Grizzly G0876 User guide

MODEL G0876

8" X 27" ENCLOSED CNC MILL

w/AUTO TOOL CHANGER

OWNER'S MANUAL

(For models manufactured since 12/22)

***Keep for Future Reference***

V2.02.23

This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and compre­hension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage
from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:

• Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equip­ment, such as those dust masks that are specially designed to filter
out microscopic particles.

Table of Contents

11

10

0.1 Machine data sheet ........................................ 3

1 Safety

1.1 Safety instructions for machinery ................... 6

1.2 Additional safety for CNC mills/lathes ............ 8

1.3 Safety instructions (warning notes) ................. 9

1.4 Intended use ............

1.5 Reasonably foreseeable misuse

1.6 Possible dangers w/CNC machines ............... 12

1.7 Qualification of personnel ............................... 12

1.8 User positions ................................................ 14

1.9 Safety devices ............................................... 14

1.10 Safety check .................................................. 17

1.11 Personal protective equipment

1.12

Safety during operation

1.13

Safety during maintenance

1.14

Disconnecting/securing CNC machine

1.15 Unattended operation ...................................... 20

1.16 Accident report ............................................... 20

1.17 Electrical system ............................................. 20

1.18 Inspection deadlines .............................. 21

1.19 Clamping devices ................................. 21

1.20

Tools and tool holding fixtures .................. 21

....................................... 10

..................... 11

..................... 18

................................... 18

............................ 19

.......... 19

2 Power supply

2.1 Availability ...................................................... 22

2.2 Full-load current rating ................................... 22

2.3 Circuit information .......................................... 22

2.4 Circuit requirements for 220V ........................ 22

2.5 Connection type ............................................. 22

2.6 Grounding instructions ................................... 23

2.7 Extension cords .............................................. 23

3 Assembly and commissioning

3.1 Scope of delivery ............................................ 24

3.2 Transport ........................................................ 24

3.3 Installation and assembly ............................... 25

3.4 First commissioning ....................................... 31

3.5 Refill central lubrication system ...................... 33

3.6 Functional test and controls ............................ 35

4 General information about CNC

4.1 Compensation of geometry

4.2 Coordinate systems on CNC machines .......... 36

4.3 NC mathmatics .............................................. 38

Trigonometric functions ................................. 39

4.4

............................. 36

User interface, machine control panel

5

5.1

Screen arrangement ................................... 40

5.2

Elements on the front panel

5.3

Controls on the control panel ...................... 46

5.4

Protection levels .......................................... 51

6

Operation

6.1 Safety .......................................................... 53

6.2

Control and indicating elements

6.3

Operational modes

6.4 Programming ............

6.5 Operation of the machine

6.6

Operational modes

6.7

Programming

6.8

Starting the program

6.9

Central lubrication system

6.10

Data interfaces and current collection

6.11

Selecting the speed .................................. 62

7

Brief instruction for 808D milling

7.1

Preparation

7.2

Switch on and referencing
Tool Setup

7.3
Workpiece setup

7.4

7.5

Create part program: part 1

7.6

Create part program: part 2
Simulate program

7.7
Test program

7.8

7.9

Machine pieces

7.10

Program restart
Additional information: part 1

7.11

Additional information: part 2

7.12

7.13

Sample program

7.14

ISO mode

7.15

Appendix

8

M - code list, M functions

8.1

M-function for milling machines

8.2

G functions to PAL

9

Notes, messages, and errors
Sinumerik 808D

.................................................. 75

.................................................... 212

.................................................... 230

.................................................... 242

...................................... 54

..................................... 61

.............................................. 61

.................................... 61

................................................. 65

......................................... 91

....................................... 142

.............................................. 146

.......................................... 150

........................................... 156

......................................... 198

...................................... 238

......................... 41

................. 53

.................................... 54

............................ 55

.......................... 62

.......................... 71

........................ 100

........................ 116

..................... 160

...................... 180

.................. 236

........................... 239

Maintenance

11.1

Operating material

11.2

Safety

.......................................................... 244

Inspection and maintenance

11.3
Sliding door interlock switch

11.4
Cooling lubricants and tanks

11.5

...................................... 243

....................... 246

........................ 249

....................... 251

........ 62

12

Wiring Diagrams

Wiring safety instructions

12.1
System wiring diagrams (1-2)

12.2

12.3

System wiring diagrams (3-4)

12.4

System wiring diagrams (5-6)
Handwheel wiring diagram

12.4

X/Y/Z motors wiring diagram

12.5

13

Parts

13.1

Housing

13.2

Base
Milling head

13.3

Milling table

13.4

13.5

X-Axis

13.6

Y-Axis
Z-Axis

13.7

Column

13.8

Auto tool changer

13.9

Electrical cabinet

13.10

Pneumatic system

13.11

Labels & cosmetics

13.12

14

Warranty & returns

Table of Contents (Cont.)

............................ 253

..................... 254

..................... 255

..................... 256

......................... 252

...................... 252

....................................................... 258

........................................................... 260

................................................ 261

................................................. 262

.......................................................... 263

........................................................ 264

........................................................ 265

........................................................ 266

......................................... 268

......................................... 269

....................................... 270

..................................... 271

.............................................. 272

Customer Service #: [phone] · To Order Call: [phone] · Fax #: [phone]

MODEL G0876 8" X 27" ATC ENCLOSED CNC MILL

Product Dimensions:

Weight ......................................................................................................................................................................... 3080 lbs.

Width (side-to-side) x Depth (front-to-back) x Height .......................................................................................71 x 65 x 79 in.

Footprint (Length/Width) ..........................................................................................................................................110 x 86 in.

Shipping Dimensions:

Type ........................................................................................................................................................................ Wood Crate

Content .......................................................................................................................................................................... Machine

Weight .......................................................................................................................................................................... 3350 lbs.

Length x Width x Height ...............................................................................................................................80 x 72-1/2 x 85 in.

Must Ship Upright .................................................................................................................................................................Yes

Electrical:

Power Requirement ................................................................................................................................ 220V, 3-Phase, 60 Hz

Full-Load Current Rating ................................................................................................................................................... 14.1A

Minimum Circuit Size ........................................................................................................................................................... 20A

Connection Type ..................................................................................................................................................... Cord & Plug

Power Cord Length ........................................................................................................................................................ 6-1/2 ft.

Power Cord Gauge .......................................................................................................................................................12 AWG

Recommended Plug Type .................................................................................................................................................15-20

Motors:

Spindle

Horsepower ...............................................................................................................................................................3 HP

Phase .................................................................................................................................................................. 3-Phase

Amps ......................................................................................................................................................................... 6.4A

Speed ............................................................................................................................................................10,000 RPM

Type ......................................................................................................................................................................... Servo

Power Transfer .................................................................................................................................................. Belt Drive

Bearings ...................................................................................................................Shielded & Permanently Lubricated

X-Axis

Horsepower ...............................................................................................................................................................1 HP

Phase .................................................................................................................................................................. 3-Phase

Amps ......................................................................................................................................................................... 2.1A

Speed ..............................................................................................................................................................4,000 RPM

Type ......................................................................................................................................................................... Servo

Power Transfer ............................................................................................................................................... Direct Drive

Bearings ......................................................................................................................Sealed & Permanently Lubricated

Y-Axis

Horsepower ...............................................................................................................................................................1 HP

Phase .................................................................................................................................................................. 3-Phase

Amps ......................................................................................................................................................................... 2.1A

Speed ..............................................................................................................................................................4,000 RPM

Type ......................................................................................................................................................................... Servo

Power Transfer ............................................................................................................................................... Direct Drive

Bearings ......................................................................................................................Sealed & Permanently Lubricated

Model G0876 (Mfd. Since 12/22)

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Z-Axis

± 0.0008 in. (0.020 mm)
± 0.0005 in. (0.013 mm)

Horsepower ............................................................................................................................................................1.3 HP

Phase .................................................................................................................................................................. 3-Phase

Amps ............................................................................................................................................................................ 3A

Speed ..............................................................................................................................................................3,000 RPM

Type ......................................................................................................................................................................... Servo

Power Transfer ............................................................................................................................................... Direct Drive

Bearings ......................................................................................................................Sealed & Permanently Lubricated

Tool Changer

Horsepower ........................................................................................................................................................ 60 Watts

Phase .................................................................................................................................................................. 3-Phase

Amps ....................................................................................................................................................................... 0.24A

Speed ...............................................................................................................................................................1360 RPM

Type ......................................................................................................................................................................... Servo

Power Transfer .................................................................................................................................................... Gearbox

Bearings ......................................................................................................................Sealed & Permanently Lubricated

Coolant Pump

Horsepower ........................................................................................................................................................ 97 Watts

Phase .................................................................................................................................................................. 3-Phase

Amps ......................................................................................................................................................................... 0.5A

Speed ...............................................................................................................................................................2800 RPM

Type .................................................................................................................................................................... Induction

Power Transfer ............................................................................................................................................... Direct Drive

Bearings ...................................................................................................................Shielded & Permanently Lubricated

Main Specifications:

Operation Information

Max Distance Spindle to Column ............................................................................................................................. 11 in.

Max Distance Spindle to Table ..........................................................................................................................16-1/2 in.

Longitudinal Table Travel (X-Axis) ...................................................................................................................12-3/16 in.

Cross Table Travel (Y-Axis) .................................................................................................................................7-3/4 in.

Vertical Head Travel (Z-Axis) .............................................................................................................................11-3/4 in.

Position Resolution .....................................................................................................................

Repeat Position Resolution ........................................................................................................

Tool Changer Info

Type .......................................................................................................................................................... Turntable Style

Capacity .................................................................................................................................................................8 Tools

Maximum Tool Weight ............................................................................................................................................. 13 lbs

Maximum Tool Diameter with Adjacent Tool .......................................................................................................2-3/4 in.

Tool Change Average Time .............................................................................................................................6 Seconds

Table Info

Table Length ............................................................................................................................................................27 in.

Table Width ..........................................................................................................................................................8-1/4 in.

Table Thickness ...................................................................................................................................................2-3/8 in.

Table Height (from Floor/Base) ................................................................................................................................45 in.

Table Weight Capacity .........................................................................................................................................220 lbs.

Number of T-Slots ...........................................................................................................................................................3

T-Slot Size ............................................................................................................................................................... 5/8 in.

T-Slots Centers ....................................................................................................................................................2-1/2 in.

X-Axis Rapid Feed Rate ...................................................................................................................................... 400 IPM

Y-Axis Rapid Feed Rate ...................................................................................................................................... 400 IPM

Z-Axis Rapid Feed Rate ...................................................................................................................................... 400 IPM

-4-

Model G0876 (Mfd. Since 12/22)

Spindle Info

BT30 x 45°

50 - 10,000 RPM

13 Gallons

Spindle Taper ........................................................................................................................................................... BT30

Pull Stud ..........................................................................................................................................................

Spindle Speed Range ...........................................................................................................................

Spindle Bearings (Size & Type) ...............................................................................................Angular Contact Bearings

Fluid Capacities

Coolant Capacity .............................................................................................................................................

Construction

Spindle Housing/Quill ................................................................................................................................................Steel

Table ................................................................................................................................................................... Cast Iron

Head ................................................................................................................................................................... Cast Iron

Column/Base ...................................................................................................................................................... Cast Iron

Stand ..................................................................................................................................................................Cast Iron

Paint Type/Finish ...................................................................................................................................................Enamel

Other Specifications:

Country of Origin ............................................................................................................................................................... China

Warranty ........................................................................................................................................................................... 1 Year

Approximate Assembly & Setup Time .....................................................................................................................1-1/2 Hours

Serial Number Location ..................................................................................................................................Machine ID Label

ISO 9001 Factory ..................................................................................................................................................................Yes

Features:

Siemens Sinumerk® CNC Controller
Servo Motors with Ball Screws on All Axes
Built-In Pendant/Hand Controller
Powerful 3 HP Spindle Motor
50–10,000 RPM Spindle Speeds
Easy Access to Table from 3 Sides
Hands-Free Tool Changes with 8-Position Automatic Tool Changer (ATC)
Rapid Table Speeds of Up to 400 in./min.
Heavy-Duty BT30 Spindle

Model G0876 (Mfd. Since 12/22)

-5-

SAFETY

For Your Own Safety, Read Instruction

Manual Before Operating This Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions.
This manual uses a series of symbols and signal words intended to convey the level of impor­tance of the safety messages. The progression of symbols is described below. Remember that
safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures. Always use common sense and good judgment.

Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.

Alerts the user to useful information about proper operation of the

NOTICE

machine to avoid machine damage.

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand this

owner’s manual BEFORE using machine.

TRAINED OPERATORS ONLY. Untrained oper­ators have a higher risk of being hurt or killed.
Only allow trained/supervised people to use this
machine. When machine is not being used, dis­connect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make your workshop kid proof!

DANGEROUS ENVIRONMENTS. Do not use
machinery in areas that are wet, cluttered, or have
poor lighting. Operating machinery in these areas
greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQUIRED. Full mental
alertness is required for safe operation of machin­ery. Never operate under the influence of drugs or
alcohol, when tired, or when distracted.

ELECTRICAL EQUIPMENT INJURY RISKS.
You can be shocked, burned, or killed by touching
live electrical components or improperly grounded
machinery. To reduce this risk, only allow qualified
service personnel to do electrical installation or
repair work, and always disconnect power before
accessing or exposing electrical equipment.

DISCONNECT POWER FIRST.
nect machine from power supply BEFORE mak­ing adjustments, changing tooling, or servicing
machine. This prevents an injury risk from unin­tended startup or contact with live electrical com­ponents.

EYE PROTECTION. Always wear ANSI-approved
safety glasses or a face shield when operating or
observing machinery to reduce the risk of eye
injury or blindness from flying particles. Everyday
eyeglasses are NOT approved safety glasses.

Always discon-

-6-

Model G0876 (Mfd. Since 12/22)

WEARING PROPER APPAREL. Do not wear
clothing, apparel or jewelry that can become
entangled in moving parts. Always tie back or
cover long hair. Wear non-slip footwear to reduce
risk of slipping and losing control or accidentally
contacting cutting tool or moving parts.

HAZARDOUS DUST. Dust created by machinery
operations may cause cancer, birth defects, or
long-term respiratory damage. Be aware of dust
hazards associated with each workpiece mate­rial. Always wear a NIOSH-approved respirator to
reduce your risk.

HEARING PROTECTION. Always wear hear­ing protection when operating or observing loud
machinery. Extended exposure to this noise
without hearing protection can cause permanent
hearing loss.

REMOVE ADJUSTING TOOLS. Tools left on
machinery can become dangerous projectiles
upon startup. Never leave chuck keys, wrenches,
or any other tools on machine. Always verify
removal before starting!

USE CORRECT TOOL FOR THE JOB. Only use
this tool for its intended purpose—do not force
it or an attachment to do a job for which it was
not designed. Never make unapproved modifica­tions—modifying tool or using it differently than
intended may result in malfunction or mechanical
failure that can lead to personal injury or death!

AWKWARD POSITIONS. Keep proper footing
and balance at all times when operating machine.
Do not overreach! Avoid awkward hand positions
that make workpiece control difficult or increase
the risk of accidental injury.

