sharp SV 4328, SV 5127, SV 6332 Operation Manual

PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

OPERATION MANUL

SV-4328ST

FVL-01E-02 FVL-01E-02

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 1 SAFETY

1.1 Safety Precautions 10

1.2 Warning Labels 10

1.3 Utilization Of Safety Device 16

1.4 Warning Lists 17

Chapter 2 Preparations For Installation

Overview 22

1. Preparation Of Set-up Area 23

2. Preparation Of Transport Route 27

3. Preparation Of Transportation Equipment 28

4. Set-up Conditions 29

5. Air/Power Sources 30

6. Recommended Foundations 32

Chapter 3 OPERATION

Before Starting Operation / Operation Flowchart 36

1. Main Operation Panel 37

1.1 Main Operation Panel Functions 37

1.2 LCD Control Panel Functions 57

1.3 Displaying PC Screen 61

2. M_CODE

2.1 M-code List

3. Setting/Changing Machine Parameters 66

4. Opening / closing Doors 70

4.1 Opening / closing Splashguard Door 70

5. Turning On/Off Power Supply 73

6. Data Registration / Editing 76

6.1 NC Program Registration ( 3 Methods ) 76

6.2 Tool Offset Registration 76

6.3 Tool Offset Value 79

64

6.4 Registration Of Workpiece Offset Value 80

7. Workpiece Attachment And Detachment 84

1. Workpiece Attachment And Detachment 84

2. Workpiece Restrictions 85

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

8. Tool Preparations 86

8.1 Tool Attachment and Detachment 86

8.2 Tool Storage Limitations 87

8.3 Tool And Retention Stud Combinations 87

9. Tool Change 91

10. Cutting Fluid Supply 92

11. Chip Disposal 93

11.1 Operation Of Lift-Up Conveyor 94

12. Automatic Operation 95

1. Program Edit Procedure 95

2. Program Configuration 96

3. Subprogram Call 98

4.Major Function And Address 100

5. Force Mirror Image 101

6. Program Edit 102

7. Add New Program 102

8. Delete Program 103

9. Program commanded Search 104

10. Edit key 105

11. Copy Program 11 0

12. Graphic Function 116

Chapter 4 PROGRAMMING

1. Commanded Description 136

1.1 G Commanded 136

1.2 F Commanded

1.3 S Commanded 141

1.4 T Function 144

1.5 G Code Composition 144

141

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 5 PROGRAM INPUT / OUT OPERATION

1. Memory Card Operation 213

1.1 Displaying The Directory 213

1.2 Searching for a File 214

1.3 Reading A File 216

1.4 Writing Files 218

1.5 Deleting A File 221

1.6 DNC Operation 222

1.6.1 Searching for a File 222

1.6.2 Executing A File 223

2 . Data Input/Output On The All I/O Screen 224

2.1 Program Input/Output 224

2.1.1 Program Input/Output 224

2.1.2 Searching For A File 225

2.1.3 Inputting A Program 227

2.1.4 Outputting Programs 229

2.1.5 Deleting A File 231

2.2 Parameter Input/Output 232

2.2.1 Searching For A Parameter 232

2.2.2 Inputting A Parameter 233

2.1.3 Outputting Parameters

2.1.4 Deleting A Program 236

235

Chapter 6 CUTTING TOOL CONDITION LIST

1. Cutting Tools use Description 237

1.1 Face Mill

1.2 End Mill 239

1.3 Boring Bar 240

1.4 Drill 241

1.5 Reamer 242

238

1.6 Tap 273

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 7 PARTS MANIUL

1. Spindle head 245

2. Column 247

3. Base 250

4. Saddle & Table 252

5. Lubrication 255

5.1 Saddle Distributor 255

5.2 Table Distributor 256

5.3 Spindle Distributor 257

5.4 Auto lubrication system 258

5.5 List of recommended lubricants for parts 259

6. Spindle 260

7. Magazine 267

1. main body 268

2. Tool disk 271

3. Cylinder mounting plate 271

4. Arm Body 272

5. Cambox 275

8. Pneumatic system 279

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

MACHINE TYPE

MACHINE SERIAL #

CONTROL TYPE

ALL SPECIFICA TIONS AND DESIGNS ARE SUBJEC TO CHANGE WITHOUT NOTIFICATION.

