GE_FANUC_Operator_Manual

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                                               GE FANUC OPERATOR MANUAL
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                                        FADAL MACHINING CENTERS, LLC

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                                                                                                                      GE FANUC OPERATOR MANUAL




                                                                     TABLE OF CONTENTS

        1.0 PRESTART CHECKING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
             1.1 OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
             1.2 AIR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
             1.3 WATER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
             1.4 FLOOD COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
             1.5 SPINDLE COOLER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

        2.0 OPERATOR PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
             2.1 POWER ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
               2.1.1 POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
               2.1.2 POWER OF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
             2.2 SAFETY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
               2.2.1 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
               2.2.2 DOOR OVRD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
               2.2.3 WORK LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
               2.2.4 ALARM MSG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
             2.3 OPERATION MODE SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
               2.3.1 AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
               2.3.2 EDIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
               2.3.3 MDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
               2.3.4 REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
               2.3.5 REF RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
               2.3.6 JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
               2.3.7 HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

        3.0 MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
             3.1 MANUAL OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
               3.1.1 MANUAL REFERENCE POSITION RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
               3.1.2 JOG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
               3.1.3 INC JOG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
               3.1.4 HANDLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
               3.1.5 JOG FEED RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

        4.0 AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
             4.1 AUTOMATIC OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
               4.1.1 MDI OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
               4.1.2 MEMORY PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
               4.1.3 DNC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
               4.1.4 MEMORY PROTECTION KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

        5.0 TEST FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
             5.1 TEST FUNCTION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
               5.1.1 SINGLE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
               5.1.2 BLOCK DELETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15


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       JULY 2005                                 TABLE OF                                                                                                                                    ii
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       5.1.3 OPTION STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
       5.1.4 MC LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
       5.1.5 DRY RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

 6.0 MACHINE SETUP FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
     6.1 SETUP MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
       6.1.1 WORK MEAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
       6.1.2 TOOL MEAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
       6.1.3 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
       6.1.4 HOME PSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
       6.1.5 LOAD PSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
       6.1.6 Z HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

 7.0 TOOL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
     7.1 MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
       7.1.1 DRUM FRWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
       7.1.2 DRUM REV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
       7.1.3 DRUM PSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
       7.1.4 TOOL REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
       7.1.5 TOOL CHNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
       7.1.6 TOOL LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
       7.1.7 REFERENCE THE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
     7.2 AUTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
       7.2.1 T-COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
       7.2.2 TOOL CHANGER COMMAND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
     7.3 TOOL MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
       7.3.1 INIT MAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
       7.3.2 TOOL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
       7.3.3 TOOL BRKN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
       7.3.4 EDIT THE TOOL/MAGAZINE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
       7.3.5 TOOL ORDER PROCEDURE (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
       7.3.6 TOOL LOADING (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
       7.3.7 TOOL CHANGER (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

 8.0 COOLANT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
     8.1 COOLANT CONTROL PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
       8.1.1 AUTO COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
       8.1.2 FLOOD COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
       8.1.3 MIST COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

 9.0 SPINDLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
     9.1 SPINDLE OPERATION PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
       9.1.1 SPDL STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
       9.1.2 SPDL CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
       9.1.3 SPDL CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
       9.1.4 MANUAL SPINDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
       9.1.5 M CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
       9.1.6 SPINDLE SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
       9.1.7 SPINDLE OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
       9.1.8 SPINDLE ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32




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 iii                                     TABLE OF CONTENTS                                                                                                     MAN-0114R1
The document is for study only,if tort to your rights,please inform us,we will delete
                                                                                                                  GE FANUC OPERATOR MANUAL



        10.0 HMOP OPERATION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
             10.1 HMOP OPERATION ON/ OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
             10.2 OVERRIDE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
             10.3 MEMORY OPERATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
             10.4 MANUAL HANDLE FEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
             10.5 MANUAL JOG FEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
             10.6 MANUAL REFERENCE RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
             10.7 MANUAL SPINDLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
             10.8 KEY SHEET LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
               10.8.1 TOOL REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
             10.9 MESSAGE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

        11.0 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
             11.1 M CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
             11.2 ALARM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
             11.3 MACHINE COLD START PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
             11.4 FANUC FILES BACKUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

        12.0 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51




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                                          1.0 PRESTART CHECKING STEPS

 1.1 OIL RESERVOIR       Examine the oil levels. Both levels should be filled up to one inch from the bottom of the
                         reservoir. The spindle oil reservoir may have oil in it for up to six months. The way lube
                         oil reservoir may run out of oil in one week.




                           NOTE:
                           VMCs with linear way systems require grease. See the Maintenance Manual on specifications on
                           the way lube and the spindle oil.




 1.2 AIR PRESSURE        Visually inspect the air pressure gauge to verify that it is set to at least 80-100 PSI. Air
                         is used to change belt ranges in the spindle, orient the spindle, activate the tool in-out
                         cylinder, and it is, also, used for the air blast during a tool change. The tool changes
                         gauge should not exceed 120 PSI.




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        1.3 WATER RESER-        Most new VMC models release water collected in the water reservoir automatically. It is
        VOIR                    advisable to place an additional water trap in the air line going to the machine.


        1.4 FLOOD COOLANT       Replenish the flood coolant level to avoid running out of coolant during execution of the
                                program.




        1.5 SPINDLE COOLER      Examine the spindle cooler reservoir once a month.
        RESERVOIR




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                                          2.0 OPERATOR PANEL LAYOUT

 2.1 POWER ON/OFF
  2.1.1 POWER ON         1. Turn On the main breaker
                         To power on the machine, press the safety lock and turn the power switch in the
                         clockwise direction.




                         2. Press the CNC ON push button. CNC will boot up and enter operating status.


  2.1.2 POWER OFF




                                                         Operator Panel B layout



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                                1. Press the CNC OFF push button.

                                2. Turn off the main breaker.
                                To power off the machine, turn the power switch in the counterclockwise direction.


                                                                    REF            INC              MIST    FLOOD    AUTO
                                 AUTO     EDIT     MDI    REMOTE            JOG            HANDLE
                                                                   RETURN          JOG              COOL    COOL     COOL


                                 SINGLE   BLOCK
                                 BLOCK    DELETE
                                                    OPT
                                                   STOP
                                                          WORK
                                                          MEAS
                                                                   X 1      X 10   X 100   X 1000     X      Y         Z

                                                                   HOME                      Z
                                 TOOL
                                 MEAS
                                           MC
                                          LOCK
                                                   DRY
                                                   RUN
                                                          TOOL
                                                          BRKN      PSN
                                                                            LOAD
                                                                             PSN           HOME       4      5         6

                                 DOOR
                                 OVRD
                                          DRUM
                                          FWD
                                                   DRUM
                                                    REV
                                                          WORK
                                                          LIGHT
                                                                   DRUM
                                                                    PSN
                                                                            WASH
                                                                            DWN
                                                                                   INIT
                                                                                   MAG
                                                                                           TOOL
                                                                                           DATA       +     TRVRS      -

                                 CYCLE    CYCLE    PRG    ALARM    TOOL     TOOL   LOAD              SPDL   SPDL     SPDL
                                                                                           FUNC
                                 STOP     START    STOP    MSG      REL     CHNG   TOOL               CW    STOP     CCW




                                GE Fanuc 18i-MB5 control is equipped with “Main B” Operator Panel. 55 Push button
                                layout is pictured above.
                                Clear key caps and custom legends have been installed as presently defined for
                                machine use. Unless otherwise noted, buttons fit with blank key caps (no legend) are
                                not defined for user-customer use.


        2.2 SAFETY FUNC-
        TIONS
         2.2.1 EMERGENCY STOP
        SWITCH
                                                                                     EMERGENCY
                                                                                     STOP




                                If you press Emergency Stop button on the machine operator’s manual, machine
                                movement stops in a moment. This button is locked when it is pressed, and can be
                                unlocked by twisting it.
                                When the emergency stop is pressed, the emergency stop command is applied to the
                                machine, and the CNC is reset, spindle and XYZ axes are stopped, and the other
                                actions are interrupted. CNC will display EMG STOP message on the screen.




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  2.2.2 DOOR OVRD        This push button enables opening machine doors without generating Feed Hold &
                         Cycle Start inhibits. While door override is applied, LED is flashing & Operator Message
                         (2006 Door open override is active) is displayed to remind that override is active.
                         Operation of Door Override push button may be selected as latching (default) or
                         momentary style by user. Latching operation provides On/Off toggle function.
                         Momentary function requires operator to hold push button while door override is
                         required.


  2.2.3 WORK LIGHT       Operator control of machine’s work light(s). Pressing push button toggles work light On/
                         Off.
                         Machine work light is set to automatically turn on with power-up of machine.


  2.2.4 ALARM MSG        Pressing this button will reset the CNC and clear the PMC message.




 2.3 OPERATION MODE
 SELECTION


  2.3.1 AUTO             Auto (Memory) Mode       (Fanuc operator manual GFZ-63534EN Section 4.1)

                         Auto Mode also is called Memory Mode. Automatic operation of part program selected
                         from program files registered in control’s program directory.


  2.3.2 EDIT             Edit Mode             (Fanuc operator manual GFZ-63534EN, Section 9)

                         Edit mode enables entering and editing of part programs stored in control’s part
                         program directory. Part programs stored on optional Data Server or memory card
                         inserted in PCMCIA card slot are not available for editing. Programs must be edited
                         before loading to storage media.


  2.3.3 MDI              Manual Data Input Mode (Fanuc operator manual GFZ-63534EN, Section 4.2)

                         MDI mode is used for simple test operation. In the MDI mode, operator can create and
                         execute a program consisting up to 10 lines from the MDI panel, which is in the same
                         format as the normal program.

