FADAL VMC 3020 User manual

SIEMENS CONTROL
Operator Manual
Fadal

2 : October 2000
SIEMENS CONTROL
Operator Manual
Fadal
Table of Contents
Siemens Manual Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-start-up Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pendant Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pendant Hard Keys Function Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Finding Machine Reference (Cold Start) . . . . . . . . . . . . . . . . . . . . . 16
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manual Data Automatic (Submode of Manual display) . . . . . . . . . . 19
Jog Modes Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Position Readout Display In Jog Mode. . . . . . . . . . . . . . . . . . . . . . 20
Incremental Jog Using The MPG Or JOG Keys . . . . . . . . . . . . . . . . 21
Setting the Increment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using MPG hand wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Jog and Rapid Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tool, Manually Loading & Unloading a Holder. . . . . . . . . . . . . . . . 25
Tools, Loading a Holder from the ATC . . . . . . . . . . . . . . . . . . . . . . 26
Establishing Spindle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Spindle Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Spindle Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settable Frames - Workpiece Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Machine Coordinate System vs. Work Coordinate System: . . . . . . . 29
Definitions of Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Base Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Zero Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tool Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Using the SET BASE soft key to set the Base Offset . . . . . . . . . . . . . 33
Using the MEASURE WORKPIECE soft key to set Base/Zero Offsets . 36
Using the MEASURE TOOL soft key to set the Tool Offset . . . . . . . 41
Using the ZERO OFFSET soft key to set the Base and Zero Offsets . . 44
Using the TOOL soft key to set the Tool Offsets . . . . . . . . . . . . . . . 46
Setting Tool Length Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tool Diameter Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Tool Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Magazine Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
R Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Coolant, Using the Coolant 1 and Coolant 2 Buttons . . . . . . . . . . . 53
To Create a New Program for Auto. . . . . . . . . . . . . . . . . . . . . . . . 55
Editing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Choosing a Program to Run in Auto . . . . . . . . . . . . . . . . . . . . . . . . 57
Auto, Running a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Mid-tape (Program) Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Dual Arm Tool Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

October 2000 Important Safety Information: Siemens Manual Safety Notices 3
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Important Safety Information
Siemens Manual Safety Notices
Warning The following notes are given to ensure your safety and to prevent any risk
of damage to the product described or other units connected to the
machine.
Warning When electrical equipment is in operation, certain parts are bound to
reach hazardous voltage levels.
The intermediate circuit of all SIMODRIVE modules remains at a hazardous
voltage level for 5 minutes after all voltages have been disconnected. See
the Instruction Manual for more details.
Only qualified personnel should perform maintenance on the device/
system. Failure to comply with warnings can result in severe injury or
material damage. Only suitably qualified personnel trained in the setup,
installation, commissioning or operation of the product should work on
the device/system.
Further Notes Whenever measuring or testing has to be performed on live equipment,
the regulations of Safety Code VBG 4.0 must be observed, in particular §
8 “Permissible Deviations when Working on Live Parts”. Suitable
electronic tools should be used.
Danger This symbol appears whenever death, severe bodily injury or substantial
material damage will occur if the appropriate precautions are not taken.
Warning This symbol appears whenever death, severe body injury or substantial
material damage could occur if the appropriate precautions are not taken.
Caution This symbol appears whenever minor body injury or material damage can
occur if the appropriate precautions are not taken.

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Important This symbol appears in the documentation whenever attention has to be
paid to something of particular importance.
Note This symbol appears in the documentation whenever a reference is made
to another subject.
Warning Repairs on equipment supplied by Fadal may only be carried out by Fadal
Service or repair centers authorized by Fadal using authorized genuine
Fadal supplied parts. Any defective parts or components are to be
replaced only by parts contained in the relevant spare parts list.
Disconnect the power supply before opening the equipment.
Emergency Stop facilities according to EN 60204 IEC 204 (VDE 0113) must
remain operative in all operating modes of the automation equipment.
Any disengaging of the Emergency Stop facility must not lead to
uncontrolled or undefined restart.
Whenever faults occurring in the automation equipment can lead to
substantial material damage or even grievous bodily injury, (i.e. are
potential dangerous faults), additional external precautions must be taken
or facilities must be provided ensuring or enforcing safe operation even
when a fault occurs (e.g. independent limit switches, mechanical
interlocks, etc.)
Caution Connecting and signal lines must be installed so as to safely prevent
inductive and capacitive interference from affecting automation functions.
Warning Correct transport, storage, erection and mounting as well as careful
operation and maintenance are essential for proper and safe operation of
the equipment. Non–compliance with warnings can result in severe bodily
injury or material damage.
Warning The modules contain electrostatically sensitive components. Before
touching an electronic module, it is necessary to be electro-statically
discharged. The simplest way of doing this is to touch an electrically
conducting grounded object (e.g. a bare metal part of a switchboard or a
plug socket protective conductor) before touching an electronic module.