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

INTRODUCTION

This manual is for this vertical machining center

Read this manual prior to beging any maintenance or repair work . Follow the intructions provided in this manual to ensure the safty of those maintaining or repairing this machine . Disregarding or not following the specific directions in this manual may lead to serious Injury or death .

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

IMPORTANT NOTICE

1. Read and undertant Chapter “1. SAFETY ” prior to machine operation to ensure safe working Conditions.

2. Designate specific operators for this machine to ensure optimum machine perfrmance and safety standards are maintained at all times .

3. Keep this manual in a clearly marked location to ensure Easy access when necessary .

4. Contact the regional SHARP office or local distributor if this manual is lost or damaged .

5. Reproduction of this manual in part or in its entirety is prohibited by SHARP .

6. Ensure this in included when moving or reseling this machine .

7. All spcifications and designs are subject to change without prior notification .

SYMBOLS IN THIS MANUAL

Supplementary expianations

Explains operation erros that will cause Alarme or stop the machine .

Explains convenient functions to be used during operations .

Indicates reference items, figures and tables providing futher information

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 1

Chapter 1 SAFETY

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 1

1.1 Safety Precautions

Safety precautions and special considerations relevant

to all machining operations must be thoroughly

understood by the operator prior to machine operation .

Careless use of the machine may result in serious

Injury and machine damage .

1.2 Warring Labels

The warring labels attached to machine at specific points

identify safety risks and provide important instructions

that must be followed ( Figure 1.1 ~ Figure 1.5 )

Warning labels are divided into 3 categories according to

levels of caution required ( Table 1.1 )

Table 1.1 DANGER / WARNING STATEMENTS

Order new labels from the nearest sales office and affix in original position

Failure to heed this warning will

Lead to death or serious injury .

Failure to heed this warning may

cause working conditions Lead to

death or serious injury .

Failure to heed this warning may

cause working conditions Lead to

minor injury or machine damage

after the following： ․When the warning labels peel off ․When the warning labels become illegible ․When the parts on which the warning labels are attached are replace .

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 1

Operator Door

Figure 1.1 LOCATION OF WARNING LABEL

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PRECISION MACHINERY TOOLS VER.2 Operator’s Manual

Chapter 1

Operation Box side

Figure 1.2 LOCATION OF WARNING LABEL

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

ETC Box side

Figure 1.3 LOCATION OF WARNING LABEL

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

Figure 1.4 LOCATION OF WARNING LABEL

Head cover

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

MAGAZINE FRONT COVER

Figure 1.5 LOCATION OF WARNING LABEL

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

1.3 Utilization of safety devices

Safety devices ( Figure 2.1 ) are installed on this machine in order to protect operators and Maintenance personnel .

Operation Door Safety Guard

Emergency Stop Button

Warning

․Confirm machine safety devices are function correctly at all times . ․If a safety devices is not functioning , or is functioning incorrectly , repair or replace immediately . ․Ensure all operators know the locations of the emergency stop buttons before operating

the machine to enable immediately use un abnormal situations or following an accident .

․Never place objects on the safety guards . ․Heed the following safety precautions at all times when operating the machine with

guards open：

→ Do not touch rotating or moving parts . → Do not touch each axis while in motion . → Exercise extreme care around parts that may be about to move .

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

1.4 Warning lists

The following tables list frequent accidents , incidents and dangerous or careless operating

Conditions , and the injuries that may result .

Ensure the contents of each table are thoroughly understood prior to machine operation .

1.4.1Inside of machining chamber

Operations：Centering , alignment , workpiece loading / unloading, changing coolant nozzle,

direction, lighting replacement , chip removal, table lubrication, tool attachment /detachment .

ACCIDENT / INCIDENT PROTENTIAL INJURIES / DAMAGE

Operator touches rotating spindle

Operator touches bladed tools Cuts , injuries to hands

Operator lifts heavy tools Strained back

Operator stands on center-trough conveyor or

the surrounding splash guard and slips .

Feed axis moves , trapping operator in

machine

Operator is struck by ATC Arm Bone fracture

Operator is struck by chips and cutting fluid

scattered during machine .

