Master_Instruction_Manual五軸加工中心操作手冊master414（英文版）

1、 INSTRUCTION MANUALMASTER6 AXES CNC WORKING CENTERSerial n.: Year: V./Hz.: NOTE: This manual is property of P.BACCI S.r.l. The company does not consider valid any copy of this manual which shouldnt correspond to the one filed in its offices.Index TOC o 2-3 h z t Titolo 1;1 HYPERLINK l _Toc37647120 U

2、ser Interface PAGEREF _Toc37647120 h 1 HYPERLINK l _Toc37647121 Operating panels PAGEREF _Toc37647121 h 2 HYPERLINK l _Toc37647122 CNC Operating Panel PAGEREF _Toc37647122 h 2 HYPERLINK l _Toc37647123 Portable keypad PAGEREF _Toc37647123 h 4 HYPERLINK l _Toc37647124 Left and right table buttons PAGE

3、REF _Toc37647124 h 6 HYPERLINK l _Toc37647125 Left and right table pedals PAGEREF _Toc37647125 h 6 HYPERLINK l _Toc37647126 Keyboard PAGEREF _Toc37647126 h 7 HYPERLINK l _Toc37647127 Guidelines for a correct use of the electrospindle PAGEREF _Toc37647127 h 9 HYPERLINK l _Toc37647129 Maintenance PAGE

4、REF _Toc37647129 h 14 HYPERLINK l _Toc37647130 General rules PAGEREF _Toc37647130 h 14 HYPERLINK l _Toc37647131 Characteristics and frequency of inspections PAGEREF _Toc37647131 h 14 HYPERLINK l _Toc37647132 Scheduled long term inspections PAGEREF _Toc37647132 h 16 HYPERLINK l _Toc37647133 Lubricati

5、on mechanical parts PAGEREF _Toc37647133 h 17 HYPERLINK l _Toc37647134 Pneumatic installation lubrication system PAGEREF _Toc37647134 h 18 HYPERLINK l _Toc37647135 Connections PAGEREF _Toc37647135 h 19 HYPERLINK l _Toc37647136 Compressed air PAGEREF _Toc37647136 h 19 HYPERLINK l _Toc37647137 Electri

6、cal PAGEREF _Toc37647137 h 19 HYPERLINK l _Toc37647139 Transportation PAGEREF _Toc37647139 h 20 HYPERLINK l _Toc37647140 Safety PAGEREF _Toc37647140 h 21 HYPERLINK l _Toc37647141 Spindles PAGEREF _Toc37647141 h 21 HYPERLINK l _Toc37647142 Mechanical parts PAGEREF _Toc37647142 h 22 HYPERLINK l _Toc37

7、647143 Electrical installation PAGEREF _Toc37647143 h 22 HYPERLINK l _Toc37647144 Pneumatic installation PAGEREF _Toc37647144 h 22 HYPERLINK l _Toc37647145 Perimeteral protection/cabin PAGEREF _Toc37647145 h 23 HYPERLINK l _Toc37647146 Programming PAGEREF _Toc37647146 h 23 HYPERLINK l _Toc37647147 G

8、eneral recommendations PAGEREF _Toc37647147 h 23 HYPERLINK l _Toc37647148 Programming PAGEREF _Toc37647148 h 24 HYPERLINK l _Toc37647149 General Functions PAGEREF _Toc37647149 h 25 HYPERLINK l _Toc37647150 Preliminary operations PAGEREF _Toc37647150 h 25 HYPERLINK l _Toc37647151 Turning on the machi

9、ning center PAGEREF _Toc37647151 h 25 HYPERLINK l _Toc37647152 Homing PAGEREF _Toc37647152 h 25 HYPERLINK l _Toc37647153 Stop a machining cycle PAGEREF _Toc37647153 h 25 HYPERLINK l _Toc37647154 Turn off the working center PAGEREF _Toc37647154 h 25 HYPERLINK l _Toc37647155 Basic programming notions

10、PAGEREF _Toc37647155 h 26 HYPERLINK l _Toc37647156 Operating head configuration parameters PAGEREF _Toc37647156 h 28 HYPERLINK l _Toc37647157 Part program management PAGEREF _Toc37647157 h 30 HYPERLINK l _Toc37647158 Line editor PAGEREF _Toc37647158 h 32 HYPERLINK l _Toc37647159 Program check PAGERE

