Matrix 0850 User manual

User
Manual
0850/0850-T1 External Thread Grinder

Edition: 08/2013
Foreword
The information in this manual refers to equipment supplied by:
MATRIX MACHINE TOOL (COVENTRY) LIMITED
Matrix House, A2 Earlplace Business Park
Fletchamstead Highway, Coventry, CV4 9XL
UNITED KINGDOM
[email protected]
http://www.matrix-machine.com
Preface
The Health & Safety section of this manual must be read and all safety related precautions
observed before proceeding with the installation of this machine.
Support
Tel: [phone]
Fax: [phone]
Email: [email protected]
If you have any queries or suggestions regarding the 0850 User Manual, please contact our
Technical Publications Department: [email protected]
This manual describes the use of the 0850 External Thread Grinder. Any options taken or
deviations from the standard are documented in each machines individual set of manuals.
Matrix Machine Tool (Coventry) Limited reserves the right to modify its products without
notification and consequently to supply machines which are not in every detail in accordance
with the descriptions and procedures in this publication.
(This manual was written using Calibri font , size 12)

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Symbols & References
The table below lists symbols used throughout this document. Bold square brackets [ ] have been
used in this manual to denote a button or key function on the operator control console.
symbol
[ ] ref
meaning
General caution
Indicates general cautionary, warning, or danger level
information
Electrical shock caution
Indicates possibility of electric shock under specific conditions
[JOG]
JOG mode selection
[MDA]
MDA mode selection
[AUTO]
AUTO mode selection
[TEACHIN]
TEACHIN mode selection
[SBLK]
SINGLE BLOCK mode selection
[RESET]
RESET program cycle, alarm message
[CYCLE
START]
CYCLE start request

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[SPINDLE
START]
Grinding spindle start request
[SPINDLE
STOP]
Grinding spindle stop request
[SP.INC]
Increase grinding spindle speed override in 10% increments
SP.DEC]
Reduce grinding spindle speed override in 10% decrements
[SP.100%]
Set grinding spindle speed override to 100%
[Hand Unit Enable]
MPG/hand unit ON/OFF toggle function
[Coolant OFF]
Coolant delivery ON/OFF toggle function
[Lights
ON/OFF]
General machine lighting ON/OFF toggle function
YES
[YES]
Dialog prompt acknowledge button
[Unlock Door]
Unlock guard door request
[Gear ON/OFF]
Gearbox ON/OFF toggle function
[SETUP]
Setup mode toggle function.
Generally selected when using any of the setting cycles
[FIN]
Acknowledge button used during setting and grinding cycle
instruction prompts or to confirm the completion of a setting
cycle sequence
[AUTO REF]
Starts referencing all machine axes in a pre-defined order

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[ROTATE]
Workpiece continuous rotate
[TAILSTOCK
ADV/RET]
Tailstock advance/retract toggle
[STEADY
OPEN/CLOSE]
Workpiece steady open/close toggle
[PROBE
ADV/RET]
Probe advance/retract toggle
WARM
UP
[WARM-UP]
Machine warm-up cycle select
X
[X]
machine X axis select
Z
[Z]
machine Z axis select
C
[C]
machine C axis select
A
[A]
machine A axis select
W2
[W2]
tailstock axis select
Menu selection
">" is used to denote the sequence of softkey presses required to get a specific screen.
Example: Matrix > Main Menu > Part Data

