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User`s Manual, ZAT-650 ATC

1. Wa Offset amounts Reference position z z _ 40 Chapter 5 Operation in the NC Code Mode Chapter 6 NC Code Reference This chapter describes in detail the extended NC codes that become available through the addition of the ATC unit 41 G43 G49 Tool length Offset Mi Format 645 H number G49 Parameter Function No error range Effective range number Offset number 0 through 16 0 through 16 Description This moves the Z axis by the specified offset amount It is used to correct for a change in tool length due to a tool change to keep the position of the tip uniform and so on G43 starts tool length offset You set the offset amount offset No 1 through No 16 in the machine ahead of time and specify the offset number with number G49 cancels tool length offset Specifying 0 zero for number with G43 simi larly cancels tool length offset If an axis movement command is present within the same block as a G43 command the end point for axis movement is the Z axis coordinate for the movement destination plus the offset When no axis movement command is present the command is taken to be for a movement distance of zero and movement along Z axis by only an amount equal to the offset is performed This is the same for both absolute and incremental coordinates G43 and G49 are commands in the same group These commands remain in effect even outside the block unt
2. 27 Points to Observe When Loading Tools a 27 Coading a TOM E 27 3 3 Selecting Tools Through Key 5 28 3 4 Important Notes on Prolonged Continuous Cutting ccccccccceecessneeeeeeeeeesneeeeeeeesseneeeeeeessenaes 29 When the Tool Holder Fails to Come Loose II 29 Howto Prevent the PO l E A ab e ian oue 29 How to Correct the Problem If It Occurs 29 Chapter 4 Operation in the RML 1 31 4 1 What Is the Tool length Offset ccccceceseeeeeeneeeeeneeeeeeeeeeeeeaeeesecaeeeseeeeeeeaeeeeseaeeeeeaeeesesaeseaeeess 32 4 2 Measurement of Tool Length and Starting Cutting 33 Stepil Measure the Tool Lengths ete E Good se 33 Step 2 Set ZO the Z axis Origin POMI oss 34 Chapter 5 Operation the NC Code Mode ccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 35 5 1 Tool Selection and Tool length Offset Tool Selection rer rrer errr rrr errr errr rere rrr errr rere reer rer etree erste treet rere errr rer errr errr rrr ire rrr irs Tool length Offset Offset Amounts for Tool Selections Made Using Key Operations 5 2 Preparations for Tool length
3. After connecting the hose secure it in place using a retainer To the compressed air lt j Without the safety cover Mount it on the back of the machine Air hose To connect To detach Insert all the way into the Pull out while pressing in the joint ring Mount the control box on the main unit With the safety cover Mount it on the left side of the cover and pull the cables inside 2 4 Installing the ATC Unit M4 x 8mm cap screw mai UI J 0 After connecting the hose secure it in place using a retaining band It is held in place by magnets The mounting location is different when you re using the optionally available safety cover Chapter 2 Implementing the ATC Unit 15 2 4 Installing the ATC Unit 5 Connect the hoses and cables Sa KECA m Screws Large Small Small Large connector connector hose hose 1 Connect the large connector to the back of the machine 3 Detach the rubber cap and press the white retaining band into the hole to attach White retaining band
4. 1 Assemble a cap screw M6 x 12 mm washer and 2 Slide the tool magazine to pass the square nuts into square nut onto each of the four corners of the tool the T slots and loosely tighten at the location on the magazine Tighten the cap screws loosely table shown in the figure Orient the magazine so that the openings face toward the left Tool magazine screw 7 Table ai wi Washer as T slot Washer Li Square nut Square nut T slot Cap screw When Using in Combination with a Rotary Axis Unit Place on the base of the rotary axis unit and loosely tighten using two cap screws M6 x 12 mm and washers Orient the magazine so that the openings face toward the front 5 Install the positioner on the spindle unit The orientation for installations differs depending on whether you are using the unit with no rotary axis unit or with the rotary axis unit When Using with No Rotary Axis Unit Positioner Secure in place with the raised area on the positioner butted flush against the spindle unit Position the slot here Screw with a knob L Spindle unit Positioner Positioner Screw with Position the slot here f a knob Chapter 2 Implementing the ATC Unit 19 2 4 Installing the ATC Unit 6 Position the tool magazine flush against the positioner then tighten the cap screws completely Perform positioning with the tool magazine standing
5. using the unit combination with a rotary axis unit position the tool magazine and the rotary axis unit within the axis movement area Take this into account in the programming to ensure that the tool does not collide with these Chapter 8 Other Information 59 8 4 Tool magazine Expansion Expansion of the installed tool magazines is possible and you can install a total of two tool magazines However expansion is not possible when you are using the ATC unit in combination with a rotary axis unit The expansion tool magazine is an optionally available item About the Installation Procedure for the Expansion Tool Magazine The procedure differs depending on whether you are installing two tool magazines at the same time when installing the ATC unit or whether you are installing an expansion tool magazine at a later time Follow the procedure that corre sponds to the situation 1 Table aQ ga BS OO A 050 Expansion tool magazine JUUN 0 J Z0 sensor base A A 60 Chapter 8 Other Information 8 4 Tool magazine Expansion Installing at the Same Time As Installation of the ATC Unit This procedure is for installing the expansion tool magazine at the same time when installing the ATC unit Procedure 1 Go to 2 4 Installing the ATC Unit and carry out Step 1 Install the Spindle a
6. Fasten the spindle tool and material securely in place Otherwise they may come loose during cutting resulting in injury Do not wear gloves a necktie or wide sleeved clothing They may become caught in the tool resulting in injury In addition to these symbols the symbols shown below are also used Set the cutting area so that the tool does not contact the tool magazine the rotary axis unit or the like Pieces of the tool or workpiece may fly off resulting in injury Do not allow liquids metal objects or flammables inside the machine Such materials Q Y can cause fire Insert the air hose firmly as far as it will go and secure it in place with a band Otherwise the air hose may fly loose and blow compressed air resulting in injury D Notice Indicates information to prevent machine breakdown or malfunction and ensure correct use 8 Point Indicates a handy tip or advice regarding use AN To Ensure Safe Use Chapter 1 System Structure This chapter describes the possible configurations using this unit 1 1 Features of the ZAT 650 The ZAT 650 is a automatic tool changer unit ATC unit that adds automatic tool changing functions to the MODELA Pro It makes it easy to perform cutting operations while using a number of tools of different types The tool length offset feature and the automatic measurement feature for tool length make it nearly unnecessary to modify pr