CHILDREN & BYSTANDERS. Keep children and
bystanders at a safe distance from the work area.
Stop using machine if they become a distraction.

GUARDS & COVERS. Guards and covers reduce
accidental contact with moving parts or flying
debris. Make sure they are properly installed,
undamaged, and working correctly BEFORE
operating machine.

FORCING MACHINERY. Do not force machine.
It will do the job safer and better at the rate for
which it was designed.

NEVER STAND ON MACHINE. Serious injury
may occur if machine is tipped or if the cutting
tool is unintentionally contacted.

STABLE MACHINE. Unexpected movement dur­ing operation greatly increases risk of injury or
loss of control. Before starting, verify machine is
stable and mobile base (if used) is locked.

USE RECOMMENDED ACCESSORIES. Consult
this owner’s manual or the manufacturer for rec­ommended accessories. Using improper acces­sories will increase the risk of serious injury.

UNATTENDED OPERATION. To reduce the
risk of accidental injury, turn machine OFF and
ensure all moving parts completely stop before
walking away. Never leave machine running
while unattended.

MAINTAIN WITH CARE. Follow all maintenance
instructions and lubrication schedules to keep
machine in good working condition. A machine
that is improperly maintained could malfunction,
leading to serious personal injury or death.

DAMAGED PARTS. Regularly inspect machine
for damaged, loose, or mis-adjusted parts—or
any condition that could affect safe operation.
Immediately repair/replace BEFORE operating
machine. For your own safety, DO NOT operate
machine with damaged parts!

MAINTAIN POWER CORDS. When disconnect­ing cord-connected machines from power, grab
and pull the plug—NOT the cord. Pulling the cord
may damage the wires inside. Do not handle
cord/plug with wet hands. Avoid cord damage by
keeping it away from heated surfaces, high traffic
areas, harsh chemicals, and wet/damp locations.

EXPERIENCING DIFFICULTIES. If at any time
you experience difficulties performing the intend­ed operation, stop using the machine! Contact our
Technical Support at [phone].

Model G0876 (Mfd. Since 12/22)

-7-

Additional Safety for CNC Mills/Lathes

You can be seriously injured or killed by getting clothing, jewelry, or long hair entangled with
rotating cutter/spindle. You can be severely cut or have fingers amputated from contact with
rotating cutters. You can be blinded or struck by broken cutting tools, metal chips, workpieces,
or adjustment tools thrown from the rotating spindle with great force. To reduce your risk of
serious injury when operating this machine, completely heed and understand the following:

UNDERSTAND ALL CONTROLS. Make sure

you understand the function and proper use of all
controls before starting. This will help you avoid
making mistakes that result in serious injury.

AVOIDING ENTANGLEMENT. DO NOT wear
loose clothing, gloves, or jewelry, and tie back
long hair. Keep all guards in place and secure.
Always allow spindle to stop on its own. DO NOT
stop spindle using your hand or any other object.

EYE INJURIES. Operator and bystanders MUST
wear ANSI-approved safety glasses to help pro­tect eyes from thrown metal shards and chips.

USE CORRECT SPINDLE SPEED. Follow rec­ommended speeds and feeds for each size and
type of cutting tool. This helps avoid tool breakage
during operation and ensures best cutting results.

INSPECT CUTTING TOOL. Inspect cutting tools
for sharpness, chips, or cracks before each use.
Replace dull, chipped, or cracked cutting tools
immediately.

UNATTENDED MACHINE. Operator MUST be
present to immediately stop machine in case of
malfunction to prevent injury to bystanders and
machine damage.

POWER DISRUPTION. In event of power outage
during operation, turn spindle switch OFF to avoid
a possible sudden startup once power is restored.

SECURE WORKPIECE TO TABLE. Clamp work­piece to table or secure in a vise mounted to table,
so workpiece cannot unexpectedly shift or spin
during operation. NEVER hold workpiece by hand
during operation.

DISCONNECT POWER FIRST. To reduce risk of
electrocution or injury from unexpected startup,
make sure mill/drill is turned OFF, disconnected
from power, and all moving parts have come to
a complete stop before changing cutting tools or
starting any inspection, adjustment, or mainte­nance procedure.

CLEAN MACHINE SAFELY. Metal chips or shav­ings can be razor sharp. DO NOT clear chips
by hand or compressed air that can force chips
farther into machine—use a brush or vacuum
instead. Never clear chips while spindle is turning.

PROPERLY MAINTAIN MACHINE. Keep
machine in proper working condition to help
ensure that it functions safely and all guards and
other components work as intended. Perform rou­tine inspections and all necessary maintenance.
Never operate machine with damaged or worn
parts that can break or result in unexpected move­ment during operation.

SAFE OPERATING LOCATION. DO NOT place
machine where it can be exposed to rain or mois­ture. Exposure to water creates a shock hazard
and will reduce life of machine.

-8-

Model G0876 (Mfd. Since 12/22)

1.3 Safety instructions (warning notes)

1.3.1 Classification of hazards

We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.

Symbol Warning alert Definition / consequence

DANGER!

WARNING!

CAUTION!

ATTENTION!

In case of specific dangers, we replace the pictogram with

INFORMATION

Impending danger that will cause serious injury or death to people.

A danger that can cause serious injury or death.

A danger or unsafe procedure that can cause personal injury or damage to
property.

Situation that could cause damage to the CNC-machine and products and
other types of damage.

No risk of injury to people.

Practical tips and other important or useful information and notes.

No dangerous or harmful consequences for people or objects.

general danger by a

warning of

Model G0876 (Mfd. Since 12/22)

injury to hands, hazardous electrical

voltage,

rotating
parts.

-9-

1.3.2 Other pictograms

Activation forbidden! Do not step into the

machine!

Wear protective boots! Use ear protection! Wear protective glasses! Read the operating instruc-

Warning: suspended loads! Warning of oxidizing sub-

stances!

Protect the environment! Contact address

Do not extinguish with

water!

Caution, danger of explo-

sive substances!

Access forbidden!

tion before commissioning!

Warning: danger of slip-

ping!

1.4 Intended use

WARNING!

In the event of improper use of the CNC machine

 will endanger personnel,
 the CNC machine and other material property of the operating company will be

endangered,

 the correct function of the CNC machine may be affected.

The CNC machine is designed and manufactured to be used for milling and drilling cold metals
or other non-flammable materials or materials that do not constitute a health hazard by using
commercial milling and drilling tools.
Using this machine it is possible to perform dry processing as well as processing by using cool-

ing lubricants.

The limit values of the balances of the tools need to be observed.
fixtures“ on page 21

The CNC machine must only be installed and operated in a dry and well-ventilated place.

The CNC machine is designed and manufactured to be used in a non-explosive environment.

If the CNC machine is used in any way other than described above or modified without the
approval of Grizzly Industrial, Inc., then the CNC machine is being used improperly.

We will not be held liable for any damages resulting from any operation which is not in accord­ance with the intended use.

 "Cooling lubricants“ on page 243

 "Tools and tool holding

express

-10 -

Model G0876 (Mfd. Since 12/22)

We expressly point out that the guarantee or CE conformity will expire, if any constructive, tech-

nicolor procedural changes are not performed by Grizzly Industrial, Inc.

It is also part of intended use that you

 the limits of performance of the CNC machine are observed,
 the operating manual is observed,
 the inspection and maintenance instructions are observed.

WARNING!

Severe injuries due to non-intended use.

It is forbidden to make any modifications or alternations to the operation values of the
CNC machine. They could endanger the personnel and cause damage to the CNC
machine.

1.5 Reasonably foreseeable misuse

Any other use other than that specified under "Intended use" or any use beyond the described
use shall be deemed as non-intended use and is not permissible.

Any other use has to be discussed with the manufacturer.

It is only allowed to process metal, cold and non-inflammable materials with the milling
machine.

In order to avoid misuse, it is necessary to read and understand the operating instructions
before first commissioning.

Operators must be qualified.

1.5.1 Avoiding misuse

 Use of suitable cutting tools.
 Adapting the speed adjustment and feed to the material and workpiece.
 Clamp workpieces firmly and vibration-free.

ATTENTION!

The workpiece is always to be fixed by a machine vice, jaw chuck or by another
appropriate clamping tool such as for the clamping claws.

WARNING!

Risk of injury caused by flying workpieces.

Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly clamped in the
machine vice and that the machine vice is firmly clamped onto the machine table.

 Use cooling and lubricating agents to increase the durability of the tool and to improve the

surface quality.

 Clamp the cutting tools and workpieces on clean clamping surfaces.
 Sufficiently lubricate the machine.
 Correctly adjust the bearing clearance and the guidings.

ATTENTION!

Do not use the drill chuck as a milling tool. Never clamp a milling cutter into a drill
chuck. Use a collet chuck with collets for the end mill.

Model G0876 (Mfd. Since 12/22)

-11-

1.6 Possible dangers caused by the CNC machine

The CNC machine has been tested for operational safety. The construction and type are state
of the art.

Nevertheless, there is a residual risk as the CNC machine operates with

 rotating parts,
 electrical voltage and currents,
 compressed air,
 rapid moves.

We have used construction resources and safety techniques to minimize the health risk to per­sonnel resulting from these hazards.

If the CNC machine is used and maintained by personnel who are not duly qualified, there may
be a risk resulting from incorrect or unsuitable maintenance of the lathe.

INFORMATION

Everyone involved in the assembly, commissioning, operation and maintenance must

 be duly qualified,
 and strictly follow these operating instructions.

In the event of improper use

 there may be a risk to personnel,
 there may be a risk of damage to the CNC machine and other material values,
 the correct function of the CNC machine may be affected.

Always switch off the CNC machine and disconnect it from the mains, when cleaning or mainte­nance work is carried out.

WARNING!

The CNC machine may only be operated with functional safety devices. Disconnect the
CNC machine immediately, whenever you detect a failure in the safety devices or when
they are not fitted!

All additional parts of the machine which had been added by the customer need to be
equipped with the prescribed safety devices.

This is your responsibility being the operating company!

1.7 Qualification of personnel

1.7.1 Target group

This manual is addressed to

 the operating companies,
 operators having sufficient specialist knowledge,
 the maintenance personnel.

Therefore, the warning notes refer to both, operation and maintenance personnel of the CNC
machine.

Determine clearly and explicitly who will be responsible for the different activities on the CNC
machine (operation, setting up, maintenance and repair). Please note the name of the responsi­ble person into an operators´s log.

INFORMATION

Unclear responsibilities constitute a safety risk!

Always lock the main switch after switching off the CNC machine. This will prevent it from being
used by unauthorized persons.

The qualifications of the personnel for the different tasks are mentioned below:

-12-

Model G0876 (Mfd. Since 12/22)

Operator

The operator has been instructed by the operating company regarding the assigned tasks and
possible risks in case of improper behaviour. Any tasks which need to be performed beyond the
operation in standard mode must only be performed by the operator, if so indicated in these
instructions and if the operator has been expressively commissioned by the operating com­pany.

Qualified electrician

With professional training, knowledge and experience as well as knowledge of respective
standards and regulations, qualified electricians are able to perform work on the electrical sys­tem and recognise and avoid any possible dangers.

Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.

Qualified personnel

Thanks to professional training, knowledge and experience as well as knowledge of relevant
regulations the qualified personnel is able to perform the assigned tasks and to independently
recognise and avoid any possible dangers themselves.

Instructed person

Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.

1.7.2 Authorized personnel

INFORMATION

Sufficient expertise is required for working on the CNC machine. No one must work on
the machine without having the necessary training, not even for a short while.

We recommend the use of the CNC software SinuTrain as an aid for training and
operation.

SinuTrain made by Siemens is the perfect software-supplement for the G0876 CNC Mill.

This training software supports the rapid training for the operation of the control Sinumerik
808D. Employees having little CNC-experience can learn the basics of the DIN-programming
by using SinuTrain and are finally able to write and test programs using SINUMERIK 808D.

Please find SinuTrain and further information on the website of Siemens.
http://www.cnc4you.siemens.com

WARNING!

Inappropriate operation and maintenance of the CNC machine constitutes a danger to
the personnel, objects and the environment.

Only authorized personnel may operate the CNC machine !

Persons authorized to operate and maintain should be trained technical personnel and
instructed by the ones who are working for the operating company and for the manufacturer.

The operating company must

 train the personnel,
 instruct the personnel in regular intervals (at least once a year) on

- all safety standards that apply to the CNC machine,

- operation of the CNC machine,

- generally accepted engineering standards.

- possible emergency situations,

Model G0876 (Mfd. Since 12/22)

-13-



check the personnel‘s knowledge level,

 document training/instruction in a operation book,
 require personnel to confirm participation in training/instructions by means of a signature,
 check whether the personnel is working safety and risk-conscious and observes the operat-

ing instructions.

 define and document the inspection deadlines for the machine.

The operator must

 be specially trained in handling and programming the CNC machine,
 know and understand the program sequence and the effects of the individual process

parameters,

 keep an operator‘s log,
 before taking the machine in operation

- have read and understood the operating manual,

- be familiar with all safety devices and instructions.

For work on the following CNC machine parts there are additional requirements:

 Electric components or operating materials: Must only be worked on by a qualified electri-

cian or person working under the instructions and supervision of a qualified electrician.

1.8 Operator positions

The operator position is in front of the CNC machine at the sight window or on the machine con­trol panel.

1.9 Safety devices

Use the CNC machine only with properly functioning safety devices.

Stop the CNC machine immediately, if a safety device fails or is faulty or becomes ineffective.

It is your responsibility!

If a safety device has been activated or has failed, the drilling machine must only be used if you

 the cause of the fault has been eliminated,
 you have verified that there is no danger to personnel or objects.

Obligations of
the operator

Additional
requirements
regarding the
qualification

WARNING!

If you bypass, remove or deactivate a safety device in any other way, you are
endangering yourself and other personnel working with the CNC machine. The possible
consequences are:

 injuries due to tools, workpieces or fragments hereof which are flying off at high

speed,

 contact with rotating or moving parts,
 fatal electrocution,
 pulling-in of clothes.

The CNC machine features the following safety devices:

 a lockable main switch,
 One EMERGENCY STOP push-button on the machine control panel, the milling head and

on the electronic handwheel,

 A locked, separating protective equipment around the CNC milling machine with sight win-

dows made of break-proof Makrolon.

 Locking switch on the separating safety devices.

-14-

Model G0876 (Mfd. Since 12/22)

1.9.1 Lockable main switch

In the "0" position, the lockable main switch can be secured against accidental or non-author­ised switching on by means of a padlock.

The power supply is interrupted by switchingoff the main plug.

Except for the areas marked by the pictogram in the margin. In these areas there might be volt­age, even if the main switch is switched-off.

Img.1-1: Main switch

WARNING!

Dangerous voltage even if the main switch is switched off.

The areas marked by the pictogram might contain live parts, even if the main switch is switched
off.

Model G0876 (Mfd. Since 12/22)

-15-

1.9.2 Emergency stop button

ATTENTION!

The EMERGENCY STOP push button immediately stops the operation of the CNC
machine.

