NCMT MAKINO A100-5XR-CD User manual

Makino A100-5XR CD
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OPERATORS MANUAL
MAKINO A100-5XR-CD
WITH
PROFESSIONAL 3 NC CONTROL

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PAGE
Power On & Reference Procedure 3
Registering Tool Nº to Pot Nº 4
Tool Offset Setting 5
Datum or Zero Setting 6
Interlocking Procedure 9
Loading of Tools Into Spindle Manually 9
Loading tools into magazine 10
Wheel Dress Routine 10
Using the Tool Magazine 11
MDI Tool Change 13
MDI B Axis move 14
Manual Change of Erowa Pallet 15
MDI Axis Movement 16
MDI Coolant Nozzle Change 16
Mid-Auto Manual Interrupt 17
Example Alarm & Alarm Recovery Procedure 18
Alarm History 19
Editing 19
Tool Life Management 22
Spindle Load Monitoring 23
G Codes 24
M Codes 26
Word Addresses 33

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Power On & Reference Procedure
1. Turn ISOLATOR On
2. Press CONTROL POWER ON button
3. Wait for EMG to go off at the bottom of the screen (takes approx 2 minutes)
4. Press the AUTO ZERO button
5. Press the START button located below the auto zero button
6. Turn the rapid override up after checking the safe movement of the
machine
7. Select B axis and jog mode , jog B axis in minus direction
8. Select Reference mode and hold down the plus direction button
9. In Reference mode , select A axis and hold down the minus direction button
10.In Reference mode , select U axis and hold down the plus direction button
11.There should now be six green lights lit
To reference the Pu and Pv axis use the following M-codes in MDI:-
M803 –Pu Axis
M806 –Pv Axis

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Registering Tool Nº To Pot Nº
The location of each tool in the magazine must be recorded on the Tool Data
Screen.
1. Select CUSTOM display button
2. The Primary Operation Screen should be displayed
3. Use extension key (MS, FC, PO) button to find Tool Detail button
4. Press Tool Detail Key
5. Press INPUT/DISPLY to highlight INPUT
6. Cursor to the required Pot Number and enter the Tool number in the PTN
column.
7. Press INPUT/DISPLAY to Lock
Extension Keys
Tool Detail Key

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Entering Tool Length and Tool Radius
1. Select CUSTOM display button.
2. Use extension key (MS, FC, PO) button to find TOOL DETAIL button
3. Press TOOL DETAIL as previous
4. Press INPUT/DISPLY to highlight INPUT
5. Press DISPLAY SHIFT(soft key) to display H-VALUE or D-VALUE
6. Move the cursor to the required tool and column (H = length D=radius)
7. Key in the Data
8. Press the INPUT button on the control panel
9. Press INPUT/DISPLAY to Lock

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Entering a known Program Zero
Available In Any Mode.
1. Press OFFSET / SETTING button
2. Press WORK soft key
3. Page and cursor to relevant offset number
4. Highlight relevant axis to be set using cursor keys
5. Key-in data e.g. -603.686
6. Press INPUT button

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Setting A Program Zero To a Component Feature
1. Load and clamp a DTI into spindle
2. Using rapid buttons and pulse handle, clock a hole or spigot of known true
position
3. Press OFFSET button
4. Press WORK soft key
5. Page and cursor to program zero offset number
6. Key in noted data from the Machine Position
7. Press INPUT button
Note: If faces of known position are used then insert test bar in spindle instead of
DTI, manually, position to the known face and add or subtract the test bar radius
of step 6.
Key in this Data

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For Z Axis
1. Manually position end of test bar to a known face.
2. Repeat steps 5 to 7 as previous page, take into account the length of the
test bar, i.e. If the Z face is to be at zero and the test bar length is 150mm,
the calculation should be:
Z Pos from screen –Test bar length
e.g. -360.035 –150 = -510.035

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To Enter Operating Area
1. Press MANUAL RELEASE button when GREEN AVAILABLE light is on
2. Keeping button pressed , open operator door
Note! If the green light is not on it is usually one of the following
A) The coolant is still on
B) A spindle is running
C) The chip conveyor is running
To Enter ATC Magazine
1. Press DOOR LOCK RELEASE button
2. Open ATC MAGAZINE door
Note! Access can only be gained if the machine operator door is closed
To Load a Tool Into Either Spindle
1. Select HANDLE mode
2. Ensure spindles, coolant and chip conveyor are turned off and stationary
3. Ensure SPINDLE ENABLE key switch is in the on position
4. Ensure SPINDLE ENABLE lamp is off for main spindle or on for dresser
spindle
5. Open operator door
6. Press TOOL UNCLAMP/CLAMP button to unclamp spindle
6. Put tool into spindle and ensure that the drive dogs are engaged
7. Press TOOL UNCLAMP/CLAMP button to clamp spindle
8. Close operators door

