCO-SPECIFIC

Switch On/Off Sequence


Switch ON the machine
Switch on the main switch at the electrical cabinet.

Open Chip guard door (with consent key) and


close again; this sequence checks the function of
the door safety switch.
Press AUX ON (auxiliary drives) for at least 1
second to activate the auxiliary drives (Hydraulic,
axes, coolant).

$8;

After a longer period of standstill press the key


multiple (every press a lubrication pulse).
REF mode is active after switching on the machine
and the auxiliary drives (independent from the
position of the mode selection switch)

$8;

;

=

Approach reference point


When the slide is near X+ or Z+ end position or in
an area with the danger of a crash, select JOG
mode and traverse free the slide by simultanous
pressing the AUX ON key and the corresponding
direction key.

=
;

( )


Press reference key.


The slides approach the reference point first in X
and afterwards in Z.
Select desired operation mode.

Notes:
After reaching the reference point the
software limit switches are active.
With an active tool turret alarm the key AUX
ON must be pressed simultanous with the
reference key, to approach te reference
point.
When an overtravel message is shown
always with approaching the reference point,
switch on the machine and press simultanuously the keys &$1 and 3 4 until the
screen display appears.
This error can occur e.g. if the axis position
was altered when the machine was switched
off (motor shaft turned).

D10

PROGRAMMING, OPERATION EMCO-SPECIFIC

SWITCH OFF SEQUENCE / OPEN MACHINE DOOR

Switch OFF the Machine


$8;

Press AUX OFF.

Switch off main switch


Notes:
Switching off the machine occurs with the
main switch.
We recommend to switch off the machine
only at ready position of the tool turret.
Interruptions of operating are done with the
RESET key.
RESET stops all running machine functions.

5(6(7

Open Machine Door


Danger:
Do not remove or bypass control or safety
devices of the machine.
These devices are installed for your own
safety and in case of elimination will increase
the risk of accidents.
For reasons of safety door safety switches are
used for supervising.

Note:
After the machine has been switched on the
door must be opened and closed once as
otherwise message "door open" is emitted.
This measure serves to check whether the
door safety switch is operating.

Door safety switch

If NC START-key is pressed with open door, message "door open" appears. The NC START command will not be executed.
To open the chip guard door the consent key must
be pressed.
Thus the door lock bolt will be released and the
door can be opened.
Therefore the following conditions must be met:
1. All spindle drives must stand still.
2. No part program must be active.

D11

MACHINE DOOR / DOOR AUTOMATIC

PROGRAMMING, OPERATION EMCO-SPECIFIC

Door Automatic (Option)


Open door automatically
On machines that are equipped with the acessory
"automatic door", the door will be opened automatically when releasing the locking bolt (with
consent key T).
In automatic mode the door will be opened
automatically with programmed stop or program
end (M0, M1, M2, M30).

Close automatic door


Machines with automatic door have a "close door"
key instead of the additional "NC start" key.
When this key is pressed simultaneous with the
consent key the door will be closed automatically.

Automatic program start


With active M96 the program will be started
automatically after closing the door.
M96 is self-holding until switching off the machine,
for safety reasons it must be activated again after
switching on the machine.
M96 is disactivated by M97.
M96/M97 also can be used without automatic
door.

D12

PROGRAMMING, OPERATION EMCO-SPECIFIC

CLAMPING DEVICE CONTROL

Clamping Device Control


Purpose
1

With automatic workpiece loading for safety


reasons prior to switching on the main spindle, it
is automatically asked if the clamping device is
within the permitted clamping area.
For this purpose the control must know certain
data of each clamping device.

2
b1

Function

(Example jaw chuck)


b2

With opened jaw chuck (1) the clamping cylinder


with bore is in front (right) position.
The sensor (2) measures the distance (b1) and
thus the condition "chuck open" is defined.
When closing the jaw chuck the piston (1) moves
backwards with the tensioning tube (traversing
movement a), thus the measurable distance
changes (b).
The new distance (b2) defines the condition
"chuck closed and workpiece clamped".

Sensors for the clamping device control

If the chuck is closed without workpiece, the piston


(1) moves until stop to the left. The distance b is
bigger than b2 and thus the control knows that no
workpiece is clamped and emits an alarm.

Condition displays of the


clamping device
The condition of the clamping device is indicated
at the additional clamping device keys:
Clamping device key dark
Clamping device open
Clamping device key clear
Clamping device closed, workpiece clamped;
the clamping device pressure is achieved, the final position of the clamping device has not been
reached.
Clamping device key blinks
Clamping device closed, no workpiece clamped;
the clamping pressure is achieved, the final position
of the clamping device has been reached.

D13

CLAMPING DEVICE CONTROL

PROGRAMMING, OPERATION EMCO-SPECIFIC

Adjustment of the clamping


device control
During this procedure the final positions of the
clamping device for the clamping condition open
and closed are adjusted (see "clamping device
key dark" and/or "clamping device key blinks").

permitted clamping area


(clamping device closed,
workpiece clamped)

Clamping
device closed

Clamping
device open

maximum clamping area

Furthermore, the permitted clamping area is


defined (see "clamping device key lights").
Note:
The adjustment of the clamping device control
must be carried out:
after each clamping device change
in case of the emission of the alarm "clamping device open missing"

Safety area

Clamping and safety areas

Procedure
Note:
Prior to the adjustment check the machine
configuration for the clamping device (chuck/
collet)!

Set operating mode selector to "JOG".

$8;

Delete actual datas


Delete the actually stored values by actuating
simultaneously the key "AUX ON" and the
clamping device key.

Open clamping device


Release key "AUX ON" and actuate clamping
device key once; the clamping device will be
opened.
Close clamping device
Actuate clamping device key once; the clamping
device will be closed.
The control computes and stores the permitted
clamping area with the help of the identified final positions.

D14

PROGRAMMING, OPERATION EMCO-SPECIFIC

CLAMPING DEVICE CONTROL

Bridging the final position


clamping device detectors

With "Key switch data protection"


Key switch - position "1"
With active single piece key the final position
sensors of the clamping devices are not active.

Application
test run without workpiece

Programming with H-word


If clamping is to be carried out in an area
exceeding the limits of the permitted clamping
area, the final position control must be switched
off (clamping in the safety area).

maximum clamping area


permitted clamping area
(clamping device closed,
workpiece clamped)

Caution:
Consider that with this possibility the survey
function is permanently switched off.
For this reason it may only be used if this
clamping state (clamping in the safety area)
cannot be changed by other measures (e.g.
collet change, chuck change, etc.).

Safety area
required clamping
area

Clamping area outside of the permitted area

Switching off the final position


detector
M-code

M93

Activate the final position detector


M-code

D15

M91/M92

STANDARD TAILSTOCK

PROGRAMMING, OPERATION EMCO-SPECIFIC

Standard Tailstock
Programming
M20

Tailstock quill backward (back position)


Tailstock quill forward
The tailstock quill moves to the
adjusted clamping position.

M21

If the tailstock quill overtravels the adjusted


position (JOG), alarm occurs.

Adjusting the detection of the


tailstock quill
The position of the tailstock quill is monitored by
the proximity switches (1) and (3).
The monitoring of the forward position of the
tailstock quill can be adjusted by traversing the
proximity switch (1).
Chose the JOG-mode.
Set the deliberated pressure for the tailstock
quill (see "Hydraulic unit" in chapter "B Description").
Clamp workpiece in clamping device, traverse
tailstock into deliberated position and clamp it.
Move Tailstock quill forward by pressing the
key

Loosen screw (2) for the proximity switch (1)


with an allen wrench, key size 5.
Traverse proximity switch into the right direction,
until message " Tailstock in intermediate position " occurs (arrow 1).
Retraverse proximity switch (1) in left direction,
until the message just disappears (arrow 2).

Clamp proximity switch in this position.


2

Control of the adjusting


Move tailstock quill backwards by pressing the
key
Press key

to move tailstock quill forwards.

There may no message appear on the screen.

Adjusting the proximiy switch

D16

PROGRAMMING, OPERATION EMCO-SPECIFIC

AUTOMATIC TAILSTOCK

Automatic Tailstock

6<67(0

Programming

PMC

M20
M21

PMCPRM

DATA

M20 H...
M21 H...

G.DATA

The tailstock moves until 20 mm before final


position in rapid motion, then with reduced feed.
If the sleeve passes over the determined positioned (JOG or H..), there is an alarm.

Parameter-Nr.

Address

0030

D0060

0031

D0062

Sleeve backward (rear final position)


Sleeve forward (first to be done
manually)
The tailstock moves to the clamping
position approached last in JOG
Sleeve backward (not less than H11)
Sleeve forward
The sleeve moves to the Z-position
indicated under H

Description

Counter
(momentary position)
Clamping position

Adjustment of the tailstock


stroke monitoring

Call-up of parameters "D0060 / D0062" on the


screen

The position of the tailstock is monitored by the


proximity detectors (5) and (6).
Setting the monitoring is carried out by displacing
the connecting link (4).
Set operating mode "JOG".

Call up parameter "D0060" via the softkeys


"PMC PMCPRM DATA G.DATA in the
system menu.

On the screen the parameter "D0060" is displayed with a value (1), e.g. "0011".
Loosen counter nut (3).
Set setting screw (2) flush with counter nut (3)
by means of Allan key.
Insert workpiece and approach tailstock against
the workpiece.
(Setting the tailstock contact pressure see under
"hydraulics" in chapter "B Description").
Turn setting screw (2) out of the tailstock until
the value (1) of the parameter "D0060" on the
screen shows more by the number 1 (e.g.
change of the value from "0011" to "0012").
Turn setting screw back again, until the value
(1) counts back again by "1" (from "0012" to
"0011").
Turn screw (2) still another rotation into tailstock.
2

Secure setting screw (2) with the counter nut


(3) in this position.

Detail drawing - tailstock, adjustment of the stroke

Exit from the parameter display with

D17

5(6(7 .

SPINDLE BRAKE / C-AXIS

PROGRAMMING, OPERATION EMCO-SPECIFIC

Spindle Brake
Programming
M10
M11

Main spindle brake on


Main spindle brake off

Manual operation
JOG mode
Brake on:

AUX ON

Brake off:

Reset

$8;

+ Spindle Stop

Note
The brake force is set at works (hydraulics)
and must be altered by a service technician
only.

C-axis
For milling surfaces (square, hexagon, etc.) the
C-axes and the tool slide must be moved in a
certain relation to each other (=hobbing).
With the "polar coordinate-interpolation" such
surfaces can be programmed easily.
Switching on the C-axis
after M5 with M52
G0 C0..360.xxx

(angle in degree)

Deselection of the C-axis


M53 or M3, M4, M5, M10
Note
Once in a program the C-axis has to be
referenced after M52 with the command G28
C...
Operation JOG of the C-axes

&

By pressing the respective "C"-key on the


operating panel of the control, the C-axis can be
moved manually in JOG operation.

&

D18

PROGRAMMING, OPERATION EMCO-SPECIFIC

WORKPIECE COLLECTION DEVICE


TOOL TURRET

Workpiece Collection
Device (Option)
The swivelling operation can only be carried out
via CNC program. Swivelling in and out is possible only with closed door.

Programming
With feed-hold function
M 23
M 24

Collecting tray backward


Collecting tray forward

Without feed-hold function


M 230
M 240
M 241

Collecting tray backward


Collecting tray forward below spindle
Collecting tray forward into waiting
position

Tool Turret
Manual operation
JOG mode, the tool turret swivels for one position
at each key press.
Swivel free at active alarm:
Press AUX-ON and tool turret key simultanously.

Influencing the Tool Turret in AUTOMATIC and JOG Mode


Aborting the swivel sequence
When aborting with EMERGENCY OFF or RESET, the tool turret looses its reference point.
Remedy:
Unlock EMERGENCY OFF, RESET, AUX ON,
chip guard door open-close, Traverse tool turret
with AUX ON and X, Z key out of the danger area,
referencing with tool turret key.

5(6(7

D19

MACRO VARIABLES

PROGRAMMING, OPERATION EMCO-SPECIFIC

Macro Variables
The control FANUC-21i offers calculating variables in order to create custom macros.
For a detailed information see Description Chapter 15).

Calling up Variables
The variables will be shown in the function "OFFSET/SETTING
[+] MACRO:
#1 - #33: local variables
cleared with Power OFF
#100 - #149: Common variables
Cleard with Power OFF
#500 - #531: Common variables
Hold on with Power OFF
#1000 and above: System variables
To read / write NC-data

Workpiece Counter
Programming

Parts Count
(corresponds to system variable #3901)

The parts counter can be programmed by using


the macro variables, programming a block with
e.g. Nxx #500=#500+1.
The number of machined parts will be displayed
in "OFFSET/SETTING no. 500 of MACRO sreen.

Shows the actual workpiece number. It is also


displayed in the main screens at the right upper
side.

Parts Required
(corresponds to system variable #3902)

Example
250 pieces are to be machined.

Shows the nominal workpiece number.

Set "Parts Required = 250".


The workpiece counter counts from 0 upwards
to 250 and emits the message "2011 - Required
Number of Pieces".

Parts Total
This value can only be set by parameter 6712. It
will be incremented with "1" by M2 or M30.

Set "Parts Required = 0".


Set "Parts Count = 0".
The workpiece counter counts from 0 upwards
to 250 and emits no message.

The Fanuc parts counter is located in the function


SETTING/OFFSET SETTING

3$*(

3$*(

Settings can only be made in the MDI-mode.


Note
See also "Fanuc-Control Description" - Chapter
11.4.9.

Function
If a nominal workpiece number is entered in the
variable "Parts Required", "Parts Count" will
count from 0 up to the nominal workpiece
number.
If the nominal workpiece number is worked off,
message "2011 - Required Number of Pieces"
will appear.
If "Parts Required" and "Parts Count" will be set
to 0, both variables counts from 0 upwards.

D20

PROGRAMMING, OPERATION EMCO-SPECIFIC

FREEPROGRAMMABLE OUTPUTS

Machining Time
The timers are located below the workpiece
counter, together with the current date and day
time.

Power On Time

Free Purpose

(corresponds to system variable #3001)

Can be used, for example, as a total timer for


coolant flow.

Displays the total time which the machine is


switched ON.

Cycle Time

Operating Time

Indicates the running time of one operation (program), excluding feed hold and stop time.

Indicates total running time, excluding stop time


and feed hold.

Date and Time

Cutting Time

(#3011 corresp. to date, #3012 corresp. to time)

(corresponds to system variable #3002)

Displays actually set date and time

Displays the total time during cutting with a


programmed feedrate (time in active Cycle
START).

Free Programmable Outputs


Output
signal
Y 7.0
Y 7.1
Y 7.2
Y 7.3
Survey

M-function
on
off
M81
M80
M83
M82
M85
M84
M87
M86

You have the possibility to set several functions


for the freeprogrammable outputs with machine
datas.

Input
signal
X 20.4
X 20.5
X 20.6
X 20.7

The output won't be resetted with M30/reset,


but only with the M-function.
The output will be resetted after a time, adjusted
with machine datas.
By setting the output a feed hold will be triggered
in this channel, in which the M-function wa
pragrammed, until the belonging input will be
"one".
By setting the output a read lockout will be
triggered in this channel, in which the M-function
wa pragrammed, until the belonging input will
be "one".

Standard Setting
The output will be resetted with the Reset-key
or with M30
(or with the M-function)
Feed hold and read lockout won't be triggerd.
For other settings please contact EMCO-Service
Department.

D21

PROGRAM INPUT, ADMINISTRATION

PROGRAMMING, OPERATION EMCO-SPECIFIC

Survey Program Input, Administration


Program input occurs in EDIT mode (

).

Listing of the most frequent edit functions:


Program block input

List programs
Press the key

352*

Enter NC commands (e.g. N90G0X9Z-6).

(eventually 2x).

The screen shows all stored programs.


Scroll list:

3$*(

and

Take over the block with

3$*( .

(2%

,16(57

Delete backward while input: &$1


Entering a block number at the beginning of a
block is not necessary.

Call program
List programs ( 352* ).

Insert block

Enter program number e.g.O1234.


Press softkey O-SRH.
When the entered program is in memory, it will
be caleed up, otherwise alarm 71 is shown.

Put the cursor on the block end (EOB sign ";")


of that block, that should be before the new
block.
Enter the new block.

Create new program


List programs ( 352* ).

Delete block

Enter free program number e.g. O5678.

Put the cursor on the beginning of the block to

Press the key sequence

,16(57

(2%

and

,16(57

be deleted and press the keys

(2%

and

'(/(7( .

The new program is opened and you can enter


the program blocks.
Rename program

Insert word

Call program.
Put cursor on program number (e.g. O1234),
enter new program number and press key

Put the cursor on that word that should be before


the new word.
Enter new word (address and value, e.g. X0)

$/7(5 .

and press key

Copy program
Call the program to be copied.
Press softkey OPRT and the right menu extension
.
key
Press softkeys EX-EDT, COPY, ALL.
Enter new program number (without O) and
press the key

,1387

Find word
Enter word (e.g. X50) or address of the word to
be found (e.g.: X).
Press cursor key

.
Alter word

Press the softkey EXEC.

Put cursor on the word to be altered.

Delete program

Enter new word and press the key

List programs ( 352* ).


Enter program number e.g.O1234 and press the
key

,16(57

Delete word

'(/(7( .

Put cursor on the word to be deleted.

The entered program will be deleted.


Delete all programs: O-9999

$/7(5 .

Press the key

'(/(7( .

D22

'(/(7( .

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / SURVEY

G-Commands - Survey
Use the following table to find the description of
the G commands in the Fanuc manuals.

The Fanuc control uses for the G commands the


allocation groups A, B, C; that means one
command has different numbers in different
groups.
The Fanuc control is programmed with the
commands of allocation group C, but the Fanuc
manuals describe the allocation group A.

Code
Grp. C
G00
G01
G02
G03
G04
*)
G05
*)
G07
G07.1
(G107)
G10
G11
G12.1
G112
G13.1
G113
G17
G18
G19
G20
G21
*)
G22
*)
G23
G24
*)
G25
*)
G26
G27
G28
G30
G31
G33
G34
G36
G37
G40
G41
G42
G50.2
(G250)
G51.2
(G251)
G52
G53

Meaning
Rapid motion
Linear interpolation
Circular interpolation/clockwise
Circular interpolation/counter-clockwise
Dwell time
Machining in quick cycle
Interpolation with fictitious axis
Cylindric interpolation
Data setting
End data setting
Mode
"Polar coordinate interpolation"
End mode
"Polar coordinate interpolation"
Selection level XpYp
Selection level ZpXp
Selection level YpZp
Longitudinal turning cycle (AD/ID)
Thread cutting cycle
Memorized traverse limit on
Memorized traverse limit off
Facing cycle
Spindle speed monitoring on
Spindle speed monitoring off
Reference position - return check
Return to reference point
Return to 2nd reference point
Cancel remaining path
Thread and oil groove cutting
Thread cutting with variable lead
Autom. tool correction X
Autom. tool correction Z
Deselection cutter radius compensation
Cutter radius compensation left
Cutter radius compensation right
Polygonal turning end
Polygonal turning
Setting local coordinate system
Setting machine coordinate system
traverse movements only in rapid motion

Example
G71 Inch input can be found in the Fanuc manuals
as G21.

Code
Grp. A

Code
Grp. C

G00
G01
G02
G03
G04
G05
G07
G07.1
(G107)
G10
G11
G12.1
(G112)
G13.1
(G113)
G17
G18
G19
G90
G92
G22
G23
G94
G25
G26
G27
G28
G30
G31
G32
G34
G36
G37
G40
G41
G42
G50.2
(G250)
G51.2
(G251)
G52

G54
G55
G56
G57
G58
G59
G65
G66
G67
G68

*)

G69

*)

G70
G71
G72
G73
G74
G75
G76
G77
G78
G80
G83
G84
G85
G87
G88
G89
G90
G91

G94
G95
G96
G97
G98
G99

Selection workpiece-coordinate system 1


Selection workpiece-coordinate system 2
Selection workpiece-coordinate system 3
Selection workpiece-coordinate system 4
Selection workpiece-coordinate system 5
Selection workpiece-coordinate system 6
Macro call
Modal macro call
Modal macro call end
Axis mirroring for double turret heads on or
tare cut mode
Axis mirroring for double turret head off or
tare cut mode end
Input in inch
Input in mm
Finishing cycle
Contour roughing cycle (ID/OD)
Face roughing cycle
Pattern repeating cycle
End face cut-in cycle
Cut-in cycle
Multiple threading cycle
Drilling cycle end
Cycle for face drilling
Cycle for face tapping
Reaming cycle axial
Side drilling cycle
Side tapping cycle
Reaming cycle radial
Absolute programming
Incremental programming
Set coordinate system or maximum spindle
speed

G92
G92.1

Meaning

*)

Workpiece coordinate system


Feed per minute
Feed per rotation
Constant cutting speed
Const. cutting speed off
Return to initial level
Return to level mit point R

Commands with different group cycles


*) see Fanuc control description

G53

D23

Code
Grp. A
G54
G55
G56
G57
G58
G59
G65
G66
G67
G68
G69
G20
G21
G70
G71
G72
G73
G74
G75
G76
G80
G83
G84
G85
G87
G88
G89

G50
G50.3
G98
G99
G96
G97

G-BEFEHLE / G00

PROGRAMMING, OPERATION EMCO-SPECIFIC

Short description G-Commands


On the following pages you will find a short description of the G-commands
of the control Fanuc 21 TB, allocation group C.
This description represents an extract from the programming instructions
for the control Fanuc 21 TB and is mainly intended as programming aid.
For detailed information referring to the individual commands see the
programming instructions for the control Fanuc 21 TB.
In case of ambiguities and contradictions the specifications in the original
Fanuc instructions are valid.

Note:
In these instructions the command classification of the allocation group
C is described as used on the Fanuc control at the EMCO machine.
In the descriptive material of Fanuc the allocation group A is described
- if you use the Fanuc material you therefore have to recode the
commands according to the scheme (see survey G-commands).

G00 Rapid Traverse


Format
N.... G00 X(U)... Z(W)...
The slides are traversed with max. speed to the
programmed target point (tool change position,
starting point for the following machining procedure).
;

Notes




A programmed slide feed F is suppressed during


G00.




The rapid speed is set definitively.


The feed override switch is limited to 100%.



Example
absolute G90
N50 G00 X40 Z56

;

incremental G91
N50 G00 U-30 W-30.5

Absolute and incremental values G00

D24

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G01

G01 Linear Interpolation (Feed)


;

Format
N... G01 X(U)... Z(W).... F....




Linear slide movements (face, longitudinal, taper


turning) at the programmed feedrate.

Example
absolute G90
N.. G95
.....
N20 G01 X40 Z20.1 F0.1





incremental G91
N.. G95 F0.1
.....
N20 G01 X20 W-25.9

S ...... Start point


E ...... End point

;

Absolute and incremental measures for G00

Insertion of Chamfers and Radii


Example
....
N 95
N 100
N 105
N 110
....

;


&




G
G
G
G

01
01
01
01

X
X
X
X

26
26
86
86

Z
Z
Z
Z

53
27
27
0

R6
C3

The movement, which is programmed in the second block, has to start at point b (drawing).
With incremental programming the distance from
point b has to be programmed.



5




Notes
Chamfers and radi can be inserted between two
G00/G01 movements only.

With single block mode the tool stops first at


point c and then at point d.

=

If the movements in one of the blocks are so


short, that there is with inserting a chamfer or
radius no intersection point, alarm no. 055
occurs.

Insertion of chamfers and radii

D25

G-COMMANDS / G01

PROGRAMMING, OPERATION EMCO-SPECIFIC

Direct Drawing Input


Commands

X2... (Z2...) A...

Tool movements

;=
 

Note:
Bold printed commands can be executed
only with the option comfort programming.

$
;=
 
;

;=
 

A1...
X3... Z3... A2...