11、F _Toc37647159 h 33 HYPERLINK l _Toc37647160 BACCI Softkeys PAGEREF _Toc37647160 h 34 HYPERLINK l _Toc37647161 Management macros PAGEREF _Toc37647161 h 35 HYPERLINK l _Toc37647162 PLUS management variables PAGEREF _Toc37647162 h 36 HYPERLINK l _Toc37647163 Working Macros PAGEREF _Toc37647163 h 36 HY

12、PERLINK l _Toc37647164 Geometric and compensation macros PAGEREF _Toc37647164 h 37 HYPERLINK l _Toc37647165 Auxiliary macros PAGEREF _Toc37647165 h 37 HYPERLINK l _Toc37647166 Dynamics PAGEREF _Toc37647166 h 38 HYPERLINK l _Toc37647167 The Master program PAGEREF _Toc37647167 h 38 HYPERLINK l _Toc376

13、47168 Masterpend example PAGEREF _Toc37647168 h 39 HYPERLINK l _Toc37647169 Automatic mode (AUTO) operating sequence PAGEREF _Toc37647169 h 40 HYPERLINK l _Toc37647170 Manual mode (MANUAL) operating sequence PAGEREF _Toc37647170 h 40 HYPERLINK l _Toc37647171 Autoprogramming PAGEREF _Toc37647171 h 41

14、 HYPERLINK l _Toc37647172 Introduction PAGEREF _Toc37647172 h 41 HYPERLINK l _Toc37647173 Available parametric programs PAGEREF _Toc37647173 h 41 HYPERLINK l _Toc37647174 Programming PAGEREF _Toc37647174 h 44 HYPERLINK l _Toc37647175 How to create a part program PAGEREF _Toc37647175 h 44 HYPERLINK l

15、 _Toc37647176 Programming with AlphaCam PAGEREF _Toc37647176 h 50 HYPERLINK l _Toc37647177 General tips PAGEREF _Toc37647177 h 50 HYPERLINK l _Toc37647178 Post processed program example PAGEREF _Toc37647178 h 51 HYPERLINK l _Toc37647179 The TG post processor (rotating table vertical axis) PAGEREF _T

16、oc37647179 h 53 HYPERLINK l _Toc37647180 Transferring the program from PC to working center PAGEREF _Toc37647180 h 55 HYPERLINK l _Toc37647181 Digitizing part origin PAGEREF _Toc37647181 h 55 HYPERLINK l _Toc37647182 Insert program in master program PAGEREF _Toc37647182 h 56 HYPERLINK l _Toc37647183

17、 Loading the program PAGEREF _Toc37647183 h 57 HYPERLINK l _Toc37647184 Activate the program PAGEREF _Toc37647184 h 57 HYPERLINK l _Toc37647185 OSAI CN network configuration PAGEREF _Toc37647185 h 58 HYPERLINK l _Toc37647186 Error messages PAGEREF _Toc37647186 h 60 HYPERLINK l _Toc37647187 Solving p

18、roblems PAGEREF _Toc37647187 h 61 HYPERLINK l _Toc37647188 Diagnostics PAGEREF _Toc37647188 h 65 HYPERLINK l _Toc37647189 Error messages PAGEREF _Toc37647189 h 66 HYPERLINK l _Toc37647190 Drive error messages PAGEREF _Toc37647190 h 68 HYPERLINK l _Toc37647191 How to visualize the code from the NC PA

19、GEREF _Toc37647191 h 69 HYPERLINK l _Toc37647192 Input/Output list PAGEREF _Toc37647192 h 70 HYPERLINK l _Toc37647193 Input PAGEREF _Toc37647193 h 70 HYPERLINK l _Toc37647194 Output PAGEREF _Toc37647194 h 72 HYPERLINK l _Toc37647195 Installation PAGEREF _Toc37647195 h 73 HYPERLINK l _Toc37647196 Pne

