mori seiki NC LATHES User Manual
FOR SAFE OPERATION
Applicable Model
NC LATHES
(CE COMPATIBLE)
This FOR SAFE OPERATION describes fundamental safety information for safe
operation. Be sure to read this information before operating the machine.
And also, keep this FOR SAFE OPERATION carefully so that it will not be lost.
SO-CENL-H2EN
• The contents of this manual are subject to change without notice due to
improvements to the machine or in order to improve the manual.
Consequently, please bear in mind that there may be slight discrepancies
between the contents of the manual and the actual machine. Changes to
the instruction manual are made in revised editions which are
distinguished from each other by updating the instruction manual number.
• Should you discover any discrepancies between the contents of the
manual and the actual machine, or if any part of the manual is unclear,
please contact Mori Seiki and clarify these points before using the
machine. Mori Seiki will not be liable for any damages occurring as a
direct or indirect consequence of using the machine without clarifying
these points.
• All rights reserved: reproduction of this instruction manual in any form, in
whole or in part, is not permitted without the written consent of Mori Seiki.
The product shipped to you (the machine and accessory
equipment) has been manufactured in accordance with the laws
and standards that prevail in the relevant country or region.
Consequently it cannot be exported, sold, or relocated, to a
destination in a country with different laws or standards.
The export of this product is subject to an authorization from the
government of the exporting country.
Check with the government agency for authorization.
990730
SIGNAL WORD DEFINITION
A variety of symbols are used to indicate different types of warning information and advice.
Learn the meanings of these symbols and carefully read the explanation to ensure safe operation
while using this manual.
<Symbols related with warning>
The warning information is classified into three categories, DANGER, WARNING, and CAUTION.
The following symbols are used to indicate the level of danger.
DANGER
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or damages to the machine.
The information described following the caution symbol must be strictly observed.
<Other symbols>
NOTE
Indicates the items that must be taken into consideration.
Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
The information described in the DANGER frame must be strictly
observed.
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
The information described in the WARNING frame must be strictly
observed.
CONTENTS
1 FOR SAFE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
2 DANGEROUSNESS OF MACHINE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
3 CONSIDERATIONS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . P-6
3-1 Before Using the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
3-2 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-12
4 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-16
5 PRECAUTIONS ON MACHINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-18
5-1 Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-18
5-2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-19
5-3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-20
5-4 Air Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-20
5-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-21
5-6 Points to Check Before Turning ON the Power for the First Time . . . . . . . . . . . P-23
5-7 Points to Check After Turning ON the Power for the First Time. . . . . . . . . . . . . P-24
6 TURNING THE POWER ON AND OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25
6-1 Before Turning the Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25
6-2 After Turning the Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-26
6-3 When Turning the Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-27
7 SAFETY PRACTICES DURING SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-28
7-1 Safety Practices when Mounting/Removing a Chuck . . . . . . . . . . . . . . . . . . . . P-37
8 SAFETY PRACTICES WHEN CHUCKING A WORKPIECE . . . . . . . . . . . . . . . . . . . . P-39
9 SAFETY PRACTICES DURING MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . P-45
10 SAFETY PRACTICES DURING PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . P-50
11 TO ENSURE HIGH ACCURACY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-55
12 SAFETY PRACTICES DURING MAINTENANCE AND INSPECTION . . . . . . . . . . . . P-57
12-1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-57
12-2 Precautions When Performing Maintenance and Inspection Work . . . . . . . . . . P-58
12-3 Disposal of Industrial Waste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-62
13 PRECAUTIONS WHEN SELECTING COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-63
14 MACHINING CHAMBER OBSERVATION WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . P-65
15 PRECAUTIONS ON INDUSTRIAL ROBOTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-67
16 CAUTION LABELS ON THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-69
17 CAUTIONS RELATING TO SPINDLE SPEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-70
18 CAUTIONS RELATING TO THE RAPID TRAVERSE RATE . . . . . . . . . . . . . . . . . . . . P-71
19 CAUTIONS RELATING TO CENTER-WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-72
20 CAUTIONS RELATING TO COORDINATE SYSTEM SETTING . . . . . . . . . . . . . . . . . P-73
21 CAUTIONS RELATING TO G CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-74
22 CAUTIONS RELATING TO M CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-75
1 FOR SAFE OPERATION
This machine is intended for use by persons who have a basic knowledge of machine tools,
including cutting theory, tooling and fixtures. Mori Seiki cannot accept responsibility for accidents
that occur as a result of operation or maintenance of the machine by personnel who lack this basic
knowledge or sufficient training.
Workpiece materials and shapes vary widely among machine users. Mori Seiki cannot predict the
chucking pressure, spindle speed, feedrate, depth of cut, etc., that will be required in each case
and it is therefore the user's responsibility to determine the appropriate settings.