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         2.3.4 REMOTE           Remote Mode               (Fanuc operator manual GFZ-63534EN, Section 4.3, 4.13)

                                Remote mode is also called DNC mode. In the mode, it is possible to perform
                                machining while a program is being read in via reader/puncher interface, or remote
                                buffer. Operator can, also, perform machining with execution of the program in the
                                memory card, which is installed in the memory card interface, which is in the left side of
                                the screen.
         2.3.5 REF RETURNE      Reference Return Mode         (Fanuc operator manual GFZ-63534EN, Section 3.1)

                                Reference Return gives an opportunity to return all the axes to the machine zero
                                position.
         2.3.6 JOG              Continuous Jog Mode          (Fanuc operator manual GFZ-63534EN, Section 3.3)

                                In the continuous jog mode, pressing the direction switch on the operator’s panel
                                moves the tool along with the selected axes in the selected direction.
         2.3.7 HANDLE           Handle (MPG) Mode            (Fanuc operator manual GFZ-63534EN, Section 3.4)

                                In the handle mode, operator can move the axes by rotating the manual pulse
                                generator on the operator’s panel.




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                                                   3.0 MANUAL OPERATION

 3.1 MANUAL OPERA-
 TION MODES
   3.1.1 MANUAL REFER-
 ENCE POSITION RETURN




                         Reference Zero:
                         Manual reference position return is to move the tool to the reference position using
                         switches and push buttons located on the operator’s panel. Fadal machines are
                         equipped with Absolute Encoders. Stored position information from the encoders will
                         initialize the current machine position at power-up. Manual referencing of axes after
                         power-up should not be required. When position is established by absolute feedback,
                         REF RETURN MODE will simply command axes to Home position.

                         Reference Procedure:
                         1. Select REF RETURN Mode

                         2. Select one axis to be referenced by X, Y, Z, 4, or 5 axes button.
                         Machine axes will move at traverse rate to home position. When each axis has
                         completed finding the reference position, the related machine coordinate will become to
                         zero. Press the JOG, JOG INC, HANDLE or AUTO, MDI, and EDIT mode keys to exit
                         the Reference mode.
                         Pressing the POS key on the MDI panel will switch to different position display which
                         includes machine coordinate, absolute coordinate, and related coordinate.
                         For referencing of machine axes, including initialization of absolute encoder positions,
                         please see separate maintenance procedure in Appendix.

                            NOTE:
                             FADAL machines do not use reference deceleration switches for establishing machine home posi-
                             tion. Dog-less reference operation is provided for referencing axes without reference switches.
                             Maintenance instructions for dog-less reference must be followed exactly, otherwise machine home
                             position will not be repeatable.



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         3.1.2 JOG OPERATION




                                1. Select JOG Mode.

                                2. Select one axis to be manually jogged by X, Y, Z, 4 or 5 axes buttons. Axis selec-
                                   tion button does not have to be held down. LED will light indicating selected axis.
                                   Pressing any axis button will automatically de-select previously selected axis. It is
                                   implemented to prevent jogging of more than one axis simultaneously.

                                3. Press and hold + or - direction button for desired direction of travel. Axis motion will
                                   continue until direction button is released. Direction LED will be lit during motion.

                                Machine axes will travel at jog rate 200 inch per minute. Feedrate Override rotary
                                switch may be used to vary jog rate.

                                4. Pressing TRVRS during continuous jog move will increase axis jog rate to traverse
                                   speed (MAX 900IPM for XY axis, 700IPM for Z axis). Feed rate rotary switch is also
                                   used to override traverse rates.
                                   NOTE:
                                    If the feedrate is at 0%, no motion will occur when using the “+/-” jog button.
                                     6030, 8030 have the Max 400ZPM for X. Y. Z.




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   3.1.3 INC JOG
 OPERATION




                         Each time a +/- button is pressed, the tool moves by the predetermined distance.

                         1. Select INCR JOG Mode.

                         2. Select one axis by X, Y, Z, 4 or 5 axes buttons, as in JOG mode.

                         3. Select desired increment of travel by using X1, X10, X100 or X1000 push buttons.

                         4. Press + or - direction button for desired direction of travel. Incremental axis motion
                            of selected distance will be commanded per each press of direction button. Direc-
                            tion LED will be lit during motion.

                         Incremental travel selection by multiplier setting (X1, X10, X100 or X1000) is based on
                         the minimum command increment used by FADAL machine, 0.0001 inch or 0.001 mm.
                         Selection of X1 will command 0.0001” or 0.001mm for each press of direction button.
                         X10 commanding 0.001” or 0.01mm, (10 x 0.0001” or 10 x 0.001mm) and so on.
                             X1:      0.0001 inch (0.001mm)
                             X10: 0.001 inch (0.01mm)
                             X100: 0.01 inch (0.1mm)
                             X1000: 0.1 inch (1.0mm)


   3.1.4 HANDLE          Handle mode is also referred to as MPG Mode (Manual Pulse Generator). By rotating
 OPERATION               the manual handle, the tool moves by the distance corresponding to the degree of
                         handle rotation.

                         1. Select Handle Mode.

                         2. Select one axis by X, Y, Z, 4 or 5 axes buttons, as in JOG mode.




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                                3. Select desired increment of travel by using X1, X10, X100 or X1000 push buttons.

                                    X1: 0.0001 inch (0.001mm)
                                    X10: 0.001 inch (0.01mm)
                                    X100: 0.01 inch (0.1mm)

                                4. Rotate manual pulse generator (MPG) clock-wise or counter clock-wise for plus or
                                   minus motion, respectively. For each detent or “click” of MPG handle, one selected
                                   increment or travel will be commanded. Direction LED will be lit during motion.
                                   NOTE:
                                    Increment travel selection by multiplier settings are used same as during INCR JOG mode. For
                                    example, selection of X10 increment with clock-wise rotation of 15 “clicks” on MPG will command
                                    0.0150” or 0.150mm of travel in plus direction.


                                   NOTE:
                                    When MPG hand wheel is rotated at a rate fast enough to exceed the axis traverse rate, the axis
                                    speed is claimped at the traverse rate and excess rotation of the hand wheel is ignored. In this case,
                                    the distance of axis travel will not equal the amount of hand wheel rotation.




         3.1.5 JOG FEED RATE    When the machine is in the JOG mode, the jog feedrate varies from 0 IPM to 240 IPM
                                since the feedrate switch changes the feedrate from 0% to120%. For example, if Jog
                                Feedrate Switch is at 100%, the feedrate changes to 200IPM.
                                This switch affects the rapid speed since it is rapid speed override switch also.
                                When the HMOP operation ON/OFF switch is turn off, the effective feed override/
                                feedrate is only related with main operator panel feed override switch.
                                When the operation ON/OFF switch is turned on, the effective feed override/feedrate
                                value is that HMOP override switch’s value multiply main operator panel feed override
                                switch’s value.
                                   NOTE:
                                    If the feed override/feed rate is at 0%, no motion will occur when using the “+/-” jog button or execut-
                                    ing the program.




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                                             4.0 AUTOMATIC OPERATION

 4.1 AUTOMATIC OPER-
 ATION MODES
  4.1.1 MDI OPERATION    In the MDI mode, a program consisting of up to 10 lines can be created in the same
                         format as normal programs and executed from the MDI panel. MDI operation is used for
                         simple test operations.
                         In order to complete this operation, follow the next procedure:

                         1. Press the MDI mode selection switch.

                         2. Press the PROG function key on the MDI panel to select the program screen.

                         3. Prepare a program to be executed by an operation similar to normal program edit-
                            ing. M30, specified in the last block can return control to the beginning of the pro-
                            gram after operation ends. Word insertion, modification, deletion, word search,
                            address search, and program search are available for programs created in the MDI
                            mode.

                         4. To entirely erase created program in the MDI mode, use one of the following meth-
                            ods:
                            • Enter address, and then press the DELETE key on the MDI panel.

                             • Alternatively, press the RESET key.

                         5. To execute a program, set the cursor on the head of the program. Push CYCLE
                            START button on the operator’s panel. By this selection, the prepared program will
                            start. When the program end (M02, M30) or ER (%) is executed, the program will
                            be erased and the operation will end. By command of M30, control returns to the
                            head of the prepared program.

                         6. To stop or terminate MDI operation in midway through, follow the next steps:
                            • Stop MDI operation.
                            Press the feed hold switch on the machine operator’s panel. The feed hold LED
                            goes on and the cycle start LED goes off.

                             • Terminate MDI operation.
                             Press the reset key on the MDI panel. Automatic operation is terminated and the
                             reset state is entered. When a reset is applied during movement, movement decel-
                             erates then stops.




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          4.1.2 MEMORY          Programs are registered in memory in advance. When one on these programs is
        OPERATION (AUTO MODE)   selected and the cycle start switch on the machine operator’s panel is pressed,
                                automatic operation starts, and the cycle start LED goes on.
                                When the feed hold switch in the machine operator’s panel is pressed during automatic
                                operation, this operation is stopped temporarily. When the cycle start switch is pressed
                                again, automatic operation is restarted.
                                When the RESET key on the MDI panel is pressed, automatic operation terminates and
                                the reset state is entered.
                                To complete this operation follow the next procedure:

                                1. Press the MEMORY (AUTO) mode selection switch.

                                2. Select the program from the registered programs doing the following steps:

                                    • Press PROG to display the program screen.

                                    • Press “+” soft key.

                                    • Press “DIR” soft key and the program library will be displayed.

                                    • Enter a program number using the numeric keys.

                                    • Press the O SRH soft key.

                                3. Press the cycle start switch on the machine operator’s panel. Automatic operation
                                   starts, and the cycle start LED goes on. When automatic operation terminates, the
                                   cycle start LED goes off.

                                4. To stop or cancel memory operation midway through, follow the steps below:

                                    • Stopping memory operation.

                                    Press the feed hold switch on the machine operator’s panel. The feed hold LED
                                    goes on and the cycle start LED goes off. The machine responds as follows:
                                    When the machine was moving, feed operation decelerates and stops.
                                    When dwell was being performed, dwell is stopped.
                                    When M, S, or T was being executed, the operation stopped after M, S, or T is fin-
                                    ished.

                                    • Terminating memory operation.

                                    Press the RESET key on the MDI panel.
                                    Automatic operation is terminated and the reset state is entered. When a reset is
                                    applied during movement, movement decelerates then stops.



