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Optimum Optimill F3, Operating Manual

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OPTIMUM

M A S C H I N E N   -   G E R M A N Y

Maintenance

Version 1.0  dated 2015-05-27 

Page 160

Original operating instructions

F3

GB

10

Maintenance

In this chapter you will find important information about

Inspection

Maintenance

Repair

of the CNC machine. 

ATTENTION!

Properly performed regular maintenance is an essential prerequisite for

operational safety,

failure-free operation,

long service life of the CNC machine and

the quality of the products which you manufacture.

Installations and equipment from other manufacturers must also be in good order and condition.

ENVIRONMENTAL PROTECTION

During work on the cooling lubricant equipment please make sure that

collecting containers with sufficient capacity for the amount of liquid to be collected 
are used.

Liquids and oils should not be split on the ground.

Clean up any spilt liquid or oils immediately using proper oil-absorption methods and dispose of
them in accordance with current environmental protection regulations.

Collect leakages

Do not re-introduce liquids spilt outside the system during repair or as a result of leakage from
the reserve tank; collect them in a collecting container for disposal.

Disposal

Never dump oil or other environmentally hazardous substances which are harmful to the envi-
ronment in water inlets, rivers or channels. Used oils must be delivered to a collection centre.
Please consult your supervisor for further information on your nearest collection point.

10.1

Operating material

10.1.1 Machine lubricants

Only use appropriate lubricants which guarantee a safe operation of the machine.
Recommended lubricant class: ISO VG68
Recommended lubricant:  guideway oil Mobil Vactra (Oil No. 2)

10.1.2 Cooling lubricants

In order to avoid interferences during operation the water-mixed cooling lubricant and the slide-
way oil or grease need to be compatible.

INFORMATION

The CNC milling machine is lacquered with a 

one-component paint

. Take this criterion into

account when selecting your cooling lubricant.
The company Optimum Maschinen Germany GmbH does not assume any guarantee for sub-
sequent damages due to unsuitable cooling lubricants.
The flashpoint of the emulsion must be higher than 140°C. 

Summary of Contents for Optimill F3

Page 1: ...GB OPTIMUM M A S C H I N E N G E R M A N Y Operating manual Version 1 0 CNC milling machine...

Page 2: ...1 Personal protective equipment 15 1 12 Safety during operation 15 1 13 Safety during maintenance 16 1 14 Disconnecting and securing the CNC machine 17 1 14 1 Using lifting equipment 17 1 14 2 Mechani...

Page 3: ...the coordinate calculation 38 4 3 2 Parameters of a triangle 38 4 3 3 Angle on a triangle 38 4 4 Trigonometric functions 39 5 User interface machine control panel 5 1 Screen arrangement 40 5 2 Elemen...

Page 4: ...ed cooling lubricants 168 11 Ersatzteile Spare parts F3 11 1 Ersatzteilbestellung Ordering spare parts 169 11 2 Elektrische Ersatzteile Electrical spare parts 169 11 3 Schaltplan Wiring diagram 169 11...

Page 5: ...ife In the paragraph Maintenance all maintenance works and functional tests are described which the operator must perform in regular intervals The illustration and information included in the present...

Page 6: ...nforms you about how to avoid dangers In addition to these operation instructions please observe the applicable laws and regulations the statutory provisions for accident prevention the prohibition wa...

Page 7: ...that can cause serious injury or death CAUTION A danger or unsafe procedure that can cause personal injury or damage to property ATTENTION Situation that could cause damage to the CNC machine and prod...

Page 8: ...igned and manufactured to be used in a non explosive environment Intended use If the CNC machine is used in any way other than described above modified without the approval of the company Optimum Masc...

Page 9: ...he workpiece is firmly clamped in the machine vice resp that the machine vice is firmly clamped on the machine table Use cooling and lubricating agents to increase the durability of the tool and to im...

Page 10: ...nnel of the CNC machine Determine clearly and explicitly who will be responsible for the different activities on the CNC machine operation setting up maintenance and repair Please note the name of the...

Page 11: ...nformation on the website of Siemens http www cnc4you siemens com WARNING Inappropriate operation and maintenance of the CNC machine constitutes a danger for the personnel objects and the environment...

Page 12: ...only be used if you the cause of the fault has been eliminated you have verified that there is no danger to personnel or objects WARNING If you bypass remove or deactivate a safety device in any othe...

Page 13: ...d off 1 9 2 Emergency stop button ATTENTION The EMERGENCY STOP push button immediately stops the operation of the CNC machine Press the EMERGENCY STOP button only if there is a risk If this push butto...

Page 14: ...after a certain time Prolonged exposure from polycarbonate windows to cutting fluids can lead to accelerated age ing i e deterioration of the mechanical properties brittleness Coolant vapours detergen...

Page 15: ...cleaned after each use and at least once a week 1 12 Safety during operation WARNING Before activating the CNC machine ensure that this will not endanger other persons or cause damage to equipment Av...

Page 16: ...ngerous materials and preparations according to para 4a of the Ordinance of Hazardous Substances In case of a fire with magnesium only use appropriate and admitted extinguishing agents Never extinguis...