Each machine is shipped with a variety of built-in safety devices. However, careless handling of
the machine can cause serious accidents. To prevent the occurrence of such accidents, all
programmers and other personnel that deal with the machine must carefully read the manuals
supplied by Mori Seiki, the NC unit manufacturer, and equipment manufacturers, before
attempting to operate, maintain, or program the machine.
Because there are so many "things that cannot be done" and "things that must not be done" when
using the machine, it is impossible to cover all of them in the Instruction Manual. Assume that
something is impossible unless the manual specifically states that it can be done.
FOR SAFE OPERATION P-1
The following manuals are supplied with your NC lathe:
I. Instruction Manuals prepared by Mori Seiki
• MAINTENANCE MANUAL
(MAINTENANCE MANUAL, MAINTENANCE INFORMATION,
INSTALLATION MANUAL, DRAWINGS)
• Operation Manual
• Programming Manual
II. NC unit Operation and Maintenance Manuals prepared by the NC unit manufacturer
III. Instruction Manuals prepared by equipment manufacturers
In addition to these manuals, ladder diagrams, parameter tables and electrical circuit diagrams are
also supplied with the machine to help with electrical maintenance. The ladder diagrams are
provided in the document box, parameter tables and electrical circuit diagrams are stored in the
document compartment inside the electrical cabinet. Please make use of these materials when
carrying out maintenance work.
Fundamental safety information is presented in the following pages.
All cautions on operation must be strictly observed when operating the machine, carrying out
maintenance work, or writing programs. Failure to observe fundamental safety information can
cause accidents in which the operator or other personnel working near the machine are seriously
injured, or the machine is damaged. All personnel that deal with the machine must carefully read
and thoroughly understand the information in the following pages before attempting programming
or operating the machine.
The vocabulary and terms used for machine parts and operations in the warnings, cautions and
notes are defined or explained in the manual texts and illustrations.
If you are unsure of the meaning of any word or expression, please refer to the corresponding
textual explanation or illustration. If you still cannot understand or are unsure of the meaning,
contact Mori Seiki for clarification.
SO-CENL-H2EN
P-2 FOR SAFE OPERATION
"Operator", as used in these cautions, means not only the operator who operates or supervises a
machine tool to perform machining, but also any person, including maintenance personnel who
maintain and inspect a machine tool or safety device or safety measures provided with it, and the
programmers who create programs used for machining, who are engaged in operations which
deal with a machine tool.
Therefore, all persons engaged in these operations must carefully read these cautions and related
materials, and thoroughly understand the contents before attempting to operate the machine.
SO-CENL-H2EN
FOR SAFE OPERATION P-3
2 DANGEROUSNESS OF MACHINE MODIFICATION
WARNING
CAUTION
Examples of accidents which can occur if the machine specifications are changed, if the machine
is modified, or if the machine is operated or run with any of the safety devices (such as the door
interlock function) or protective covers or doors removed, are presented below.
The machine specifications are set before shipping so that the customer's
safety is ensured and the machine can deliver its full performance. Never
change the settings nor modify the machine in any case. Changing the
settings or modifying the machine without consultation may degrade
safety assurance or cause accidents involving serious injuries, impaired
machine performance, and considerable shortening of the machine
service life. If the specifications and/or settings have to be changed, or
the machine has to be modified to meet new machining requirements, or
due to changes in the operating conditions, consult Mori Seiki.
Mori Seiki cannot accept responsibility for any accident that occurs due to
the machine specifications being changed, or the machine being
modified, by the customer.
When changing machine parts that have broken or become faulty, or replacing
consumable parts that have been used for their service lives, be sure to use genuine
parts specified by Mori Seiki. The use of parts not specified by Mori Seiki will be
regarded as a modification and Mori Seiki will not accept responsibility for any accident
that occurs as a result of using such parts.
1. The operator will become entangled with
the spindle if the spindle starts while the
operator is touching the chuck or
workpiece.
2. The operator will become entangled with
the spindle if the operator touches the
chuck or the workpiece while the spindle
is rotating.
The accidents described above, in which the
operator becomes entangled with the rotating
parts of the machine, will result in serious injury
or death.
SO-CENL-H2EN
P-4 FOR SAFE OPERATION
.
3. A workpiece will fly out if the spindle
rotation is started while the workpiece is
not clamped correctly.
4. A workpiece and/or chuck jaw will fly out
if the cutting tool (turret) is hit against the
workpiece due to programming error.
5. A workpiece will fly out due to
excessively heavy cutting force or
lowered workpiece gripping force of the
chuck caused by centrifugal force.
6. The workpiece could fly out when
performing chuck work or center-work
since it is possible to start the spindle
and perform automatic operation even if
the chuck is unclamped.
7. The workpiece could fly out when
performing center-work since it is
possible to start the spindle and perform
automatic operation even if the
workpiece is not supported by the center.
