FRYER CM Series User manual

CM SERIES
FRYER / SIEMENS 828 CONTROL
MAINTENANCE MANUAL
70 Jon Barrett Road, Patterson, NY 12563, USA | www.fryermachine.com | v: 845.878.2500 | f: 845.878.2525
Ver 1.0

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TABLE OF CONTENTS
1.0 - SAFETY INFORMATION
Safety Information ................................................................................................................................................. 3
1.01 Mechanical Safety ......................................................................................................................................... 4
1.02 Electrical Safety ............................................................................................................................................ 5
2.0 - BASIC INSTALLATION
2.1 WHERE TO PLACEYOUR MACHINE
2.11 Foundation .................................................................................................................................................... 6
2.12 Environmental Conditions ............................................................................................................................. 6
2.2 UNLOADINGYOURMACHINE ................................................................................................................. 6
2.3 RECEIVING YOURMACHINE ............................................................................................................................... 6
2.4 UNPACK AND PLACEYOURMACHINE ............................................................................................................ 7
2.5 PRIOR TO THE ARRIVAL OF THE TECHNICIAN
2.51 Installation Safety Instructions ....................................................................................................................... 7
2.52 Cleaning & Lubricating Machine .................................................................................................................... 7
2.53 Line Voltage Check ....................................................................................................................................... 7
2.54 Electrical Precautions .................................................................................................................................... 7
2.6 LEVELING THE MACHINE
2.61 Leveling Procedure ....................................................................................................................................... 9
3.0 - GENERAL INFORMATION
3.1 MAINTENANCESCHEDULE CHART ................................................................................................................ 10
3.2 MACHINE COMPONENTS
3.21 Axis LubricationSystem……………………………………………………………………………………….......... 12
3.22 Electrical System…………………………………………………………………………….................................. 12
3.23 Pneumatic System ....................................................................................................................................... 13
3.24 Automatic Tool Changer .............................................................................................................................. 14
3.25 Spindle ......................................................................................................................................................... 14
3.26 Flood Coolant System……………………………………………………………………………………............... 15
3.27 Fryer Tool Probe………………………………………………………………………….…………………............ 16
3.28 Fryer Part Probe………………………………………………………………………………............................... 17
3.3 BASIC MACHINE PROCEDURES
3.31 Set Axis Home Position................................................................................................................................ 18
3.32 Check Axis Backlash.................................................................................................................................... 19
3.33 Adjusting Backlash Compensation............................................................................................................... 20
3.34 Working with Waycovers.............................................................................................................................. 20
3.35 Check / Adjusting Ballscrew Endplay........................................................................................................... 21
3.36 Check Axis Belts.......................................................................................................................................... 21
4.0 - 828 CONTROL.............................................................................................................................
4.1 ACCESSING MACHINE PARAMETERS ............................................................................................................ 22
4.2 ACCESSING THESOFTWARE VERSION ......................................................................................................... 22
4.3 REVERTTO THEFACTORYSET PASSWORD ................................................................................................ 22
4.4 ADJUSTING INPUTVOLTAGEPARAMETERS .................................................................................................. 23
4.5 M-CODES .................................................................................................................................................................. 24
4.6 ALARMS
4.61 Siemens Alarms........................................................................................................................................... 25
4.62 Fryer PLC Alarms and Descriptions............................................................................................................. 25
4.63 Clearing an Alarm........................................................................................................................................ 26