7. Return the tool tool holder to the magazine before you switch off the power As a rule you should never power down while the spindle is gripping a tool 26 Chapter 3 Basic Operation 3 2 Usage and Handling of the Tool Magazine Points to Observe When Loading Tools Always make sure the machine is in the following state before performing tasks such as loading or changing a tool tool holder Performing such tasks incorrectly may result in injury or malfunction The spindle must not be gripping a tool Cutting operations must have ended and operation stopped Loading a Tool Loading Location Load the tool tool holder as shown in the figure You may load it in any stock or load more than one When loading carefully clean away any buildup of cutting waste on the tool holder and magazine 2 Tool holder Stopper A Stopper A Stopper B Tool magazine 21 Insert the groove on the tool holder into stopper A and while lifting it up slightly press it in as far as it will go Adjustment of the Stopper B Adjust the height of the stoppers B to match the loaded tools Lower it if it strikes the tool holder and raise it if it does not reach the tool Also the stopper B has two notches one large and one small If the diameter of the end mill is 5 mm or less reinstall the
8. position after correction Tool length B KREE Tool length C To enable this it is necessary to measure the length of each tool and register save these measurements in the machine ahead of time There are two registration methods one where the tool lengths are measured automatically and one where you measure the tool lengths and register the values yourself In the RML 1 mode tool length offset is always performed according to the registered tool lengths Tool length offset is carried out when a tool select operation is performed regardless of whether it is performed by an instruction from the computer or by key operation 32 Chapter 4 Operation in the RML 1 Mode 4 2 Measurement of Tool Length and Starting Cutting This section describes the preparations up to starting cutting using a program that supports automatic tool changes When the preparations are complete you simply use the program to specify the tool numbers you want to use for cutting There is no need to perform operations such as resetting Z0 after every tool change Step 1 Measure the Tool Lengths This section explains how to measure tool length automatically The procedures are different depending on whether you are using the unit in combination with a rotary axis unit Procedure 1 Load the magazine with the tools you want to use for cutting When using with no rotary axis unit When using in combination with a rotary axis unit Connect the ZO
9. stopper B orienting it to use the small notch Large notch Small notch Chapter 3 Basic Operation 27 3 3 Selecting Tools Through Key Operations When you want to select a tool using key operations follow the steps below The operation differs slightly depending on whether you are using RML 1 or the NC code command set Procedure 1 Display the main menu Use the dial to select ATC then S13 2 Use the dial to choose TOOL SELECT then press the EN 13 gt 1 TOOL SELECT TER key 2 OFFSET NUMBER 3 Use the dial to select the number of the tool you want to 13 1 gt 1 TOOL1 grasp then press the ENTER key If you are in the NC code 2 TOOL2 mode then press the ENTER key a second time The unit moves to retrieve the tool from the stock number you selected If a tool is already gripped then it is changed Also compressed air is blown Stock No 1 from the air nozzle and the chucking portion at this time to clean away cuttings No 2 No 3 W If you are in the NC code mode then tool length offset is not enabled in this operation and only the tool selection operation is performed Eg See 5 1 Tool Selection and Tool length Offset 4 Use the dial to select RETURN then press the ENTER 13 1 5 RETURN ka The gripped tool is returned to the magazine Notice Important Note When RELEASE Is Selected If RELEASE is selected in step 3 or 4 above a forced release of the
10. 1 Menu Items 13 gt 6 MAGAZINE SETUP This moves the spindle to the reference position when installing a magazine The reference position changes automatically de pending on whether a rotary axis unit is installed MAGAZINE POS1 This moves the spindle to the magazine adjustment position MAGAZINE POS2 This moves the spindle to the magazine adjustment position This is displayed only when 13 gt 7 NO OF STOCKS is set to 8 It is used when an expansion magazine is installed MAGAZINE1 OFT This displays the magazine X and Y direction correction values that were set when the magazine was installed MAGAZINE2 OFT This displays the magazine X and Y direction correction values that were set when the magazine was installed This is displayed only when 13 gt 7 NO OF STOCKS is set to 8 It is used when an expansion magazine is installed 13 gt 7 NO OF STOCKS Saved Yes Default 4 Setting range 4 or 8 This sets the number of tools housed Set this to 8 when the number of tool magazines is expanded to two Note that when the ATC unit is used in combination with the rotary axis unit the setting is fixed at 4 The number of stocks and the like displayed by 13 gt 1 TOOL SELECT 13 gt 2 OFFSET NUMBER and 13 gt 3 LENGTH SCAN changes according to this setting It also affects 13 gt 6 MAGAZINE SETUP PAUSE gt AIR PRESS This is added to the menu that appears when you press the PAUSE key Like 13 gt 5
11. 13 gt 3 TOOL LENGTH 13 gt 3 TOOL LENGTH Saved Yes Default 0 mm Setting range 115 00 through 115 00 mm This manually sets the offset amount for tool length offset You can make individual settings for offset No 1 through No 16 The menus cannot be used to assign offset amount numbers to tools This is specified by the program The 16 registered offset amounts are shared by the RML 1 mode and the NC code mode 13 gt 4 AIR PRESS This displays the pressure of the compressed air supplied to the control box The machine pauses while this menu is displayed 13 gt 5 MAGAZINE SETUP This moves the spindle to the reference position when installing a magazine The reference position changes automatically de pending on whether a rotary axis unit is installed MAGAZINE POS1 This moves the spindle to the magazine adjustment position MAGAZINE POS2 This moves the spindle to the magazine adjustment position This is displayed only when 13 gt 6 NO OF STOCKS is set to 8 It is used when an expansion magazine is installed MAGAZINE1 OFT This displays the magazine X and Y direction correction values that were set when the magazine was installed MAGAZINE2 OFT This displays the magazine X and Y direction correction values that were set when the magazine was installed This is displayed only when 13 gt 6 NO OF STOCKS is set to 8 It is used when an expansion magazine is installed 52 Chapter 7 Menu Reference 7