$

;=
 

$
;=
 
=
;

;=
 
$

X2... Z2 ... R...


X3... Z3...

or
3

;=
 

A1 ... R...
X3... Z3... A2...

$
;=
 
=

;=
 
$

X2... Z2... ,C...


X3... Z3...
or
4

&
;=
 

A1... ,C...
X3... Z3... A2...

$
;=
 
=

;=
 

;
X2... Z2... R1...
X3... Z3... R2...
X4... Z4...

;=
 

or
5

A1... R1...
X3... Z3... A... R 2...
X4... Z4...

$

;=
 

D26


$
;=
 

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G01

Commands
X1... Z 1... ,C 1...
X3... Z 3... ,C 2...
X4... Z4...
6

Tool movements

&

$

;=
 

or

&
;=
 

A1... ,C 1...
X3... Z3... A2... ,C2...
X4... Z4...

;
X2... Z 2... R1...
X3... Z 3... ,C 2...
X4... Z4...
7

;=
 

&

A1... R1...
X3... Z3... A2... ,C2...
X4... Z4...

$

;=
 

X2... Z 2... ,C 1...


X3... Z 3... R2...
X4... Z4...


$
;=
 

;=
 
;=
 

or

;=
 

;=
 

or

$
;=
 

$

&

A1... ,C 1...
X3... Z3... A2... R2...
X4... Z4...

;=
 

$
;=
 

Note:
The following G commands must not be used
for the blocks with chamfer or radius.

Missing intersection point coordinates need not


to be calculated.
In programs angles (A), chamfers (C) and radi
(R) can be programmed directly.
The following block after a block in which C or
R was specified, has to be a block with G01.
To command a chamfer is possible only with
the comma-character ",C". Otherwise alarm for
illegal use of C-axis will appear.

G-Codes in group 00:


G05, G7.1, G10, G11,
G27, G28, G30, G31,
G92, G92.1,
G52, G53,
G72, G73, G74, G75, G76, G77, G78
G-Codes in group 01:
G02, G03, G20, G21 and G24

The input of angles (A) is possible with the


option comfort programming only.

They must not be used between the blocks with


chamfer or radius, which define the succession
numbers.

D27

G-COMMANDS / G02, G03

PROGRAMMING, OPERATION EMCO-SPECIFIC

G02 Circular Interpolation


Clockwise
G03 Circular Interpolation
Counterclockwise
*

*

Format
N... G02 X(U)... Z(W)... I... K... F...
or
N... G02 X(U)... Z(W)... R... F...

0 .

X,Z ............ End point of the arc


U,W, I,K .... Incremental circle parameters
(Distance from start point to centre
of arc, I is related to X, K to Z)
R ................ Radius of arc

The tool will be traversed to the target point along


the defined arc with the programmed feed F.

Rotational direction and parameter of an arc

Note
Programming the value 0 for I and K can be
omitted.
With the input of R only an arc < 180 can be
done. R is alway entered positive.

G04Dwell
Format
N... G04 X(U)...
or
N... G04 P...

[sec]
[msec]

The tool movement will be stopped at the last


reached position for a dwell defined by X,U or P sharp edges - transititions, cleaning cut-in ground,
precise stop
Note
With address P no decimal point is allowed
The dwell time starts at the moment when the
tool movement speed is zero.
t max. = 2000 sec, t min. = 0,1 sec
input resolution 100 msec (0,1 sec)
Examples
N75 G04 X2.5 (U2.5)
N95 G04 P1000

D28

(dwell time= 2.5sec)


(dwell time = 1 sec =
1000 msec)

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G10

G10 Data Setting


With the command G10 control data can be
overwritten, parameters can be programmed, tool
data can be written etc.
In user practice G10 is mainly advisable to program the workpiece zero point.

Attention
The format G10 P0 X(U).. Z(W).. and/or G92
X(U).. Z(W).. is placed above all other zero
point shifts (from G52 to G59)!
The shift is not displayed on the screen!
Attention with programs which were programmed for former control types (Fanuc 0T, Fanuc 21-T).

Zero point shift G92


Format

Remedy
First call up G10 P0 X0 Z0 (reset of the zero
point shift in G92) and input the following
two blocks:
G10 L2 P1 X(U).. Z/W).. ;
G54 ;

N.. G10 P0 X(U).. Z(W)..


P0.....selection zero point shift G92
Input/Display (MDI mode)
OFFSET/SETTING "+" (2) "W-SHIFT"

G92 is placed above G54 to G59 and EXT!


Therfore the shifts of G54 to G59 and EXT
will be added to the shift of G92!

Zero point shift with workpiece


coordinate systems G54 to G59
In general with this control it is advisable to use
one of six preset workpiece coordinate systems
G54 to G59 when setting a workpiece-zero point
shift, since here all overwritten values can be
controlled and reproduced on the screen at any
time. (The description of the commands G54 to
G59 is carried out later in this chapter.)
Format
Notes:
The call-up of the selected workpiece coordinate
system in the program must be carried out in
the next block.
By calling up the external workpiece coordinate
system the basis of all coordinate systems called
up in the following is shifted by the dimension
entered there.
The selected workpiece coordinate system can
be overwritten or replaced by another one within
a program as often as you want by means of
the format mentioned above.
The workpiece coordinate systems overwritten
in this way can be controlled after reading in
under the function SETTING / OFFSET under
picture WORK.

N.. G10 L2 P1 X(U).. Z(W)


(overwrites workpiece coordinate system G54)
N.. G54
(calls up workpiece coordinate system G54 in the
program)
G10 L2 ............ overwriting the entered workpiece
coordinate system.
P0 .................... selection of the external workpiece coordinate system.
P1 (...bis P6) .. selection of the workpiece coordiante system G54 (...to G59).
Input/Display (MDI mode)
OFFSET/SETTING "WORK"
(see descriptions G54 to G59)

D29

G-COMMANDS / G20

PROGRAMMING, OPERATION EMCO-SPECIFIC

G20 Longitudinal Turning Cycle

;

8

(OD/ID Machining Cycle)

;

Format

=

N... G20 X(U)... Z(W)... F...


(straight)
or
N... G20 X(U)... Z(W)... R... F... (taper)

X(U), Z(W) ..... Absolute (incremental) coordinates


of the contour point K
;

R [mm] ........... Incremental taper dimension in X


with direction (+/-)

Longitudinal turning cycle without taper

Notes
;

8

This cycle is modal and will be deselected by a


G command of the same group.
For following blocks only the altered coordinates
have to be programmed (see example).

;

5

A negative taper parameter (-R) defines the


taper as shown in the drawing.
=

;

Longitudinal turning cycle with negative taper R


;



N100
.....
N110
N115
N120
N125
N130

  
 

=

Example: G20 Longitudinal turning cycle

D30

G91
G20 U-4 W-66 F0.18
U-8
U-12
U-16
G00 .....

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G21, G24

G21Thread Cutting Cycle

;
=


8

Format
N... G21 X(U)... Z(W)... F... ............... (straight)
or
N... G21 X(U)... Z(W)... R... F... ........... (taper)

;

=

F ......... Thread pitch [mm]

R [mm] ........... Incremental taper dimension in X


with direction (+/-)

Straight thread cutting cycle


Notes

;
=

This cycle is modal and will be deselected by a


G command of the same group.

5


For following blocks only the altered coordinates


have to be programmed (see example).


8
;

A negative taper parameter (-R) defines the


taper as shown in the drawing.

=
)
Tapered thread cutting cycle

G24 Face Turning Cycle

;


8

;

Format
N... G24 X(U)... Z(W)... F... ............... (straight)
or
N... G24 X(U)... Z(W)... R... F... ........... (taper)

=

R ......... Incremental value of the taper in Z axis

Notes
;

This cycle is modal and will be deselected by a


G command of the same group (G0, G1, G2).

Face turning cycle without taper

For following blocks only the altered coordinates


have to be programmed (see example).

;

8

;

5
=

.:
=

A negative taper parameter (-R) defines the taper


as shown in the drawing.

;

Face turning cycle with negative taper R

D31

G-COMMANDS / G28, G33

PROGRAMMING, OPERATION EMCO-SPECIFIC

G28 Reference Point Return


(approach reference point)
Format
N... G28 X(U)... Z(W)... C(H)...
X,Z,C ..... absolute coordinates of the intermediate position
U,W,H ... incremental coordinates of the intermediate position
The G28-instruction is used to approach the
reference point via an intermediate position (X(U),
Z(W)).
First the withdrawal is carried out to X(U) and/or
Z(W), subsequently the reference point is approached. Both movement sequences are carried
out with G00!
Note:
After the first selection of the C-axis (with M52)
the command
G28 C0
must be carried out to reference the C-axis.

G33 Thread Cutting


Format
N... G33 X(U)... Z(W)... F...

;
:

F ......... Thread pitch [mm]


Straight, tapered an scroll threads can be cut.
Because of no automatic return to the start point,
the multiple threading cycle G78 will be preferred.
Machining routines like knurling are also possible.

;

8

=

Note
With taper threading the thread pitch has to be
defined with the higher value in X or Z axis.
Continuous thread cutting is possible (multiple
threads)

)
Measures for thread cutting

D32

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / CUTTER RADIUS COMPENSATION

Cutter Radius Compensation


During tool measurement the tool tip is measured
only at two points (touching the X and Z axes).
The tool offset therefore only describes a theoretical cutter tip.
This point is traversed on the workpiece in the
programmed paths.

With movements in the axis directions (longitudinal and face turning) the points on the tool tip
touching the axes are used.

Tool tip radius and theoretical cutter tip

No dimensional errors are therefore produced on


the workpiece.

With simultaneous movements in both axis


directions (tapers, radii) the position of the
theoretical cutter point no longer coincides with
the point on the tool tip actually cutting.
Dimensional errors occur on the workpiece.
Maximum dimensional error without cutter radius
compensation with 45 movements:
Tool tip radius 0,4 mm 0,16 mm path distance
0,24 mm distance in X and Z.
If cutter radius compensation is used, these
dimensional errors are automatically calculated
and compensated by the control.

Movements parallel to the axes and oblique

For the cutter radius compensation you must enter


the cutter radius R and the cutter position T when
entering the tool data.

The cutter position is indicated by a number (see


draft).

To decide the cutter position look at the tool as it


is clamped on the machine.

Cutter position

D33

G-COMMANDS / CUTTER RADIUS COMPENSATION

PROGRAMMING, OPERATION EMCO-SPECIFIC

Tool pathes with selection / cancellation of the cutter radius compensation

*

*
*

*

Frontal approach or leaving of an edge point

Approach or leaving an edge point at side behind


programmed tool path
real traversed tool path

*

With arcs always the tangent of the end or start


point of the arc will be approached.
The approaching path to the contour and the
leaving path from the contour must be larger than
the tool tip radius R, otherwise program interruption with alarm.
If contour elements are smaller than the tool tip
radius R, contour violations could happen. The
software computes three blocks forward to
recognize this contour violations and interrupt the
program with an alarm.

5
5
*
Approach or leaving an edge point behind

Tool pathes with program run with active cutter radius compensation

*

*

*
*
Tool path at an inner edge

Tool path at an outer edge > 90


programmed tool path
real traversed tool path

*

With arcs always the tangent of the end or start


point of the arc will be approached.

If contour elements are smaller than the tool tip


radius R, contour violations could happen. The
software computes three blocks forward to
recognize this contour violations and interrupt the
program with an alarm.

5
*

Tool path at an outer edge < 90

D34

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / CUTTER RADIUS COMPENSATION

G40 Cancel Cutter Radius


Compensation
The radius compensation will be cancelled with
G40. Cancellation is only permitted in combination
with a linear traversing command (G00, G01)
G00 or G01 can be programmed in the same block
or as the first traversing movement after cancellation.

G41 Cutter Radius


Compensation Left
If the programmed tool path (viewed in the
direction of machining) is on the left of the material
to be machined, the radius compensation is to be
selected with G41.
Notes
No direct change between G41 and G42 - cancel
with G40 previously.
Cutter radius R and cutter position T must be
defined.
Selection is only permitted in conjunction with
G00 or G01.
Change of tool correction is not possible with
active cutter radius compensation.

Definition G41 cutter radius compensation left

G42 Cutter Radius


Compensation Right
If the programmed tool path (viewed in the
direction of machining) is on the right of the
material to be machined, the radius compensation
is to be selected with G42.
Notes see G41!

Definition G42 cutter radius compensation right

D35

G-COMMANDS / G52

PROGRAMMING, OPERATION EMCO-SPECIFIC

G52 Local Coordinate


During programming in a workpiece coordinate
system (G54 to G59) a "subsidiary coordinate
system" can be set up within the selected
workpiece coordinate system to facilitate the
programming of certain functions.
Such an additive coordiante system is called a
local coordinate system.
Format
N.. G52 X(U).. Z(W).. C(H).. ;
(Setting up a local coordinate system)
N.. G52 X(U)0 Z(W)0 C(H)0 ;
(Deleting a local coordinate system)
The workpiece zero point set in the selected
workpiece coordinate system is shifted by the positive and negative dimensions indicated in the
local coordinate system.
After deleting the local coordinate system the zero
point is reset to the workpiece zero point originally
set in the selected workpiece coordinate system.

Local
coordinate system
IP

G54: workpiece
coordinate system 1

Local
coordinate system
G55

G56

G57

G58

_
IP G59: workpiece
coordinate system 6

Origin of the machine coordinate system


Reference point

Note
During the set-up of local coordinate systems,
workpiece and machine coordinate systems
remain unchanged.
Traverse commands immediately after the
selection or deselction of the local coordinate
system must be absolute dimension commands.

Attention:
By pressing the RESET key the existing local
coordinate system is deleted and during the
subsequent block search it is overread.
Also if coordinates for any axis of the local
coordinate system are set newly, the existing
local coordinate system is deleted.

D36

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G53, G54-G59

G53 Selection of the Machine


Coordinate System
A coordinate system with its origin on the machine
zero point is called machine coordinate system.
After switching on the machine the machine
coordinate system must be set by reference point
approach prior to indicating the command G53.
G53 is a G-code effective once for the selection
of the machince coordinate system. Commands
are thus only valid in the block with G53 and are
exclusively traversed in rapid motion!
Format
N.. G53 X.. Z..
Notes
With command G53 cutting radius correction
and tool correction are switched off.
G53 must be indicated in absolute dimension.
With incremental dimension values the command
G53 is ignored.

G54 to G59 Selection of a


Workpiece Coordinate System
A coordinate system used for machining workpieces is called workpiece coordinate system. It
is determined by a machining program and is to
be set prior to machining start. A workpiece
coordinate system already set can be altered by
shifting the point of origin.
Six (specified via G54 to G59) preset workpiece
coordinate systems and an external workpiece
coordinate system are available:
EXT
G54
G55
G56
G57
G58
G59

D37

workpiece coordinate system 0


workpiece coordinate system 1
workpiece coordinate system 2
workpiece coordinate system 3
workpiece coordinate system 4
workpiece coordinate system 5
workpiece coordinate system 6

G-COMMANDS / G54-G59

PROGRAMMING, OPERATION EMCO-SPECIFIC

All workpiece coordinate systems specified via


G54 to G59 are shifted altogether via the EXT
workpiece coordinate system.

Workpiece coordinate
system 3 (G56)

Workpiece coordinate
system 4 (G57)

FS4

Workpiece coordinate
system 5 (G58)

ZO

S1

FS

FS

ZOF

Workpiece coordinate
system 2 (G55)

ZO

Workpiece coordinate
system 1 (G54)

ZO

ZOFS5
EXO

FS

ZOF

S6

Workpiece coordinate
system 6 (G59)

Machine zero point

EXOFS: ..................... external workpiece zero point value


ZOFS1 ZOFS6 ..... workpiece zero point correction value
There are two possibilities to set the workpiece
coordinate systems:
(1) Input via the manual input keyboard
(operating mode MDI function OFFSET /
SETTING softkey WORK).
(2) Programming via G10: separate shift of the
individual workpiece coordinate systems
including the external work coordinate system
(see chapter G10).
Notes
The workpiece coordinate systems 1 to 6 are
set after reference point approach.
The coordinate system G54 is selected during
switch-on.

D38

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G70, G71, G72

G70 Measuring in Inches


Format
N5 G70
By programming G70 the following values will be
converted to inches:
Feedrate F [mm/min, inch/min, mm/rev, inch/
rev]
Offset values (zero point, geom., wear, ...)
[mm, inch]
Movement pathes [mm, inch]
Display of actual position [mm, inch]
Speed [m/min, feet/min]

Remark:
It is also possible to exchange the control from
metric-system to inch-system in the "SETTING
screen" "SETTING", by inserting "1" as the
"INPUT UNIT".
All the coordinate systems in the control screen
will be converted immediately, including all of
the tool offsets.
The programs themselves will not be converted!
Before running the machine with the converted
measuring system:
Switch machin OFF and ON, to perform a
reference point return.

Notes
For clearness G70 should be defined in the first
block of the program
The measuring system which was programmed
last will be active - also after main power off/on.
To get back to the origin measuring system it is
best to use the MDI mode (e.g. MDI G70 Cycle
Start)

G71Metrical Measuring
Format
N5 G71
See G70!

G72 Finishing Cycle


Format
N... G72 P... Q...
P... ...... Block number of the first block for the program of finishing shape.
Q ........ Block number of the last block for the program of finishing shape.
After rough cutting by G73, G74, G75 the G72
command permits finishing.
The programmed shape between P and Q which
was also used for rough cutting, will be repeated
without cutting depth division and without finishing
offset.
Notes
F, S and T functions specified between P and Q
are only effective for G72. They are not effective
for G73, G74 and G75!
The finishing cycle G72 must only be programmed after the cycles G73, G74 and G75.

D39

G-COMMANDS / G73

PROGRAMMING, OPERATION EMCO-SPECIFIC

G73 Contour Roughing Cycle


(Stock removal in turning)
Format
N... G73 U 1... R...
N... G73 P... Q... U 2+/-... W+/-... F... S... T...
first block

&



8


8

U1 [mm] depth of cut, incremental,


without sign, in the drawing
shown as U 1
R [mm] retract height
second block P ........... block number of the first
block for the programmed
shape
Q .......... block number of the last
block for the programmed
shape
U2 [mm] distance and direction of
finishing offset in X direction (diameter or radius
designation), in the drawing
shown as U2/2
W [mm] Distance and direction of
finishing offset in Z direction, incremental, without
sign
F, S, T Feed, speed, tool

Program instruction

Turning cycle contour

Before machining the tool is at point C. Between


the block numbers P and Q a contour (A to A' to
B) will be programmed, it will be machined with
the corresponding cutting depth division onto the
defined finishing offset (2. block, in the drawing
U2/2).
Contour without undercut
The first contour block from A to A' must contain
a G0 or G1 movement in X direction only.
Contour with undercut
The first contour block from A to A' must contain
a G0 or G1 movement in X and Z direction.

Contour without undercut

Notes
F, S and T functions between P and Q are
ignored.
The point C (tool position before the cycle) must
be out of the contour.
The first movement from A to A must be G00 or
G01, is permitted in X only (G00 X...) and must
be programmed in absolute coordinates.
Between P and Q no subroutine call is permitted.
By using G73 as an OD Roughing Cycle:
Coordinate X C has to be greater than XB.
By using G73 as an ID Roughing Cycle:
Coordinate X C has to be less than X B.

Contour with undercut

Undercut

D40

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G73

Example contour turning cycle with G73:


Machining the contour shown beside.
Program:
O2000
N10 G95 G1
F0.5
N11 G0 X85
Z20
N12 T0101
N20 M3 S3000
N30 G00 X85
Z2
(Start point for cycle)
N40 G73 U2
R2
N50 G73 P60
Q120 U2
W1
(Contour turning cycle)
N60 G0 X10
N70 G1 Z-15
N80 X30
N90 X60 Z-30
N100 Z-40
N110 X70
N120 X80 Z-50
N130 G0 X85
Z20
N140 S3000
F0.6 T0202
(Select finishing tool)
N150 G0 X85
Z2
(Start point for finishing)
N160 G72 P60
Q120
(Finishing cycle)
N170 M30

;













=

Example contour turning

D41

G-COMMANDS / G74

PROGRAMMING, OPERATION EMCO-SPECIFIC

G74 Face Roughing Cycle


(Stock removal in facing)
Format
N... G74 W 1... R...
N... G74 P... Q... U+/-... W2+/-... F... S... T...

&
$

first block

W1 [mm] depth of cut in Z, incremental, without sign, in the


drawing shown as W 1
R [mm] retract height
second block P ........... block number of the first
block for the programmed
shape
Q .......... block number of the last
block for the programmed
shape
U [mm] distance and direction of
finishing offset in X direction (diameter or radius
designation), in the drawing
shown as U/2
W2 [mm] Distance and direction of
finishing offset in Z direction, incremental, without
sign, in the drawing shown
as W2
F, S, T Feed, speed, tool


Program instruction

:

8

Tool path

:

Face Roughing cycle contour

Before machining the tool is at point C. Between


the block numbers P and Q a contour (A to A' to
B) will be programmed, it will be machined with
the corresponding cutting depth division onto the
defined finishing offset (2. block, in the drawing
W2).
Notes
F, S and T functions between P and Q are
ignored.
The point C (tool position before the cycle) must
be out of the contour.
The contour between A' and B has to be
programmed decreasing, that means the diameter has to decrease.
The first movement from A to A must be G00 or
G01, is permitted in Z only (G00 X...) and must
be programmed in absolute coordinates.
Between P and Q no subroutine call is permitted.

D42

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G74

Example Facing cycle with G74:


Machining the contour shown beside.

Program:
O2001
N10 G95 G1
F0.5
N11 G0 X85
Z20
N12 T0303
N20 M3 S3000
N30 G00 X85
Z2
(Start point for facing cycle)
N40 G74 W2
R2
N50 G74 P60
Q120 U2
W1
(Facing cycle)
N60 G0 Z-35
N70 G01 X80
Z-35
N80 Z-30
N90 X50 Z-25
N100 X30 Z-15
N110 X20
N120 Z0
N130 G0 X85
Z20
N140 S3000
F0.6 T0404
(Select finishing tool)
N150 G0 X85
Z2
(Start point for finishing)
N160 G72 P60
Q120
(Finishing cycle)
N170 M30

;












Example facing cycle

D43

G-COMMANDS / G75

PROGRAMMING, OPERATION EMCO-SPECIFIC

G75 Pattern Repeating Cycle


Format
N... G75 U 1+/-... W 1+/-... R...
N... G75 P... Q... U 2... W2... F... S... T...
first block

U1 ................. Start point for the cycle in


the X axis (radius designation), in the drawing
shown as U 1
W1 ................ Start point of the cycle in
the Z axis, in the drawing
shown as W 2
R .......... number of repetitions (equal
to cut division)
second block P ........... block number of the first
block for the programmed
shape
Q .......... block number of the last
block for the programmed
shape
U2 [mm] distance and direction of
finishing offset in X direction (diameter or radius designation), in the drawing
shown as U/2
W2 [mm] Distance and direction of
finishing offset in Z direction, incremental, without
sign, in the drawing shown
as W2
F, S, T Feed, speed, tool

88
 

:
 :

&

8


:

Pattern repeating

The G75 cycle allows machining parallel to the


shape of the workpiece, the pattern will be shifted
to the finished shape step by step.
Application for semifinished products (forged, cast
parts)

Example:
O2002
N1
G95 G0
N5
T0707
N10 G75 U5
N15 G75 P20
N20 G0 X20
N30 G1 Z-15
N40 X40
N50 X70 Z-30
N60 Z-40
N70 X75 Z-50
N80 X80
N90 M30


















=

X85
M3
W5
Q80

Z0
S2000
R5
U2
W1

F0.5

The contour in N20 (20/0) - N80 (80/-50) will be


machined in 5 infeeds.

