Jung J630D User manual

J630D
26.7.02 i
Table of contents
0.1 Safety of the machine......................................................................................................5
0.2 Measures to be taken in the event of damage incurred during transit ............................7
0.3 General terms and conditions of delivery........................................................................9
1. Safety.....................................................................................................................................11
1.1 Symbols used in these Operating Instructions..............................................................11
1.2 Use for the intended purpose........................................................................................13
1.3 General safety regulations ............................................................................................15
1.3.1 Important information about the Operating Instructions.....................................16
1.3.2 Protective and safety equipment........................................................................17
1.3.3 Transport............................................................................................................17
1.3.4 Commissioning...................................................................................................18
1.3.5 Machining...........................................................................................................18
1.3.6 Maintenance / malfunctions / faults / repairs......................................................18
1.3.7 Disposal .............................................................................................................19
1.3.8 Grinding wheels .................................................................................................19
1.3.9 Magnetic chucks ................................................................................................21
1.3.10 Coolants.............................................................................................................21
1.3.11 Other accessories / work equipment..................................................................22
1.3.12 Personal protective equipment / work clothing...................................................22
1.3.13 Operator qualifications .......................................................................................23
2. Technical data / transportation / commissioning..............................................................25
2.1 Technical data...............................................................................................................25
2.2 Noise measurement ......................................................................................................27
2.3 Floor space drawing......................................................................................................29
2.4 Transport dimensions (machine only) ...........................................................................31
2.5 Transport instructions....................................................................................................33
2.5.1 Transport by crane.............................................................................................34
2.5.2 Transport by fork-lift truck ..................................................................................36
2.6 Preparation for commissioning......................................................................................37
2.6.1 Transportation safeguards on the PA 31K (optional).........................................39
2.7 Storage..........................................................................................................................41
2.7.1 Temporary storage.............................................................................................41
2.7.2 Installation..........................................................................................................41
2.8 Electrical connections....................................................................................................43
2.8.1 Connection to power systems with an r.c.c.b. circuit-breaker............................44
2.9 Definition of machine axes............................................................................................45
3. Machine control unit / remot control panel........................................................................47
3.1 Control unit....................................................................................................................47
3.2 Machine control unit......................................................................................................51
3.3 Remote control panel....................................................................................................55
4. Functional description of the operating modes ................................................................57
4.1 Changing the operating mode: important instructions and safety regulations...............57
4.2 Setting-up mode............................................................................................................59
4.3 Semi-automatic mode ...................................................................................................61
4.3.1 Control functions and restrictions.......................................................................61
4.3.1.1 Switching the grinding spindle motor on ................................................61