12. 2 Pull in the small connector and the small hose through the hole in the top of the spindle and connect to the air cylinder 4 Connect the large hose to the air nozzle and secure with the white retaining band The joint rotates freely 16 Chapter 2 Implementing the ATC Unit 2 4 Installing the ATC Unit Bundle the hoses and cables together and secure with the black retaining bands Ensure enough slack that the hoses and cables do not catch or snag when the spindle head moves from side to side Next go on to Step 3 Install the Tool Magazine Chapter 2 Implementing the ATC Unit 17 2 4 Installing the ATC Unit Step 3 Install the Tool Magazine This procedure requires one tool holder Be sure to have it on hand before you start The mounting location of the tool magazine differs depending on whether you re using the ATC unit in combination with a rotary axis unit 8 Point To Install the Expansion Tool Magazine t Refer to 8 4 Tool magazine Expansion Procedure 1 Supply compressed air to the ATC unit Pull up the knob on the air regulator then adjust so that the meter reads 0 5 to 0 65 MPa After adjusting press in the knob to return it to its ori
13. 56 8 2 Corrective Action for Error Messages ccccccccssceceeseeeeneeeeesseseneeeeeeseceseeeeeesseesaeeeeeessssiaeeeeensanees 57 8 3 X Y and Z AXIS TravelsS T A A E A E A E 59 8 4 Tool magazine Expansion neisa a a A Aa EEEE EE SANAAT AE DARNE 60 About the Installation Procedure for the Expansion Tool Magazine 60 Installing at the Same Time As Installation of the ATC Unit Installing an Additional Tool Magazine at a Later Time 8 5 Extended RML 1 Commands 0000 lttteeeeetoeoeeeoetooooeeeeooooooueoseoooooeeeoeoooooenoeeoooooeneeoooonnneeseooonnaaseeoeoen 826 SPECIICATIONS k R N RA od es ANE one PAYS onn Other company names and product names are trademarks or registered trademarks of their respective holders Copyright 2002 Roland DG Corporation http www rolanddg com Table of Contents ANTo Ensure Safe Use About A WARNING and A CAUTION Notices WARNING Used for instructions intended to alert the user to the risk of death or severe injury should the unit be used improperly Used for instructions intended to alert the user to the risk of injury or material damage should the unit be used improperly Z CAUTION Material damage refers to damage or other adverse effects caused with respect to the home and all its furnishings as well to domestic animals or pets About the Symbols The A symbol alerts the user to important instructions or warnings The specific meaning
14. HIGH TORQUE then press the ENTER key 10 2 SPINDLE UNIT lt HIGH TORQUE gt 2 Open the spindle cover 3 Adjust the orientation of the air nozzle to blow away any buildup of cutting waste from the stock area on the top surface of the magazine Adjust the air nozzle as required so that it does not strike the tool workpiece or other areas during operation gt Bottom surface of the spindle 45 mm 2 in 25 mm 1 in Align the nozzle tip with the height of Orient the nozzle tip toward the center the bottom surface of the spindle then of the spindle angle it downward 24 Chapter 2 Implementing the ATC Unit Chapter 3 Basic Operation Common for RML 1 and NC Codes This chapter describes the most basic operations that you should know before you try to use the unit Be sure to read it before you start work 25 3 1 Important Notes on Switching the Power On and Off Important Notes When Switching On the Power When the power is switched on while the spindle is gripping a tool a forced release of the tool is performed Inadvertent operation while in this state may result in the tool being dropped so be sure to give attention to this point Pressing the ENTER key after switching on the power performs a forced release immediately without a return to the magazine Carry out this operation while securely supporting the tool by hand to keep it from being dropped Before You Switch Off the Power
15. Holders Use tools that meet the following conditions Required Tool Dimensions Taper shank Dia 45 mm or less Pull stud i Dia 10 mm or less JBS4002 15 45 special 18 mm or more when gripped _ 110 mm or less Mi Dimension Drawing of the Taper shank Area Gauge surface abe 5 7 24 taper pe Unit mm 12 Chapter 2 Implementing the ATC Unit 2 4 Installing the ATC Unit The installation methods are partly different depending on whether the unit is to be used in combination with a rotary axis unit When you are using the units in combination finish installing the rotary axis unit before you install the ATC unit Step 1 Install the Spindle and the Cylinder Procedure 1 In the following operation you move the spindle head to the left 1 Close the spindle cover on the main unit 2 Switch on the power to the machine then press the ENTER key The spindle head moves to the left 2 Switch off the power and unplug the power cord Q Be sure to switch off the power before you attempt installation Otherwise unintended operation of the machine may result in injury 3 Install the air nozzle on the spindle unit Tighten using a wrench 14 mm Air nozzle 4 Align the pin on the back of the spindle unit with the pin hole on the slider and support it with your hand 5 Insert the cap screw M4 x 25 mm at the
16. LENGTH SCAN then press the EN 13 gt 2 LENGTH SCAN TER koy Chapter 5 Operation in the NC Code Mode 37 5 2 Preparations for Tool length Offset 38 5 Specify the tool length to register as a particular offset amount number Use the dial to select the offset number Pressing the ENTER key inputs it and moves the cursor to the next one Repeat this procedure to make the settings for all the stocks In this example tools A through D are registered as offsets No 1 through No 4 8 Point If you select offset No 0 for a stock that stock is not measured You can skip measurement of stocks where no tool is loaded When you have made the settings for all stocks and the screen shown at right appears press the ENTER key The machine sequentially grasps each tool starting with stock No 1 and brings it into contact with the sensor STOCK No 1 2 3 4 OFFSET No 1 2 B EN Stock No 1 No 2 No 3 No 4 Offset No 1 No 2 No 3 No 4 AWA 5 3 5 5 a 5 a TOOL LENGTH SCAN ENTER TO START 8 Point D Notice If the sensor and the tool are far apart and making con If contact occurs while the Z key is depressed cor tact takes a long time then hold down the Z key rect measurement is impossible Be
17. PRESS 13 gt 5 AIR PRESS 0 50 MPa 13 6 MAGAZINE SETUP 13 6 gt 1 MAGAZINE POS1 2 MAGAZINE1 OFT STOCKS THEN ENTER ane 13 6 gt 2 MAGAZINE1 X 0 0mm Y 0 0mm 13 7 NO OF STOCKS 13 gt 7 NO OF STOCKS ARE YOU SURE lt 4 gt DECIDED BY ENTER TAKE OFF TOOLS FROM Pause menu PAUSE gt AIR PRESS PAUSE AIR PRESS lt 0 50 MPa gt Chapter 7 Menu Reference 47 7 2 NC Code Menu Flowchart Main menu gt 13 ATC 13 1 TOOL SELECT 13 1 TOOL SELECT 13 1 gt 1 TOOL 1 2 LENGTH SCAN 2 TOOL 2 3 TOOL LENGTH 3 TOOL 3 4 AIR PRESS 4 TOOL 4 5 MAGAZINE SETUP 5 RETURN 6 NO OF STOCKS 6 RELEASE 7 To Main Menu 7 To Main Menu lt END gt SELECT AND ENTER TOOL OFFSET No lt 0 gt 13 2 LENGTH SCAN STOCK No 1 2 3 4 TOOL LENGTH SCAN OFFSETNo 0 0 0 0 ENTER TO START 13 3 TOOL LENGTH 13 3 gt 1 OFFSET NO 1 13 3 gt 1 OFFSET NO 1 2 OFFSET NO 2 lt 0 00mm gt 3 OFFSET NO 3 5 13 3 2 OFFSET NO 2 lt 0 00 gt 16 OFFSET NO 16 17 To ATC Menu lt END gt 13 3 gt 16 OFFSET NO 16 lt 0 00mm gt 13 4 AIR PRESS 13 gt 4 AIR PRESS lt 0 50 MPa gt Next page 48 Chapter 7 Menu Reference 7 2 NC Code Menu Flowchart Previous page 13 5 MAGAZINE SETUP 13 551 MAGAZINE 1 2 MAGAZINE1 OFT STOCKS THEN ENTER 13 552 MAGAZINE1 OFT X 0 0mm Y 0 0mm 13 6 NO OF STOCKS 13 gt 6 NO OF STOCKS ARE YOU SURE 4 DECIDED BY ENTER TAK