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  4.1.3 DNC OPERATION    By activating automatic operation during the DNC operation mode (REMOTE), it is
                         possible to perform machining (DNC operation) while a program is being read in via
                         reader/puncher interface, or remote buffer. If the floppy cassette directory display option
                         is available, it is possible to select files (programs) saved in an external input/output unit
                         of a floppy format (Handy file, Floppy Cassettes, or FA card) and specify (schedule) the
                         sequence and frequency of execution for automatic operation.
                         To use the DNC operation function it is necessary to set the parameters related to the
                         reader/punch interface and remote buffer in advance.
                         To complete this procedure follow the next procedure:

                         1. Search for the program to be executed.

                         2. Press the REMOTE switch on the machine operator’s panel to set REMOTE mode,
                            then press cycle start switch. The selected file is executed.

                         During DNC operation, the program currently being executed is displayed on the
                         program check screen and program screen.
                         The number of displayed program blocks depends on the program being executed.



                         DNC Operation procedure with memory card:




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                                1. Set the parameter of No.0020 to 4 in the setting screen in advance.

                                2. Change to REMOTE mode.

                                3. Press PROG function key on the MDI panel.

                                4. Push “+” soft key twice.

                                5. When “DNC-CD” soft key is pressed, the following screen is displayed.

                                The screen can be scrolled by page key. An arbitrary file number is input, and “F SRH”
                                soft key is pressed. Then the arbitrary file name is displayed at the top of DNC
                                operation (memory card) screen.

                                6. Input the file number which is going to be executed.

                                7. Press the “DNC-ST” soft key, the file name will be displayed in the right side of
                                   DNC FILE NAME:
                                   For example, DNC FILE NAME:O0053

                                8. Press the CYCLE START button to execute the program selected.



          4.1.4 MEMORY          This key is used to prevent part programs, offset values, parameters, and setting data
        PROTECTION KEY          from being registered, modified, or deleted erroneously.
                                When the key is in the On position “I”, the memory is protected and operator can’t
                                change any data in the CNC. When the key is in the Off position “O” operator is able to
                                register/modify/delete the part programs, offset values, parameters and setting data.




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                                                    5.0 TEST FUNCTION

 5.1 TEST FUNCTION
 MODES



  5.1.1 SINGLE BLOCK     Single Block                 (Fanuc Operator Manual GFZ-63534EN, III, Section 5.5)

                         Single Block Mode executes part program block by block. Single block mode is
                         implemented to toggle On/Off with press of button.
                         Pressing the single block switch starts the single block mode. When the cycle start
                         button is pressed in the single block mode, the tool stops after executing a single block
                         in the program. Check the program in the single block mode by executing the program
                         block by block.



  5.1.2 BLOCK DELETE     Block Skip                  (Fanuc Operator Manual GFZ-63534EN, II, Section 12.2)

                         Skip execution of program Block (/). Multi level Block Skip is not supported. Block
                         Delete is implemented to toggle On/Off with press of button.



  5.1.3 OPTION STOP      Optional Stop on M01          (Fanuc Operator Manual GFZ-63534EN, II, Section 11.1)

                         Option Stop is implemented to toggle On/Off with press of button. Executing program
                         will stop at M01 when option stop button is On. Operator needs to push CYCLE START
                         button to restart the program. It does not affect the program when the option stop button
                         is Off


  5.1.4 PROGRAM STOP     M00 or M01 Program Stop        (Fanuc Operator Manual GFZ-63534EN. III, Section 40.1)

                         Program Stop indicator LED is lit when part program execution is stopped by M00 or
                         M01 part program.




  5.1.5 MC LOCK          Machine Lock (Test Mode) (Fanuc Operator Manual GFZ-63534EN, III, Section 5.1)


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                                Machine Lock enables execution of part program without axis motion, but M/S/T
                                command still is able to execute. This button is for test purposes. Machine lock is
                                implemented to toggle On/Off with press of button.
         5.1.6 DRY RUN          Dry Run Feed Rate               (Fanuc Operator Manual GFZ-63534EN, III, Section 5.4)

                                This feed rate forces program federate to fixed “dry run” rate to speed non-cutting
                                testing of part programs. Dry Run is implemented to toggle On/Off with press of button.
                                The tool is moved at the feed rate specified by a parameter regardless of the feed rate
                                specified in the program. This function is used for checking the movement of the tool
                                under the state that the workpiece is removed from the table. Press the Dry Run switch
                                on the machine operator’s panel during automatic operation. The tool moves at the
                                feed rate 900/700 IPM when the feed rate is overridden by 100%. The rapid traverse
                                switch can also be used for changing the feed rate. The Dry Run feed rate changes as
                                shown in the table below according to the rapid traverse switch and parameters.

                                            For X and Y axis, w hen the D R Y R U N button is “O N ”.
                                   R apid traverse button                       Program com m and

                                                                                R apid traverse          Feed

                                   ON                                           700IPM                   500IPM

                                   O FF                                         900* Feedrate            500*Feedrate
                                                                                override IPM             override IPM
                                                                                                         *1


                                            For Z axis, when the DR Y RUN button is “ON”.
                                   Rapid traverse button                        Program command

                                                                                Rapid traverse           Feed

                                   ON                                           700IPM                   500IPM

                                   OFF                                          700* Feedrate            500*Feedrate
                                                                                override IPM             override IPM
                                                                                                         *1

                                   *1. Speed is Clam ped to m axim um feedrate 500IPM

                                   NOTE:
                                    When the machine is in the Auto/Remote mode, operator can only turn on Dry Run by pressing Dry
                                    Run & Func key at the same time.




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                                             6.0 MACHINE SETUP FUNCTION

 6.1 SETUP MODES
  6.1.1 WORK MEAS        Work Offset Setting        (Fanuc Operator Manual GFZ-63534EN, III, Section 11.4.14)

                         This measurement simplifies setup of work/fixture offsets using Measurement B
                         feature. Please refer the Fanuc operator manual for the details.


  6.1.2 TOOL MEAS        Tool Length               (Fanuc Operator Manual GFZ-63534EN, III, Section 11.4.14)

                         This measurement simplifies setup of tool length offsets using Measurement B feature.
                         Please refer the Fanuc operator manual for the details.


  6.1.3 FUNCTION         Function button   FUNC

                         Horizontal mounting of Operator Panel in Fadal pendant exposes operator buttons to a
                         more varied environment. To prevent accidental activation of selected operator panel
                         operations, the FUNC button is required to be pressed in combination with desired
                         operator panel function.
                         Operator Panel functions currently requiring FUNC button are:

                         HOME PSN                 LOAD PSN               Z HOME               INIT MAG
                         TOOL DATA                TOOL CHNG              LOAD TOOL
                         SPDL CCW                 SPDL CW                TOOL BRKN




  6.1.4 HOME PSN         Macro Program Positioning Axes to Home Position FUNC

                         Pressing this button will call the macro program which commands axes to machine
                         position of X0.0 Y0.0 Z0.0 using G53 traverse moves. Program will command Z-axis to
                         0.0 first, before X & Y axes motion are commanded.
                         FUNC button must be pressed simultaneously with HOME PSN to execute program.




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         6.1.5 LOAD PSN         Macro Program Positioning Axes to Table Load PSN FUNC
                                Pressing this button will call the macro program which commands axes to machine
                                position of X0.0, Z0.0, and Y plus limit position using G53 traverse moves. Table
                                position is in front and center. When control is set for metric operation, macro program
                                will automatically command to X0.0, Y+Limit, Z0.0 in mm units FUNC button must be
                                pressed simultaneously with LOAD PSN to execute program.


         6.1.6 Z HOME           Macro Program Positioning Axes to Table Load PSN         FUNC

                                Pressing this button will call the macro program which commands Z-axis to machine
                                position of Z0.0 using G53 traverse move.
                                FUNC button must be pressed simultaneously with Z HOME to execute program.




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                                                    7.0 TOOL OPERATION

 7.1 MANUAL OPERA-
 TION




  7.1.1 DRUM FWD         Manual Index of Tool Drum in Forward Direction

                         Commands are manually jogging or indexing of the tool drum in forward direction.
                         Forward direction is defined as indexing of tool pots in rising order:... 23, 24, 1, 2, 3,...
                         Rotating is counter clock-wise when looking at the back of tool operator station.
                         Jog Mode is required. Operator may hold down button for indexing of multiple tool pots,
                         or press momentarily to index one tool. DRUM PSN button can be used to display tool
                         pot at tool change (bottom) position. Operator message will update while tool carousel
                         is being manually rotated.


  7.1.2 DRUM REV         Manual Index of Tool Drum in Reverse Direction

                         Commands are manually jogging or indexing of the tool drum in reverse direction.
                         Reverse direction is defined as indexing of tool pots in decreasing order:... 3, 2, 1, 24,
                         23,... Rotating is clock-wise when looking at the back of tool drum from the operator
                         station.
                         Jog Mode is required. Operation is same as used for DRUM FWD.


  7.1.3 DRUM PSN




                         Display of Tool Drum Position by Operator Message

                         Use of this button activates display of Operator Message containing tool pocket number
                         at tool change (button) position of carousel.
                         DRUM PSN message is set to automatically turn on with power-up of machine. Position
                         of Tool Drum is maintained in battery backed PMC Data table while machine is powered
                         down.
                         Operator may turn the message On/Off at any time using DRUM PSN push button.




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         7.1.4 TOOL REL         Tool Release (Draw Bar Open)

                                This button is for manually loading/uploading a tool holder. Operator must be prepared
                                to catch tool from spindle cartridge immediately upon pressing button. Spindle air is
                                turned on along with release of tool. Draw bar will open after pressing the button more
                                that 1 second and remain open while push button is still held.
                                Spindle must be stopped with control in JOG or HANDLE modes to enable tool release.

                                Unloading tool procedure:
                                1. The tool holder must be held in the left hand with the thumb and the first finger
                                   grasping the holder below “V” groove. No other fingers should have contact with the
                                   holder or the tool in the holder. The area below the “V” groove is called the safe
                                   zone. The safe zone is the only place where the tool holder should be held.


                                                 RETENTION KNOB




                                                 V GROOVE



                                                 SAFE ZONE



                                2. Press the TOOL REL button. Keep the TOOL REL button pressed until the tool is
                                   completely out of the spindle.

