USER MANUAL
Contents
1. n 51 7 6 Machine floor Space eer 54 54 DAB VO T 55 mi cemere EET 56 1 Safety 11 Intended Use This machine is a numerically controlled machine tool designed to shape cold metal by the application of rotating cutting tools capable of performing two or more machining processes e g boring drilling milling thread tapping at one set up of a workpiece and incorporating automatic facilities to Select and change tools from a magazine Change the position of the workpiece relative to the spindle mounted cutter Select and apply spindle speeds and axis feeds Control ancillary services e g coolant flow This machine is intended for use in an industrial environment and must not be used in the residential commercial and light industrial environment Materials to be cut in this machine are Steel Iron Iron casting Bronze Brass Copper and Aluminium Materials not suitable to be cut in this machine are Graphite Wood Plastic Magnesium alloy Consult the agent for the material not listed above 1 2 Important Safety Notice and Warning It is the user s responsibility to be acquainted with the legal obligations and requirements in the use and application of the machine 1 2 1 Safe installation It is the customer s responsibility to ensure the machine is installed in a safe operating position w2. cond d ucc oU oon ac 25 3 1 Foundation Preparation eee 25 3 2 Power PrepatallOli ccce tite tense oer use 25 3 2 1 Line Configuration 25 3 3 RED 25 3 4 Machine Lifting zeerste neee eee 26 3 5 Leveling of Rr 26 gigi 3 6 Before Power ON triene pr 27 3 6 1 ert 27 3 6 2 Power COMING CTO 2 4 2225 8 52225 28 SE CM c DR 29 3 7 First Time E 29 3 7 1 Rotation Direction of 30 3 7 2 30 o 31 4 1 Ql 31 4 2 Reference or ZERO RETURN or the Machine 31 4 3 Machine Warm up om 31 4 4 Spindle 11100 32 4 5 Interrupting reste 32 4 6 JODS UMS 32 4 7 ee 33 4 8 Jog Axis Dy MPO 34 4 9 Tool 34 4 10 Large Tool 34 B Maintenance 37 5 1 Routine
3. DB 08 a KEHO 96 16 0 800666 D OREN 52552 13 EN SM eem 2452 CLE El EO Wi Lo pm ofF LI ol gg 9 EO 559 ON TIONIdS L 96 prt 96 081 29 DG 2 09 001 OL 001 04 15 1 Power ON Turn the power of the controller 8 2 Power OFF OFF the power of controller o OFF 3 Mode selection From Left to right CW EDIT Program editing mode TAPE PC connection mode AUTO Program execution mode MDI Manual Data Input mode single block command tool offset etc HANDLE Axis movement by hand wheel on Remote jog unit JOG Slow movement of axis ZERO RETURN Return to the zero point of each axis 4 Rapid movement Rapid moving axis in JOG mode b Feed rate override Effective for commands or program in MDI AUTO or TAPE modes Override from 0 to 150 In JOG mode the axis will move in speed ranging from O to 1260mm min for JOGGING and DRY RUN ene 6 Rapid movement speed override 4 Effective in modes RAPID ZERO RETURN or the commands GOO in program execution 7 Spindle speed override 80 99 70 100 60 50 7 120 8 Over travel alarm release Once the axis moved over travel and machine halted keep pressing this button and jog t
4. M17 Door close M19 Spindle orientation M20 Spindle orientation reset M23 Spindle CW amp air blast ON M24 Spindle CCW amp air blast ON M25 Spindle STOP amp air blast OFF M29 Rigid Tap mode 295 M30 End of program spindle amp coolant reset amp rewind program M31 Control output 1 ON CUSTOM USE M32 Control output 1 OFF M33 Use timer control output 2 OFF CUSTOM USE M34 Use input signal control output 3 OFF CUSTOM USE M35 Hydraulic index rotary CW 90 deg OPTION 45 SYN LA Function Description User Manual MBV Series M36 Hydraulic index rotary CCW 90 deg OPTION M47 Coolant Through Spindle pump ON M48 Override cancel ON M49 Override cancel OFF M51 Coolant 2 ON M52 Coolant 2 OFF M53 Coolant Through Tool ON M54 Coolant Through Tool OFF M60 Put tool from spindle to magazine carousel magazine M61 Get tool from magazine to spindle carousel magazine M67 Chip conveyor CCW M68 Chip conveyor CW M69 Chip conveyor OFF M71 Pocket DOWN arm type ATC M72 Pocket UP arm type ATC M73 Jig No 1 CLAMP M74 Jig No 2 CLAMP M75 Jig No 3 CLAMP M76 Jig No 4 CLAMP M77 Jig No 1 UNCLAMP M78 Jig No 2 UNCLAMP M79 Jig No 3 UNCLAMP M80
5. 37 5 1 1 AY HS 37 5 1 2 Weekly In addition to daily routine 38 5 1 3 Yearly In addition to weekly routine 38 5 2 PRENNE TET 38 5 2 1 Automatic Lubrication 38 See ennen en eee 38 5 3 rie 25 tert re 39 5 3 1 Machine 39 5 Trouble Uu Sx uA KU US dens OU MER 40 6 1 pe 40 6 2 Cooling Coolant and lubrication system 40 6 3 Door switch tiae neues eene t 40 6 4 Alarm messages and remedies 40 T 43 7 1 Power requirements mE mo ET 43 Pneumatic requirements 43 7 3 Spindle run in 43 7 4 M function Codes MON 45 rne 7 5 User Definable Parameters 48 7 5 1 Parameters editing 48 522 Timer tabletten hen 49 5 9 GOUNIGE DR 51 7 5 4 Keep Relay
6. i m 1 Signal from magazine counter is type A K06 5 PLC use 06 6 PLC use 0 Air blow not stopped by M09 K06 7 d 1 Air blow by MO9 K07 0 0 Reverse the chip auger by pressing reverse button t Reverse the chip auger by pressing forward button first then reverse button K07 1 K07 2 K07 3 K07 4 K07 5 K07 6 K07 7 53 SYNT AGE ee BY Series 7 6 Machine floor space MBV 6 MBV 8 650 2100 1625 475 Ej 1865 834 54 User Manual SYN LAE MBV Series MBV 10 em d S Y ae EL E 2 2650mm 0 540m s I D N Oj 38 p 2650mm 180 2180mm 2560mm 55 wia e MBV 12 me 1100 00 4 3150 00 56
7. or 51 Address DISCRIPTION K02 2 0 Activate tool magazine ZERO RETURN 1 Inactivated tool magazine ZERO RETURN K02 3 0 Coolant cannot be activated unless spindle is rotating 1 Coolant is independent to spindle rotating K02 4 0 The speed override disable is cancelled after pressing RESET default 1 The speed override disable is NOT cancelled after pressing RESET K02 5 0 Signal from CTS pressure sensor is type A 1 Signal from CTS pressure sensor is type B 0 No fixture function 1 Activate fixture functions K02 7 0 Ignore signal from clamp sensor of fixture 1 Accept signal from clamp sensor of fixture K03 0 0 Spindle rotation is limited by fixture 1 Spindle rotation is NOT limited by fixture K03 1 0 The 4th axis unclamp while modes changed 1 The 4th axis clamp while modes changed 0 Display Interlock alarm 2031 when the front door was opened during program 2 1 Display Interlock alarm 2031 when the front door was opened 0 Oil chiller exists 1 No oil chiller 0 Ignore alarm signal from oil chiller K03 4 za 1 Accept alarm signal from oil chiller K03 5 0 Clamp the 4th axis after power ON 11 Unclamp the 4th axis after power ON K03 6 0 Signal from CTS filtering sensor is type A 1 from CTS filtering sensor is type B K03 7 0 Tool clea