Example Pattern repeating

D44

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G76

G76 Face Cut-in Cycle


(Deep Hole Drilling Cycle for end face
peck drilling)

Format
N... G76 R...
N... G76 X(U)... Z(W)... P... Q... F...
first block

R [mm]

sec. block X(U), Z(W)

4
$

or
Z(W)

Absolute (incremental)
drilling depth
P [m]
Incremental feed in X
direction (no sign); P <
tool width!
Q [m] ...... Cutting depth in Z direction (no sign)
F ............... Feed rate

5

8

3
3
=

retraction height for chip


breaking (incremental
without sign), drawing:
R1
Absolute (incremental)
coordinates of the contour edge point K

Notes:
Without addresses X(U) and P G76 can be used
as drilling cycle (Move tool to X=0 before!)
With cut-in cycle the infeed P has to be smaller
than tool width B.

Deep hole drilling / Face Cut-in Cycle

Example:
Axial groove, 10mm wide and 10mm deep
T1212 ; (axial cut-in tool 3mm width)
G96 S120 M4 ;
G0 X80 Z1 ;
G76 R0.5 ;
G76 X94 Z-10 P2800 Q4000 F0.06 ;
G0 X150 Z100 ;
M5 ;

D45

G-COMMANDS / G77

PROGRAMMING, OPERATION EMCO-SPECIFIC

G77Side Cut-in Cycle (X Axis)


Format
N... G77 R...
N... G77 X(U)... Z(W)... P... Q... F...

first block R [mm]

Retraction height for chip


breaking, in the drawing
shown as R 1
sec. block X(U), Z(W) Absolute (incremental) coordinates of K
P [m] Cutting depth in X direction
(no sign)
Q [m] Incremental infeed in Z
direction (no sign)
F ........... Feed

8

Note
The infeed Q must be smaller than tool width B.
Tool width will not be taken into consideration
with this cycle.

5

Example:
Radial groove, 10mm wide and 10mm deep

Cut-in cycle in X

T1111 ; (radial cut-in tool 3mm width)


G96 S120 M4 ;
G0 X102 Z-20 ;
G77 R0.5 ;
G77 X80 Z-27 P4000 Q2800 F0.06 ;
G0 X150 Z100 ;
M5 ;

D46

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G78

G78Multiple Threading Cycle


(Thread cutting OD/ID)
Format
N... G78 P 1... Q1... R1...
N... G78 X(U)... Z(W)... R 2... P 2... Q2... F...
first block:
P1 .................. is a 6 digit parameter divided in digit
couples:
PXXxxxx
The first two digits of this parameter
define the number of finishing cuts
PxxXXxx
The next two digits define the
chamfer value PF (see drawing)

Note:
Negative taper parameter R defines the taper
as shown in the drawing.
By using G78 as an OD Threading Cycle:
Coordinate X S has to be greater than X K
By using G78 as an ID Threading Cycle:
Coordinate XS has to be less than X K

PxxXXxx=

PF [mm] 10
F

PxxxxXX
3


Defines the flank angle of thread in


[] .
(allowed: 80, 60, 55, 30, 29, 0)

8

Q1 ................. Minimum cutting depth [m] incremental


R1 ................. Finishing
offset
[mm]
incremental
4

3
)

second block X(U), Z(W) Absolute (incremental)


coordinates of the point K
R2 [mm] Incremental taper value
with sign (R=0 cylindrical
thread)
P2 [m] Thread depth (always positive), in the drawing shown
as P2
Q2 [m] Cutting depth of the first cut
(radius value) without sign
F [mm] Thread pitch

3

5

Multiple threading cycle

Formulars for the calculation of the cutting depth


for point K in X (metric system):
Example:

Thread O.D. (external thread):

N5 T0505 (Thread O.D. M602) ;


G97 S800 M3 ;
G0 X60.5 Z2 ;
G78 P041060 Q150 R0.1 ;
G78 X57.546 Z-20 P1226 Q150 F2 ;
G0 X150 Z150 M5 ;

t = 0,6134 pitch
Thread I.D. (internal thread):
t = 0,5413 pitch

D47

G-COMMANDS / G98, G99

PROGRAMMING, OPERATION EMCO-SPECIFIC

Drilling cycles with driven tools


Survey of the drilling cycles
G-code Drilling axis
G80

G83

Z -axis

Hole machining
( direction)

P rocedure at the
bore bottom

Withdrawal
(+direction)

Applications
Cycle end

Cutting feed
interrupting

Dwell time

R apid motion

Cycle for face


drilling

Intermis s ion 
s pindle in counterclockwis e direction

Cutting feed

Cycle for face


tapping

Cutting feed

F ace reaming cycle

G84

Z -axis

Cutting feed

G85

Z -axis

Cutting feed

G87

X-axis

Cutting feed
interrupting

Dwell time

R apid motion

S ide drilling cycle

G88

X-axis

Cutting feed

Intermis s ion 
s pindle in counterclockwis e direction

Cutting feed

Cycle for s ide


tapping

G89

X-axis

Cutting feed

Dwell time

Cutting feed

Cycle for s ide


reaming

Systematics G98/G99
Starting
level

*

G98 .... After reaching the drilling depth the tool


moves to the starting level
G99 .... After reaching the drilling depth the tool
moves to the withdrawal level - defined
by R-parameter

Start

*

If no G98 o G99 is active, the tool returns to the


starting level. If G99 (withdrawal on withdrawal
level) is programmed, the address R must be
defined. With G98, R can be omitted!

Start

R defines the position of the withdrawal level with


reference to the last Z-position (initial position for
drilling cycle). With a negative value for R, the
withdrawal level is below the initial position, with
a positive value above the initial position.

Withdrawal in
withdrawal level

Withdrawal
level

Starting
level

Withdrawal in
starting level

Withdrawal behaviour G98, G99

Operating sequence
1: The tool traverses with rapid motion from the
initial position (S) to the level defined by R
(R).
2: Cycle specific drilling up to final depth (E).
3: a: With G98 the withdrawal is carried out up
to the starting level (initial position S).
b: with G99 up to the withdrawal level (R).
4: With the NC-parameter "5102#6" can be
defined, how the parameter R has to be
programmed in dependent upon G90/G91:
inremental distance ............................. set to 0
absolute distance ................................ set to 1

E
D

(


5

Operating sequence G98, G99

D48

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G80, G83, G87

G80 Delete Drilling Cycle (G83 to G89)

G83 Face Drilling/Face Peck Drilling Cycle

Format
N... G80

G87 Side Drilling/Side Peck Drilling Cycle


Format G83
N... G98(G99) G83 X(U)... C(H)... Z(W)... R...
Q... P... F... (M...) (K...)

The drilling cycles must be deselected by G80 or


another G-code of group 1 (G00, G01, ...), since
they are modally effective.

Format G87
N... G98(G99) G87 Z(W)... C(H)... X(U)... R...
Q... P... F... (M...) (K...)

Starting
level

G98(G99) .. withdrawal to starting level (withdrawal level)


X(U) ........... G83: hole position absolute (incremental) in the X-axis
G87: drilling depth absolute (incremental) in the X-axis
Z(W) .......... G83: drilling depth absolute (incremental) in the Z-axis
G87: hole position absolute (incremental) in the Z-axis
C [] ........... drilling position
R [mm] ...... incremental value of the withdrawal
level with reference to the starting
point in the Z/X-axis (with sign)
Q [m] ....... drilling depth per infeed for peck drilling
P [msec] .... dwell time on the hole bottom:
P1000 = 1 sec
F ................ feedrate
(M) ............. M-code for C-axis clamping (when
parameter "5110" is defined)
(K) ............. number of the cycle repetitions (to be
used only for incremental programming)

G83 (G99)

=
;

Starting
level

G83 (G98)

=
;

Face drilling cycle G83

Starting
level

G87 (G98)

=
;

Notes
Setting of parameter "5101#2":
Set 1: Drill reacts back to R after each step
Set 2: Drill reacts back to specified distance in
parameter "5114".
It is not necessary to program C, X and Z within
the cycle for the position of the hole, if in the
previous block before the tool has been already
traversed to the drilling position. In this case
just the drilling depth (Z for G83, X for G87)
needs to be commanded.
Unless Q is specified, a division of cuts is not
carried out, i. e. drilling to Z-end point in one
movement. Therefore, Q has to be called
together with each following drilling position
command.

=
;

Starting
level

G87 (G99)

Side drilling cycle G87

D49

G-COMMANDS / G83, G87

PROGRAMMING, OPERATION EMCO-SPECIFIC

Example - G83 drilling cycle / deep-hole drilling


cycle in Z-direction (with driven tool axial
cycle)
N3 T0303;
M52 ;

(drill, driven tool axial)


selection of the main spindle
as C-axis.
G28 C0 ;
refenence C-axis (necessary
only once after first call of
M52 in program)
M13 ;
(or M14) selection of driven tool
with clockwise tool rotation
normally (read note)
G97 S2000 ;
constant spindle speed.
G0 X50 Z10 C30 ;
positioning the tool.
G83 Z-42 R-8 Q6000 F0.5 ;
(bore 1 (Q6000 = 6mm cutting depth per feed
during deep-hole drilling).).
C150 Q6000 ;
bore 2.
C270 Q6000 ;
bore 3.
G80 M15 ;
deselection drilling cycle
and switch off speed of the
tool.
M53 ;
deselection of the main
spindle as C-axis.

Note:
The direction of rotation for the drilling tools
normally is fixed for right hand tools.
The reason to change the direction of rotation
depends on the design of the tool holder, when
the gear of the holder reverses it's direction.

Example - G87 drilling cycle / deep-hole drilling


cycle in X-direction (with driven tool radial
cycle)
N7 T0707
M52 ;

(drill, driven tool radial);


selection of the main spindle
as C-axis.
G28 C0 ;
reference. C-axis (necessary
only once after first call of
M52 in program).
M13 ;
(...or M14)...selection driven
tool and sense of rotation of
the tool (read note).
G97 S2000 ;
constant spindle speed.
G0 X50 Z-20 C30 ; positioning the tool.
G87 X18 R-6 Q6000 F0.5 ;
(bore 1 (Q6000 = 6mm cutting depth per feed
during deep-hole drilling).)
C150 Q6000 ;
bore 2.
C270 Q6000 ;
bore 3.
G80 M15 ;
deselection drilling cycle
and switch off speed of the
tool.
M53 ;
deselection of the main
spindle as C-axis.

D50

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G84, G88

G84 Cycle for face tapping with/


without compensation chuck
G88 Cycle for side tapping with/
without compensation chuck
Tapping without compensation chuck is named
"Rigid Tapping".
Face tapping and side tapping (G84 and G88)
can be performed in conventional mode or in rigid
mode.

G84 (G99)

Starting
level
=
;

Format G84
N... G98(G99) G84 X(U)... C(H)... Z(W)... R...
P... F... (M...) (K...)
Format G88
N... G98(G99) G88 Z(W)... C(H)... X(U)... R...
P... F... (M...) (K...)

G84 (G98)

Starting
level

G98(G99) .. withdrawal to starting level (withdrawal


level)
X(U) ........... G84: hole position absolute (incremental) in the X-axis
G88: drilling depth absolute (incremental) in the X-axis
Z(W) .......... G84: drilling depth absolute (incremental) in the Z-axis
G88: hole position absolute (incremental) in the Z-axis
C[] ............ drilling position
R [mm] ...... incremental value of the withdrawal
level with reference to the starting
point in the Z/X-axis (with sign)
P [msec] .... dwell time at the hole ground:
P1000 = 1 sec
F ................ feed
(M) ............. M-code for C-axis clamping (when
parameter "5110" is defined)
(K) ............. number of the cycle repetitions (to be
used only for incremental programming)

=
;

Cycle for face tapping G84


G88 (G99)

G88 (G98)

=

=
;

General
The spindle turns clockwise for right hand taps.
At the bottom of the hole the spindle changes
its direction to retract the tool counterclockwise.

Starting
level

Starting
level

;

Cycle for side tapping G88


Note:
In case, that the direction of the tool will even
not change its direction with M13/M14 to
clockwise, the special invertion command
M214 has to be used to reverse the direction
of the tool rotation.

D51

G-COMMANDS / G84, G88

PROGRAMMING, OPERATION EMCO-SPECIFIC

During the tapping feedrate and spindle override


are without function, and assumed to 100%
Tapping with comensation chuck:
In conventional mode, the tool will rotate or stop
in synchronization with the motion along the
tapping axis (Z for G84 and X for G88).

Notes:
The direction of rotation for the drilling tools
normally is fixed for right hand tools.
The reason to change the direction of
rotation depends on the design of the tool
holder, when the gear of the holder reverses
it's direction.

Rigid tapping:
M29 Sxxxx has to be programmed in a block
before the cycle.
The spindle motor is controlled like a servomotor, so that a faster tapping is possible.

Do not insert a dwell in the cycle for tapping


with longitudinal compensation.
For bigger drills insert the commands M10/
M11 (main spindle clamp/unclamp) in order
to ensure, that the mainspindle keeps its
position.

Mode "Feed per minute":


The pitch of the thread equals from feed divided
by the spindle speed.
Mode "Feed per rotation":
The feedrate is equal to the screw lead (=pitch).

Example - G84 rigid tapping cycle:


without longitudinal compensation in Zdirection (with driven tool/axial cycle)

Example - G88 rigid tapping cycle:


without longitudinal compensation in Xdirection (with driven tool/radial cycle)

N4 T0404

N8 T0808

(tap M6x1, driven tool


axial);
M52 ;
selection of the main
spindle as C-axis.
G28 C0 ;
reference C-axis
(necessary only once
after first call of M52 in
program).
M214 ;
reverse of rotation direction (necessary only
for left hand thread read note)
M13 ;
selection driven tool
G97 ;
selection of constant
spindle speed [rpm]
G0 X50 Z10 C30 ;
positioning of the tool.
M29 S1000 ;
selection tapping without
longitudinal compensation
and speed for tool.
G84 Z-20 R-6 P500 F1; thread 1.
C150 ;
thread 2.
C270 ;
thread 3.
G80 M15 ;
deselection drilling cycle
and switch off speed of
the tool.
M53 ;
deselection of the main
spindle as C-axis.

M52 ;
G28 C0 ;

M214 ;

M13 ;
G97 ;
G0 X80 Z-30 C30 ;
M29 S1000 ;

G88 X50 R-6 P500 F1;


C150 ;
C270 ;
G80 M15 ;

M53 ;

D52

(tap M6x1, driven tool


radial);
selection of the main
spindle as C-axis.
reference C-axis
(necessary only once
after first call of M52 in
program).
reverse of rotation direction (necessary only
for left hand thread read note)
selection driven tool
selection of constant
spindle speed [rpm]
positionining the tool.
selection tapping without
longitudinal compensation and speed for tool.
thread 1.
thread 2.
thread 3.
deselection drilling cycle
and switch off speed of
the tool.
deselection of the main
spindle as C-axis.

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G84, G88

Example - G84 drilling cycle for tapping with


longitudinal compensation in Z-direction (with
driven tool/axial cycle)

Example - G88 drilling cycle for tapping with


longitudinal compensation in X-direction (with
driven tool/radial cycle)

N1 T0101

N2 T0202

M52 ;
G28 C0 ;

M214 ;

M13 ;
G97 S1000 ;

G0 X50 Z10 C30 ;


G84 Z-20 R-6 P0 F1 ;
C150 ;
C270 ;
G80 M15 ;

M53 ;

(tap M6x1, driven tool


axial);
selection of the main
spindle as C-axis.
reference C-axis
(necessary only once
after first call of M52 in
program).
reverse of rotation direction (necessary only
for left hand thread)
selection driven tool
selection of constant
spindle speed [rpm] and
speed for tool
positioning of the tool.
thread 1.
thread 2.
thread 3.
deselection drilling cycle
and switch off speed of
the tool.
deselection of the main
spindle as C-axis.

M52 ;
G28 C0 ;

M214 ;

M13 ;
G97 S1000 ;

G0 X80 Z-30 C30 ;


G88 X50 R-6 P0 F1 ;
C150 ;
C270 ;
G80 M15 ;

M53 ;

Example - G84 rigid tapping cycle without longitudinal compensation in Z-center line (with
main spindle/axial cycle)
N10 T1010
M204 ;
M3 ;
G97 S1000 ;

G0 X0 Z10 ;
M29 S1000 ;
G84 Z-20 R-6 P0 F1 ;
C150 ;
C270 ;
G80 M5 ;

(tap M6x1, fixed tool axial);


for left hand thread only
selection of main spindle
selection of constant
spindle speed [rpm] and
speed for tool
positioning of the tool.
select rigid mode
thread 1.
thread 2.
thread 3.
deselection drilling cycle

D53

(tap M6x1, driven tool


radial);
selection of the main
spindle as C-axis.
reference C-axis
(necessary only once
after first call of M52 in
program).
reverse of rotation direction (necessary only
for left hand thread)
selection driven tool
selection of constant
spindle speed [rpm] and
speed for tool
positionining the tool.
thread 1.
thread 2.
thread 3.
deselection drilling cycle
and switch off speed of
the tool.
deselection of the main
spindle as C-axis.

G-COMMANDS / G85, G89

PROGRAMMING, OPERATION EMCO-SPECIFIC

G85 Cycle for Face Reaming


G89 Cycle for Side Reaming
Format G85
N... G98(G99) G85 X(U)... C(H)... Z(W)... R...
P... F... (K...) (M...)

G85 (G99)

Starting
level

Format G89
N... G98(G99) G89 Z(W)... C(H)... X(U)... R...
P... F... (K...) (M...)

=
;

G98(G99) .. withdrawal to starting level (withdrawal level)


X(U) ........... G85: hole position absolute (incremental) in the X-axis
G89: drilling depth absolute (incremental) in the X-axis
Z(W) .......... G85: drilling depth absolute (incremental) in the Z-axis
G89: hole position absolute (incremental) in the Z-axis
C[] ............ drilling position
R [mm] ...... incremental value of the withdrawal
level with reference to the starting
point in the Z/X-axis (with sign)
P [msec] .... dwell time at the hole bottom:
P1000 = 1 sec
F ................ feed
(K) ............. number of cycle repetitions (only for
incremental programming)
(M) ............. M-code for axis clamping (when
parameter "5110" is defined)

G85 (G98)

Starting
level
=
;

Reaming cycle G85


G89 (G99)

G89 (G98)

=

=
;

Notes
If G99 (withdrawal to withdrawal level) is
programmed, the address R must also be
defined. With G98 R can be omitted!
It is not necessary to program C, X and Z within
the cycle for the position of the hole, if in the
previous block before the tool has been already
traversed to the drilling position. In this case
just the drilling depth needs to be commanded.

Starting
level

Starting
level

;

The withdrawal to the start point is carried out


with the double feed speed, which has been
programmed in block G85/G89.

Cycle for side reaming G89

A division of the cut is not possible by indicating


the Q-parameter.

D54

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G85, G89

Example - G85 drilling cycle / reaming cycle in


Z-direction (with driven tool/axial cycle)
N5 T0505
M52 ;

(reamer, driven tool axial);


selection of the main spindle
as C-axis.
G28 C0 ;
reference. C-axis
(necessary only once after
first call of M52 in program).
M13 ;
(...or M14)...selection driven
tool with clockwise tool rotation normally (read note)
G97 S2000 ;
constant spindle speed.
G0 X50 Z10 C30 ; positioning the tool.
G85 Z-32 R-8 P500 F0.5 ; bore 1.
C150 ;
bore 2.
C270 ;
bore 3.
G80 M15 ;
deselection of the drilling
cycle and switch off speed
of the tool.
M53 ;
deselection of the main spindle
as C-axis
Note:
The direction of rotation for the drilling tools
normally is fixed for right hand tools.
The reason to change the direction of rotation
depends on the design of the tool holder, when
the gear of the holder reverses it's direction.

Example - G89 Drilling cycle / reaming cycle


in X-direction (with driven tool/radial cycle)
N9 T0909
M52 ;

(reamer, driven tool radial);


selection of the main spindle
as C-axis
G28 C0 ;
reference. C-axis
(necessary only once after
first call of M52 in program).
M13 ;
(...or M14)...selection driven
tool with clockwise tool rotation normally (read note)
G97 S2000 ;
constant speed of the tool.
G0 X50 Z-40 C30 ; positioning the tool.
G89 X28 R-6 P500 F0.5 ; bore 1.
C150 ;
bore 2.
C270 ;
bore 3.
G80 M15 ;
deselection of the drilling
cycle and switch off speed
of the tool.
M53 ;
deselection of the main spindle
as C-axis

D55

G-COMMANDS / G12.1, G13.1

PROGRAMMING, OPERATION EMCO-SPECIFIC

G12.1/G13.1
Polar Coordinate Interpolation
Level of the polar
coordinate
interpolation

The polar coordinate interpolation is adequate for


machining the end face of a turned part or grinding
the camshaft on lathes.

&
Rotary axis
(virtual axis)

It converts a command programmed in the


Cartesian coordinate system into the movement
of a linear axis X (tool movement) and a rotating
axis C (workpiece rotation) for the path control.
The rotary axis C serves as axis address for the
second (virtual) axis.
This axis is set immediately after programming
G12.1 at coordinate C0.
Here an angle of 0 is supposed as tool position.

Linear axis

;
Origin of the
workpiece coordinate
system

Format
N.. G12.1 ;
:
N.. G13.1 ;
Notes:
Also with diameter programming for the linear
axis (X-axis) radius programming is used for
the rotary axis (C-axis).

starts the operating mode and enables polar coordinate interpolation


geometry program (based on Cartesian coordinates)
terminates the operating mode polar coordinate interpolation.

G12.1 chooses a level (G17) in which the polar


coordinate interpolation is carried out.
The level G18 used by G12.1 before programming
is deleted.
It is reestablished by means of the command
G13.1 (polar coordinate interpolation end).

Cutter position 0 must be assigned to the tool in


the offset data.
However, the miller radius must be entered.
In G12.1- mode the coordinate system must not
be altered.

After switching on the machine or with a system


RESET the condition "polar coordinate interpolation" is also cancelled, (G13.1) selected and
the level defined by means of G18 is used.

G12.1 and/or G13.1 must be programmed in


the mode "cutter radius compensation off" (G40)
and cannot be started or terminated within
"cutter radius compensation on" (G41 or G42).
G12.1 and G13.1 are to be programmed in separate blocks.
In a block between G12.1 and G13.1 an
interrupted program cannot be brought to a new
start.

G-codes which may be programmed in the


mode "polar coordinate interpolation:

G-Code
Use
G01
Linear interpolation
G02, G03 Circular interpolation
G04
Intermission

The arc radius with circular interpolation (G2


oder G3) can be programmed by means of an
R-command and/or via I- and J-coordinates.

G40, G41, Cutter radius compensation


(polar coordinate interpolation is applied on the
G42
tool path after the tool compensation)

In the geometry program between G12.1 and


G13.1 no rapid motion (G0) must be programmed (see adjoining scheme).

G65, G66,
User macro command
G67
G98, G99 Feed per minute, feed per rotation

D56

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G12.1, G13.1

Example 1 - polar coordinate interpolation


X- axis with diameter programming and C-axis
with radius programming.
N1 T0101 (end mill Dm 10);
driven tool axial / miller radius 5.0, cutter
radius position 0.
M13 ;
(...or M14)...selection driven tool
and direction of the tool rotation.
G97 S1000
constant speed of the tool.
M52 ;
selection of the main spindle as
C-axis
G28 C0 ;
reference. C-axis (necessary
only once after first call of M52
in program).
G52 C.. ;
poss. shift of angle of C-axis.
G40 G0 X60 C0 Z-6 ;
Positioning the tool in rapid motion (poss.
deselection cutter radius compensation).
G12.1 ;
start of the polar coordinate
interpolation.
G42 G1 X34.64 C10 F0.1 ;
to point S in feed and selection cutter radius
compensation.
C0 ;
to point 1.
X17.32 C-15 ;
to point 2.
X-17.32 ;
to point 3.
X-34.64 C0 ;
to point 4.
X-17.32 C15 ;
to point 5.
X17.32 ;
to point 6.
X34.64 C0 ;
to point 7.
C-10 ;
to point E.
G40 X60 Z10 ; move away from the part in the
feed and deselection cutter radius
compensation.
G13.1
end of the polar coordinate interpolation.
G52 C0 ;
poss. reset of offset of the angle
in the C-axis.
M53 ;
poss. deselection of the main
spindle as C-axis.
G0 X150 Z150 M15 ;
Release in rapid motion and speed driven
tool off.