Operator is splashed by cutting fluid dripped

from ceiling .

Hand(S) caught when closing S/ G door Bone fracture

Spindle is rotated with a tool incorrectly

clamped while door is open .

Amputation or entanglement of hand(s)

resulting in serious injury

Bone fracture

Damage to eyes or cuts / burns to skin

Damage to eyes

Injury or death

Spindle is rotated prior to cleaning of tapered

section while door is open

Spindle is rotated with a bladed tool incorrectly

mounted while door is open .

Unblance tools are rotated at high speed while

door is open.

Injury or death

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

1.4.2Tool Magazine , Tool Magazine Door

Operations：Tool replacement and lubrication

ACCIDENT / INCIDENT PROTENTIAL INJURIES / DAMAGE

Operator touches bladed tools Cuts or puncture injuries to hands

Operator lifts heavy tools Strain back

T-serch or tool change is commanded when

tool is incorrectly stored in pot

T-search or tool change is commanded when

tool blade is mounted incorrectly .

Operator works on oily floor Bone facture , injury cause by falling

Operator enters tool magazine without turning

OFF machine power

Operator insert hand into tool magazine

during operation

Injury or death

Cuts to hands or bone fractures

1.4.3 Cutting Fluid, Chips, Cutting Fluid Supply Unit, and Chip Disposal Unit

Operations：Regular machining , cutting fluid replenishment , tank cleaning , filter replacement .

ACCIDENT / INCIDENT PROTENTIAL INJURIES / DAMAGE

Operator inhales large quantities of cutting fluid mist . Respirator organ damage

Insufficient cutting fluid . Fire

Contact with chemical additives . Skin damage .

Operator inserts hands into conveyor or tank without

Turning OFF machine power

Operator cleans machine without wearing protective

glove .

Filter is replace without prior cleaning Cuts or puncture injuries to hands

Operator works on top of the machine when anchor bolts

are used incorrectly and machine is unstable .

Contact with cutting fluid . Skin irritation

Entanglement of hands resulting in

serious Injury .

Cuts or puncture injuries to hands

Bone fracture ; injury caused by falling

1.4.4 Signal lamp

Operations：Signal lamp bulb replacement

ACCIDENT / INCIDENT PROTENTIAL INJURIES /DAMAGE

Working in elevated locations . Falling , bone facture

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

1.4.5 Spindle Coolant Oil

Operations：cleaning

ACCIDENT / INCIDENT PROTENTIAL INJURIES /DAMAGE

Oil temperature exceeds flashpoint . Flashpoint of spindle coolant oil (VG32 )： Approximately 20℃

Inappropriate operating methods Fluids may damage eyes or skin or be

Fire

accidentallyingested or inhaled by operator .

1.4.6 Machine Surrounding Area.

ACCIDENT / INCIDENT PROTENTIAL INJURIES /DAMAGE

Cables and piping are exposed on the floor . Falling

1.4.7Electric System.

ACCIDENT / INCIDENT PROTENTIAL INJURIES /DAMAGE

Operation without turning OFF main power switch .

Improper wiring

Loosening of screws in terminal block

Electric shock, machine malfunction,

abnormal operation, or fire

Machine malfunction, abnormal operation,

or fire

Machine malfunction, abnormal operation, or

fire

Door of machine controller and cover of terminal

box are left open .

Damage to cables on floor surrounding the machine

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Electric leak, machine malfunction,

abnormal operation, or fire

Electric leak, machine malfunction,

abnormal operation, or fire

PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 1

1.4.8 Parameters.

ACCIDENT / INCIDENT PROTENTIAL INJURIES /DAMAGE

An NC or machine parameter not outline in this

manual is change

Before performing maintenance on the servo amp, spindle amp, turn off the machine power

stop

High voltage current flows through components inside the terminal box .

High voltage current continues to flow on the primary side of the main power switch

even after the switch is turned off .

Electrical current continues to flow to lamps outlets in the machine controller even after

the main power switch us turned off .

switch and confirm that the red LED indicator( charged ) for each device is extinguished .

Serious injury or death, damage to workpiece

or machine .

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

PREPARATIONS_FOR_INSTALLATION

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

OVERIEW

Prior to machine installation, perform the following preparations to ensure all installation conditions are satisfied ：

Preparation of set-up area .