Workpiece is not held by the
tailstock spindle.
Workpiece is not clamped by
the chuck correctly.
As described above, a workpiece or a chuck
jaw, disengaged from the chuck due to some
reason, flies out to hits the operator or a
person standing near resulting in serious injury
or death.
8. The operator will be caught or entangled
by moving parts such as turret during
axis feed or indexing motions, resulting
in serious injury or death.
SO-CENL-H2EN
FOR SAFE OPERATION P-5
9. The operator or a person standing near
the machine will be splashed with chips
and coolant during machining, resulting
in injury or health problems (particularly if
chips or coolant get into the eyes).
10. It is possible to turn the power ON even
when the electrical cabinet door is open:
this means that the operator could touch
a live part inside the electrical cabinet
and sustain an electric shock, resulting in
serious injury or death.
SO-CENL-H2EN
P-6 FOR SAFE OPERATION
3 CONSIDERATIONS BEFORE OPERATING THE MACHINE
The cautions that must constantly be born in mind when operating the machine are listed below.
3-1 Before Using the Machine
Listed below are important cautions that apply to all machine-related work (machine operation,
maintenance, inspection, programming, etc.).
DANGER
1. Never touch a switch, button, or key with wet hands.
If it is not properly grounded or is leaking current, you could receive
an electric shock.
2. Before starting machine operation, check that there is nobody inside
the protective cover or close to rotating or moving parts of the
machine. Never touch or stand near the rotating or moving parts of
the machine while it is operating; you could be seriously injured by
being entangled in the rotating parts or crushed by the moving parts.
3. Never operate the machine with the protective cover removed or
while interlocks or other safety devices are ineffective, since the
machine could operate in an unexpected manner, causing accidents
involving serious injuries.
Contact Mori Seiki, the NC unit manufacturer or relevant equipment
manufacturer immediately if the protective cover or safety devices
are damaged.
4. Always lock out the power to the machine before carrying out work
inside the machine – such as setup work or cleaning the inside of
the machine – and before carrying out inspections, repairs, or
maintenance work. In addition, set the main switch to the OFF
position and lock it, and place "PERSONNEL INSIDE MACHINE" or
"UNDER MAINTENANCE" signs around the machine to stop anyone
from switching on the power or operating the machine while the
work is in progress. If work inside the machine or inspection or
maintenance work is carried out with the power switched on,
machine elements could be moved, and the personnel carrying out
the work could be seriously injured by being entangled in the
rotating parts or crushed by the moving parts of the machine.
SO-CENL-H2EN
5. Always switch off the power before carrying out inspection or
maintenance work in the electrical cabinet or on motors and
transformers. If work has to be done while the power is switched on,
it must be carried out by a qualified electrical engineer, taking the
proper precautions; there is a danger of electric shock.
FOR SAFE OPERATION P-7
DANGER
WARNING
6. Cover power supply cables that are run along the floor with rigid
insulated plates to prevent them from being damaged. Damage to
the insulation of the power supply cable could cause electric
shocks.
7. Even after the power is turned off, some devices will remain charged
and the temperature of motors, lights inside the machine, etc., will
remain high. Make sure that the charge has been discharged or the
temperature has fallen before carrying out maintenance work or
inspections on these devices. If you touch these devices/units
carelessly while they are still charged or while the temperature is
still high you could receive an electric shock or be burned.
8. Check that all cables are properly insulated before using the
machine. There is considerable danger of electric shock if damaged
cables are used.
1. Keep the floor area around the machine tidy and clean; do not leave
things lying on it, and clean up spilled water or oil immediately. If
you fail to do this, plant personnel may injure themselves by tripping
over or slipping on the floor.
2. Before operating the machine, check the area where you will have to
stand and walk to make sure you can operate the machine safely. If
you do not check your footing beforehand, you could loose your
balance while working and injure yourself by putting your hands in a
dangerous place while trying to find support, or by falling over.
3. Before using a switch, button, or key, check visually that it is the one
you intend to use, and then press or set it decisively. Pressing the
wrong switch, button, or key by mistake can cause accidents
involving serious injuries or damage to the machine.
4. Keep the doors closed during machine operation. Leaving the
machine running or operating it with doors open could cause
accidents involving serious injuries or damage to the machine; plant
personnel could be seriously injured by being entangled in the
rotating parts of the machine, crushed by its moving parts, struck by
broken tools, workpieces or jaws flying out of the machine, hit by
flying chips, or splashed with coolant.
5. The parameters are set on shipment in accordance with the machine
specifications; do not change them without first consulting Mori
Seiki. If the parameters are changed without consultation, the
machine may operate in an unexpected manner, causing accidents
involving serious injuries or damage to the machine.
