MasterInstructionManual五軸加工中心操作手冊master414（英文版）

1、rel.09/2004 instruction manualmaster6 axes cnc working centerinstruction manual master 1serial n.: year: v./hz.: instruction manual master iinote: this manual is property of p.bacci s.r.l. the company does not consider valid any copy of this manual which shouldnt correspond to the one filed in its o

2、ffices.instruction manual master iiiindexuser interface . 1operating panels. 2cnc operating panel. 2portable keypad . 4left and right table buttons. 6left and right table pedals. 6keyboard. 7guidelines for a correct use of the electrospindle.9maintenance. 14general rules. 14characteristics and frequ

3、ency of inspections.14scheduled long term inspections . 16lubrication mechanical parts. 17pneumatic installation lubrication system.18connections . 19compressed air. 19electrical. 19transportation. 20safety. 21spindles . 21mechanical parts . 22electrical installation. 22pneumatic installation . 22pe

4、rimeteral protection/cabin. 23programming. 23general recommendations. 23programming. 24general functions. 25preliminary operations. 25turning on the machining center. 25homing. 25stop a machining cycle . 25turn off the working center. 25basic programming notions. 26operating head configuration param

5、eters.28part program management . 30instruction manual master ivline editor . 32program check. 33bacci softkeys. 34management macros. 35plus management variables. 36working macros . 36geometric and compensation macros.37auxiliary macros. 37dynamics. 38the master program. 38masterpend example. 39auto

6、matic mode (auto) operating sequence .40manual mode (manual) operating sequence.40autoprogramming. 41introduction . 41available parametric programs. 41programming. 44how to create a part program. 44programming with alphacam. 50general tips. 50post processed program example. 51the tg post processor (

7、rotating table vertical axis).53transferring the program from pc to working center .55digitizing part origin. 55insert program in master program. 56loading the program . 57activate the program . 57osai cn network configuration. 58error messages. 60solving problems. 61diagnostics. 65error messages. 6

8、6drive error messages. 68how to visualize the code from the nc .69input/output list. 70input . 70output . 72instruction manual master vinstallation. 73pneumatic installation . 74components list . 74wiring diagram . 75user interfaceinstruction manual master user interface2operating panelscnc operatin

9、g panel1. stop buttonstops axes and spindle rotation. does not shut down the machine.2. power supply lamp3. selector for overstroke recoverenables the recovering of an axis from overstroke. when an axis falls in overstroke, the machine shuts down and a message appears on the screen. the procedure to

10、 take the axis back within the operative limits is the following:pay attention to incorrect use !instruction manual master user interface3switch the selector to the right hand positionpush the reset buttonturn on the machine, using button (9)switch the selector (11) to “manual” and move the axis in

11、the proper direction within the limitsswitch back the selector (3) to the left hand position.4. power on lh table vacuum pump button5. power on rh table vacuum pump button6. not applicable 7. emergency stop buttonshuts down the machine8. not applicable9. auxiliaries on button10. not applicable11. se

12、lector manual / automatic12. vacuum pumps stop button13. dust and chips belt conveyor on/off button (optional)the axis in overstroke must be clearly identified and the procedure must be followed carefully !instruction manual master user interface4portable keypad1. emergency stop buttonstops axes and

13、 spindles. does not shut down the machine. 2. x-manual movement buttonmoves x axis in continuous manual mode in negative direction. 3. x+ manual movement buttonmoves x axis in continuous manual mode in positive direction.4. z-manual movement buttonmoves z axis in continuous manual mode in negative d

14、irection. 5. z+manual movement buttonmoves z axis in continuous manual mode in positive direction.6. p-manual movement buttonmoves p axis in continuous manual mode in negative direction. 26431013121114155987116instruction manual master user interface57. p+ manual movement buttonmoves p axis in conti