Page 17: ...uipment are of sufficient load bearing capability and are in perfect condition Fasten the loads carefully Never walk under suspended loads 1 14 2 Mechanical maintenance work Remove or install protecti...

Page 18: ...hat arising foreseeable defects can be detected in time The relevant electro technical rules must be followed during the inspection The inspection prior to initial commissioning is not required if the...

Page 19: ...ing instructions F3 GB Please follow the requirements of the Water Resources Law when operating decommissioning or disassembling the CNC machine or parts hereof Detailed information regarding this can...

Page 20: ...50Hz 2 5 KW performance spindle drive 1 5 KW Torque 10 Nm Speed 200 4000 min 1 Spindle seat ISO 30 BT 30 x 45 Power of the coolant lubricant pumps W 95 Tank capacity l 50 Connection MPa 0 8 8 bar Air...

Page 21: ...cy 2 8 Milling table Height mm Installation plan F3 on page 27 Depth mm Width mm Total weight kg 1400 X axis mm 355 Y axis mm 190 Travel of Z axis mm 245 Z axis Distance spindle milling table mm 20 un...

Page 22: ...degree of the noise emission and the degree of the noise disturbance it is not possible to use it reliably to determine if further precaution measures are required or not The following factors influe...

Page 23: ...05 27 Page 23 Original operating instructions F3 GB 2 12 Tools and tool holding fixtures CAUTION When using tools with larger diameters or at higher speeds The balancing of the tools has to amount to...

Page 24: ...OPTIMUM M A S C H I N E N G E R M A N Y Technical data Version 1 0 dated 2015 05 27 Page 24 Original operating instructions F3 GB...

Page 25: ...may occur if the machine or parts of the machine tumble or fall down from the forklift truck or from the transport vehicle Follow the instructions and information on the transport box WARNING The use...

Page 26: ...s damaged during transport WARNING The use of unstable lifting and load suspension equipment that might break under load can cause severe injuries or even death Machine mounting on page 28 3 3 Install...

Page 27: ...issioning Version 1 0 dated 2015 05 27 Page 27 Original operating instructions F3 GB 3 3 2 Installation plan F3 A A 0 06 A A 1600 850 700 2010 1165 680 1445 1540 135 495 495 1735 P20 Electrical connec...

Page 28: ...anchored assembly in order to attain a firm connection to the ground An anchored assembly is always reasonable if parts are manufactured to the maximum capacity of the CNC machine ATTENTION An insuffi...

Page 29: ...o operate the machine it is necessary to remove this plug and to connect the machine directly with a power supply Firmly connect the CNC machine to the terminal box It is not allowed to connect the ma...

Page 30: ...st be followed There are three common types of FI ELCB RCD AC to detect AC fault currents A to detect AC fault currents and pulsating DC fault currents provided the DC current reaches zero at least on...

Page 31: ...are lubricated by the cooling lubricant Do not start up the pumps without cooling lubricant INFORMATION Use a water soluble environmentally friendly emulsion as cooling lubricant procured from a speci...

Page 32: ...e EC safety data sheet gives you information about the water hazard class They need to be environmentally friendly and workplace friendly Thus they need to be free of nitrite PCB chlorine and nitrosat...

Page 33: ...ing points automatically The cycle time is fixed and can not be changed The discharge volume per cycle can be reduced however should remain at the factory set ting Function Lubricator is a motor drive...

Page 34: ...3 GB Reducing the discharge volume per cycle To reduce oil delivery remove lock screw measure A turn adjusting screw clockwise increasing A by B dimension as shown on table Choke manifold system Centr...

Page 35: ...g door and turn on the coolant supply Check if cooling agent flows WARNING Never change the dosing of the cooling lubricant supply when a program is running If no coolant is flowing and thus the rotat...

Page 36: ...system and the polar coordinate system 4 2 1 Cartesian coordinate system A Cartesian coordinate system also called a rectangular coordinate system possesses two coordinate axes two dimensional Cartes...

Page 37: ...tem also called machine zero point cannot be changed Any tool moves are generally defined in a standardized right handed coordinate system Turns from X to Y are created in Z direction which result in...

Page 38: ...order to calculate the missing coordinates the relations valid for a triangle are very useful There are several options to describe a triangle Some of the following parameters e g corners angles or si...

Page 39: ...s between the angles and the sides of a rec tangular triangle With the help of these trigonometric functions it is possible to calculate unknown leg lengths with an unknown angle and a known leg It is...

Page 40: ...808D OPM Operation Img 5 1 Screen arrangement 1 2 6 7 5 3 4 13 11 12 10 8 9 Status area Application area Active operating area Actual value window Active operating mode T F S window Alarm and message...

Page 41: ...of the operating instructions for SINUMERIK 808D OPM Operation Description Vertical and horizontal softkeys Calls specific menu functions Return key Returns to the next higher level menu Menu extensi...

Page 42: ...left of the cursor Delete key Deletes the selected file or character Insert key Tab key Indents the cursor by several characters Toggles between the input field and the selected program name Input key...

Page 43: ...d Cursor keys Cursor keys up down left right keys Next window key No function is assigned to this key Reserved for future use End key Moves the cursor to the end of a line Page up key Scrolls upwards...