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Table of Contents
1Health & Safety.................................................................................................................................10
1.1 General Safety......................................................................................................................................10
1.2 Understanding Safety Rules & Regulations..........................................................................................11
1.3 Know your machine .............................................................................................................................11
1.4 Maintain a safe working area...............................................................................................................11
1.5 Electricity..............................................................................................................................................12
1.6 Workshop hygiene ...............................................................................................................................12
1.7 Cancer of the skin caused by oil...........................................................................................................13
1.8 Machine Guards...................................................................................................................................13
1.9 Grinding Wheels...................................................................................................................................14
1.10 Machine User .......................................................................................................................................16
1.11 Service and Maintenance.....................................................................................................................16
2Liability Exclusions ............................................................................................................................17
3Machine Overview............................................................................................................................18
3.1 General layout......................................................................................................................................18
3.2 Axis configuration ................................................................................................................................21
3.3 Machine configuration.........................................................................................................................22
3.4 Machine floor layout (with 800L coolant system) ...............................................................................23
3.5 Machine floor layout (with optional high pressure 3000L coolant system) ........................................24
3.6 Minimum workshop height requirement ............................................................................................25
4Technical Data ..................................................................................................................................26
5Dresser System .................................................................................................................................29
5.1 Fixed Helix backplate (standard)..........................................................................................................29
5.2 Adjustable Helix backplate (option).....................................................................................................31
5.3 Dressing Spindle...................................................................................................................................34
5.4 Single-point diamond holder (option) .................................................................................................35
6Grinding Spindle ...............................................................................................................................37
6.1 Spindle Warm-Up.................................................................................................................................38
6.2 Grinding Wheel Speed Chart................................................................................................................39
6.3 Handling Grinding Wheels ...................................................................................................................40
6.4 Checking the grinding wheel................................................................................................................41
6.5 Mounting the grinding wheel ..............................................................................................................41
7Workhead.........................................................................................................................................42
7.1 Standard Workhead .............................................................................................................................42
7.2 Power operated workhead chuck (option)..........................................................................................43
7.2.1 3-Jaw chuck arrangement....................................................................................................................43
7.2.2 Opening and closing the chuck manually.............................................................................................44
8Powered workpiece support steady (option) .....................................................................................45
8.1 Operating the steady ...........................................................................................................................46
8.2 Fine Adjustment Screws.......................................................................................................................47
8.3 Procedure for fine alignment of the steady rest..................................................................................48
8.4 Steady Clamping Pressure....................................................................................................................49
9Tailstock ...........................................................................................................................................50
9.1 Manual Tailstock (standard) ................................................................................................................50
9.2 Pneumatic Tailstock (option) ...............................................................................................................52
9.2.1 Manual Operation Procedure ..............................................................................................................54
9.3 Travelling Tailstock (option).................................................................................................................55
9.3.1 Manual Operation Procedure ..............................................................................................................56
9.3.2 Setting the tailstock advance and retract positions.............................................................................57
9.4 Taper Adjust Procedure .......................................................................................................................58
10 Workpiece probing (option) ..........................................................................................................59
10.1 Fitting the probe unit to the work table ..............................................................................................60

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10.2 Enabling the probe system signal interface.........................................................................................62
10.3 Setting the probe offsets .....................................................................................................................62
10.3.1 Probe Offsets screen............................................................................................................................62
10.3.2 Procedure for establishing offsets .......................................................................................................63
10.3.3 Part Offset ............................................................................................................................................67
10.3.4 Testing Auto Pitch-in and correcting the Probe 1 offset .....................................................................68
11 Automatic doors (option) ..............................................................................................................70
11.1 Manual door operation........................................................................................................................71
12 Two-hand auto cycle start (option)................................................................................................72
12.1 Procedure for starting an automatic cycle using two-handed start buttons.......................................73
13 ANDON Light (option) ...................................................................................................................74
14 Standard coolant system (800L, upto 5bar working pressure).........................................................75
14.1 Switching on the coolant system .........................................................................................................76
14.2 Stage 1 - magnetic separator filtration ................................................................................................77
14.3 Stage 2 –centrifugal filtration..............................................................................................................77
14.4 Stage 3 –oil cooling .............................................................................................................................77
14.5 Stage 4 - Oil distribution.......................................................................................................................78
14.6 Stage 5 - Oil Return ..............................................................................................................................78
15 Optional HP coolant system (3000L, upto 70bar working pressure).................................................79
15.1 Switching on the coolant system .........................................................................................................79
16 Automatic Fire System (option) .....................................................................................................82
16.1 Principle of operation...........................................................................................................................82
16.2 What happens in the event of a fire? ..................................................................................................83
16.3 Fire System Low Maintenance .............................................................................................................83
16.4 Manual triggering of the fire extinguisher...........................................................................................84
17 Operator Console..........................................................................................................................85
17.1 HMI panel.............................................................................................................................................85
17.2 Machine Control Panel (MCP)..............................................................................................................87
17.3 CNC operating modes ..........................................................................................................................89
17.4 Program Cycle Start/Reset...................................................................................................................90
17.5 Axis selection and speed controls........................................................................................................91
17.6 Axis Reference......................................................................................................................................93
17.7 Grinding Spindle Controls ....................................................................................................................94
17.8 Command functions.............................................................................................................................95
17.9 Handheld Unit ......................................................................................................................................99
18 Automatic Wheel Balancer (SBS 4500) ......................................................................................... 100
18.1 Block diagram.....................................................................................................................................100
18.2 Integral Balancer Unit ........................................................................................................................101
18.3 Vibration sensor location...................................................................................................................102
18.4 Control Panel......................................................................................................................................103
19 Dialog Programming.................................................................................................................... 104
19.1 Displaying the Main Menu .................................................................................................................104
19.2 Work piece Manager..........................................................................................................................105
19.2.1 Create and Load a new workpiece.....................................................................................................105
19.2.2 Load an existing workpiece................................................................................................................106
19.2.3 Unload the workpiece........................................................................................................................106
19.3 Part Data ............................................................................................................................................107
19.3.1 Edit and Verify Part Data....................................................................................................................107
19.3.2 Explanation of the Input Parameters.................................................................................................108
19.3.3 Taper In/ Taper Out............................................................................................................................110
19.4 Thread Data (PMHMI)........................................................................................................................112
19.4.1 Create New Thread ............................................................................................................................112
19.4.2 Thread Parameter List........................................................................................................................118
19.4.3 Thread Type 1.....................................................................................................................................119
19.4.4 Thread Type 2.....................................................................................................................................120

