tornos DECO 13a User manual

QUICK REFERENCE
DECO 13a
en 300417
Printed in Switzerland Copyright 1999−2008

Δ WARNING !
Before handling the machine, read first the
information contained in the instructions
entitled “SAFETY REGULATIONS”.
These instructions are based on the information available at the moment of
their publication. Although the very best has been done to make them as
comprehensive and precise as possible they do not purport to cover all
details of the hardware and software nor to anticipate every contingency.
TORNOS S.A. give no guarantee nor assume any responsibility for the
exactitude and the sufficiency of the information contained in this document.
The contents of the instructions remain the property of TORNOS S.A.,who
reserve the right to modify, complete or correct them at any time.
The original language of the instructions to be referred to is French.
The hazards of misinterpreting the instructions can be considerably reduced
by following the training courses organized and offered by TORNOS S.A.
TORNOS SA − CH−2740 MOUTIER − http://www.tornos.ch

QUICK REFERENCE − DECO 13A
en 300417 − 04/08 3
CONTENTS
1. GENERAL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 ZERO DATUM SYMBOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 AXIS TRAVEL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 NC KEYBOARD 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 CONTROL PANEL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 CONTROL PANEL DESCRIPTION 8. . . . . . . . . . . . . . . . . .
1.6 G−FUNCTIONS (PREPARATORY) 9. . . . . . . . . . . . . . . . . .
1.7 FUNCTION GROUPS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 G9XX MACROS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 GLOBAL PART VARIABLES 15. . . . . . . . . . . . . . . . . . . . . . . .
1.10 GLOBAL PROGRAM VARIABLES 16. . . . . . . . . . . . . . . . . . .
1.11 M−FUNCTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12 T−FUNCTIONS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13 KINEMATICS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.14 AXIS NO. 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. OPERATE MACHINE FUNCTIONS 30. . . . . . . . . . . . . . . . . .
2.1 REFERENCING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Reference All Axes 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Reference Axis by Axis: 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 MANUAL DATA INPUT (MDI) OPERATION 32. . . . . . . . . . .
2.3 JOG AN AXIS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 INCREMENT AN AXIS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 AUTO MODE 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 RUN A PROGRAM AT 5% FEEDRATE FORWARD 36. . . .
2.7 EDIT TOOL WEAR OFFSET 36. . . . . . . . . . . . . . . . . . . . . . . .
2.8 DISABLE X3−Z3−S3 & X4−Y4−Z4 AXIS 37. . . . . . . . . . . . . .

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3. DOWNLOAD A PROGRAM 38. . . . . . . . . . . . . . . . . . . . . . . .
3.1 DOWNLOAD A PROGRAM OVER RS−232 CABLE 38. . . .
3.2 DOWNLOADING A PROGRAM OVER RS−232 39. . . . . . .
3.3 DOWNLOAD A PROGRAM WITH MEMORY CARD 41. . . .
3.4 DOWNLOADING A PROGRAM WITH MEMORY CARD: 42
3.5 RESTORE OFFSETS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. DRIVE 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 (307005) S2 DRIVE (X2 / Y2) 46. . . . . . . . . . . . . . . . . . . . . . .
4.2 (307009) S5 DRIVE (X4) 47. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Arrangement of the drive belt S5 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 (307010) S6 DRIVE (X1 / Y1) 48. . . . . . . . . . . . . . . . . . . . . . .
4.4 (307011) S3 DRIVE (X3 / Z3) 49. . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Arrangement of the drive belt S3 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. MISCELLANEOUS 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 BASIC STEPS ON WINDOWS 50. . . . . . . . . . . . . . . . . . . . . .
5.2 COPY ON SAME DISK 50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 COPY ONTO ANOTHER DISK 50. . . . . . . . . . . . . . . . . . . . . .
5.4 CYCLE THROUGH WINDOWS, ETC. 50. . . . . . . . . . . . . . . .
5.5 COPY / PASTE 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 BASIC TB−DECO STEPS TO SET UP A PROGRAM 51. .
5.7 REFILLING CHUCKING HYDRAULICS 52. . . . . . . . . . . . . .
5.8 MODIFYING TOOL SUPPORT POSITION IN DATABASE 53

QUICK REFERENCE − DECO 13A
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1. GENERAL
1.1 ZERO DATUM SYMBOLS
Machine Zero, fixed point on the machine
Part Zero, moving point on the part face
Tool Zero, reference point for tool geometries
1.2 AXIS TRAVEL
Axes Position
min. Position max. Reference point Travel
X1 −14 mm ∅56 mm ∅56 mm ∅35 mm
X2 −14 mm ∅56 mm ∅56 mm ∅35 mm
Y1 −3 mm 155 mm 0 mm 158 mm
Y2 −3 mm 155 mm 0 mm 158 mm
Z1 0 mm 255 mm 0 mm 255 mm
X3 −144 mm ∅230 mm ∅−144 mm ∅187 mm
Z3 −160 mm 0 mm 0 mm 160 mm
X4 −310 mm ∅−6 mm ∅0 mm ∅158 mm
Y4 −1 mm 299 mm 296 mm 300 mm
Z4 0 mm 160 mm 160 mm 160 mm