Page 44: ...he EasyXLanguage function For more information about this function refer to the SINUMERIK 808D Function Manual USB interface Connects to a USB device Examples Connects to an external USB memory sticke...

Page 45: ...LT B Opens the Program operating area ALT M Opens the Alarm operating area ALT N SHIFT Opens the System operating area ALT H Calls the online help system ALT L Enables input of lowercase letters ALT S...

Page 46: ...Drive voltage Push button with indicator light Indicator light On drive voltage activated Indicator light Off drive voltage deactivated 1 2 5 3 4 6 7 8 9 10 11 12 Excerpt from the manual of the operat...

Page 47: ...ing mode MDA Manual program input automatic execution Program control keys all with LED status indicators Program test key Disables the output of setpoints to axes and the spindle The control system o...

Page 48: ...only in JOG mode Pressing this key rotates the magazine clockwise LED on The magazine rotates clockwise LED off The magazine stops clockwise rotation INFORMATION The F3 does not have a tool changer T...

Page 49: ...g mode rotates the chip conveyor in reverse order Releasing the key changes the chip conveyor to the previous forward rotation or stop state LED on The chip conveyor starts reverse rotation LED off Th...

Page 50: ...rapid traverse speed while pressing the relevant axis key Inactive key No function is assigned to this key Incremental feed keys with LED status indicators Sets increments desired for the axis to trav...

Page 51: ...software release ATTENTION Before you boot the control system with default machine data make sure that you havebacked up your data otherwise all data is lost after rebooting with the default machineda...

Page 52: ...sword is set and no protection level interface sig nal is set The protection level 7 can be set from the PLC user program after you set the bits in the user interface In the menus listed below the inp...

Page 53: ...he CNC machine immediately in the event of any failure in operation and make sure that it cannot be started up accidentally or without authorization Notify the person responsible immediately of any mo...

Page 54: ...anual resp part programming For this kind of programming the programs must be created manually and entered in the con trol unit The direct programming in the DIN Code is a complex method which require...

Page 55: ...5 1 Turning on the CNC machine Switch on the main switch Lockable main switch on page 12 Wait until the control is completely started Press the push button Drive control ON Unlock the Emergency Stop p...

Page 56: ...e zero points you cannot start and run programs in the control With the beginning of the reference point approach the axes should be located in a ccentral position as possible The following informatio...

Page 57: ...es can be moved manually Use the Increment button to specify the increment or press the JOG button again to stop the increment again If possible read the upcoming mes sages on the display remove the e...

Page 58: ...er to the mode JOG Press the Offset key on the machine control panel Press the Tool list softkey For the following working steps please proceed as described in Operation and programming of the Siemens...

Page 59: ...dle head 6 5 6 Clamping the workpiece ATTENTION The workpiece is always to be fixed by a machine vice jaw chuck or by another appropriate clamping tool such as for the clamping claws When setting and...

Page 60: ...ng Construction data are transmitted semi automatically to an executable program by means of the CAD CAM program for instance a 3D CAD program including downstream co processor For this kind of progra...

Page 61: ...ntrol is equipped with the following data interfaces X130 Ethernet port RJ45 connector only 808D ADVANCED USB connection Connection for power supply 6 11 Selecting the speed The correct speed is an im...

Page 62: ...4 1194 1911 796 1592 11900 19000 5 955 1529 637 1274 9550 15900 6 796 1274 531 1062 7900 13200 8 597 955 398 796 5900 9900 10 478 764 318 637 4700 7900 12 398 637 265 531 3900 6600 14 341 546 227 455...

Page 63: ...amp INFORMATION Friction during the cutting process causes high temperatures at the cutting edge of the tool The tool should be cooled during the milling process By cooling with an appropriate coolant...

Page 64: ...nit describes the 808D PPU and MCP functionality the coordinate system of a milling machine and how to enter passwords to access the system Content Basic Theory PPU Function of keyboard MCP mode Chang...

Page 65: ...chine functions The machine functions can be activated with the appropriate keys Axis movement OEM keys MCP Moving axis MCP OEM keys 808D PPU has eight vertical softkeys abbr SKs on the right of the s...

Page 66: ...t the user s right to access the system Tasks such as Basic Operating Advanced Operating and commissioning functions all depend on the passwords No password Customer s password Manufacturer s password...

Page 67: ...it Content SEQUENCE Switch on the machine End PPU Function of keyboard MCP mode Changing Reference the machine Switch on the machine Please note the explicit switching on rules as specified by the ma...

Page 68: ...s not referenced the non referenced symbol circle is displayed between the axis identifier and the value The axes are referenced with the corresponding axis traversing keys The traversing direction an...

Page 69: ...tent SEQUENCE Start spindle End User interface Machine coordinate system Load tool into active position Create tool edge Move machine with handwheel Create tool Measure tool JOG spindle Execute M func...

Page 70: ...tool Milling tool Tapping tool Ball end mil tool Drilling tool New milling tool Tool list Tool No milling tool Identifier A tool must have been created and selected before creating a tool edge Use D c...

Page 71: ...s as required Please select the right tool edge for machining according to requirement Step 2 New edge Reset edge Delete edge Back User data Sett data R var Work offset Tool wear Tool list Tool list A...