18. loca tion shown in the figure then tighten using the hexagonal screwdriver Chapter 2 Implementing the ATC Unit 13 2 4 Installing the ATC Unit 6 Pass the belt through under the motor pulley and engage on the spindle pulley Note that the spindle belt is packed with the main unit 7 While pressing down on the belt engaged on the spindle pulley turn the motor pulley in the direction of the arrow to attach the belt 8 Turn the motor pulley several times so as to position the belt on the motor pulley and spindle pulley as shown in the figure Install the air cylinder Position the notch flush against the slider and secure in place with the four cap screws M4 x 15 mm Notch Slider k Next go on to Step 2 Install the Control Box 14 Chapter 2 Implementing the ATC Unit Spindle belt Spindle pulley Air cylinder Slider Step 2 Install the Control Box Procedure 1 2 supply Make sure that the power to the main unit is switched off and its power cord is unplugged Ifyou re using the optional safety cover remove the back panel M4x8mm p cap screw Install the air regulator and air hoses on the control box Control box Air regulator At
19. sensor included with the main unit and Detach the sensor cover on the rotary axis unit then place the ZO sensor on the sensor base 3 Display the main menu Use the dial to select ATC then S13 4 Use the dial to select LENGTH SCAN then press the EN 13 3 LENGTH SCAN 4 TOOL LENGTH The machine sequentially grasps each tool starting with stock No 1 and brings it into contact with the sensor 8 Point Notice If the sensor and the tool far apart and making If contact occurs while the Z key is depressed cor tact takes a long time then hold down the Z key rect measurement is impossible Be sure to release the This makes the lowering speed faster Release the Z key before contact is made key before contact is made with the sensor 5 When all the tools have been measured and operation stops the procedure has ended Remove the ZO sensor Alternatively attach the sensor cover 1 Notice After measuring the tool lengths do not improperly replace a tool with a different one or change the sequence or the tools Doing so destroys the correspondence between the actual tool lengths and the offset values and may result in cutting in at unexpected depths Chapter 4 Operation in the RML 1 Mode 33 4 2 Measurement of Tool Length and Starting Cutting Step 2 Set ZO the Z axis Origin Point After you finish measuring the tool lengths you make the setting for ZO Pr
20. straight up Using excessive force to position the tool magazine flush against the positioner may cause the tool magazine to tilt making correct positioning impossible When Using with No Rotary Axis Unit Positioner Unit Positioner 9 e O LI LI LI 7 Remove the positioner 8 Close the spindle cover then press the EN AFTER MAGAZINE1 SET Make sure the positioner is detached then press the ENTER key twice The spindle moves to the tool magazine calibration posi TAKE OFF POSITIONER THEN PUSH ENTER D Notice PUSH ENTER TO MOVE TO MAGAZINE CHECKPOS Be sure to detach the positioner Performing this opera tion without removing it may cause malfunction When Using with No Rotary Axis Unit When Using in Combination with a Rotary a ES Sin 20 Chapter 2 Implementing the ATC Unit 9 Correct the positioning of the tool magazine and the spindle When Using with No Rotary Axis Unit Calibration location 1 Spindle Datum Calibration Calibration a location 2 surface Calibration Calibration location 3 Front of the unit d location 3 For calibration location 1 2 Completely Completely flush flush Ensure that the L shaped hexago nal wrench is completely flush with the spindle and the tool magazine If a gap is produced with the tool
21. 16 in Maximum tool diameter Diameter 10 mm 3 8 in Tool holder format Taper shank JBS4002 15T 7 24 taper Pull stud JBS4002 15P 45 special Tool selection method Direct changing type fixed address specification Compatible compressed air 0 7 to 1 MPa and 50 L min or more Spindle speed 3 000 to 12 000 rpm Operating temperature 5 to 40 41 to 104 F Operating humidity 35 to 80 no condensation Packed dimensions 785 W x 310 D x 235 H mm 31 W x 12 1 4 D x 9 1 4 H in 12 5 kg 27 6 1b Packed weight The cutting range of the MDX 650A when installed with the ATC unit is as follows No rotary axis unit installed 540 X x 450 Y x 155 Z mm 21 1 4 X x 17 11 16 Y x 6 1 16 Z in 64 When combined with the rotary axis unit When the MDX 650A is equipped with both an ATC unit and a rotary axis unit the XYZ axis travels are the same as when no ATC unit is installed The actual cutting area is restricted by such factors as the size of the workpiece that can be loaded in the rotary axis unit Chapter 8 Other Information C Roland 1000000172 R5 050722
22. 4 Descriptions of NC Code Menu Items 13 gt 6 NO OF STOCKS Saved Yes Default 4 Setting range 4 or 8 This sets the number of tools housed Set this to 8 when the number of tool magazines is expanded to two Note that when the ATC unit is used in combination with the rotary axis unit the setting is fixed at 4 The number of stocks and the like displayed by 13 gt 1 TOOL SELECT and 13 gt 2 LENGTH SCAN changes according to this setting It also affects 13 gt 5 MAGAZINE SETUP PAUSE gt AIR PRESS This is added to the menu that appears when you press the PAUSE key Like 13 gt 4 AIR PRESS this displays the supplied air pressure The machine pauses while this menu is displayed Chapter 7 Menu Reference 53 54 Chapter 8 Other Information This chapter describes maintenance procedures error messages and remedies specifications and other matters 55 8 1 Daily Maintenance Cleaning and Lubrication Carefully clean away cutting waste using a vacuum cleaner and brush Buildup of cuttings on the taper shank may affect runout precision and the like clean thoroughly on a daily basis If there is buildup of grease or other grime wipe it away thoroughly using a soft dry cloth In user performed maintenance no lubrication is necessary Maintenance for the Air Regulator The air regulator is equipped with a filter on which water and dust collect over time Drain off water before it becomes full Stop t
23. AIR PRESS this displays the supplied air pressure The machine pauses while this menu is displayed Chapter 7 Menu Reference 51 7 4 Descriptions of NC Code Menu Items 13 gt 1 TOOL SELECT This grasps or releases a tool TOOL 1 TOOL 2 TOOL 3 These get or change the tool loaded in the magazine Specifying the stock number where the tool you want to grasp is load makes SELECT AND ENTER appear so specify the offset number you want to apply to the tool A tool select operation is performed and tool length offset with the specified offset amount equivalent to G43 is applied Specifying offset No 0 causes no tool length offset to be performed RETURN This returns the acquired tool to the magazine RELEASE This performs a forced release of the acquired tool No operation to return the tool to the magazine is performed so take care to keep the tool from being dropped You use this when you want to remove a tool by hand 13 gt 2 LENGTH SCAN This automatically measures the lengths of the tools loaded in the magazine and registers the values as offset amounts Measure ment uses the ZO sensor and sensor base which are not required when the ATC unit is combined with the rotary axis unit The length from the spindle end to the tool tip is measured Executing this menu item displays a screen for specifying which offset number to register the measured tool length You can check and adjust the measurement results with