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4.3.1.2 Switching the grinding spindle motor off ................................................62
4.3.1.3 Positioning the axes at the normal feed rate or in rapid traverse mode.62
4.3.1.4 Positioning the axes incrementally.........................................................62
4.3.1.5 Starting the automatic reciprocating function.........................................63
4.3.1.6 Stopping the automatic reciprocating function .......................................63
4.3.1.7 Activating a manual infeed during an automatic reciprocating motion...63
4.3.1.8 Setting the reversing positions for the reciprocating motion in
the X-axis directly...............................................................................................64
4.3.1.9 Setting the reversing positions for the reciprocating motion in
the Z-axis directly...............................................................................................65
4.3.1.10Teaching an X- or Z-axis reversing position with the remote
control panel.......................................................................................................66
4.4 Automatic mode ............................................................................................................67
4.4.1 Special functions in automatic mode..................................................................67
4.4.1.1 Interrupting a program cycle (26) and continuing machining at the
breakpoint (not possible with creep-feed grinding technology)..........................67
4.4.1.2 Program cycle interrupted during a dressing cycle ................................68
4.4.1.3 Cancelling a function..............................................................................68
4.4.1.4 Measurement.........................................................................................68
4.4.2 Sequence of operations in an automatic program cycle....................................69
5. Functions of the machine....................................................................................................71
5.1 Functions of the control unit / machine..........................................................................71
5.1.1 Important warning for all programs ....................................................................72
5.1.2 Function tree structure of the Machine Jung module in setting-up and semi-auto-
matic mode....................................................................................................................73
5.1.3 Function tree structure of the Machine Jung module in automatic mode...........75
5.1.4 Machine Jung module........................................................................................76
5.1.4.1 System data ...........................................................................................78
5.1.4.2 Statistics.................................................................................................79
5.1.4.3 Simulation ..............................................................................................80
5.1.4.4 Program overview..................................................................................81
5.1.5 Function tree structure of the Program Jung module.........................................83
5.1.6 Program Jung module........................................................................................85
5.1.6.1 Function tree structure of the File Manager...........................................87
5.1.6.2 File manager..........................................................................................89
5.1.7 Bereich Dienste Bedienbaum-Struktur...............................................................93
5.1.8 Service module ..................................................................................................95
5.2 Traversing to the reference point ..................................................................................97
5.3 Tool management .........................................................................................................99
5.3.1 Function tree structur.........................................................................................99
5.3.2 Tool management generally.............................................................................101
5.3.3 Grinding wheel management...........................................................................101
5.3.4 Dresser management.......................................................................................105
5.4 Setting actual values...................................................................................................109
5.4.1 Setting actual values for table dressing ...........................................................109
5.4.1.1 Setting actual values with a single diamond /PA30/130T (optional) ....110
5.4.1.2 Probing control in the AT Y-axis and the AT Z-axis (optional).............112
5.4.2 Setting actual values for the AF65 dressing head (optional)............................114
5.4.2.1 Probing manually with confirmation .....................................................115
5.4.3 Setting actual values for the PA 31K dressing head (optional)........................115
5.4.4 ISetting actual values for grinding....................................................................117
5.4.4.1 Probing control in the AT Y-axis and the AT Z-axis (optional).............118
5.5 Creating and modifying grinding programs .................................................................121
5.5.1 Grinding program functions..............................................................................121
5.5.1.1 Automatic probing in the grinding program ..........................................122
5.5.2 Function tree structure for surface grinding .....................................................123
5.5.3 Surface grinding...............................................................................................125

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26.7.02 iii
5.5.4 Function tree structure for plunge grinding ......................................................129
5.5.5 Einstechschleifen .............................................................................................131
5.5.5.1 Reciprocating plunge grinding technology...........................................132
5.5.5.2 Creep-feed grinding technology (optional)...........................................133
5.5.6 Function tree structure for face grinding (optional) ..........................................137
5.5.7 Face grinding (optional) ...................................................................................139
5.5.8 Function tree structure for stationary plunge grinding (optional)......................141
5.5.9 Stationary plunge grinding (optional) ...............................................................143
5.5.10 Function tree structure for Z - Y reciprocating path grinding (optional)............147
5.5.11 Z - Y reciprocating path grinding (optional)......................................................149
5.5.12 Bahnpendelschleifen X - Y (Option) Bedienbaum-Struktur..............................153
5.5.13 X - Y reciprocating path grinding (optional)......................................................155
5.5.14 Special programs (optional) .............................................................................158
5.5.14.1Special multiple plunge grinding program (optional))..........................159
5.5.14.2Special multiiple plunge grinding ........................................................162
5.6 Dressing......................................................................................................................165
5.6.1 Function tree structur.......................................................................................165
5.6.2 Description of dressing.....................................................................................167
5.6.3 Dressing program functions .............................................................................167
5.6.4 Setting up PA 31K (optional)............................................................................168
5.6.5 Dressing technology input................................................................................170
5.6.5.1 CD mode (optional)..............................................................................172
5.6.6 Selecting a geometry for face dressing............................................................173
5.6.7 Dressing procedure with an MA65 (optional)...................................................174
5.6.8 Dressing procedure with a Diaform DG 5/1 grinding wheel profile
dresser (optional) ........................................................................................................175
5.7 Dressing contours created in "Grips" ..........................................................................177
5.7.1 Creating a contour, saving it and transferring it to the NC by means of a
postprocessor run........................................................................................................177
5.7.2 Loading a contour from the NC to the NCU.....................................................178
5.8 Transferring data from an external "Grips computer" to the "OP31 control unit".........179
5.8.1 Important setups on the "Grips computer" .......................................................179
5.8.2 Important setups on the "OP31".......................................................................180
5.9 Important directory settings in GRIPS 32 (optional)....................................................183
5.10 Batch mode .................................................................................................................185
5.10.1 Saving programs for batch mode.....................................................................185
5.10.2 Selecting batch mode.......................................................................................185
5.10.3 Dressing (reprofiling) and grinding a new contour in batch mode....................187
5.10.4 Editing stored batch programs .........................................................................188
5.11 Warm-up/follow-up program........................................................................................189
6. Dressers ..............................................................................................................................191
6.1 Overview of dressers...................................................................................................191
6.1.1 General rules for using dressers......................................................................191
6.2 Single diamond (optional)............................................................................................193
6.3 AT35 / AT35D (Option)................................................................................................195
6.4 MA65 (optional)...........................................................................................................197
6.4.1 Functions..........................................................................................................197
6.4.2 Dressing with MA65 .........................................................................................197
6.4.3 Operating the MA65 with enclosed machines..................................................197
6.5 Diaform grinding-wheel profiling tool DG5/1 (optional)................................................199
6.6 Optidress-E optical profile dressing system (optional)................................................201
6.7 AF65 (optional)............................................................................................................203
6.8 PA 31K (optional)........................................................................................................205
6.8.1 General description..........................................................................................205
6.8.2 Installation and commissioning ........................................................................206