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4.7 WORKING WITH FILES
4.71 File Types..................................................................................................................................................... 26
4.72 Back-Up An 828 Archive File to A USB Stick............................................................................................... 26
4.73 Reloading an Archive File ........................................................................................................................... 27
4.74 Backing Up Tool Data on the 828 Control.................................................................................................... 27
4.8 ADDING A SOFTWARE OPTION TO AN 828 CONTROL .............................................................................. 28
4.9 SET UP THE NETWORK DRIVE IN AN 828 ....................................................................................................... 31
5.0 - AUTOMATIC TOOL CHANGER
5.1 CAROUSEL TYPE ATC OPERATION
5.11 Safety Rules -- READ BEFORE OPERATING ATC ..................................................................................... 33
5.12 Manual Operation of the Tool Changer........................................................................................................ 33
5.13 Setting Tool Change Height…………………………………………………………………………………....…... 34
5.14 Recovering from a Tool Change Failure...................................................................................................... 35
5.15 Tool Carousel HOME Position and Tool Bin# Reset.................................................................................... 35
5.16 Spindle Orient Adjustment ........................................................................................................................... 36
6.0 –DRAWINGS AND PARTS LIST ......................................................................................
6.1 828 CONTROL ELECTRICAL PANEL LAYOUT ............................................................................................... 37
6.2 828 CONTROL FRONT PANEL LAYOUT ......................................................................................................... 38
6.3 CM-15 BASE ASSEMBLY DRAWING ........................................................................................................... 39
6.4 CM-15 ENCLOSURE ASSEMBLY DRAWING ...................................................................................................40
6.5 CM-15 SB-BASE / TABLE / SADDLE ASSEMBLY DRAWING........................................................................... 41
6.6 CM-15 COLUMN & HEAD ASSEMBLY DRAWING .......................................................................................... 42
6.7 CM-15 COOLANT SYSTEM ASSEMBLY DRAWING ............................................................................. 43
6.8 CM-15 TOP COVER ASSEMBLY DRAWING .................................................................................................... 44
6.9 CM-15 MACHINE ASSEMBLY PARTS LIST .................................................................................................... 45
6.10 CM-20 BASE ASSEMBLY DRAWING .............................................................................................................. 56
6.11 CM-20 COLUMN & HEAD ASSEMBLY DRAWING ...................................................................................... 57
6.12 CM-20 COOLANT SYSTEM ASSEMBLY DRAWING ................................................................................... 58
6.13 CM-20 SHEETMETAL ASSEMBLY DRAWING ............................................................................................. 59
6.14 CM-20 TOP COVER ASSEMBLY DRAWING ................................................................................................. 60
6.15 CM-20 MACHINE ASSEMBLY PARTS LIST .................................................................................................. 61

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1.0 SAFETY INFORMATION
READ BEFORE INSTALLING OR OPERATING
NOTE: THIS MACHINE IS AUTOMATICALLY CONTROLLED AND MAY START AT
ANY TIME.
All CNC machines contain hazards from rotating parts, belts and pulleys, high voltage electricity, noise, and
compressed air. When using CNC machines and their components, basic safety precautions, including all
appropriate LOTO procedures must always be followed to reduce the risk of personal injury and mechanical
damage.
It is the machine owner’s responsibility to make sure all personnel who are involved in installation and operation of this
machine are thoroughly acquainted with the procedures and safety instructions provided herein BEFORE theyperform
any actual work.
Only Fryer factory-trained service personnel should troubleshoot and repair theequipment.
Do not modify or alter this equipment in any way without first consulting Fryer Machine. Any modification or alteration of
this equipment could lead to personal injury and/or mechanical damage and could void your warranty.
1. Keep machine and area around it clean and well lit. Never allow chips, coolant, or oil to remain on the floor. Do not
leave loose objects on or aroundmachine.
2. Use appropriate eye and ear protection while operating the machine. ANSI-approved impact safety goggles and
OSHA-approved ear protection are recommended to reduce the risks of eye injury and hearingloss.

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3. Keep all loose clothing, hair, and jewelry away from the machine at all times.
4. Gloves are easily caught in moving parts. Take them off before using themachine.
5. Always wear safety shoes with steel toes and oil-resistantsoles.
6. Do not paint, alter, deface, or remove any warning plates from the machine. Replacement plates are available
from Fryer Machine Systems.
7. Keep flammable liquids and materials away from the work area and hotchips.
8. Coolant and oils can make surfaces on the machine slippery. They can also present an electrical hazard if the
machine has power on. Therefore, do not stand on any part of the machine at any time.
9. Keep vises, clamps, fixtures, or work pieces from extending beyond the back edge of the table.
10. Check for damaged parts and tools before operating the machine. Any part of a tool that is damaged should be
properly repaired or replaced. Do not operate the machine if any component does not appear to be functioning
correctly.
11. Improperly clamped parts machined at high speeds/feeds may be ejected and puncture the safety door.
Machining oversized or marginally clamped parts is not safe.
12. To avoid tool changer damage, ensure that tools are properly aligned with the spindle drive lugs when loading
tools.
13. Windows must be replaced immediately if damaged or severely scratched –contact the factory for replacement
panels.
14. Do not attempt to operate the machine before all the installation instructions have been completed.
15. Be sure to review the maintenance section of this manual for instructions to keep your machine running properly.
1.01 Mechanical Safety
1. Always press Emergency Stop when the machine is not inuse.
2. Never operate the machine with any cover or shield open orremoved.
3. Never reach into the work area when the spindle is turning or if the machine is in automatic mode.
4. Put the machine in manual mode and be sure last programmed function has been completed before reaching
inside of the work area.
5. The functions of the machine make it impossible to eliminate all pinch points. Be particularly aware of the
following pinch points:
a. Spindle and tool rotation
b. Indexing of ATC and tools
c. Table, saddle, and head.
6. Do not operate machine without axis motor covers or axis waycovers in place.
7. Report any loose, worn, or broken parts to your supervisor. The same action should be taken if any unusual noise
or machine action occurs.
8. The electric components are protected from normal moisture resulting from humidity or use of water-based
coolants. DO NOT however, use a water hose to clean the machine or the area around it.
9. Never touch a machine control device or electrical component when your hand iswet.