Press the EMERGENCY STOP button only if there is a risk! If this push button is
actuated in order to switch off the CNC machine in the standard operation the tool or
workpiece might get damaged.

After having actuated the EMERGENCY STOP button, turn the knob of the particular push
button to the right in order to restart the machine.

Img.1-2: Emergency-stop push button

1.9.3 Control technical protection

WARNING!

If you bypass a controller you endanger yourself and other persons working on the CNC
machine.

 injuries due to tools, workpieces or fragments hereof which are flying off at high

speed,

 contact with rotating parts,
 fatal electrocution,
 pulling-in of clothes.

If you temporarily bypass a controller in exceptional cases (e.g. during electrical repairs), you
must continuously monitor the CNC machine.

-16 -

Model G0876 (Mfd. Since 12/22)

1.9.4 Polycarbonate windows

Polycarbonate viewing window in chip protection, must be visual inspected by the customer
responsible personnel at regular intervals to guarantee the operational safety of the CNC
machine.

Polycarbonate viewing panes are subject to an ageing process and are classified as wear
parts.

The aging of polycarbonate windows can not be detected by visual inspection. It is therefore
necessary to replace the polycarbonate windows after a certain time.

Prolonged exposure from polycarbonate windows to cutting fluids can lead to accelerated ag­ing, i.e. deterioration of the mechanical properties (brittleness). Coolant vapours, detergents,
greases and oils or other corrosive substances from the operator side can also lead to a deteri­oration of the polycarbonate windows. The result in reduced impact resistance of the polycar­bonate windows.

 "Cleaning and replacing of the polycarbonate windows“ on page 248

1.9.5 Prohibition, warning and mandatory labels

INFORMATION

All warning and mandatory signs must be legible. They must be checked regularly.

1.10 Safety check

Check the CNC machine at least once per shift. Inform the person responsible immediately of
any damage, defects or changes in the operating function.

Check all safety devices

 at the beginning of each shift (when the machine is operated continuously),
 once per day (during one-shift operation),
 once per week (when operated occasionally),
 after all maintenance and repair work.

Check that prohibition, warning and information signs and the labels on the CNC machine

 are legible (clean them, if necessary)
 and complete (replace them, if necessary).

INFORMATION

Organise the checks according to the following table;

General check

Equipment Check OK

Protective housing Switching function, firmly bolted and not damaged

Signs,
Markers

Sight window

Installed and legible

Check for mechanical damage (scratches, cracks).

cracks,

 "Polycarbonate windows" on page 17

Date: checked by (signature):

Model G0876 (Mfd. Since 12/22)

-17-

Functional check

KOk c e hCtnempiuqE

EMERGENCY STOP
push button

Switch cabinet cooling The cabinet cooling must be running.

Separating protective
equipment around the
CNC machine

After actuating an EMERGENCY STOP push button the CNC
machine must be switched off.

If the protective equipment is open it must not be possible to
start program.

Date: checked by (signature):

1.11 Personal protective equipment

For certain work personal protective equipment is required.

Protect your face and your eyes: Wear a safety helmet with facial protection when performing
work where your face and eyes are exposed to hazards.

Wear protective gloves when handling pieces or tools with sharp edges.

Wear safety shoes when you assemble, disassemble or transport heavy components.

Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).

Before starting work make sure that the required personal protective equipment is available at
the work place.

CAUTION!

Dirty or contaminated personnel protective equipment can cause illness. It must be
cleaned after each use and at least once a week.

1.12 Safety during operation

WARNING!

Before activating the CNC machine, ensure that this will not endanger other persons or
cause damage to equipment.

Avoid any unsafe work methods:

 The instructions mentioned in these operating instructions have to be strictly observed dur-

ing assembly, operation, maintenance and repair.

 Do not work on the CNC machine, if your concentration is reduced, for example, because

you are taking medication.

 Stay on the CNC machine until the program is termi-

nated.
The running program can be identified by means of
the signal lamp.

- Green light: Program run active

- Yellow light: Malfunction

- Red light: Actuated emergency stop push button

Img.1-3: Signal lamp

 Safely and firmly clamp the workpiece in place, before switching the CNC machine on.
 Never change the dosing of the coolant supply during operation.

-18-

Model G0876 (Mfd. Since 12/22)



Never open the sliding door of the separating protective unit when the CNC

program is

running.

WARNING!

When chipping magnesia materials (aluminum-/magnesium alloys), spontaneously
inflammable or explosive particles (powder, dust, chips) might be generated, which
might cause a fire and/or explosion.

Magnesium is a dangerous material. In case of a fire with magnesium, only use
appropriate and admitted extinguishing agents. Never extinguish using water. If
burning magnesium is extinguished with water, this might lead to dangerous reactions
(hydrogen gas). Water would be decomposed in its components hydrogen (H) and
oxygen (O).

Only the following extinguishing agents are permissible:

 solid extinguishing agent of fire class D (fires involving metals)
 dry covering salts for magnesium
 a mixture of sand and cast chips
 argon (Ar) or nitrogen (N

)

2

If fine mist and smoke is generated at the workplace, suction units must be provided in
order to avoid the accumulation of ignitable mixtures and emissions.

We provide information about the specific dangers when working with and on the CNC machine
in the descriptions for these types of work.

1.13 Safety during maintenance

Inform the operators in good time of any maintenance and repair works.

Report all safety-relevant changes and performance characteristics of the CNC machine. Any
changes must be documented, the operating instructions updated and machine operators
instructed accordingly.

1.14 Disconnecting and securing the CNC machine

Turn off the main switch of the CNC machine before starting any maintenance or repair work.

Use a padlock to prevent the switch from being turned on without authorization and keep the
key in a safe place.

All machine parts as well as all dangerous voltages are switched off.

Excepted are only the positions which are marked with the adjoining pictogram. These positions
may be live, even if the main switch is switched off.

Place a warning sign on the CNC machine.

WARNING!

Live parts and moves of machine parts can injure you or others dangerously!

Proceed with extreme care if you cannot switch off
switch due to required works (e.g. functional control).

Model G0876 (Mfd. Since 12/22)

-19 -

1.14.1 Using lifting equipment

WARNING!

The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death. Observe the accident prevention regulations
issued by your Employers Liability Insurance Association or other supervisory
authorities responsible for your company.

Check that the lifting and load-suspension equipment are of sufficient load-bearing
capability and are in perfect condition.

Fasten the loads carefully.

Never walk under suspended loads!

1.14.2 Mechanical maintenance work

Remove or install protection safety devices before starting or after completing any mainte­nance work; this include:

 covers,
 safety instructions and warning signs,
 grounding cables.

If you remove protective or safety devices, re-fit them immediately after the completing the
work.

Check if they are working properly!

1.15 Unattended Operation

CNC machines are designed for unattended operation. However, it may not be safe to let your
machining process run unmonitored. As it is the shop owner’s responsibility to set up the
machine safely and use best practice machining techniques, it is also their responsibility to
manage the progress of these methods. The machining process must be monitored to prevent
damage in case of a hazardous situation.

For example, if there is a risk of fire due to the machined material, an appropriate fire suppres­sion system must be installed to reduce the risk of harm to personnel, equipment and the build­ing. Have a specialist supplier install monitoring tools, before allowing machines to run
unattended.

It is especially important to select monitoring equipment that can immediately perform an appro­priate action without human intervention to prevent an accident, should a problem be detected.

1.16 Accident report

Inform your supervisors immediately in the event of accidents, possible sources of danger
and any actions which almost led to an accident (near misses).

There are many possible causes for "near misses".

The sooner they are notified, the quicker the causes can be eliminated.

INFORMATION

We provide information about the specific dangers when working with and on the CNC machine
in the descriptions for these types of work.

1.17 Electrical system

Have the machine and/or the electric equipment checked regularly. Immediately eliminate all
defects such as loose connections, defective wires, etc.

-20-

Model G0876 (Mfd. Since 12/22)

A second person must be present during work on live components to disconnect the power in

the event of an emergency. Disconnect the machine immediately if there is a malfunction in the
in case of failure of the power supply!

The operator of the machine must ensure that the electrical systems and operating equipment
are inspected with regards to their proper condition, namely,

 by a qualified electrician or under the supervision and direction of a qualified electrician,

prior to initial commissioning and after modifications or repairs, prior to recommissioning

 and at certain intervals.

The deadlines must be set so that arising, foreseeable defects can be detected in a timely man­ner.

The relevant electro-technical rules must be followed during the inspection.

The inspection prior to initial commissioning is not required if the operator receives confirma­tion from the manufacturer or installer that the electrical systems and operating equipment com­ply with the accident prevention regulations, see conformity declaration.

Permanently installed electrical systems and operating equipment are considered constantly
monitored if they are continually serviced by qualified electricians and inspected by means of
measurements in the scope of operation (e.g. monitoring the insulation resistance).

1.18 Inspection deadlines

Define and document the inspection deadlines for the machine.

1.19 Clamping devices for workpieces and tools

ATTENTION!

Attention when taking over existing clamping devices. Pleased thoroughly check that
the clamping device is appropriate for your CNC machine.

 Only use clamping devices with a complete inherent rigidity.
 Contact the manufacturer of the clamping device regarding the reuse of clamping

devices after damage to the clamping device due to collisions.

 Correctly insert the workpiece and make sure that the machine is proper working

condition.

1.20 Tools and tool holding fixtures

CAUTION !

When using tools with larger diameters or at higher speeds!

The balancing of the tools has to amount to

 0 - 6000 min
 from a speed of 6000 min

according to DIN / ISO 1940.

-1

- G 6,3

-1

- G 2,5

Model G0876 (Mfd. Since 12/22)

-21-

POWER SUPPLY

Before installing the machine, consider the avail­ability and proximity of the required power supply
circuit. If an existing circuit does not meet the
requirements for this machine, a new circuit must
be installed. To minimize the risk of electrocution,
fire, or equipment damage, installation work and
electrical wiring must be done by an electrician or
qualified service personnel in accordance with all
applicable codes and standards.

or equipment damage
may occur if machine is
not properly grounded
and connected to power

The full-load current rating is the amperage a
machine draws at 100% of the rated output power.
On machines with multiple motors, this is the
amperage drawn by the largest motor or sum of all
motors and electrical devices that might operate
at one time during normal operations.

The full-load current is not the maximum amount
of amps that the machine will draw. If the machine
is overloaded, it will draw additional amps beyond
the full-load rating.

If the machine is overloaded for a sufficient length
of time, damage, overheating, or fire may result—
especially if connected to an undersized circuit.
To reduce the risk of these hazards, avoid over­loading the machine during operation and make
sure it is connected to a power supply circuit that
meets the specified circuit requirements.

For your own safety and protection of

Note: Circuit requirements in this manual apply to

a dedicated circuit—where only one machine will
be running on the circuit at a time. If machine will
be connected to a shared circuit where multiple
machines may be running at the same time, con­sult an electrician or qualified service personnel to
ensure circuit is properly sized for safe operation.

This machine is prewired to operate on a power
supply circuit that has a verified ground and meets
the following requirements:

A power supply circuit includes all electrical
equipment between the breaker box or fuse panel
in the building and the machine. The power sup­ply circuit used for this machine must be sized to
safely handle the full-load current drawn from the
machine for an extended period of time. (If this
machine is connected to a circuit protected by
fuses, use a time delay fuse marked D.)

Availability

Electrocution, fire, shock,

supply.

Full-Load Current Rating

Circuit Requirements for 220V

Nominal Voltage .........208V, 220V, 230V, 240V

..........................................................60 Hz

Cycle
Phase
Power Supply Circuit
Plug/Receptacle
Cord

.................................................... 3-Phase

......................... 20 Amps

........................... NEMA 15 -20

........“S”-Type , 4-Wire, 12 AWG, 300 VAC

Full-Load Current Rating at 220V ...14 .1 Amps

-22-

property, consult an electrician if you are
unsure about wiring practices or electrical
codes in your area.

Model G0876 (Mfd. Since 12/22)

We do not recommend using an extension cord
with this machine.
cord, only use it if absolutely necessary and only
on a temporary basis.

Extension cords cause voltage drop, which can
damage electrical components and shorten motor
life. Voltage drop increases as the extension cord
size gets longer and the gauge size gets smaller
(higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must
be in good condition and contain a ground wire
and matching plug/receptacle. Additionally, it must
meet the following size requirements:

Improper connection of the equipment-grounding
wire can result in a risk of electric shock. The
wire with green insulation (with or without yellow
stripes) is the equipment-grounding wire. If repair
or replacement of the power cord or plug is nec­essary, do not connect the equipment-grounding
wire to a live (current carrying) terminal.

Check with a qualified electrician or service per­sonnel if you do not understand these grounding
requirements, or if you are in doubt about whether
the tool is properly grounded. If you ever notice
that a cord or plug is damaged or worn, discon­nect it from power, and immediately replace it with
a new one.

Serious injury could occur if you connect

process. DO NOT connect to power until

Grounding Instructions

This machine MUST be grounded. In the event
of certain malfunctions or breakdowns, grounding
reduces the risk of electric shock by providing a
path of least resistance for electric current.

The power cord and plug specified under “Circuit
Requirements for 220V”
has an equipment-grounding wire and a ground­ing prong. The plug must only be inserted into
a matching receptacle (outlet) that is properly
installed and grounded in accordance with all
local codes and ordinances (see figure below).

No adapter should be used with plug. If
plug does not fit available receptacle, or if

process. DO NOT connect to power until

on the previous page

GROUNDED

15-20 RECEPTACLE

15-20 PLUG

Current
Carrying

Grounding Pin

Blades

Serious injury could occur if you connect
machine to power before completing setup

instructed later in this manual.

Extension Cords

Typical 15-20 plug and receptacle.

machine to power before completing setup

instructed later in this manual.

machine must be reconnected for use on a
different type of circuit, reconnection must
be performed by an electrician or qualified
service personnel, and it must comply with
all local codes and ordinances.

Model G0876 (Mfd. Since 12/22)

If you must use an extension

Minimum Gauge Size ...........................10 AWG

Maximum Length (Shorter is Better).......50 ft.

-23-

3 Assembly and commissioning

INFORMATION

The CNC-machine is delivered pre-assembled. It is delivered in a transport box.

3.1 Scope of delivery

Compare the delivery volume with the attached packing list.

Check the status of the CNC machine immediately upon receipt and claim possible damages at
the last carrier also if the packing is not being damaged. In order to ensure claims towards the
freight carrier we recommend you to leave the machines, devices and packing material for the
time being in the status at which you have determined the damage or to take photos of this sta­tus. Please inform us about any other claims within six days after receipt of delivery.

Check if all parts are firmly seated.

3.2 Transport

WARNING!

Severe or fatal injuries may occur if the machine or parts of the machine tumble or fall
down from the forklift truck or from the transport vehicle. Follow the instructions and
information on the transport box:

 Centers of gravity

 Load suspension points

(Marking of positions for the load
suspension point)

 Prescribed transportation position

(Marking of the top surface)

 Means of transport to be used

 Weights

WARNING!

The use of damaged lifting and load suspension equipment without sufficient load
capacity that might break under load can cause severe injuries or even death.