SO-CENL-H2EN
P-8 FOR SAFE OPERATION
WARNING
6. The machine specifications are set before shipping so that the
machine can deliver its full performance. Changing the settings
without consultation may lead to accidents involving serious
injuries, impaired machine performance, and considerable
shortening of the machine service life. If the specifications and/or
settings have to be changed or the machine has to be modified to
meet new machining requirements or due to changes in the
operating conditions, consult Mori Seiki.
7. Before operating or programming the machine, or performing
maintenance work, carefully read the instruction manuals provided
by Mori Seiki, the NC unit manufacturer and the equipment
manufacturers so that you fully understand the information they
contain. Keep these instruction manuals safely so that you do not
lose them. If you do lose an instruction manual, contact Mori Seiki,
the NC unit manufacturer, or the relevant equipment manufacturer. If
you attempt to operate the machine without having carefully read the
instruction manuals first, you will perform dangerous and erroneous
operations which may cause accidents involving serious injuries or
damage to the machine.
8. Always observe the instructions in the caution labels stuck to the
machine. Carefully read the Safety Guidelines supplied with the
machine so that you fully understand them. If the writing on the
labels becomes illegible, or if the labels are damaged or peel off,
contact Mori Seiki. Also contact Mori Seiki if you cannot understand
any of the labels. If you operate the machine without observing the
instructions on the labels, or without understanding them properly,
you will perform dangerous and erroneous operations which may
cause accidents involving serious injuries or damage to the
machine.
SO-CENL-H2EN
9. Never operate, maintain, or program the machine while under the
influence of alcohol or drugs. Your concentration will be impaired,
you may loose your balance and fall against dangerous parts of the
machine, and you may operate the machine incorrectly, causing
accidents involving serious injuries or damage to the machine.
10. Machine operators and authorized personnel working inside the
plant and in the vicinity of the machine must put their clothing and
hair in order so that there is no danger they will be entangled in the
machine. If you have uncontrolled long hair or loose clothing and it
gets caught in the machine, you will be seriously injured by being
entangled in the rotating parts of the machine or crushed by its
moving parts. Always wear safety shoes, eye protectors and a
helmet.
FOR SAFE OPERATION P-9
WARNING
11. The machine is equipped with interlock functions such as the door
interlock, chuck interlock, tailstock spindle interlock (applies only to
machines equipped with a tailstock) and electrical cabinet door
interlock to ensure the operator's safety. All the interlock functions
must be ON when operating the machine. If you have to operate the
machine with the interlocks released, you must recognize that there
are many hazards involved and pay particular attention to safety
while operating the machine in this condition. After finishing the
necessary work, you must switch the interlocks back ON.
If the machine is operated with the interlocks released, it may
operate in an unexpected manner, causing accidents involving
serious injuries or damage to the machine.
12. The door interlock function serves only to protect the machine
operator from accidents that can be prevented by inhibiting manual
and automatic operation of the spindle, axis movement, and all other
operations in automatic operation when the door is opened and
while it is open; it will not afford protection against other hazards.
For example, each machine user will machine a variety of workpiece
types and use a variety of workpiece holding fixtures, cutting tools,
and cutting conditions; you are still responsible for ensuring safety
with regard to the hazards that can arise from these user-specific
conditions.
13. If the door interlock function is released, the machine is able to
operate with some limitations while the door is open, exposing you
to danger. In daily production operation, the door interlock function
must be set "valid" and the key operating the switch must be
removed from the switch and kept safely.
When shaping soft jaws, measuring the tool offset data, program
check, test cutting or carrying out other setup work, it may be
necessary to release the door interlock function. If you have to carry
out work while the interlock function is released, you must recognize
that there are many hazards involved and pay particular attention to
safety.
While the door interlock function is released, the warning lamp
blinks in red and the warning buzzer beeps intermittently. You must
recognize that the door interlock function is in the released state
when the warning lamp is blinking in red and the warning buzzer is
beeping intermittently. After finishing the necessary work, you must
switch the interlock function back valid.
SO-CENL-H2EN
P-10 FOR SAFE OPERATION
WARNING
14. Before operating the machine, memorize the locations of the
emergency stop buttons so that you can press one immediately from
any location and at any time while operating the machine. The
emergency stop buttons are used to stop all operations in the event
of an emergency. If there is an obstacle in front of an emergency
stop button it will not be possible to press it immediately when an
emergency occurs and this could cause accidents involving serious
injuries or damage to the machine.
15. Always switch the tailstock spindle interlock function ON before
carrying out center-work operations. If this function is OFF, it will be
possible to start automatic operation when the tailstock spindle is
extended, even though it may not support the workpiece correctly. If
automatic operation is started in this condition, the workpiece will fly
out, causing serious injuries or damage to the machine. (Applies
only to machines equipped with a tailstock.)
16. Adjust the position of the tailstock body so that the workpiece is
securely held by the tailstock spindle center when the tailstock
spindle is extended.