24. E OFF TOOLS FROM Pause menu PAUSE AIR PRESS PAUSE AIR PRESS 0 50 MPa gt Chapter 7 Menu Reference 49 7 3 Descriptions of RML 1 Menu Items 13 gt 1 TOOL SELECT This grasps or releases a tool TOOL 1 TOOL 2 TOOL 3 These get or change the tool loaded in the magazine You specify the stock number where the tool you want to grasp is loaded Performing tool selection applies tool length offset with the offset amount corresponding to the tool RETURN This returns the acquired tool to the magazine RELEASE This performs a forced release of the acquired tool No operation to return the tool to the magazine is performed so take care to keep the tool from being dropped You use this when you want to remove a tool by hand 13 gt 2 OFFSET NUMBER Saved Yes Default STOCK 1 1 STOCK 2 2 STOCK 3 3 Setting range 0 through 16 This sets the associations between stock numbers and tool length offsets offset numbers Selecting a stock number and pressing the ENTER key displays the screen for specifying the offset number you want to associate with the stock number This makes it possible to set 16 offset amounts in advance and call up the appropriate one according to the tool you re using Note that setting an offset number to 0 causes tool length offset not to be applied The amount of tool length offset corresponding to the selected tool is determined by 13 gt 2 OFFSET NUMBER 13 gt 3 LENGT
25. H SCAN and 13 gt 4 TOOL LENGTH 13 gt 3 LENGTH SCAN This automatically measures the lengths of the tools loaded in the magazine and registers the values as offset amounts Measure ment uses the ZO sensor and sensor base which are not required when the ATC unit is combined with the rotary axis unit The length from the spindle end to the tool tip is measured The offset number where a measured tool length is registered depends on the setting for 13 gt 2 OFFSET NUMBER You can check and adjust the measurement results with 13 gt 4 TOOL LENGTH 13 gt 4 TOOL LENGTH Saved Yes Default 0 mm Setting range 115 00 through 115 00 mm This manually sets the offset amount for tool length offset You can make individual settings for offset No 1 through No 16 You enter the length to the tool tip referenced from any desired height Positive values correct upward and negative values correct downward It is also acceptable to anticipate a reference tool and enter a positive value if longer than the reference tool or a negative value if shorter The settings made with 13 gt 2 OFFSET NUMBER determine which offset amount numbers are assigned to which tools The 16 registered offset amounts are shared by the RML 1 mode and the NC code mode 13 gt 5 AIR PRESS This displays the pressure of the compressed air supplied to the control box The machine pauses while this menu is displayed 50 Chapter 7 Menu Reference 7 3 Descriptions of RML
26. Hold down the key and switch on the power to the MDX 650A Ver 1 0 2 Version information is displayed ROM Ver indicates the firmware version 3 After verifying release the key Table of Contents To Ensure Sate USO ai raaa aaa aea a ae a aa a aaa a aaaea aeieea daidan Eii 3 Chapter 1 System Structure n kn a aa on ai ponp 5 1 1 Features of the ZAT 650 bl00eeltteeeeetooooeeeootooooeeeotooooueeeoeooeooeeeoeooeoooaeorooooaeooroooooeeeseooooooaoeenseeeooononn 6 1 2 Possible System Configurations Using the 2 650 7 Installable Combinations 7 Chapter 2 Implementing the ATC Unit 9 2 1 List of Included tems vien vle Di sy sanl a aie 10 2 2 Conditions for Compressed Air 11 Usable TOO HAE S nd edie evista dies atid 12 2 4 Installing the ATO UNT ain eesti anaran ieioea a etl ena a de Oke 13 Chapter 3 Basic Operation Common for RML 1 and NC Codes 25 3 1 Important Notes on Switching the Power and Off 26 Important Notes When Switching On the Power 26 Before You Switch Off the Power l 26 3 2 Usage and Handling of the Tool Magazine
27. LEASE 3 Press the ENTER key to enter the forced release mode 4 While supporting the tool with one hand lightly tap the front of the spindle unit using a plastic hammer or wooden mallet Tapping the spindle unit dislodges the tool more effectively than tapping the tool itself 5 Mount the removed tool in the magazine 6 Press the ENTER key The error is cleared and initialization starts Chapter 3 Basic Operation 29 30 Chapter 4 Operation in the RML T Mode This chapter explains basic operations when the RML 1 command set is selected 31 4 1 What ls the Tool length Offset When a tool is changed and the tool length changes the cutting position along the Z axis also changes When the tool is changed it is necessary to perform some operation that takes the tool length into consideration such as for example resetting ZO the Z axis origin point The tool length offset is a function that automatically adjusts the Z axis position while taking the tool length into account In short it is sufficient to set ZO only once at the start Then after the tool is changed adjustment to keep the ZO position the same is performed automatically Before tool length offset After tool length offset Spindle unit Reference position 1 Offset Offset Offset 7 value A value B value C m Tool length A Aligned with the reference
28. Offset Step 1 Perform Automatic Measurement of Tool Step 2 Make the Settings for the Workpiece Coordinate System Step 3 Make the Preparations in the Program Table of Contents 1 Table of Contents Chapter 6 NC Code 41 643 G49 Tool length Offsets kite oke ao sea fay ve s knn va ak kata swa kaskad 42 MOG Tool SEIESCUHON sce v s eka vin a ba deor GO Po 43 Chapter 7 Menu Reference eeceeeeeeeeeeeeseesneesneeeeeeeeeeeeeeessneneneneeeeeeeeeees 45 721 RML 1 Menu Flowehattt el tis a 46 7 2 NC Code Menu FIOWCHAIL ae a 48 7 3 Descriptions of RML 1 Menu 50 7 4 Descriptions of NC Code Menu 52 Chapter 8 Other Information 55 821 Daly MaiMtenanGe e FL A Rd en 56 Cleaning and LAabriCatiON ban a ot ea at do A 56 Maintenance for the Air Regulator ooo 56 Inspection of the Spun le ns an po e bas