Check that the lifting and load suspension equipment has sufficient load capacity and
that it is in perfect condition.

Observe the accident prevention regulations.

Fasten the loads carefully.

Never walk under suspended loads!

 Check the substructure. The substructure must bear the load.
 Disassemble the lateral parts of the wooden box.
 The CNC machine is lifted and transported with an appropriate handling device to the instal-

lation place by means of a fork-lift truck.

 Disassemble the clamping bolts which are used to fix the machine on the pallet.

-24-

Model G0876 (Mfd. Since 12/22)

 Lift the CNC machine carefully from the pallet of the transportation box by means of a crane

or a fork-lift truck.

"Total weight on page 3.



 Bring the CNC machine with an appropriate handling device, e.g. Electric pallet truck or

fork-lift truck at their firm position.

 Make sure that no add-on-pieces are damaged or cause paintwork is damaged during

transport.

WARNING!

The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death.

3.3 Installation and assembly

3.3.1 Requirements regarding the installation site

Organize the working area around the CNC machine according to the local safety regulations.
The working area for operating, maintenance and repair must not be restricted.

INFORMATION

The main switch of the CNC machine must be freely accessible.

Model G0876 (Mfd. Since 12/22)

-25-

3.3.2 Installation plan

Connection compressed air

3.3.3 Machine mounting

1641

Electrical supply connection

530530152

Anchor-free assembly

 Align the CNC machine with a machine spirit level. The slope deviation of all levels must not

exceed 0.04/1000mm.

 Adjust the height by screwing in or screwing out of the levelling screw. Screwing in the lev-

elling screw causes that the rubber plate lifts itself as on the drawing from the same ele­ment.

 Fix the height adjustment by the the jackscrew with the help of the counternut.
 Check the alignment of the machine after a few days of usage.

-26-

Model G0876 (Mfd. Since 12/22)

Jackscrew

Counternut

Img.3-1: Oscillating element

Anchored assembly

Use the anchored assembly in order to attain a firm connection to the ground. An anchored
assembly is always reasonable if parts are manufactured to the maximum capacity of the CNC
machine.

ATTENTION!

An insufficient rigidity of the substructure leads to superposition of vibrations between
the CNC machine and the substructure (natural frequency of the components). Critical
speeds and moves in the axis with displeasing vibrations are rapidly achieved in case of
insufficient rigidity of the whole system and will lead to bad milling results.

 Check the correct alignment of the machine after a few days of usage.

3.3.4 Corrosion protection

 A corrosion protection is applied on the machine table and on the guiding surfaces for trans-

port and storage. Remove the anti-corrosive agent from the CNC machine before first com­missioning. Therefore, we recommend you to use paraffin.

Model G0876 (Mfd. Since 12/22)

-27-

3.3.5 Electrical connection

 Check the fusing (fuse) of your electrical supply according to the technical instructions

regarding the total connected power of the milling machine.

 Firmly connect the machine.

CAUTION!

Install the connection cable of the machine in such a way that people will not stumble
over it.

Please verify if the type of current, voltage and protection fuse correspond to the values speci­fied. A protective earth ground wire connection must be available.

With an internal EMC filter the leakage current of the frequency converter of milling spindle is
greater than 3.5 mA. We ask for due attention while executing machine tests within
the framework of industrial safety guidelines.

ATTENTION!

When delivered the machine is equipped with a plug for electrical connection. It only
serves for acceptance and test purposes. In order to operate the machine it is necessary
to remove this plug and to connect the machine directly with a power supply.

Firmly connect the CNC machine to the terminal box. It is not allowed to connect the machine
using a standard 16A CEE plug, since the stray current of the frequency converter is exceed­ing the admissible value of 3.5mA.

ATTENTION!

Depending on the quality of the network, there is a risk of machine malfunctions under
extreme conditions. If necessary and in order to exclude retroactive effects on the
internal power supply system, the operator should install a line filter on the machine.
Therefore, at workplaces with lots of powerful consumers, it might also be necessary to
use a system for network compensation. Please consult your electricity supplier
regarding this.

ATTENTION!

Frequency converters (drive regulators) might trigger the Fl circuit breaker of your
electrical supply. In order to avoid malfunction, an Fl circuit breaker switch sensitive to
pulse current or to universal current may be required.

ATTENTION!

Ensure that all 3 phases (L1, L2, L3) and the ground wire are connected correctly.

The neutral conductor (N) of its power supply is not connected.

-28-

Model G0876 (Mfd. Since 12/22)

3.3.6 Current in the Protective Earth Ground Wire

The degree of the leakage current in the protective earthing conductor depends on whether the
internal EMC filter in the Emerson M200 frequency converter is used for spindle rotation speed
control or not. The standard frequency converter is fitted with an internal EMC filter. Instructions
on how to remove the internal filter is in the converter manual.

 With the EMC filter, the leakage current is 15.4 mA AC 230V 50Hz (1 phase supply, phase-

neutral power supply, neutral point earthed).

 Without an EMC filter, the leakage current is <1.9 mA (phase-neutral power supply, neutral

point earthed).

Therefore, a fixed earth connection is required and the minimum cross section of the protective
earthing conductor must conform to local safety regulations for devices with high leakage cur­rent. This is achieved by providing a permanent fixed earthing connection with two independ­ent conductors, each having a cross section the same as the power supply cord or greater. To
simplify this, the converter is provided with two earth terminals. Both earthing connections are
required to comply with the standard EN 61800-5-1.

Since a direct current may be caused by the frequency converter in the protective earthing con­ductor, if an upstream residual current device (ELCB / RCD) is required in the network, the fol­lowing guidelines must be followed:

There are three common types of FI (ELCB / RCD):

 AC - to detect AC fault currents
 A - to detect AC fault currents and pulsating DC fault currents (provided the DC current

reaches zero at least once every half cycle).

 B - to detect AC fault currents, pulsating DC fault currents and smooth DC residual currents.

Type AC should never be used in converters.

Type A can only be used for single-phase converters.

Type B must be used for 3-phase converters.

When using an external EMC filter, to avoid false error shutdowns, a time delay of at least 50
ms is required. The leakage current can exceed the threshold trigger value for an error shut­down if the phases are not switched on at the same time.

Line systems

The CNC milling machine is designed for TN and TT line systems with a grounded neutral
point.

Prohibited operation

Operation on TN line systems with grounded external conductors is prohibited.

Operation on TT line systems without grounded neutral points is prohibited.

Operation on IT line systems is not permitted. In an IT line system, all of the conductors are
insulated with respect to the PE protective conductor – or connected to the PE protective con­ductor through an impedance. Operation on an IT line system is not permitted.

Permissible line supplies

Operation on TN and TT line systems

TN line system

The TN line system in accordance with IEC 60364-1 (2005) transmits the PE conductor to the
installation via a conductor. Generally, in a TN line system the neutral point is grounded There
are versions of a TN line supply with a grounded line the conductor, e.g. with grounded L1.

A TN line system can transfer the neutral conductor N and the PE protective conductor either
separately or combined.

Model G0876 (Mfd. Since 12/22)

-29-

TT system

In a TT line system, the transformer grounding and the installation grounding are independent
of one another. There are TT line supplies where the neutral conductor N is either transferred –
or not.

3.3.7 Connection compressed air supply

 Open the cover and connect the compressed air supply with at least 6.5 bars to the quick-

action coupling of the compressed air maintenance unit.

 Adjust a pressure of 6.3 bars using the set screw of the maintenance unit.

Manometer

Compressed air supply

Compressed air drainage

Img.3-2: Compressed air maintenance unit

ATTENTION!

In order to ensure a failure-free operation of the machine it is necessary that the required
air pressure is continuously applied on the machine at constant quality. In case of
insufficient air supply, for instance interruptions occur during tool change.

Air pressure switch

Pneumatic oiler

Cylinder tool clamping

Cylinder tool clamping

Solenoid valve

Compressed air service unit

Filter

Pressure controller

Manometer

Pneumatic oiler

Throttle valve

Drip feed lubricator

Cylinder tool changer

Throttle valve

Throttle valve

Quick exhaust valve

Solenoid valve

Air pressure switch

-30-

Model G0876 (Mfd. Since 12/22)

3.4 First commissioning

3.4.1 Refilling the cooling lubricant

INFORMATION

The CNC machine is delivered without cooling lubricant.

 Fill the coolant / lubricant tank with an appropriate cooling lubricant via the machining room

CNC machine.

Img.3-3: Level indicator coolant / lubricant

ATTENTION!

Failure of the pumps in case of dry running. The pumps are lubricated by the cooling
lubricant. Do not start up the pumps without cooling lubricant.

"Cooling lubricants“ on page 243



Level indicator

INFORMATION

Use a water-soluble environmentally friendly emulsion as cooling lubricant procured
from a specialist retailer.

Make sure that the cooling lubricant is properly absorbed.
Respect the environment when disposing of lubricants and coolants. Follow the
manufacturer’s disposal instructions.

3.4.2 Cooling lubricants

INFORMATION

The lathe is lacquered with a one-component paint. Consider this fact when selecting your cool­ing lubricant.

The company Grizzly Industrial, Inc. does not assume any guarantee for subsequent
damages due to unsuitable cooling lubricants.

The flashpoint of the emulsion must be higher than 140°C.

When using non-water-miscible cooling lubricants (oil content > 15%) with a flashpoint, ignitable
aerosol air mixtures might develop. There is a potential danger of explosion.

The selection of cooling lubricants and slideway oils, lubricating oils or greases as well as their
care are being determined by the machine operator or operating company.

Therefore, Grizzly Industrial, Inc. cannot be held liable for machine damages caused by
unsuitable coolants and lubricants as well as by inadequate maintenance and servic-ing of the
coolant. In case of problems with the cooling lubricant and the slideway oil or grease, please
contact your mineral oil supplier.

Model G0876 (Mfd. Since 12/22)

-31-

CAUTION!

The cooling lubricant needs to be checked at least weekly, including during downtimes,
with regard to its concentration, ph-value, bacteria and fungal decay.

 "Cooling lubricants and tanks" on page 251

We would like to ask you to have the following machine-related properties of the cooling lubri­cant confirmed in writing by the manufacturer of the cooling lubricant.

 The products must comply with the provisions of the current statutory regulations and the

employers' liability insurance association.

 Request documentation for the products such as the product description VKIS and EC

safety data sheet from the cooling lubricants manufacturer. The EC safety data sheet gives
you information about the water hazard class.

They need to be environmentally friendly and workplace-friendly. Thus, they need to be free of
nitrite, PCB, chlorine and nitrosatable diethanolamine (DEA), according to TRGS 611.

 The manufacturer should be able to provide a certificate concerning skin tolerance.
 The mineral oil content according to DIN 51417 should be at least 40% in the concentrate.
 If possible, it should be universally applicable for all chippings and materials.
 Long service life of the emulsion e.g. long-term stable and resistant to bacteria.
 Safe corrosion protection according to DIN 51360/2.
 Re-emulsifiable and non-adhesive according to VKIS sheet 9: Sticking and residue behav-

iour.

 It should not attack the varnish of the machine according to VDI 3035.
 It should not attack any machine elements (metals, elastomers).
 Low foaming behaviour of the emulsion.
 It should be as finely dispersed as possible in order to avoid clogging in the needle slot

screen.

-32-

Model G0876 (Mfd. Since 12/22)

3.5 Refill central lubrication system

The CNC machine is equipped with a central lubrication system.

INFORMATION

The CNC milling machine is delivered without lubricating oil. The central lubrication system is
depending on the model in the working area on the column of the spindle or at other locations.

 Refill the reservoir with oil through the fill cap.

 "Cooling lubricants“ on page 243

Fill cap

Img.3-4: Old type of central lubricating system

Img.3-5: Second type of central lubricating system

Type: DRB 12210
Pressure 2.5 MPa
Power 10 Watt
Connection 230V ~ 50Hz / 115V ~ 60Hz
filling quantity 2 litres
discharge volume 96 ml / min

Fill cap

Model G0876 (Mfd. Since 12/22)

-33-

Setting the jumpers

Factory setting

30

5

prohibited

15

40

65

10

75

20

30

20

45

70

Switch-on time (seconds)

5

10

25

50

75

Interval (minutes)

30

55

80

35

60

85

90

INFORMATION

The factory setting is 75 minutes as the interval between lubrication cycles and
30 seconds for the ON period of the lubrication oil pump.

Operating indicator lights DRB 12210

Status Description Note:
In Operation The red LED lights Oil is supplied to the lubrication points
Idling cycle The red LED flashes Pause between the lubrication cycles

The pressure relief valve of the central lubrication system is factory set to a pressure of 2.5
MPa.

95

100

105

110

-34-

Model G0876 (Mfd. Since 12/22)

3.6 Functional test and controls

Rotation coolant pump

 Check the direction of rotation of the CNC machine. There must be a right-handed rotating

field. If the direction of rotation is wrong, exchange two of the three phase conductors. At
this, the correct direction of rotation only refers to the drive of the cooling lubricant pumps.

INFORMATION

The rotational direction of the coolant pump can not be checked in the built in state. If no cool­ant flows the rotational direction of the coolant pump may be wrong.

Proceeding to set the direction of rotation:

 

"Turning on the CNC- machine“ on page 55

 Close the sliding door and turn on the coolant supply.
 Check if cooling agent flows.

Img.3-6: Coolant supply

Coolant supply

WARNING!

Never change the dosing of the cooling lubricant supply when a program is running.

 If no coolant is flowing and thus the rotational direction of the coolant pump may be wrong,

- first check the coolant level in the coolant tank,

- and then replace two of three phases (e.g. L1 and L2) in the control cabinet on the circuit
breaker of the engine of coolant pump against each other.

WARNING!

Swapping the phases must be performed by a qualified electrician!

 Check all oil levels and filling levels of lubricants in the reservoirs.
 Perform a safety test.

3.6.1 Warming up the machine

ATTENTION!

If the CNC machine and in particular the milling spindle is immediately operated at
maximum load when it is cold it may result in damages.

If the machine is cold, e.g. directly after having transported the machine, it should be
warmed up at a spindle speed of only 500 1/min for the first 30 minutes.

Model G0876 (Mfd. Since 12/22)

-35-

4 General information about CNC

4.1 Compensation of geometry

It is necessary to be able to measure any currently actual position of the CNC-controlled axis in
order to perform tool moves on workpieces.The measured value is related to a machine fixed
zero position and is compared to the target position which is predefined by the programs.

Required knowledge:

 coordinate systems of the machine and workpiece
 reference points of the machine, tool and workpiece
 type of distance measurement
 options of dimensioning and dimension compensation

Basics:

For chip removal relative moves between the tool and the workpiece are required. For program­ming all moves are related to the resting workpiece.

4.2 Coordinate systems on CNC-machine tools

Types of coordinate systems

Coordinate systems allow the exact description of all points on a working plane, respectively in
an area.

Generally they are divided into

 Cartesian coordinate system and
 the polar coordinate system

4.2.1 Cartesian coordinate system

A Cartesian coordinate system also called a rectangular coordinate system possesses two
coordinate axes (two-dimensional Cartesian coordinate system) or also three coordinate axes
(three-dimensional Cartesian coordinate system) which are perpendicular to one another in
order to exactly describe the points.