Page 72: ...MCS state a handwheel will be shown beside the axis symbols showing the axis is chosen and can be controlled with a handwheel Move machine with handwheel Select the required override increment accordi...

Page 73: ...the PPU Press the CYCLE START key on the MCP Start spindle T S M Tool change Spindle speed Spindle direction Activate zerooffset Other M function rpm Back Sett Meas tool Meas work Set rel Face cutt Pr...

Page 74: ...ly to zero point Use a setting block Use SELECT key to set the reference point as workpiece In real measurement the reference point can be set as either workpiece or fixed point if required Enter 0 fo...

Page 75: ...d position the tool at the location X0 or a of the workpiece or a Move directly to zero point Use a setting block Enter 0 at X0 Enter 0 at Y0 This is the value of the width of a setting block if it is...

Page 76: ...kwise direction Machine coordinate system JOG spindle Please make sure all the machine axes are in safe positions before executing the M function Press the Machine key on the PPU Press the T S M SK on...

Page 77: ...offset A tool must have been loaded into the spindle Press the Machine key on the PPU Press the JOG key on the MCP Before measuring the spindle can be started as follows Press the T S M SK on the PPU...

Page 78: ...have be created and measured before it can be used to set the workpiece offset Make sure the active tool is the measured tool As the following red frame shows 808D provides the user with three method...

Page 79: ...Press the corresponding SK of the first icon on the right hand side of the PPU Press the appropriate SK to select the feed axis which needs to be set up Press the axis traverse keys to move the tool t...

Page 80: ...P3 Save P4 Set WO Workpiece measurement center of rectangle Work offset G54 Offset Compensation data have been activated T S M Set rel Meas work Meas tool Face cutt Save P4 Set WO Back Sett This meth...

Page 81: ...ould be tested appropriately Press the Delete file SK on the PPU Enter the test program recommended on the right can also be customized G54 select offset panel as required T1 D1 G00 X0 Y0 Z5 Press the...

Page 82: ...viors at corners Milling circles and arcs Moving to a fixed position Controlling the spindle Setting a delay in the program A standard program structure is not needed but is recommended in order to pr...

Page 83: ...orage location for the program Programs can only be created in the NC Create a new program with the New SK on the right of the PPU Step 1 Step 2 Step 3 Create program Name Type Length Date Time Execut...

Page 84: ...M6 N15 S5000 M3 G94 F300 N20 G00 X100 Y100 Z5 N25 G01 Z 5 N30 Z5 N35 G00 Z500 D0 G71 With G71 at the header the geometry data will be in the metric unit system the feedrate in the default metric syste...

Page 85: ...G53 Z500 D0 G500 G54 With G500 unequal to 0 and be activated the value in G500 will be added to the value in G54 X50 Y50 G500 X G500 Y X50 Y50 G54 X G54 Y G54 X0 G500 X G500 Y G54 Y0 Machine coordinat...

Page 86: ...e coordinate system Tools and motion Feedrate Spindle speed Feed type Spindle direction In the program the feed rate is defined with F Two types of feed rate are available 1 Feed per minute G94 2 Feed...

Page 87: ...cutter radius compensation it should be decided whether the feed rate should be calculated along the contour of the workpiece or along the path defined by the center point of the cutting tool When us...

Page 88: ...35 Y50 N40 X100 N45 G02 X125 Y15 I 12 J 35 N50 G01 Y0 N55 X0 N60 G40 X 20 Y 20 N35 G00 Z500 D0 Note N45 can also be written as follows N45 G02 X125 Y15 CR 37 Two common types of defining circles and a...

Page 89: ...point Moving to a fixed position The following functions can be used to influence the operation of the spindle M3 accelerate to programmed speed clockwise M4 accelerate to programmed speed counter clo...

Page 90: ...illing holes Tapping Milling slots and spigots The two radii and the chamfer shown in the diagram can be produced with the code marked in the program below actual effect RND Radii CHR Chamfer specifie...

Page 91: ...drilling actual effect With the OK SK the values and cycle call will be transferred to the part program as shown below This will drill a hole at the current position With the Modal call SK holes will...

Page 92: ...ing Center drilling Deep hole drilling Boring Thread Hole pattern Deselect modal Edit Cont Drill Mill Active Sim Re comp Retract plane absolute Modal call Cancel OK actual effect With the OK SK the va...

Page 93: ...TS 0 5 Stops at the start position for 0 5 s for VARI 1 removal active DTS 0 Unit is r FRF 1 range 0 001 1 Original effective feed rate remains unchanged Feed rate modulus VARI 0 Interruption in drill...

Page 94: ...ing the vertical SKs and then select Rigid tapping and parameterize the cycle according to requirement Tapping Drill Thread Rigid tapping Retract plane absolute Modal call Cancel OK With the OK SK the...

Page 95: ...AXH VARI DAM and VRT please see Page 93 Parameters Meanings Remarks DTB 0 7 Pause 0 7 s during final tapping to thread depth discontinuous cutting SDAC 5 Spindle state after cycle is M5 Enter values 3...