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ESD notes Electrostatically Sensitive Modules
Important!
Handling of ESD modules:
When handling electrostatically sensitive devices, make sure that operator,
workplace and packing material are properly grounded.
Generally, electronic modules must not be touched unless work has to be
carried out on them. When handling PC boards make absolutely sure that
you do not touch component pins or printed conductors.
Touch components only if
–you are permanently grounded by means of an antistatic chain,
–you are wearing ESD (Electro Static Device) boots or ESD boots
with grounding strips in conjunction with ESD flooring.
Modules may only be placed on electrically conductive surfaces (tables
with ESD tops, conductive ESD foam plastic, ESD packing bags, and/or
ESD transport containers).
Keep modules away from visual display units, monitors or TV sets (the
minimum distance from screen must be more than 10 cm).
Modules must not be allowed to come into contact with electrically
insulating materials such as plastic films, insulating table tops or clothing
made of synthetic fibers.
Measurements on modules are allowed only if:
–the measuring instrument is properly grounded (e.g. equipment
grounding conductor), or
–the probe is briefly discharged before measuring with a potential-
free measuring instrument (e.g. touch the unpainted metal parts
of the control housing)
The equipment may be used only for the applications stated in the manual
and only in conjunction with devices and components recommended and
authorized by Fadal.

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Should any questions or problems arise in studying this manual, please
contact the Fadal Service Department.
Safety Warnings
1) WARNING! WEAR ANSI OR CE APPROVED SAFETY GLASSES AT ALL
TIMES. Everyday glasses are not designed for protection. Only ANSI or CE
approved safety glasses have impact resistant lenses. Hearing protection
must be worn when operations exceed 90 decibels (85 decibels-CE) .
2) KEEP DOORS CLOSED WHILE MACHINING.
3) WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties,
rings, bracelets, or other jewelry that might get caught in moving parts or
areas of potential electric shock. Non-slip footwear is recommended.
4) CONTAIN LONG HAIR. Tie long hair back and wear protective hair
covering to contain long hair.
5) USE A NIOSH OR CE APPROVED DUST MASK OR RESPIRATOR.
Protection is recommended when cutting operations are dusty, or exceed
the permissible exposure limit.
6) KEEP WORK AREA CLEAN. Good housekeeping practices encourage
safety.
7) Read SPINDLE, MANUALLY LOADING & UNLOADING A HOLDER in the
Operator’s Manual.
8) DO NOT OPERATE THE MACHINE UNDER THE INFLUENCE OF DRUGS
OR ALCOHOL, PRESCRIBED OR OTHERWISE.
9) READ THE SAFETY WARNINGS SUPPLIED WITH ALL TOOLING.
10) MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best
performance and to reduce the risk of injury. Follow instructions for
lubrication and for changing accessories.
11) REMOVE ADJUSTING KEYS AND WRENCHES. Always check that keys
and wrenches are removed from tools and tooling before starting the
machine.
12) DO NOT EXCEED THE MANUFACTURER’S RECOMMENDED
MAXIMUM RPM FOR THE TOOL. When tools are placed in the spindle,