15、nuous manual mode in positive direction. 8. a- manual movement buttonmoves a axis in continuous manual mode in negative direction. 9. a+ manual movement buttonmoves a axis in continuous manual mode in positive direction.10.q- manual movement buttonmoves q axis in continuous manual mode in negative d

16、irection.11.q+ manual movement buttonmoves q axis in continuous manual mode in positive direction.12.c- manual movement buttonmoves c axis in continuous manual mode in negative direction.13.c+ manual movement buttonmoves c axis in continuous manual mode in positive direction.14.led portable keypad e

17、nabledthe led is on if the keypad is enabled by the proper softkey.15.digitize axis position buttonto be used in self-learning mode.16.override potentiometerenabled when the keypad is enabled, both in manual and automatic mode.other buttons possibly present can be used to move additional axes (optio

18、nals).instruction manual master user interface6left and right table buttons 1. emergency stop button shuts down the machine.2. start/ door button in manual mode: allows the opening and closing of the loading door.in automatic mode: allows only the closing of the loading door and the start of the wor

19、king cycle. 3. stop buttonstops axes and spindles rotation. does not shut down the machine.left and right table pedalsthe pedal allows to clamp / unclamp the pieces on their respective tables, with the following modalities:manual mode (selector and cn)pressing the pedal with the loading door open ca

20、uses the blockage of the piece at low pressure (pneumatic clamps) and by vacuum (if the vacuum pump has been turned on); pressing the pedal again (with the loading door open) the piece will be unblocked. when the loading door is closed pushing the proper button, if the piece is blocked the clamping

21、pressure goes up to high pressure.automatic mode (selector and cn)pressing the pedal with the loading door open causes the blockage of the piece at low pressure (pneumatic clamps) and by vacuum (if the vacuum pump has been turned on); pressing the pedal again (with the loading door open) the piece w

22、ill be unblocked. when the loading door is closed pushing the proper button, if the piece is blocked the clamping pressure goes up to high pressure.321instruction manual master user interface7in automatic mode the opening of the loading door is driven by program (unblock command), then it is possibl

23、e to unblock the piece using the pedal; the piece can be automatically unblocked inserting the auto-unblock command in the program.keyboardkeyfunctionmove cursor one character left in the rowmove cursor one character right in the rowscroll down pp, or select upper line scroll up pp, or select lower

24、linemove cursor up 9 rowsmove cursor down 9 rowsmove cursor at the end of the linemove cursor at the beginning of the linemove cursor at the beginning of the ppmove cursor at the end of the pppguppgdncrtlcrtlcrtlhomecrtlendinstruction manual master user interface8delete first character on the cursor

25、 left delete the character on which the cursor is positionedcut selected line in the cursor position: characters on its left are moved to the next row. create a new row before the selected line when the cursor is placed on the first character.create a new row moving up the selected line. accept data

26、 inserted in input windows.backspacedelendinstruction manual master user interface9guidelines for a correct use of the electrospindleheating upthe heads must be heated up to 35c before using; to reach this temperature turn on the spindle at 3000 rpm for at least 10 minutes. this will let the bearing

27、 and the rotating parts operate at the optimal temperature.when the electrospindle is loaded at a lower temperature, the bearings will undergo an untimely consuming and will lose the preload.choosing the tooluse only tools with a diameter and weight included in the table of page 11.tools and toolhol

28、ders must be balanced in g1 and re-balanced after every sharpening. vibrations caused by an unbalanced tool can rapidly destroy the bearings.caution !the use of elements (tool holder shafts, spacers etc.) which do not respect the indicated requirements, or their uncorrect assembly may cause the tool

29、 breaking during its rotation and the subsequent projection of metallic parts around the machinetool qualitytools must always be sharpened in order to reduce the cutting forces and the spindle working temperature.heat generated by the spindle may overheat the bearings and the lubricant causing the e

30、vaporation of the lubricating components: this will result in life reduction for the bearings and thus for the spindle.instruction manual master user interface10cleanlinesskeep rigorously cleaned cones, shafts and tool calmping chucks. contamination by dust may cause a disalignment and an uncertain