&



6 tartpoint
WDUWSNW



;

(ndpoint
QGSNW


point
S
1
2
3
4
5
6
7
E


X
34,64
34,64
17,32
-17,32
-34,64
-17,32
17,32
34,64
34,64

C
10
0
-15
-15
0
15
15
0
-10

D57

G-COMMANDS / G12.1, G13.1

PROGRAMMING, OPERATION EMCO-SPECIFIC

Example 2 - polar coordinate interpolation with


cutter radius compensation

X-axis with diameter and C-axis with radius


programming.
N1 T1212;

(end mill Dm10, axial driven tool,


cutter radius 5.0, cutter radius
position 0)
M13 ;
(or M14) rotation direction
G97 S1000 ;
constant spindle speed
M52 ;
selection on C-axis
G00 X120.0 C0 Z... ; positioning at the starting
position
G12.1 ;
start of the polar coordinate
interpolation
G42 G01 X40.0 F... ;

C10.0
geometry
G03 X20.0 C20.0 R10.0 ;
program
G01 X-40.0 ;
(based on
C-10.0 ;
Cartesian
G03 X-20.0 C-20.0 I10.0 J0 ; coordinates in
G01 X40.0 ;
X-C'plane)
C0 ;

G40 X120.0 ;

G13.1 ;
polar coordinate interpolation end
Z... ;
X... C... ;
M30 ;

virtual axis

&

programmed
tool path

&
N204

N203
N202

N205
N206

=

N207

tool path after cutter


radius
compensation
tool

N201
N200

;

Polar coordinate interpolation with cutter radius


compensation

D58

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G7.1

G7.1 Cylindrical interpolation


This function enables the development of a
cylinder surface in programming.
In this way e.g. programs for cyclindrical cam
machining on lathes can be created.
The traverse amount of the rotary axis C programmed by indication of the angle is converted
in the control into the distance of a fictitious linear
axis along the external surface of the cylinder.
Thus, it is possible that linear and circular
interpolations on this area can be carried out with
another axis.

Format
G1 G19 G90 W0 H0 ;
G7.1 C.. ;
:
G7.1 C0 ;
G18 ;

(or G1 G19 G91 Z0 C0 ;) determine centre of the reference level (PRM1022#C=6).


(or G7.1 H.. ;) activates the mode cylinder interpolation with indication of the
cylinder diameter (in [mm] for the calculation of the path feed rate.
Geometry program.
(or G7.1 H0 ;) terminates the mode cylinder interpolation.
reset to the original plane

Calculating of Y[mm]- into C[]-coordinates for


path programming

Cp =

With G19 the level is determined in which the


rotary axis C is preset in parallel to the Y-axis.
The block structure for the geometry program is
then as follows:
G1 Z.. [in mm] C.. [in ] ; linear interpolation.
G2 (G3) Z.. [in mm] C.. [in ] R.. [in mm] ; circular
interpolation.

Yp [mm ] 360[]
2 Rcyl [mm ]

Cp [] .............. distance to move in C-axis


Yp [] .............. drawing distance to be calculated
Rcyl [mm] ........ radius of the cylinder surface
Notes:
The reference point of the cylinder must be
entered incrementally, since otherwise it would
be approached by the tool!

G3) must be programmed via an R-command


and must not be programmed in degree and/or
via K and J-coordinates.

In the offset data cutter position 0 must be


allocated to the tool. However, the miller radius
must be entered.

In the geometry program between G7.1 C.. and


G7.1 C0 no rapid motion (G0) and/or positioning
procedures causing rapid motion movements
(G28) or drilling cycles (G83 to G89) must be
programmed.

In mode G7.1 the coordinate system must not


be changed.

The feed entered in the mode cylindric interpolation is to be considered as traverse speed
on the unrolled cylinder area.

G7.1 C.. and/or G13.1 C0 must be programmed


in the mode "cutter radius compensation off"
(G40) and cannot be started or terminated within
"cutter radius compensation on" (G41 or G42).
G7.1 C.. and G7.1 C0 must be programmed in
separate blocks.
In a block between G7.1 C.. and G7.1 C0 an
interrupted program cannot be restarted.
The arc radius with circular interpolation (G2 or

D59

G-COMMANDS / G7.1

PROGRAMMING, OPERATION EMCO-SPECIFIC

Example 1 - cylinder interpolation


X-axis with diameter programming and C-axis with
angle programming.

N2 T0202 (end mill Dm 12); driven tool radial / cutter radius 6.0, cutter radius position 0.
M13
(...or M14)...selection driven tool and sense or rotation of the tool.
G97 S1000
constant speed of the tool.
M52 ;
selection of the main spindle as C-axis.
G28 C0 ;
reference. C-axis (necessary only once after after first call of M52).
G52 C.. ;
poss. shift of the angle of the C-axis.
G40 G0 X60 C0 Z-100 ;
positioning the tool in rapid motion (poss. deselection cutter radius
compensation).
G19 W0 H0 ;
(or G19 G91 Z0 C0).. determine incrementally centre point of the reference
level.
G7.1 C57.299;
start of the cylinder interpolation with cylinder diameter notation in [mm].
G42 G1 G94 Z-120 F350 ; selection cutter radius compensation outside the workpiece on point S.
X48 F100 ;
feed in X.
C30 F250 ;
to point 1.
G2 Z-90 C60 R30 F250 ;
to point 2.
G1 Z-70 ;
to point 3.
G3 Z-60 C70 R10 ;
to point 4.
G1 C150 ;
to point 5.
G3 Z-70 C190 R75 ;
to point 6.
G1 Z-110 C230 ;
to point 7.
G2 Z-120 C270 R75 ;
to point 8.
G1 C360 ;
to point 9.
X60 F350 ;
move away in X.
G40 Z-100 ;
deselection cutter radius compensation outside the workpiece.
G7.1 C0 ;
end of the cylinder interpolation by deselection of the cylinder radius.
G95 ;
deselection G94 (feed in mm/min).
G52 C0 ;
poss. reset of the shift of the angle in the C-axis.
M53 ;
poss. deselection of the main spindle as C-axis.
G0 X150 Z150 M15 ;
release in rapid motion and speed driven tool off.
G18 ;
reset to original plane

D60

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G51.2, G50.2

G51.2 / G50.2 Polygonal Turning

During polygonal turning, workpiece and tool are


turned in a certain relation to each other in order
to produce workpiece contours.
By changing the transmission ratio between tool
and workpiece or changing the number of cutting
tools the part contour can be altered.
The advantage compared with polar coordinate
interpolation is to be found in the shorter machining
time, however, the part contour is not exactly polygonal.
Polygonal turning is mainly used for the production
of e.g. collar head screws and hexagonal screws.

Format:
G51.2 P... Q... ;
P ...... integer number 1 to 9
transmission number of the main spindle
Q ..... integer number 1 to 9
transmission number of the axis of the
driven tool (=Y-axis)
Negative sign for Q is negative sense of
rotation of the tool.
Q-... Negative sign for Q means negative direction of the tool rotation.
G250;Spindle synchronisation OFF

$%
P:Q = 1:2

%
$
D

Example 1:
transmission ratio P:Q = 1:2
single-edged tool

G51.2 P1 Q2 ; (or Q-2)


The use of a tool with a cutter signifies that the
cutter tip describes an ellipse, with "A+B" as long
and "AB" as short side.
You receive the marked area in the adjoining
picture as workpiece contour.

A ...... workpiece radius


B ...... workpiece radius

Polygonal turning with single-edged tool

D61

G-COMMANDS / G51.2, G50.2

PROGRAMMING, OPERATION EMCO-SPECIFIC

Example 2:
Transmission ratio P:Q = 1:2
double-edged tool (offset 180)

P:Q = 1:2

G51.2 P1 Q2
A rectangle results as workpiece contour (see
adjoining picture).
Example 3:
transmission ratio P:Q = 1:2
three-edged tool (offset 120)
G51.2 P1 Q2
A hexagon results as workpiece contour (see
adjoining picture).

Polygonal turning with double-edged tool

Notes:
For thread-cutting an error occurs at the starting
point during synchronous operation.
During thread-cutting the synchronization is to
be switched off with G50.2.

P:Q = 1:2

The following signals are effetive and/or not


effective for the axis of the driven tools (Y-axis)
in synchronous operation:
valid signals :
- machine look
- servo off
invalid signals:
- feed stop
- lock
- oversteering
- test run (in block G51.2 the rotation signal is
not waited for during the test run).

Polygonal turning with three-edged tool

The Y-axis cannot be approached with a traverse command "Y...", it can only be indicated with
the ratio to the main spindle speed.
In the position display of the Y-axis during the
movement of the Y-axis the machine coordinate
values change from 0 to the parameter setting
(traverse amount per rotation).
Absolute and/or relative coordinate values are
not updated.

To return to the reference point the command


"G28 V0" must be entered.
In case of the input of G50.2 the Y-axis would
stop in an undefined position. This could cause
problems in case that the same contour is to be
machined with two tools (roughing finishing).

Absolute position recognition cannot be applied


to the Y-axis.

By programming "G28 V0" first the tool and


spindle are brought into the same position prior
to further machining similar to the first machining
procedure (the tool starts turning as soon as the
spindle receives the "one rotation signal" of the
position encoder).

Manual continuous feed or handwheel feed are


not possible if the Y-axis works in synchronous
operation.
The Y-axis in synchronous operation does not
belong to the number of the simultanously
controlled axes.

The Y-axis for the control of the tool rotation


during polygonal turning is the 4 th axis.

D62

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G51.2, G50.2

Example for Polygonal Turning:


Hexagon with key size 32mm

G0X110Z80M5
N11T909
driven 3-edge tool, dia 100 mm
G97S1000M4
Main spindle ON, counterclockwise
M214
reverse of rotation direction of
driven tool (necessary only for
left hand thread)
G0X32Z5
Positioning of the tool
G51.2P1Q2
(or Q-2)
transmission ratio P:Q = 1:2
G1Z-5F.1
machining
G0 X100 Z20
Releasing position
G50.2
Synchronization OFF
M5
Spindle stop
G0X150Z20
Tool changing position
...

D63

G-COMMANDS / G90, G91, G92

PROGRAMMING, OPERATION EMCO-SPECIFIC

G90 Absolute Programming

G92 Adjustment for maximum


Spindle Speed

Format
N... G90

Format
N... G92 S...

The addresses have to be programmed as


following:
X ......... Diameter
U+/- .... Incremental in diameter (except some
cycles)
Z+/- .... Absolute (referred to the workpiece zero
point)
W+/- ... Incremental (actual) traverse distance

(Spindle speed limit)

With the command G92 the max. spindle speed


can be declared (rpm) for the constant cutting
speed (G96).

Notes
Direct switchover from block to block between
G90 and G91 is permitted.
G90 and G91 may also be programmed with
some other G functions
(N... G90 G00 X... Z...).

G92.1 Coordinate System


Setting
See alse to "Attention" on this side!
Format
N... G92 X... Z...
oder
N... G92 U... W...

G91 Incremental Programming

(Set coordinate system)


(Shift coordinate system)

Example
You want to shift your workpiece zero from the
right to the left side of the workpiece
Diameter of workpiece = 30 mm
Length of workpiece = 100 mm

Format
N... G91
The addresses have to be programmed as
following:
X,U ..... Diameter
Z,W .... Incremental (actual) traverse distance
with sign

Program
N... G90 ................... Programming absolute

... .............................. Workpiece zero point right


... .............................. Right side of contour is

Notes see G90.

finished
N180 G00 X35 ........ Retract
N185 Z-100 ............. Movement distance = workpiece length
N190 G92 X35 Z0 . New zero point on the left
side

Attention
The format G10 P0 X(U).. Z(W).. and/or G92
X(U).. Z(W).. is placed above all other zero
point shifts (from G52 to G59)!
The shift is not displayed on the screen!
Attention with programs which were programmed for former control types (Fanuc 0T, Fanuc 21-T).

... .............................. Workpiece zero point left


... .............................. Machine left side
N305 G00 X35 ........ Retract
N310 Z100 ............... Movement distance = workpiece length
N315 G92 X35 Z0 . Workpiece zero point left
again

Remedy
First call up G10 P0 X0 Z0 (reset of the zero
point shift in G92) and input the following two
blocks:
G10 L2 P1 X(U)... Z(W)... ;
G54 ;

... .............................. etc.


Zero offset with G92 is modal and it is not
cancelled through M30 or RESET!
In this way, do not forget to reset the zero offset
G92 before program is finished.
When zero offset will be inserted incrementally,
the values U and W will be added to the last valid
zero offset.

D64

PROGRAMMING, OPERATION EMCO-SPECIFIC

G-COMMANDS / G94, G95, G69, G97

G94Feed Rate in Minutes


The entry of the command G94 means that all
values programmed under "F" (feed) are in mm/
min.

G95Feed Rate in Revolutions


The entry of the command G95 means that all
commands programmed under "F" are in mm/
revolution.

G96Constant Cutting Speed


Unit: m/min
The control continually computes the spindle
speed corresponding to the respective diameter.

G97Constant Rotational Speed


Unit: rev/min

D65

M-COMMANDS

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-Commands - Survey
Code
M00
M01
M02
M03
M04
M05
M08
M09
M10
M11
M13
M14
M15
M20
M21
M23
M24
M25
M26
M29
M30
M39
M40
M48
M49
M50
M52
M53
M57
M58
M60
M61
M66
M67
M68
M69
M70
M71
M72

Meaning

Code

Programmed stop
Selective stop
Program end
Main spindle ON in clockwise direction
Main spindle ON in counter-clockwise direction
Main spindle stop
Coolant ON
Coolant OFF
Spindle clamping ON
Spindle clamping OFF
Driven tool - spindle ON in clockwise direction
Driven tool - spindle ON in counter-clockw. dir.
Driven tool - spindle stop
Tailstock backward
Tailstock forward
Collecting tray backward
Collecting tray forward (swivel under spindle)
Open clamping device
Close clamping device
Tapping without longitudinal compensation for
driven tools

M80
M81
M82
M83
M84
M85
M86
M87
M90
M91
M92
M93
M94
M95
M96
M97
M98
M99
M103

Program end
AWZ positioning ON
AWZ positioning OFF
hydr. tool probe swivel IN in working area
hydr. tool probe swivel OUT
Deselection direction logic
Selection C-axis
Deselection C-axis (also with M10)
Spindle oscillation ON (S....frequency)
Spindle oscillation OFF
Tool probe calibration
Start of tool measuring
Bar feed / bar loading magazine feed ON with
feed stop

M104
M108
M109
M113
M114
M190
M191
M204

Bar feed / bar loading magazine feed ON


without feed stop
Bar feed / bar loading magazine feed OFF
Start bar change (without feed stop / read-in
release)
Precise stop fine
Flushing pump for spindle ON
Flushing pump for spindle OFF

Meaning
Reset freely programmable exit 1
Set freely programmable exit 1
Reset freely programmable exit 2
Set freely programmable exit 2
Reset freely programmable exit 3
Set freely programmable exit 3
Reset freely programmable exit 4
Set freely programmable exit 4
Manual chuck
Tensile clamping device
Pressure clamping device
Cancel final position monitoring (no alarm if part
clamped and final position reached )
Bar feed, bar feed magazine active
Bar feed, bar feed magazine not active
Auto Cycle Start with closed door ON
Auto Cycle Start with closed door OFF
Call-up subroutine
Subroutine end
Main spindle ON in clockwise direction with
waiting time, until spindle speed is reached
Main spindle ON in counter-clockwise direction
with waiting time, until spindle speed is reached
SINIS minimal coolant ON (option)
SINIS minimal coolant OFF
Driven tool - spindle ON in clockwise direction
with waiting time, until spindle speed is reached
Driven tool - spindle ON in counter clockw. dir.
with waiting time, until spindle speed is reached
automatic changing of screen OFF
autom. changing of screen ON (into alarm mode)
Reverse of rotation direction for main spindle ON
(M3 = M4, M4 = M3)

M205

Reverse of rotation direction, main spindle OFF


(M3 = M3, M4 = M4)

M214

Reverse of rotation direction for driven tool ON


(M13 = M14, M14 = M13)

M215

Reverse of rotation direction for driven tool OFF


(M13 = M13, M14 = M14)

M230
M240
M241

Collect. tray forward below spindel (without feedhold)

Collecting tray backward (without feed hold)


Collect. tray forward to wating pos.l (without feedhold)

$WWHQWLRQ
If you switch from the main spindle over to the driven tool spindle or vice-versa, the command M3, M4, M13, M14
must be programmed in a separate line.
M-code and S-code must not be programmed in one line, the S-code must be programmed in the next line.

D66

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-COMMANDS / M0-M21

M0 Programmed Stop
Unconditional

M8 Coolant ON

These command effects a stop in the execution


of the part program.
Main spindle, feed and coolant will be switched
off.
The chip protection door can be opened without
triggering an alarm.

M9 Coolant OFF

With "NC START"

The coolant will be switched on.

The coolant will be switched off.

M10 Spindle clamping ON


Spindle clamping is activated

the program run can be

M11 Spindle clamping OFF

continued. After that the main drive will be


switched on with all values which were valid
before.

Spindle clamping is switched off

M13 Driven Tool ON Clockwise

M1 Programmed Stop
Conditional

The driven tool is switched on provided that a


spindle speed or cutting speed has been programmed, the chip protection door is closed and
a workpiece correctly clamped.

M01 works like M00, but only if the key 237


6723 was
pressed.
With "NC START"

M14 Driven Tool ON


Counterclockwise

the program run can be

continued. After that the main drive will be


switched on with all values which were valid
before.

The same conditions as described under M13 apply


here, but counterclockwise rotation direction.

M2 Main Program End

M15 Driven Tool Off

M02 works like M30.

The tool drive is braked electrically.


At the program end the driven tool is automatically
switched off.

M3 Main Spindle ON Clockwise


The spindle is switched on provided that a spindle
speed or cutting speed has been programmed,
the chip protection door is closed and a workpiece
correctly clamped.
M03 must be used for all right-hand cutting or
overhead clamped tools.

M20 Tailstock BACK


M21 Tailstock FORWARD
The main spindle must be stopped for traversing
the tailstock
The main spindle can not be switched on and
NC Start will be ignored, as long as the tailstock
is in an undefined position (not in front or back
end position)
If the tailstock is in an intermediate position after
power on, it traverses to the back end position
automatically after pressing the AUX ON key.
After pressing the tailstock key the screen
shows the message "Tailstock in intermediate
position" as long as the tailstock reaches a
defined position (back end position or clamping
position). The tailstock can be positioned in tip
mode.

M4 Main Spindle ON
Counterclockwise
The same conditions as described under M03
apply here.
M04 must be used for all left-hand cutting or normal clamped tools.

M5 Main Spindle Off


The main drive is braked electrically.
At the program end the main spindle is automatically switched off.

D67

M-COMMANDS / M25-M87

PROGRAMMING, OPERATION EMCO-SPECIFIC

M23 Workpiece Collection


Device BACK

M39 Driven Tool Positioning ON


M40 Driven Tool Positioning
OFF

The collecting tray flaps back and leaves the


working room.

The positioning of the driven tool will be activated


or deselected.

M24 Workpiece Collection


Device FORWARD

M50 Direction Logic CANCEL of


Tool Change

The collecting tray flaps forward to catch the


workpiece.

Effective blockwise.
The following tool change will be done clockwise
(not necessarely on the shortest way).

The swivel sequence can occur only via CNC program. Swivel in and swivel out is possible only
with closed door.
The supervision records only the swivel movement but not the needed time. That means: The
execution time for the commands "workpiece tray
back" and "workpiece tray forward" must be
considered with programming (G4 - dwell time)

M52 Selection Main Spindle as


C-axis
M53 Deselection Main Spindle
as C-axis

M25 OPEN Clamping Device

The main spindle is defined as C-axis.


Deselection can also be carried out by means of
M10 (spindle clamping).

M26 CLOSE Clamping Device


Notes

M70 Precise STOP Fine

If you change the clamping device, check the


clamping direction and adapt the machine configuration with M90-92.
Open and close the clamping device is possible
only with main spindle stop.
The program run will be continued only after the
clamping device is opened or closed completely.
Opening the clamping device (manual or with
M25) is completed only after the pressure switch
and the end position proximity switch have
acknowledged..

If M70 is programmed in a traversing block, the


following traverse movement will be started only
after the axes have reached the target point (short
axis stop).

M80-87 Freely Programmable


Exits
see earlier in this chapter

Manual operating
Clamping device key

M29 Selection Rigid Tapping


(without longitudinal
compensation)
Is programmed in connection with S-code immediately before the cal of cycle G84 or G88

M30 Program END


With M30 all drives are switched off and the
control is returned to the start of the program.
Moreover, the counter level is increased by 1.

D68

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-COMMANDS / M90-M97

Machine Configuration M90-M95


The M functions M90 - M95 describe the configuration of the machine (type of clamping device,
bar feed / loader active, not active).
The control requires these data to control and
supervise the corresponding functions correctly.
Procedure
Set the key switch "data protection" on position
1.
For the corresponding change at the machine
(e.g. other clamping device) enter the respective M function in the MDI mode.
The set machine configuation is kept, until it is
deselected by an opposite M function (also after
switching off the machine).

M94 Bar Feed / Bar Loader


Active

M90 Manual Chuck


(no clamping supervision)

M95 Bar Feed / Bar Loader not


Active

M91 PULL Clamping Device


Clamping device that closes when the connecting
tube pulls, e.g.:
EMCOTURN 325:
Pneumatic jaw chuck, that clamps from outside
to inside
Pneumatic collet chuck

M96 Automatic Cycle-Start


when Door Closed
(Option)

EMCOTURN 345:
Hydraulic jaw chuck

The machining program starts as soon as the chip


guard door is closed.
The option "automatic cycle start when door
closed" can also be used without automatic door.
For safety reasons this function must be activated
again (M96) after every machine off-on.

M92 PUSH Clamping Device


Clamping device that closes when the connecting
tube pulls, e.g.:
EMCOTURN 325:
Pneumatic jaw chuck, that clamps (a tubular
workpiece) from inside to outside

M97 CANCEL M96

EMCOTURN 345:
Hydraulic collet chuck

M93 Clamping Limit Monitoring


CANCEL
No clamping supervision

D69

M-COMMANDS / M98-M99

PROGRAMMING, OPERATION EMCO-SPECIFIC

M98 Subprogram Call


Format
N... M98 P...
P ......... The first four digits from the right determine the subprogram number, the other
digits the number of repetitions.
Notes
M98 can be designated in the same block as
the movement command (e.g. G01 X25 M98
P25001).
Main program

When the count of repetitions is not specified,


the subprogram is called once (M98 P5001).

Subprogram




103


103


When the programmed subroutine does not exist


an alarm occurs.

2




1[[[[0

A two loop subprogram call can be executed.


(N... M98 P25001 ; the program will be called
two times)

M99 Subprogram End,


Jump Instruction

2




1[[[[0

Format
N... M99 P...
M99 in the main program
Without jumping address:
Jump to the program start.
With jumping address Pxxxx:
Jump on block no. xxxx

Subroutine call from a main program

M99 in the subprogram


Without jumping address:
Jump to the calling up program, on the next block
after the calling up block (see drawing).
With jumping address Pxxxx:
Jump to the calling up program on block no. xxxx
Note
M99 must be the last command in the subprogram.
The jump-back occurs automatically into the
next following block in the main program.
M99 cannot be used internal the main program
as a jump instruction.
To perform a jump instruction in the main program it is possible to use the command GOTO
For example:
To jump from the actual position in program to
block number N12, program the command
GOTO12 in a seperate block.