8. S command must be inputed in AUTO or MDI modes Then change modes to manual and press this button Spindle speed override can be used to adjust the spindle speed 50 120 26 Spindle STOP Effective in manual mode Edi STOP 27 Spindle CCW Effective in manual mode S command must be inputed in AUTO or MDI modes Then change modes to manual and press this button Spindle speed override can be used to adjust the spindle speed 50 120 28 Data editing key switch Effective in EDIT and MDI modes User M SYNTATE 5 MBV Series 2 Program Tool data Work coordinate data and diagnostic parameters CANNOT be edited if this switch was turned OFF 29 Cycle START Effective in AUTO mode fo In MDI mode type in single block command and press this button to execute it In AUTO mode press this button to execute the program in memory In TAPE mode press this button to execute the program in memory of external devices PC or tape machine Resume the program execution which was halted by Feed Hold 30 Feed Hold Effective in AUTO mode Halt the programe execution Axis movement will be stopped yet the spindle keeps spinning E 31 Emergency STOP Any mechanical movement will be stopped Power of servo system will be cut OFF Rotate the knob CW to release it 32 X axis movement Effective in JOG mode x a Move X axis in positive direction 33 Y axi
9. 0 Accept signal of limit switches of three axis K00 5 1 Ignore signal of limit switches of three axis K00 6 0 Mirror image can be cancelled by RESET t Mirror image cannot be cancelled by RESET K00 7 0 M38 can be cancelled by MO8 M13 M14 M38 cannot be cancelled by M08 M13 M14 K01 0 0 DOOR INTERLOCK ALARM is effective in MDI amp SBK modes DOOR INTERLOCK ALARM is NOT effective in MDI SBK modes K01 1 0 Coolant M08 can be cancelled by RESET 1 Coolant M08 cannot be cancelled by RESET K01 2 0 Whenever there is a LUBE Alarm spindle stop after M02 or M30 1 Whenever there is a LUBE Alarm spindle stop immediately K01 3 0 Whenever there is a LUBE Alarm spindle will be stopped 11 Whenever there is a LUBE Alarm Spindle will NOT be stopped K01 4 0 Coolant and air blow will be halted during M00 MO1 Coolant and air blow will NOT be halted during 00 01 0 Signal from lubrication unit level sensor is type A K01 5 1 Signal from lubrication unit level sensor is type 0 Signal from lubrication unit pressure sensor is type A K01 6 a 1 Signal from lubrication unit pressure sensor is type K01 7 0 When a LUBE Alarm exists program can be executed in single block mode 11 When a LUBE Alarm exists program cannot be executed K02 0 K02 1 0 Display FEED HOLD with command or Do not display FEED HOLD with command
10. 3 If the message 000 P S ALARM showed up after editing parameters the power must be cycled OFF and ON to make the modification effective 48 SYN LA 7 5 2 Timer table User Manual MBV Series Timer NO ADDRESS DATA ms DISCRIPTION Timer 1 TOO 20000 Chip auger ON time Timer 2 T02 1500 Pneumatic pressure low alarm delay time Timer 3 T04 500 Power ON delay time Timer 4 06 3000 Tool pocket up abnormal delay time Timer 5 708 3000 Tool pocket down abnormal delay time Timer 6 T10 10000 Oil coolant separator OFF time Timer 7 T12 10000 Oil coolant separator ON time Timer 8 T14 0 Door interlock unlock time Timer 9 T16 240000 Chip auger OFF time Timer 10 T18 3000 CTS pressure delay time Timer 11 T20 50 Next tool call delay time Timer 12 T22 1500 Spindle STOP delay time Timer 13 T24 30000 Automatic power off delay time Timer 14 T26 500 Rigid tapping torque output delay time Timer 15 T28 0 Coolant level high malfunction delay Timer 16 T30 50 T code signal delay time Timer 17 T32 0 reserved Timer 18 T34 20000 Lubrication unit pressure abnormal delay time Timer 19 T36 20000 Lubrication ON time at the first activation after power ON Timer 20 T38 20000 Lubrication ON time in each activation Timer 21 T40 Tool change arm down OK delay time Timer 22 T42 Reserved Timer 23 T44 3000 Oil chiller abnormal delay time Timer 24 46 CTS filt
11. Jig No 4 UNCLAMP M85 Tool UNCLAMP M86 Tool CLAMP M89 Tool No Arrange M93 Mirror image X ON M94 Mirror image Y ON M95 Mirror image CANCEL 46 SYN LA Function Description User Manual MBV Series M98 CALLING OF SUBPROGRAM M99 END OF SUBPROGRAM 47 PO 7 5 User Definable Parameters 7 5 1 Parameters editing NOTE Do not change the parameters that you do not fully understand The warranty may be void if parameters were set incorrectly and damage the machine 1 Turn the mode selection to MDI mode SETTING 2 Press key 3 Press soft key SETING 4 Move cursor to SETTING HANDY 00000 N00000 7 E PARAMETER WRITE 0 DISABLE 1 ENABLE PARAMETER WRITE TV CHECK 0 0 OFF 1 ON PUNCH CODE 1 0 EIA 1 150 and type 1 then press INPUT UNIT 0 0 MM 1 INCH 0 0 3 CHANNEL NO 0 0 1 0 0 0 1 10 11 0 PROGRAM NO 0 SEQUENCE NO VO CHANNEL SEQUENCE NC INPUT TAPE FORMAT SEQUENCE STOP SEQUENCE STOP 5 An alarm message 100 gt S 0 P S ALARM showing up en 15 06 99 1 SETNG If I GR f which means the C P parameters editing mode was ON Note CAN 1 To remove the 100 P S ALARM message press and 2 1 simultaneously 2 The DATA EDITING KEY must be turned ON while editing PMC parameters
12. KEEP your hair away from moving parts PROTECT your eyes Wear safety glasses with side shields at all times PROTECT your head Wear a safety helmet when working near overhead hazards PROTECT your feet Always wear safety shoes with steel toes and oil resistant soles PROTECT your hands Make sure the spindle is stopped before manually changing a tool PROTECT your hands Make sure the spindle is stopped before manually changing a workpiece PROTECT your hands Make sure the spindle is stopped before manually clearing away swarf or oil Use a brush or chip scraper NEVER use you hands PROTECT your hands Make sure the spindle is stopped before SYNT AG manually adjusting the work piece or fixture or coolant nozzle PROTECT your hands Make sure the spindle is stopped before you take measurements PROTECT your hands Make sure the spindle is stopped before you move a safeguard Never reach round a safeguard PROTECT your hands Make sure the machine is switched off and electrically isolated before making any mechanical adjustment PROTECT your hands Beware sharp edges of cutting tools when changing and handling tools PROTECT your eyes and the machine Never use a compressed air hose to remove swarf or to clean out air vents Gloves are easily caught in moving parts TAKE THEM OFF before you turns on the machine Loose objects can become flying projectiles REMOVE all loose items wrenches chuck keys rags etc from the