31、tool blockage: this will force the operator to lock the nuts with a torque higher than suggested, damaging shaft or toolholder screws.warnings on bearing lubricationthe bearings are lubricated for life duration with kluber isoflex topas nb52 or lubcon l182. anyway for a possible bearings relubricati

32、on the same grease must be used: a different grease type in great quantity irretrievably damages the spindle. coolinguse the spindle only when connected to the cooling system.use only 4 bar non lubricated air!instruction manual master user interface11caution! fexampletool weight2.5 kgspindle speed15

33、000 rpmerror0.3 mmf = (2.5 x 15000 2 x 0.3) / 91000 185 kg (1850 n)instruction manual master user interface12tool suggested dimensionssizemax shaft diameterspindle speed (rpm)max tool diameter (mm)max tool weight (kg)6000 / 9000150109000 / 12000130712000 / 150001105er4025 mm15000 / 180008056000 / 90

34、0014049000 / 12000130412000 / 150001102.5er3220 mm15000 / 18000802.5these data are just spindle related: for each tool the constructor maximum rpm must be respected toospacers suggested tolerances(see(see(see nextnextnext pagepagepage forforfor drawing)drawing)drawing)instruction manual master user

35、interface13max 0.005 mmmax 0.005 mmspindle shaftdistanziali / spacersdangertoolerrorinstruction manual master user interface14maintenancegeneral rulesthe master machine has been designed to reduce maintenance to a minimum.in order to avoid failures and troubles the rules below must be followed:keep

36、the machine clean and in orderavoid any possible damagedo not let temporary remedies become definitivethe strict observance of periodical maintenance interventions is extremely important: all the machine components must be regularly controlled in order to avoid possible failures.all the intervention

37、s must be compatible with and in strict observance of the operator safety rules. when an intervention on the electric installation is necessary, it is indispensable to put the main switch on the cabinet door in “off” position in order to guarantee the safe access to the cabinet when an intervention

38、on the pneumatic installation is necessary, it is indispensable to disconnect the machine from the general installation using the lever near the frl groupcharacteristics and frequency of inspectionsdailydailydaily maintenancemaintenancemaintenance lubricator operating check (pneumatic installation)

39、lubricator oil level check (pneumatic installation)check and empty out the condensate tank in the frl groupcheck the lubricating oil level in the tank of the pneumatic installation pump carefully clean the machine, avoiding air blasts that may bring chips into the dust protectionssubstitute the dama

40、ged componentsweeklyweeklyweekly maintenancemaintenancemaintenance carefully clean inside the electric cabinet with a vacuum cleaner instruction manual master user interface15check the operation of every button and pedal check the correct operation of the lubricating pump check the axes correct oper

41、ation clean the noise filter under the z axis balancing cylindermonthlymonthlymonthly maintenancemaintenancemaintenance carefully clean with a vacuum cleaner inside the machine and under the dust protectionscheck the operation of every button and pedalcheck proximity and microswitches correct operat

42、ioncheck the axes correct operationcheck the pneumatic installation correct operation check the chain of the z axis balancing device and grease it if necessaryit is strongly recommended to change the chain of the z axis balancing system every year.we remind you that the scheduled maintenance has to

43、be integrated with special interventions, when necessary.moreover we entrust the operator working on the machine to report any problem to the ones responsible for maintenance and installation.instruction manual master user interface16scheduled long term inspectionsvisual check of the installation (w

44、ires, parts, cable carrier chains) and replacement of damaged parts if needed.six monthscheck installation functionality (emergency stops, buttons etc.)six monthscheck electrical, electronic and electro mechanic components, and electrical cabinet wirings.one yearelectrical installationcheck operatin

45、g head electrical collector and change brushesone yearvisual check of the installation (pipes, valves, etc)six monthsclean the installation18 monthslubricating systemcheck installation functionality and pump delivery headsix monthsvisual check of the installation (pipes etc.)six monthscheck electrov