D70

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-COMMANDS / M103-M215

M103 Main Spindle ON clockwise


with Waiting Time

M204 Reverse of Rotation Direction of the Main Spindle


ON

Same code as M3, but:


The following blocks only then will be executed, if
the spindlespeed has been reached.

This command reverses the commands M3 and


M4: M3=M4, M4=M3.

M205 Reverse of Rotation Direction of the Main Spindle


OFF

M104 Main Spindle ON counter


clockwise with Waiting Time
Same code as M4, but:
The following blocks only then will be executed, if
the spindlespeed has been reached.

This command delets the reverse the commands


M3 and M4: M3=M3, M4=M4.

M113 Driven Tool ON clockwise


with Waiting Time

M214 Reverse of Rotation Direction of Driven Tool ON

Same code as M13, but:


The following blocks only then will be executed, if
the spindlespeed of driven tool has been reached.

M214 reverses the commands M13 and M14


(driven tool on): M13=M14, M14=M13.

M114 Driven Tool ON counter


clockwise with Waiting Time

M215 Reverse of Rotation Direction of Driven Tool OFF

Same code as M14, but:


The following blocks only then will be executed, if
the spindlespeed of driven tool has been reached.

M215 delets the reverse the commands M13 and


M14: M13=M13, M14=M14.

D71

M-COMMANDS / BAR FEED, BAR LOADER

PROGRAMMING, OPERATION EMCO-SPECIFIC

Bar Feed / Bar Loader Interface


General
The signals from the machine to the loader are
free programmable in the part program via M
functions.
The signals from the loader to the machine can
be called free in the part program and can be
used for jumps (branches) or waiting loops.
The part program will always be started
automatically by the machine, also at bar end.

M Functions
M57
M58
M66
M67
M68
M69
M71
M72

Main spindle swing on


Main spindle swing off
Bar feed / Bar loader FEED ON with feed
stop/input release
Bar feed / Bar loader FEED ON without
feed stop/input release
Bar feed / Bar loader FEED OFF
Start bar change without feed stop/input
release
Turn Spindle and clean clamping device
ON
Turn Spindle and clean clamping device
OFF

Control signal (MACRO variable)


Bar end ........................................................ #1000
Loader has pushed forward ........................ #1001
Start after bar change ................................. #1002
By means of these signals (MACRO variable) you
can branch in the part program and call or skip
corresponding program parts or program a waiting
loop.

Activate / Deactivate
M94
M95

D72

Activate bar feed / bar loader


Deactivate bar feed / bar loader

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-COMMANDS / BAR FEED, BAR LOADER

Program Example for Operating a Bar Feed


Used functions
M67

Bar feed / Bar loader FEED ON without


feed stop/input release
(aktive until M68 FEED OFF)

M68

Bar feed / Bar loader FEED OFF

N20 IF [#1000EQ0] GOTO 10


Query whether signal "bar end" is active.
The MACRO variable #1000 is compared with
zero (EQ0).
When signal "bar end" is active (#1000 = 0) the
program jumps to block number 10.
This creates an infinite loop (waiting loop), as long
as "bar end" is active.

Program
%
:5000
M94

Activate bar feed / bar loader

G0 X20 Z100 T101


M25
M67
G1 G94 F1000 Z150
M26
M68

Place bar stop


Open clamping device
Bar feed ON
Accompany bar to stop position
Close clamping device
Bar feed OFF

N10
N20 IF [#1000EQ0] GOTO 10

Block number for jump address


Query for bar end

G0 X50 Z180
T202
G0 X30 M3 S3000
G1 G95 F0.3 Z150
....
....
....
G0 X50 Z180
M30
%

Approach free position

Regular bar feed

Infinite loop at bar


end

Part machining

Alternative
When the bar feed / bar loader gives the signal
"loader has pushed forward", you need not to program the function "bar feed OFF" (M68).

Note
This programming example was created for
the EMCOTURN 325.
On other machines a larger traversing area
can be programmed.

Changes in program:
M66 Bar feed / Bar loader FEED ON with feed
stop/input release instead of M67
Cross out M68 (bar feed OFF).

D73

M-COMMANDS / BAR FEED, BAR LOADER

PROGRAMMING, OPERATION EMCO-SPECIFIC

Program Example for Operating the Bar Loader EMCO LM800

Note
This programming example was created for
the EMCOTURN 345.
Mind the machining area on other machines.

%
:2000

(example for loaderprogram with MKE LM 800)

G28U0W0
G92S5000
G10P0Z-200
T0202
G0X100Z50
X0Z30
Z-15
M25
M66
G1G94F6000Z0.4
G4X0.5
IF[#1000EQ1]GOTO10
G1G94F8000Z250
M69
G0Z0.4
N20
IF[#1002EQ0]GOTO20
M66
N10 M26
M66
G0Z30
X150Z120
G95
T1212
.......................
M30

(bar stop)

(pick up position)
(clamping device opening)
(feed in ON)
(feed out position 0.4 for facing)
(delay time)
(check end of bar:
if "yes", control will read next line, if "not" jump to line number N10)
(position to trop the rest pice)
(start bar change)
(position for the new bar)
(check barfeed feeded forward)
(feed in ON)
(clamping device closing)
(check barfeed feeded backward)
(index position)

(standard program to machine the part)


(end of program)

Information:
Keep-relay:
aktivate lader:

K1 = 1xxx1xxx
M94

D74

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-COMMANDS / BAR FEED, BAR LOADER

Program Example for Operating the Bar Loader Kupa LM


Used functions
M66

Bar feed / Bar loader FEED ON with feed


stop/input release

M69

Start bar change

IF [#1000EQ1] GOTO 66
Query whether signal "bar end" is not active.
The MACRO variable #1000 is compared with one
(EQ1).
When signal "bar end" is not active (#1000 = 1)
the program jumps to block number 66 and a normal bar feed will be done.
When signal "bar end" is active, no jump is done
and the rest piece will be ejected and the bar
change will be proceeded.

Note
This programming example was created for
the EMCOTURN 345.
Mind the machining area on other machines.
Subprogram for bar loader
% :1000 (KUPALOADER SPF)
M94
T0404
G0 X0 Z-20
M25
IF [#1000 EQ1] GOTO 66

Activate bar loader


Place bar stop
Stop position
Open clamping device
Jump over bar change

G0 X0 Z150
M24
G4 X3
M66
M23
G4 X1
G0 X0 Z20
M69

Approach free position


Swivel in workpiece tray
Dwell
Bar feed - eject rest piece
Swivel out workpiece tray
Dwell
Stop position
Bar change

N66 M66
G1 G94 F2000 Z.5
M26
G4 X.5
G0 X120 Z100
(M66)

Bar feed until bar stop


Bar stop pushes bar to clamping position
Close clamping device
Bar feed
Dwell
Approach tool change position
Some KUPA-types (software versions) need this command,
when an alarm occurs remove this command out of the program.
Subprogram end

M99
Main program
% :1234 (MAINPROGRAM)
G28 U0 W0
G92 S4000
G10 P0 Z-200
M98 P1000

Approach reference point


Spindle speed limit
Zero offset
Subprogram call

Bearbeitung
N300 M30

Program end

D75

Bar change

M-COMMANDS / BAR FEED, BAR LOADER

PROGRAMMING, OPERATION EMCO-SPECIFIC

Program Example for Operating a Bar Loader


(not for Kupa LM and EMCO LM800 loaders)
Used functions
M67

Bar feed / Bar loader FEED ON without


feed stop/input release
(aktive until M68 FEED OFF)

M68

Bar feed / Bar loader FEED OFF

M69

Start bar change

IF [#1000EQ1] GOTO 10
Query whether signal "bar end" is active.
The MACRO variable #1000 is compared with one
(EQ1).
When signal "bar end" is not active (#1000 = 1)
the program jumps to block number 10 - the bar
change will be skipped.
IF [#1002EQ0] GOTO 100
Query whether signal "start after bar change" is
active.
The MACRO variable #1002 is compared with
zero (EQ0).
When signal "start after bar change" is not active
(#1002 = 0) the program jumps to block number
100.
This creates an infinite loop (waiting loop), until
"start after bar change" is active.

Alternative to the following program


When the bar feed / bar loader gives the signal
"loader has pushed forward", you need not to program the function "bar feed OFF" (M68).
Changes in program:
M66 Bar feed / Bar loader FEED ON with feed
stop/input release instead of M67
Cross out M68 (bar feed OFF).

Note
This programming example was created for
the EMCOTURN 325.
Mind the machining area on other machines.

D76

PROGRAMMING, OPERATION EMCO-SPECIFIC

M-COMMANDS / BAR FEED, BAR LOADER

Subroutine for bar loader


%
:1000 (KUPA-BAR LOADER-CYCLE-METR)
M94

Activate bar loader

T202
G0 Z10
X0 Z0
M25
M66
G1 G94 F1000 Z0
IF [#1000EQ1] GOTO 10

Swivel in bar stop


Position bar stop
Open clamping device
Bar feed on
Bar forward
Inquiry bar end

M25
G0 Z100
M67
G1 G94 F1000 Z100
G4 X2

Open clamping device


Releasing the bar stop
Bar feed on
Residual workpiece ejection
Dwell time 2 seconds

M25
T202
G0 X0 Z3
M69

Open clamping device


Bar stop
Position bar stop at beginning of bar
Start bar change

Bar change

N100
IF [1002EQ0] GOTO 100

Block no. for jump address


Inquiry start after bar change

Waiting loop at
bar change
end

T202
G0 X0 Z3
M66
G1 G94 F1000 Z3
M26

Bar stop
Position bar stop
Bar feed on
Bar forward
Close clamping device

G0 X100 Z100
T1212
G96 S120 M4 G95 F.15
G0 Z10
X38 Z0
G1 X-1 F.15 M8
G0 X150 Z10 M5 M9
GOTO 30

Jump to program end

N10 M26
G0 X100 Z80
G95

Close clamping device


Bar stop backward
Selection feed in mm/r

N30 M99
%

Subroutine end

Normal bar feed

Residual
workpiece ejection

Bar feed after bar


change

Rough facing device


First part
machining

D77

Normal part
machining

REVERSING PLAY COMPENSATION

PROGRAMMING, OPERATION EMCO-SPECIFIC

Reversing Play Compensation


Only for EMCOTURN 325.
The control compensates the reversing play of
the slides.
After every readjustment of the slideways the
reversing play must be measured and entered
into the machine parameters. See "F Maintenance
and Readjustment works".
To alter the parameter first set write enable:
Set the key switch "data protection" on position
1.
Select MDI mode (

).

2))6(7
Press the key 6(77,1*
.

Press the softkey SETING


Move the cursor on PARAMETER WRITE.
Enter: 1

,1387

The screen shows alarm 100.


Cancel alarm 100 with &$1

5(6(7 .

Now the machine parameters can be altered.

Input of the reversing play


Press the key

6<67(0.

Press the softkey PARAM.


Enter: 1851 and softkey NO.SRH.
The scren shows: 1851 BACKLASH X, Z
Enter the measured values for the reversing play
in X and Z.

Notes:
To avoid accidentally altering reset the write
enable parameter back to 0 (is done automatically when switching off the machine).
For Emcoturn 345-II:
The reversing play for the driven tool has to
be adjusted by setting a compensation value
in the parameter "5321" (\#1):
1 revolution = 4096 increments

D78

PROGRAMMING, OPERATION EMCO-SPECIFIC

CHIP CONVEYOR, OPEN DOOR

Chip conveyor
Programming:
While the programming is running, the chip
conveyor is switched on in certain intervals, runs
for the period set in C8 and is switched off again.
The intermission time between the running
periods is programmed in the counter C 12 (ex
works: 200 s).
Only the time in which the program is active is
calculated.
If the chip conveyor is switched on (LED above
conveyor key is illuminating), it runs according
to the running time C8 even if the program is
terminated.

6<67(0

Manual operation:
Switch on chip conveyor:
Forward: press key less than 1 second, forward
run for time C8 (LED is illuminating).
Backward: press key more than 1 second, reverse
run as long as key is pressed (LED is flashing
slowly), in the subsequent forward run for time
C8.

PMC

PMCPRM

COUNTR

Interrupt chip conveyor:


For emptying etc. press simultaneously AUX ON
and chip conveyor key (LED is flashing quickly).
Switch on again with chip conveyor key.

C08 = Run Time [sec]


C12 = Intermission Time [sec]

Adjustment of run time/intermission time of the


chip conveyor

Note
To avoid contaminations of the emulsion, the
chips are to be removed from the working area
prior to operation end.
Thus, a manual after-running of the chip
conveyor is recommended.

Program interruption to
open the door
Sequence:
Set feed override switch to 0%.

Press key NC Stop.

Door can be opened (consent key)..


Close door

Press key NC Start.

Set override switch to 100 %.

D79

TOOL DATA MEASURING

PROGRAMMING, OPERATION EMCO-SPECIFIC

Tool Data Measuring with Scratching


Clamp a worpiece with measured diameter and
length and return the slides of the machine to
reference point.
Start spindle in MDI mode
(M03/M04 S ....)
Swivel in the desired tool.
X correction
Scratch with the tool on the diameter of the
workpiece (B).
2))6(7
and the softkey GEOM.
Press the key 6(77,1*

;

Select tool station number of the respective tool

with cursor keys

$
'

Press the softkey OPRT.

=

Enter the workpiece diameter e.g. 47.


Press the softkey MEASUR.
The X value will be taken over into the tool data
register.

/
;

Z correction
Scratch with the tool on the face of the workpiece (A).

Dimensions for scratching method:


A
Scratching on face
B
Scratching on circumference
D
Work piece diameter
L
Work piece length + chuck length

2))6(7
Press the key 6(77,1*
and the softkey GEOM.

Select tool station number of the respective tool


with cursor keys

Press the softkey OPRT.


Enter the length L (workpiece length + chuck
length - see drawing), e.g. = % 72.
Press the softkey MEASUR.
The Z value will be taken over into the tool data
register.

Repeat this sequence for every required tool.

D80

PROGRAMMING, OPERATION EMCO-SPECIFIC

TOOL DATA MEASURING

Tool Data Measuring with the Optical Preset Device


Mount optical preset device
Clamp gauge with toolholder in tool turret disk.
MANUAL mode, traverse gauge into the reticule
of the optical preset device (at open door in
setup mode with consent key).
Press key

326

and softkey REL.

Press keys ; $ and  .


Softkey PRESET drcken (X-Wert wird gelscht).
Press the keys = % and  .
Press the softkey PRESET (Z value will be
deleted).
Set mode selection switch to INC 1000 and traverse in W to position -20 mm (= length of the
gauge).
Set W value to 0 again ( = % ,  , PRESET).
Swivel in tool and traverse it into the reticule.
2))6(7
.
Press the key 6(77,1*

Press the softkey OPRT.


Select tool station number of the respective tool
with cursor keys

X correction
Set cursor to the X-value of the selected offsetnumber.
Press the key ; $ and the softkey INP C.
X value is taken over into the tool data memory.
Z correction
Set cursor to the Z-value of the selected offsetnumber.
Press the key = % and the softkey INP C.
Z value is taken over into the tool data memory.

D81

SERIAL DATA INTERFACE

PROGRAMMING, OPERATION EMCO-SPECIFIC

Serial Data Interface


You can send data (programs, tool data, machine
data) from the control to the PC (e.g. for archive)
or also create programs at a PC and send it to the
control.

SCREEN
SD
RD
RS

Signal names

CS

SCREEN
SD
RD
RS
CS
DR
0V
CD
RI

DR
0V
CD
RI

Schielding
Transmit data
Receive data
Request to send
Clear to send
Data send ready
Ground
Data terminal ready
Ring indicator

Transmission cable
To transmit data between control and Personal
Computer you need a cable with the pin assignement as shown beside.

Serial interface - occupation


machine side
(D-Sub 25)

PC-side
(D-Sub 9)

Settings for data transmission


Standard values of the control:
9600 baud
2 Stop bits
7 Data bits
Parity even
Please set your PC equivalent to the control.

Transmission of NC-programs

female connection,
9 poles

EDIT mode
Press key

6<67(0

3 x press the right menu extension key


Press the following softkeys:
ALL IO, PROGR, OPRT, PUNCH, EXEC.
Data will be transmitted. The transmission is
executed successfully, when no error message
appears.
plug connection
25-poles

Cable connection machine-PC

D82

E Maintenance of the machine


Maintenance survey
Note:
Pay attention to the maintenace instructions
in the enclosed manuals in chapter "E Additional Instructions"!

Danger:
All maintenance work may only be carried out
with the machine switched off.

1000 h

11

200 h

12

40 h

8h

5
1

8h

40 h

200 h

12

8
12

1000 h
2000 h

15

13

14

check, if necessary supplement

change cooling lubricant

oil, change oil

clean, if necessary exchange

grease

battery change

E1

SURVEY

No.

MAINTENACE

Inspection-maintenance item

Activity

Interval [h]

Details
see

clamping device pressure, clamping device function

to be checked

D5

power clamping chuck

to be greased

D5

hydraulics - system pressure, oil level

to be checked

D8

cooling lubricant level

to be checked

D10

collet chuck

to be oiled

40

D6

bright parts on the machine

to be oiled

40

D6

cooling lubricant tank

to be cleaned

40

D10

central lubricating system - oil level

to be checked

40

D7

cooling lubricant concentration

to be checked

200

D10

10

all hoses

to be checked

200

11

hydraulics

12

main motor, feed motors - belt tension

13

tool turret

14
15

D6
)

oil change

1000*

to be checked

2000

D8
D12

oil change

2000**

cooling lubricant

to be changed

2000

D10

buffer battery of Sinumerik 810D/840D

to be changed

if necessary

D13

*) first hydraulic oil change after approx. 500 h


**) Pay attention to the maintenance-notes in the added instructions of the manufactorer of the tool turret

Filling quantities
Hydraulics ........................................................ 10 l
Central lubrication system ............................. 2,7 l
Cooling lubricant tank ................................... 230 l

Lubricant
recommendations
Application

Denomination acc. to DIN

Hydraulics

Hydraulic oil:
HLP DIN 51524 ISO VG 32

Central lubrication
collet chuck
bright parts

Slideway oil:
CGLP DIN 51502 ISO VG 68

power chuck

Grease

E2

Recommendation
BP
Energol HLP 32
Hyspin AWS 32
CASTROL
Nuto H 32
ESSO
DTE Oil 32
MOBIL
Tellus S 32
SHELL
Hyd HLP 32
OMV
943 AW/32
TRIBOL
CASTROL
Magnaglide D 68
KLBER
Lamora Super Pollad 68
MOBIL
Vactra 2
OMV
Glide 68
TRIBOL
1060/68
EMCO
Sliding paste
Grease MS 3
CASTROL
Altemp Q NB 50
KLBER
Topfit 3284
MOLUB ALLOY
Signum LM
OMV
F 80
RHM
4020/460-2
TRIBOL

MAINTENANCE

COOLING LUBRICANTS

Cooling lubricants
BP-recommendation

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E3

COOLING LUBRICANTS

MAINTENACE

Chlorin-free coolants

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Hints for cooling lubricant selection:


An incorrectly selected or used sooling lubricant
may show decisive effects on the manufacturing
process and thus, cause high costs indirectly.
After the end of service life cooling lubricants
represent special waste that need supervision and
have to be disposed of adequately. The disposal
costs accuring are of decisive influence on the
economy or the cooling lubricant use.
If machining is carried out with high power, the main
task of a cooling lubricant consists in an effective
cooling of tool and workpiece. Therefore use of
water-soluble cooling lubricants is to be preferred.
For complicated machining processes better results
can be achieved with non-water soluble cooling
lubricants.
High efficiency for flushing away the chips is
influenced less by the type of cooling lubricant than
by the kind and arrangement of the cooling lubricant
nozzles as well as by the quantity and pressure of
the cooling lubricant stream.
In addition the following items are to be observed:
Disposal (cleavage-, decomposition property)

Content mateials (chlorine, nitrite, phenols, etc.)


Corrosion protection
Viscosity
Resistence to aging, serving life
Resistence against microorganisms
Emulsifying capacaty
Foaming behaviour
Dirt elimination property
Wetting capacity
Filtering capacity
Transparency
Compatibility with metals, plastics
Residual behaviour
Inflammability
odour
Compatibility with health (formation of mist, skin
compatibility, toxicity, cancerogenity,..)
Non-water soluble sooling lubricants are generally
without problems.
Problems occur with the formation of mist and chip
deoiling.

E4

MAINTENANCE

CLAMPING DEVICES

Clamping pressure and


clamping dev. function
Clamping pressure and clamping device function
must be controlled at least every 8 hours (daily)
to be able to detect possible errors or damage in
time.

Clamping pressure
The clamping pressure set for clamping device
1 (3) and 2 (4) can be read at the manometers
(1) or (2).
Check all control lines to the valves and
clamping cylinder for damage.

Clamping device function


1

Check total condition of clamping device every


day and remove dirt.

Clamping dev. manometer and clamping device


Reduce clamping pressure to approx. 34 bar
and open and close clamping device via control
keyboard.
The clamping device must move perfectly.

Power chuck
Danger:
Maintenance work on the chuck may only
be carried out during standstill of the
machine.
Also observe the instruction supplied with
the chuck.

Every 8 operating hours


Lubricate the chuck at all existing 6 grease
nipples (5) and (6).
Remove clamping jaws from guides and clean
the guides and oil them slightly.

Every 1000 operating hours


Dismantle chuck, clean all parts and grease
them again.
5
(3)

During the cleaning intervals check smooth


running of the chuck.
It must be possible to open and close the chuck
perfectly with a clamping pressure of approx.
4 bar.

6
(3)

Grease nipples on power chuck

E5

CLAMPING DEVICES/BRIGHT PARTS

MAINTENACE

Collet chuck
Danger:
Maintenance work on mounted collet chucks
may only be carried out during standstill of
the machine.
The general condition of the collet chuck has to
be checked every day and possible dirt has to be
removed from the collet chuck.
Lubrication interval ...... every 40 operating hours
Slightly oil movable parts of the collet chuck
with slideway oil.

Caution:
The collets should be free from oil during use,
otherwise the clamping force may be reduced
by too little friction.

slightly oil

Maintenance of collet chuck

Bright parts
Danger:
Cleaning and oiling of parts in the working
area of the machine may only be carried out
during standstill of the machine.

The bright parts such as cover sheets and plate


covers have to be cleaned every week.
Then slightly oil the parts with slideway oil.

slightly oil bright parts

Visual examination of all


hoses
To increase the operational safety, all hoses
(hydraulic, pneumatic, collant device) should be
checked for leaks in regular intervals (all six
month).
Therefore dismount cover sheets ans check, if
hoses fret or are wet or damaged.

E6

MAINTENANCE

CENTRAL LUBRICATION

Central lubrication
The slide guides are supplied with slideway oil
via the central lubrication.
The lubrication is carried out automatically
according to the way traversed of the individual
slides.

Oil level check


Interval of checks ......... every 40 operating hours
Check oil level in the oil tank
Check lubricant lines and connection points for
tightness and penetrability.
The oil tank (1) with the slideway oil is on the rear
side of the machine and can be seen via an
opening in the machine shell.
The oil level must be between the two limit marks
on the tank.
If the oil level is too low, an alarm message is
indicated by the control.
If necessary, refill slideway oil in the charging hole
(oil quality see "Lubricant recommendations").
1

Central lubrication at the machine

Air inclusions
In case of air inclusions in the lubricant lines
slightly untighten the screw connections upstream
of the dosing elements and actuate lubricant pump
until oil flows out without bubbles from the
screwed connections.
Retighten screwed connections.