On a two-dimensional Cartesian coordinate system, e.g. on the X, Y-coordinate system, each
point is clearly defined on the plane by indicating the coordinates (X,Y).

The distance from the Y-axis is called the X-coordinate and the distance from the X-axis is
called Y-coordinate. Those coordinates may possess positive or negative algebraic signs.

The three-dimensional Cartesian coordinate system is required to display and determine the
position of special workpieces, e.g. milling parts.

In order to clearly describe a point in the space, three coordinates are required which are
named according to the corresponding axes X-, Y- or Z-coordinates.

Such three-dimensional coordinate systems with positive and negative areas on the coordinate
axis allow the exact description of any locations, e.g. in the working area of a milling machine,
independent from where the zero point of the workpiece is set.

-36-

Model G0876 (Mfd. Since 12/22)

4.2.2 Polar coordinate system

In the Cartesian coordinate system a point is described by e.g. its X- and Y-coordinate. For
rotation-symmetric outlines, e.g. circular drilling images the required coordinates can only be
calculated with considerable effort.

In the polar coordinate system a point is described by means of its distance (radius r) to the
coordinate origin and its angle (a) to the defined axis. The angle (a) is related to the X-axis of
the X, Y coordinate system. In opposite direction it is negative.

4.2.3 Machine coordinate system

The machine coordinate system of the CNC machine tool is determined by the manufacturer. It
cannot be changed. The position of the origin point for the machine coordinate system, also
called machine zero point cannot be changed.

Any tool moves are generally defined in a standardized, right-handed coordinate system.

Turns from +X to +Y are created in +Z direction, which result in a right-handed screw.

Z-axis:

According to the standard it is
equal to the working spindle or
continues in positive direction
starting from the workpiece.For
milling it continues directed to the
spindle perpendicular on the
clamping surface (only for perpen­dicular milling machines) for sev­eral spindles one main spindle is
determined.

X-axis:

Continues horizontally and paral­lel to the clamping surface

for vertical Z-axis: +X to the right

for horizontal Z-axis: +X to the left
.

Img.4-1: Vertical Z-axis

Y-axis:

At a right angle to the Z- and X- axis in a way that a right-handed coordinate system is resulting

4.2.4 Workpiece coordinate system

The workpiece coordinate system is determined by the programmer. It can be changed. The
location of the origin point for this workpiece coordinate system, also called workpiece origin
point is generally user-defined.

Model G0876 (Mfd. Since 12/22)

-37-

4.2.5 Rotary axes and secondary axes

NC machines with rotary table or swivel head

Rotary axis: A B C

Positive turn around X, Y, Z (right- hand-rule)

NC machines with several feed axes

Secondary axis: U V W

Parallel to the X-,Y-,Z-axis

4.3 NC mathematics

4.3.1 Basics of the coordinate calculation

For the CNC programming the corresponding points of the outline which is to be machined
need to be entered. In most cases if the drawing is suitable for NC purposes, it is possible to
directly transfer these coordinate points from the drawing. In some cases it may be necessary
to calculate the coordinates.

In the frame of the automation those coordinates are calculated by an NC programming sys­tem at external working places and the data are directly transferred to the machine. Therefore,
in most cases the NC programming is directly performed on the product (3D pattern) in the con­struction or in the process engineering department.

For the computer-aided programming the switch and path information are entered over the key­board in the dialogue using the menu technique.

4.3.2 Parameters of a triangle

In order to calculate the missing coordinates the relations valid for a triangle are very useful.
There are several options to describe a triangle. Some of the following parameters e.g. corners,
angles or sides are being used.

4.3.3 Angle on a triangle

The angles on a triangle determine the type of triangle. Depending on the size of the individual
angles we distinguish between acute-angle, obtuse angle or rectangular triangles.

On triangles the following relation is applied:

the sum of the angles a, b and g in a triangle always amounts to 180°.

a + b + g = 180°

If two angles are known it is possible to determine the third unknown angle by means of this for­mula.

Rectangular triangle

The rectangular triangle has a special meaning in the analytic geometry as the sides of such a
triangle are having a definite mathematic relation to one another.

On a rectangular triangle the single sides are specially named.

 The longest side is located opposite to the right angle and is named hypotenuse.
 The two sides of the triangle which are forming the right angle are named cathetus.
 The side opposite the angle a is named opposite leg.
 The side adjacent to the angle a is named adjacent leg.

On a rectangular triangle the right angle is described by an quarter circle and a point in the
angle.

In a rectangular triangle it applies:

In a rectangular triangle you can calculate the missing leg if the other leg lengths are known. To
do so, use the Pythagorean theorem.

-38-

Model G0876 (Mfd. Since 12/22)

The Greek Pythagoras (from about 580 to 496 before Jesus Christ) had been the first person to

prove the following mathematic relation which had later on been named the Pythagorean the-

a

b

orem.

The sum of the cathetus square is equal to the hypotenuse square and expressed as a
equation:

a² + b² = c²

c

4.4 Trigonometric functions

The trigonometric functions describe the relations between the angles and the sides of a rec­tangular triangle. With the help of these trigonometric functions it is possible to calculate
unknown leg lengths with an unknown angle and a known leg. It is depending on which side
and which angle are known in order to choose the appropriate trigonometric function e.g. the
sinus function, the cosine function or the tangent function.

For the calculation of unknown legs the corresponding equation needs to be transformed as
described in the following example:

Known are: the angle and the length of the adjacent leg

Looking for: the length of the opposite leg

It applies: tan alpha = opposite leg / adjacent leg

The results is:

opposite leg = adjacent leg x tan alpha

Model G0876 (Mfd. Since 12/22)

-39-

5 User interface, machine control panel

5.1 Screen arrangement

1

8

2

9

3

10

4115126

13

7

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

1

2

5

6

7

3

8

10

11

12

Img.5-1: Screen arrangement

4

9

13

Status area Application area

Active operating area Actual value window

Active operating mode T, F, S window

Alarm and message prompt area

Operating window with program block
Mode Display / Data Display

Tip and softkey area

Current time and date

Program file name

Program status indication

Active program control modes

Information line

Horizontal softkey bar

Vertical softkey bar

-40-

Model G0876 (Mfd. Since 12/22)

5.2 Elements on the PPU (Panel Processing Unit) front

1

2

3

4

Img.5-2: Panel Processing Unit

Elements on the PPU

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

Vertical and horizontal softkeys

Calls specific menu functions

Return key

Returns to the next higher-level menu.

Description

Menu extension key

No function is assigned to this key. Reserved for future use.

Alphabetic and numeric keys

You use these keys to enter characters or NC commands.

Holding down <SHIFT> while pressing an alphabetic or numeric key
allows you to enter the upper character shown on the key.

Model G0876 (Mfd. Since 12/22)

-41-

Elements on the PPU

5

6

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

Description

Control keys

Shift key

Control key

Alternate key

Space key

Backspace key

Deletes a character selected to the left of the cursor.

Delete key

Deletes the selected file or character.

Insert key

Tab key

• Indents the cursor by several characters.

• Toggles between the input field and the selected program name.

Input key

• Confirms your entry of a value.

• Opens a directory or program.

Alarm cancel key

Cancels alarms and messages that are marked with this symbol

-42-

Model G0876 (Mfd. Since 12/22)

Elements on the PPU

7

8

9

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

Description

Menu function key

Opens the wizard main screen.

Help key

Calls the context-sensitive help for the selected window, alarm,
message, machine data, setting data, or end-user wizard.

Cursor keys

Cursor keys

up/down/left/right keys

Next window key

No function is assigned to this key. Reserved for future use.

End key

Moves the cursor to the end of a line.

Page up key

Scrolls upwards on a menu screen

Page down key

Scrolls downwards on a menu screen

Selection key

• Toggles in selection lists and selection fields between several
options.

• Enters the "Set-up menu" dialog at NC start-up.

Model G0876 (Mfd. Since 12/22)

-43-

Elements on the PPU

101112

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

Description

Operating area keys

Opens the "Machine" operating area

Opens the "Program" operating area

Opens the "Offset" operating area

Opens the "Program" operating area

USB interface

Status LEDs

Pressing this key opens the "Alarm" operating area.

Holding down <SHIFT> while you press this key opens the "System"
operating area.

Enables user's extension application, for example, to generate user
dialogs with the EasyXLanguage function.

For more information about this function, refer to the SINUMERIK 808D
Function Manual.

Connects to a USB device

Examples:

• Connects to an external USB memory sticker to transfer data
between the USB sticker and the CNC.

• Connects to an external USB keyboard for use as an external NC
keyboard.

LED "POK"

Lights up green: The power supply for the CNC is switched on.

LED "RDY"

Lights up green: The CNC is ready for operation.

LED "TEMP"

Unlit: The CNC temperature is within the specified range.

Lights up orange: The CNC temperature is out of range.

-44-

Model G0876 (Mfd. Since 12/22)

5.2.1 Key combination

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Opera­tion"

Element Description

<ALT> + <X> Opens the "Machine" operating area

<ALT> + <V> Opens the "Program" operating area

<ALT> + <C> Opens the "Offset" operating area

<ALT> + <B> Opens the "Program" operating area

<ALT> + <M>

<ALT> + <N>

<SHIFT> +

<ALT> + <H>

<ALT> + <L>

<ALT> + <S>

<=>

<CTRL> + <B> Selects text in program blocks.

<CTRL> + <C> Copies the selected text.

<CTRL> + <D> Shows pre-defined slides on the screen.

<CTRL> + <P> Captures screens

<CTRL> + <R> Restarts the HMI

<CTRL> + <S> Saves start-up archives

Opens the "Alarm" operating area

Opens the "System" operating area

Calls the online help system.

Enables input of lowercase letters.

Applicable only when the user interface language is Chinese.

Calls the input method editor for entering Chinese characters.

Calls the pocket calculator. Note that this function is not applicable in
MDA mode.

Model G0876 (Mfd. Since 12/22)

-45-

5.3 Controls on the machine control panel

1

89

10

5

6

7

2

Img.5-3: Machine control panel

Controls on the machine control panel

12

Element Function

34

Drive voltage

Push button with indicator light

• Indicator light On, drive voltage activated

• Indicator light Off, drive voltage deactivated

-46-

K11

Manual tool change

Enables or disables the manual tool change.

The manual tool change is only possible with the sliding door open.

Model G0876 (Mfd. Since 12/22)

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

1

2

3

4

5

Element Description

<Emergency stop button>

Activate the button in situations where

• life is at risk.

• there is the danger of a machine or workpiece being damaged.

All drives will be stopped with the greatest possible braking torque.

Handwheel key (with an LED status indicator)

Controls the axis movement with external handwheels.

Tool number display

Displays the current tool number

Operating mode keys (all with LED status indicators)

Operating mode "JOG"

Operating mode "REF. POINT" (reference point approach)

Operating mode "AUTO" (automatic mode)

Operating mode "MDA"

Manual program input, automatic execution

Program control keys (all with LED status indicators)

Program test key

Disables the output of setpoints to axes and the spindle. The
control system only "simulates" the traverse movements in order to
verify the correctness of the program.

Conditional stop key

Stops the program at every block in which miscellaneous function
M01 is programmed.

Model G0876 (Mfd. Since 12/22)

-47-

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

6

Element Description

Rapid override key

Adjusts axis feedrate override

Single block key

Activates single block execution mode

User-defined keys (all with LED status indicators)

Machine luminaire control key

Pressing this in any operating mode switches on/off the machine
luminaire.

LED on: The machine luminaire is switched on.

LED off: The machine luminaire is switched off.

Coolant control key

Pressing this key in any operating mode switches on/off the coolant
supply.

LED on: The coolant supply is switched on.

LED off: The coolant supply is switched off.

Safety door control key

When all axes and the spindle stop operation, pressing this key
unlocks the safety door.

LED on: The safety door is unlocked.

LED on: The safety door is locked.

Clock wise magazine rotation

(active only in JOG mode)

Pressing this key rotates the magazine clockwise.

LED on: The magazine rotates clockwise.

LED off: The magazine stops clockwise rotation.

Reference point approach of the magazine

(active only in JOG mode)

Pressing this key approaches the magazine to the reference point.

LED on: The magazine is reference point approached.

LED off: The magazine is not yet referenced.

Counterclockwise magazine rotation

(active only in JOG mode)

Pressing this key rotates the magazine counterclockwise.

LED on: The magazine rotates counterclockwise.

LED off: The magazine stops counterclockwise rotation.

-48-

Model G0876 (Mfd. Since 12/22)

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

7

Element Description

Forward rotation of the chip conveyor

(active only in JOG mode)

Pressing this key in any operating mode starts the forward rotation

of the chip conveyor.

LED on: The chip conveyor starts forward rotation.

LED off: The chip conveyor stops rotation.

INFORMATION

The G0876 does not have a chip conveyor. Therefore,

the key has no function.

Reverse rotation of the chip conveyor

(active only in JOG mode)

Keeping pressing this key in any operating mode rotates the chip
conveyor in reverse order.

Releasing the key changes the chip conveyor to the previous
forward rotation or stop state.

LED on: The chip conveyor starts reverse rotation.

LED off: The chip conveyor stops reverse rotation.

INFORMATION

The G0876 does not have a chip conveyor. Therefore,

the key has no function.

Axis traversing keys

User-defined keys

INFORMATION

The <K11> button is associated with the manual tool

change.

X axis key

Traverses the X axis in the positive direction.

X axis key

Traverses the X axis in the negative direction.

Z axis key

Traverses the Z axis in the negative direction.

Z axis key

Traverses the Z axis in the positive direction.

Model G0876 (Mfd. Since 12/22)

-49-

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

8

9

Element Description

Y axis key

Traverses the Y axis in the positive direction.

Y axis key

Traverses the Y axis in the negative direction.

Rapid traverse overlay key

Traverses the selected axis at rapid traverse speed while pressing
the relevant axis key.

Inactive key. No function is assigned to this key.

Incremental feed keys (with LED status indicators)

Sets increments desired for the axis to traverse.

Spindle control keys

Starts the spindle counterclockwise

Stops the spindle

Starts the spindle clockwise

Spindle speed override switch

Makes the spindle rotate at the specified speed override.

Program state keys

-50-

Model G0876 (Mfd. Since 12/22)

Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"

10

Element Description

Cycle stop key

Stops the execution of NC programs

Cycle start key

Starts the execution of NC programs

Reset key

Resets NC programs

Cancels alarms that meet the cancel criterion.

Feedrate override switch

Traverses the selected axis at the specified feed rate override.

5.4 Protection levels

SINUMERIK 808D provides a concept of protection levels for enabling data areas. Different
protection levels control different access rights.

The control system delivered from SIEMENS is set by default to the lowest protection level 7
(without password).

If the password is no longer known, the control system must be reinitialized with default
machine data. All passwords are then reset to default passwords for this software release.

ATTENTION!

Before you boot the control system with default machine data, make sure that you
havebacked up your data; otherwise, all data is lost after rebooting with the default
machine data.