13. a semi permanent means with the printing clearly visible Only qualified and competent maintenance engineers should carry out machinery maintenance work Working live electrical equipment must be carried out by only suitably qualified electricians WARNING Over travel limit switches proximity switches and_ interlock mechanisms including all functional parts should not be removed or modified When working in high places use steps or a ladder which are maintained daily for safety Use only fuses cable s etc from reputable recognized manufacturers CAUTION The maintenance person should check that the machine operates safety after the work is completed Maintenance and inspection data should be recorded and kept for reference 5 1 Routine Inspection 5 1 1 Daily 37 1 CJ 22 6 7 Check pressure gauges for proper reading Air pressure 5 5bar 80psi Hydraulic pressure 68bar 986psi Check that there is sufficient oil in the air lubricator Check motors and other parts for abnormal noises Check the lubrication of sliding parts for evidence of proper lubrication Check safety covers and safety devices for proper operation Check coolant level and fill as necessary Clean dirt and chips from the axes and empty the swarf trays 5 1 2 Weekly In addition to daily routine 1 2 3 Clean chips and dirt from the entire machine and wipe down Clean the air filter at the re
14. machine before starting PREVENT objects from flying loose Securely clamp and locate the work piece NEVER operate a machine tool after taking strong medication using non prescription drugs prescription drugs or consume alcohol which may impair concentration ALWAYS make sure the working and cutting zone is safeguarded KEEP the work area well lighted Ask for additional lighting if needed DON T slip Keep your work area clean and dry Remove swarf oil and obstacles NEVER lean on the machine Stand away when machine is running DON T get trapped Avoid pinch points caused between other machines and the machine you are working PREVENT cutter breakage Use correct cutter speed and axis feed rate for the job Make manual over ride adjustments of axis feed rate or spindle speed if you notice unusual noise or vibration Ask your supervisor for help if you need it PREVENT cutter breakage Rotate the spindle in a clockwise direction for right handed tools counter clockwise for left handed tools Use the correct tool for the job User M SYNTAGE P Series PREVENT work piece and cutter damage Never start the machine when the cutter is in contact with the work piece Dull and damaged tools break easily Inspect tools and tool holders Keep tools sharp Keep overhang short KEEP all lubrication reservoirs maintained at the correct level Always keep to the maintenance schedule Certain materials such as magnesium are high
15. INE guard or somewhere that washdown coolant can t reach after machining Oil coolant condensation might be accumulated inside of HeadStock and effect machine operating in good condition It needs to be check or clean out 39 6 Trouble shooting 6 1 ATC system 1 Tools falling down when arm rotating Tool can not be clamped well due to arm grip or stop pin is seized or arm and spindle are not aligned 2 Emergency Stop Button was pressed during tool changing 1 Release the Emergency Stop Button 2 Edit the Keep Relay 5 4 1 and 5 5 1 3 Change the mode to HANDLE 4 Press CYCLE START the tool arm will rotate CW Press FEED HOLD the tool arm will rotate CCW 6 2 Cooling Coolant and lubrication system 1 Lubrication oil level too low Refill lubrication oil into tank 2 Lubrication pressure too low Refill lubrication oil or replace whole lubricator unit 3 Coolant pumps noise Pump sealing is break down or chip materials invade into pump 6 3 Door switch system 1 Front door is opened Close front door or replace interlock switch 6 4 Alarm messages and remedies Alarm No Alarm Message Cause Remedy 1010 POCKET DOWN OR The sensors of Pocket UP Check the sensors on cylinder of UP SENSOR ERROR and DOWN are both Pocket UP amp DOWN Replace activated damaged one and press RESET 1033 3 AXES NOT HOME All three axes not in Press RESET to clear this alarm HOME posi
16. MP light up 2 p 1 Y 2 4 gt 3 Press X Y 4 buttons Axes will move until the ZERO POINT INDICATION LAMP light up Y 4 Note If any of the Machine axes are already over the referencing point it may be necessary to manually move the axis away in jog mode before beginning the reference procedure 4 3 Machine Warm up If the machine is used to produce components immediately after being started following a long idle period sliding parts may be worn 31 User M SYNTAGE P MBV Series due to lack of oil and thermal expansion of the machine can jeopardize machining accuracy To prevent this condition always warm the machine up We recommend that the machine is Warmed up prior to operation by running all axes for 20 minutes at the speed of actual cutting in the automatic operation mode The spindle speed should be gradually increased up to actual cutting speed 4 4 Spindle Warm up In case that the spindle will continue running for a long time once start working it is recommended to warm up the spindle with the spindle run in procedures as described in the Appendix 4 5 Interrupting Operation 2 When leaving the machine temporarily after completing a job turn off the power the operator panel with the Emergency Stop button and turn off the main isolator 4 6 Jobs Finished Always clean the machine and supporting equipment down after use Remove and
17. O 1 NOT CLAMP As described Check the Jig No 1 This alarm can be neglected if K13 5 set as 1 1054 JIG NO 2 NOT CLAMP As described Check the Jig No 2 This alarm can be neglected if K13 6 set as 1 1055 JIG NO 3 NOT CLAMP As described Check the Jig No 3 This alarm can be neglected if K13 7 set as 1 1056 JIG NO 4 NOT CLAMP As described Check the Jig No 4 This alarm can be neglected if K14 0 set as 1 1058 DGN K5 4 1 K5 4 was set to 1 while Set K5 4 0 trying to execute M06 tool changing 1058 DGN K5 5 1 K5 5 was set to 1 while Set K5 5 0 trying to execute M06 tool changing 1061 MAG NOT ORITATION Tool magazine not in Check the pot counting sensor or position magazine home position sensor 1062 MUST ZERO RETURN Trying to start machining ZERO RETURN all axes before program without ZERO start the machining program RETURN of the machine 42 SYN LA User Manual MBV Series 7 Appendix 7 1 Power requirements Please refer to the number on nameplate on machine for more accurate information 7 2 Pneumatic requirements Unit Value Pressure bar gt 5 5 Flow rate Litre min gt 400 Dew point at ATM Pressure 17 or lower Note The air supply must be clean 40micron particulate size and dry Do not connect direct to a compressor with a short pipe as water oil may condense out and cause a potential seizure of the spindle bearings through the air purge