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19.4.5 Thread Type 3.....................................................................................................................................121
19.4.6 Thread Type 4.....................................................................................................................................122
19.4.7 Thread Type 5.....................................................................................................................................123
19.4.8 Thread Type 6.....................................................................................................................................124
19.5 Create New Tool.................................................................................................................................125
19.6 Grinding Cycle Overview....................................................................................................................130
19.6.1 Part Counter (option).........................................................................................................................131
19.7 Dressing Cycle Overview ....................................................................................................................132
19.8 Setting Cycles Menu...........................................................................................................................133
19.9 New Wheel Cycle ...............................................................................................................................135
19.9.1 Explanation of the Input Parameters.................................................................................................136
19.9.2 Procedure for executing the NEW WHEEL setting cycle - if diamond ROLL fitted.............................141
19.9.3 Procedure for executing the NEW WHEEL setting cycle - if diamond DISC fitted .............................142
19.10 Work Datum Setting Cycle .................................................................................................................143
19.10.1 Explanation of the Input Parameters.................................................................................................143
19.10.2 Setup method 1 –grind direction from right-to-left .........................................................................144
19.10.3 Setup method 2 –grind direction from left-to-right .........................................................................144
19.10.4 Procedure for executing the WORK DATUM setting cycle ................................................................145
19.11 Barelling function (option).................................................................................................................146
19.11.1 Explanation of the Input Parameters.................................................................................................147
19.12 Probe system setup (option)..............................................................................................................148
19.12.1 Explanation of the Input Parameters.................................................................................................148
19.12.2 Procedure for setting up the probe system.......................................................................................149
19.13 Pitch-IN Setting Cycle.........................................................................................................................151
19.13.1 Explanation of the Input Parameters.................................................................................................151
19.13.2 Pitch-in to workpiece with a pre-cut thread......................................................................................152
19.13.3 Pitch-in to a blank or non-threaded workpiece.................................................................................152
19.13.4 Procedure for executing the PITCH-IN setting cycle..........................................................................153
19.14 Next Wheel Setting Cycle (option).....................................................................................................154
19.15 Auto Dress Utility Cycle......................................................................................................................155
19.15.1 Explanation of input parameters .......................................................................................................156
19.15.2 Procedure for using the Auto Dress cycle..........................................................................................157
19.16 Correction Utilities Menu...................................................................................................................158
19.17 Lead Correction..................................................................................................................................159
19.17.1 Explanation of input parameters .......................................................................................................159
19.17.2 Procedure...........................................................................................................................................161
19.17.3 Applying lead correction ....................................................................................................................162
19.18 Taper Correction ................................................................................................................................163
19.18.1 Explanation of input parameters .......................................................................................................164
19.18.2 Positive Taper Error............................................................................................................................165
19.18.3 Negative Taper Error..........................................................................................................................165
19.18.4 Procedure...........................................................................................................................................166
19.19 Diameter Correction ..........................................................................................................................167
19.19.1 Explanation of input parameters .......................................................................................................167
19.19.2 Applying diameter correction ............................................................................................................168
19.19.3 Procedure...........................................................................................................................................168
19.20 Profile Correction...............................................................................................................................169
19.20.1 Explanation of input parameters .......................................................................................................170
19.20.2 Procedure...........................................................................................................................................171
19.21 Barrelling Correction..........................................................................................................................172
19.21.1 Procedure...........................................................................................................................................172
19.22 Cycle Data - Grind Table.....................................................................................................................173
19.22.1 Procedure to edit Grind cycle variables.............................................................................................174
19.22.2 Grinding Zones ...................................................................................................................................175
19.22.3 Explanation of parameters.................................................................................................................176