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10. Never clean up chips while the machine is running or is in automatic mode.
11. Do not file workpieces being rotated under power.
12. At the end of the workday the machine should be placed in "EMERGENCY STOP MODE"
13. When restarting a machine after it has been shut down always assume it has been altered. Recheck all phases of
the job as though you were running the firstpiece.
14. Never run the spindle until hands, feet, and body are well clear of the work area.
1.02 Electrical Safety
1. WARNING: Electrical enclosures contain high voltage. Disconnect equipment from power source before opening
cabinets.
2. Before replacing a fuse, switch off the machine.
3. Immediately turn off powerif:
•Power problems develop
•In the event of electricalstorms.
•Ambient temperatures exceed 105 degrees Fahrenheit (40 degrees C)
4. The electrical power must meet the specifications in this manual. Attempting to run the machine from any other
source can cause severe damage and will void the warranty.
5. The electrical panel should always be closed and locked except duringservice.
6. When the main circuit breaker is on, there is high voltage throughout the electrical panel and some components
operate at high temperatures, therefore extreme caution is required.
7. Do not reset a circuit breaker until the reason for the fault isinvestigated.
8. Never service the machine with the power connected.

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2.0 BASIC INSTALLATION
2.1 WHERE TO PLACE YOUR MACHINE
Thank you for choosing Fryer Machine Systems. You have purchased a high quality, custom crafted machine tool
designed and built to provide years of trouble-free service. To ensure that your machine is properly installed we ask that
you review the following information prior to the shipment of your machine.
2.11 Foundation
Your foundation must be a minimum 6“(150mm) thick concrete slab floor and should be placed on a single slab with no
seams. Be sure to leave space around the machine for leveling components and access to the electrical cabinet.
If your floor does not meet these specifications, contact the factory for further recommendations.
Install the machine on the first or second floor. Take the stress of ceiling and foundation into careful consideration to
ensure that the machine load can beoffset.
2.12 Environmental Conditions
Generally, the machine will be installed in the following conditions. However, these may change over a period of time or
in response to seasonalchanges.
•Supply voltage: +/- 10% of voltage listed on serial numbertag.
•Source frequency: ±2 Hz of frequency listed on serial numbertag
•Temperature effects dimensional accuracy, therefore, ambient temperatures should not exceed 105
degrees Fahrenheit. Also avoid exposing the machine to direct sunlight or heat rays which can change
the environmentaltemperature.
•Relative Humidity: Less than 80% (Temperature changes should not cause condensation)
•Atmosphere: Free from excessive dust, fumes, corrosive gases, andsalt
•Avoid exposing the machine to abnormalvibration.
2.2 UNLOADING YOUR MACHINE
Fryer machines are shipped on skids designed for forklift offloading. Be sure your forklift is rated for the proper weight of
the machine.
Note: If you are using a crane for offloading, please contact the factory in advance for instructions as damage can occur
if supported in the wronglocations.
2.3 RECEIVING YOUR MACHINE
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we can make sure your machine is packaged to fit into your dooropenings.
1. Fryer machines are carefully packed to avoid damage in transit; however, we ask that you UNWRAP AND
INSPECT YOUR MACHINE AS THOROUGHLY AS POSSIBLE PRIOR TO SIGNING THE BILL OF LADING. If
a digital camera is available, pictures should be taken before the machine is moved further. Pictures should be
sent to [e-mail].
2. Place the machine in its location and complete inspection. If there is any damage to your machine, Fryer should
be notified immediately. This will enable us to provide replacement parts before the service technician arrives
install the machine.
3. If you have any questions about any of these installation instructions or other questions about your new Fryer
Machine Systems machine, please call the Fryer Service Department and one of our trained technical staff will be
happy to assist you.