                                Loading tool procedure:
                                1. The tool holder must be held in the left hand with the thumb and the first finger
                                   grasping the holder below the “V” groove. No other fingers should have contact with
                                   the holder or the tool in the holder. The area bellow “V” groove is called the safe
                                   zone. The safe zone is the only place where the tool holder should be held.




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                         2. Place the holder into the spindle after pressing the TOOL REL button, not before.
                            The keys on the nose of the spindle must fit into the key-ways on the tool holder
                            flange.

                         3. Release the TOOL REL button to lock the tool into the spindle.
                            NOTE:
                              When loading a holder into the spindle, inspect the taper for chips and dents. Remove any chips or
                             dents from the taper with a flat stone.
                             Confirm the retention knob is securely tightened before placing the tool in the spindle.
                             After load a tool holder info the spindle, operator needs to edit the magazine management to write
                             the spindle tool number into the SPDL1 column, and then use the TOOL CHNG to load the spindle
                             tool into the magazine/carousel.


  7.1.5 TOOL CHNG        Macro Program Execute Tool Change                       FUNC
                         (Only for DATC)

                         Pressing this push button will execute macro program O8988. Program executes swap
                         of tool between spindle cartridge and current position of TOOL DRUM.
                         This button is for manually unloading of tools between spindle and tool drum, or loading
                         of tool to specific tool drum pot. Operator can position tool drum prior to use of TOOL
                         CHNG button.
                         During tool loading, operator may input tool number into spindle window on Tool
                         Magazine screen. Tool Change cycle will move tool number to magazine. Alternatively,
                         operator may edit magazine table once tools are loaded. Upon removal of tool from
                         spindle, operator should delete tool number from spindle window on Tool Magazine
                         screen.
                         FUNC button must be pressed simultaneously with TOOL CHNG to execute program.


  7.1.6 TOOL LOAD        Macro Program for Loading Tools                       FUNC

                         Machine with DATC:
                         Pressing this push button will execute the macro program O8989. Program searches
                         for and positions to empty tool pot in tool drum. Then executes swap of new tool from
                         spindle cartridge into empty tool pot.
                         This function is provided for manual tool loading from to tool drum. Operator to input
                         tool number from spindle window on Tool Magazine screen so that tool number can be
                         loaded to magazine, or edit magazine and spindle tool data after tools are loaded.
                         FUNC button must be pressed simultaneously with LOAD TOOL to execute program.

                         FUNC+LOAD TOOL procedure
                            • Manually load the tool to the spindle according the TOOL REL procedure.
                            • Press JOG or HANDLE mode.
                            • Press OFFSET/SETTING key on the MDI panel.
                            • Press “+” soft key below the LCD screen.


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                                    • Press TL-MNG soft key.
                                    • Press MAG to enter the tool data management screen.
                                    • Press “OPRT” soft key.
                                    • Press EDIT soft key, the EDITING will be displayed on the screen.
                                    • Move the cursor to the most right column: SPDL1.
                                    • Input the tool number of the current spindle tool into the Spindle Tool column.
                                    • Press INPUT, the tool number will be displayed in the SPDL1 column.
                                    • Press FUNC+LOAD TOOL, tool will be loading the magazine automatically, and
                                      the MAG management will be updated.
                                    • Press OPRT.
                                    • Press END to end the tool management editing.
                                   NOTE:
                                    Operator need register the tool into the management first before load the new tool.

                                Machine with ATC:
                                Press the push button with FUNC button will execute the macro program O8989.
                                Program positions to specific tool pot in tool drum, and then load the spindle tool into
                                the specific tool pot.
                                This function is provided for manually loading tools from spindle to TOOL DRUM.
                                Operator input tool number from spindle window on Tool Magazine screen so that tool
                                number can be loaded to magazine, or edit magazine and spindle tool data after tools
                                are loaded.
                                FUNC button must be pressed simultaneously with LOAD TOOL to execute program.

                                FUNC+LOAD TOOL procedure
                                   • Manually load the tool to the spindle according the TOOL REL procedure.
                                   • Press JOG or HANDLE mode.
                                   • Press OFFSET/SETTING key on the MDI panel.
                                   • Press “+” soft key below the LCD screen.
                                   • Press TL-MNG soft key.
                                   • Press MAG to enter the tool data management screen.
                                   • Press “OPRT” soft key.
                                   • Press EDIT soft key, the EDITING will be displayed on the screen.
                                   • Move the cursor to the most right column: SPDL1.
                                   • Input the tool number of the current spindle tool into the Spindle Tool column.
                                   • Press INPUT, the tool number will be displayed in the SPDL1 column.
                                   • Press FUNC+LOAD TOOL, tool will be loading the magazine automatically, and
                                     the MAG management will be updated.
                                   • Press OPRT.
                                   • Press END to end the tool management editing.
                                   NOTE:
                                    Operator need register the tool type into the management first before load the new tool.




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                            NOTE:
                             If the tool management screen, MAG has the same tool already, operator should clear this maga-
                             zine pot using EDIT and take the tool out from that magazine manually first before try to load
                             another tool.


   7.1.7 REFERENCE THE    1. Press REF RETURN button.
 DRUM (ONLY FOR DATC)
                          2. Press X1 button. The drum will automatically move to the number 1.



 7.2 AUTO OPERATION
  7.2.1 T-COMMAND (TOOL   Eight digit T-Word may be programmed in block with or without M06 code.
 NUMBER)                  T-Word programmed in block by itself will position tool carousel with position tool
                          carousel with programmed tool at 6 o’clock position (DATC) for next tool change.
                          Rotation of carousel will not inhibit continued execution of part program (FIN) as
                          carousel is away from work area. For DATC, this enables cycle time reduction of part
                          program execution, by allowing next tool to be immediately ready for tool change.
                          Programming T-Word after M06 will command positioning of carousel, followed by
                          immediate tool change. T-Word must be programmed following M06 in block, as T-
                          Word is argument passed to M06 macro program.
                          Programming T-code of tool that is already at tool change (6 o’clock) position will
                          command no activity by tool carousel, as requested tool, is already at tool change
                          position.
                          T-Word may be used to position tool carousel by pocket number when combining with
                          M100 miscellaneous code.

                          M100T5: Position carousel to tool pocket #5. Pocket #5 will be selected regardless of
                          tool number in pocket, or if pocket empty.



   7.2.2 TOOL CHANGER     ATC:
 COMMAND                  M06 Txx command from part program executes tool change cycle for carousel type
                          ATC tool changer. M06 command calls macro program O9021, which executes
                          required Z-axis motion commands & special Miscellaneous Codes (M- Codes) for
                          execution of the tool change cycle.
                          Tool number (T-Command) must always follow M06 code in program block. M06
                          programmed in block without T-Code following, or T-Code preceding M06 is illegal
                          syntax for this machine.

                          M06 T10: Proper Command Syntax
                          M06:      Illegal, Macro Error 3020 will result
                          T05 M06: Illegal, Macro Error 3020 will result


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                                   NOTE:
                                    Tool changer syntax on other makes/models of machines using GE Fanuc or Fanuc controls may
                                    differ. Operation of syntax on this machine is as listed above, and not selectable.

                                WARNING !
                                1. Special M-Codes contained in macro program O9021 must never be used in end-
                                   user part programs without specific permission of Fadal Machining Centers. Any
                                   use other than in O9021 macro cycle is the responsibility of the machine user/oper-
                                   ator/programmer. Machine damage can occur.

                                2. End-user should always refer to Fadal Machining Centers Operator Manual: appli-
                                   cable to this machine, for proper M-Codes to be used during part programming.

                                3. Macro program O9021 must never be edited without permission of Fadal Machin-
                                   ing Centers. Machine damage can occur.


                                DATC:
                                M06 command from part program executes tool change cycle for “dual arm” type DATC
                                tool changer. M06 command calls program O9020, which executes required Z-axis
                                motion commands & special Miscellaneous Codes (M-Codes) for execution of the tool
                                change cycle.
                                Tool number (T-Command) must follow M06 code in program block, when M06 and Txx
                                code are programmed in the same block. T-Code preceding M06 in same block is
                                improper syntax for this machine. T-Code may be programmed alone, in previous block
                                to provide positioning of TOOL DRUM prior to tool change. This method improves part
                                program cycle time.

                                T10:          Tool Drum positions, following operations will continue
                                               while drum.
                                G01 X . . ., Positions to Tool from pocket containing T10 tool.
                                ...,
                                ...,
                                M06:         Tool change. T10 will be inserted into spindle, old tool to
                                               empty pocket. D and/or H codes must be added after tool
                                               change for offsets as required.
                                M06:T4       Legal. Tool Drum will position during tool change.
                                T05M06: Illegal command. Tool changes as intended will not occur.

                                Programming M06, without programming a new tool number, will not command a swap
                                of tools between the carousel and spindle. When no new tool number has been
                                specified, and the active tool is already in the spindle, it is expected that no tool change
                                is required.




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                            NOTE:
                             Tool changer syntax on other makes/models of machines using GE Fanuc or Fanuc controls may
                             differ. Operation of syntax on this machine is as listed above, and not otherwise selectable.

                         WARNING !
                         1. Special M-Codes contained in macro program O9020 must never be used in end-
                            user part programs without specific permission of Fadal Machining Centers. Any
                            use other than in O9020 macro cycle is the responsibility of the machine user/oper-
                            ator/programmer. Machine damage can occur.

                         2. End-user should always refer to Fadal Machining Centers Operator Manual: appli-
                            cable to this machine, for proper M-Codes to be used during part programming.

                         3. Macro program O9020 must never be edited without permission of Fadal Machin-
                            ing Centers. Machine Damage could occur.


 7.3 TOOL
 MANAGEMENT
  7.3.1 INIT MAG         Macro Program Initial Tool Magazine Data                            FUNC

                         Pressing this push button will execute macro program O8986 which initials tool data
                         from magazine. Tool numbers in all tool drum pots are initialized to the related pocket
                         number. Tool number in the spindle is initialized to “0” indicating no tool in the spindle.
                         So, operator should take the tool off from the spindle after execution of this function.
                         FUNC button must be pressed simultaneously with INIT/CLR MAG to execute program.
                            NOTE:
                             Please take off the spindle tool after execute this function since this function clears the spindle tool
                             number to zero. Ignore this note to take off the tool from the spindle will cause tool changer crash.



