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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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.

J630D
26.7.02 5
0.1 Safety of the machine
The J630D machine has been designed in line with the present state of the art in
engineering as well as generally recognized safety rules and regulations. It com-
plies with the EU Machinery Directive. The X-radiation generated by the monitor
is adequately shielded in accordance with statutory requirements. Nevertheless,
the risk of personal injury (or in extreme cases death) to the operator or third par-
ties as well as damage to the machine or other equipment cannot be ruled out
completely.
The machine is equipped with various safety devices intended to protect the user
and other persons. Safe operation is not dependent on mechanical / electrical
functions alone however, but also on
• Your own sense of personal responsibility
• Correct handling in accordance with regulations

J630D
26.7.02 7
0.2 Measures to be taken in the event of damage incurred during
transit
Any damage to the exterior or losses must be recorded in the appropriate manner
on the freight note before the machine/system is accepted and reported immedi-
ately to the insurer and K.Jung GmbH.
In the event of damage that has occurred not being detected until the machine/
system is unpacked, leave the machine/system as you found it and notify the car-
rier in writing that confirmation of the damage incurred is required. Complaints in
this case must be made within 6 days of receiving the consignment.

J630D
26.7.02 9
0.3 General terms and conditions of delivery
Prices
We reserve the right to charge the prices valid on the day of delivery.
Reservation of title
We retain full title to all deliveries pending settlement of all payments due on this
supply contract. Our deliveries may only be pledged subsequent to full payment
of all claims arising from the delivery.
Passage of risk
The risk for our delivery shall pass to the ordering party immediately following dis-
patch of the delivery from the works, including in those cases in which carriage
prepaid delivery is agreed. Should shipment be delayed at the request of the or-
dering party, the full risk shall pass to ourcustomer on the day on which readiness
for dispatch is notified.
Liability for defective delivery
We provide a 6-month warranty on all deliveries made by us, whereby we under-
take toremedy alldefects and damagesto the supplied goods atno charge, to the
extentthatsuchdefectsanddamagesareverifiablycausedbydefectivematerials
or faulty work performed in the workshop. The 6-month warranty period always
commences on the day on which the risk passes to the customer.
JUNGsparepartsinstalledbyother companiesor by thecustomerarenot subject
to warranty or warranty claims.
Special conditions for new machines
Wefurnish afull12-monthwarrantyonallnewJUNG grindingmachinesdelivered
for one-shift operation up to a maximum of 2000 operating hours. The warranty
period shall terminate as soon as the stipulated number of operating hours has
been exceeded.
We shallrepair defectsand damages to ournew machines atno charge withinthe
warranty period.
The warranty period always commences on the day on which the risk passes to
the customer; should machines be commissioned by K. JUNG Service, this is the
day on which the commissioned machinery is transferred to the customer.
General limitations
All defects detected shall be notified to us immediately.
No warranty is assumed under any circumstances for ensuing damages or for da-
magesduetoextraneouscauses.Nowarrantyis assumed,goodwillservicesdue,
extended liability applicable or compensation paid for defects and damages ari-
sing as a result of improper operation. This disclaimer also applies to defects ari-
sing due to the use of incorrect technology, unsuitable tools, coolants and
machining parameters or ambient temperature or vibration conditions which pre-
vent the machinery from functioning or being used to the required level of precisi-
on. Notwithstanding the customer’s right to rectification of defects at no charge,
the customer shall not be entitled to assert any claims or rights on the basis of dis-
advantages suffered, regardless of the legal standing of the same. Our warranty

J630D
10 26.7.02
expires as soon as the customer takes action to remedy an identified defect itself
to the extent that such action is undertaken without the written authorization of K.
JUNG GmbH. This applies in particular to manipulation of the operating hours me-
ter. In such cases, all reworking costs incurred as a result shall be borne by the
customer and performance of the requisite work shall be contingent on written
acknowledgment of this proviso.
The successful operation of the supplied machinery is dependent on the deploy-
ment of specialist trained operators and regular professional maintenance and
servicing appropriate to the specificuse made of themachinery. The customer be-
arssoleresponsibilityforselectingthecorrectmachiningtechnologyaswellasfor
high-quality machining results.
Other provisions
Warranty rights only apply to the agreed place of delivery and may not be trans-
ferredtothirdparties.Installationandcustomerserviceworkissubjectexclusively
to our general installation terms, conditions and rates. We will gladly send details
on request. Unless otherwise agreed in writing, all further details are governed by
the latest version of our Terms and Conditions of Delivery VDW 502 / ORGALIME
/ ECE or INCOTERMS. These Terms and Conditions of Delivery are thus a con-
stituent part of the purchase or supply contract and no other terms and conditions
are recognized by us.
K.JUNG GmbH

J630D
1. Safety 26.7.02 11
1. Safety
1.1 Symbols used in these Operating Instructions
Draws attention to a potentially dangerous situation which could
result in serious personal injury or death.
Draws attention to a potentially dangerous situation which could
result in minor personal injury. This symbol is also used if there is a
risk of damage to the machine or equipment.
Draws attention to a potentially problematic situation in which either
the product itself or an object in its vicinity could be damaged.
Also used to indicate important information.
Instructions for using the machine or other useful information.

J630D
1. Safety 26.7.02 13
1.2 Use for the intended purpose
The surface and profile grinding machine is a machine tool which is installed at a
fixed location (stationary grinding machine). It is designed solely for machining
workpieces with suitable grinding wheels. The grinding wheel and the workpiece
are continuous path-controlled, in other words the grinding process is positively
guided. The workpieces must be secured in position on the machine table using
suitable clamping devices, and appropriate steps taken to prevent them from mo-
ving, slipping or flying off. Failure to take such precautions means yourun the risk
of the grinding wheel bursting as a result of workpieces toppling over or flying off.
In addition, workpieces or wheel fragments may be catapulted out of the machi-
ne's working envelope.
'Use for the intended purpose' also includes:
– Careful attention to the instructions contained in the Operating Instructions,
and in particular to all other information provided in the safety section and
on the machine's safety plates.
– Compliance with all national and international safety and protection regula-
tions, standards, codes of practice and statutoryrequirements applicable to
activities of any kind on or with the machine.
– Observance of all servicing and maintenance intervals.
All other forms of use which deviate from the above, and in particular failure to
heed the information contained in the Operating Instructions or comply with the
statutory requirements for machine owners as well as with any other safety regu-
lations, are considered to be contrary to the intended purpose.
Dressing the grinding wheels with a manually guided diamond is not considered
to be in accordance with the intended purpose of the machine.
Workpieces must not under any circumstances be positioned at the grinding
wheel by hand,for example in order to grind the edgesas with a grinding pedestal.
Misuse or use contrary to the intended purpose can result in either
the machine itself and/or products in its vicinity being damaged or
destroyed. Personal injury or, in extreme cases, death may ensue if
the danger zone around the machine is not kept clear.
No liability for injuries to persons or damage to property of any kind
will be assumed by the manufacturer if the machine:
• is not used in accordance with its intended purpose,
• is not maintained correctly or adequately,
• is not operated correctly,
• is operated or used by persons without suitable qualifications,
is not operated in accordance with the safety instructions contained
in this section and in the other relevant sections of the Operating
Instructions.