Page 96: ...Deselect modal Re comp Sim Active Mill Drill Cont Edit Center point of hole circle 1st axis Cancel OK Parameters Meanings CPA 36 Center of hole circle horizontal coordinate is 36 absolute value CPO 24...

Page 97: ...te Renumber Search Mark On Paste Re comp Simu Active Mill Drill Cont Edit Copy By selecting the New file SK the contour turning data can be inserted into Sub Program File SPF You can edit and change i...

Page 98: ...om the technical drawing After completing the steps the system will return to the edit interface Press Technical interface on the PPU to return to the interface for setting the cycle data After finish...

Page 99: ...wance at the bottom plane is 0 mm FFP1 300 Tool feed rate on plane is 300 mm min FFD 100 Feed rate after inserting the tool in the material is 100 mm min VARI 111 Use G1 to perform rough machining and...

Page 100: ...se the SLOT2 cycle The cycle can be found and parameterized via the Mill SK The relevant cycle can be found using the vertical SKs on the right Select slot using the vertical SKs and parameterize the...

Page 101: ...een the effective work piece horizontal coordinate in positive direction and the first circle slot is 165 INDA 90 Incremental angle angle between the slots is 90 INDA 0 cycle will calculate the increm...

Page 102: ...OPTIMUM M A S C H I N E N G E R M A N Y 808D Page 102 Operating and Programming Milling Create Part Program Part 2 Brief instruction 808D Milling...

Page 103: ...rogram Description This unit describes how to simulate a part program before executing it in AUTO mode Content Basic Theory End Simulate program Axis do not move Simulate program Axis do not move The...

Page 104: ...he control is not in the correct mode a message will be displayed at the bottom of the screen If this message is displayed at the bottom of the screen press the AUTO mode key on the MCP Step 3 Press t...

Page 105: ...asic Theory End Program Execution Dry Run Before the part program can be loaded and executed in AUTO mode it must be tested using the simulation function mentioned previously Program Execution Press t...

Page 106: ...e required position The position is now highlighted Enter the required feedrate in mm min enter 2000 in the example Press the Input key of the PPU Press the Machine key on the PPU Press the Prog cont...

Page 107: ...how to use the Time counter function and how to machine pieces and the compensation setting for the tool wear Content Basic Theory End Time Counter Piece Machining User interface Tool Wear Make sure...

Page 108: ...n Required Actual shows the number of workpieces that have been machined Piece Machining Make sure the program is correct before machining pieces Set the program in the ready to start status as shown...

Page 109: ...nsation Set the tool length wear parameter of axis X in Length X the sign determines the direction of wear compensation Set the tool length wear parameter of axis Z in Length Z the sign determines the...

Page 110: ...e key on the PPU Press the Auto key on the MCP Press the Block search SK on the PPU Block Search Press the Interr point SK on the PPU and the cursor will move to the last interrupted program line Note...

Page 111: ...must always be set to 0 Make sure the correct tool is selected before continuing Press the CYCLE START key on the MCP to execute the program Alarm 010208 is shown at the top prompting to press the CYC...

Page 112: ...DVANCED Time change Help Manual face cutting Save data Gear change RS232 USB RS232 USB RS232 is used to transfer the programs to and from the NC Step 1 Press Program Manager on the PPU Press the RS232...

Page 113: ...PCIN to start the receive function Press the Send SK on the PPU The PPU will display a window showing the progress of the transfer If there is a problem during transfer of the part program a window w...

Page 114: ...5 Use Cursor Select to select the required part program The selected program will be highlighted Press the Copy SK on the PPU Press the USB SK on the PPU Use the Copy and Paste SKs to transfer the pa...

Page 115: ...ata storage end is displayed the input data activation effect Step 2 Set the PC s static IP address Ensure PC PG is connected using a network cable to rear X130 PPU Ethernet port Open the PC s network...

Page 116: ...tivate the settings In this folder you can put some machining program Step 4 Add the network drive on the PPU side to activate the shared folder and online processing In the Network drive configuratio...

Page 117: ...Button to open network drive to PC PG This will re establish the connection with PC PG This will be shown with the text Connection succeeded You can now see the content of the shared folder with all t...

Page 118: ...Press the Help key on the PPU The help information related to the current topic will be shown on screen Press the OEM Manual SK on the PPU The online help manual of the OEM will be shown on the screen...

Page 119: ...data in the Face Milling window according to the machining requirement Use the button on the right side of the PPU to select the cutting path of the tool during machining Press the OK SK on the PPU T...

Page 120: ...buffering The following block is not executed until all preprocessed and saved blocks have been executed in full The preceding block is stopped in exact stop as with G9 Arithmetic parameters Meaning A...

Page 121: ...level Press the HMI SK on the PPU Press the Date time SK on the PPU Enter a new Date and Time Press the OK SK on the PPU Press the Cancel SK on the PPU to abort the operation Save data Save data enab...

Page 122: ...llowing M codes can be used to change gear in the part program Gear stages M40 M41 M42 M43 M44 and M45 are available M40 Automatic gear selection M41 Gear stage 1 M42 Gear stage 2 M43 Gear stage 3 M44...