20、umatic installation PAGEREF _Toc37647196 h 74 HYPERLINK l _Toc37647197 Components list PAGEREF _Toc37647197 h 74 HYPERLINK l _Toc37647198 Wiring diagram PAGEREF _Toc37647198 h 75User InterfaceOperating panelsCNC Operating PanelSTOP BUTTONStops axes and spindle rotation. Does not shut down the machin

21、e.POWER SUPPLY LAMPSELECTOR FOR OVERSTROKE RECOVERPAY ATTENTION TO INCORRECT USE !Enables the recovering of an axis from overstroke. When an axis falls in overstroke, the machine shuts down and a message appears on the screen. The procedure to take the axis back within the operative limits is the fo

22、llowing:Switch the selector to the right hand positionPush the RESET buttonTurn on the machine, using button (9)Switch the selector (11) to “manual” and move the axis in the proper direction within the limitsSwitch back the selector (3) to the left hand position.The axis in overstroke must be clearl

23、y identified and the procedure must be followed carefully !POWER ON LH TABLE VACUUM PUMP BUTTONPOWER ON RH TABLE VACUUM PUMP BUTTONNot applicable EMERGENCY STOP BUTTONShuts down the machineNot applicableAUXILIARIES ON BUTTONNot applicableSELECTOR MANUAL / AUTOMATICVACUUM PUMPS STOP BUTTON DUST AND C

24、HIPS BELT CONVEYOR ON/OFF BUTTON (OPTIONAL)Portable keypad16178951514111213103462EMERGENCY STOP BUTTONStops axes and spindles. Does not shut down the machine. X-MANUAL MOVEMENT BUTTONMoves X axis in continuous manual mode in negative direction. X+ MANUAL MOVEMENT BUTTONMoves X axis in continuous man

25、ual mode in positive direction.Z-MANUAL MOVEMENT BUTTONMoves Z axis in continuous manual mode in negative direction. Z+MANUAL MOVEMENT BUTTONMoves Z axis in continuous manual mode in positive direction.P-MANUAL MOVEMENT BUTTONMoves P axis in continuous manual mode in negative direction. P+ MANUAL MO

26、VEMENT BUTTONMoves P axis in continuous manual mode in positive direction. A- MANUAL MOVEMENT BUTTONMoves A axis in continuous manual mode in negative direction. A+ MANUAL MOVEMENT BUTTONMoves A axis in continuous manual mode in positive direction.Q- MANUAL MOVEMENT BUTTONMoves Q axis in continuous

27、manual mode in negative direction.Q+ MANUAL MOVEMENT BUTTONMoves Q axis in continuous manual mode in positive direction.C- MANUAL MOVEMENT BUTTONMoves C axis in continuous manual mode in negative direction.C+ MANUAL MOVEMENT BUTTONMoves C axis in continuous manual mode in positive direction.LED PORT

28、ABLE KEYPAD ENABLEDThe LED is on if the keypad is enabled by the proper softkey.DIGITIZE AXIS POSITION BUTTONTo be used in Self-learning mode.OVERRIDE POTENTIOMETEREnabled when the keypad is enabled, both in Manual and Automatic mode.Other buttons possibly present can be used to move additional axes

29、 (optionals).Left and right table buttons 123EMERGENCY STOP BUTTON Shuts down the machine.START/ DOOR BUTTON In manual mode: allows the opening and closing of the loading door.In automatic mode: allows only the closing of the loading door and the start of the working cycle. STOP BUTTONStops axes and

30、 spindles rotation. Does not shut down the machine.Left and right table pedalsThe pedal allows to clamp / unclamp the pieces on their respective tables, with the following modalities:Manual Mode (selector and CN)Pressing the pedal with the loading door open causes the blockage of the piece at low pr

31、essure (pneumatic clamps) and by vacuum (if the vacuum pump has been turned on); pressing the pedal again (with the loading door open) the piece will be unblocked. When the loading door is closed pushing the proper button, if the piece is blocked the clamping pressure goes up to high pressure.Automa

32、tic Mode (selector and CN)Pressing the pedal with the loading door open causes the blockage of the piece at low pressure (pneumatic clamps) and by vacuum (if the vacuum pump has been turned on); pressing the pedal again (with the loading door open) the piece will be unblocked. When the loading door