18. SYN We USER MANUAL for MBV Series With Fanuc Revised September 2013 digi rne 5 1 1 Intended USE nasa eet eee es 5 1 2 Important Safety Notice and 5 1 2 1 Safe installation e 5 1 2 2 6 12 3 DOWAAI ei 6 1 2 4 Authorized personnel and 6 1 2 5 Safe working 6 1 3 Safety Urea NI ar 7 1 4 Safety 10 1 4 1 Emergency OP deedeetee 10 1 42 Guard 10 1 4 3 10 1 4 4 Pedes NETT 10 1 4 5 Cabinet door lock and 0 0 0212 11 1 5 Warning AD p 11 1 6 Residual 11 13 2 1 Consumption NIBIOrlal 13 2 1 1 Lubrication oil for linear rail and ballscrew 13 2 1 2 Lubrication oil for pneumatic system 13 2 1 3 Cutting fluid 13 c P OMGE A AT 13 2 2 Operation 15 2 3 eee 23 2 4 Spindle Tooling Been 23 2 5 Dimensions of work 1 24 2 6 Tool Magazine and 24 2 7 Chip REMON ee 2 24 Installation
19. ar of the electrical cabinet Check all polycarbonate vision panels for signs of damage crazing cracking etc or reduced visibility and replace if necessary Contact your distributor for details Check the spindle cooler chiller is running properly and the coolant temperature is near the temperature setting Check the spindle front draining hole from labyrinth is not jammed by dirt Check the air purging at the spindle nose Run the spindle for 10 seconds and stop Listen or feel the air flowing from the gap between the spindle shaft and housing 5 1 3 Yearly In addition to weekly routine 1 Remove the filter from the air filter bottle and clean replace 2 Check spindle drive belt condition and tension 3 4 Check the integrity of the electrical connections and inspect Check the condition of the linear rail wipers the condition of the insulation Check condition of coolant filters and replace if necessary 5 2 Lubrication 5 2 1 Automatic Lubrication System Lubricator supply icc oil to lubricate ballscrew once time every 15 minutes Oil discharge volume can be adjusted by a handle and illustration on the oil tank 5 2 2 FRL unit 38 User M P MBV Series FRL unit offer air cleaning and air lubricating function The lubricating oil discharge rate could be adjusted by a knob on FRL unit 5 3 Cleaning 5 3 1 Machine Interior Chip might spatter and accumulated inside of MAGAZ
20. as executed if this button was In the 20 seconds period this function can be cancelled if CYCLE START or RESET or this button was pressed Coolant Coolant pump will be activated if this button was ON vise versa In AUTO mode coolant pump will be activated by M08 command stopped by 09 or this button 16 o 19 17 Extra coolant optional Extra Coolant pump will be activated if this button was ON and vise versa 8 In AUTO mode coolant pump will be activated by M51 command or stopped by M52 or this button E C zi 18 F switch work lamp 19 F2 switch Orientation manual modes Lamp will light up when orientation don 8 20 switch Coolant Through Spindle pump optional 2 5 User Manual SYNTAK MBV Series 21 Chip conveyor forward optional Effective in AUTO and manual modes S e 4 22 Chip conveyor reverse optional Effective in AUTO and manual modes NE 6 u 1 23 Tool magazine rotation Effective in manual mode Direction of rotation determined in other software switch nsi R 24 Automatic door optional Effective in manual mode Open and close the automatic door If automatic door not existed this button can be used to release the door interlock 25 Spindle CW Effective in manual mode
21. aulic system 22 2 3 Remote Jog Axis selection Movement of one division 1 or 10 or 100 um 100 divisions round CW positive CCW negative 2 4 Spindle Tooling Tooling with a balance level of G2 5 or better should always be used Failure to do so will reduce spindle life and surface finish and may invalidate the machine warranty For safe operation make sure the tool holder and pull stud combination meet the standard below BT 40 DIN 40 CAT 40 7 24 TAPER 23 SYN LA 2 5 Dimensions of work table User Manual MBV Series 6 4 2 LIP wi i m N o o CA i 1 ea 128 l MBV 6 MBV 8 o o A Lo o 9 1 1 L LE MBV 10 MBV 12 Model A B C D F Number of T slots MBV 6 700 450 82 5 95 78 4 MBV 8 800 450 82 5 95 102 4 MBV 10 1120 600 100 100 102 5 MBV 12 1320 600 100 100 102 5 2 6 Tool Magazine and ATC 2 7 Chip Removal Tools magazine ATC cam box Tool Change Arm Chips were washed away from the interior of machine and flow into the chute where the chip screw augers or chip conveyor located Then chips were collected at the exit of screw auger or conveyor 24 3 Installation 31 Foundation Preparation The machine sho
22. cable to the machine main isolator has sufficient current carrying capacity to handle the electric power used Cables which must be laid on the floor must be protected against chips oil and coolants penetration which might cause damage In the event of power failure turn off the main circuit breaker 28 digi immediately Fuses and circuit breakers should be replaced only with suitably rated alternatives Safety devices should be replaced only with the machine manufacturers recommended parts Protect the CNC unit operating panel and electric cabinet etc from shocks which could cause a failure of malfunction Connect the power cable to main power terminal block Ensure the sign rotation of R S T phases Connect the ground cable to the Earth bar 3 6 3 Misc Check the condition of the warning labels If they are missing or become illegible order replacements from your distributor according to the part number on the label plate Do not remove warning labels After unpacking the machine clean all rust preventatives from the machine with a non volatile cleaning fluid Lightly lubricate each sliding part before trying to operate the machine Manually operate the lubricating oil pump until oil oozes out from the slide way wipers Oil volume should be filled to the indicated level Check and top up if necessary Use recommended oil brands and appropriate levels for all lubricating systems See the ins