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2.4 UNPACK AND PLACE YOUR MACHINE
To make certain that your machine installation goes smoothly, it is important that the following items are completed prior
to the arrival of the Fryer authorized service technician. This will ensure that our technician is able to provide you with
the maximum amount of training during his allocated time with you.
1. Have your rigger move the machine to the operating location, remove it from the skid and install on ALL leveling
pads.
2. Remove all packaging material and thoroughly clean the machine and inspect for hiddendamage.
3. Remove all large assemblies from skids and stage next to machine to facilitate ease of assembly.
4. Install leveling pads and level machine. Level with a precision level, using the leveling screws and pads provided
with the machine.
2.5 PRIOR TO THE ARRIVAL OF THE TECHNICIAN
2.51 Installation SafetyInstructions
Initial start-up of the machine must be performed by a Fryer Machine Systems authorized servicetechnician.
2.52 Cleaning & Lubricating Machine
All protective coatings (cosmoline) must be removed before using the machine.
Be cautious when selecting a suitable cleaning agent. Paraffin applied with a clean brush will soften theprotective
coating. The protective coating can then be removed with clean rags.
•WD-40 or a similar product is recommended for cleaning the machine. Do not use gasoline or any other
flammable solution to clean the machine.
•Clean all exposed ways of the bed andsaddle.
2.53 Line Voltage Check
Line voltage must be ± 10% of the voltage listed on the serial numbertag.
2.54 Electrical Precautions
ELECTRICAL SCHEMATICS FOR YOUR MACHINE ARE LOCATED IN THE ELECTRICAL
CABINET AND IN THIS MANUAL.
Wiring
1. Ensure that all local electrical codes aremet.
2. Do not connect to the power distribution panel any power cables for devices that can cause line noise, such as
welders and high frequency quenchingmachines.
Grounding
INITIAL POWER-UP SHOULD ONLY BE PERFORMEDBY
A FRYER TECHNICIAN OR FACTORY AUTHORIZED
REPRESENTATIVE.

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You should always refer to your local electrical code to be sure you are grounding to code. Generally, use a grounding
wire with a cross section of more than 14 mm and a resistance to ground of less than 100 ohms. This wire size should be
greater than AWG (American Wire Gauge) No. 5 and SWG (British Legal Standard Wire Gauge) No.6.
Generally, the machine should be grounded to a separate grounding rod. If an independent ground cannot be provided
for the machine, prepare the ground connection asfollows:
1. Connect a single conductor to its own grounding terminal. This will avoid possible serious accidents resulting from
ground currents that might otherwise flow in the NC machine if a peripheral device should malfunction.
2. Be careful when using concrete reinforcing rods as grounding points. These reinforcing rods often are used to
ground equipment because they usually offer a resistance to ground of less than 100 ohms. In doing so, make the
connection as follows: (This also applies to connecting ground wires to regular groundingterminals)
3. Do not use the same grounding reinforcing rod or grounding terminal for other devices since this could lead to line
noise such as produced electric welders and high frequency quenchingmachines.
4. Use a grounding terminal with an adequate electrical performance rating and which is durable.
5. A separate grounding wire should be used, one whose length is as short aspossible.
6. Check the resistance to ground by actualmeasurement.
7. This should measure less than 100 ohms if the single device is connected to its own groundingrod.
Desirable Independent Grounding: Earth resistance: Less than 100 ohms Common Grounds:
Resistance to ground = 100/the number of devices connected to the grounding(Ω)
NEVER GROUND EQUIPMENT INSERIES!
Connection of Power Line
1. Make sure that the incoming power is compatible with the requirements of the machine tool (voltage, amperage,
phasing). All this information can be found on the machine’s serial number tag.
2. Power wires, grounding and over-voltage protection should comply with the local electrical code.
3. DO NOT connect if the incoming power is different from the power requirements of the machine. Contact a
qualified electrician.
NOTE: Electrical installation should only be completed by a qualified electrician.

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2.6 LEVELING THE MACHINE
Before attempting to use the machine, it will be necessary to accurately level it.
•Screw the leveling bolts (with nut) into the holes in the base of the machine. Set a leveling pad under.
•Please prepare the following tools to adjust machine level:
•Precision level (0.0005”/ft. or 0.013mm/1000mm accuracy)
•Two adjustable 32mm wrenches
•Clean the bed way and cross slide surfaces thoroughly and set one of the precision levels on the flat bed way
in the longitudinal direction, and the other on the cross slide, perpendicular to the first (if there is only one
level available, then use it on both directionsalternately).
•Adjust the six leveling bolts located the bottom of the machine base until the machine is leveled to within
0.001”/ft. (0.08mm/1000mm) in both directions.
•Lock the nuts on the leveling bolts, and re-check to see whether the level of machine is still correct. Repeat as
necessary until machine level is obtained with leveling bolts locked.
•After initial installation, check the level once a week for the first month, then check monthly thereafter.
2.61 Leveling Procedure
Step 1
•Set up your precision level in the middle of the machine table parallel to the X-axis.
•With the table centered in the X and Y-axis, adjust the machine’s four outside leveling studs to achieve
level.
•Be sure that the center leveling pads are not touching and that all four outside pads have load.
•Also check to make sure that the machine casting is not touching the floor.
Step 2
•Now rotate the level 90 degrees so it is parallel to the Y-axis and again check level.
•Adjust the four outside leveling studs as needed.
•If any adjustments are required to achieve level, you must go back and re-check level with the level parallel
to the X-axis.
•Repeat the adjustment process until the machine is perfectly level with the level parallel to both axes without
further adjustment.