After making this adjustment, clamp the tailstock body to the bed. If
the tailstock body is not clamped to the bed, or if the position of the
tailstock body is incorrectly adjusted, it will be possible to start
automatic operation when the tailstock spindle is extended, even if
the workpiece is not supported by the tailstock spindle center. If
machining is carried out while the workpiece is not supported by the
tailstock spindle center, the workpiece will fly out, causing serious
injuries or damage to the machine. (Applies only to machines
equipped with a tailstock.)
SO-CENL-H2EN
17. To prevent hazardous situations, the plant or equipment supervisor
must bar entry to the plant or the vicinity of the machine to anyone
with insufficient safety training. Allowing persons without sufficient
safety training unhindered into the plant and the vicinity of the
machine could cause accidents involving serious injuries.
18. Because of the inertia of the moving parts of the machine, they may
not be stopped immediately when the emergency stop button is
pressed. Always confirm that all operations have stopped before
going near these parts. If you approach the moving parts of the
machine without due care you may be entangled in them and
seriously injured.
FOR SAFE OPERATION P-11
WARNING
CAUTION
19. Do not leave articles such as tools and rags inside the machine. If
the machine is operated with such articles inside it they may become
entangled with a tool and thrown out of the machine, and this could
cause accidents involving serious injuries or damage to the
machine.
20. When the machine is running, operating noise of 85 dB or higher
may be produced, depending on the cutting conditions and other
factors.
When an operator works near the machine, either the cutting
conditions must be changed to limit the generation of noise or the
operator must wear protective gear, suited to the level of generated
noise, which will not inconvenience the performance of the intended
work. Working in a noisy environment might impair an operator's
hearing or cause other health problems.
1. User programs stored in the memory, parameters set before shipping, and the
offset data input by the user, can be destroyed or lost due to incorrect operation
or other causes. To protect data against destruction and loss, back it up using an
external I/O device (option), or other device.
If you fail to make backup files, Mori Seiki cannot accept responsibility for any
problem resulting from destroyed programs or lost parameter data and/or offset
data.
Keep the parameter table supplied with the machine in a safe place. Note that if
the data is destroyed it will take some time to set the parameters again.
2. Never touch chips or the cutting edges of tools with your bare hands since you
may be injured.
3. Take care not to stumble over the footswitch since you may be injured.
4. If it becomes necessary to perform a memory clear operation, contact Mori Seiki
first. If a memory clear operation is performed without due care, the entire
memory contents may be deleted, making the machine inoperable.
5. The machine operator must have normal sensory perception. If a person who
has an abnormality affecting any sense operates the machine, he/she will not be
able to accurately confirm the machine status and surrounding conditions by eye/
ear/touch. Sensory confirmation is extremely important when operating the
machine and an inability to make such confirmations properly could cause
accidents involving serious injuries or damage to the machine.
6. Ensure that the workplace is adequately lit. If there is insufficient light, the
operator may trip over something or be unable to perform or check work
accurately, and this could cause accidents involving serious injuries or damage to
the machine.
SO-CENL-H2EN
P-12 FOR SAFE OPERATION
CAUTION
NOTE
7. Remove any obstacles around the machine.
Secure adequate space around the machine for working and adequate
passageway, considering both ease of operation and safety. If there are any
obstacles or if there is insufficient space or passageway, the operator may trip
and fall or be unable to work properly, and this could cause accidents involving
serious injuries or damage to the machine.
8. Stack products (workpieces) stably. If they are not stacked stably they may fall
and injure the machine operator. Unstable stacking may also damage the
products (workpieces), causing defects.
9. Keep the area around the machine clean; remove chips and foreign matter near
the machine. If left, chips and foreign matter may cause plant personnel to fall
and injure themselves.
10. Use a working bench strong and stable enough to support the weight of the
workpieces and tools. If an unstable working bench is used the workpieces and
tools could fall off and injure the machine operator.
If a machine alarm or NC alarm occurs, check its meaning by referring to the alarm list in
the instruction manual or ladder diagram, and take appropriate action. If this is ineffective,
consult Mori Seiki or the NC manufacturer and take action only when you understand
clearly what to do.
3-2 Before Operating the Machine
The cautions that you must be aware of before operating the machine are listed below.
WARNING
1. Never stand in front of the spindle or other rotating parts. Never
stand in front of the chuck, since the workpiece, cutting tools, or
chuck jaws might fly out, particularly during test cutting, causing
accidents involving serious injuries.
2. Before starting spindle rotation, check that the workpiece is securely
clamped. Or, if performing center-work, check that the tailstock
spindle center securely supports the workpiece. (Applies only to
machines equipped with a tailstock.)
If the workpiece is not securely clamped or supported, it will fly out
when the spindle is rotated, causing serious injuries or damage to
the machine.