23. circuit An air drier unit is recommended 7 3 Spindle run in procedures Max Spindle Speed 12000 rpm 10000 rpm 8000 rpm Speed rpm Time Speed rpm Time Speed rpm Time 1000 5m 1000 5m 1000 5m 5000 3s 5000 3s 5000 3s 2000 5 2000 5m 2000 5m 10000 3s 10000 3s 9000 3s 3000 5 3000 5m 3000 5m 12000 3s 4000 5m 4000 5m 4000 5m 5000 5m 5000 5m 5000 5m 6000 5m 6000 5m 6000 5m 7000 5m 7000 5m 7000 5m 8000 5m 8000 5m 8000 5m 9000 5m 9000 5m 10000 5m 10000 5 11000 15 43 SYN LA Max Spindle Speed 12000 rpm 10000 rpm 8000 rpm Speed rpm Time Speed rpm Time Speed rpm Time 12000 15m 44 User Manual MBV Series U M 7 4 M function Codes Function Description MOO Program stop spindle amp coolant MO1 Optional Program stop spindle amp coolant MO2 End of program spindle amp coolant Spindle run CW M04 Spindle run CCW MO5 Spindle stop MO6 Tool change 07 Air blast MOS Coolant ON MO9 All coolants OFF M10 4 axis clamp M11 4 axis unclamp M12 Air blast OFF M13 Spindle CW amp coolant ON M14 Spindle CCW amp coolant ON M15 Spindle STOP and coolant OFF M16 Door open
24. ck any debris in the inlet of pump or any mechanical failure of pump or motors Press the RESET button on the overload relay 1043 NO OF PARTS The number of parts to be Press RESET to clear this alarm REACH machined is achieved 1044 MAG POCKETS ARE tool register table is Check any empty pot in the tool FULL full while trying to execute register table D1 D24 command to load tool into magazine in MDI mode 1046 ARM MOTOR The motor of ATC arm is Check any mechanical failure of FAILURE overloaded or damaged motor Press the RESET button on the overload relay 1047 CHIP MOTOR As described Check any chips stocked in the OVERLOAD chip conveyor or any mechanical failure of motor Press the RESET button on the 41 SYN LA User Manual MBV Series Alarm No Alarm Message Cause Remedy overload relay 1049 TOOL NO The tool number in the Correct the tool number either in DULICATED POT spindle is identical tothe the spindle or in the tool pot XX XX SPDL NO tool number registered in tool pot XX 1050 SPINDLE OIL As described Check the spindle oil cooler and COOLER ERROR correct the problem following the instructions from the oil cooler manufacturer 1051 DUPLICATE TXX IN The tool number is Correct the tool number either in POT YY amp ZZ identical in tool pots YY the tool pots YY or ZZ and ZZ 1052 JIG NOT CLAMP As described Check the Jig 1053 JIG N
25. dispose of chips and clean the covers and windows etc Return each machine component to its initial condition Check wipers for damage and replace if necessary Check coolants hydraulic oils and lubricants for level amp contamination Change them if you suspect they are contaminated Clean the filter on the top of the coolant tank Turn off the power first on the control panel with the emergency stop button and then at the main isolator before leaving the machine at 32 end of the shift 4 7 Jog Axis To manually jog an axis first turn the mode selection switch to JOG mode Turn the axis movement override to desired speed 0 1260mm min Press the button corresponding to the desired axis and direction 4 Z t Y 7 4 1 For rapid movement press the RAPID MOVEMENT button together with button of desired axis and direction The feed rate of RAPID JOG can be overrided by RAPID MOVEMENT SPEED override FO and 100 are set in parameters 25 50 33 gigi tis 4 8 Jog Axis by MPG To manually move axis using the Handwheel first turn the mode selection switch to HANDLE mode Then use the knobs and MPG on remote jog box 4 9 Tool Loading Unloading In JOG or HANDLE mode press AUTOMATIC DOOR to unlock the guard door uu Open guard door of machine While holding the tool press and hold the clamp unclamp butt
26. e the machine s weight If the machine is to be lifted by Fork Truck the minimum capacity should be 12096 of the machine weight and with a minimum tine length of 2 000mm 3 5 Leveling of Machine a Make sure the location of the machine is exactly where you need it to be Ensure allowance for access for operation cleaning and maintenance is provided See the installation dimensional drawing for minimum clearances b Locate the floor pads which are packed with the associate kit and position them on the floor under each jack bolt When satisfied 26 User M P Series lower the machine gently onto the pre located pads Ensure jack bolts are screwed down to provide a 10 to 15mm gap from the underside of the base casting to the floor c If you use skates then employ the jack bolts with suitable support packing to raise the machine enough to remove the skates and finally set onto the floor pads 3 6 Before Power ON 3 6 1 Grounding a The machine must be grounded in order to protect personnel and the machine from electrical hazards Grounding must be in accordance with the standards for electrical equipment b Ideally the grounding point should be as close as possible to the mach
27. er OK delay time Timer 25 T48 Reserved Timer 26 T50 2000 Fixture No 1 4 Clamp delay time Timer 27 T52 2000 Fixture No 1 4 Unclamp delay time Timer 28 T54 n a Timer 29 T56 Fixture Clamp delay time Timer 30 T58 Pocket UP OK delay time Timer 31 T60 Pocket DOWN OK delay time Timer 32 T62 n a Timer 33 T64 Gear change time Timer 34 T66 Gear shift abnormal detection time Timer 35 T68 Gear change duration time 49 gigi Timer 36 T70 ZF gearbox oil pressure low delay time 50 digi 7 5 3 Counter Counter NO ADDRESS DATA sec DISCRIPTION 11 C40 600 Lubrication activation interval 7 5 4 Keep Relay list Address DISCRIPTION K00 0 0 Program cannot be executed without ZERO RETURN of axes 11 Program can be executed even without ZERO RETURN of axes 0 Display alarm message when the air pressure is low 1 6 1 Do not display alarm message even the air pressure is low 0 Z axis with counter weight K00 2 1 2 axis with pneumatic counter balance and pressure sensor 0 Z axis must be in ZERO position before X Y axis start moving during ZERO RETURN by pressing CYCLE START 1 All axis moving at same time during ZERO RETURN by pressing CYCLE START K00 4 0 Manual absolute value ABS is set by parameter 1 Manual absolute value ABS is set by control panel