29. Roland Automatic Tool Changer ZAT 650 User s Manual Thank you very much for purchasing the product To ensure correct and safe usage with a full understanding of this product s performance please be sure to read through this manual completely and store it in a safe location Unauthorized copying or transferral in whole or in part of this manual is prohibited The contents of this operation manual and the specifications of this product are subject to change without notice The operation manual and the product have been prepared and tested as much as possible If you find any misprint or error please inform us Roland DG Corp assumes no responsibility for any direct or indirect loss or damage which may occur through use of this product regardless of any failure to perform on the part of this product Roland DG Corp assumes no responsibility for any direct or indirect loss or damage which may occur with respect to any article made using this product Roland DG Corporation Supported Firmware MODELA Pro MDX 650A firmware version 3 0 or later is required in order to install this unit Before you attempt installation follow the steps below to verify the firmware version If the firmware version is earlier than version 3 0 contact your authorized Roland DG Corp dealer or Roland DG Corp service center Checking the Firmware Version Follow the steps below to verify the firmware version of the MDX 650A ROM Ver 3 0 1
30. ecause the pressure of the compressed air was higher than permitted This appears when the pressure of the compressed air is excessively high First readjust the air pressure to 0 5 to 0 65 MPa When the display changes to ENTER TO CONTINUE press the ENTER key The error is cleared and the operation resumes OPERATING ERROR CAN T RELEASE TOOL The tool cannot be released This appears when the grasped tool could not be released for some reason Switch off the power and make sure the air pressure is within the permitted range Also make sure that no air hoses or cables have come loose Switch on the power again When NOW CATCHING TOOL ENTER TO RELEASE appears press the ENTER key to try performing a forced release Be careful not to let the tool fall at this time If this operation fails to release the tool then contact your Roland DG Corp service center 58 Chapter 8 Other Information 8 3 X Y and Z axis Travels When the ATC unit is installed the MDX 650A s axis travels are as follows When Using with No Rotary Axis Unit The X axis travel changes lt When Using in Combination with a Rotary Axis Unit When the MDX 650A is equipped with both an ATC unit and a rotary axis unit the XYZ axis travels are the same as when no ATC unit is installed The actual cutting area is restricted by such factors as the size of the workpiece that can be loaded in the rotary axis unit D Notice When you
31. en press the ENTER key NO 1 THEN ENTER The spindle moves to the tool holder and the tool chang ing height of the spindle is adjusted automatically The screen shown at right is displayed while adjustment is in NOW SCANNING progress TOOL CHANGE POSITION 13 When the spindle moves to the VIEW position height adjustment is complete Next go on to Step 4 Make Settings and Adjust 8 Point To Verify the Correction Values That Have Been Set 1 Press the ENTER key to display the main menu gt 13 ATC 2 Use the dial to select ATC then press the ENTER key 14 To Coordinate 3 Use the dial to select MAGAZINE SETUP then press the ENTER key 13 gt 6 MAGAZINE SETUP 7 NO OF STOCKS 4 Use the dial to select MAGAZINE POS1 then press the ENTER key 13 65 1 MAGAZINE POS The set correction values are displayed 2 MAGAZINE1 OFT 13 6 gt 2 MAGAZINE1 OFT X 0 3mm Y 0 1mm t Refer to Chapter 7 Menu Reference Chapter 2 Implementing the ATC Unit 23 2 4 Installing the ATC Unit Step 4 Make Settings and Adjust Procedure 1 In the following operation set the spindle type to HIGH TORQUE 1 Press the EXIT key to display the main menu gt 13 ATC 14 Coordinate 2 Use the dial to select OTHERS then press ENTER key gt 10 OTHERS 11 SELF MODE 3 Use the dial to select SPINDLE UNIT then press the ENTER key 10 gt 2 SPINDLE UNIT 3 BUZZER 4 Use the dial to select
32. ginal position D Notice Do not adjust the regulator at higher than 0 7 MPa Do ing so may damage the ATC unit 2 In the following operation you move the spindle to the maga zine adjustment location 1 Close the spindle cover on the main unit 2 Switch on the power to the main unit then press the ENTER key After X 0 Y 0 initialization the coordinate view screen appears Z 0 5000 RPM 3 Press the ENTER key to display the main menu gt 13 ATC 4 Use the dial to select ATC then press the ENTER key 14 To Coordinate 5 Use the dial to select MAGAZINE SETUP then press the ENTER key 13 gt 6 MAGAZINE SETUP 7 NO OF STOCKS 6 Use the dial to select MAGAZINE POS1 then press the ENTER key 13 6 gt 1 MAGAZINE POS1 2 To ATC MENU 7 Make sure there are no obstructions then press the ENTER key again The TAKE OFF TOOLS FROM spindle moves to the magazine adjustment location STOCKS THEN ENTER 3 When the screen shown at right appears open the spindle AFTER MAGAZINE1 SET cover on the main unit PUSH ENTER KEY Q Be sure to carry out installation with the spindle cover open Performing the operation with the cover closed may result in injury due to unintended operation of the machine 18 Chapter 2 Implementing the ATC Unit 2 4 Installing the ATC Unit 4 Loosely secure the tool magazine When Using with No Rotary Axis Unit
33. he supply of compressed air then loosen the knob at the bottom of the bowl a little at a time Remaining pressure may cause water to spray out below so use cloths or the like to contain the spray If the inside of the bowl is dirty with dust then remove the bowl and clean it Stop the supply of compressed air loosen the knob at the bottom of the bowl a little at a time Then turn the bowl to remove it wash it with a neutral detergent Do not use solvents such as paint thinner They may degrade the bowl resulting in breakage when air pressure is applied Inspection of the Spindle Unit The service life of the spindle for the ATC unit is around 5 000 hours total rotation time We recommend early inspec tion and replacement For replacement parts contact your Roland DG Corp service center 56 Chapter 8 Other Information 8 2 Corrective Action for Error Messages If an error message appears on the machine s display take action as described below If this action does not correct the problem or if another error message appears contact your Roland DG Corp service center NO ATC UNIT The ATC menu item was executed but no ATC unit is installed The ATC menu item can be executed only when an ATC unit is installed After a short interval the machine automatically returns to the original screen NOW CATCHING TOOL ENTER TO RELEASE The power was switched on while a tool was in a gripped state When the
34. il a new G43 or G49 command is received The offset amount for offset No 0 is always 0 zero You cannot register any value for offset No 0 Registering an Offset Amount Registration of offset No 1 through No 16 is performed by key operations on the machine Specification by a program is not possible For more information see chapter 5 Sample Program To Data start 00001 Program number G90 Specify absolute coordinates G49 M66 T2 Get tool in stock No 2 GOO H1000 1000 Positioning G43 2 1000 Start tool length offset with offset No 1 and move to corrected position F10 55000 MAS Rotate spindle G01 42000 Y2000 Linear interpolation movement MQ5 Stop spindle G49 M66 Cancel tool length offset and return tool M30 Program end To Data end 42 Chapter 6 NC Code Reference MO6 Tool Selection Mi Format MOG T number Parameter Function No error range Effective range number Stock number O through 4 O through 4 or 0 through 8 O through 8 When expansion magazine is installed Description This gets changes or returns a tool loaded in the magazine You specify the stock number where the tool you want to get or change is loaded with number Specifying 0 zero returns the tool Here number signifies a stock number in the magazine It does not directly specify the tool itself Also M06 has no tool length offset function Do not specify more than one M06 o