  7.3.2 TOOL DATA        Macro Program Loads Tool Management Data                            FUNC

                         Pressing this push button will execute macro program O8987 which demonstrates
                         loading of tool management data by part program command. Tool numbers 1-24 (1-
                         maximum of tool pocket numbers) are loaded as well as tool groups demonstrating tool
                         life setting by count and by time. The default setting is not tool management for those
                         tools of this function. FUNC button must be pressed simultaneously with TOOL DATA
                         to execute program.
                            NOTE:
                             User may setup the tool management function by manually setup the tool management screen
                             according their requirement.




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          7.3.3 TOOL BRKN       Tool Broken                                           FUNC

                                Pressing TOOL BRKN and FUNC button at the same time is a shortcut to mark active
                                tool as broken/ damaged in the tool management. This function enables operator to
                                mark tool as damaged without editing Tool Management Data. Tool management will
                                not select a damaged tool for use, from the tool group.


         7.3.4 EDIT THE TOOL/   Edit the tool data:
        MAGAZINE LIST               • Press MDI button.
                                    • Press OFFSET/ SETTING.
                                    • Press “+” soft key.
                                    • Press TL-MNG soft key.
                                    • Press TOOL soft key to enter the tool data page.
                                    • Press OPRT soft key.
                                    • Press EDIT soft key to start editing the tool data.
                                    • Press OPRT soft key gain after editing is finished.
                                    • Press END soft key to exit tool data the editing mode.

                                Edit the Magazine data:
                                    • Press MDI button.
                                    • Press OFFSET/SETTING.
                                    • Press “+”soft key.
                                    • Press TL-MNG soft key.
                                    • Press MAG soft key to enter the magazine data page.
                                    • Press OPRT soft key.
                                    • Press EDIT soft key to start editing the magazine data.
                                    • Press OPRT soft key again after editing is finished.
                                    • Press END soft key to exit magazine data the editing mode.



          7.3.5 TOOL ORDER      Procedure:
        PROCEDURE (ONLY FOR     1. Move the drum to the number 1.
        ATC)

                                2. Execute the M11 to establish the tool order (the pocket number1) in the MDI mode.

                                3. Cycle the power.
                                   NOTE:
                                    If user does not cycle the power after M11, that may cause the tool changer crash happening.




          7.3.6 TOOL LOADING    Turret (ATC) open for loading:
        (ATC)                   1. Change the machine to the MDI mode and execute the M150.


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                             M150 M-Code is provided to emulate Fadal control operation for manual tool
                             change. M150 will return tool in the spindle to carousel pocket and raise Z-axis to
                             clear tools. Carousel in left “out” position, enables operator to rotate carousel to
                             next tool.
                            NOTE:
                             M151 command may be used to pick up next tool, if desired. M150 will position above carousel
                             when no tool is in the spindle to be returned.

                         2. Change the mode to Jog, and use the DRUMFWD/DRUM REV button to rotate the
                            turret.
                            Operator can press FUNC+DRUM POS button to display the drum current position.

                         3. Change the machine to the MDI mode and execute the M151.
                            M151 M-Code is provided to emulate Fadal control operation for manual tool
                            change. M151 will proceed from position machine left by M150 cycle. After operator
                            has manually indexed tool carousel to desired new tool, executing M151 will pick
                            up operator-selected tool from carousel and return carousel to home position.
                            NOTE:
                             When user loads tools into the turret, they can place tools in the turret and use DRUM FWR/DRUM
                             REV button to put the next tool in the turret until all the tools are placed in the turret. Rotate the turret
                             until the first tool is in the number one position before setting the tool order (using M11 to establish
                             tool order).

                         WARNING !
                         1. M150 is provided for MDI use only to return tool to carousel. Use of the M150/M151
                            commands is responsibility of the machine operator. Machine damage may occur in
                            unintended use.

                         2. M151 is provided for MDI use only after M150 command for return of active tool to
                            carousel, and positioning of Z-axis above the carousel. Use of M150/M151 is the
                            responsibility of the machine operator. Machine damage can occur during unin-
                            tended use.

                         3. M150/M151 commands should never be used during Automatic execution of part
                            programs.


   7.3.7 TOOL CHANGER    1. Press the RESET to disable the alarm.
 (RECOVERY ATC)

                            NOTE:
                             If the alarm can not be disable, operator may cycle the power to clear the alarms.

                         2. Execute the M186 in the MDI mode to get the turret to the home position if the Z
                            axis still is in the home position.



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                                   NOTE:
                                    User may move the Z axis to the safe area before return of the slide according to the real situation.

                                3. Move to the cold start position using either REF RETURN or G28.

                                4. Use the DRUM FWD/DRUM REV button to rotate the turret to the number 1.

                                5. Execute the M11 to establish the drum number 1. Cycle the power.

                                6. Double check the tool management to see if it is right. Edit it to make it right if it
                                   needs.




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                                                 8.0 COOLANT OPERATION

 8.1 COOLANT CON-
 TROL PUSH BUTTONS


 8.1.1 AUTO COOL         AUTO COOL push button selects automatic control of coolant by programmed M-Code.

                             AUTO COOL button toggles on/off, as indicated by LED. While AUTO COOL is
                             active, manual coolant control buttons MIST COOL AND FLOOD COOL are
                              inhibited. AUTO COOL “OFF” enables control of coolant. AUTO COOL is defaulted
                             to “ON” condition at power-up.

                         When AUTO COOL is on, the following M-Code is used to control the coolant system:
                             M-Code:
                             M7: Mist coolant ON; Coolant though spindle ON
                             M8: Flood coolant ON
                             M9: Mist coolant, Flood coolant, coolant though spindle OFF


 8.1.2 FLOOD COOL        FLOOD COOL turns on/off the flood coolant pump when the AUTO COOL is off.


 8.1.3 MIST COOL         MIST COOL turns on/off the mist coolant pump and coolant through spindle solenoid
                         when the AUTO COOL is off.
                            NOTE:
                             FLOOD COOL and MIST COOL may be turned on simultaneously. MIST COOL also turns on the
                             coolant through spindle pump if the machine has this option.




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                                                      9.0 SPINDLE OPERATION

        9.1 SPINDLE OPERA-
        TION PUSH BUTTONS



         9.1.1 SPDL STOP        Manual Spindle Stop

                                SPDL STOP applies stop to spindle running in either CW or CCW direction. SPDL
                                STOP button is inhibited when CYCLE START LED is on, indicating automatic cycle is
                                active. SPDL STOP does not cancel active spindle speed “S” word command. SPDL
                                STOP may be used from any automatic or manual mode.


         9.1.2 SPDL CW          Manual Spindle Start Clock-Wise & Spindle Jog CW                     FUNC

                                SPDL SW provides dual functions, based on operating mode of control.


         9.1.3 SPDL CCW         Manual Spindle Start Counter Clock-Wise & Spindle Jog CCW               FUNC

                                SPDL CCW, also, provides dual function, based on operating mode of control.




                                                                     DI,
                                                                   M AUTOor
                                                      JOGMode
                                                                       OTE ode
                                                                   REM M
                                                        X                        Jog Spindle in CWdirection
                                       SPDL CW
                                                                       X         Spindle Start in CWdirection
                                                        X                        Jog Spindle in CCWdirection
                                      SPDL CCW
                                                                       X         Spindle Start in CCWdirection




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   9.1.4 MANUAL SPINDLE    Spindle jog speed is defined in PMC data table. Spindle Speed Override rotary switch is
 SPEED                     applied to spindle jog speed. Spindle will jog while FUNC+ SPNDL CW/CCW button is
                           held. Spindle will stop when CW/CCW button is released.


   9.1.5 M CODE / S CODE   M command:
                               M3:    Spindle CW rotate.
                               M4:    Spindle CWW rotate.
                               M5:    Spindle Stop.
                               M41:   Spindle low gear range.
                               M42:   Spindle high gear range.

                           S command: Spindle rotation speed command
                           The spindle speed can be specified directly by address S followed by a maximum five-
                           digit value (min-1). The unit is rotation per minute (RPM).
                           The S command must be specified with M3/M4 command in the same block to run the
                           spindle. Using M5 command or pressing RESET can stop the spindle.

                               Example: S10000; spindle rotation speed is 10000RPM.
                                        M3 S2000 (Spindle CW, 2000RPM).
                                        M4 S2000 (Spindle CCW, 2000RPM).
                                        M5 Spindle stop.

                             NOTE:
                              Use of FUNC+SPDL CW/CCW as spindle start in MDI, Auto & Remote Modes is inhibited when
                              Cycle Start LED is on, and also by state of door interlock. Programmed “S” word must be active for
                              use of buttons for spindle start. Care should also be used in CW/CCW rotation.


   9.1.6 SPINDLE SPEED     The spindle speed of Fadal VMC has the different configuration.
 RANGE
                           For EMCD, 2016, 2216, 3016 machines with maximum spindle speed 7.5K, the spindle
                           has a single range30-7500 RPM.
                           For 2216, 3016 machines with maximum spindle speed 15K, the spindle has a single
                           range 30-15000 RPM.
                           For 3020, 4020, 4525, 5020, 6030, 8030, 6535 40T machines with maximum spindle
                           speed 15K with a electrical high/low, the spindle range is as follows:

                           Low range: 30-2500
                           High range: 2501-15000

                           The VMC machines with mechanical Hi/Lo and the maximum speed Is 10K, the spindle
                           ranges are as follows:

                           Low range: 30-2500
                           High range: 2501-10000




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          9.1.7 SPINDLE            Spindle override 50%-120%
        OVERRIDE                   This switch will adjust the commanded spindle speed by 50% to 120%.


          9.1.8 SPINDLE ORIENTA-   Spindle orientation command for tool changer:
        TION
                                   M190 : Spindle orientation
                                   Execution of the M5/M3/M4 command or pressing the RESET key will release the
                                   spindle orientation command.

                                   M19: Spindle special orientation command for cycles
                                       M19 positions spindle aligned with X & Y plane to provide for proper tool alignment during M19 ori-
                                       ent cycles which is used during Fine Boring and Back boring canned cycles.