Page 123: ...em MDA M H function Subprogram Polar coordinates Machine coordinate Additive workpiece offsets User interface Coordinate rotation ROT AROT Scaling Program example Program jump Program skip Calculator...

Page 124: ...m and then executed Subprogram for positions of the four pockets Example The structure of a subprogram is identical to that of the main program but a subprogram contains M17 end of program in the last...

Page 125: ...to the plane activated with G17 to G19 In addition the third axis perpendicular to this plane can be specified When doing so spatial specifications can be programmed as cylindrical coordinates The po...

Page 126: ...recurring shapes arrangements in various positions on the workpiece When selecting a new reference point for dimensioning This results in the current workpiece coordinate system N10 G17 X Y plane N20...

Page 127: ...scale change SCALE X Y Z programmable rotation offset absolute ASCALE X Y Z programmable offset additive to existing offset incremental If a program contains SCALE or ASCALE this must be programmed i...

Page 128: ...0 5 0 0 300 100 0 11 5 5 3 N70 LAB2 N75 M01 N80 ROT RPL 100 N85 REPEAT LAB1 LAB2 P1 N90 M01 N95 AMIRROR X 1 N100 AROT RPL 20 N105 M01 N110 REPEAT LAB1 LAB2 P1 N115 AROT RPL 10 N120 ATRANS Y 60 N125 A...

Page 129: ...This block must be located within the program The unconditional jump command requires a separate block GOTOF label Jump forward in the direction of the end block of the program GOTOB label Jump backw...

Page 130: ...Z5 N85 T2 D1 M6 Tool change N90 S5000 M3 G94 F300 N95 G00 X60 Y55 Z10 Method 1 Using code at the beginning of the program block N95 this string will be skipped without execution Using code to add a re...

Page 131: ...ffsets and enter the results on the screen Press the SK on the PPU Press this SK to delete the contents in the calculator Press this SK to exit the calculator screen Use this SK to accept the input an...

Page 132: ...milling cycles and the corresponding machining diagrams with detailed explanations Content Drawing End Machine coordinate system Milling program 1 Milling program 2 Milling program 3 Make sure all th...

Page 133: ...h13 mm width 10 mm corner radius 4 mm groove base point coordinate X 13 Y16 angle between groove vertical axis and plane X axis is 0 feedrate 300 mm min milling direction G2 rough machining use G1 ver...

Page 134: ...illing circular groove depth 5 mm radius 7 5 mm groove basic point coordinate X0 Y0 the clamping angle between the groove vertical axis and plane X axis is 0 finish machining allowance 0 1 mm milling...

Page 135: ...nce 0 1 mm along the direction parallel to the X axis to perform the rough machining N80 N90 start point X0 Y0 the length and the width are 50 mm feedrate 250 mm min finishing allowance 0 along the di...

Page 136: ...tart N130 T3 D1 N140 MSG Please change to Tool No 3 N150 M05 M09 M00 N160 S5000 M3 G94 F300 N170 G00 X 6 Y92 N180 G00 Z2 N190 G01 F300 Z 10 N200 G41 Y 90 N210 G01 X12 RND 5 N220 G01 Y97 CHR 2 N230 G01...

Page 137: ...ling direction G3 slot edge finishing allowance 0 2 mm complete machining ways finishing machining feedrate 250 mm min spindle speed rate 3000 r min Slot milling end N430 SUPA G00 Z300 D0 N440 SUPA G0...

Page 138: ...feed modules is 1 select Z axis as the tool axis machining type is delayed milling tool axis is Z axis minimal depth 5 mm every retraction is 1 4 mm drilling depth stops for 0 6 s reinsert lead dista...

Page 139: ...Y 808D Page 139 Sample Program Brief instruction 808D Milling Operating and Programming Milling Machining Process SUB_PART_3 SPF G17 G90 DIAMOF G0 X7 Y0 G1 Y61 35 G2 X13 499 Y86 I AC 57 J AC 61 35 G1...

Page 140: ...can be run in 808D ISO mode Content Basic Theory End ISO function switch ISO program transfer and operation ISO code explanation Siemens standard machining codes are implemented in DIN mode The 808D...

Page 141: ...of M30 G291 G290 commands must be set separately in a line If ISO is displayed at the top of the screen it is activated ISO code Description Compare with DIN G00 Orientation rapid traverse As DIN G1...

Page 142: ...nction G04 G04 X5 0 delay 5 s G04 P5 delay 5 ms N5 G90 T1 M06 N10 M3 S2000 spindle rotation N20 G99 G81 X300 Y 250 Z 150 R 10 F120 after orientation drilling back to R point N30 X1000 after orientatio...

Page 143: ...iate feed Motion at the bottom of the hole none Retraction motion Z fast feed G73 application example program M3 S1500 spindle rotation G90 G99 G73 X0 Y0 Z 15 R 10 Q5 F120 after orientation drill 1st...

Page 144: ...back to R point G98 Y 750 after orientation drill 6th hole back to start plane G80 cancel fixed cycle G28 G91 X0 Y0 Z0 back to reference point M5 spindle rotation stop M30 G82 Drilling cycle countersi...

Page 145: ...ne With command G98 with operation in red line Origin spindle CW after pause R point Z point spindle CW after pause Origin R point Z point P P G86 boring cycle Common programming structures G86 X Y Z...