PD[

PLQ
1

Lubrication in case of major


periods of standstill

Central lubrication / detail

If the machine is not used for a major period, the


lubrication should be activated manually prior
and after the period of standstill.
To do this, press the "AUX ON" key approx. 10
times. Whenever you press, a lubricating impulse
is transmitted.

$8;

E7

HYDRAULICS

MAINTENACE

Hydraulic unit
Danger:
Maintenance work at the hydraulics may only
be carried out with the machine switched off
and with reduced hydraulic pressure.

Reduction of hydraulic pressure


After switching off the machine the hydraulic
pressure is decreased automatically down to a
residual pressure.
The residual pressure must be reduced by a
service engineer prior to every maintenance work.
Open door (1) at the rear side of the machine.
Open the accumulator drain valve (2) with an
allen wrench..
Wait a few seconds, until the residual pressure
is reduced to 0, then close the valve (2).
Carry out maintenance work.

Reduction of hydraulic pressure

Installation of lines

Additional regular checks

By changing and installation of hydraulic lines


note the following points:

Pay attention to noises


Monitor oil level
Check for leaks
In addition we would like to draw your attention to
the following:

Never use brute force in order to avoid transverse forces and stresses in pipes and equipment.
Ensure the pipes are fastened well.

VDI-guidelines, commissioning and maintenance of hydraulic equipment, VDI-3027


Prosals of the CE TOP

Do not use hemp or putty as sealants.


This can result in contamination and thus
functional breakdowns.
In order to prevent external leaks, observe the
installation instructions of the manufactorers of
screwed joints.
We recommend screwed joints with flexible
sealing elements.

Cleanliness
Pay attention to the cleanliness to the following:
for the enviroment
for units, line connections, equipment

Ensure hose lines are laid correctly.


Avoid scuffing or knocking the lines.

for the hydraulic oil


Caution - pay attention to contamination,
moisture
Only fill using filters (system filters or mobile
filter stations with fine filters)

E8

MAINTENANCE

HYDRAULICS

Hydraulic oil change


Attention:
Upon purchase of the machine the hydraulic
system is equipped with a special initial filling
oil.
The first oil change including filter change
must therefore be carried out after 500
operation hours at the latest.
Interval .................... every 1000 operation hours
Filling quantity ................................................. 10 l

The hydraulic oil should be changed in hot


operation state.
With each oil change the oil filter, too, has to be
changed.
Switch off machine and reduce residual pressure
in the hydraulic system (see side before).
Open oiling screw (1).

Open oil drain screw (3) and drain used


hydraulic oil into a suitable container.
Close drain screw (3) again.
Dismount filter (4) by opening the four hexagon
socket screws (5) and replace it.
Fill in new hydraulic oil.
The oil level can be controlled at the oil level
gauge (2).
Mind not to fill beyond the maximum mark
(approx. 10 l).

Attention:
Pay attention to the positions of the hydraulic
cylinders by refilling hydraulic oil:
Door autom.: door closed
Tailstock:
moved backwards (right side)
Clamping cyl.: forwards (chuck open / collet
closed)

Maintenance work at the hydraulics

Dispose used oil and filter according to the environmental regulations.


Close door.
Switch on machine and check pressure on the
manometer.
The pressure varies between 70 and 80 bar.

E9

COOLANT DEVICE

MAINTENACE

Coolant device

Danger:
Maintenance work at the cooling system may
only be carried out during standstill of the
machine.

Drawing out the


cooling lubricant tank
For refilling the cooling lubricant or for cleaning,
the cooling lubricant tank can be drawn out
forward.

A
Open door (1) at the rear side of the machine.
Swivel out backward coolant pump (4) and
possibly jetting pump on the sheet (2) (see
direction of arrow in fig. on the opposite).
The pump brackets engage in swivelled-out
state.

Draw coolant tank forward.

View of the machine from the rear

Carry out maintenance work.


1

Insert coolant tank again.

Swivel coolant pump in again by slightly lifting


the rail (3).
Close door (1).

Swivelling out the coolant pump - view A

E10

MAINTENANCE

COOLANT DEVICE

Cooling lubricant level


Check interval ....................... 8 operation hours
The cooling lubricant level is checked at the front
side of the machine on the display (2) of the
cooling lubricant tank (1).
When refilling the cooling lubricant observe the
composition and the miscibility of the existing liquid (also see cooling lubricant recommendations).

Attention:
Use fundamental only chlorine-free coolants.
The share of chlorine in the coolant is
responsible for the rusting of bright machine
parts.
1

Display of the cooling lubricant level

Cleaning the cooling lubricant


tank
Cleaning interval ............. 200 operation hours
Remove dirt from coolant tank and inserted
sieves (chips, etc.).
Check return flow lines for cleanness and rinse
them if necessary.

Notes:
Dispose cooling lubricants acc. to environmental requirements (special waste!)
Do not use fluorine chlorinated hydrocarbons (e.g. trichloroethylene, trichloroethane etc.) for cleaning the tank.
During cleaning mind complete elimination
without residues of deposits!
Remaining contaminations are sites of
growth for bacteria which attack the newly
filled emulsion and reduce its service life.
Use rags and solvents only sparingly.
Dirty cleaning rags (cleaning paper) have to
be disposed of as special waste.

E11

BELT TENSION

MAINTENACE

Belt tension
Check the belt tension of the drives in regular
intervals according to the table below.
In addition the belts have to be checked for their
general condition.
In case of defects such as severe contamination
with lubricants and cooling lubricants or fractures
or similar, the belts have to be changed.
Control interval ................ 2000 operation hours
Belts to be controlled (acc. to equipment of
machine):

Danger:
The belt tensions may only be checked with
the machine switched off.
Make sure that the machine is protected
against unauthorized start-up!

Control of belt tension

drive

main spindle (spindle 1) 65, 45


counter spindle (spindle 2) 65, 45
X-slide
Z-slide
Z2-slide (Z-stroke of spindle 2)

impression
depth

E [mm]

control force
Fp [N]
initial
assembly

belt type

order-no.

after
run-in

Spindle 1 65

7,3

120-143 98-120

Polyflex 4-grooves, 11M-1400 mm

ZRM 471 114

Spindle 1 45

7,2

86-102

Polyflex 4-grooves, 11M-1320 mm

ZRM 471 113

Spindle 2 65

4,1

104-123 85-104

Polyflex 4-grooves, 11M-975 mm

ZRM 471 109

Spindle 2 45

4,2

87-103

71-87

Polyflex 3-grooves, 11M-925 mm

ZRM 471 110

Slides X, Z, Z2

2,0

11

11

HTD 5M-25-450; 90 teeth

ZRM 600 903

70-86

E12

MAINTENANCE

CHANGE OF BATTERY

Change of battery in the


control
Siemens 810 D/840 D
In the control battery-buffered storages and clock
units are used to save data in case of power
failure.
Buffer time of the batteries .......... min. 3 years
The buffer batteries are monitored by the control.
If the buffer tension falls below a certain value a
message is emitted on the screen by the control.
To avoid data loss the buffer batteries have to be
changed within 6 weeks after the first display of
this message.

Danger:
Never try to reactivate batteries by heat or
other means or to recharge them.
The batteries may run out and/or explode!

Change of battery in the hard


disk unit MMC
Battery:
Order no. (Siemens) ...... 6FC5 247-0AA18-0AA0

Note:
To avoid data loss the control must not be
switched off during the battery change.

Remove back cover of control.


Take out plug X11 (2) and pull battery (1) out of
the fixing device.
Insert new battery into fixing device and insert
plug X11 again.
Remount cover of control.
1

Buffer battery on the hard disk unit MMC

E13

CHANGE OF BATTERY

MAINTENACE

Change of the battery ventilator


insert of the NC-CPU board
(Sinumerik 840D)
Ventilator insert:
Order no. (Siemens) ...... 6FC5 247-0AA06-0AA0

Danger:
The exchange of the ventilator insert may
only be carried out with the machine switched
off.
The exchange must be carried out within 15
minutes after switching off the machine,
since the data can be protected only during
this period.

Switch off machine.


Open switch cabinet of the machine.
The ventilator insert (3) is situated on the NCU
box (1).
Press catch (2) on the ventilator insert (3) to
the top and at the same time pull out insert.
Introduce new ventilator insert (3), mind engaging of the catch (2).
Close switch cabinet.

Ventilator insert on the NC-CPU board

Change of the battery of the


CCU-board (Sinumerik 810D)
4

Battery:
Order-n.. (Siemens) ....... 6FC5 247-0AA18-0AA0
Switch off machine.
Open switch cabinet of the machine.
Pull out CCU-board (5) of the CCU-box (7) after
untightening of the 4 screws (4).
Danger:
The CCU-board has to be handled with care,
because it is an very high sensitiv electronical
part.
Change battery (6) with a new one of the same
type.
The buffer of the stored datas will be inherited
of a capacitor for approx. 15 min.
Set CCu-board (5) in CCU-box (7) and tighten
the screws (4).

Battery on the CCU-board

E14

F Additional instructions

Sauter

Tool Turret

Knoll

Chip Conveyor

Bristol

Electrostatic Airfilter

F1

F2

BA

O p e r a t i n g

640 e

i n s t r uc ti on s

for
Disk-Type Tool Turret
with electrical drive
and slide unit
0.5.453.216 - 085 612
087 822
104 410
105 672

Type plate at turret housing

Series

Size

0.5.453.2 16
F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\640db.fm

085 612

Classification
number
Identification
number
Order
number

Gear
ratio

Edition:

02-04-05

Table of contents

Safety information . . . . . . . . . . . . . . . . . . . . 5
1.1

Use within specifications . . . . . . . . . . . . . . . . . . . . . . 5

1.2

Required skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3

Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6

Liability and warranty . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.8

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.9

Symbols in instructions for specific actions . . . . . . . . 8

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm

1.10 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product description . . . . . . . . . . . . . . . . . . 11
3.1

The parts of the turret and the slide unit. . . . . . . . . . 11

3.2

Possible options and deviating designs . . . . . . . . . . 13

3.3

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.4

Admissible loads and dimensions . . . . . . . . . . . . . . 17

Table of contents

Assembly and installation . . . . . . . . . . . . . 19


4.1

As-delivered condition . . . . . . . . . . . . . . . . . . . . . . . 19

4.2

Fitting the turret-drive motor . . . . . . . . . . . . . . . . . . . 20

4.3

Fit turret onto the machine . . . . . . . . . . . . . . . . . . . . 22

4.4

Align turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.5

Fitting the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.6

Align tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.7

Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . 27

4.8

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.9

Cooling lubricant supply . . . . . . . . . . . . . . . . . . . . . . 28

4.10 Determination of reference point . . . . . . . . . . . . . . . 29

Additional equipment, toolholders and


spindle units . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm

Toolholders and spindle units. . . . . . . . . . . . . . . . . . 30

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1

Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.2

Check lubricant of turret gearbox chambers . . . . . . 34

6.3

Bevel gears and roller bearings on gearbox nose . . 35

6.4

Spindle units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.5

Slide unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of contents

Fault finding and repair . . . . . . . . . . . . . . . 36


7.1

Faults and remedies. . . . . . . . . . . . . . . . . . . . . . . . . 36

7.2

Engaging the ratchetting clutch . . . . . . . . . . . . . . . . 39

7.3

Determining belt tension on the slide unit . . . . . . . . 41

7.4

Belt replacement belt tension . . . . . . . . . . . . . . . . 41

7.5

Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.6

Replacing the cooling lubricant valve . . . . . . . . . . . . 46

7.7

Replacing and setting the proximity switches. . . . . . 47

Replacement parts . . . . . . . . . . . . . . . . . . . 54
8.1

Proximity switches . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.2

Tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3

Cooling lubricant system . . . . . . . . . . . . . . . . . . . . . 57

8.4

Gear head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.5

Housing and indexing unit . . . . . . . . . . . . . . . . . . . . 61

8.6

Carrier and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.7

Slide unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Ordering replacement parts

Appendix
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP-1039 e
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK-1226 e

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm

Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP-446 e

Safety information

Safety information
The disk-type tool turret corresponds to the state of the art and
the recognized technical safety rules. Nevertheless hazards
and risks can occur.

1.1

Use within specifications


Install and operate turret only in machines complying with the
relevant regulations for workspace protection.

1.2

Required skills
Only trained and competent personnel may work on the disktype tool turret; this personnel must have been instructed in
accordance with the operating instructions and directly on the
disk-type tool turret.

1.3

Electrical installation
All work on the electrical system is to be carried out by a
competent specialist engineer only in order to avoid any
incorrect installation which may cause a hazard of injury to
persons or damage to equipment.

1.4

Hydraulic system
IMPORTANT
On delivery, the cylinders of the turret are filled with hydraulic oil
and its openings are plugged.

1.5

Disposal

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

Comply with all national and regional disposal regulations and


laws.

Liability and warranty

1.6

Liability and warranty

The information contained in these Operating Instructions is in


conformity with the knowledge at the point of printing.
Subject to modifications which occur within the framework of
continuous further development.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

All liability and warranty shall be excluded if

use within specifications is not complied with,

the disk-type tool turret including accessories is incorrectly


operated,

the disk-type tool turret including accessories is


incompetently repaired and maintained,

conversions and functional changes are implemented without


approval by the manufacturer,

no original replacement parts are used,

no spindle heads complete with position locking device


according to product information PI 29.3 are used,

no tool holders with a cylinder shank according to DIN 69 880


are used.

Warnings

1.7

Warnings
WARNING1
Designates a potentially hazardous situation which may cause
serious injury or even death.
WARNING1
Risk of electric shock due to high voltages!
WARNING1
Risk of injury due to a hanging load!
CAUTION1
Designates a potentially hazardous situation which may cause
damage to the product or property in its vicinity.
IMPORTANT1
For application notes and other useful information.

Disconnect energy supply


Before continuing work release machines.

1.8

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

Symbols
Designates an instruction for a specific action. Specific actions
to be executed in sequence are additionally numbered.
Designates additional information.

1) Classification of signal words according to ANSI Z535.4

Symbols in instructions for specific actions

1.9

Symbols in instructions for specific actions

Use lifting gear.

Maximum load XXX kg,


for inclined pull of 45 maximum load YYY kg.
max.
YYY kg

max.
xxx kg

Tightening torque of 23 Nm

23 Nm

Screw M10, quality 12.9, at marked places lubricated with


MoS2, tightening torque 70 Nm.

M10 - 12.9

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

1.10

MoS2

70 Nm

Visual inspection

Abbreviations
adm.

admissible

a.o.

among others

approx.

approximately

fig.

figure

if nec.

if necessary

incl.

inclusive

max.

maximum

Transport

Transport
WARNING
Serious injury hazard (crushing) to fingers and hands posed by any
unexpected and sudden slide unit movements.
Therefore:
Before each transportation, the slide must be brought into its
bottom position and held there in position by means of the
transport retainer device (1). To this end, use retaining plate
complete with 2 bolts M10X20.

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_tr.fm

Before the turret is operated or the motors installed the transport


packing (1) must be removed!

Transport

WARNING
Do not stay underneath or within the swivelling range of
hanging loads!
IMPORTANT

Slinging

Screw in ring bolts DIN 580 on the turret housing and on slide unit
up to the contact surface. A further ring bolt must be screwed into
the fastening hole of the SAUTER tool disk.

Make sure that the hoisting angle at the ring bolts does not exceed
45. Use the ring bolt only for transporting the tool turret with the
tool disk and tool drive.

Size of turret
Ring bolts

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_tr.fm

Mass of turret with motor and


standard tool disk
(without toolholders)
max. dimensions:
Length (without motor)
Width
Height

.16
2 M16
approx. 300 kg

approx. 515 mm
approx. 450 mm
approx. 550 mm

Lift

Use lifting gear.

10

Product description

3
3.1

Product description
The parts of the turret and the slide unit

3
4

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm

Tool disk

Electric supply

Turret drive motor

Hydraulic supply/Cooling lubricant connection

Turret housing

11

Product description

7
6

10

Locating disk

Slide unit

Tool holder

Locating hole

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm

10

Setbold bore for clamping the tool holders

12

Product description

3.2

Possible options and deviating designs


Cooling lubricant valve
IMPORTANT
The cooling lubricant transfer of the disk-type tool turret can be designed variously. The standard version as well as the option medium
pressure cooling lubricant device, are described in these Operating
instructions. However, the design of your disk-type tool turret could
deviate from these.
Standard version

7 / 14 bar

see chapter 8.3, page 57

Medium pressure
cooling lubricant device

25 bar

see chapter 8.3, page 57

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm

with
Fluid Rotary Feedthrough

see Operating Instructions


BA 691 for
Fluid Rotary Feedthrough

13

Technical data

3.3

Technical data
Turret
Turret size

0.5.453. ...

.216

Number of indexing positions

(8) 12 (24)

Adm. mass moment of inertia of tool disk


with holders
Maximum unbalanced load (load torque) of tooling

kgm2

2.5

Nm

32

Operating times 1)
Turret rotation per 30 indexing step

incl. acceleration and braking

0.14

rotation only

0.06

0.14

min-1

18

bar

50

cm3

35

Turret unlock or lock


Maximum indexing frequency 2)
Hydraulic operating pressure

10 %

Hydraulic fluid volumes:


Turret unlock or lock
Mass

Turret including tool disk and slide unit

kg

approx. 300

Maximum tooling

kg

approx. 60

+50 .... +104

+10 ... +40

bar

bar

14

bar

25

Ambient temperature range

Adm. cooling lubricant pressure

constant flow

flow cut off during indexing

with medium pressure valve (Option)

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm

1) Conditions:

standard
version

hydraulic supply adequately dimensioned


turret at operating temperature
with the given mass moment of inertia
without any non-productive times caused by the control

2) There may possibly occur a reduction in the permissible switching


frequency, depending on the cutting efficiency of the tool drive.

14

Technical data

Turret and tool drive


Turret size

0.5.453. ...

.216

Turret drive
max. adm. motor speed

with SW1) 270

min -1

4,000

with SW 340

min -1

2,000

max. adm. motor torque

Nm

10

Turret drive ratio

12

Tool drive S3 - 40%ED, 10 min


max. adm. motor speed
max. adm. motor torque 2)

min
Nm

Drive ratio
Coupling according to DIN 5480
(standard version, further possibilities on request)



8,000
10
2
16x0.8

Use together with SAUTER Spindle units series


0.5.941. ... with patented integrated spindle locking
system, according to Product information PI 29.3,
shank diameter 30mm.
1) SW: Spanner width of the tool disk

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm

2) The torques specified refer to processing without shock loads. When


processing is subject to shock loads (e.g. milling) a reduction in the
values by up to 50% or more needs to be taken into account!

15

Technical data

Slide unit
Turret size

0.5.453. ...

.216

Slide unit drive:

max. adm. motor speed


max. adm. motor torque
max. motor torque continuous duty

min -1
Nm

Nm

Drive ratio of the synchronous belt drive

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm

4,000

Height of stroke

mm

40

Stroke inclusive overshoot

mm

48

Pitch of ball spindle

mm

Quick motion speed

m/min

10

Adm. cutting force for turning

kN

Positioning accuracy

10

16

Admissible loads and dimensions

3.4

Admissible loads and dimensions

carriage
of the machine

additional
fixing device

Illustration corresponds to right-hand version


( left-hand version - mirror image ).

Maximum tangential torque 1) Ttan

Nm

1,500

equivalent tangential torque Fy

5,500

mm

265

mm2

2.5

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ld.fm

at tool overhang D
equivalent
chip cross section A
(St60; ks 2.200 N/mm 2 )

17

Admissible loads and dimensions

Adm. axial load1)

Fz

at tool overhang D
Adm. radial load1)

Fx

8,000

mm

220

10,000

Loads with a calculated safety 1,3

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ld.fm

1) The admissible loads apply when processing without shock loads. In combined
and/or shock load situations (interruptions in cutting), the values will reduce!

18

Assembly and installation

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_li.fm

4.1

Assembly and installation


As-delivered condition

The disk-type tool turret is supplied aligned in Position 1, with or


without tool disk and AC servomotor in accordance with the order.

The pistons have been bled and connections A1 / B1 und L1 are


closed with plastic plugs to prevent hydraulic oil from escaping.

Parts, which are not possible to assemble or parts, which are


necessary for the assembly, are enclosed loose.

The disk-type tool turret has been test run.

The slide unit is locked in its bottom position by means of a


transport retaining device.

The drive motor for the slide unit is not fitted (motor not included in
the scope of delivery).

1.

see Hydraulic diagram HP-... in the appendix to these operating instructions

19

Fitting the turret-drive motor

4.2
4.2.1

Fitting the turret-drive motor


Motor shaft with key groove according to DIN 6885/1

10

7
6

3 2

1. Check the height of the feather key (10) on the motor shaft (1).
If necessary replace or adapt feather key (according to motor
manufacturer).
2. Mount ratchetting clutch (2) on motor shaft (1).
Secure screw (3) with suitable locking fluid (e.g. LOCTITE 221).
3. Check:

Are marking (7) on motor support (8) and pin (6) in pinion (5)
in line?

Is slot (4) in ratchetting clutch (2) in line with the pin (6)?

Is the sealing ring (9) in place and undamaged?

4. Mount AC motor with ratchetting clutch (2) and make sure that
slot (4) and pin (6) engage.
IMPORTANT
Set proximity switch S10 Ratchetting clutch engaged,
F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ac.fm

see chapter 7.7.4 Proximity switch S10 Ratchetting clutch engaged, page 51.

20

Fitting the turret-drive motor

4.2.2

Motor shaft with key clamping hub

TA

2 1

1. Check whether circlip (9) is fitted in the hub of the ratchetting


clutch (2).
2. Fit the ratchetting clutch (2) on motor shaft (1), make sure that the
circlip (9) is in touch with the end face of the motorshaft (1).
3. Tighten hexagon socked screw on ratchetting clutch (2).
Tightening torque TA
[Nm]
M6 DIN 912-12.9

17

M8 DIN 912-12.9

41

M10 DIN 912-12.9

83

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ac.fm

4. Check:

Are marking (6) on motor support (7) and pin (5) in pinion (4)
in line?

Is slot (3) in ratchetting clutch (2) in line with the pin (5)?

Is the sealing ring (8) in place and undamaged?

5. Mount AC motor with ratchetting clutch (2) and make sure that
slot (7) and pin (8) engage.
IMPORTANT
Set proximity switch S10 Ratchetting clutch engaged,
see chapter 7.7.4 Proximity switch S10 Ratchetting clutch engaged, page 51.

21

Fit turret onto the machine

4.3

Fit turret onto the machine

3, 4

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_arm.fm

IMPORTANT
The hole for the pivot bush (2) must already exist in the slide in the
required position and quality.

1. Mount turret together with pivot bush (2) and fasten with screws
and washers (3,4) supplied.
2. Note the tightening torque!

M16 - 12.9

MoS2

280 Nm

22

Align turret

3. Make electrical connections,


see Wiring diagram EP-... and Function diagram SK-... in the appendix to
these Operating Instructions.

4. Make hydraulic system connections,


see Hydraulic diagram HP-... in the appendix to these Operating Instructions.

Central lubrication (1) is not included within the scope of delivery of the
turret.
(For details on how to connect the central lubrication system, see the
operating instructions of the machine).

4.4

Align turret

Pivot bush

1. Lock turret.
2. Align the connecting surface (1) or face surface (3) of the tool disk
parallel or vertical to the feed axes (2).

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_arm.fm

3. Note the tightening torque!

M16 - 12.9

MoS2

280 Nm

23

Fitting the tool disk

4.5

Fitting the tool disk

Working position

(if tool disk not already fitted)

1. Remove the cover plate (2).


2. Clearly mark the rotational position of the teeth (tooth gap to tooth,
item 8) on both bevel gears.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm

3. Remove the coupling sleeve (6), for that:

Loosen circlip (3),

Withdraw the coupling sleeve (6).