                                     NOTE:
                                      M19 should be used for the Fine Boring and Black Boring canned cycles only. Using M19 for other
                                      purposes may cause machine crash.




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                                         10.0 HMOP OPERATION GUIDE




                                                                                         EMERGENCY
                                                                                         STOP
                         SINGLE LED



                                                                                        OPERATION ON/OFF




                                                                                  OVERRIDE SWITCH

                         INPUT KEY
                         WITH LEDx20




                         MANUAL
                         PULSE
                         GENERATOR




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                                CAUTION: (refer to FANUC HMOP manual)
                                Please hold the handy machine operator’s panel through belt. When operator holds the
                                handy machine operator’s panel without using belt, the handy machine operator’s panel
                                may be dropped. This unit has an enabling switch. When operator is surprised with
                                unexpected motion, he should release the enabling switch.


        10.1 HMOP OPERA-        Turn on this switch for the purpose of selecting the operation by handy machine
        TION ON/OFF SWITCH      operator’s panel. Turn off this switch for operation by main operator’s panel. When
                                HMOP ON/OFF switch is turned on, the operator is permitted to use machine using
                                HMOP only. If HMOP ON/Off switch is turned off, the operator is permitted to use
                                machine using pendant.

                                CAUTION:
                                Please do not turn off the operation ON/OFF switch in the situation when operator
                                exposes himself to danger. When the operation ON/OFF switch is turned off, the
                                operation from main operator’s panel is possible, but it is dangerous.


        10.2 OVERRIDE           The function of this switch is same as the feed rate switch on the main operator panel.
        SWITCH                  When the operation ON/OFF switch is turned on, the effective override value is that
                                HMOP override switch’s value multiply main operator panel feed override switch’s
                                value.


                                Example: The operation switch is on.
                                    Main operator panel feed override is 80%
                                    HMOP feed override is 50%
                                    The effective feed override for the machine is 40%
                                    80% x 50% = 40%

                                When the operation ON/OFF switch is turned off, the effective feed override is only
                                related with main operator panel feed override switch.



                                The keys for each of the next procedures are shaded.




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 10.3 MEMORY
                             XYZ                           SPINDL             SPINDL
 OPERATION                                 REF                                               RESET
                             456                           START              STOP
 PROCEDURE
                                                           SPINDL             SPINDL
                            HANDLE        JOG
                                                            INC                DEC                 +
                                                           TOOL
                             Xn            MEM                                MESSAGE        RAPID
                                                           REL(F1)
                            SINGLE      DRY                CYCLE              FEED
                            BLOCK       RUN                START              HOLD                  -
                             • Refer the FANUC operator manual to select the program and call it out to mem-
                             ory to run.
                             • Turn on the HMOP operation ON/OFF switch.

                             • When the [MEM] key is pushed, mode is changed to MEM operation mode.

                             • When the [CYCLE START] key is pushed, automatic operation is started.

                             • When the [FEED HOLD] key is pushed, automatic operation is stopped.
                             • When the [RESET] key is pushed, CNC is reset. Reset and rewind signal should
                             be on for rewinding part program.

                             • Override can be applied to feed rate speed by the override switch on handy
                             machine operator’s panel. Set feed rate override signal from 0% to 120% according
                             to the override switch position.

                             • For test operation [DRY RUN] and [SINGLE BLOCK] are available.

                             • One axis position is displayed normally. When the [XYZ456] key is pushed next
                             axis position is displayed.



 10.4 MANUAL HANDLE          XYZ                           SPINDL             SPINDL
 FEED PROCEDURE                            REF                                               RESET
                             456                           START              STOP
                                                           SPINDL             SPINDL
                            HANDLE        JOG                                                   +
                                                            INC                DEC
                                                           TOOL
                             Xn            MEM                                MESSAGE        RAPID
                                                           REL(F1)
                            SINGLE       DRY               CYCLE              FEED
                                                                                               -
                            BLOCK        RUN               START              HOLD

                             • When the [HANDLE] key is pushed, mode is changed to manual handle feed
                             mode.



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                                    • The axis, which is moved by MPG, is selected by pushing the [XYZ456] key sev-
                                    eral times.

                                    • When [Xn] key is pushed, manual handle feed amount selection is applied.
                                    Please select X1-X10-X100 by pressing several times of this key.

                                    • When the [RESET] key is pushed, the moving axis is stopped.



        10.5 MANUAL JOG             XYZ                           SPINDL             SPINDL
        FEED PROCEDURE                            REF                                               RESET
                                    456                           START              STOP
                                                                  SPINDL             SPINDL
                                   HANDLE        JOG                                                   +
                                                                   INC                DEC
                                                                  TOOL
                                    Xn            MEM                                MESSAGE        RAPID
                                                                  REL(F1)
                                   SINGLE      DRY                CYCLE              FEED
                                                                                                      -
                                   BLOCK       RUN                START              HOLD

                                    • When the [JOG] key is pushed, mode is changed to manual continuous feed
                                    mode.

                                    • The axis, which is moved by the [JOG] key, is selected by pushing the [XYZ456]
                                    key several times.

                                    • When the “+” key is pushed, the desired axis moves to positive direction. When
                                    the “-” key is pushed, the desired axis moves to negative direction.

                                    • When the [RAPID] key is pushed, at the same time, rapid traverse is selected.

                                    • Override can be applied to manual feed rate by the override switch on the handy
                                    machine operator’s panel. Set manual feed rate override signal from 0% to 120%
                                    (0 IPM to 240 IPM) according to the override switch position.

                                    • When the [RESET] key is pushed, the moving axis are stopped.




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 10.6 MANUAL                 XYZ                            SPINDL             SPINDL
 REFERENCE RETURN                          REF                                                 RESET
                             456                            START              STOP
                                                            SPINDL             SPINDL
                            HANDLE         JOG                                                    +
                                                             INC                DEC
                                                            TOOL
                             Xn            MEM                                 MESSAGE         RAPID
                                                            REL(F1)
                            SINGLE       DRY                CYCLE              FEED
                                                                                                 -
                            BLOCK        RUN                START              HOLD

                             • When the [REF] key is pushed, mode is changed to manual continuous feed
                             mode and manual reference position return selection signal “ZRN” is asserted.

                             • The axis, which is moved for manual reference position return, is selected by
                             pushing the [XYZ456] key several times.

                             • When the “+” key or the “-” key is pushed, the axis moves to the direction of ref-
                             erence position.

 10.7 MANUAL
 SPINDLE CONTROL
                             XYZ                            SPINDL             SPINDL
                                           REF                                                 RESET
                             456                            START              STOP
                                                            SPINDL             SPINDL
                            HADNLE         JOG                                                    +
                                                             INC                DEC
                                                            TOOL
                             Xn            MEM                                 MESSAGE         RAPID
                                                            REL(F1)
                            SINGLE       DRY                CYCLE              FEED
                                                                                                 -
                            BLOCK        RUN                START              HOLD

                             • When [SPINDL START] key is pushed, spindle motor is rotated to the direction
                             which is designed with the speed at the decided override.

                             • When [SPINDL STOP] key is pushed, spindle motor is stopped.

                             • When [SPINDL INC] key or the “SPINDL DEC” key is pushed, override of speed
                             is changed. The changing rate is 50% - 120%.

 10.8 KEY SHEET          FANUC standard key sheet A is as follows. This key sheet is put on the standard unit.
 LAYOUT




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                                Tool Release Button (F1 Function)


         10.8.1 TOOL REL            XYZ              REF                 SPINDL                 SPINDL             RESET
                                    456                                  START                  STOP
                                   HADNLE            JOG                 SPINDL                 SPINDL                  +
                                                                          INC                    DEC
                                    Xn               MEM                 TOOL                   MESSAGE            RAPID
                                                                         REL(F1)
                                   SINGLE         DRY                    CYCLE                  FEED                    -
                                   BLOCK          RUN                    START                  HOLD

                                Same function as the TOOL REL button on the operator panel.
                                It is used for manually loading/unloading a tool holder use HMOP when the HMOP
                                switch is on. Operator must be prepared to catch tool from spindle cartridge
                                immediately upon pressing button. Spindle air is turned on along with release of tool.
                                Draw Bar will open after pressing the button more than 1 second and remain open
                                while push button is still held. Spindle must be stopped, with control in JPG or HANDLE
                                modes to enable tool release.
                                   NOTE:
                                    Please refer the operator panel A section for more detail about release function.


        10.9 MESSAGE KEY        When the “MESSAGE” key is pressed, the screen is changed to user message screen.
                                The next message screen is displayed after another pressing the “MESSAGE” key.
                                When the “XYZ456” key is pressed, the screen returns to the screen according to each
                                mode.




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                                                         11.0 APPENDIX

 11.1 M CODE LIST
                          M Command Description                           Remark

                                                                          See Unit II, Section 11.1 of 16i/18i Operator’s
                          M00         Program Stop                        Manual
                                                                          See Unit II, Section 11.1 of 16i/18i Operator’s
                          M01         Optional Program Stop               Manual
                                                                          See Unit II, Section 11.1 of 16i/18i Operator’s
                          M02         End-of-Program                      Manual
                                                                          See Unit II, Section 11.1 of 16i/18i Operator’s
                          M30         End-of-Program                      Manual
                                                                          See Unit II, Section 12.3 of 16i/18i
                          M98         Sub-Program Call                    Operator’s Manual
                                                                          See Unit II, Section 12.3 of 16i/18i
                          M99         Sub Program End                     Operator’s Manual
                          M03         Spindle Start Forward
                          M04         Spindle Start Reverse
                          M05         Spindle Stop
                                                                          Macro Call O9020(DATC). Pass Tool
                                                                          number in macro call
                                                                          Macro Call O9021(ATC). Pass Tool
                          M06         Run Tool Change Cycle , M6 Txx      number in macro call
                                      Coolant ON - Mist Coolant/Coolant
                          M07         Thru Spindle                        Mist Coolant (Coolant 2) Receptacle
                          M08         Coolant ON - Flood Colant
                          M09         Coolant OFF
                                      Set Tool Carousel position to 1     Need to take off the tool from spindle and cycle
                          M11         (ATC Tool Changer ONLY)             the power
                                      FANUC canned cycle positioning,     Canned Cycles, spindle orients normal to X/Y
                          M19         (Not for spindle orientation)       axes
                          M20         Wash Down, Toggle ON/OFF            option
                                                                          When the machine the MIDACO pallet
                          M20         MIDACO pallet change 1              option
                          M20         Does nothing                        Standard.
                          M22         Chip Conveyor Toggle ON/OFF         option
                          M29         Rigid Tap                           M29 Sxxxx in block prior to G84
                          M41         Low Gear Select
                          M42         High Gear Select
                                      100% Spindle Speed Override
                          M48         Forced                              Spindle speed will override selection.
                                      100% Spindle Speed Override
                          M49         Released
                          M60         A Axis Brake ON