Protection level Locked by Area

0 Siemens password Siemens, reserved

1 Manufacturer password Machine manufacturers

2 Reserved

3 - 6 End-user password

(Default password: "CUSTOMER")

End users

7 No password End users

Model G0876 (Mfd. Since 12/22)

-51-

Protection level 1

Protection level 1 requires a manufacturer password. With this password entry, you can per­form the following operations:

 Entering or changing all machine data
 Conducting NC commissioning

Protection level 3-6

Protection level 3-6 requires an end-user password. With this password entry, you can perform
the following operations:

 Entering or changing part of the machine data
 Editing programs
 Setting offset values
 Measuring tools

Protection level 7

Protection level 7 is set automatically if no password is set and no protection level interface sig­nal is set. The protection level 7 can be set from the PLC user program after you set the bits in
the user interface.

In the menus listed below the input and modification of data depends on the set protection
level:

 Tool offsets
 Work offsets
 Setting data
 RS232 settings
 Program creation / program correction

5.4.1 Passwords

INFORMATION

Usually the machine operator does not need to change the password.

5.4.2 Change passwords

Step 1

The service mode is opened with the appropriate key combination. In the service mode, the
password can be activated and deactivated.

 Press Shift+ System Alarm

Step 2

Set
password

Change
password

Delete
password

Enter customer’s or manufacturer’s password.

Change customer’s or manufacturer’s password.

Delete customer’s or manufacturer’s password.

Set
password

Change
password

Delete
password

-52-

Model G0876 (Mfd. Since 12/22)

6 Operation

6.1 Safety

Commission the CNC machine only under the following conditions:

 The CNC machine is in proper working order.
 The CNC machine is used as intended.
 The operating manual is followed.
 All safety devices are installed and activated.

Eliminate or have all malfunctions rectified promptly. Stop the CNC machine immediately in the
event of any failure in operation and make sure that it cannot be started up accidentally or with­out authorisation. Notify the person responsible immediately of any modification.

 "Safety during operation“ on page 18

6.2 Control and indicating elements

Img.6-1:

No

.

1

10

3

10

7

8

2

9

11

10

Designation

1 Touch-switch to release and clamp the tool.

2 Milling spindle

3 Tool change system incl. magazine disk

7 Milling table

8 Signal lamp (if the indicator lamp lights up green --> CNC- program is running)

9 Machine control panel

10 Emergency-stop button

Handwheel for manual travelling with Emergency Stop push button and acknowl-

11

edgement button

Model G0876 (Mfd. Since 12/22)

-53-

Signal lamp

Pos.

1

Colour Meaning

No.

6.3 Operational modes

Manually controlled operation

The manually controlled operation is possible in the "JOG" and "MDA" operating modes. Refer
to chapter "Manual mode" of the operating instructions of "SINUMERIK 808D".

In JOG mode, you can perform the following machining operations:

 Measuring tools
 Measuring the workpiece
 Setting parameters for face machining of a workpiece blank
 Setting the spindle speed and direction, activating other M function and changing the tool,
 Setting the axis positions in the relative coordinate system.

In MDA mode, you can create programs, load existing programs from directories in the "Pro­gram Manager" into the MDA buffer, or execute the current program.

Automatic mode

2

3

Red Lights up when activity the EMERGENCY STOP push button

1

Orange

2

Green

3

Lights up when a disturbance or in set-up operation such as

opened safety housing

Lights up in the operating mode "automatic mode" resp. "pro-

gram run"

Refer to chapter "Setup machine" of the operating instructions for "SINUMERIK 808D".

6.4 Programming

For further working steps please proceed as described in the operating instructions "Part pro­gramming, system, programming and cycles“ for SINUMERIK 808D.

Manual resp. part programming:

For this kind of programming, the programs must be created manually and entered in the con­trol unit. The direct programming in the DIN-Code is a complex method which requires lots of
skills. Nowadays this task is mostly taken over by CAD/CAM systems which directly create an
operating program using a graphical user interface.

Automatic programming:

Construction data are transmitted (semi-) automatically to an executable program by means of
the CAD/CAM program (for instance a 3D-CAD program including downstream co-processor).
For this kind of programming, a 3D model is designed using a PC. The motion-sequence of the
machine is calculated by means of an operating sequence which is predefined by the user.
These programs access the tool data base which includes all tool parameters (speed, feed,
diameter, etc.). Due to this systematic program structure, the user is able to create a complete
program in a short period of time without having any knowledge of the individual program com­mands and their syntax.

-54-

Model G0876 (Mfd. Since 12/22)

6.5 Operation of the machine

6.5.1 Turning on the CNC- machine

 Switch on the main switch. 
 Wait until the control is completely started.
 Press the push button "Drive control ON"
 Unlock the "Emergency Stop push buttons"

- on the spindle head (not visible in the picture),

- on the MCP,

- on the electronic handwheel.

 Close - if not yet closed - the sliding door.
 Press the push button "Reset" .

2

"Lockable main switch“ on page 15

1

.

2

.

3

1

3

2

Img.6-2: Operating area

6.5.2 Reference point approach after turning on

INFORMATION

After turning on the G0876 must first be referenced. Without existing reference
points (machine zero points) you cannot start and run programs in the control.

With the beginning of the reference point approach the axes should be located in a
central position as possible.

The following information indicated serve as preliminary information. Further
information can be found in the Siemens manual.

Model G0876 (Mfd. Since 12/22)

-55-

After switching on, the G0876 is in the mode reference

point approach area, the LED on the <REF POINT> button
lights.

As long as the axes are not referenced,
the symbol (circle) between the axis and
the corresponding value is displayed.

 The axes are referenced with the

"axis traversing keys."

Make sure that the "feed override switch"
is not set to "zero".

+

 Traverse each axis to the machine

zero point until the referenced sym­bol is shown on the respective axis.

Once the axis approaches the refer­ence point, the referenced symbol must
shown next to the axis.

+

+

-56-

Model G0876 (Mfd. Since 12/22)

After returning to the "JOG" mode, the axes can be moved

manually. Use the Increment button to specify the incre­ment, or press the <JOG> button again to stop the incre­ment again.

 If possible, read the upcoming mes-

sages on the display, remove the
error messages, such as e.g. insuffi-

cient compressed air, ....

 Default values for example should

apply for the feed rate in the "JOG"
mode, be entered on the side of the
standard values .
Press the button <OFFSET> to get
to the settings.

 For the following working steps,

please proceed as described in
„Operation and programming“ of the
Siemens SINUMERIK 808D Opera­tion instructions.

Model G0876 (Mfd. Since 12/22)

-57-

6.5.3 Using the electronic handwheel

The electronic handwheel can always be used when

 the CNC- machine is referenced,
 the LED on the button <HANDWHEEL> lights up.

Press the button <HANDWHEEL> on the machine control panel to use the electronic hand­wheel.

Pos.

No.

1

4

5

1

3

2

3

2

4

5

WARNING!

A manual movement of axes with open door is not possible. The G0876 has
no acknowledgment button to allow movement of axes with open slide door.

The lock switch on the slide door may only be unlocked for maintenance and repair
work.

Meaning Description

Rotary switch

Rotary switch

Hand wheel Hand wheel for individual axes travel.

<EMERGENCY

STOP button>

Push button/

acknowledge-

ment button

Selector switch for individual axes con-

trol.

Selector switch for the feed speed (3

stages).

The EMERGENCY STOP push button

switches off the CNC- machine.

In the setting mode it is necessary to

actuate the acknowledgement button

in order to expressively allow the
movement of the individual axes.

-58-

Model G0876 (Mfd. Since 12/22)

6.5.4 Insert tool

INFORMATION

Before you can run a CNC program, at least one tool must have been created and
measured in the tool memory.

 Change over to the mode <JOG>.

 Press the "Offset" key on the

machine control panel.

 Press the "Tool list" softkey
 For the following working steps,

please proceed as described in
„Operation and programming“ of
the Siemens SINUMERIK 808D
Operation instructions.

6.5.5 Manual tool change

ATTENTION!

Hold your tool if there is a tool inserted in the spindle.

 Press the push button "Open/Close door" and open the sliding door.
 Check that the LED on the push button <K11>lights up.

Press - if necessary - the push button <K11>. The manual tool change is
thereby enabled again.

 Press the push button "manual tool change" to loosen or to clamp the tool.

K11

Img.6-3: Spindle head

Model G0876 (Mfd. Since 12/22)

Push button manual
Changing the tool

-59-

6.5.6 Clamping the workpiece

ATTENTION!

The workpiece is always to be fixed by a machine vice, jaw chuck or by another
appropriate clamping tool such as for the clamping claws.

When setting and using already created programs observe the safety clearance in order
to avoid collisions with the selected clamping means.

WARNING!

Risk of injury caused by flying workpieces.

 Clamp the workpiece in the machine

vice.

 Make sure that the workpiece is firmly

clamped in the vise.

6.5.7 Manual tool change

ATTENTION!

Hold your tool if there is a tool inserted in the spindle.

 Press the push button "Open/Close door" and open the sliding door.
 Check that the LED on the push button <K11>lights up.

Press - if necessary - the push button <K11>. The manual tool change is
thereby enabled again.

 Press the push button "manual tool change" to loosen or to clamp the tool.

Workpiece

Machine vice

Img.6-4: Clamping the workpiece

K11

Img.6-5: Spindle head

-60-

Push button manual
Changing the tool

Model G0876 (Mfd. Since 12/22)

6.5.8 Turning off the CNC- machine

 Push the EMERGENCY stop push button.

For a long-term standstill of the CNC machine, switch it off at the main switch.



"Disconnecting and securing the CNC machine“ on page 19

6.6 Operational modes

Manually controlled operation

The manually controlled operation is possible in the "JOG" and "MDA" operating modes. Refer
to chapter 5 "Manual mode" of the operating instructions of "SINUMERIK 808D".

Automatic mode

Refer to chapter 6 "Setup machine" of the operating instructions for "SINUMERIK 808D".

6.7 Programming

For further working steps please proceed as described in the operating instructions "Part pro­gramming, system, programming and cycles“ for SINUMERIK 808D.

Manual resp. part programming:

For this kind of programming, the programs must be created manually and entered in the con­trol unit. The direct programming in the DIN-Code is a complex method which requires lots of
skills. Nowadays this task is mostly taken over by CAD/CAM systems which directly create an
operating program using a graphical user interface.

Automatic programming:

Construction data are transmitted (semi-) automatically to an executable program by means of
the CAD/CAM program (for instance a 3D-CAD program including downstream co-processor).
For this kind of programming, a 3D model is designed using a PC. The motion-sequence of the
machine is calculated by means of an operating sequence which is predefined by the user.
These programs access the tool data base which includes all tool parameters (speed, feed,
diameter, etc.). Due to this systematic program structure, the user is able to create a complete
program in a short period of time without having any knowledge of the individual program com­mands and their syntax.

DIN Code and ISO Code:

Use the procedure for switching or activating the programming language in the manual opera­tion and programming of the "SINUMERIK 808D".

6.8 Starting the program

Adjusting the dosing for the coolant supply on the spindle head before starting the program.
Any change in the dosing must only be performed during the setup operation. The requirement
of coolant supply is switched on over your CNC- programs.

WARNING!

Never change the dosing of the cooling lubricant supply and never seize into the
machine when a program is running.

CAUTION!

Before startin
must be closed.

 Completely close the separating protective equipment.
 Change to "AUTO/MDA" mode.

g the program, the sl

iding door of the separating protective equipment

Model G0876 (Mfd. Since 12/22)

-61-

For the following working steps, please proceed as described in „Operation and

programming“ of the Siemens "SINUMERIK 808D" Operation instructions.

V

6.9 Central lubrication system

The CNC machine is equipped with a central lubrication system.

The lubricating system is used to maintain an oil film on the slideways, the bearings, the ledges
and the ball screws and to reduce their wear.

In case of a failure or a fault in the central lubricating system, a stick-slip effect may occur. This
effect describes the jerky sliding of solid bodies moving opposite one another. For instance:
creaking doors and rattling windscreen wipers.

6.10 Data interfaces and current collection

When connecting data interfaces make sure that the data cable runs to the control unit interface
via the shortest possible distance. The cable routing can be conducted along the measuring
system lines. However the cable in the switch cabinet must never be routed near the drive units
of the NC axis or the frequency converter itself. Electromagnetic radiation causes errors during
data transfer (EMC problems).

The control is equipped with the following data interfaces.

 X130 Ethernet port (RJ45 connector, only 808D ADVANCED)
 USB connection
 Connection for power supply

6.11 Selecting the speed

The correct speed is an important factor for milling. The speed determines the cutting speed by
which the cutting edges cut the material. By selecting the correct cutting speed, the service life
of the tool is increased and the working result is optimized.

The optimum cutting speed mainly depends on the material and on the material of the tool. With
tools (milling cutters) made of hard metal or ceramic insert it is possible to work with higher
speeds than with tools made of high-alloy high speed steel (HSS). You will achieve the optimal
cutting speed by selecting the correct rotation speed.

In order to determine the correct cutting speed for your tool and for the material to be cut you
may refer to the following standard values or a table reference book.

The required speed is calculated as follows:

------------

n

=

 d

-1

n = speed in min

V = cutting speed in m/min (meter per minute)

d = tool diameter in m (Meter)

(revolutions per minute)

6.11.1 Standard values for cutting speeds

[ m/min ] with high-speed steel and hard metal in upcut milling.

Tool Steel Grey cast iron

Plain mill and side milling cutters [ m/min ]

Relieved form cutters [ m/min ] 15 - 24 10 - 20 150 - 250

-62-

10 - 25 10 - 22 150 - 350

Al

alloy

age-hardened

Model G0876 (Mfd. Since 12/22)

Inserted -tooth cutter with SS [ m/min ] 15 - 30 12 - 25 200 - 300

Inserted-tooth cutter with HM [ m/min ] 100 - 200 30 - 100 300 - 400

The results are the following standard values for speeds in dependence of the
milling cutter diameter, cutter type and material.