35. in adjustment value is displayed the screen shown in the figure ap pears Pressing the ENTER key moves the spindle to the VIEW position Calibration location 3 M Datum plane L shaped hexagonal wrench Calibration location 1 Calibration surface If a gap is produced with the spindle press the key PUSH ENTER TO SET Y OFFSET 0 0mm PUSH ENTER TO MOVE TO NEXT CHECK POS PUSH ENTER TO SET Y OFFSET 0 0mm PUSH ENTER TO MOVE TO NEXT CHECK POS PUSH ENTER TO SET X OFFSET 0 0mm PUSH ENTER TO MOVE TO VIEW POSITION If the difference between the adjustment values for calibration location 1 and cali bration location 2 is 0 5 mm or more the message shown at right appears If this happens press the ENTER key then redo the operation from step 4 on page 19 TILTED TOO MUCH TRY TO SET AGAIN Chapter 2 Implementing the ATC Unit 2 4 Installing the ATC Unit 10 When you are using the ATC unit with no rotary ZO sensor base axis unit mount the ZO sensor base on the magazine Secure it in place using two cap screws M4 x 35 mm This is not necessary when you re using the ATC unit in combination with a rotary axis unit Tool holder 11 Mount the tool holder in stock No 1 For information on how to mount the tool holder refer to 3 2 Usage and Handling of the Tool Magazine 12 Make sure the screen shown at right is dis SET TOOL IN STOCK played th
36. l Magazine and refer to steps 4 through 9 in that section 6 Mount the ZO sensor base on the added tool magazine When doing this go to 2 4 Installing the ATC Unit find Step 3 Install the Tool Magazine and refer to step 10 in that section 7 Go to 2 4 Installing the ATC Unit find Step 3 Install the Tool Magazine and carry out steps 11 through 13 in that section Perform adjustment of the spindle height Install the tool holder on the first tool magazine 8 Go to 2 4 Installing the ATC Unit and carry out the operations in Step 4 Make Settings and Adjust Chapter 8 Other Information 61 8 4 Tool magazine Expansion 62 Installing an Additional Tool Magazine at a Later Time This procedure is for adding an expansion tool magazine later after the ATC unit has already been installed Procedure 1 Remove all tools from the tool magazine 2 Remove the ZO sensor base 3 Follow the steps below to set the number of stocks to 8 1 Press the ENTER key to display the main menu 2 Turn the dial to choose ATC then press the ENTER key 3 Turn the dial to select NO OF STOCKS then press the ENTER key 4 Turn the dial to select 8 then press the ENTER key Make sure of the setting then press the ENTER key again 4 Next follow the steps below to move the spindle to the adjusted position of the magazine 1 Press the EXIT key to go back to the previous menu screen 2 Turn the dial
37. l to select ATC then S13 ATC press the ENTERI key 14 To Coordinate 2 Use the dial to select TOOL LENGTH then press the EN 13 gt 3 TOOL LENGTH 3 Turn the dial to select the offset number you want to adjust 13 3 gt 1 OFFSET NO1 Press the ENTER key Use the dial to adjust the value then press the ENTER key 13 35 1 OFFSET NO1 When the actual tool length is longer than the registered value cutting in lt 0 00mm gt is deeper than intended In such cases you increase the value Conversely when cutting in is too shallow you reduce the value Setting the Offset Value Manually You can enter tool lengths offset amounts you measured yourself by using a procedure similar to the one in the preceding Tool length Adjustment Measure the length to the tool end referenced from a particular location on the tool holder You may use any location on the tool holder as the reference but it must be consistent for all tools In this way you register the measured lengths as offset amounts You can also get the same results by deciding on any one tool as a reference tool and entering the differences from this tool For instance if there is a tool that is 15 mm shorter than the reference tool you make the corresponding offset amount 15 mm Also you make the offset amount for the reference tool itself 0 no tool length offset The reference position in this case is the tip of the reference tool Reference tool L m
38. magazine Ifagap is produced with the tool magazine press the A key 1 Bring the included L shaped hexagonal wrench into contact with calibration loca tion 1 Use the A and W keys to move the head and adjust the positioning of the spindle so that the L shaped hexagonal wrench is completely flush with both the spindle and tool magazine Each press of the key moves the table 0 1 mm 2 When you have finished adjusting the positioning press the ENTER key After the locked in adjustment value is displayed the screen shown in the figure ap pears Pressing the ENTER key moves the spindle to the right as seen from the front of the unit 3 Bring the L shaped hexagonal wrench into contact with calibration location 2 Adjust the positioning of the spindle in the same way as you did in step 1 4 When you have finished adjusting the positioning press the ENTER key After the locked in adjustment value is displayed the screen shown in the figure ap pears Pressing the ENTER key moves the spindle vertically 5 Bring the L shaped hexagonal wrench into contact with calibration location 3 Use the a and gt keys to move the table and adjust the positioning of the tool magazine so that the L shaped hexagonal wrench is completely flush with both the spindle and tool magazine Each press of the key moves the head 0 1 mm 6 When you have finished adjusting the positioning press the ENTER key After the locked
39. magazine press the lt a key 1 Bring the included L shaped hexagonal wrench into contact with calibration loca tion 1 Use the and b gt keys to move the head and adjust the positioning of the spindle so that the L shaped hexagonal wrench is completely flush with both the spindle and tool magazine Each press of the key moves the head 0 1 mm 2 When you have finished adjusting the positioning press the ENTER key After the locked in adjustment value is displayed the screen shown in the figure ap pears Pressing the ENTER key moves the table to the back 3 Bring the L shaped hexagonal wrench into contact with calibration location 2 Adjust the positioning of the spindle in the same way as you did in step 1 4 When you have finished adjusting the positioning press the ENTER key After the locked in adjustment value is displayed the screen shown in the figure ap pears Pressing the ENTER key moves the spindle vertically 5 Bring the L shaped hexagonal wrench into contact with calibration location 3 Use the A and keys to move the table and adjust the positioning of the tool magazine so that the L shaped hexagonal wrench is completely flush with both the spindle and tool magazine Each press of the key moves the table 0 1 mm 6 When you have finished adjusting the positioning press the ENTER key After the locked in adjustment value is displayed the screen shown in the figure ap pears Pres