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1.3 NC KEYBOARD
from 1 to 6
from 7 to 12
13
14
1. POSITION (Display all axes)
2. PROGRAM (Output / Input a program)
3. OFFSET SETTING
4. SHIFT
5. CANCEL
6. INPUT (Enter data)
7. SYSTEM (Access to data)
8. MESSAGE (Display messages / alarms)
9. GRAPH (Display axis position)
10. ALTER (e.g. replace characters)
11. INSERT
12. DELETE
13. HELP
14. RESET

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1.4 CONTROL PANEL
6
12345
F1 F2 F3 F4 F5
789
10 11 12 13 14 15
16 17 18 19
20 21 22 23 24 25

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1.5 CONTROL PANEL DESCRIPTION
1. Emergency Stop
2. NC ON
3. NC OFF
4. Power ON
5. Power OFF
F1−F5 Functions
6. Axis / Channel Selector
7. Mode Selector
8. Axis speed variation
9. Key Selector
10. Axis Feedrate Override (decr.)
11. Axis Feedrate Override (incr.)
12. Spindle Speed Override (decr.)
13. Spindle Speed Override (incr.)
14. Program BACKWARD (inactive)
15. Program FORWARD
16. Open Main Spindle Collet
17. Close Main Spindle Collet
18. Open Pickoff−Spindle Collet
19. Close Pickoff−Spindle Collet
20. CYCLE START
21. Program Stop
22. CYCLE STOP
23. Coolant ON
24. Adjust Coolant
25. Coolant OFF

QUICK REFERENCE − DECO 13A
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1.6 G−FUNCTIONS (PREPARATORY)
Code Function Grp. M/S
G01 Linear interpolation 10 S
G02 Circular interpolation, cw 10 S
G03 Circular interpolation, ccw 10 S
G04 Dwell [s] at 100% override 1 S
G13 Loop Start 1 S
G26 Circular chamfer link
L = radius 2 S
G27 Linear chamfer link
L = width 2 S
G28 Referencing 10 S
G33 Threading, constant lead 9 S
G34 Threading, increasing lead 9 S
G35 Threading, decreasing lead 9 S
G40 Cutter compensation cancel 2 M
G41 Cutter compensation, left 2 M
G42 Cutter compensation, right 2 M
G52 Cancel all zero offsets (datum shifts).
Coordinate system begins at Machine Zero and
is again valid for the axis / axes concerned.
1 M
G53 Cancel all additional zero offsets (datum shifts),
programmed via G54 and G55. 1 M
G54 Additional zero offset (datum shift) against cur-
rent coordinate system. This offset is additional
for the axes concerned.
1 M

QUICK REFERENCE − DECO 13A
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M/SGrp.FunctionCode
G55 Additional zero offset (datum shift) against ini-
tial coordinate system (Part Zero).
Cancels G54.
1 M
G56 Zero offset (datum shift) against Machine Zero.
Initial G56 settings, processed at each program
start, are those entered in Part Manager
1 M
G58 Save all zero offsets (datum shifts) and reset
them for the axes concerned to cut with respect
to Machine Zero
1 M
G59 Restore all zero offsets (datum shifts) saved via
last G58 for the axes concerned 1 M
G68* Cancel G69 2 M
G69 Calculate 360 modulo for rotary axis 2 M
G70 Inch data input (not for tools) 2 M
G71* Metric data input 2 M
G81 Linear extension for cutter compensation 2 M
G82* Circular extension for cutter compensation 2 M
G83 Permute axes for main plane of interpolation 2 M
G84 Permute axes for main plane of interpolation 2 M
G85* Reestablish main plane as specified in Opera-
tion Line. Cancels G83 or G84 2 M

QUICK REFERENCE − DECO 13A
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M/SGrp.FunctionCode
G90* Absolute dimension 2 M
G91 Incremental dimension 2 M
G94 Asynchronous feedrate [mm/min] 2 M
G95* Synchronous feedrate [mm/rev] 2 M
G100 Rapid traverse (unproductive) 2 S
G113 Loop End 1 S
G130 Start of threading specification 8 S
G131 End of threading specification 8 S
G190* Exact stop (between segments) 2 M
G191 Continuous contouring
(if angle = 0) 2 M
G250 Cancel polygoning 4 S
G251 Spindle ON (specified by hundreds) for polygo-
ning 4 M
G314 Path >πfor G02/G03 function 2 S
G350 Cancel polygoning 4 S
G351 Spindle ON (specified by hundreds) for polygo-
ning 4 M

QUICK REFERENCE − DECO 13A
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M/SGrp.FunctionCode
G550 Cancelling of polygon mode S5 spindle activa-
ted over G551. Polygon mode to be cancelles
over a M505 or M503 S function.
G551 Activation of S5 spindle (identified by hundreds)
in polygon mode
R2 Q−0 does not reverse the sense of rotation
R2 Q−1 reverses the sens of rotation
G900 Initialize spindles with settings specified for part
G901 Initialize sequences
*Functions active by default for new operation
Grp. Function Group Nb.
MModal:
Function remains active until replaced by another function of
same group
SSequential:
Function remains active in programmed segment only.