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6.8.3 Calculating the basic dimension on the PA 31K ..............................................206
6.8.4 Transferring the basic dimension to the VG2 presetting device.......................207
6.8.5 Adjusting the diamond reference dimension....................................................207
6.8.6 Mounting the diamond in the single-diamond holders......................................208
6.8.7 Adjusting and mounting the single-diamond holders with the diamonds .........208
6.8.8 Fitting the clamping bolt ...................................................................................210
6.8.9 Changing the diamond holder..........................................................................210
6.8.10 Changing the Erowa plate................................................................................211
7. Accessories ........................................................................................................................213
7.1 Permanent electromagnetic chucks............................................................................213
7.1.1 Activating the gripping force.............................................................................214
7.1.2 Mounting instructions.......................................................................................214
7.1.3 Regrinding a magnetic chuck...........................................................................214
7.2 Coolant cleaning systems (optional) ...........................................................................217
7.2.1 Activate the colant cleaning system.................................................................218
7.2.2 Functional description......................................................................................218
7.2.3 Connection to the central coolant cleaning system for the optional
NS - ZS3......................................................................................................................219
7.3 Coolants......................................................................................................................221
7.3.1 General rules for working with coolants...........................................................221
7.3.2 Skin protection plan..........................................................................................223
7.4 Grinding mist extractor (optional)................................................................................225
7.5 Cross-slide cooling system..........................................................................................227
7.5.1 Maintenance.....................................................................................................229
7.6 Grinding wheel flange (optional)..................................................................................231
7.6.1 Flanging and balancing a grinding wheel.........................................................232
7.6.1.1 Flanging a grinding wheel....................................................................232
7.6.1.2 Balancing a flanged grinding wheel statically.......................................233
7.7 Grinding wheel flange in conjunction with a manual HSK tool-holder (optional).........235
7.7.1 Clamping the flange onto the grinding spindle.................................................235
7.7.2 Unclamping the flange from the spindle...........................................................236
7.7.3 Important note: clamping bolt...........................................................................236
7.8 Semi-automatic balancers (optional)...........................................................................237
7.9 Dividing heads (optional).............................................................................................239
7.10 Grinding spindle drive with a second speed range up to
206,7 ft/s (optional)...............................................................................................................241
7.10.1 Changing the speed.........................................................................................241
8. Error and status messages ...............................................................................................243
8.1 NC error messages: from 65000 to 65999..................................................................243
8.2 NC status messages: from 67000 to 67999................................................................253
8.3 Channel 1 messages: from 510000 to 511315 ...........................................................257
8.3.1 Feed lock and halt dwell time 510100 - 510131..............................................257
8.3.2 NC-start locked 510300 - 510315....................................................................260
8.4 Axis error messages 600100 - 600815 .......................................................................261
8.4.1 Axis 1, 600100 - 600115..................................................................................261
8.4.2 Axis 2, 600200 - 600215..................................................................................262
8.4.3 Axis 3, 600300 - 600315..................................................................................263
8.4.4 Axis / spindle 4, 600400 - 600415....................................................................263
8.5 User error and status messages 700000 - 700063.....................................................265
8.6 NC Siemens system errors .........................................................................................271
9. Maintenance / servicing / disposal ...................................................................................273
9.1 Maintenance and servicing instructions ......................................................................273