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verify the current RPM commanded in the control before starting the
spindle.
13) SECURE TOOLS PROPERLY IN THEIR HOLDERS.
14) SECURE WORK. Use common machining practices for holding
(fixturing) material to be machined.
15) REMOVE ALL TOOLS FROM THE SPINDLE AND TOOL CHANGER before
servicing and changing accessories such as tooling, fixtures, indexers, the
tail stock of a fourth axis and any fourth axis or fourth-fifth axis
combination, etc.
16) ALWAYS DEBUG A NEW PROGRAM before running it in the AUTO
mode. (See DEBUG PROGRAM in the User’s Manual.)
17) The machine tool MUST be connected to a grounded, metal,
permanent wiring system, or to a system having an equipment-grounding
conductor.
18) DO NOT OPERATE THE MACHINE IN AN UNSAFE ENVIRONMENT. Do
not use the machine in damp or wet locations, or expose to rain. Keep the
work area well lighted.
19) DO NOT FORCE TOOL. Tools are designed to perform properly and
safely at proper rates. Keep tools sharp.
20) USE THE CORRECT TOOL. Do not attempt to use tools or attachments
to perform a job for which they were not designed.
21) DON’T OVERREACH. Keep proper footing and balance at all times.
Use a steady object for support when reaching over the machine.
22) REDUCE THE RISK OF UNINTENTIONAL STARTING. Power off the
machine at the main disconnect switch and use the proper lockout/tagout
procedures while working within the chip enclosure, or when there is
potential for a release of energy.
23) POWER OFF THE MACHINE AT THE MAIN DISCONNECT SWITCH AND
LOCK OUT WHEN WORKING INSIDE ANY OF THE ELECTRONIC CABINETS.
24) USE RECOMMENDED ACCESSORIES. Refer to the User’s Manual for
FADAL recommended accessories. Unapproved accessories increase the
risk of injury.

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25) NEVER STAND ON OR IN THE MACHINE. Besides the risk of slipping or
falling, serious injury could occur if a tool is unintentionally contacted.
26) CHECK FOR DAMAGED PARTS. Always check all parts for binding,
breakage, and any other condition that will affect the proper operation of
the machine and/or increase the risk of injury. Damaged or missing parts
must be repaired or replaced BEFORE operating the machine.
27) NEVER LEAVE THE MACHINE UNATTENDED. Turn the power off to the
machine when leaving the machine unattended. Never leave the machine
until it comes to a complete stop.
28) DO NOT DISCONNECT THE FRONT DOOR SAFETY SWITCHES.
29) WIPE UP SPILLS. Immediately cover with absorbent material and wipe
up coolant and oil spills around the machine. Correct the cause of the
leakage to prevent any hazards.
30) ELECTRICAL INSTALLATION OF THE MACHINE MUST BE DONE BY A
QUALIFIED ELECTRICIAN.
31) ONLY FADAL OR FADAL DISTRIBUTOR FACTORY AUTHORIZED
INDIVIDUALS MAY INSTALL THE MACHINE.
32) USE PROPER SAFETY GLOVES WHEN HANDLING SHARP OR JAGGED
EDGES. Do not wear gloves around rotating machinery.
33) DO NOT USE AIR HOSES TO BLOW CHIPS OFF YOUR BODY OR
CLOTHES. Serious injury to your eyes, hearing, and skin could result. Do
not blow towards others.

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Fadal/Sinumerik 810D CNC
Power On
Pre-startup Checks
1) Examine the oil levels. Both should be filled before the levels are
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 for specifications on the way lube and the spindle oil.
2) 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 for the
air blast during a tool change. The tool changer gauge should
not exceed 120 PSI.
3) Most new VMC models release water collected in the water
reservoir automatically. It is advisable to place an additional
water trap in the air line going to the machine.

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4) Replenish the flood coolant level to avoid running out of coolant
during execution of the program.
5) Examine the spindle cooler reservoir once a month.
6) To power on the machine, press the safety lock and turn the
power switch in the clockwise direction.

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Pendant Layout
The table on the following pages shows the various buttons on the
pendant. A brief description of the function of each button is given to
assist the operator in becoming familiar with the control. Refer to the
Siemens operator manuals for detailed instructions on how to use these
buttons.
MCP
Display Screen
Soft Keys
Keypad Hard Keys
MPG
Axis SelectorOverride
E-Stop
Spindle
Override
Feed
Override
Hard Keys

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Pendant Hard Keys Function Guide
Table 1: Pendant Keypad Hard Keys
Key Name and Function
System/Alarm Button
Displays alarms/messages screen. When the shift key is
pressed at the same time that this button is pressed the
main menu of the operator screen is displayed.
Alarm Acknowledge
Resets CNC soft alarms.
Cursor Buttons (left, right, up, down)
Moves the cursor around the display screen.
End Button
Moves the cursor to the end of the program.
Help / Information Button
Toggles between test and graphic displays in Shop Mill.
Active when displayed on lower line of display.
Input Button
Used to accept entry of data.
Insert Button
Used to edit the existing data entry.