Preparation of transport route .

Preparation of transportation equipment .

Set-up conditions

Air / power sources

Recommended Foundations

Machine installation is to be performed by specialized personnel only .

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

1. PREPARATION OF SET-UP AREA

Prior to installation, confirm spacing requirements . Maintenance area refers to the maintenance space required after installation .

Maintenance Height

Figure 1.1 SIDE VIEW OF MACHINE

2825mm

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

4600

Figure 1.2 TOP VIEW OF MACHINE

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

3200mm

Figure 1.3 FRONT VIEW OF MACHINE

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

Figure 1.4 OPERATOR POSITION VIEW OF MACHINE

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

2. Preparation Of Transport Route

Prepare the machine transport route referring to the machine size at shipment ( Table 2.1 )

Item Height Width Depth

Machine Body 3100mm 3200mm 2825mm

When lifting the machine body using a crane the total height requirement necessary to Provide adequate lifting space is 500mm plus the height of the lifting equipment . ( Figure 2.1 )

500mm

4250mm

2750mm

Figure 2.1 MACHINE BODY AT SHIPMENT

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

3. Preparation Of Transportation Equipment

Prior to transportation of the machine, prepare equipment capable of supporting the

size and standing weight of the machine such as a crane, fork lift truck .

Table 3.1 MACHINE WEIGHT AT SHIPMENT

Item Weight ( including lifting equipment )

Machine body Approx. 8000Kg

Handling Unpackaged Machine Handle the Unpackaged Machine by a Forklift

1. The unpackaged machine approximately weighs 7.5 tons. The forklift used for handling the

machine should have a safe load capacity greater than 9 tons so as to avoid accidents.

2. Check if there is any person or obstacle in the way while moving the machine.

Please evacuate people and remove obstacles before moving so as to avoid collision and

ensure the safety of personnel and machinery.

3. Adjust forks of a forklift to a proper position before moving. Pay attention to the barycenter

of the machine. Place it at the loading center of a forklift so as to avoid losing balance and

causing accidents.

4. When the machine is lifted by the forks, pay attention to the height the forks go. If the

barycenter is at a higher position, it may swing and lose balance and then cause accidents.

5. If the sight is hindered while moving the machine, please back the vehicle. Meanwhile, ask

someone to help give directions to ensure safety. Drive the forklift as slowly as possible

Figure 3.1 Handle the Unpackaged Machine by a Forklift

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

4. SET-UP CONDITIONS

Table 4.1 SET-UP CONDITIONS

Set-Up Location And Environmental Conditions

Ambient Temperature：10 to 40 degrees

(optimum 26±1 degree )

Relative Humidity：35 to 70% ( no condensation )

Temperature Fluctuation：less than 1 degree / 1 hr

Well-illuminated

Free from direct sunlight

Dust-free

Available space for storing raw materials, finished workpieces and tools.

Available space for maintenance work .

Adequate space around machine to open doors completely

Required electrical power sources

A level foundation strong enough to support the weight of the machine

Appropriate distance from factory air ducting / inlets ( air flow )

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PRECISION MACHINERY TOOLS VER.2 Operator’ s Manual

Chapter 2

5. AIR / POWER SOURCE

Table 5.1 AIR / POWER SOURCE ( 1 )

Item Specifications

Electrical Source

Maximum Power Consumption 20 KVA ( Standard ) 35 KVA ( Including Options )

Total Power Requirements

Air Source

Air Dryer Should be ordered or unless provided by customer

Air Filtration Unit 5μm + 0.3μm + Moisture Remover

AC200/220V ± 10% & 50/60HZ ± 2%

Actual：

20 * 0.7 = 14 KVA ( Standard )

35 * 0.7 = 25 KVA ( Including Options )

0.5 to 0.8 MPa

660L / min ( ANR) without scale with air blow Dew point temperature： -20 degrees or less

•Clean air is to be provided：Equivalent to ISO 1.5.1

standard as specified by ISO 8573-1

•Max. particle diameter：0.0001mm or less

•Dew point at max pressure：Below 7 degrees

•Max oil concentration ：0.01 mg/m³ or less

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