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                                 M61         A Axis Brake OFF
                                 M62         B Axis Brake ON
                                 M63         B Axis Brake OFF
                                 M64         M64/65 Output ON
                                 M65         M64/65 Output OFF
                                             M66/67 Output ON, Chip
                                 M66         Conveyor ON
                                             M66/67 Output OFF, Chip
                                 M67         Conveyor ON
                                             M68/69 Output ON, Wash Down
                                 M68         ON
                                             M68/69 Output OFF, Wash Down
                                 M69         OFF
                                             M78/79 Output ON, Cooled spindle
                                 M78         ON(2016 & 3016L)                 option
                                             M78/79 Output OFF, Cooled
                                 M79         spindle OFF(2016 & 3016L)        option
                                 M80         MIDACO Pallet Changer 2               When the machine has MIDACO pallet option
                                 M85         A Axis Rotary Table Enable
                                 M86         A Axis Rotary Table Disable
                                 M87         B Axis Rotary Table Enable
                                 M88         B Axis Rotary Table Disable
                                             Position Tool Drum to Pocket by T-
                                 M100        Word Ex: “M100 T05”
                                              Return the current tool to ATC
                                 M150        carousel(ATC ONLY)                    Only use it with M151
                                             Tranfer the tool from carousel into
                                 M151        spindle.(ATC ONLY)                    Only use it with M150
                                                                                   Orient Tool to angle required for Tool
                                 M190        Spindle Orient for tool changer       Change




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 11.2 ALARM LIST         1. If it is a alarm related with CNC, please refer the CNC operator manual appendix.
                         2. Machine alarm lists.


                                                          Table 1: Alarm list

                           ALARM
                                                                  DESCRIPTION
                            NO.

                          2004          Operator function inhibited/check door overrides. alarm in
                                        cycle...
                          2005          Machine door opens. Feed hold on cycle start is inhibited
                          2006          Door override is active
                          2007          Close machine door to continue or reset to cancel operation
                          2010          Press cycle start to restart spindle
                          2011          Press cycle start to resume program command
                          2020          Low lube oil level refill vactra-2 or equivalent
                          2026          Air-oil fault, illegal table data for air-oil intervals
                          2027          Air-oil fault feed hold/spindle stop forced. See other messages
                          2030          Air-oil low oil pressure fault
                          2031          Air-oil upper bearing pressure failed fault
                          2032          Air-oil lower bearing pressure failed fault
                          2033          Air-oil high oil pressure while pump turned off
                          2034          Air-oil fault. Safety stop machine or stop will be forced
                          2035          Air-oil spindle air/vac pressure failed fault
                          2036          Air-oil level low. Please, refill reservoir
                          2037          Correct fault & use alarm -MSG PBTO all air-oil messages
                          2043          Chip conveyor overload trip maintenance must reset overload
                          2044          Tool arm overload trip maintenance must reset overload
                          2045          Tool magazine overload trip maintenance must reset overload
                          2046          Washdown pump overload trip maintenance must reset over-
                                        load
                          1050          Initial shift fail, CYC CTRT inhibit


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                                                        Table 1: (Continued) Alarm list

                                   ALARM
                                                                       DESCRIPTION
                                    NO.

                                  1051          Lost low gear during operation
                                  1052          Lost HI gear during operation
                                  1054          High to low gear shift failed
                                  1055          Low to high gear shift failed
                                  1083          Tool up at machine on failed
                                  1084          Tool up at drum rotation failed
                                  1086          Stored tool illegal, see OPR MSG
                                  1090          No empty tool pockets available
                                  1091          Invalid tool MGMT data for search
                                  1092          Optional tool MGMT search illegal
                                  1093          Empty pot search illegal data
                                  1094          Empty pot search invalid pot
                                  1095          Tool MGMT search protected
                                  1096          Tool changer initial fault. see msg
                                  1097          No tool changer, cycle start inhibited
                                  1104          ATC tool count switch missing
                                  1110          ATC carousel extend failed
                                  1111          ATC carousel retract failed
                                  1112          ATC carousel e-stop alarm
                                  1120          M85 window R/W data error
                                  1132          5th axis brake on, command halted
                                  1134          4th axis brake on command halted
                                  1360          M84 LOGR CALIB data zero error
                                  1361          M84 LOGR SPDL speed calc error



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                                                 Table 1: (Continued) Alarm list

                            ALARM
                                                                DESCRIPTION
                             NO.

                          1362           M84 low gear shift error
                          1363           M84 LOGR WINDR read sample error
                          1364           M84 LOGR ARBITRARY data error
                          1365           M84 LOGR REV count windr error
                          1366           M84 LOGR COUNT windr error
                          1367           M84 LOGR data out of range error
                          1370           M84 LOGR DISP ratio math error
                          1371           M84 LOGR ratio range error
                          1372           M84 LOGR WINDW par set error 1
                          1373           M84 LOGR WINDW par set error 2
                          1374           M84 LOGR CALIB spindle start error
                          1376           M84 belt calib cycle inhibited
                          1380           M84 high calib data zero error
                          1381           M84 high spindle calc error
                          1382           M84 high gear shift error
                          1383           M84 high windw read sample error
                          1384           M84 high arbitrary data error
                          1385           M84 high rev count windw error
                          1386           M84 high FDBK count windw error
                          1387           M84 high data out of range error
                          1390           M84 high display ratio math error
                          1391           M84 high ration range error
                          1392           M84 high windw par set error 1
                          1393           M84 high calib spindle start error
                          1400           M84 #3741 calc error
                          1401           M84 #3742 calc error


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                                                        Table 1: (Continued) Alarm list

                                   ALARM
                                                                        DESCRIPTION
                                    NO.

                                  1402          M84 max low windw error
                                  1403          M84 #3751 max hi window error
                                  1404          M84 #3751 calc error
                                  1405          M84 shift spindle window error
                                  1406          M84 #3736 calc error
                                  1407          M84 #3736 window error
                                  1410          M84 #3752 window error
                                  1411          M84 #3762 window error
                                  1800          Adaptive feed hold on
                                  1803          Adaptive alarm limit
                                  1804          Adaptive PID error
                                  1805          Adaptive speed error
                                  1806          Adaptive command error
                                  1807          Adaptive function error
                                  2057          PWR down req’d to CLR alarm 1050. Check air pressure 80-
                                                90PSI
                                  2060          Z axis tool change PROX switch not confirming tool change
                                                position
                                  2061          TOOL DRUM pot not up for rotation of tool drum
                                  2062          TOOL DRUM pot not in down position for access by tool
                                                arm
                                  2063          TOOL ARM not in position for tool removal from spindle
                                  2064          DRAWBAR not released for removal of tool from spindle
                                  2065          TOOL ARM not in position for tool insertion into spindle
                                  2066          DRAW BAR not clamped on new tool in spindle
                                  2067          TOOL ARM not returned to park position at end of tool
                                                change



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                                                 Table 1: (Continued) Alarm list

                            ALARM
                                                               DESCRIPTION
                             NO.

                          2070           TOOL CHANGE command aborted tool change service
                                         mode active
                          2071           TOOL CHANGE command aborted spindle frwd, rev, orient
                                         active
                          2075           TOOL CHANGE & SPINDLE, e-stop forced alarm PB to
                                         clear
                          2076           Tool change service mode set
                          2077           Tool chng alarm, alarm PB to CLR cycle start inhibited
                          2081           Current ATC carousel position reset to pocket #1
                          2082           Tool drum at pocket #[I220, D500] press drum position to
                                         clear msg
                          2087           Stored tool value of 1-99999999 is not in legal range to
                                         #[I220,R6134]
                          2100           Axis inhibit by midaco pallet changer
                          2100           No tool changer selected correct K5.X & cycle power
                          2101           Illegal VMC tool changer setting correct K5.X & cycle
                                         power
                          2102           VMC & HMC tool changer both set correct K5.X & cycle
                                         power
                          2131           Use M61 to release 4th axis brake prior to axis command
                                         block
                          2131           Use M62 to release 5th axis brake prior to axis command
                                         block
                          2140           Adaptive warn limit
                          2377           M84 belt calibration active




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        11.3 MACHINE COLD       Fadal Fanuc VMC comes with absolute encoder which is setup in the Fadal already.
        START PROCEDURE         The machine will remember the position even if it is powered off. We need to make the
                                cold start position again if the alarm No.300 appears on the screen which can be
                                caused by low battery or disconnect the servo motor encoder.

                                Follow the next procedure:
                                1. Prepare: In MDI mode input G21 to change machine to Metric display.

                                    1.1 Press the MDI push button on the operator panel A.

                                     1.2 Press PROGRAM key one/two times on the MDI panel until PROGRAM (MDI) screen is dis-
                                    played.

                                    1.3 Press G21 using MDI panel.

                                    1.4 Press EOB key on the MDI panel.

                                    1.5 Press INSERT key.

                                    1.6 Press CYCLE START push button on the operator panel A.

                                    1.7 Make sure the screen is changed to Metric Mode (X***,*** is displayed).

                                    1.8 Press REF RETURN push button on the operator panel A.

                                    1.9 Press Z push button on the operator panel A (Manual Z axis zero return).

                                    1.10 Press X push button on the operator panel A (Manual X axis zero return).

                                    1.11 Press Y push button on the operator panel A (Manual Y axis zero return).

                                    1.12 Preparation is done.

                                2. Reference all the axes.

                                     2.1 Press REF RETURN and select reference mode, then push X/Y/Z key to move X/Y/Z axis to
                                    zero position. CNC screen will display X0Y0Z0.