QUICK REFERENCE − DECO 13A
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1.7 FUNCTION GROUPS
Each G−function belongs to a group 1 to 10. Group No. specifies proces-
sing order for these functions in a block.
Functions are processed in the following order:
Group 1 : System Commands
Group 2 : Modal G−Functions
Group 3 : Spindle Rotation Commands
Group 4 : Polygoning Spindle Commands
Group 5 : Spindle Commands for Phase Adjustment
Group 6 : Spindle Positioning Commands
Group 7 : Spindle ON/OFF Commands
Group 8 : Header/Footer Threading Commands
Group 9 : Threading Commands
Group 10 : Axis Commands
Group 11 : Basic M Commands
Group 12 : Additional M Commands
Group 13 : Machine Cycles
Note:
Tool call to be programmed either in a separate
line or together with Group 10.

QUICK REFERENCE − DECO 13A
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1.8 G9XX MACROS
G900 Spindle ON
G901 Program sequence.
To be inserted once only at each program start
G902 Override limit
G903 Tool change (indexing)
G904 Workpiece cutting−off at constant surface speed
G910 Initialize (INIT.PGM) Initial cutoff
G911 Z1 Zero Offset (PIECE.PGM)
G912 Feeding (PIECE.PGM)
G913 Deburring + waste ejection from guidebush (END_BAR.PGM)
G914 Spindle feed for new bar insertion, initial cutoff
(NEW_BAR.PGM)
G915 Additional offset in Z3.
Resets to Part Zero acc. to Z1 position.
G916 Additional offset in Z4 for anticipated partpickoff
G917 Polygoning T25
G920 Test if part is withheld at end of cycle (INIT.PGM)
G921 Calculate part pickoff position (PIECE.PGM)
G923 Eject part from pickoff−spindle
G933 Threading cycle (tapping)
G977 Drilling / chip clearing cycle

QUICK REFERENCE − DECO 13A
en 300417 − 04/08 15
1.9 GLOBAL PART VARIABLES
#3000 Cutoff Tool No
(11,12,13,14,15,21,22,23,24,25).
#3001 Bar diameter 
#3002 Initial cutoff feedrate (after RESET and new bar)
[mm/rev;inch/rev]
#3003 Positive part length 
#3004 Feeding allowance for offset tool 
#3005 Positive deburring shift 
#3006 Guidebush type 0= fixed 1=rotating 2=Habegger
#3007 Open collet dwell [s]
#3008 Close collet dwell [s]
#3009 Part pickoff length 
#3010 Pickoff−spindle collet geometry 
#3011 Retract after part−pickoff 
#3012 Pickoff−spindle approach distance 
#3014 Z1 retract to eject waste 
#3015 Z1 feed to insert new bar 
#3016 S1 speed to feed next part [rpm]
#3017 Ejection method: 0 = Gripper
1 = Tray + Ejector
2 = Gripper + Ejector
#3018 Part gripping length 
#3019 Longueur de barre utilisée
= each time [mm] [inch]

QUICK REFERENCE − DECO 13A
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1.10 GLOBAL PROGRAM VARIABLES
#2011 X1 Position <PR> at end−of−cutoff, accounting for
LX of cutoff tool
#2012 Z1 Position <PR> for cutoff
(part length)
#2013 Z4 Position <MC> before part in cutoff position and
accounting for #3012
#2014 Z4 Position <MC> for part pickoff acc. to #3009
#2015 Z4 Position <MC> for retract after part pickoff
#2016 G56 Z4 Zero Offset to enter before 1st backwork
#2017 For long parts, bar position for clamping
#2018 Add−on zero offset Z1 for bar feed
#2019 G56 Z3 Zero Offset to enter before 1st frontwork (T31 − T34)
#2020 Cutoff Tool No. to be used by TB−Wizards
#2021 Save Z1 Position <MC> after feed over G912. This data will be
used in Macro G915.
#2022 For long parts, value of the cutting tool geometry on cutting
side.
#2025 For long parts, approach position clamping <PR> on G100, X1
and X2 axes
#2026 For long parts, <PR> clamping pos.,X1 and X2 axes
#2029 Pos. <PR> of Z4 before extraction taking into account T50