Tool diameter

[ mm ] shell end mill and

plain milling cutter

35 91 - 227 91 - 200 1365 - 3185

40 80 - 199 80 - 175 1195 - 2790

45 71 - 177 71 - 156 1062 - 2470

50 64 - 159 64 - 140 955 - 2230

Tool diameter

[ mm ]

Form cutters

4 1194 - 1911 796 - 1592 11900 - 19000

5 955 - 1529 637 - 1274 9550 - 15900

6 796 - 1274 531 - 1062 7900 - 13200

8 597 - 955 398 - 796 5900 - 9900

10 478 - 764 318 - 637 4700 - 7900

12 398 - 637 265 - 531 3900 - 6600

Steel

10 - 25 m/min

Steel

15 - 24 m/min

Grey cast iron

10 - 22 m/min

Speed [ min-1 ]

Grey cast iron

10 - 20 m/min

Speed [ min-1 ]

Al alloy

age-hardened

150 - 350 m/min

Al alloy

cured 150 - 250

m/min

14 341 - 546 227 - 455 3400 - 5600

16 299 - 478 199 - 398 2900 - 4900

6.11.2 Standard values for speeds with HSS – Eco – twist drilling

Material

Steel, unalloyed,

up to 600 N/mm

Structural steel, alloyed,
quenched and subsequently

drawn, up to 900N/mm

Structural steel, alloyed,
quenched and subsequently

drawn, up to 1200 N/mm

Stainless steels up to 900 N/

2

e.g. X5CrNi1810

mm

1): Speed [ n ] in r/min

2): Feed [ f ] in mm/r

3): Cooling: E = Emulsion; oil = cutting oil

2

2

2

2345678910

1)

5600 3550 2800 2240 2000 1600 1400 1250 1120

n

2)

0.04 0.063 0.08 0.10 0.125 0.125 0.16 0.16 0.20

f

1)

3150 2000 1600 1250 1000 900 800 710 630

n

2)

0.032 0.05 0.063 0.08 0.10 0.10 0.125 0.125 0.16

f

1)

2500 1600 1250 1000 800 710 630 560 500

n

2)

0.032 0.04 0.05 0.063 0.08 0.10 0.10 0.125 0.125

f

1)

2000 1250 1000 800 630 500 500 400 400

n

2)

0.032 0.05 0.063 0.08 0.10 0.10 0.125 0.125 0.16

f

Drill diameter Cooling

3)

E

E/oil

Oil

Oil

Model G0876 (Mfd. Since 12/22)

-63-



The above mentioned indications are standard values. In some cases it may be advanta-

geous to increase or decrease these values.

 When drilling a cooling or lubricating agent should be used.
 For stainless materials (e.g. VA – or NIRO steel sheets) do not center as the material would

compact and the drill bit will become rapidly blunt.

 The workpieces need to be tensed in flexibly and stably (vice, screw clamp).

INFORMATION

Friction during the cutting process causes high temperatures at the cutting edge of the tool. The
tool should be cooled during the milling process. By cooling with an appropriate coolant lubri­cant you will achieve a better working result and longer durability of the tool.

INFORMATION

Use a water-soluble and non-pollutant emulsion as a cooling agent. This can be acquired from
authorised distributors.

Make sure that the cooling agent is properly retrieved. Respect the environment when dispos­ing of any lubricants and coolants. Follow the manufacturer’s disposal instructions.

INFORMATION

The CNC milling machine is lacquered with a one-component paint. Observe this fact when
selecting your cooling lubricant.

-64-

Model G0876 (Mfd. Since 12/22)

7 Brief instruction 808D Milling

Basic Theory

The 808D panel
processing unit (PPU)
is used to input data
to the CNC and to
navigate to operating
areas of the system.

Operating area

navigation

The 808D machine control panel
(MCP) is used to select the
machine operating mode :

JOG - MDA - AUTO

Mode navigation

Menu navigation

PPU

Function of

keyboard

MCP mode

Changing

Basic knowledge of programming for milling is required, before operating
of a machine !

The information provided in this brief insruction contains merely general descriptions or
characteristics of performance which in actual case of use do not always apply as
described or which may change as a result of further development of the products.

This brief instruction is not the replacement for Siemens 808D manuals and only serves
as a reference for quickly find already-known operations and functions.

7.1 Preparation

Description

This unit describes the 808D PPU and MCP functionality, the coordinate system of a
milling machine and how to enter passwords to access the system.

Content

PPU

PPU

Function of

Function of

keyboard

keyboard

MCP mode

MCP mode

Changing

Changing

MCP

MCP

Moving

Moving axis

axis

coordinate

coordinate

Passwords

Passwords

User

User

interface

interface

Machine

Machine

system

system

MCP

MCP
OEM

OEM
keys

Model G0876 (Mfd. Since 12/22)

End

-65-

Basic Theory

PPU

Function of

keyboard

The 808D panel
processing unit (PPU)
is used to input data
to the CNC and to
navigate to operating
areas of the system.

Menu navigation

MCP mode

Changing

The 808D machine control panel
(MCP) is used to select the
machine operating mode :

JOG - MDA - AUTO

Operating area

navigation

Mode navigation

-66-

Model G0876 (Mfd. Since 12/22)

Preparation

MCP

808D (PPU) has eight
vertical softkeys (abbr.
SKs) on the right of the
screen. These SKs can
be activated with the
corresponding button
(located on the right).

808D (PPU) has eight horizontal SKs on the bottom of the screen. These SKs can
be activated with the corresponding button (located below).

User

interface

Axis

feedrate

Act. val.
REL

Act. val.
Work(WCS)

Meas.
tool

Meas.
work.

Set
REL

Face
cutt.

Sett.T,S,M

Moving

axis

Axis movement

The 808D machine control panel (MCP)
is used to control manual operation of the
axis.

The machine can be moved with the
appropriate keys.

MCP
OEM

keys

The 808D machine control panel (MCP)
is used to control OEM machine
functions.

The machine functions can be activated
with the appropriate keys.

OEM keys

Model G0876 (Mfd. Since 12/22)

-67-

User

interface

Axis

feedrate

808D (PPU) has eight
vertical softkeys (abbr.
SKs) on the right of the
screen. These SKs can
be activated with the
corresponding button
(located on the right).

Act. val.
REL

Act. val.
Work(WCS)

Meas.
work.

Meas.
tool

Set
REL

Face
cutt.

Sett.T,S,M

808D (PPU) has eight horizontal SKs on the bottom of the screen. These SKs can
be activated with the corresponding button (located below).

-68-

Model G0876 (Mfd. Since 12/22)

Preparation

SEQUENCE

Machine

Step 1

Step 2

Passwords at the control are used to set the user’s right to
access the system. Tasks such as ”Basic Operating”,
“Advanced Operating” and commissioning functions all
depend on the passwords.

No password

Customer’s password

Manufacturer’s password

Customer’s password = CUSTOMER

Manufacturer’s password = SUNRISE

Machine operator

Advanced operator

OEM engineer

Changing
password

The service mode is opened with the
appropriate key combination.
In the service mode, the password
can be activated and deactivated.

Enter customer’s or manufacturer’s password

Change customer’s or manufacturer’s password

Delete customer’s or manufacturer’s password

Usually the machine, operator does not need to change the
password.

End

+

Passwords

Set
password

Change
password

Delete
password

Set
password

Change
password

Delete
password

coordinate

system

The Sinumerik 808D uses a
coordinate system which is
derived from the DIN 66217
standard.

The system is an international
standard and ensures
compatibility between machines
and coordinate programming.

The primary function of the
coordinate system is to ensure
that the tool length and tool
radius are calculated correctly in
the respective axis.

Model G0876 (Mfd. Since 12/22)

-69-

SEQUENCE

Passwords

Passwords at the control are used to set the user’s right to
access the system. Tasks such as ”Basic Operating”,
“Advanced Operating” and commissioning functions all
depend on the passwords.

No password

Customer’s password

Manufacturer’s password

Customer’s password = CUSTOMER

Changing

Manufacturer’s password = SUNRISE

password

Step 1

Usually the machine, operator does not need to change the
password.

The service mode is opened with the
appropriate key combination.
In the service mode, the password
can be activated and deactivated.

Step 2

Machine operator

Advanced operator

OEM engineer

+

Set
password

Change
password

Delete
password

Set
password

Change
password

Delete
password

End

Enter customer’s or manufacturer’s password

Change customer’s or manufacturer’s password

Delete customer’s or manufacturer’s password

-70 -

Model G0876 (Mfd. Since 12/22)

Switch On and Referencing

7.2 Switch On and Referencing

SEQUENCE

Please note the explicit switching on rules as specified by the
machine manufacturer.

Turn on the main switch of the machine.

Make sure you perform the following operation!

Step 1

Step 2

End

Switch on

the machine

PPU

Function of

keyboard

Switch on

the

machine

Release all the EMERGENCY STOP
buttons on the machine!

Description

This unit describes how to switch the machine on and reference it.

Content

Switch on

Switch on

PPU

the

the machine

Function of

machine

keyboard

MCP mode

Reference

Changing

the

machine

End

Model G0876 (Mfd. Since 12/22)

-71-

SEQUENCE

Switch on

Switch on

PPU

the machine

the

Function of

machine

keyboard

Please note the explicit switching on rules as specified by the
machine manufacturer.

Turn on the main switch of the machine.

Make sure you perform the following operation!

Step 1

Step 2

Release all the EMERGENCY STOP
buttons on the machine!

-72-

End

Model G0876 (Mfd. Since 12/22)

Switch On and Referencing

SEQUENCE

MCP mode

After completing the referencing procedure for
all axes, the referenced symbol is displayed
next to the axis identifier.

After returning to JOG mode, use the axis
traversing keys to move the machine manually.

The machine can now be operated in JOG
mode.

During normal operation (JOG),the referenced
symbol is not shown on the screen.

Step 3

End

Reference

Changing

machine

Step 1

the

If your machine is configure with ABS encoder, you
do not need to reference the axis of the machine.

If your machine is fitted with INC encoder, After
power on, the machine must first be referenced!

Step 2

After power on, the machine will be in the
reference point approach mode (default).

If the axis is not referenced, the non­referenced symbol (circle) is displayed
between the axis identifier and the value.

The axes are referenced with the
corresponding axis traversing keys.

The traversing direction and keys are
specified by the machine manufacturer.

Model G0876 (Mfd. Since 12/22)

-73 -

Switch On and Referencing

After completing the referencing procedure for
all axes, the referenced symbol is displayed
next to the axis identifier.

Step 3

End

After returning to JOG mode, use the axis
traversing keys to move the machine manually.

The machine can now be operated in JOG
mode.

During normal operation (JOG),the referenced
symbol is not shown on the screen.

-74 -

Model G0876 (Mfd. Since 12/22)

Tool Setup

7.3 Tool Setup

SEQUENCE

Please make sure the system is in JOG mode.

Press “Offset” on the PPU.

Press the “Tool list” SK on the PPU.

A tool must have been created and measured
before executing the program.

Step 1

Create

tool

Tool
list

Description

This unit describes how to create and set up tools.

Content

Create

tool

Create tool

edge

Load tool into

active

position

Move

machine with

handwheel

Start

spindle

Measure

tool

Machine

JOG

coordinate

spindle

system

User

Execute M

interface

function

End

Model G0876 (Mfd. Since 12/22)

-75-

SEQUENCE

Create

tool

A tool must have been created and measured
before executing the program.

Step 1

Please make sure the system is in JOG mode.

Press “Offset” on the PPU.

Press the “Tool list” SK on the PPU.

Tool
list

-76-

Model G0876 (Mfd. Since 12/22)

Tool Setup

SEQUENCE

Step 2

A tool must have been created and selected
before creating a tool edge!

Use “D” code to specify the tool edge. The system activates tool edge
no. 1 per default at the start.

Press the “Offset” key on the PPU.

Press the “Tool list” SK on the PPU.

Or

Use direction keys to select the tool which

needs to add a tool edge.

Press the “Edges” SK on the PPU.

Press the “New edge” SK on the PPU.

Step 1

Create

tool edge

User
data

Work
offset

R
var.

Set
data

Tool
wear

Tool
list

Lenght1

Radius

Geometry

Tool list

Type

Back

New
edge

Reset
edge

Delete
edge

Tool
list

Edges

New

edge

The range of tool numbers which can be created
by this system is 1 ~32000.

The machine can be loaded with a maximum of
64 tools / 128 tool edges.

Press the “New tool” SK on the PPU.

Select the type of tool required.

Tool list

Tool No.:

Enter the ”Radius” of the milling tool.

milling tool

Press the “OK” SK on the PPU.

Enter “1” at “Tool No.”

New milling tool

Identifier

New
tool

Milling

tool

Drilling

tool

Tapping

tool

Ball end

mil. tool

Press the “Input” button on the PPU.

Model G0876 (Mfd. Since 12/22)

-77-

Create

tool edge

A tool must have been created and selected
before creating a tool edge!

Step 1

Use “D” code to specify the tool edge. The system activates tool edge
no. 1 per default at the start.

Press the “Offset” key on the PPU.

Press the “Tool list” SK on the PPU.

Use direction keys to select the tool which

needs to add a tool edge.

Tool list

Type

Lenght1

Geometry

Radius

New
edge

Reset
edge

Delete
edge

Tool
list

Or

Tool
list

Tool
wear

Work
offset

Press the “Edges” SK on the PPU.

Press the “New edge” SK on the PPU.

R
var.

Set
data

Back

User
data

Edges

New

edge

-78 -

Model G0876 (Mfd. Since 12/22)

Tool Setup

SEQUENCE

The red circle shows the actual active tool
many tool edges have been created and the related data for each tool edge.

Step 2

Load tool into

Spindle

A tool must have been created in the system
before it can be loaded into the active position.

Press the “Machine” key on the PPU

Press “CYCLE START” on the MCP

Press the “Back” SK on the PPU

Press the “JOG” key on the MCP

Press the “T.S.M” SK on the PPU

Enter tool number “1” in “T”

T,S,M

Tool change
Spindle speed

Spindle direction
Activate zerooffset

Other M function

rpm

Back

Sett.

Meas.
tool

Meas.
work.

Set

rel

Face

cutt.

Press ´CYCLE START´

to activate above functions.

back

A new tool edge can be added in this way and different lengths and radii can be
entered as required.

and tool edge,the purple circle shows how

Tool list

Type

Lenght1

Geometry

Radius

Active tool no

Tool
list

Tool
wear

Work
offset

R
var.

Sett.

data

A maximum of nine tool edges can be created for each tool!

Different tool lengths and radii can be saved in different tool edges as
required.

Please select the right tool edge for machining according to
requirement!

New
edge

Reset
edge

Delete
edge

Back

User
data

Model G0876 (Mfd. Since 12/22)

-79 -

Load tool into

Spindle

T,S,M

Tool change
Spindle speed
Spindle direction
Activate zerooffset
Other M function

Press ´CYCLE START´

Set
rel

A tool must have been created in the system
before it can be loaded into the active position.

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Press the “T.S.M” SK on the PPU

Enter tool number “1” in “T”

rpm

to activate above functions.

Meas.
work.

Meas.
tool

Face
cutt.

Back

Sett.

Press “CYCLE START” on the MCP

Press the “Back” SK on the PPU

back

-80-

Model G0876 (Mfd. Since 12/22)

Tool Setup

SEQUENCE

The tool are usually loaded manually into the spindle.

The tool will be automatically

A handwheel can control the axis motion instead of the “JOG” button.

Move

Select the required override increment

according to the buttons on the right(this

selection fits all axes)

The handwheel increment is “0.001 mm”

The handwheel increment is “0.010 mm”

The handwheel increment is “0.100 mm”

The selected axis can now be moved with the handwheel.

Press “JOG” on MCP to end the function of

“Handwheel”.

Notes: If set the MD14512[16]=80, the system will deactivate the function of
MCP for selecting the axis of handwheel, the user will have to activate
“Handwheel” function with PPU softkey.

Select the required axis on
the right of the PPU; the
selected axis is shown with a

√

Handwheel

Handwheel

Axis

Number

machine with

handwheel

loaded into the spindle with an automatic tool changer.

Make sure there is no obstruction when moving
the tool to avoid a crash.