3. Do not start the spindle unless the machine's left side cover and
cylinder cover are removed. If you fail to observe this warning you
could be seriously injured by being entangled in the rotating parts of
the machine.
SO-CENL-H2EN
FOR SAFE OPERATION P-13
WARNING
4. Never stand near the moving parts of the machine during a zero
return operation or rapid traverse operation, since each axis is
returned to the zero point (or fed) at the rapid traverse rate.
Before starting a zero return operation or rapid traverse operation,
always make sure that no one is standing near the moving parts, that
the moving parts can be fed to the zero point (or fed) without
interference, and that you are moving the axis in the correct
direction.
Failure to observe these warnings could cause accidents involving
serious injuries or damage to the machine: personnel could be
crushed by the moving parts of the machine, and the moving parts
could strike obstacles.
5. Never stand near the moving parts of the machine during a jog feed
operation, since each axis is fed at the jog feedrate set with the
feedrate override dial.
Before starting jog feed operation, always make sure that no one is
standing near the moving parts and that the moving parts can be fed
without interference.
Failure to observe these warnings could cause accidents involving
serious injuries or damage to the machine: personnel could be
crushed by the moving parts of the machine, or the moving parts
could strike obstacles.
CAUTION
6. Never remove burrs on a workpiece by hand while it is clamped by
the chuck or while it is fixed inside the machine. If the machine were
to start for some reason you would be seriously injured: you could
be entangled by the rotating parts of the machine or crushed by its
moving parts. You could also injure yourself by losing your balance.
Always remove the workpiece and perform the work outside the
machine.
1. When machining bar stock on a machine equipped with a bar feeder or spindle
through-hole, use straight workpieces only. When machining bar stock with a
diameter smaller than that of the spindle (or draw bar), always use guide bushes
in order to prevent vibration. If you use a bent workpiece or fail to use guide
bushes, the machine will vibrate and the workpiece will shake; this could cause
damage to the machine. It will also seriously affect machining accuracy.
2. Do not touch the lamp that illuminates the interior of the machine since, if a
halogen lamp or incandescent lamp is used, it will be very hot and will burn you.
Also wait some time before touching the lamp after turning the power OFF.
SO-CENL-H2EN
P-14 FOR SAFE OPERATION
CAUTION
3. Never operate the machine without the shield cover of the chuck opening/closing
footswitch and the lock device in place.
If you step on the footswitch by mistake, or drop something on it, the chuck will be
unclamped and the workpiece that it was gripping will fall out, and this could
cause damage to the machine.
4. Specify a spindle speed limit that is lower than the lowest of the individual
allowable speed limits for the chuck, fixture, and cylinder. If you do not follow this
instruction, the workpiece could come off the chuck, causing damage to the
machine.
5. Clamp workpieces and cutting tools securely. Determine the depth of cut and
cutting feedrate for test cutting with safe operation as the first priority; do not give
priority to productivity when making these determinations. If you fail to observe
this warning, the tool or workpiece could fly, causing damage to the machine.
6. Before starting the spindle in manual operation, set the spindle speed setting
switch to the lowest setting. After starting the spindle, increase the spindle speed
to the required speed gradually.
When stopping the spindle, first lower the spindle speed by setting the spindle
speed setting switch to the low speed position and then stop it.
If the spindle is started at the high speed setting, the workpiece and chuck jaws
could fly, causing damage to the machine.
7. For the machine equipped with the proximity switches for zero return, when the
axis feed switch which moves the axis away from the zero point is pressed in the
zero return mode, the axis will be fed in the opposite direction of the zero point at
the set rapid traverse rate while the switch is pressed; make sure that you feed
the axis in the correct direction.
For the machine not equipped with the proximity switches for zero return, when
the axis feed switch which moves the axis away from the zero point is pressed in
the zero return mode, the axis will be fed in the direction of the zero point at the
set rapid traverse rate while the switch is pressed; make sure that you feed the
axis in the correct direction.
Also make sure that you feed the axis in the correct direction whenever you use
an axis feed switch to feed an axis at a rapid traverse rate or jog feedrate.
Feeding an axis in the wrong direction could cause damage to the machine; the
moving parts could strike obstacles.
SO-CENL-H2EN
FOR SAFE OPERATION P-15
CAUTION
8. Select the appropriate chucking pressure and tailstock spindle thrust force
(applies only to machines equipped with a tailstock) for the workpiece shape and
material, and the cutting conditions. If you cannot determine the appropriate
chucking pressure, contact the chuck manufacturer or cylinder manufacturer. If
you cannot determine the appropriate spindle thrust force (applies only to
machines equipped with a tailstock), contact Mori Seiki. If the chucking pressure
or spindle thrust force (applies only to machines equipped with a tailstock) is not
set appropriately in accordance with the shape and material of the workpiece
being machined and the cutting conditions, the workpiece could come off the
chuck during machining, causing damage to the machine. Incorrect setting could
also distort the workpiece.