46、alves correct functioning (overheating and/or stops) and replacement if needed.one yearpneumatic installationcheck of frl groups and replacement if neededone yearvisual check of mechanical components (slides, sliding blocks, main screws) and wearing components (dust covers and other protections)six

47、monthscheck correct tension of transmission beltsone yearmechanicscheck tightening of mechanical parts (lock nuts, flanges, other components)one yearinstruction manual master user interface17lubrication mechanical partsthe master machine is equipped with an automatic centralized lubrication system;

48、the lubrication time intervals are controlled by the cnc. periodically check the working and efficiency of the automatic lubrication system!for the automatic lubrication system refilling, the use of one of the following products is recommended:nlgi-0 (or equivalent)nlgi-1 (or equivalent) use only gr

49、ease resistant to high pressure. otherwise if oils and soaps inside grease are separated, soaps can solidify and obturate the pneumatic installation.instruction manual master user interface18pneumatic installation lubrication system the lubricant in the pneumatic installation must be periodically ch

50、ecked and in case refilled with one of the products listed here, or with an hydraulic oil class iso/uni f or iso/uni h.agiposo 10essonuto h 5mobilvelocite oil no.4q8puccini 4ptexaco300 oil 5totalazolla zs 15tab.2there are no noticeable differences between the oils here indicated. pneumatic system lu

51、bricationhere pneumatic oil from tab.2instruction manual master user interface19connectionscompressed airsuggested diameter for compressed air tube = 1/2optimal line pressure = 6,5 barpipe connection diameter = 25 mm outer / 17 mm innerair consuming at 6 bar = 200 l/min for 2 spindles version 360 l/

52、min 4 spindles versionelectricalnominal voltage = 380 volts / 50hz or external autotransformer (optional)connection type = 3 phases + 1 ground connectionmaximum resistance to the ground = 20 ohmmaximum installed power = (see label on left side of the upright) plant view of a typical master layoutnot

53、e: the machining center auxiliaries can be turned on only if both connections (compressed air and electricity) are present!instruction manual master user interface20instruction manual master user interface21transportationwhen transported in a container the biggest part of the machine (basement and o

54、perating head) must be unloaded using a crane, by means of 4 ropes each 4m long and 2 poles to be inserted in the provisional holes in the basement. uplifting ropes and poles are not supplied with the machine and must be properly dimensioned, like the crane and any other component used for this oper

55、ation. the ropes anchored to the poles on the basement rear part (the opposite side with respect to the operating head) must be aside the basement, while those on the fore part must be placed approximately 400mm away from the basement in order to balance the moment due to the machine weight distribu

56、tion.uplifting scheme:the holes for uplifting poles have a diameter of 80mm.machine weight is about 4000kg. once uloaded with the crane, the basement can be moved with a forklift expediently dimensioned.the electric cabinet has 4 hooks to fix ropes for lifting. the two y tables can be unloaded and m

57、oved using a forklift.rear ropes aside the basement40cm40cmfore ropes 400mm away from the basementinstruction manual master user interface22safetyfor a safe operation with master machining center it is necessary to strictly follow the procedures herein described. notwithstanding all the safety devic

58、es which are included in the machine, an improper or unconscious use can cause serious damage to the machine itself or serious injuries to the operator.spindlesbefore turning on the spindles it is fundamental to:-make sure that tools have been mounted only after cleaning the conical inlet of the spi

59、ndle-make sure that tools are properly tightened-make sure that the programmed rpm is less than the maximum rpm allowed by the mounted tool (for double exit spindles, tools mounted on both exits must be considered) -make sure that tool dimensions and weight and programmed rpm are suitable for the sp

60、indle power characteristics-make sure that the programmed rotation direction is the right one for the mounted tools when these are in work-if the spindle has to be turned on reverse, verify the presence and tightening of the counter lock nut (or other suitable anti-unscrewing devices)-if a perimeter