33、is closed pushing the proper button, if the piece is blocked the clamping pressure goes up to high pressure.In Automatic mode the opening of the loading door is driven by program (unblock command), then it is possible to unblock the piece using the pedal; the piece can be automatically unblocked ins

34、erting the auto-unblock command in the program.KeyboardKEYFUNCTIONMove cursor one character left in the rowMove cursor one character right in the rowScroll down PP, or select upper line Scroll up PP, or select lower linePgUPMove cursor up 9 rowsPgDnMove cursor down 9 rowsCRTLMove cursor at the end o

35、f the lineCRTLMove cursor at the beginning of the lineHomeCRTLMove cursor at the beginning of the PPCRTLEndMove cursor at the end of the PPBackSpaceDelete first character on the cursor left DelDelete the character on which the cursor is positionedEndCut selected line in the cursor position: characte

36、rs on its left are moved to the next row. Create a new row before the selected line when the cursor is placed on the first character.Create a new row moving up the selected line. Accept data inserted in input windows.Guidelines for a correct use of the electrospindleHEATING UPThe heads must be heate

37、d up to 35C before using; to reach this temperature turn on the spindle at 3000 RPM for at least 10 minutes. This will let the bearing and the rotating parts operate at the optimal temperature.When the electrospindle is loaded at a lower temperature, the bearings will undergo an untimely consuming a

38、nd will lose the preload.CHOOSING THE TOOLUse only tools with a diameter and weight included in the table of page 11.Tools and toolholders must be balanced in G1 and re-balanced after every sharpening. Vibrations caused by an unbalanced tool can rapidly destroy the bearings.CAUTION !THE USE OF ELEME

39、NTS (TOOL HOLDER SHAFTS, SPACERS ETC.) WHICH DO NOT RESPECT THE INDICATED REQUIREMENTS, OR THEIR UNCORRECT ASSEMBLY MAY CAUSE THE TOOL BREAKING DURING ITS ROTATION AND THE SUBSEQUENT PROJECTION OF METALLIC PARTS AROUND THE MACHINETOOL QUALITYTools must always be sharpened in order to reduce the cutt

40、ing forces and the spindle working temperature.Heat generated by the spindle may overheat the bearings and the lubricant causing the evaporation of the lubricating components: this will result in life reduction for the bearings and thus for the spindle.CLEANLINESSKeep rigorously cleaned cones, shaft

41、s and tool calmping chucks. Contamination by dust may cause a disalignment and an uncertain tool blockage: this will force the operator to lock the nuts with a torque higher than suggested, damaging shaft or toolholder screws.WARNINGS ON BEARING LUBRICATIONThe bearings are lubricated for life durati

42、on with KLUBER ISOFLEX TOPAS NB52 or LUBCON L182. Anyway for a possible bearings relubrication the same grease must be used: a different grease type in great quantity irretrievably damages the spindle. COOLINGUse the spindle only when connected to the cooling system.Use only 4 bar non lubricated air

43、!CAUTION! EXAMPLETool weight2.5 kgSpindle speed15000 RPMError0.3 mmF = (2.5 x 15000 2 x 0.3) / 91000 185 kg (1850 N)TOOL SUGGESTED DIMENSIONSSIZEMAX SHAFT DIAMETERSPINDLE SPEED (RPM)MAX TOOL DIAMETER (mm)MAX TOOL WEIGHT (kg)ER4025 mm6000 / 9000150109000 / 12000130712000 / 15000110515000 / 18000805ER

44、3220 mm6000 / 900014049000 / 12000130412000 / 1500011015000 / 1800080These data are just spindle related: for each tool the constructor maximum RPM must be respected tooSPACERS SUGGESTED TOLERANCES(SEE NEXT PAGE FOR DRAWING)MaintenanceGeneral rulesThe MASTER machine has been designed to reduce maint

45、enance to a minimum.In order to avoid failures and troubles the rules below must be followed:keep the machine clean and in orderavoid any possible damagedo not let temporary remedies become definitiveThe strict observance of periodical maintenance interventions is extremely important: all the machin

46、e components must be regularly controlled in order to avoid possible failures.All the interventions must be compatible with and in strict observance of the operator safety rules. WHEN AN INTERVENTION ON THE ELECTRIC INSTALLATION IS NECESSARY, IT IS INDISPENSABLE TO PUT THE MAIN SWITCH ON THE CABINET