9. Coordinate values and M, S, T, G, and F codes in the blocks skipped during
sequence number search operations do not change the coordinate values or
modal M, S, T, G, and F codes in the NC.
When searching for a block part way through a machining process and restarting
machining from that point, specify the M, S, T, G, and F codes, and workpiece
coordinate system, etc., in the MDI mode after carefully checking the status of the
machine and the NC. If machining is restarted without specifying this information,
the machine may operate in an unexpected manner, causing damage to the
machine.
10. In order to open the electrical cabinet door, you must place the main switch in the
OPEN RESET position. If the main switch is at a position other than OPEN
RESET, it will not be possible to open the door. Attempting to force the door open
in this situation could cause damage to the electrical cabinet door or the main
switch.
11. When clamping or unclamping the chuck, pay sufficient care so that hand or
fingers will not be caught by the chuck or the chuck jaws. If caught by the chuck
or chuck jaws, hand or fingers will be injured.
SO-CENL-H2EN
P-16 FOR SAFE OPERATION
4 FIRE PREVENTION
Failure to observe the following warnings may result in a fire or machine damage. Mori Seiki is not
liable for any fire whose cause is other than a product defect.
1. When machining using coolant
• Recieve the MSDS (MATERIAL SAFETY DATA SHEET) from the coolant
manufacturer directly yourself as the customer and use coolant without any chemical
effects on the machine. Take careful note of the effects on the human body and the
storage method described in the MSDS.
• Before starting automatic operation, check the amount of coolant in the coolant tank,
and replenish coolant if necessary. When insufficient coolant is applied to the cutting
point, the machined part will heat up due to insufficient cooling, and this may result in a
fire.
2. When machining using flammable coolant (not recommended)
• Do not use a flammable coolant such as oil-based coolant, as it has high risk of a fire
which may spread to the entire machine. If a flammable coolant is used out of
necessity, any consequent fire or accident must be dealt with as the users'
responsibility.
• Always monitor the machining process and do not carry out unmanned operation.
Install appropriate automatic fire extinguishing equipment to quickly extinguish fire at
an early stage.
• Check the flash point and the ignition point of the coolant to be used. Manage the
material of the tools and workpieces, and tool wear so that the temperature during
machining does not exceed these points.
• When coolant becomes a mist inside the machine, it may burn explosively in
abnormal temperature conditions. Change the coolant discharge method so that no
coolant mist becomes suspended inside the machine, or install equipment to collect
the coolant mist generated.
• Use an explosion-proof mist collector.
• Check the instructions on coolant in the manuals in advance, and follow them.
3. When machining without using coolant (including dry cutting and semi-dry cutting)
• Check and manage the materials of the tools and workpieces to be used to prevent fire
due to heat generated in the machining process.
SO-CENL-H2EN
FOR SAFE OPERATION P-17
4. When machining workpieces made of flammable material
• Always monitor the machining process and do not carry out unmanned operation.
Install appropriate automatic fire extinguishing equipment to quickly extinguish fire at
an early stage.
• Check and manage the tools and machining conditions to be used so that the
temperature during machining does not exceed the ignition point.
• Materials such as magnesium may burn explosively when exposed to water while
burning. Check the fire-fighting methods and equipment in advance, and install the
equipment at suitable locations for quickly extinguishing fire.
5. Before starting automatic operation
• Reconfirm that all parts of the tools and tool holders are securely tightened.
Insufficient tightening leads to insufficient tool clamping, and may result in an accident
or a fire caused by heat.
• Reconfirm that the workpiece is securely clamped. If a workpiece is not clamped
securely, it may shift and make contact with a tool, resulting in a fire caused by heat.
• Do not use worn or damaged tools. If worn or damaged tools are used, chips may clog
them, resulting in a fire caused by heat.
• Before starting automatic operation, reconfirm that the tools and programs to be used
are correct. Failure to use the correct tools and programs may result in an accident or
a fire. Especially with a program in which the same pattern is executed repeatedly,
confirm that the tool is selected correctly before starting the second set of repetitions
after the first machining.
• Create a program after confirming the machining conditions so that the heat generated
by rubbing is minimal. Creating programs without this consideration may result in a
fire or machine damage.
• The conversational programming function creates NC programs based on general
machining conditions, but the final responsibility for determining the machining
conditions rests with the user. Mori Seiki is not liable for the machining outcome of the
conversational programming function.
• During and after machining, completely remove chips if necessary. Failure to remove
chips completely may result in a fire, depending on the workpiece material and
machining conditions.