Page 146: ...Using G98 spindle start Z point spindle stop Using G99 R point Press the USB SK on the PPU ISO program transfer and operation Step 1 The ISO mode function provided by the 808D can easily operate the...

Page 147: ...291 in MDA mode and execute When the Reset is not used the H list in the tool list is open Note Every tool only can use the H value corresponding to the edge In the graphic above T2 H1 cannot be execu...

Page 148: ...130 Y50 R10 N140 X50 R10 N150 Y 50 R10 N160 X40 N170 X0 N180 G03X 20Y 70R20 N190 G1G40X0 N200 G0Z50 N210 T2M6 N220 M3S3000F100 N230 G43H2Z50 N240 G0X40Y 40 N250 Z20 N260 G81Z 2R10 N270 Y40 N290 X 40 N...

Page 149: ...S2500M8 N80 MCALL CYCLE82 50 0 2 0 2 0 N90 CYCLE802 111111111 111111111 40 40 40 40 40 40 40 40 N100 MCALL N110 T3D1M6 quill deep hole drilling N120 M3S2500M8 N130 MCALL CYCLE83 50 0 2 20 5 3 0 5 1 1...

Page 150: ...ermediate point CT Circular interpolation tangential transition G33 Thread cutting with constant lead G331 Thread interpolation G332 Thread interpolation retraction Group 2 Non modally valid motion dw...

Page 151: ...e G19 Y Z plane Group 7 Tool radius compensation Name Meaning G40 Tool radius compensation OFF G41 Tool radius compensation left of contour G42 Tool radius compensation right of contour Group 8 Settab...

Page 152: ...Name Meaning G94 Feedrate mm min G95 Feedrate F in mm spindle revolutions Group 16 Feedrate override modally effective Name Meaning CFC Feedrate override with circle ON CFTCP Feedrate override OFF Gr...

Page 153: ...spindle in negative direction anti clockwise M05 Stopping the milling spindle M06 Automatic tool change M07 M08 Cooling lubricant pump ON M09 Cooling lubricant pump OFF M10 M11 M12 M13 M14 M15 M16 M1...

Page 154: ...n 1 0 dated 2015 5 27 Page 154 Original operating instructions F150 TC CNC GB M64 M65 M66 M67 M68 M69 M70 M71 M72 M73 M74 M75 M76 M77 M78 M79 M80 M81 M82 M83 M84 M85 M86 M87 M88 M89 M90 M91 M92 M93 M9...

Page 155: ...olation clockwise G3 Circular interpolation anti clockwise G4 Retention period G9 Accurate stop G10 Travelling in rapid feed in polar coordi nates G11 Linear interpolation with polar coordinates G12 C...

Page 156: ...f MGZ is active 700002 Air pressure is not enough bigger 0 6 Mpa 700003 The door is open 700004 The power sequence is wrong 1L 2L 3L change 700005 User alarm 06 700006 User alarm 07 700007 User alarm...

Page 157: ...zine when alarm or tool not retracted 700040 Start ATC when Z axis not in tool change pos 700041 Move Z axis when ATC not in original position 700042 ATC not finish action in monitor time 700043 Chang...

Page 158: ...messages and error messages Version 1 0 dated 2015 05 27 Page 158 Original operating instructions F3 GB 700063 User alarm 64 700064 User alarm 65 700065 User alarm 66 700066 User alarm 67 700067 User...

Page 159: ...manual Additional useful manuals and information Training Manual Operation and Programming Milling PLC Manual subroutines Describes e g making a connection to the RS232 interface Online help for prog...

Page 160: ...ages Do not re introduce liquids spilt outside the system during repair or as a result of leakage from the reserve tank collect them in a collecting container for disposal Disposal Never dump oil or o...

Page 161: ...the machining task We would like to ask you to have the following machine related properties of the cooling lubri cant confirmed in writing by the manufacturer of the cooling lubricant The products mu...

Page 162: ...ocumentation Record all tests and works in a operator s log resp log book 10 2 1 Preparation WARNING Only carry out work on the CNC machine if the main switch is switched off and secured against resta...

Page 163: ...ge 14 Sight window Cleaning Clean the polycarbonate sight windows using a suitable cleaning agent Compressed air supply Draining Drain the compressed air service unit on page 166 Start of work Daily a...

Page 164: ...Fill level control Check the liquid level and refill if required Every month Gear belt Spindle head Check Readjusting Replacing Check the drive belt on wear and excessive clear ance If required readj...

Page 165: ...months after commissioning of the CNC machine In the following cases an immediate replacement is strongly recommended plastic deformation distortion by previous impact stress cracks Damage to the edg...

Page 166: ...circuit boards or parts around the connector Also avoid hitting these parts with the vacuum We recommend that the electrical cabinet is cleaned every 1000 operating hours 10 4 Interlock switch sliding...

Page 167: ...there is an increase in nitrite content to more than 20 ppm mg 1 or nitrate content to more than 50 ppm mg 1 there is an increase in the N nitrosodiethanolamine NDELA to more than 5 ppm mg a CAUTION C...