                                3. Install the tool.

                                    3.1 Press JOG push button on the operator panel A.

                                    3.2 Press TOOL REL push button on the operator panel and keep it. (Draw Bar will be released)

                                    3.3 Put the tool inside of spindle nose.

                                    3.4 Release the TOOL REL push button.



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                         4. Find out X axis zero position manually, make the cold start.

                             4.1 Press HANDLE and select MPG mode, press X1/X10/X100 to select MPG resolution, and press
                             X select to select X axis.

                             4.2 Use TAPE MEASURE find out the X axis middle point of the table, and make a mark.

                             4.3 Use MPG move the X axis to the X axis middle potion mark.

                             4.4 Record the X coordinate displayed on the CNC screen as A.

                             4.5 Press MDI push button on the operator panel A.

                             4.6 Press SYSTEM key on the MDI panel.

                             4.7 Press PARAMETER soft key below the LCD screen.

                             4.8 Press 1850 using MDI panel.

                             4.9 Press NO.SRH soft key below the LCD screen (Parameter 1850 will be displayed).

                             4.10 Move the cursor to X.

                             4.11 Press the X coordinator as following format: 34560 (3.456x10000).

                             4.12 Press INPUT key on the MDI panel (34560 will be displayed on the parameter 1850X column)
                                         ***Alarm 000 will pop up on the alarm window.
                             4.13 Power OFF the CNC (Press “O” button on the operator panel B).

                             4.14 Power ON the CNC (Press “T” button on the operator panel B).
                                        ***Alarm 300X will be displayed on the screen (it is normal).
                             4.15 Press JOG push button on the operator panel A.

                             4.16 Press X push button on the operator panel A.

                             4.17 Press “-” minus push button to move the X axis 55.0mm or more (press “+” push button if
                             machine is 2016, 3016, EMCD, 2216).

                              4.18 Press “+” plus push button to move the X axis middle position (press “-” push button if machine
                             is 2016, 3016, EMCD, 2216).

                             4.19 Press REF RETURN push button.

                             4.20 Press X push button. (X axis will automatically move to the zero position)

                              4.21 In case if zero position is wrong, repeat the previous steps starting with pressing MDI push
                             button of the operator panel A.

                             4.22 Double check the cold start position using tape measure.


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                                    4.23 Press RESET key on the MDI panel. That will reset the 300 alarm.

                                5. Find out Y axis zero position manually, make the cold start.

                                    5.1 Install the indicator on the spindle.

                                    5.2 Repeat the same procedure as 4.1-4.23 to find out the Y axis cold start position.

                                6. Find out Z axis zero position manually, make the cold start.

                                    6.1 Install tool on the arm (DATC) or Magazine (ATC).

                                    6.2 Measure the height of the tool.

                                    6.3 Install the tool on the spindle.

                                    6.4 Use MPG move the Z axis to the same height as the tool on the ARM/Magazine.

                                    6.5 Repeat the same procedure as 4.5-1.23 to find out the Z axis cold start position.

                                7. Repeat the same procedure for A/B axis.

                                8. Cold Start setup is finished.



        11.4 FANUC FILES        Please prepare the compact flash card.
        BACKUP PROCEDURE
                                Backup of data files procedure:
                                1. Power on VMC.
                                2. Place flash card in pendant’s drive. (Located to left of pendant display).
                                3. Power on pendant “I” key.
                                4. Wait for pendant to boot up.
                                5. Press “System” key on pendant.
                                6. Press “Edit” key on pendant.
                                7. Soft key “+” twice.
                                8.
                                9. Soft key “ALL IO”.
                                10. Soft key “PRGRM”.
                                11. Soft key “OPRT”.
                                12. Soft key “PUNCH”.
                                13. Enter file name “1”.
                                14. Soft key “EXEC”.            File called “1.)08504” should be created
                                15.
                                16. Soft key “<“.


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                         17.   Soft key “PARAM”.
                         18.   Soft key “OPRT”.
                         19.   Soft key “PUNCH”.
                         20.   Enter file name “2”.
                         21.   Soft key “EXEC”.       File called “2.) CNCPARAM.DAT” should be created
                         22.
                         23.   Soft key “<“.
                         24.   Soft key “OFFSET”.
                         25.   Soft key “OPRT”.
                         26.   Soft key “PUNCH”.
                         27.   Enter file name “3”.
                         28.   Soft key “EXEC”         File called “3.) TOOLOFST.DAT” should be created
                         29.
                         30.   Soft key “<“.
                         31.   Soft key “+” (next page).
                         32.   Soft key “MACRO”.
                         33.   Soft key “OPRT”.
                         34.   Soft key “PUNCH”.
                         35.   Enter file name “4”.
                         36.   Soft key “EXEC”           File called “4.) MACROVAR.DAT” should be created
                         37.
                         38.   Soft key “<“.
                         39.   Soft key “PITCH”.
                         40.   Soft key “OPRT”.
                         41.   Soft key “PUNCH”.
                         42.   Enter file name “5”.
                         43.   Soft key “EXEC”          File called “5.) PITCHERR.DAT” should be created
                         44.
                         45.   Soft key “<“.
                         46.   Soft key “WORK”.
                         47.   Soft key “OPRT”.
                         48.   Soft key “PUNCH”.
                         49.   Enter file name “6”.   File called “6.) WORK-G54.DAT” should be created
                         50.   Soft key “EXEC”
                         51.
                         52.   Soft key “<“.
                         53.   Soft key “+” (next page).
                         54.   Soft key “TOOL”.
                         55.   Soft key “OPRT”.
                         56.   Soft key “PUNCH”.
                         57.   Enter file name “7”.
                         58.   Soft key “EXEC”           File called “7.) TOOL-MNG.DAT” should be created
                         59.
                         60.   Soft key “<“.
                         61.   Soft key “MAG”.


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                                62. Soft key “OPRT”.
                                63. Soft key “PUNCH”.
                                64. Enter file name “8”.
                                65. Soft key “EXEC”           File called “8.) MAGAZINE.DAT” should be created
                                66.
                                67. Soft key “<“.
                                68. Soft key “CUSTOM”.
                                69. Soft key “OPRT”.
                                70. Soft key “PUNCH”.
                                71. Enter file name “9”.
                                72. Soft key “EXEC”             File called ”9.) CUSTOMIZ.DAT” should be created
                                73.
                                74. Soft key “<“.
                                75. Soft key “STATUS”.
                                76. Soft key “OPRT”.
                                77. Soft key “PUNCH”.
                                78. Enter file name “10”.
                                79. Soft key “EXEC”              File called “10.) STATUS.DAT” should be created
                                80.
                                81. Soft key “<“.
                                82. Soft key “+” five(5) times.
                                83. Soft key “PMC”.
                                84. Soft key “IO”.
                                85. Soft key “M-CARD”.
                                86. Soft key “WRITE”.
                                87. Soft key “LADDER”.
                                88. File name should appear as “PMC-SB.000”.
                                89. Soft key “EXEC”.             File called “11.) PMC-SB.000” should be created
                                90.
                                91. Soft key “<“.
                                92. Soft key “IO”.
                                93. Soft key “M-CARD”.
                                94. Soft key “WRITE”.
                                95. Soft key “PARAM”.
                                96. File name should appear as “PMC-SB.PRM”.
                                97. Soft key “EXEC”.            File called “12.) PMC-SB.PRM” should be created
                                98.
                                99. Soft key “<“ two (2) times.
                                100.Soft key “SYSTEM”.
                                101.Soft key “OPRT”.
                                102.Soft key “PUNCH”.
                                103.Soft key “EXEC”.         File called “13.) SYS_CONF.DAT” should be created




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                                                           12.0 INDEX


                         A
                         Air Pressure 1
                         Alarm List 41
                         Alarm MSG 5
                         Auto 5
                         Auto Cool 29
                         Auto Operation 23
                         Automatic Operation Mode 11

                         B
                         Block Delete 15

                         C
                         Coolant Control Push Buttons 29

                         D
                         DNC Operation 13
                         Door OVRD 5
                         Drum FWD 19
                         Drum PSN 19
                         Drum REV 19
                         Dry RUN 16

                         E
                         Edit 5
                         Edit the Tool Magazine List 26
                         Emergency Stop 4

                         F
                         Fanuc Files Backup Procedure 48
                         Flood Cool 29
                         Flood Coolant 2
                         Function 17

                         H
                         Handle 6
                         Handle Operation 9
                         HMOP Operation ON/OFF Switch 34
                         Home PSN 17


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                                I
                                INC Jog Operation 9
                                INIT Mag 25

                                J
                                Jog 6
                                Jog Feed Rate 10
                                Jog Operation 8

                                K
                                Key Sheet Layout 37

                                L
                                Load PSN 18

                                M
                                M Code / S Code 31
                                M Code List 39
                                Machine Cold Start Procedure 46
                                Manual Handle Feed Procedure 35
                                Manual Jog Feed Procedure 36
                                Manual Operation 19
                                Manual Operation Modes 7
                                Manual Reference Position Return 7
                                Manual Reference Return 37
                                Manual Spindle Control 37
                                Manual Spindle Speed 32
                                MC LCK 15
                                MDI 5
                                MDI Operation 11
                                Memory Operation Procedure 35
                                Memory Protection 12
                                Memory Protection key 14
                                Message Key 38
                                Mist Cool 29

                                O
                                Oil Reservoir 1
                                Operation Mode Selection 5
                                Option Stop 15
                                Override Switch 34

                                P
                                Power on 3
                                Power off 3


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                         Program Stop 15

                         R
                         Remote 6
                         Ref return 6
                         Reference the drum 23

                         S
                         Spindle cooler reservoir 2
                         Single block 15
                         Spdl stop 30
                         Spdl CW 30
                         Spdl CCW 30
                         Spindle Speed range 31
                         Spindle override 32
                         Spindle orientation 32

                         T
                         Tool meas 17
                         Tool rel 20, 38,
                         Tool chng 21
                         Tool load 21
                         Tool changer command 23
                         Tool data 25
                         Tool brkn 26
                         Tool order procedure 26
                         Tool loading 26
                         Tool changer 27

                         W
                         Work light 5
                         Work meas 17

                         Z
                         Z Home 18




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