Press the “Machine” key on the PPU

Press the “Handwheel” key on the MCP

Select the axis you want to move with the

appropriate keys. on the MCP

Under “WCS” or
“MCS” state, a handwheel will be shown beside
the axis symbols, showing the axis is chosen,
and can be controlled with a handwheel.

Model G0876 (Mfd. Since 12/22)

-81-

Select the required override increment

according to the buttons on the right(this

selection fits all axes)

The handwheel increment is “0.001 mm”

The handwheel increment is “0.010 mm”

The handwheel increment is “0.100 mm”

The selected axis can now be moved with the handwheel.

Press “JOG” on MCP to end the function of

“Handwheel”.

Notes: If set the MD14512[16]=80, the system will deactivate the function of
MCP for selecting the axis of handwheel, the user will have to activate
“Handwheel” function with PPU softkey.

Handwheel

Axis

Number

Handwheel

Select the required axis on
the right of the PPU; the
selected axis is shown with a

√

-82-

Model G0876 (Mfd. Since 12/22)

Tool Setup

SEQUENCE

Start the spindle before adjusting tools as follows:

Press “Reset” on the MCP to stop the spindle

rotation

Press the “Back” SK on the PPU

A tool must have been created and loaded
before it can be measured!

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Press the “Meas. tool” SK on the PPU

Press the “Measure manual” SK on the PPU

Measure length

OPTIMUM

Step 1

Measure

tool

Meas-
tool

Measure

manual

back

Select “M3” using the “Select” key on the PPU

Start

spindle

A tool must have been loaded and rotated to the
position.

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Press the “T.S.M” SK on the PPU

Enter “500” at “Spindle speed”

T,S,M

Tool change
Spindle speed
Spindle direction
Activate zerooffset
Other M function

Press ´CYCLE START´

Set
rel

rpm

to activate above functions.

Meas.
work.

Press the “CYCLE START” key on the MCP

Meas.
tool

Face

cutt.

Back

Sett.

Model G0876 (Mfd. Since 12/22)

-83-

Press “Reset” on the MCP to stop the spindle

rotation

OPTIMUM

Press the “Back” SK on the PPU

Measure

tool

A tool must have been created and loaded
before it can be measured!

Step 1

Measure length

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Press the “Meas. tool” SK on the PPU

Press the “Measure manual” SK on the PPU

back

Meas­tool

Measure
manual

-84-

Model G0876 (Mfd. Since 12/22)

Tool Setup

SEQUENCE

Press the axis keys on the MCP to move

Use “SELECT” key to set the reference point as

“workpiece” (In real measurement, the reference

point can be set as either “workpiece” or “ fixed

point” if required.)

Enter “0” for “Z0”

(If the setting block is used, then the value would

be thickness a)

Press the “Set length” SK on the PPU

The measured tool length is now shown in “Length (L)”. This value is also saved in the
length value column of the corresponding tool list at the same time.

Measure diameter

Press the “Diameter” SK on the PPU

Step 2

Set

length

Diameter

Tool measurement maual

Use workpiece

Ref. point

Workpiece

Length (L)

Set
REL

Meas.
work.

Meas.
tool

Face
cutt.

Sett.

Back

Set

length

the tool to the set position above the

workpiece.

Note: The following text describes the required
settings in the workpiece coordinate system

“X / Y / Z” zero points as:“X0” / “Y0” / “Z0”

Press the “Handwheel” key on the MPC

and position the tool at location Z0 or a of

the workpiece.

Move directly to zero point

or

a

Use a setting block.

Model G0876 (Mfd. Since 12/22)

-85-

Use “SELECT” key to set the reference point as

“workpiece” (In real measurement, the reference

point can be set as either “workpiece” or “ fixed

point” if required.)

Enter “0” for “Z0”

(If the setting block is used, then the value would

be thickness a)

Tool measurement maual

Ref. point

Length (L)

Set
REL

Meas.
work.

Meas.

tool

Press the “Set length” SK on the PPU

The measured tool length is now shown in “Length (L)”. This value is also saved in the
length value column of the corresponding tool list at the same time.

Step 2

Measure diameter

Press the “Diameter” SK on the PPU

Use workpiece

Workpiece

Face
cutt.

Set
length

Back

Sett.

Set
length

Diameter

-86-

Model G0876 (Mfd. Since 12/22)

Tool Setup

SEQUENCE

Press the axis keys on the MCP to move

Enter “0” at “X0”

Enter “0” at “Y0”

(This is the value of the width of a setting block if it

is used.Select one of X0/Y0 according to

requirement.)

Press the ”Set diameter” SK on the PPU

Press the “Back” SK on the PPU

Set

diameter

Tool measurement manual

Workpiece edge

Diameter

Meas.
tool

Meas.
work.

Set
rel

Face
cutt.

Set
diameter

Back

Sett.

back

the tool to the set position.

Press the “Handwheel” key on the MCP

and position the tool at the location

X0 or a of the workpiece.

Move directly to zero point

or

Use a setting block.

a

Model G0876 (Mfd. Since 12/22)

-87-

Enter “0” at “X0”

Enter “0” at “Y0”

(This is the value of the width of a setting block if it

is used.Select one of X0/Y0 according to

requirement.)

Tool measurement manual

Set
rel

Press the ”Set diameter” SK on the PPU

Press the “Back” SK on the PPU

Workpiece edge

Diameter

Meas.
work.

Meas.
tool

Face
cutt.

Set
diameter

Back

Sett.

Set
diameter

back

-88-

Model G0876 (Mfd. Since 12/22)

Please make sure all the machine axes are in
safe positions before executing the M function!

Press the “Machine” key on the PPU

Press the “T.S.M” SK on the PPU.

Use the direction key to move the highlighted

cursor to “Other M function” and enter “8”. This

will start the coolant.

Press “CYCLE START” on the MCP.

The coolant function button on MCP is active.

Press the “Reset” key on the MCP to stop the

coolant function.

Press the “Back” SK on the PPU.

User

interface

Execute M

function

T,S,M

Tool change

Spindle speed
Spindle direction
Activate zerooffset

Other M function

rpm

Back

Sett.

Meas.

tool

Meas.
work.

Set

rel

Face
cutt.

Press ´CYCLE START´

to activate above functions.

8

SEQUENCE

Machine

JOG

coordinate

spindle

system

A tool must be loaded to the spindle.

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Press the spindle direction key on the MCP to

start/stop the spindle.

Press “Spindle left” on the MCP to start the

spindle in the counter-clockwise direction.

Press “Spindle stop” on the MCP to stop the

spindle.

Press “Spindle right” on the MCP to start the

spindle in the clockwise direction.

Model G0876 (Mfd. Since 12/22)

-89-

Tool Setup

User

Execute M

interface

function

Please make sure all the machine axes are in
safe positions before executing the M function!

Press the “Machine” key on the PPU

Press the “T.S.M” SK on the PPU.

Use the direction key to move the highlighted

cursor to “Other M function” and enter “8”. This

will start the coolant.

T,S,M

Tool change
Spindle speed
Spindle direction
Activate zerooffset
Other M function

Press ´CYCLE START´

Set

rel

8

rpm

to activate above functions.

Meas.
work.

Meas.

tool

Press “CYCLE START” on the MCP.

The coolant function button on MCP is active.

Press the “Reset” key on the MCP to stop the

coolant function.

Back

Face
cutt.

Sett.

-90-

Press the “Back” SK on the PPU.

Model G0876 (Mfd. Since 12/22)

Workpiece Setup

7.4 Workpiece Setup

Description

SEQUENCE

A tool must have been loaded into the spindle.

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Before measuring, the spindle can be started as follows:

Press the “T.S.M” SK on the PPU.

Enter “500” at “Spindle speed”

Select “M3” using the “Select” key on the PPU

Press the “CYCLE START” key on the MCP

Manual

start

spindle

T,S,M

T,S,M

Tool change
Spindle speed
Spindle direction
Activate zerooffset
Other M function

rpm

Back

Sett.

Meas.

tool

Meas.
work.

Set

rel

Face
cutt.

Press ´CYCLE START´

to activate above functions.

500

M3

This unit describes how to set the workpiece offset and test the tool results.

Content

Manual

start

spindle

Create

workpiece

offset

Test tool

offset results

End

Model G0876 (Mfd. Since 12/22)

-91-

SEQUENCE

Before measuring, the spindle can be started as follows:

T,S,M

Manual

start

spindle

A tool must have been loaded into the spindle.

Press the “Machine” key on the PPU

Press the “JOG” key on the MCP

Press the “T.S.M” SK on the PPU.

Enter “500” at “Spindle speed”

Select “M3” using the “Select” key on the PPU

T,S,M

Tool change
Spindle speed
Spindle direction
Activate zerooffset
Other M function

Press ´CYCLE START´

Set

rel

500

M3

rpm

to activate above functions.

Meas.
work.

Meas.
tool

Face

cutt.

Back

Sett.

-92-

Press the “CYCLE START” key on the MCP

Model G0876 (Mfd. Since 12/22)

Workpiece Setup

SEQUENCE

A tool must have be created and measured
before it can be used to set the workpiece
offset.

Make sure the active tool is the measured tool!

As the following red frame shows, 808D provides the user with three methods of using
tools to simplify the operating process.

Press the “Machine” key on the PPU.

Press the “JOG” key on the MCP.

Press the “Meas. work.” SK on the PPU.

Create

workpiece

offset

Meas.
work.

T,S,M

Set
rel

Meas.
work.

Meas.
tool

Face
cutt.

Back

Sett.

Press “Reset” on the MCP to stop the spindle

Press the “Back” SK on the PPU

rotation

Model G0876 (Mfd. Since 12/22)

-93-

Create

workpiece

offset

A tool must have be created and measured
before it can be used to set the workpiece
offset.

Make sure the active tool is the measured tool!

Press the “Machine” key on the PPU.

Press the “JOG” key on the MCP.

Press the “Meas. work.” SK on the PPU.

Meas.
work.

As the following red frame shows, 808D provides the user with three methods of using
tools to simplify the operating process.

Back

T,S,M

Set
rel

Meas.
work.

Meas.
tool

Face
cutt.

Sett.

-94-

Model G0876 (Mfd. Since 12/22)

Workpiece Setup

SEQUENCE

This method is normally for setting the zero point of the workpiece at the

Using a tool that has a measured “Tool leng
position on the workpiece. Using either JOG or Handwheel, scratch an edge and then
calculate the zero point of the workpiece.

The process of setting the “X” zero point (“X0”) is described below.

Method 1

Press the “Handwheel” key
on the MCP to position the
tool at the X0 edge of the
workpiece.

Select “Save in” Offset “G54” (or other

offset).

Select “Measuring direction” as “-”.

(This value should be chosen according to

realities)

Set “Distance” as “0”.

Press the “Set WO” SK on the PPU.

“Step 2” must be repeated for the setting of Y and Z zero points.

If you change the tool because of wear/damage during the machining process, you
must remeasure the length of the tool.

Set
WO

edge of the workpiece.

th & radius”, move the tool to a known

Press the corresponding SK of the first icon on

the right-hand side of the PPU.

Press the appropriate SK to select the feed axis

which needs to be set up.

Press the axis traverse keys to move the tool to

the required setting position in the X axis.

Model G0876 (Mfd. Since 12/22)

-95-

Press the “Handwheel” key
on the MCP to position the
tool at the X0 edge of the
workpiece.

Select “Save in” Offset “G54” (or other

offset).

Select “Measuring direction” as “-”.

(This value should be chosen according to

realities)

Set “Distance” as “0”.

Press the “Set WO” SK on the PPU.

Set
WO

“Step 2” must be repeated for the setting of Y and Z zero points.

If you change the tool because of wear/damage during the machining process, you
must remeasure the length of the tool.

-96-

Model G0876 (Mfd. Since 12/22)

Workpiece Setup

SEQUENCE

This method is normally used for setting the workpiece zero point at the

Using tools with a measured “length and radius
rectangular workpiece. Using either JOG
calculate the zero point of the workpiece.

This method is normally used for setting the zero points at the center
point of a circular workpiece.

Using tools with a measured “length and radius”, move them to the three edges of the
circular workpiece. Using either JOG or Handwheel, scratch an edge and then calculate
the zero point of the workpiece.

Press the corresponding SK of the third icon on

the right-hand side of the PPU.

Press the ”Save P1” SK on the PPU to save the

coordinate axis of the 1st position in the system.

Observing the figure on the PPU, move the coordinate axis following the orange arrow
to move the tool to the specified position and scratch the edge of the workpiece.

Repeat the process for positions 2 and 3.

(When the setting is complete, the buttons will be

shown in blue.)

Press the “Set WO” SK on the PPU.

You have then finished
setting the zero point of
the workpiece as the
center point of the circular
workpiece.

Method 3

Save P1

Set
WO

Save P1

Save P2

Save P3

Workpiece measurement, center of circle

Work offset

Offset

Compensation data have been activated!

T,S,M

Set

rel

Meas.
work.

Meas.
tool

G54

Face
cutt.

Back

Sett.

Set

WO

Method 2

center point of a rectangular workpiece.

”, move them to the four edges of the

or Handwheel, scratch an edge and then

Press the corresponding SK of the second icon on

the right-hand side of the PPU.

Observing the figure on the PPU, move the coordinate axis following the orange arrow
to move the tool to the specified position and scratch the edge of the workpiece.

Save P1

Press the ”Save P1” SK on the PPU to save the

coordinate axis of the 1st position in the system.

Repeat the process for positions 2, 3 and 4.

(When the setting is complete, the buttons will be

shown in blue.)

Save P1

Save P2

Save P3

Save P4

Press the “Set WO” SK on the PPU.

You have then finished

Set
WO

setting the zero point of

Workpiece measurement, center of rectangle

Work offset

Offset

Compensation data have been activated!

T,S,M

Set
rel

Meas.
work.

Meas.
tool

G54

Face
cutt.

Save P4

Set
WO

Back

the workpiece as the
center point of the
rectangular workpiece.

Sett.

Model G0876 (Mfd. Since 12/22)

-97-

This method is normally used for setting the zero points at the center

Method 3

point of a circular workpiece.

Using tools with a measured “length and radius”, move them to the three edges of the
circular workpiece. Using either JOG or Handwheel, scratch an edge and then calculate
the zero point of the workpiece.

Press the corresponding SK of the third icon on

the right-hand side of the PPU.

Observing the figure on the PPU, move the coordinate axis following the orange arrow
to move the tool to the specified position and scratch the edge of the workpiece.

Press the ”Save P1” SK on the PPU to save the

coordinate axis of the 1st position in the system.

Repeat the process for positions 2 and 3.

(When the setting is complete, the buttons will be

shown in blue.)

Press the “Set WO” SK on the PPU.

You have then finished

Workpiece measurement, center of circle

Work offset

Offset

Compensation data have been activated!

T,S,M

Set

rel

Meas.
work.

Meas.
tool

G54

Face
cutt.

Set
WO

Back

setting the zero point of
the workpiece as the
center point of the circular
workpiece.

Sett.

Save P1

Save P1

Save P2

Save P3

Set
WO

-98-

Model G0876 (Mfd. Since 12/22)