47、 DOOR IN “OFF” POSITION IN ORDER TO GUARANTEE THE SAFE ACCESS TO THE CABINET WHEN AN INTERVENTION ON THE PNEUMATIC INSTALLATION IS NECESSARY, IT IS INDISPENSABLE TO DISCONNECT THE MACHINE FROM THE GENERAL INSTALLATION USING THE LEVER NEAR THE FRL GROUPCharacteristics and frequency of inspectionsDail

48、y maintenance Lubricator operating check (pneumatic installation) Lubricator oil level check (pneumatic installation)Check and empty out the condensate tank in the FRL groupCheck the lubricating oil level in the tank of the pneumatic installation pump Carefully clean the machine, avoiding air blasts

49、 that may bring chips into the dust protectionsSubstitute the damaged componentsWeekly maintenance Carefully clean inside the electric cabinet with a vacuum cleaner Check the operation of every button and pedal Check the correct operation of the lubricating pump Check the axes correct operation Clea

50、n the noise filter under the Z axis balancing cylinderMonthly maintenance Carefully clean with a vacuum cleaner inside the machine and under the dust protectionsCheck the operation of every button and pedalCheck proximity and microswitches correct operationCheck the axes correct operationCheck the p

51、neumatic installation correct operation Check the chain of the Z axis balancing device and grease it if necessaryIt is strongly recommended to change the chain of the Z axis balancing system every year.We remind you that the scheduled maintenance has to be integrated with special interventions, when

52、 necessary.Moreover we entrust the operator working on the machine to report any problem to the ones responsible for maintenance and installation.Scheduled long term inspectionsELECTRICAL INSTALLATIONVisual check of the installation (wires, parts, cable carrier chains) and replacement of damaged par

53、ts if needed.six monthsCheck installation functionality (emergency stops, buttons etc.)six monthsCheck electrical, electronic and electro mechanic components, and electrical cabinet wirings.one yearCheck operating head electrical collector and change brushesone yearLUBRICATING SYSTEMVisual check of

54、the installation (pipes, valves, etc)six monthsClean the installation18 monthsCheck installation functionality and pump delivery headsix monthsPNEUMATIC INSTALLATIONVisual check of the installation (pipes etc.)six monthsCheck electrovalves correct functioning (overheating and/or stops) and replaceme

55、nt if needed.one yearCheck of FRL groups and replacement if neededone yearMECHANICSVisual check of mechanical components (slides, sliding blocks, main screws) and wearing components (dust covers and other protections)six monthsCheck correct tension of transmission beltsone yearCheck tightening of me

56、chanical parts (lock nuts, flanges, other components)one yearLubrication mechanical partsThe MASTER machine is equipped with an automatic centralized lubrication system; the lubrication time intervals are controlled by the CNC. Periodically check the working and efficiency of the automatic lubricati

57、on system!For the automatic lubrication system refilling, the use of one of the following products is recommended:NLGI-0 (or equivalent)NLGI-1 (or equivalent) Use only grease resistant to high pressure. Otherwise if oils and soaps inside grease are separated, soaps can solidify and obturate the pneu

58、matic installation.Pneumatic installation lubrication system The lubricant in the pneumatic installation must be periodically checked and in case refilled with one of the products listed here, or with an hydraulic oil class ISO/UNI F or ISO/UNI H.AGIPOso 10ESSONuto H 5MOBILQ8Puccini 4PTEXACO300 Oil

59、5TOTALAzolla ZS 15There are no noticeable differences between the oils here indicated. Pneumatic system lubricationConnectionsCompressed airSuggested diameter for compressed air tube = 1/2Optimal line pressure = 6,5 barPipe connection diameter = 25 mm outer / 17 mm innerAir consuming at 6 bar = 200

60、L/min for 2 spindles version 360 L/min 4 spindles versionElectricalNominal voltage = 380 Volts / 50Hz or external autotransformer (optional)Connection type = 3 PHASES + 1 GROUND CONNECTIONMaximum resistance to the ground = 20 OhmMaximum installed power = (see label on left side of the upright) Plant