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9.1.1 Maintenance and service list............................................................................274
9.1.2 Maintenance and servicing instructions...........................................................275
9.1.3 Regular maintenance of the coolant system....................................................276
9.2 Setting the table reversal and limit positions in the X-axis with hydraulic valves........277
9.3 Lubrication plan...........................................................................................................279
9.3.1 Important instructions for working with oils ......................................................279
9.3.2 Recommended lubricating oils.........................................................................279
9.3.3 Recommended hydraulic oils...........................................................................279
9.3.4 Recommended grease (for optional PA31K) ...................................................279
9.3.5 Lubrication instruction plate .............................................................................280
9.3.6 Diagram of the central lubrication system........................................................281
9.3.7 Drain valves for the used oil of fully enclosed machines (optional)..................282
9.3.8 Maintenance unit for optional equipment.........................................................282
9.3.9 Lubricating points on the PA 31K (optional).....................................................283
9.4 Hydraulic plan..............................................................................................................285
9.4.1 Charging/extracting the hydraulic oill ...............................................................287
9.5 Pneumatic plan............................................................................................................289
9.6 Grinding spindle ..........................................................................................................291
9.6.1 Eliminating radial runout and releasing tension ...............................................291
9.6.2 Removing and installing the grinding spindle...................................................292
9.7 Traversing clear of the hardware limit switches in the X, Y and Z-axes......................295
9.8 Traversing clear of a mechanical stop in the E, U and W-axes (optional PA 31K) .....297
9.9 Replacing the battery (control unit) .............................................................................299
9.9.1 Replacing the battery for the MMC 103 display ..............................................299
9.9.2 Replacing the battery for the NCU ...................................................................300
9.10 Disposal.......................................................................................................................303
9.10.1 Disposal of the machine...................................................................................303
10. Appendixes .........................................................................................................................305
10.1 We want to know what you think.................................................................................305
10.2 Form for signatures.....................................................................................................307
10.3 Inspection protocol for coolants that can be mixed with water....................................309

Operating Instructions
J630D

J630D
26.7.02 3
Delivery data
Customer data
Manufacturer’s address
K.Jung GmbH
Jahnstraße 80-82, 73037 Göppingen
Postfach 640, 73006 Göppingen
Germany
Telephone: [phone]
Telefax: +49 (0)7161/612-213
Spare parts and customer service
See address above
Service Department
Telephone: [phone]
Telefax: +49 (0)7161/612-169
Hotline: [phone] or +49 (0)7161/612-207
Spare parts: +49 (0)7161/612-125
Overhauls / repairs: +49 (0)7161/612-151
Model: Surface and profile grinding machine
Type: J630D
Machine number:
Order number:
Registration number: 04-07-2002
Inventory number:
Location:

J630D
4 26.7.02
Dear customer,
The machine you just have purchased is a quality product from
K.Jung GmbH.
The aimofthese Operating Instructions is to help familiarize you with the machine
and the various applications for which it is intended.
The relevant national requirements relating to accident prevention and environ-
mental protection must also be heeded in addition to the instructions contained in
these Operating Instructions. The respective legally binding rules and regulations
governing safe and proper work practices in the country in which the machine is
used, as well as at its operating location, must likewise be observed.
The owner of the machine must prepare Instructions for Use in accordance with
UVV ZH I/172 (Safety Through Instructions), taking account of the technical docu-
mentation and all statutory requirements.
The descriptions and specificationscontained in these Operating Instructions are
subject to change in the event of technical modifications that are necessary to im-
prove the machine.
The electrical documentation can be found in the control cubicle of the machine.
We want to know what you think:
We continuously strive to improve thequality and safety of our products, including
the Operating Instructions supplied with our machines. Please notify us of any de-
fects or errors you discover in our products.
You can send us your comments, criticisms or suggestions for improvements by
post or by fax. Please use the form contained in the Appendix.
© 2002 K.Jung GmbH, Jahnstr. 80-82, D - 73037 Göppingen
All rights reserved
No part of these Operating Instructions may be reproduced without the prior permission of K.Jung GmbH.