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19.22.4 End-threading parameters.................................................................................................................178
19.22.5 How to set the start and end points for end-thread grinding ...........................................................179
19.23 Cycle Data –Dress Table ....................................................................................................................180
19.23.1 Procedure to edit Dress cycle variables.............................................................................................180
19.23.2 Explanation of parameters.................................................................................................................181
19.24 Load and Run the Grind Cycle............................................................................................................182
19.25 Cycle Stop/interrupt...........................................................................................................................183
19.25.1 Procedure for Cycle Interrupt ............................................................................................................184
19.25.2 Resume the cycle ...............................................................................................................................185
19.25.3 Make a correction to the diameter and then resume the cycle........................................................185
20 Access Level Key Switch .............................................................................................................. 186
21 Programming M/S/T Codes ......................................................................................................... 187
22 Maintenance............................................................................................................................... 189
22.1 Lubrication System.............................................................................................................................189
22.2 Electrical Control Cabinet (ECC) .........................................................................................................190
22.3 Services Cabinet (SC)..........................................................................................................................191
22.4 Fume Extractor...................................................................................................................................192
22.5 Recommended oils/fluids/additives ..................................................................................................193
22.6 Coolant System ..................................................................................................................................195
22.7 Preparing the Spindle Chiller Unit......................................................................................................196
1.1.1 Oil Cooler Unit ...............................................................................................................................197
2.1.1 Working Mode Of Cooler Unit Controller......................................................................................197
22.8 General Maintenance Schedule.........................................................................................................200
22.9 Pressurised air supply to machine .....................................................................................................202
22.10 Cleaning the coolant system centrifuge.............................................................................................203
22.11 Power Chuck maintenance ................................................................................................................208
23 Troubleshooting Guide................................................................................................................ 209
23.1 Oil Cooler Unit fault codes .................................................................................................................209
23.2 Machine Diagnostic Screens ..............................................................................................................213
23.3 Alarm Messages .................................................................................................................................217
23.4 Recovering from an axis software travel limit condition...................................................................228
23.5 Air conditioning unit alarm codes......................................................................................................229
23.6 Coolant System Technical Data..........................................................................................................230

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1Health & Safety
This machine carries the CE Mark and complies with the Machinery Directive 89/392 as amended by
the EC Directive 91/368.
The Safety Provisions are based on the draft European provisional standard for grinding machinery
designated as document CEN/TC143/N141E.
The standard provides for both Operating and Setting modes and these are described in the
Operating section of this manual.
Matrix Machine Tool has a safety record of which it is justly proud and in issuing this user manual
they would like to bring to your operator’s attention to Section 7 of the Health & Safety at Work Act
1974, which requires that the supplied machine is designed and constructed as far as reasonably
practicable to be safe and without risk to health.
1.1 General Safety
Matrix machines are constructed for maximum operator safety under standard operating conditions,
when recommended instructions are followed in the assembly and operation of the machine and its
equipment.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual. Proper operation of the machine promotes safety for the operator and all
workers in the vicinity.
Particular attention must be paid to the appropriate pages of this manual where the following
symbols are shown.
Indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury or damages to the machine. The information described following
the caution symbol must be strictly observed.
Indicates risk of electrical shock
Power source work must be entrusted to an electrician with a license to carry out
electrical work. If a person without knowledge of electrical safety practices attempts
this work, he or she could be electrocuted and possibly seriously injured or the
machine could be seriously damaged.
Become familiar with material, inspection and mounting of grinding wheels, wheel speed limitations
and correct setting and securing of wheel guards.
Many factories have wheel mounting specialists who because of their experience and knowledge, are
designated the responsibility for properly mounting the wheel. When possible, such persons with this
responsibility should be consulted to supervise or perform the work.
In reading the following guidelines for safety, it should be recognized that it is the responsibility of
each individual to observe the prescribed rules as outlined. All warning and danger signs must be
observed and obeyed. All actual or potential danger areas must be reported to your immediate
supervisor.