4. Force back piston (5) to the stop - direction disk-type tool turret
central point, perhaps slightly open vent screw E.
5. Put the T-slot nuts (7) into their correct angular positions.
6. Fit tool disk (1) in the correct angular position
[- fitting area (9) -].

24

Fitting the tool disk

7. Slightly slacken the screw in the working position to allow the tool
disk to be aligned later. It is covered by the coupling sleeve (6).
8. Insert coupling sleeve (6) in marked position (marking in turret axis
direction) into gearing, using bush (4).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm

9. Insert circlip (3).

25

Align tool disk

4.6

Align tool disk

1. Lock turret with prescribed pressure.


2. Unscrew cover plate (1).
3. Insert plug gauge (4) in locating hole (2) of the tool disk. Put the dial
gauge to machine spindle, scan the plug gauge (4) above and
below.
4. Twist the tool disk, until dial gauge display - difference equals zero.
CAUTION
If this is not done, clutch problems and bearing damage can occur.
5. Tighten screws.

M8 - 12.9

MoS2

39 Nm

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm

IMPORTANT
The screw is covered in working position (3) by the coupling sleeve
and is accessible only after swivelling the tool disk.
6. Screw on the cover plate (1); remember the sealing rings
[are they in place and undamaged?].

26

Electrical installation

4.7

Electrical installation

Circuit,
see Wiring diagram EP-... and Function diagram SK-... in the appendix to
these Operating Instructions.

4.8

Hydraulic system

Circuit,
see Hydraulic diagram HP-... in the appendix to these Operating Instructions.

Filtering 20 m

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ehk.fm

Description of the hydraulically actuated functions

Lock and unlock turret.

Disengage and engage turret drive.

Disengage and engage tool drive.

The functions are initiated via a 4/2-way valve.

All pistons can be bled separately.

The turret has 3 connections: A / B / L.

The leakage oil port L is provided to allow leakage oil to be returned


and to protect the gearbox chamber from overpressure.

27

Cooling lubricant supply

4.9

Cooling lubricant supply

Transmitted through a valve (1) in the working position.


Supply pressure,
see Technical data Turret.

Connection, designated K, on rear bedding plate (2).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ehk.fm

IMPORTANT
In order to achieve an extended service life of the cooling lubricant
valve, it is recommended to filtrate the cooling lubricant by 100 m.
Post-connected loads (spindle units with internal cooling lubricant
guide a.o.) may require a higher degree of filter fineness.
Note and comply with the manufacturer's instructions!

28

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ref.fm

Determination of reference point

4.10

Determination of reference point

1.

Hydraulic pressure: 10 bar !

2.

Lock turret in position 1.

3.

Put marking (2) between tool disk (1) and


cooling lubricant ring (3).

4.

Rotate coupling sleeve until marking (4) points to turret axis.

5.

Unlock turret hydraulically, proximity switch S5 (8) energized.

6.

By means of AC motor, rotate tool disk (1) clockwise (as viewed


on the tool disk (1)) until the proximity switch S1
Reference point turret (5) is deenergized and then energized
again.

7.

Rotate tool disk (1) further until the zero pulse is detected at the
rotary encoder (6). The reference point offset is determined from
this zero pulse.

8.

Rotate tool disk (1) further until the two markings (2) on the tool
disk (1) and on the cooling lubricant ring (3) are positioned exactly
one above the other.

9.

Check the function with spindle units in place.

10. Increase pressure: Hydraulics approx. 50 bar.

29

Additional equipment, toolholders and spindle units

Additional equipment, toolholders and


spindle units
This turret has been designed for use with the following toolholders
and additional equipment:

5.1

toolholders with cylinder shank for stationary tools

spindle units with cylinder shank for drive tools

Toolholders and spindle units

Use only toolholders, spindle units and plugs with O-ring in


accordance with DIN 69 880 Part 1 (July 1990 Issue).
For information on SAUTER toolholders and spindle units for the
SAUTER disk-type tool turret 0.5.450/460.2.../3... please ask for
Product information PI 29.3.
The warranty loses its validity if defective third-party makes
are used.

CAUTION
Functional faults may be caused by an ingress of chips and
contamination. Close open tool locations and cooling lubricant bores by
means of closing plugs Z2-30 according to DIN 69 880.

If at all possible, change the toolholder in a horizontal position!

Clean contact surfaces of tool disk and toolholder.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm

Tightening torques for the locking screws for the thrust pieces

Shank diameter d1
DIN 69 880
[mm]

Max. tightening torque TA max


[Nm]

20

10

25

10

30

25

40

50

50

50

30

Toolholders and spindle units

5.1.1

Installing/changing the toolholders

Chips
Cooling lubricant

TA max

5
6

1. Check the sealing rings (4) on the new toolholder (6) [make sure
they are in place and undamaged!].
2. Pay attention to position of the aligning shoulder (2); if necessary
modify.
3. Unscrew pressure pieces (1).
4. Remove toolholder (6) or seal plug (3) to be replaced.
5. Insert new toolholder. Tighten thrust piece (1) with 20% of
maximum tigthening torque.
6. Align toolholder to centre of rotation with set screws (5).
7. Firmly screw on pressure piece (1). Observe tightening torques,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm

see table Tightening torques for the locking screws for the thrust pieces, page
30.

31

Toolholders and spindle units

5.1.2

Installing/changing the spindle units


CAUTION
Do not change tools while the tool disk is in the working position as
this can cause overloading of the drive train!

1 - ENgaged

2 - DISengaged

1. Check:

Are the sealing rings in place and undamaged?

Is the clutch profile undamaged and has it been cleaned?

Is the spindle locking mechanism engaged?

2. Remove toolholder (6) or seal plug (3) to be replaced.


3. Insert new holder. Tighten thrust piece with 20% of maximum
tigthening torque. Observe index position of spindle units (7).
4. Align holder to centre of rotation with set screws (5). [Necessary
with angled spindle units]. If necessary modify aligning shoulder.
5. Firmly screw on thrust piece (1). Observe tightening torques,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm

see table Tightening torques for the locking screws for the thrust pieces, page
30.

32

Maintenance

Maintenance

WARNING
Danger of serious injury in result of
sudden movement of the slide unit.
Before start working with the slide unit
secure the slide in lowest stop position.

Clearing required prior to any works

6.1

Use the EMERGENCY-OFF switch of the machine.

Set motor protection switch for disk-type tool turret into OFF
position.

Lubricant table

Lubrication of the roller bearings, bevel gears and seals

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm

Element

Amount of lubricant

Roller
bearings

Initially:
Fill 1/3 of bearing space

Seals

Fill space around sealing lips

Toothing

Fill teeth gaps

Lubricant

ISOFLEX NBU 15

Manufacturer

Klber

33

Check lubricant of turret gearbox chambers

6.2

Check lubricant of turret gearbox chambers

The condition of the lubricant must be checked after no more than


4,000 operating hours. Before checking, remove the
proximity switch S1 Reference point turret (1) or
VSTI plug (2).

Possible conditions of the turret chamber when checking

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm

Condition of
grease

Grease
None left

Severely
used

Mixed with water

Mixed with oil

Cause

Natural wear

Turret sealing
defective

Hydraulic seals
in turret defective

Action
needed

Add approx. 20 g of
grease

Risk of breakdown! Call for


service (Check
turret sealing).

If oil loss 1 cm3/


minute: Call for
service.

34

Bevel gears and roller bearings on gearbox nose

6.3

Bevel gears and roller bearings on gearbox nose

6.4

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm

6.5

Bevel gears (1) and roller bearings (2) can be accessed after
removing the cover plate (3). Regrease the bevel gears and check
for unwanted cooling lubricant after 4,000 operating hours, see table
Lubrication of the roller bearings, bevel gears and seals, page 33.

Spindle units

Clean clutch profile each time before using.

Lubricant should be checked according to the conditions of use but


after no more than 2,000 operating hours.

Slide unit

The guide of the slide unit is greased by the centralized lubricating


system of the machine.

Proportioning by intergrated proportioning valves.

The number of grease pulses may be adapt to the machine. The


minimal number of gear pulses is 1 pulse per hour.

35

Fault finding and repair

Fault finding and repair

WARNING
Danger of serious injury in result of
sudden movement of the slide unit.
Before start working with the slide unit
secure the slide in lowest stop position.

7.1

Faults and remedies

Fault

Cause

Remedy

Implementation

1. Turret
gears damaged

replace damaged
parts

service

drive motor defective

replace motor

user

axis misaligned relative


to locating disk

align the axle to


the locating disk

service

proximity switch S1
defective or misadjusted

check proximity
switch, replace if
necessary, or readjust

does not engage /


disengage

clutch sleeve damaged

replace damaged
parts

user

does not rotate

drive motor defective

replace motor

user

gearwheels damaged

replace damaged
parts

service

does not swivel

does not lock

user,
see 7.7.1,
page 47

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm

2. Tool drive

36

Fault finding and repair

Fault

Cause

Remedy

Implementation

3. Center height
is not correct,
tool disk
misaligned relative
to locating disk

collision with turret in a


locked condition

turn back tool disk


in ring groove, and
align

service

4. Cooling lubricant
is not being
transferred

outlet between
tool disk and turret

cooling lubricant valve


damaged

replace damaged
parts

cooling lubricant valve/


line blocked

blow cooling
lubricant valve and
line clear

cooling lubricant valve


leaking

replace cooling
lubricant valve

user,
see 7.6, page 46

user

user
see 7.6, page 46

5. Ratchetting clutch

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm

is disengaged

preset torque exceeded

engage ratchetting
clutch as per
manual,
adjust the current
limiter at the motor

user
see 7.2, page 39

37

Fault finding and repair

Fault

Cause

Remedy

Implementation

6. Slide unit
center heigth no
longer correct

no movement
possible in slide
direction

incorrect
positioning in slide
direction

turret displaced in slide


unit

realign turret

user

drive motor defective

replace motor

user

synchronous belt torn

replace
synchronous belt

see 7.4, page 41

proximity switch S13


misadjusted

check proximity
switch, replace if
necessary, or
readjust

motor shaft encoder or


control unit defective

replace motor

user
see 7.7.5, page 53

user

Service
SAUTER Feinmechanik GmbH
Carl-Zeiss-Strae 7
D-72555 Metzingen
Germany
Telephone
Fax
Telex
e-mail

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm

user

++49 (0) 7123 926 0


++49 (0) 7123 926 193
254 328 wisa
service@sauter- gmbh.com

38

Engaging the ratchetting clutch

7.2

Engaging the ratchetting clutch

Variant A

Variant B

CAUTION
After disengaging the ratchetting clutch check the locking state!

7.2.1

Variant A: Motor with brake


Procedure, if the turret is unlocked:

1. Dismount tool in working position.


2. Turn the tool disk (7) manually until ratchetting clutch (2) engages.
3. Check on proximity switch S10 (1).
4. Drive to reference point.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_kupp.fm

Procedure, if the turret is locked:

1. Dismount tool in working position.


2. Rotate coupling sleeve (6) with hexagon wrench (5) until ratchetting
clutch (2) engages.
3. Check on proximity switch S10 (1).
4. Drive to reference point.

39

Engaging the ratchetting clutch

7.2.2

Variant B: Motor without brake


Procedure, if the turret is unlocked:

1. Turn tool disk by hand approximately to position 1 1.5.


2. Put out the tool in position 1.
3. Lock hydraulically => turret is locked.

Procedure, if the turret is locked:

1. Rotate coupling sleeve (6) jerky with hexagon wrench (5) until
ratchetting clutch (2) engages.
2. Check on proximity switch S10 Ratchetting clutch engaged (1).
3. Drive to reference point.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_kupp.fm

IMPORTANT
The ratchetting clutch has only one latching position.

40

Belt replacement belt tension

7.3

Determining belt tension on the slide unit

5N

s/2
s

7.4

Belt replacement belt tension

F:\Sauter\FRAME-AR\TD\0-5-453-\453_riem.fm

1. Move to lowest stop position.


2. Switch off power to turret.
3. Unscrew the 3 screws (2).

41

Belt replacement belt tension

4. Use the drive motor to move the plate (4) such that the
synchronous belt can be removed.
5. Remove existing synchronous belt (1) and clean abrasions from
turret.
6. Mount new synchronous belt.
7. Tense synchronous belt (1) by lever in hole (3) - pay attention to
test load,
see chapter 7.3 Determining belt tension on the slide unit, page 41

8. Fasten the screws (2).

F:\Sauter\FRAME-AR\TD\0-5-453-\453_riem.fm

9. Move away lever.

42

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm

Basic setting

7.5
Basic setting

43

Basic setting

1.

Install turret hydraulically. Reduce hydraulic pressure to 10 bar for


the purposes of setting.

2.

Install turret electrically, without AC servo motor.

3.

Unlock hydraulically (pressure approx. 10 bar). If not possible via


control, relocate connector on hydraulic valve.

4.

Turn tool disk by hand approximately to position 1 1.5.

5.

Lock hydraulically.

6.

Align tool disk (1) in accordance with description,


see chapter 4.6 Align tool disk, page 26

7.

Mark exactly the rotational position of tool disk (1) and cooling
lubricant ring (3).

8.

Turn gearwheel (6) by hand until pin (11) and marking (18) line up.

9.

Unlock hydraulically, take down proximity switch S4, place round


sock (9) - approx. 15 mm thick - between control piston (5) and
housing.

10. Lock hydraulically; marking on tool disk (1) must be in line with
that of the cooling lubricant ring (3).
11. Pull plug (7), take down the bore-circlip ring (17), remove the
pinion shaft (13) to the back, until the gearing (12 and 16) is
disengaged.
12. Turn coupling sleeve (4) until marking - centre tooth - is in line with
the turret axis.
13. Carefully place straight spindle unit, centered locking, in working
position and tighten.
14. Unlock disk-type tool turret hydraulically. Do not remove round
sock (9), mark rotational position of spindle locking mechanism
with a pencil (15).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm

15. Move pinion shaft (13) axial until the gearing (12) is engaged; go
on moving and try, if it is possible to engage the gearing (16)
without big expenditure of force. Displace the pinion shaft in the
gearing until it is possible to engage both gearings (12 and 16)
without big expenditure of force. While doing it the marking (15) at
the spindle unit (14) must not twist.
IMPORTANT
In case of best gearing it is not possible to assemble the neighbouring
rotational positions.
16. Lock hydraulically and observe the spindle head while doing so.
When locking, the rotational position at the spindle head should be
maintained.
If necessary, correct as described under step 15.

44

Basic setting

17. Fit bore-circlip ring (17) and plug (7).


18. Fit AC servo motor with ratchetting clutch in correct position and
install electrically.
19. Hydraulically unlock disk-type tool turret, remove round sock (9),
and add proximity switch.
20. Increase hydraulic pressure up to 50 bar.
21. Determine reference point,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm

see chapter 4.10 Determination of reference point, page 29.

45

Replacing the cooling lubricant valve

7.6

Replacing the cooling lubricant valve

1
2

1. Unscrew the grub screw (1), through several turns.


2. Remove the valve carrier (2). The valve bushing (3) is now
accessible.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_akm.fm

3. Install in reverse order.

46

Replacing and setting the proximity switches

7.7

Replacing and setting the proximity switches


For location of the proximity switches,
see Wiring diagram EP-... in the appendix to these Operating Instructions.

7.7.1

Proximity switch S1 Reference point turret

0.6

Changing the proximity switch

1. Loosen clamps (1).


2. Pull out holder (2) for proximity switch (5), measure
dimension X and note this.
3. Unscrew thrust screw (3).
4. Unscrew proximity switch (5).
5. Fit new proximity switch with existing sealing ring and
disk (4), and screw into holder (2); but replace sealing ring, if
necessary.
IMPORTANT
If necessary, redetermine the reference point after replacing
proximity switch S1,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NhS.fm

see chapter 4.10 Determination of reference point, page 29.

47

Replacing and setting the proximity switches

Setting the proximity switch


1. Put the turret into any defined position (pos. 1... 4..) - lokked
or unlocked.
2. Set the proximity switch (5) according to the noted
dimension X, or measure dimension a with depth gauge,
paying attention to hole (10) and gear (9).
Set proximity switch (5) to X = a - 0.6 and lock with thrust
screw (3), during that control dimension X.
3. Insert holder (2) and fasten.
4. Electrically install proximity switch (5).
5. Check - proximity switch energized.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NhS.fm

6. Check - proximity switch deenergized when hole (10) under


proximity switch.

48

Replacing and setting the proximity switches

Proximity switch S4 Checking turret drive disengaged and


proximity switch S5 Checking turret drive engaged

0.6

7.7.2

Changing the proximity switch


1. Loosen clamps (1) and pull out holder (2).
2. Measure dimension X and note.
3. Unscrew thrust nut (4) and inset (5).
4. Unscrew proximity switch (3).
5. Screw the new proximity swich in the holder (2).
6. Set the proximity switch according to the noted dimension X
or measure dimension a with depth gauge, set proximity
switch to X = a - 0.6 and counterlock with inset (5) and
thrust nut (4), during that control dimension X.
7. Position holder (2) in hole and fix with clamps (1).
8. Install proximity switch (3) electrically.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NhS.fm

Setting the proximity switch


1. Lock turret;
proximity switch S4 can now be set.
Unlock turret;
proximity switch S5 can now be set.
2. Loosen clamps (1); turn holder (2) until proximity switch (3) is
deenergized.
3. Move back through about 90.
4. Fix holder (2) with clamps (1).
5. Check switching function several times.

49

Replacing and setting the proximity switches

7.7.3

Proximity switch S6 Checking tool drive engaged and


proximity switch S7 Checking tool drive disengaged
1

Eccentric

0.6

S6

Engaged

0.6

Disengaged

S7

Replacing the proximity switch


1. Unscrew clip and pull proximity switch (2) out from eccentric
bush (1).
2. Fit new proximity switch (2).
3. Fit new proximity switch (2) with gap to switching surface.
4. Take cable through hole (4) in terminal box and install
electrically,
see Wiring diagram EP-... in the appendix to these Operating
Instructions.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NhS.fm

Setting the proximity switch


1. Lock turret;
proximity switch S6 can now be set.
Unlock turret;
proximity switch S7 can now be set.
2. Undo fixing screw (3); set proximity switch (2) to correct gap
with 0.6 mm shim.
3. With eccentric bush (1), set proximity switch centre on
circuit board.
4. Check switching function several times.

50

Replacing and setting the proximity switches

Proximity switch S10 Ratchetting clutch engaged

0.6

7.7.4

Changing the proximity switch


1. Loosen clamps (1) and pull out holder (2).
2. Measure dimension X and note.
3. Unscrew thrust nut (4) and inset (5).
4. Unscrew proximity switch (3).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NhS.fm

5. Screw new proximity switch into holder (2).


6. Set proximity switch according to noted dimension X or
measure dimension a with depth gauge, set proximity switch
to X = a - 0.6 and counterclock with inset (5) and
thrust nut (4), during that control dimension X.
7. Position holder (2) in hole and fix with clamps (1).
8. Install proximity switch (3) electrically.

51

Replacing and setting the proximity switches

Setting the proximity switch


1. Ratchetting clutch engaged.
2. Slightly slacken clamps (1).
3. Set initial state for proximity switch as attenuated (LED on),
turn holder (2) if necessary.
4. Turn holder (2) until signal change is detected as
unattenuated (LED off).
5. Turn back holder (2) by approx. 45 (LED on).
6. Fix holder (2) with clamps (1).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NhS.fm

7. Check: rotate ratchetting clutch by 360; the LED must be


permanently illuminated.

52

Replacing and setting the proximity switches

7.7.5

Proximity switch S13 Reference point slide unit

3
0.6
2

Changing the proximity switch

1. Loosen setscrew (3).


2. Pull out bush (2), measure dimension X and note.
3. Unscrew proximity switch (1).
4. Screw new proximity switch into bush (2) and fasten with
setscrew (3) - maximum tightening moment 0.2Nm!
IMPORTANT
If necessary, redetermine the reference point of the slide unit after
replacing of proximity switch S13.

Setting the proximity switch

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_NS_S13.fm

1. Set the proximity switch according to the noted dimension X


or measure dimension a with depth gauge, set proximity
switch to X = a - 0.6, during that control dimension X.
2. Insert bush (2) and fasten.
3. Electrically install proximity switch (1).
4. Check - proximity switch energized.
5. Check - proximity switch deenergized.

53

Replacement parts

8
8.1

Replacement parts
Proximity switches

IMPORTANT
Only use the order form if you wish to order any replacement parts.

Table: Summary: Proximity switches

Denomination
S1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_NHS.fm

S4
S5

Proximity switch
Reference point turret

Proximity switches
Turret drive
disengagedand
Turret drive
engaged

Figure

Denomination

2 3 4

Ident
No.

Qty.

Proximity switch

004 157

Sealing ring

061 465

Thrust ring

061 466

O-ring

060 308

Proximity switch

076 749

Thrust nut DIN 46320

081 754

Inset DIN 46320

081 755

O-ring

060 308

2
3
4

54

Proximity switches

Table: Summary: Proximity switches

Denomination
S6
S7

S10

Figure

Proximity switches
Tool drive
engaged and
Tool drive
disengaged
Proximity switch
Ratchetting clutch
engaged

Denomination
1
2
3

Ident
No.

Qty.

Proximity switch

076 749

Eccentric bush

059 349

Clip

034 133

Proximity switch

004 157

Thrust nut DIN 46320

081 754

Inset DIN 46320

081 755

O-ring

060 308

Proximity switch

004 157

Bush

036 515

Setscrew DIN 913 - 45H

000 245

3
4

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_NHS.fm

S 13

Proximity switch
"Reference point slide unit"

55

Tool disk

8.2

Tool disk

Clamping for tool holders


DIN 69880 (standard)

1)

d
[mm]

Ident-N

Qty.

18

067 502

..1.)

22

042 973

1.)

28

042 784

1.)

36

043 287

1.)

42

043 951

1.)

Number of positions

F:\Sauter\FRAME-AR\TD\0-5-695-\eng\760_8_WzSch.fm

IMPORTANT
Only use the order form if you wish to order any replacement parts.

56

Cooling lubricant system

8.3

Cooling lubricant system


The cooling lubricant transfer of the disk-type tool turret can be
designed variously,
see chapter 3.2 Possible options and deviating designs, page 13.

1
2

6 5

9 8

IMPORTANT

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_KE16.fm

Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

060 885

FU-groove ring

064 593

O-ring

036 588

Spaghetti hose

0.6m

for standard version


4

101 904

Cooling lubricant valve, complete

of this:
5

033 424

Bush

059 658

O-ring

57

Cooling lubricant system

No.

Ident-No.

Denomination

Qty.

for medium pressure valve


7

101 353

Cooling lubricant valve, complete

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_KE16.fm

of this:
8

086 925

Bush

058 501

O-ring

58

Gear head

8.4

Gear head

10

140
130

120

100
90
20
80

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GeKo16.fm

70

60

30

50

40

IMPORTANT
Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

10

039 405

FU groove ring

20

084 301

Angular ball bearing

59

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GeKo16.fm

Gear head

No.

Ident-No.

Denomination

Qty.

30

062 201

Deep groove ball bearing

40

067 468

O-ring

50

085 017

Rotary shaft seal

60

030 013

Stepped ring

70

058 521

O-ring

80

067 467

O-ring

90

084 912

Surface ring

100

062 132

O-ring

120

067 228

O-ring

130

062 351

O-ring

140

058 521

O-ring

60

Housing and indexing unit

8.5

Housing and indexing unit

220

150
210
200

230

190

210
240

180

250

170
260

160

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GuIndex16.fm

150

IMPORTANT
Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

150

077 321

ROTO surface ring

160

058 076

O-ring

170

064 915

T-slot nut

11

61

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GuIndex16.fm

Housing and indexing unit

No.

Ident-No.

Denomination

Qty.