Page 168: ...ased on initial filing Measures in accordance manufacturer s rec ommendations 1 0 based on initial filing Replace cooling lubricant clean cooling lubri cant circulation system Usage concentration Manu...

Page 169: ...teilliste The article no is located in the spare parts list Die Seriennummer befindet sich am Typschild The serial no is on the type plate Wenn Sie Ersatzteile anfragen die unterschiedliche L ngen auf...

Page 170: ...tzteile Spare parts F3 Version 1 0 2015 05 27 170 Originalbetriebsanleitung F3 DE GB 11 4 Geh use Housing Abb 11 1 Geh use Housing 1 2 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 23 19 20 21 22 23 24 25 26...

Page 171: ...I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 171 Originalbetriebsanleitung F3 DE GB 11 5 Unterbau Substructure Abb 11 2 Unterbau Substructure 38 39 40 41 42 43 44 45 46 47...

Page 172: ...atzteile Spare parts F3 Version 1 0 2015 05 27 172 Originalbetriebsanleitung F3 DE GB 11 6 Fr skopf Milling head Abb 11 3 Fr skopf Milling head 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72...

Page 173: ...A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 173 Originalbetriebsanleitung F3 DE GB 11 7 Fr stisch Milling table Abb 11 4 Fr stisch Milling table 86 87 88 89 90 91 92 93 94 95 96 97 98 99...

Page 174: ...M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 174 Originalbetriebsanleitung F3 DE GB 11 8 Fr stisch Milling table Abb 11 5 Fr stisch Milling table 106 107 108 109 109 110 109 110 110 111...

Page 175: ...A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 175 Originalbetriebsanleitung F3 DE GB 11 9 S ule Column Abb 11 6 S ule Column 120 121 122 123 123 124 124 125 126 127 128 129 129 130 131 132 1...

Page 176: ...0350041028 29 F hrungsstange Guide rod 2 0350041029 30 Abdeckung Cover 1 0350041030 31 Abdeckung Cover 1 0350041031 32 Sicherheitsschalter Safety switch 1 0350041032 33 Glasscheibe Glass pane 1 03500...

Page 177: ...r guides Y Axis 2 03500410101 102 Kugelumlaufspindel Ball screw 1 03500410102 103 Platte Plate 2 03500410103 104 Winkel Angle 1 03500410104 105 Maschinenfu Machine foot 1 03500410105 106 Abdeckung Cov...

Page 178: ...ariabel Motor 2 B3108 Schottverschraubung 3 B8216 Beh lterdichtung 0 475 l 21433 Beh lterdichtung 1 Liter 4 B8807 F llstandschalter 0 475 l B7760 F llstandschalter 1 Liter 5 H0402 O Ring F lstandschal...

Page 179: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 179 Originalbetriebsanleitung F3 DE GB 11 11 Schaltplan...

Page 180: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 180 Originalbetriebsanleitung F3 DE GB...

Page 181: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 181 Originalbetriebsanleitung F3 DE GB...

Page 182: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 182 Originalbetriebsanleitung F3 DE GB...

Page 183: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 183 Originalbetriebsanleitung F3 DE GB...

Page 184: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 184 Originalbetriebsanleitung F3 DE GB...

Page 185: ...OPTIMUM M A S C H I N E N G E R M A N Y Ersatzteile Spare parts F3 Version 1 0 2015 05 27 185 Originalbetriebsanleitung F3 DE GB...

Page 186: ...cepted 12 3 Storage ATTENTION In case of wrong and improper storage electrical and mechanical machine components might get damaged and destroyed Store packed and unpacked parts only under the intended...

Page 187: ...CAP C omputer A ided P lanning CNC C omputerised N umerical C ontrol NC N umericial C ontrol ATC A utomatic T ool C hanger Workpiece piece to be milled drilled or machined Spindle head Milling head u...

Page 188: ...ority before it exports such goods Optimum Maschinen Germany GmbH is not obliged to supply any information and does not grant any warranty as to whether the contrac tual products comply with the corre...

Page 189: ...operating manual is disregarded Inattentive or incorrect handling and use of improper equipment Unauthorized modifications and repairs Insufficient installation and safeguarding of the machine Disreg...

Page 190: ...8 3 Disposing of the old device INFORMATION Please take care in your interest and in the interest of the environment that all component parts of the machine are only disposed of in the intended and a...

Page 191: ...d electrical and electronic components Applicable in the countries of the European Union and other European countries with a sepa rate collecting system for those devices The sign on the product or on...

Page 192: ...e following other EU Directives have been applied EMC Directive 2014 30 EC Low Voltage Directive 2014 35 EC The safety objective meet the requirement of EC Directive 2006 42 EC The following harmonize...

Page 193: ...ion 20 29 Electronics 18 Emergency stop button 13 Environmental conditions 22 Error messages 156 I Insert tool 58 Inspection 163 Inspection plan for water mixed cooling lubricants 168 Installation pla...

Page 194: ...1 0 dated 2015 05 27 Page 194 Original operating instructions F3 GB T Tool commissioning 58 Tool changer 22 Tools 23 Torques of servo motors 21 Transport 25 U Using electronic handwheel 58 Using lifti...

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