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Wheel Dress Routine’s
Initial Dressing of Wheels
This must be performed when you replace a worn grinding wheel with a new
wheel:
1. Replace the worn wheel with the correct new wheel
2. Select the required program O6*** (e.g. T103 = O6103)
3. Run the program in automatic taking care on first time (e.g. SINGLE
BLOCK)
4. Visually check the new wheel
Manual Dressing of Wheels
1. Select the required program O7*** (e.g. T103 = O4103)
2. In the EDIT mode, enter the required dress amount in the A value (e.g.
A=0.4)
3. Run the program in automatic taking care on first time (e.g. SINGLE
BLOCK)
4. Visually check the dressed wheel

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Using The Tool Magazine
NOTE: If the TLS alarms you will see a code flash in the display POT NO. & TOOL
NO. It will read A18 000_.
If at any point you enter the wrong figure press ‘C’ to reset
alarms
A18 0006 –operator door not shut
A18 0009 –tool I.D. not in tool data
To bring a tool into the draw you must be in mode ‘CHG TOOL’
To view what tool/pot is in the Ready Position select ‘NEXT TOOL’
To view what tool/pot is in the Spindle select ‘SPDL TOOL’

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To Call A Pot Number To The Drawer
On the magazine control panel:
1. Press the POT key on the Number Pad
2. Enter the required POT number
3. Press TOOL SEARCH Key
4. (The tool is delivered to the drawer)
5. Press TLS UNLOCK
6. Rotate the drawer handle and open the tooling drawer
7. When loading a dresser ensure ‘deep slot is down’
8. Close the drawer and manually lock using the handle
9. Press TLS UNLOCK
10.Press FINISH
To Call A Tool Number To The Drawer
On the magazine control panel:
1. Ensure the display is shown as a tool number
2. Enter the required Tool number
3. Press TOOL SEARCH Key
4. (The tool is delivered to the drawer)
5. Press TLS UNLOCK
6. Rotate the drawer handle and open the tooling drawer
7. When loading a dresser ensure ‘deep slot is down’
8. Close the drawer and manually lock using the handle
9. Press TLS UNLOCK
10.Press FINISH
To view tools which are in an alarm state:-
Simply push the ‘ALM TOOL SEARCH’ and the next alarmed tool will be brought
into the carousel. If more than one tool is alarmed the select ‘ALM TOOL SEARCH’
again and the next alarmed tool comes into the draw, and so on until the tools
loop

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Main Spindle Tool Change In MDI
1. Reduce RAPID switch to minimum
2. Reduce FEEDRATE switch to zero
3. Select SINGLE BLOCK
4. Select MDI mode button
5. Press PROGRAM button
6. Key-in the following, G65 P9800 T101 (T101 is the tool we are selecting);
7. Press INSERT button
8. Press CYCLE START
9. Increase RAPID and FEEDRATE switches safely (observing actual axis
movement).
Dresser Spindle Tool Change In MDI
1. Reduce RAPID switch to minimum
2. Reduce FEEDRATE switch to zero
3. Select SINGLE BLOCK
4. Select MDI mode button
5. Press PROGRAM button
6. Key-in the following, G65 P9801 T1001 (T1001 is the tool we are selecting);
7. Press INSERT button
8. Press CYCLE START
9. Increase RAPID and FEEDRATE switches safely (observing actual axis
movement).

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Moving The B Axis In MDI
1. Reduce RAPID switch to minimum
2. Reduce FEEDRATE switch to zero
3. Select SINGLE BLOCK
4. Select MDI mode button
5. Press PROGRAM button
6. Key-in index position i.e. M11; G0 G90 B90. M10;
7. Press INSERT button
8. Press CYCLE START