28. gineers shall be authorized the User Company and properly trained in the use of the machine 1 2 5 Safe working practice Workholding devices lifting equipment tooling and their use shall be the responsibility of the user It is the user s responsibility to protect against the hazards caused by swarf leaking oil or coolant and their use Use of proprietary oil or coolant is the responsibility of the user Special instructions from the suppliers concerning their use should 6 be carefully read and understood before use To prevent body injury safe working practices should be employed when operating or servicing the machine 1 3 Safety Cautions List It is the user s responsibility to ensure all local regulations and safety instructions are followed Users should consult with their own safety representative to ensure that all such regulations are known and acted upon DON T run the machine until you have made clear to your supervisor that you understand the potential hazard of spindle rotation the throwing of coolant and the throwing of swarf from the cutting process DON T run the machine until you have read and understood all manuals provided with the machine DON T run the machine for the first time without a qualified instructor Ask your supervisor for help when you need it DON T get caught in moving parts Remove watches rings jewellery neckties and loose fitting clothes
29. he axis away from travel limit Then zero return the axis 9 Single block execution switch s Effective in AUTO mode Only one block will be executed when the CYCLE START was pressed if this switch was turned ON 10 Ignore marked blocks switch Blocks with marked will be ignored if this switch was ON ig td d D 11 Dry run 5 In AUTO MDI or TAPE modes the F command will be overrided by Feedrate override knob if this button was GOO will also overrided by Rapid movement speed override knob if proper parameter 1410 was set Es 12 Air blow optional Compressed air will be ON at blowing nozzle if this button was ON The compressed air will be OFF if there were commands M06 or in program M15 will turn ON the compressed air and M16 will turn it OFF HLX User Manual SYNTAK MBV Series 13 Optional program halt 01 will be effective program halted if this button was ON Need to press CYCLE START to resume program execution ps E i S 14 Axis movement lock Axis movement will be halted if this button was Program gt keeps execution and M S T commands were not affected Lp zi Machine must be ZERO RETURN after this function 15 Automatic power off Machine will be automatically powered OFF 20 seconds setting b in diagnostic parameter after M30 w
30. ine c A qualified electrician must carry out the grounding work otherwise serious injury death or accidents involving machine damage could result d The machine must be grounded in one of the following ways 1 Independent grounding Regardless of the type of grounding system used the earth loop impedance of the supply which connects the machine to ground earth must not exceed 1 ohm e Never ground the machine in the manner shown in the illustration below 27 more than one grounding conductor wire can be connected to a single terminal If the grounding conductors are connected in the manner shown in the illustration above a faulty connection at one of the terminals could cause grounding current to be fed back to the machine resulting in serious accidents Once the electrical and air supplies are provided make the connection to the machine The delivery dimensional drawing gives details of input locations 3 6 2 Power connection ON NO ACCOUNT MUST YOU SWITCH ON THE MACHINE WE PREFER YOU TO REMOVE YOUR ISOLATOR FUSES OR TRIP CIRCUIT BREAKERS A qualified electrician should only carry out connection of the power lead to the machine Cables cords or electric wires of which insulation is damaged can produce current leaks and electric shocks Check their condition before connecting Ensure the power
31. ine before cleaning the machine through the side door access panels 2 Introduction 21 Consumption Material 2 1 1 Lubrication oil for linear rail and ballscrew Lubrication oil for linear rail and ballscrew are as follow Qt y Recommended oil 4 liter FEBIS K68 ESSO VACTRA NO 2 MOBIL TONNA OIL T68 SHELL 2 1 2 Lubrication oil for pneumatic system Oil for pneumatic system is recommended to use same specification of ESSO TERESSO 32 or SHELL TELLUS OIL 32 Total quantity oil for machine in every half year need 120 cc 2 1 3 Cutting fluid Cutting fluid and mixing ratio with water are recommended by following table The micro biological condition should be monitored and controlled via sterilization or replacement of coolant Marker Castrol No Type Application Dilution ratio with water 1 SYNTIOL 9913 Aluminum cutting only 1 15 2 ALUSBL B Aluminum cutting only 1 15 3 HYSOL X Various material cutting 1 20 MBV 6 MBV 8 MBV 10 MBV 12 Tank capacity L 220 220 440 520 2 1 4 Oil for chiller Hydraulic oil or lubrication oil with viscosity 4 300cSt The 13 User M SYNT ATE P Series temperature of the environment should also be taken into consideration The hotter the weather a less viscous fluid should be used User Manual MBV Series SYNTANS 2 2 Operation Panel
32. ion with this machining centre must fit within the working envelope available Under no circumstances must any such workholding device be used when it would require the need to override defeat the safety interlocks fitted as standard to this machine 1 4 Safety Devices 1 4 1 Emergency Stop Make yourself aware of the location of the emergency stop push buttons which should be well known so that they can be operated at any time without the need to look for them Test the push buttons periodically for their correct operation The emergency stop push buttons is located on the operator panel Hard wired over travel switches on both ends of all 3 axes to check whether the axis has traveled beyond the allowed boundary Once the Emergency Stop button is pressed or any of the over travel limit switches have been operated the machine will stop immediately and the power supply to the drives is removed and go into an Emergency Stop condition 1 4 2 Guard Machine equipped front door ATC door side door and full guard as safety device to protect operator Doors are not allowed open in any time when machining 1 4 3 Window Machine equipped with 6 mm thickness PC safety glass on front and side guard The window impact resistance capacity is at 8 39kg m Any crack on the window is not allowable 1 4 4 Door Interlock The machine has 1 interlocked main access door at the front The main door is shot bolted shut a