SO-CENL-H2EN
P-18 FOR SAFE OPERATION
5 PRECAUTIONS ON MACHINE INSTALLATION
5-1 Installation Site
CAUTION
1. When installing the machine, refer to the installation drawing and other
instructions and provide sufficient maintenance area to allow the chip conveyor (if
featured) and coolant tank to be removed, and the electrical cabinet door to be
opened and closed, without difficulty. Also ensure that the doors of the machine
and NC unit will be able to be opened without interference. If you do not provide
sufficient maintenance area it will not be possible to carry out maintenance work
properly and the life of the machine will be shortened.
2. Choose an installation site that is as free as possible from dirt, dust, and mist. If
dirt and dust adhere to the cooling fan fitted inside the machine its cooling
capability will be impaired and this could cause machine faults.
3. Install the machine at a site where it will not be reached by chips, water, and oil
scattered from other machines. These could cause machine faults.
4. Install the machine at a site where the ambient temperature remains within the
range 10 to 35°C and the humidity does not exceed 75% RH (with no
condensation). Failure to comply with these conditions could cause trouble in the
electrical systems of the NC unit and peripheral devices and cause machine
faults.
5. The machine must not be installed at a site subject to excessive vibration (greater
than 4.9 m/s
2
). Excessive vibration could cause machine faults and will
adversely affect machining accuracy.
NOTE
1. Install the machine at a site where neither it nor the NC unit is subject to direct
sunlight. Direct sunlight will raise the temperature and cause thermal displacement,
adversely affecting machining accuracy.
2. Make sure the floor is strong enough to support the machine. The floor must not be
sloped or irregular in any way. Twisting or other distortion of the machine will
adversely affect machining accuracy.
SO-CENL-H2EN
5-2 Power Supply
FOR SAFE OPERATION P-19
DANGER
WARNING
Only a qualified electrical technician should perform work involving the
power cable connections. If the work is done by a person unfamiliar with
the necessary safety precautions when performing electrical work, he/she
may receive an electric shock.
1. For the power supply, provide isolated wiring directly from the input
power supply. If there is an excessive voltage drop, for example due
to insufficient capacity of the factory power supply, the machine
may malfunction, causing accidents involving serious injuries or
damage to the machine.
Item Range
Nominal power source voltage
fluctuation range (200/220 VAC)
Voltage drop
Frequency fluctuation range
(50/60 Hz)
Momentary power failure Less than 10 msec.
Voltage impulse
+10%/−15%*
Within 15% of normal voltage
for 0.5 seconds
±1 Hz
1.5 ms or less at the peak value
with 200% or less effective
value (rms) of line voltage
Waveform distortion of AC voltage 7% or less
Imbalance in line voltages 5% or less, or within 10 V
Select a primary power cable by accurately calculating the power
supply capacity at the supply side. Using an inappropriate cable
could lead to fire, injury, or damage to the machine.
2. Do not install the machine close to major sources of electrical noise,
such as electric welders and electrical discharge machines. If the
voltage supply is not stable, the machine may malfunction, leading
to accidents involving serious injuries or damage to the machine.
If noise is continually entering the machine through power cables, it
can cause breakage or burning of electrical or electronic devices
inside the electrical control panel and this can lead to fire.
SO-CENL-H2EN
P-20 FOR SAFE OPERATION
NOTE
1. * Voltage fluctuation (drop) during spindle or servo system acceleration must be
2. A breaker less than 100 A requires a cable with a temperature resistance of 60°C or
3. UL486 listed terminals shall be used for connecting power supply.
5-3 Grounding
DANGER
less than 7%.
If voltage is lower than 200 V during servo system acceleration/deceleration,
actual acceleration/deceleration time may be elongated than the theoretical
time.
higher; a breaker exceeding 100 A requires that of 75°C or higher.
1. Grounding work is essential. If grounding work is not performed,
the machine operator could receive an electric shock.
2. The grounding wire should be as short as possible and should have
the same thickness as the power wires. Perform class D grounding
work with the grounding resistance of 100
Ω
or less. If the
grounding is ineffective, there will be a danger of electric shock.
WARNING
5-4 Air Supply
CAUTION
3. Check for earth faults and short circuits after completing the
grounding work.
1. The machine must be grounded independently of other machines. If
electric welders or electric discharge machines are grounded to the
frame of the plant building, do not connect the ground wire of the
machine to the plant frame. If the ground wire is not connected
independently, the machine could malfunction due to electrical noise
from other machines, causing accidents involving serious injuries or
damage to the machine.
2. Use the M8 terminal suitable for the grounding cable.
1. Use only clean and dry air of 0.5 MPa (72.5 psi) having a pressure dew point at
10°C or less.
If you use air that is moist or has a high concentration of dust, the pneumatic
devices could malfunction, causing damage to the machine. (Applies only to
machines equipped with pneumatic devices.)
2. Make sure that the air source can supply the specified volume of air. If it has
insufficient capacity, the pneumatic devices could malfunction, causing damage
to the machine. (Applies only to machines equipped with pneumatic devices.)
SO-CENL-H2EN
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