180

077 298

FU groove ring

190

058 951

O-ring

200

063 466

O-ring

210

076 787

Surface ring

220

074 390

O-ring

230

058 665

O-ring

240

060 801

O-ring

250

040 937

Thrust needle roller and cage assembly

260

079 073

Added-process part

62

Carrier and gearbox

8.6

Carrier and gearbox


320
330

340
310
350
300
290
360
280

370
380
390
400

410

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_TuG16.fm

IMPORTANT
Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

280

033 929

Rotary shaft seal

290

077 325

Needle roller and cage assembly

300

036 584

Needle bearing cup with open end

310

084 404

Auxiliary cylinder

320

000 008

DU bush

330

076 677

Deep groove ball bearing

63

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_TuG16.fm

Carrier and gearbox

No.

Ident-No.

Denomination

Qty.

340

084 030

Inner ring of needle roller bearing

350

076 677

Deep groove ball bearing

360

066 853

O-ring

370

065 138

Rotary shaft seal

380

073 354

Deep groove ball bearing

390

076 753

O-ring

400

058 501

O-ring

410

067 228

O-ring

64

Slide unit

8.7

Slide unit

Motor Fanuc 2/3000


with brake

Motor Siemens
1 FT6061 with brake

MA =2.9Nm

MA =12Nm

IMPORTANT
Only use the order form if you wish to order any replacement parts.

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ers_SchlE.fm

No.

Ident-No.

Denomination

Qty.

085 794

Synchronous belt

085 788

Axial angular contact ball bearing

65

Ordering replacement parts

FAX

Company:

++49 (0) 7123926193

Street:
++49 (0) 71239260
Post Code
Location:
service@sauter-gmbh.com
Name:
After Sales Service
SAUTER Feinmechanik GmbH
Postfach 1551
D-72545 Metzingen
Germany

Assembly

Ident-N

Tel.:
Fax:

Denomination

Read off the following data from the type plate and always complete.

Typ
Ident-Nr.
Com. Nr.

We will be pleased to answer your enquiries and receive your feedback information.

Qty.

Anhang

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\640_Anhang.fm

Appendix

Wiring diagram . . . . . . . . . . . . . . . . . . . . .EP-1039 e

Function diagram . . . . . . . . . . . . . . . . . . . SK-1226 e

Hydraulic diagram . . . . . . . . . . . . . . . . . . . HP-446 e

67

Installation and
Operating Instructions
Hinge band conveyor type S
GB

Hinge band conveyor type S

Table of contents
Page
1

Description of machine and functions .............................................................................. 5

Danger and safety instructions .......................................................................................... 6


2.1 General instructions ....................................................................................................... 6
2.2 Instructions for repair and maintenance work and malfunctions ................................... 7

Unpacking and handling ..................................................................................................... 8


3.1 Unpacking ...................................................................................................................... 8
3.2 Handling ......................................................................................................................... 8

Assembly and installation ................................................................................................ 9


4.1 Screwing together several container parts .................................................................... 9
4.2 Electrical connection ...................................................................................................... 9
4.3 Loosening the tension device hinge band .................................................................... 10
4.4 Mounting the hinge band ............................................................................................. 12
4.5 Mounting the shackle type connectors ........................................................................ 13
4.6 Mounting the locking bolts ........................................................................................... 14
4.7 Tensioning the hinge band ........................................................................................... 16

Switching on and operating ............................................................................................. 18


5.1 Before initial operation ................................................................................................. 18
5.2 Switching on ................................................................................................................. 18
5.3 Switching off ................................................................................................................ 18

Maintenance ....................................................................................................................... 19
6.1 Adjusting the drive shaft .............................................................................................. 19
6.2 Changing the broach bars ........................................................................................... 19
6.3 Checking the hinge bande tension ............................................................................... 20
6.4 Changing individual hinge band plates ......................................................................... 20
6.4 Maintenance table ....................................................................................................... 18

Information on coolants / tanks ....................................................................................... 21

Maintenance table ............................................................................................................. 22

Eliminating malfunctions ................................................................................................. 25

10 Accessories ....................................................................................................................... 26
10.1 Stripping device ........................................................................................................... 26

Hinge band conveyor type S

1 Description of machine and functions


Function
-

Conveying metal shavings and small parts

Prepurifying the cooling lubricant (for wet processing)

Scope
-

Decentral use in single and interlinked machine tools

Central use for waste disposal from machine groups and entire production areas

Suitable for long swarfs, snarl chips, wool-type filings, dry and wet processing

Mode of operation
-

Loose material falls in feed opening onto the endless hinge band

Continuous transfer of the loose material to the discharge opening

Throwing the loose material at the discharge opening into the container or another
conveyer for removal.
- Do not use the plant for other than the intended purposes.
- Note the Regulation for the Prevention of Accidents (Unfallverhtungsvorschrift) VBG 10 when operating the plant.
- The discharge station must be visible during machine controlled operation.

Noise level: < 70 dB(A)


Optional equipment
-

Coolant tank
Coolant purification systems (e.g. magnetic separator, centrifugal separator,
band filter, superfine strainer)
Low lift and jetting pumps for purification elements and machines
Swarf mill
Brush-off device
Sustainer
Chip carriage
Sieve drum
Piping with aggregates, valves, etc.

Since nearly every plant is constructed for the special needs of the customer, deviations from the form and position of the parts and structural
components described in this documentation may occur. In this case the operating instructions should be applied analogously.

Hinge band conveyor type S

2 Danger and safety instructions


2.1 General instructions
- Always observe all statements and instructions in the
operating instructions delivered with the plant.
- It is forbidden for unqualified persons to work at the plant.
- Observe correct fastening if components were installed by
customer.
- Never bypass safety contrivances (e.g. safety clutch).
- The operation of safety contrivances must always be
guaranteed.

- Work on the electrical plant may only be carried out by


qualified personnel.
- Observe the relevant VDE requirements and connection
requirements of the responsible Electricity Board.

- Do not stand in or reach into the feed opening.

- Do not reach into the discharge opening.

- Cover the scraper belt and all driving elements before


starting.
- Do not remove covers while plant is in operation.

Hinge band conveyor type S

2.2 Instructions for repair and maintenance work and for malfunctions

- Switch off the main switch.


- Secure the plant against being started accidentally.

- Ensure that the plant is dead.

- Depressurize the plant.

- Close pipe valves.


- Remove all noxious materials.
- Coolants must not enter the environment.

- When handling chips, wear protective clothing, safety boots


and protective gloves.

Hinge band conveyor type S

3 Unpacking and handling


3.1 Unpacking
Scraper conveyors over 8 m in length are delivered in several container parts.
The hinge bands of divided conveyors are rolled up on separate pallets.
For conveyors in several parts, scraper belts are rolled up on separate pallets.
Small parts (screws, sealings etc.) are delivered loose in the scraper conveyor
container or in separate packing.
If mounting rails are required for inserting the hinge band, they are fastened to the
hinge band or pre-mounted on the hinge band conveyor and lacquered in red.
Mounting rails must absolutely be preserved because the hinge band cannot be
inserted without them.

3.2 Handling
- Do not stop beneath suspended loads!

By crane:
Always transport by crane if no longer in the
original packing. Use the suspension devices
provided (e.g. eye hooks, lifting screws)

By stacker truck:
Only in the original packing and
with the greatest of care.

Hinge band conveyor type S

4 Assembly and installation


- Put plant on even ground!
- Ensure a firm and secure position.
- Secure the plant against being started accidentally.

4.1 Screwing together several container parts


-

Join container parts at the joint locations and align in parallel.


Note identification markings (2) of the container flanges.
The identification marking (numbers or symbols) must agree with that of the opposite
flange (3).

(1)

1
2

Insert the sealings supplied (1) and join container parts completely.

Align the containers such that all bore holes are in alignment with the container flanges
opposite.

Insert but do not tighten hexagon head screws and hexagon nuts.

Drive in preassembled rollpin spring (4).

Tighten hexagon head screws

4.2 Electrical connection


-

Connect power supply to motor(s) and pump(s)

Note the correct direction of rotation (see arrow)


9

Hinge band conveyor type S

4.3 Loosening tension device hinge band


Type 1
type 1
Model with flange bearing:
-

Remove the top coverings (2)

Loosen the fastening screws (4) on both


sides of the gearing end frame but do not
unscrew completely

Loosen clamping bolts (3) on both sides of


the gearing end frame and turn backward
completely

Loosen hexagon head cap screw (5) on


both sides and remove hand guard (6)

Push backward gearing end frame (1)


against the conveying direction to the stop

Tighten fastening screws (4) on both sides


of the gearing end frame

Mount hinge band mounting rails


(see Chapter 4.4)

6
5

3
4

Type 2
2

type 2
Model with pedestal bearing:
-

Dismantle protective covering at the drive

Loosen the fastening screws (1) on the drive


motor (2)

Turn back clamping bolts (3) on both sides

Release the tension of the drive chain by


moving the drive motor in the direction of
the arrow (2)

Loosen the fastening screws (4) on the


pedestal bearing

On both sides, evenly screw in the clamping


screws (6) and tighten the hinge band in the
direction of the arrow

Tighten the fastening screws (4) at the


pedestal bearing

Mount hinge band mounting rails


(see Chapter 4.4)

10

1
1
3

6
4

Hinge band conveyor type S

Type 3
Model with band support:
-

Disassemble hand guard (1) on the left and on


the right by removing the fastening screw (6)

Loosen the fastening screws (2) on both sides


of the drive motor (3) but do not unscrew
completely

Loosen lock nuts (4) of the clamping bolts (5)

Turn back the clamping bolts (5) completely

Push backward the drive motor against the


conveying direction (direction of arrow) to the
stop

Tighten fastening screws (2) on both sides of


the drive motor

Mount mounting rails (see chapter 4.4)

Type 3

2
2

2
5

Type 4

Type 4

Deflection side model:


-

Loosen lock nuts (2) of the clamping bolts (3)


on both sides

Open the clamping bolts (3) at the guide roller


as far as possible

Press the guide roller (1) towards the


discharge opening (direction of arrow)

Fix clamping bolts (3) with lock nuts (2)


in loosened position on both sides

Mount mounting rails (see chapter 4.4)

2
3
11

Hinge band conveyor type S

4.4 Mounting the hinged band


1
For heavy, divided hinge bands, mounting rails
(2) are included in the delivery. The hinge band
cannot be inserted without mounting rails!
Keep mounting rails (2) !

2
3

4
-

Position the beginning of the hinge band (3) on the


mounting rails (2)
The driver webs (6) of the hinge band point
upward in conveying direction.
The side rims (5) of the hinge band must
be closed at the back (against conveying
direction).

Turn the drawing chain wheel (1) so that the first


roller (3) of the hollow pin chain can be pushed into
a tooth space

Insert the hinge band into the container (4)

Insert the hinge band up to the guide sprocket


wheel using the drive motor in jogging skip or the
crank handle
- Danger of injuries during the
inserting procedure:
- Never touch movable parts of the
hinge band conveyor with the
hands!
- Do not pull or push the hinge band
without the proper tools!

5
6

7
If the hinge band jams and piles up:
Briefly change the sense of rotation of drive
motor or crank handle.
-

When the hinge band has reached the guide


sprocket wheel:

Use a hook (7) or a suitable tool to pull the hinge


band around the chain wheel. At the same time,
switch on or slowly move on the drive motor in
jogging skip

12

Hinge band conveyor type S

- Danger of injuries!
- Never pull the hinge band around
the guide sprocket wheel by hand
-

Continue the inserting procedure until the


beginning of the hinge band has reached the
drawing chain wheels.

Steadily pull the hinge band with a hook or a


suitable tool in conveying direction to avoid
piling up or jamming.

Switch off the drive motor


9

Only Type S2:

Position the beginning of the hinge band on


the mounting rails (10)
Insert a roller (8) between the cover plates
(9) of the hollow pin chains and fasten with
locking bolts (11). Blocking of the hinge
band (12) is thus rendered more difficult

10
11
12

Depending on the hinge band size, two or


more people are needed for inserting. The
drive motor or a crank handle can be used
for inserting. See chapter 6.2 for mounting
the crank handle

4.5 Mounting the shackle type connectors


-

Insert the roller (3) between the cover


plates (2) of the hollow pin chain (only
required for Type S2)

Connect the ends of the hollow pin chains


with shackle type connectors (1)

The bolts of the shackle type


connectors (1) point outward.
-

Place the cover plates (4) onto the


inserted shackle type connectors

Mount the locking rings (5)

Remove the mounting rails


13

Hinge band conveyor type S

4.6 Mounting the locking bolts


Type 1
Type 1
Model with flange bearing:
-

Turn the hinge band such that the


connecting brackets of the hinge band
plates are flush with the mounting
boring (4)
Mount a washer (2) with split-pin (1) on
the locking bolt (3)

Join the hinge band plates.

Put the locking bolts (3) through the


shackle type connectors (7) and the
connecting brackets (6) of the joint
hinge band plates

Mount the second washer (2) and split-pin


(1) on the locking bolt

1
3
2

1
2

Type 2
Type 2
Model with pedestal bearing:
-

Turn the hinge band such that the


connecting brackets (6) of the hinge
band plates are accessible through
the oblong hole (5)

Mount a washer (2) with split-pin (1) on


the locking bolt (3)

Join the hinge band plates

Put the locking bolts (3) through the


shackle type connectors (7) and the
connecting brackets (6) of the joint
hinge band plates

Mount the second washer (2) and split-pin


(1) on the locking bolt

1
3

1
2

Dismantling is carried out in reverse


order

3
7
14

Hinge band conveyor type S

Type 3
Type 3

with band support:


-

Turn the hinge band such that the


connecting brackets of the hinge band
plate are in flush with the mounting
boring (8)

Mount a washer (2) with split-pin (1)


on the locking bolt (3)

Join the hinge band plates

Put the locking bolts (3) through the


shackle type connectors (7) and the
connecting brackets (6) of the
joint hinge band plates

Mount the second washer (2) and


split-pin (1) on the locking bolts

1
1

3
2

Type 4
Deflection side model:
-

Turn the hinge band such that the


connecting brackets (6) of the hinge
band plates are accessible through the
oblong hole (8)

Mount a washer (2) with split-pin (1)


on the locking bolt (3)

Join the hinge band plates

Put the locking bolts (3) through the


shackles type connectors (7) and the
connecting brackets (6) of the joint
hinged band plates

Type 4
8

2
3

Mount the second washer (2) and


split-pin (1) on the locking bolt

Dismantling is carried out in


reverse order.

3
7

15

Hinge band conveyor type S

4.7 Tensioning the hinge band


Type 1

Type 1
Model with flange bearing:
-

Loosen the fastening screws (3) on both


sides of the gearing end frame

Loosen the lock nuts (1) of the clamping


bolts (2) on both sides

On both sides, evenly screw in the clamping


bolts in the direction of the arrow

Check hinge band tension as described in


chapter 6.3

Tighten the lock nuts of the clamping screws

Tighten the fastening screws (3) at the gear


end frame

1
2

Type 2

Type 2

Model with pedestal bearing:


-

Loosen the fastening screws (1) at the


drive motor (2)

Turn back the clamping bolts (3) on both


sides

Loosen the fastening screws (4) on the


pedestal bearing on both sides

On both sides, evenly screw in the clamping


bolts (5) and tension the hinge band in the
direction of the arrow

Check hinge band tension (see chapter 6.3)

Tighten the fastening screws (4) at the


pedestal bearing

Tension the drive chain by means of the


clamping bolts (3) by moving the drive
motor (2) in the direction of the arrow

Check the chain tension of the drive


chain (see chapter 8)

16

1
1
3

5
4

Hinge band conveyor type S

Type 3
Type 3

with band support:


-

Loosen the fastening screws (1) on both


sides of the gearing end frame (4), but
do not unscrew completely

Loosen the lock nut (2) of the clamping


bolt (3) on both sides

On both sides, evenly tighten the


clamping bolts while checking the hinge
band tension continuously as described
in chapter 6.3

Tighten lock nuts (3)

Tighten fastening screws (1) on bothsides


of the gearing end frame (4)

4
1
3
2
Type 4
Deflection model:
-

Loosen lock nuts (2) on both sides

On both sides, evenly tighten the clamping


bolts (3) in the direction of the arrow

Check hinge band tension continuously as


described in chapter 6.3

Check the adjustment of the guide roller (1)


(see chapter 6.3)

Tighten lock nuts (2)

Type 4

2
3
17

Hinge band conveyor type S

5 Switching on and operating


5.1 Before initial operation
-

Electrical components must be connected by qualified personnel (note voltage, frequency,


strength of current and direction of rotation)

Do a leak test on pipings for liquids (possible transport damage)

Set all switches at 0 or OFF

Fill up with required liquids (coolants, lubricants, oils, etc.)

The entire installation must be free of coarse parts (tools, etc.)

5.2 Switching on
- Make sure that nobody is in the danger area of the hinge band conveyor!
- For the operation of the installation, the regulations for prevention of
accidents VBG 10 must be observed!
- All danger areas accessible to people must be covered!

Sequence for switching on:


-

Lifting pump(s)*
Low lift pump(s)*
Scraper conveyor
Auxiliary aggregates (swarf mill, sieve drum, magnetic drum etc.)*
Jetting pump(s)*

5.3 Switching off


Switch off scraper conveyors with coolant system with a time delay of approx. 5 mins. to
the processing machine (purification of the coolant)
Sequence for switching off:
-

Jetting pump(s)*
Low lift pump(s)*
Lifting pump(s)*
Auxiliary aggregates (swarf mill, sieve drum, magnetic drum etc.)*
Scraper conveyor

*if supplied with this model

18

Hinge band conveyor type S

6 Maintenance
6.1 Adjusting the drive shaft
Only necessary if distance A is not the
same on both sides
-

Loosen the axial shaft locks on both sides of


the drive shaft bearings

Move the chain wheels with the shaft in an


axial direction until distance A is the same on
both sides

Fasten the axial shaft locks on both sides

6.2 Attaching the manual crank


Examples for the use of the crank
handle:
Aligning the hinge band for dismantling
Loosening coarse parts blocking the
hinge band
Reversing mode when not possible with
drive motor
-

Loosen connection between drive motor and


safety clutch. If necessary remove drive motor.

Expel the rollpin spring of the safety clutch

Remove the safety clutch from the drive shaft

Attach the manual crank to the drive shaft and


insert hexagon head screw. If necessary
make manual crank as illustrated.

A
12

mm

00

mm

25

M8

26

35

M10

36

19

Hinge band conveyor type S

6.3 Checking the hinge band tension


Switch off the hinge band conveyor and secure
against unintended start-up

Check the hinge band tension between the drive


shaft and container bottom

~ 10 mm

Hinge band tension:


When applying moderate pressure from
below, the hinge band must give approx.
10 mm
Dimension A must be the same on both
sides

6.4 Changing individual hinge band plates


-

Dismantle the hinge band

Cut off the heads (3) of the connecting bolts (1) using appropriate tools (e.g. by means of a
abrasive cutting-off machine, saw, etc.) on one side

Pull the connecting bolts (1) out of the hinge band plate

Remove hinge band plate (2)


2
Hinge band plate

2
1

Hinge band plate


with scraper

2
Hinge band plate
with driver rail

1
3

To install a new hinge band, clamping bolts (1) (with borings), washers
and split-pins have to be used.
Mind the length of the connecting bolts such as they do not rub at the container.
20

Hinge band conveyor type S

7 Information on coolants / tanks


-

Circulate coolants continuously (weekend circulation recommended)

Do not feed any organic matter

Avoid foreign oil charge

Temperature should be below 25C for emulsion, if possible

pH-value should be within neutral range

Hardness of the initial water should not exceed 15 dH

Hardness due to upgrading must not exceed 20 dH

Cleaning the coolant tanks


-

Cleaning intervals greatly depend upon the kind of processing, material, coolant and
working hours; no general interval can therefore be specified
A cleaning interval between four and eight weeks is recommended as standard value

21

Drive
- Drive chain (only for model
with flange bearing with
chain drive)

Interval

3 months

Action

Safety instructions/
remarks

Check tension and tighten if necessary,


lubricate drive chain

Steps:
- Remove protective covering
(1)
- Loosen hexagon head cap
screw (2)
- Press take-up pulley (4) in
the direction of the arrow (5)
against drive chain (3) (force
of pressure approx. 20 N)
- Tighten hexagon head cap
screw (2)
- Mount protective covering
(1)

1
5

- Drive chain (only for model


with pedestal bearing with
chain drive)

3 months

Check tension and tighten if necessary,


lubricate drive chain

Hinge band conveyor type S

- Remove protective covering


Loosen hexagon head cap
screws (7)
- Evenly unscrew hexagon
head cap screws (8) in the
direction of the arrow (6)
until the tension of the drive
chain is approx. 20 N
- Tighten hexagon head cap
screws (7)
- Mount protective covering

8 Maintenance table

22

Subassembly/
component

Subassembly/
component

Interval

Action

Safety instructions/
remarks

- Bearing of drive shaft and


lateral axis, chain wheels

---

Check wear and smooth running

Check and replace if necessary


when changing the hinge band

Hinge band

3 months

Check tension and tighten if necessary

For setting, see Chapter 4.5

3 months

Check for damage

Replace damaged parts

- Motor(s)

---

See operating instructions of manufacturer

- Wiring

3 months

Check for ruptures and damage

Replace defective wiring

- Level switch

3 months

Check function

Exceed both switch points by


manual actuation

- Protective gear

3 months

Check function

Sieve basket

---

Empty and clean

Pumps

---

See operating instructions of manufacturer

Containers

6 months

Check for leaks, damage and corrosion

Hazardous substances must in


no case penetrate

6 months

Check stability

Container must be safely and


solidly fastened

---

Check guide rails for wear

Check when changing the hinge


band

Electrical equipment

Hinge band conveyor type S

23

24

Subassembly/
component
Coolant tanks

Interval

500
working
hours

Action

Safety instructions/
remarks

Check for contamination (sludge deposits) and


clean, if need be.

Depending on the tooling method,


the interval may be greatly
shortened.
Coolant tanks are special accessories and are therefore not installed in
every plant.

Hinge band conveyor type S

Remedy

Drive motor races, hinge band does not


move

Drive chain torn (for model with chain drive)

Replace drive chain

Rollpin spring of the safety clutch on the


drive sheared off

Drive in new rollpin spring

Hinge band blocked by large parts, safety


clutch has triggered

Remove parts
Turn the drive band in reverse
direction if necessary (see Chapter 6.2)
After restarting, the safety clutch
automatically reengages and
continues to operate

Safety clutch defective (loud rattling noise)

Immediately switch off swarf conveyor


Inform service technician or replace complete safety clutch
Never bridge the safety clutch or
modify the setting

Accumulation of swarfs in front of the guide


sprocket wheel

Dismount hinge band and look


over installation

Axial shaft lock loose

Adjust drive shaft (see Chapter


6.1)

Hinge band does not move centrally


(strikes the hand guard on one side)
25

Hinge band conveyor type S

Possible causes

9 Eliminating malfunctions

Malfunction

Hinge band conveyor type S

10 Accessories
10.1 Stripping device
Scope
-

Used in case snarl chips are forming as well as in case chips are conglutinating
(e.g. due to oil)

Function
-

By means of spring pressure (4) a movable scraper (1) will be moved along the
hinge band (2)

Conglutinated chips will be eliminated

2
A
1

4
B

Setting
-

The stripping device (1) has to fit close to the hinge band (2) (A)

Move stripping device fully in the direction of the arrow (B) until it reaches the stop

Set the adjusting screw (3) to a distance (C) of 2 mm approx between the screw (3)
and the scraper (1).

26

22174/S-bed-gbV1.3.p65/08.01W

Khlmittelreinigungsanlagen
Spnefrderanlagen
Nieder- und Hochdruckpumpen

KNOLL Maschinenbau GmbH


Schwarzachstr. 20, Postf. 1362
D-88342 Bad Saulgau

Telefon
Telefax
E-mail
web

07581/2008-0
07581/2008-140
info@knoll-mb.de
www.knoll-mb.de