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Manual Change of Erowa Pallet
1. Use JOG and HANDLE modes to move axes to a convenient load/unload
position
2. Close operator door
3. Select M.D.I. mode
4. Press PROGRAM button
5. Key in M589;
6. Press INSERT button.
7. Press CYCLE START button
8. Machine is now fixed in handle mode and control box on front of machine
is used for the following steps (instead of a robot loader)
9. Turn keyswitch to HAND mode
10.Press DOOR OPEN to open front up/down door
11.Ensure pallet/fixture is supported manually or by crane, hoist etc.
12.Press CHUCK UNCLAMP to release Erowa pallet
13.Present new pallet/fixture to the Erowa system
14.Press CHUCK CLAMP to clamp new Erowa pallet
15.Press DOOR CLOSE to close front up/down door
16.Turn keyswitch to AUTO mode
17.Press RESET to finish loading sequence and return to main machine control
panel
Note: M589 is linked with subprogram O9022, upon sending M589 the
machine will launch program O9022, at the end of O9022 is the second M589.
When the control reads the second M589 is when Work Change Request is
activated. To avoid any machine movement delete all content within sub-
program O9022 except the M589, or add into the sub-program aa jump which
avoids all data except the M589

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Axis Move In MDI
1. Reduce RAPID switch to minimum
2. Reduce FEEDRATE switch to zero
3. Select MDI mode button
4. Select SINGLE BLOCK
5. Press PROGRAM button
6. Key-in axis movement i.e.G0 G90 G54 X 100. Y100.;
7. Press INSERT button
8. Press CYCLE START
9. Increase RAPID and FEEDRATE OVERRIDES' switch safely (observing actual
axis movements).
Nozzle Change In MDI
1. Reduce RAPID switch to minimum
2. Reduce FEEDRATE switch to zero
3. Select MDI mode button
4. Select SINGLE BLOCK
5. Press PROGRAM button
6. Key-in G65 P9821 A3. (A is the number of the required nozzle)
7. Press INSERT button
8. Press CYCLE START
9. Increase RAPID and FEEDRATE OVERRIDES' switch safely (observing actual
axis movements).
10.Current nozzle will be replaced with the requested one

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Mid Auto Manual Interruption
1. Press FEED HOLD
2. Press COOLANT ON/OFF to turn off coolant
3. Turn off dresser coolant (angle plate coolant) if in use
4. Ensure SPIDLE ENABLE light is off
5. Press SPINDLE STOP to stop main spindle
6. Press SPINDLE ENABLE to illuminate light
7. Press SPINDLE STOP to stop dresser spindle
8. Select HANDLE MODE
9. Press MANUAL RELEASE button and pull open door (green lamp must be
on)
10.Carry out manual operation i.e. wheel inspection
11.Close door
12.Select MEMORY MODE
13.Press SPINDLE START to start dresser spindle
14.Press SPINDLE ENABLE to turn lamp off
15.Press SPINDLE START to start main spindle
16.Press COOLANT ON/OFF to turn on coolant
17.Turn on dresser coolant (angle plate coolant) if required
18.Press SINGLE BLOCK
19.Reduce RAPID switch to minimum
20.Reduce FEEDRATE switch to zero
21.Press CYCLE START
22.Increase RAPID OVERRIDE and/or FEEDRATE switches safely
21. CONTINUE IN SINGLE BLOCK UNTIL IT IS SAFE FOR FULL AUTO
Note: if at any point you have pushed the reset button you must not continue
as you will have lost your place in the program and all non-modal information.

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Alarm Recovery Procedure
1. Remedy problem
2. Press RESET on main panel for NC alarm
3. Press ALARM RESET M/C button for machine alarm
4. Select JOG or RAPID mode
5. Select Z axis button
6. Press '+' button to retract spindle
7. Increase rapid on JOG OVERRIDE switch if necessary
Makino M/C Alarms
Alarm number will be displayed, with a description of the alarm
Press NEXT ALARM soft key if next alarm exists
Recovery procedure can mean pressing alarm reset soft key or if it is displayed the
retry soft key.
To Clear Makino M/C Alarms Press ALARM RESET M/C button

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Alarm History
1. Press CUSTOM button
2. Use (MS, FC or PO) soft key to find ALARM soft key
3. Press ALARM soft key
4. Press ALARM RECORD soft key
The last 20 alarms are displayed, number one being the last one.

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Program Editing
Main Program Number is preceded by the letter O. Program ends M30.
Sub Program Number is preceded by the letter O. Program ends M99.
TO LOAD PROGRAM
1. EDIT mode
2. PRGRM button
3. Key-in program number e.g.O1234
4. READ button
5. EXECUTE button
TO PUNCH PROGRAM FROM MEMORY
1. EDIT mode
2. PROGRAM button
3. Key-in program number e.g.O1234
4. PUNCH button
5. EXECUTE button
TO CHANGE A STORED PROGRAM NUMBER
1. EDIT
2. PROGRAM button
3. Cursor to program number
4. Key-in new program number
5. Press the HOME (ALTER) button