QUICK REFERENCE − DECO 13A
en 300417 − 04/08 17
1.11 M−FUNCTIONS
Code Function Note Res
p. M/S
M1 Program stop, optional Enter in a
separate block
DO1921
no M
M2 Program stop unconditional with reset (DO1922) no M
M8 Coolant ON (DO1904) no M
M9 Coolant OFF (DO1905) no M
M10 Close spindle collet (clamp) (DO1901) yes M
M11 Open spindle collet (unclamp) (DO1900) yes M
M20 End−of−part signal;
It increments Part Counter (DO1923) no S
M32 Tool break check on Sens.1 (DO1942) no S
M33 Part pres. check on Sens.1 (DO1943) no S
M34 Tool break check on Sens.2 (DO1944) no S
M35 Part pres. check on Sens.2 (DO1945) no S
M36 Tool break check on Sens.3 (DO1946) no S
M37 Part pres. check on Sens.3 (DO1947) no S
M45 HP pump On (DO1950) yes S
M46 HP pump Off (DO1951) yes S
M60 Load a new bar (DO1927) no S
M82 Barfeeder thrust ON (DO1931) no S
M83 Barfeeder thrust OFF (DO1932) no S
M84 Feed pickoff−spindle ejector (DO1954) yes S
M85 Retract pickoff−spindle ejector (DO1955) yes S
M101 Program stop at end−of−table (DO1920) no S

QUICK REFERENCE − DECO 13A
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M/SRes
p.
NoteFunctionCode
M103 S1 spindle rotating ON (cw) (DO1700)
Disregards
Param. W.
no S
M104 S1 spindle rotating ON (ccw) (DO1700)
Disregards
Param. W.
no S
M105 S1 spindle OFF (DO1700)
Disregards
Param. W.
no M
M110 Close pickoff−spindle collet (DO1903) yes S
M111 Open pickoff−spindle collet (DO1902) yes S
M118 S1 spindle synchro phase Disregards
Param. W. no M
M119 S1 spindle positioning Disregards
Param. W. no M
M150 Adjust feedrate (DO1940) no M
M151 Cancel M150 (DO1941) no M
M160 Feed manipulator (DO1906) yes S
M161 Retract manipulator (DO1907) yes S
M164 Close manipulator gripper (DO1935) yes S
M165 Open manipulator gripper (DO1936) yes S
M168 Check part missing in pickoff spindle (DO1970)
M169 Check workpiece present inside pic-
koff−spindle collet (DO1971)
M170 Enable Z4 torque limit (DO1890) no S
M171 Disable Z4 torque limit (DO1891) no S

QUICK REFERENCE − DECO 13A
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M/SRes
p.
NoteFunctionCode
M172 Enable Z4 servo−lag check (DO1892) no S
M173 Disable Z4 servo−lag check (DO1893) no S
M180 Long parts, forth travel of ejector (DO1980)
M181 Long parts, back travel of ejector (DO1981)
M182 Long parts, forth travel of ejection
actuator (DO1982)
M183 Long parts, back travel of ejection
actuator (DO1983)
M184 Long parts, workpiece tilting ON (DO1984)
M185 Long parts, workpiece tilting OFF (DO1985)
M186 Long parts, check ejector forth (DO1986)
M187 Long parts, check ejector on back (DO1987)
M188 Long parts, check ejector actuator
forth (DO1990)
M189 Long parts, check if ejection actuator
back (DO1991)
M191 Adjust guidebush (DO1924) no S
M192 Open guidebush (DO1926) no S
M198 Switch S1 spindle to rotary axis mode Disregards
Param. W. no M
M199 Switch S1 back to spindle mode
speed.
Cancel M198
Disregards
Param. W. no M

QUICK REFERENCE − DECO 13A
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M/SRes
p.
NoteFunctionCode
M203 S2 spindle rotating ON (cw) (DO1701 if 4
spindles)
Disregards
Param. W.
no S
M204 S2 spindle rotating ON (ccw) (DO1701 if 4
spindles)
Disregards
Param. W.
no S
M205 S2 spindle OFF (DO1701 if 4
spindles)
Disregards
Param. W.
no M
M218 S2 spindle synchro phase Disregards
Param. W. no M
M219 S2 spindle positioning Disregards
Param. W. no M
M303 S3 spindle rotating ON (cw) (DO1702 if 4
spindles) Dis-
regards
Param. W.
no S
M304 S3 spindle rotating ON (ccw) (DO1702 if 4
spindles) Dis-
regards
Param. W.
no S
M305 S3 spindle OFF (DO1702 if 4
spindles) Dis-
regards
Param. W.
no M
M403 S4 spindle rotating ON (cw) (DO1703 if 4
spindles) Dis-
regards
Param. W.
no S