33. ith all service pipes and cables clear of the operation area so as not to cause a hazard Access must be allowed for safe maintenance swarf and oil disposal including safe stacking of machined and un machined components eee 1 2 2 Machine guarding This Machine is fitted with completely enclosed guards as standard In certain cases and tooling applications additional guarding may have to be provided by the user The standard machine guarding has special safety interlocks on the guard doors that comply with the Machinery Directive Guards and interlocks must be kept fully maintained and tested by the customer and shall not be removed The guards are made with clear observation windows having high impact resistance to provide operator safety and a clear unobstructed view of the operations in process The opening of any guard door provides access to potential hazard areas Opening of the front working area guard doors is not allowed whilst the spindle is rotating but it is still possible to manually initiate axis movements whilst these doors are open albeit at a reduced traverse rate Extreme care must therefore be used at all times 1 2 3 Software Unauthorized changing of machines software or control parameters is hazardous and is not permitted The machine maker will not accept any liability whatsoever for unauthorized changes in this area 1 2 4 Authorized personnel and training Operating service and maintenance en
34. ly flammable in dust and chip form See your supervisor before working these materials PREVENT fire Keep flammable liquids and materials away from the work area and from hot swarf PREVENT the machine from moving unexpectedly When leaving the machine unattended not producing leave switched in the MANUAL mode DON T use the machine in a volatile atmosphere Electrical devices fitted to the machine are for normal factory use and are not explosion proof ALWAYS keep the machine clean and do not let swarf collect ALWAYS keep the area around the machine clean and tidy Opening the guards creates the potential for residual coolant and swarf to fall to the swarf tray and possibly to the floor Good housekeeping minimizes the potential for trips slip or fall of all personnel INFORM all other personnel who approach the machine about the hazards described in this safety list When making adjustments with spanners always ensure that the required leverage is safely applied Always avoid slippage Always apply the leverage by pulling never by pushing Always use the correct size spanner Ensure the spanner is not damaged Do not use organic chemical solvents to clean the machine guards or compressed air services equipment The windows are manufactured from bulletproof polycarbonate sheet This material does deteriorate with age and should be exchanged within the time period described later in this manual Any workholding device used in conjunct
35. nd can only be opened once the spindle is stationary and there is no program running Power On Safety Circuit Allows the operator to execute certain tasks whilst the front door is open SYNT AGE Limited machine functionality is available to the operator whilst the main door is open The handwheel and jog keys are allowed to move the machine axes at feed rates of 1260mm min and less Spindle operation is prohibited whilst the main door is open as the spindle contactor is hard wired through the door interlock switch Selection of automatic program running is prohibited until the doors are shut 1 4 5 Cabinet door lock and switch The main power switch of machine must be shut off and turned further CCW to open the cabinet door 1 5 Warning Labels Most of the warning labels are self explained as following 1 6 Residual Risks The machine tool has been designed and manufactured to the highest standards but still your attention is drawn to the following RESIDUAL RISKS existing within the machine SYNT AG Always check that the cutting tool product you are using is approved to run at the selected speed If non suitable cutting conditions are selected coolant can splash and swarf can escape over the sides of the guard Failure of the Z axis servo motor brake could allow the head to fall when the power is OFF Do not operate the machine with the side door access panels removed Isolate the mach
36. ning time defined by timer in PLC t Tool cleaning time NOT defined by timer in PLC 0 Pocket DOWN after magazine rotation K04 0 1 Pocket UP after magazine rotation K04 1 0 Flash alarm lamp 1 Rotating alarm lamp K04 2 0 Machine Lock switch MLK NOT effective 11 Machine Lock switch MLK effective K04 3 0 Spindle halt only in AUTO mode f1 Spindle halt in any mode K04 4 K04 5 0 with automatic door Bere 1 without automatic door K04 7 4th axis NOT effective 4th axis effective 52 Address DISCRIPTION K05 0 K05 1 K05 2 K05 3 0 ATC arm motor jog NOT effective default K05 4 1 ATC arm motor jog is effective if pocket down spindle oriented Z axis in ZERO position K05 5 0 ATC arm motor jog NOT effective default 7 1 5 4 1 ATC arm motor jog is effective anyway K05 6 0 Tool change at 2nd Home position of Z axis 1 Tool change at 1st Home position of Z axis K05 7 0 Tool change after all three axis at Zero position 1 Tool change after Z axis at Zero position KO06 1 0 Lubrication unit controlled by external timer 1 Lubrication unit controlled by PLC 0 Signal from tool arm is type B K06 2 g ii 1 Signal from tool arm is type A 0 No display of coolant level low alarm K06 3 1 Display coolant level low alarm 0 Signal from magazine counter is type B K06 4
37. on on the machine head to release the tool See illustration Replace tool and release the button to clamp Close guard door of machine Using AUTO or MDI load the correct tool number into the Magazine 4 10Large Tool management Large tool is the tool with diameter larger than the allowable diameter as described on the label near tool magazine This kind of tool can be used providing the adjacent tool pots are empty For arm type tool changer the tool number is independent to the pot number of magazine Therefore a carefully management of the tool number of large tool is necessary In this machine the usable tool numbers are Standard tools 1 through 79 unique number Large tools 80 through 98 unique number Separator tool 99 virtual tools in the adjacent pots of large 34 User M SYNT ATE P MBV Series tool No tool 0 These number should be input in the data table D1 D20 or D24 depending on the capacity of the tool magazine There was another data table D51 D70 or D74 where the tool type information was stored Standard tools 33 Large tools 66 Separator tool 99 No tool 0 There was another data table D100 D108 where the large tool number was registered The tool number in spindle was logged in D457 Procedure to input the tool information 1 In HANDLE mode press the magazine rotation button to turn the pot No 1 at the ready pot position bottom of the magazine the parame