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Next Window Button
Goes to the top of the next active display.
Offset/Parameters Button
Displays the offsets screen and offset soft keys menu.
Page Down Button
Page down the screen display.
Page Up Button
Page up the screen display.
Position Button
Displays the position screen and the main soft key menu
of the active mode (Manual / Auto).
Program Manager Button
Displays the program manager screen.
Program Button
Displays the program edit screen.
Table 1: Pendant Keypad Hard Keys
Key Name and Function

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Table 2: Machine Control Panel Keypad Hard Keys
Key Name and Function
Auto Button
Initiates the automatic mode.
Coolant 1 Button
Toggles the coolant 1 feature on and off. Works in
combination with M7 and M9 codes.
Coolant 2 Button
Toggles the coolant 2 feature on and off. Works in
combination with M8 and M9 codes.
Feed Start Button
Feed start (Slide Start).
Feed Stop Button
Stop feed (Slide Hold).
Increment Jog Button
Activates Incremental sub-mode of Manual Mode. Allows
incremental JOG by JOG keys or MPG (hand wheel).
Jog Button
Initiates Manual Mode. Note: Reference, Incremental Jog
and MDA are all sub-modes of the Manual Mode.
MDA Button
Used to access Manual Data Automatic mode in ISO. Not
active in Shop Mill. In Shop Mill MDA is accessed via a soft
key in the Manual Mode.

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Jog - Button
Use for jogging in the negative direction.
Manual Pulse Generator Button
Activates the MPG mode of the manual screen. The LED
above the button will be lit when the MPG mode is active.
Jog + Button
Use for jogging in the positive direction.
Rapid Jog Button
Use in conjunction with the JOG “+” and “-” buttons.
Activates the rapid JOG feed rate.
Reference Button
Activates the Reference submode of the Manual Mode.
Reset Button
Resets the currently active program and some alarms.
Note: Using the reset button will reset the program to its
beginning.
Spindle On Button
Turns the spindle on in the last programmed direction and
RPM, (S-word). Note that on early production models the
text on the key reads “SPINDLE RIGHT”.
Spindle Stop Button
Stops the spindle.
Table 2: Machine Control Panel Keypad Hard Keys
Key Name and Function

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Finding Machine Reference (Cold Start)
The FADAL machine tool has software limits and does not contain position
limit switches. Therefore, the machine tool must be physically located at
set alignment marks. The Siemens control automatically powers on in the
machine reference mode. It is recommended that the machine be shut
down at its axis alignment position to simplify the Power On procedure.
NC Cycle Start Button
Starts the execution of the CNC in Auto Mode or
operation in Manual Mode.
NC Cycle Stop Button
Stops the execution of CNC program, control waits for
NC Cycle Start signal or Reset signal.
Tool In/Out Button
Activates the drawbar to manually load or unload a tool
from the spindle. This button is active only in the Manual
Mode.
Turret CCW Button
Rotates the turret in a counterclockwise direction. This
button is active only in the Manual Mode.
Turret CW Button
Rotates the turret in the clockwise direction. This button is
active only in the Manual Mode.
Work Light Button
Toggles the machine work lights on and off.
Table 2: Machine Control Panel Keypad Hard Keys
Key Name and Function

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To align each axis, place the machine in JOG:
1) Press the MPG hard key until the LED above the key is lit.
2) Find the alignment marks for each axis using the axis selector
switch and the MPG.
3) Press the REF hard key button “reference point return”. Use the
Axis selector switch to select the desired axis.
Select the X axis then press + hard key button.
Select the Y axis then press + hard key button.
Select the Z axis then press + hard key button.
Select the A axis then press + hard key button.
Select the B axis then press + hard key button.
When each axis has completed finding the reference position this
symbol will appear to the left of the axis. Press the JOG, MPG or
AUTO hard keys to exit the Reference submode.
Note: In the reference mode the position display will indicate the actual position
in WCS (X, Y, Z) or MCS (X1, Y1, Z1). The ACT. VAL. MCS soft key can be
used to toggle between the WCS and MCS coordinate display.

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Note: The reference symbol is to the left of the axes names.

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Operating Modes
Manual Data Automatic (Submode of Manual display)
1) Press the JOG hard key.
2) Press the MDA soft key.

20 Fadal/Sinumerik 810D CNC: Jog Modes Of Operation October 2000
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Jog Modes Of Operation
Position Readout Display In Jog Mode
1) Press the JOG hard key.