38. s movement Y Effective in JOG and ZERO RETURN modes Move Y axis in positive direction Z axis movement Effective in JOG and ZERO RETURN modes Move Z axis in positive direction 34 4 20 User Manual SYNTAK MBV Series 35 4 axis movement Effective in JOG and ZERO RETURN modes Move 4 axis in positive direction 2 X axis movement Effective in JOG and ZERO RETURN modes Move X axis in negative direction 36 I 37 Y axis movement Effective in JOG mode Move Y axis in negative direction Z axis movement Effective in JOG mode Move Z axis in negative direction 38 4 axis movement Effective in JOG mode 4 Move 4 axis in negative direction 39 40 Axis ZERO point indication lamps Lamp light when each axis moved to zero point X Y 2 4 41 Status lamps ATC Light up when ATC is ready Moo oo Light up if the commands were executed and effective 42 Alarm lamps SPINDLE NC LUBE PRESS Li Spindle Spindle motor over temperature or over load Spindle speed incorrect Spindle orientation incorrect Fuse broken NC Program error Operation error Over travel Controller malfunction 21 User M P MBV Series LUBE lubrication oil level too low only single block execution allowed PRESS Low pressure of pneumatic or hydr
39. ters editing screen 3 DATA EDITING KEY must be turned ON 4 Press 5 Press softkey PMC 6 Press softkey 7 Press softkey DATA 8 Enter the tool information to related address Example Pot number Address Tool number Address Tool type 0000 DO 99 D50 99 35 SYN LA User Manual MBV Series 36 0001 01 8 051 33 0002 02 50 052 33 0003 03 3 D53 33 0004 D4 51 D54 33 0005 D5 52 D55 33 0006 D6 6 D56 33 0007 D7 9 D57 33 0008 D8 10 D58 33 0009 D9 2 D59 33 0010 D10 5 D60 33 0011 D11 7 D61 33 0012 D12 12 D62 33 0013 D13 13 D63 33 0014 D14 14 D64 33 0015 D15 99 D65 99 0016 D16 85 D66 66 0017 D17 99 D67 99 0018 D18 92 D68 66 0019 D19 99 D69 99 0020 D20 0 D70 0 Address Tool number D100 99 D101 85 D102 92 D103 0 D104 0 D105 0 D106 0 D107 0 D108 0 Address Tool number D457 1 5 Maintenance DANGER Before carrying out any maintenance work ensure that the machinery is switched off and disconnected from the main power supply Also ensure that the necessary warning signs and or locks are appointed to stop any unauthorized persons from switching the power on to the machine until the work is complete and the machinery is safe to operate The above warning signs or indications should be secured by
40. tion when and then ZERO RETURN the axes trying to execute M06 command 1034 Z AXIS NOT HOME Z axis not in HOME Press RESET to clear this alarm position when trying to and then ZERO RETURN the Z execute M06 command axis 1035 T COMMAND gt 98 The tool number in T Press RESET to clear this alarm 40 SYN LA User Manual MBV Series Alarm No Alarm Message Cause Remedy command is larger than then correct the tool number 98 1037 T NO NOT The tool number in T Press RESET to clear this alarm REGISTERED command was not then correct the tool number registered 1038 LOW AIR PRESSURE As described Check the supply of compressed air and the pressure switch 1039 ATC NOT READY Arm is not in Home Check the sensor of arm position position Spindle not in tool Execute M87 in MDI mode to get clamped condition into tool clamped condition Or check the tool clamped sensor 1040 CTS SYS SUCK O L Coolant pump including Check any debris in the inlet of CTS system overload pump or any mechanical failure of pump or motors Check the phase of power supplying through the relay Press the RESET button on the overload relay 1041 4TH AXIS CLAMPED 4th axis is still Press RESET to clear this alarm clamped while executing and execute unclamp command in command to move 4th MDI mode axis Check the clamp unclamp sensor 1042 OIL COOLER FAUILE Cil cooler overload Che
41. truction plate at the rear of the machine The coolant system comprises of a separate tank which houses the coolant pumps and is located beneath the front and left sides of the machine 3 7 First Time Power ON 29 3 7 1 Rotation Direction of Motors The rotation of 3 phase motors of pumps chips removal and fans might be reversed due to the different phase sequence of city power U V and W Please confirm the rotation of all the coolant pumps and cooling fans 3 7 2 Spindle Run in The grease inside the bearings of spindle might be concentrated by gravity due to temperature variation during the transportation and storage It is a MUST to run the spindle following the procedures described in Appendix Negligence of these procedures might void the warranty of the spindle 30 4 Operation 4 1 Power ON OFF Never turn off power during automatic operation or with the spindle or axes running unless an emergency occurs It is better to interrupt the program by pressing the Cycle Stop push button Ensure that all Emergency Stop Buttons are unlocked Turn the machine on at the isolator Press the power ON button on the control panel and the machine will take a few moments to boot up 4 2 Reference or ZERO RETURN the Machine 1 Turn the mode selection switch to ZERO RETURN 2 Press Z button Z axis should move upward until the ZERO POINT INDICATION LA
42. uld be sited on a flat area maximum fall 3mm in 3 m free from cracks and expansion joints The composition of the floor and sub structure should be of suitable construction to bear the weight of the machine Any friable areas should be made good using recognized building construction techniques If doubt exists we recommend you consult your building architect 3 2 Power Preparation 3 2 1 Line Configuration The machine is designed to operate from a 3 phase AC incoming power source with an earth star point as shown in the right This incoming line short circuit current must be at least 2kA Sv Phase W Phase In other cases such as those examples shown in figures below an isolating transformer of 15kVA or larger capacity with an earth grounded WYE secondary is required between the incoming lines and the machine The incoming line short circuit current must again be least 2kA Other Incoming Line Configurations 7 T 3 3 Unpacking 25 SYNT AGE eee The machine was fixed on a skid during which could be pulled to the opening of container and then moved by a fork lifter Select a chain according to the weight of the machine Tie the chain to the skid and make sure the connection is secured Slowly pull the machine and monitor the gap between the machine and the wall of the container 3 4 Machine Lifting Any lifting cables and slings must be rated to tak
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