40. mber of pieces ATC spindle unit Air cylinder Tool magazine Control box Air regulator ZO sensor base Air hose Air nozzle Positioner Cap screws M4 x 8mm M4 x 15 mm M4 x 25 mm M4 x 35 mm M6 x 12 mm Screws with a knob Square nuts Washers Wrenches Hexagonal screw driver for M4 cap screws L shaped hexagonal wrench for M6 cap screws Retaining bands black _ BRIN I DN BBW le fe l e e te m m Retaining band white compressed air supply must be procured separately See 2 2 Conditions for Compressed Air for the requirements A tool holder must be procured separately See 2 3 Usable Tool Holders for the requirements The meter on the air regulator does not face directly upward but this is normal and not a problem 10 Chapter 2 Implementing the ATC Unit 2 2 Conditions for Compressed Air The ATC unit requires compressed air Provide a compressor or other compressed air supply that meets the following conditions Air pressure 0 7 to 1 MPa Air volume 50 L min or more at 0 7 to 1 MPa air pressure The piping from the ATC unit is as shown below Provide suitable air hoses joints and the like e Hose outer diameter 10 mm polyurethane tubing Do not supply compressed air to the regulator at higher than 1 MPa Doing so may damage the regulator Chapter 2 Implementing the ATC Unit 11 2 3 Usable Tool
41. n for getting the tool If the error occurred for some other cause then switch off the power eliminate the cause then carry out the procedure again NO ZO SENSOR SET SENSOR THEN ENTER An attempt was made to carry out automatic measurement of tool length while the ZO sensor was not con nected The ZO sensor is required in order to execute LENGTH SCAN although this is not required when the rotary axis unit is in stalled Connect the ZO sensor place it on the sensor base then press the ENTER key The machine clears the error then restarts measurement TOOL LENGTH TOO LONG SHORTEN IT AND ENTER Automatic measurement cannot be performed because the tool is too long On executing LENGTH SCAN if the tool is too long and measurement cannot be performed this message appears and the tool is returned to the magazine Replace the tool with one of the specified length then press the ENTER key The machine clears the error then restarts measurement Chapter 8 Other Information 57 8 2 Corrective Action for Error Messages AIR PRESSURE SHORT Operation was interrupted because the pressure of the compressed air was lower than permitted This appears when the pressure of the compressed air is insufficient First readjust the air pressure to 0 5 to 0 65 MPa When the display changes to ENTER TO CONTINUE press the ENTER key The error is cleared and the operation resumes AIR PRESSURE TOO HIGH Operation was interrupted b
42. nd the Cylinder and Step 2 Install the Control Box to perform installation 2 Before you perform Step 3 Install the Tool Magazine in 2 4 Installing the ATC Unit make the following settings 1 Close the spindle cover on the machine and switch on the power 2 Press the ENTER key After initialization ends the coordinate view screen appears 3 Press the ENTER key to display the main menu 4 Turn the dial to choose ATC then press the ENTER key 5 Turn the dial to select NO OF STOCKS then press the ENTER key 6 Turn the dial to select 8 then press the ENTER key Make sure of the setting then press the ENTER key again 7 Press the EXIT key three times to go back to the coordinate view screen 3 Go to 2 4 Installing the ATC Unit find Step 3 Install the Tool Magazine and carry out steps 1 through 9 in that section Perform positioning for the first tool magazine carrying out the instructed operations up through completely tightening the cap screws Then correct the positioning of the tool magazine and the spindle 4 When the screen shown at right appears open the spindle cover again AFTER MAGAZINE SET PUSH ENTER KEY 5 Secure the added tool magazine in place Install the positioner perform positioning then tighten the cap screws Then correct the positioning of the tool magazine and the spindle When doing this go to 2 4 Installing the ATC Unit find Step 3 Install the Too
43. ocedure 1 Operate the keys to grasp any tool You may choose any tool whose tool length has been measured 2 Make the ZO setting with the grasped tool Make the setting with any tool that has been measured You do not need to set this individually for every tool to be used in cutting 3 Return the grasped tool to the magazine This completes the preparations When you send cutting data from a program the tool specified by the program is automatically grasped and cutting starts Because tool length offset is applied the position of the tool tip remains uniform when one tool is changed for another 34 Chapter 4 Operation in the RML 1 Mode Chapter 5 Operation in the NC Code Mode This chapter explains basic operations when the NC command set is selected and the basics of NC code programming 35 5 1 Tool Selection and Tool length Offset Tool Selection To grasp a desired tool or return it to the magazine you use M06 This code only selects a tool Tool length offset is not enabled Tool length Offset This function is used to correct for discrepancies between the tool length anticipated by a program and the actual tool length Using this eliminates the need for the program to take changes in tool length into account when a tool change is performed and makes it unnecessary to redo the setting for the workpiece origin every time the tool is changed To start and cancel tool length offset you use G43 and G49 Before to
44. of the symbol is determined by the design contained within the triangle The symbol at left means danger of electrocution The Q symbol alerts the user to items that must never be carried out are forbidden The specific thing that must not be done is indicated by the design contained within the circle The symbol at left means the unit must never be disassembled The symbol alerts the user to things that must be carried out The specific thing that must be done is indicated by the design contained within the circle The symbol at left means the power cord plug must be unplugged from the outlet Z WARNING Do not disassemble repair or modify Let compressed air out of the air regu Doing so may lead to fire or abnormal lator before removing the bowl operation resulting in injury The bowl or the like may fly off resulting in injury Do not use while in an abnormal state i e emitting smoke burning odor unusual noise or the like Doing so may result in fire or electrocu tion Immediately switch off the power unplug the power cord from the electrical out let and contact your authorized Roland HA DG Corp dealer or service center l Do not apply solvents such as thin ner cutting oils or direct rays of the sun to the bowl of the air regulator They may degrade the bowl resulting in breakage when air pressure is applied A To Ensure Safe Use 3 AN To Ensure Safe Use AACAUTION
45. ograms even when using tools of different lengths You can also combine the unit with the rotary axis unit making it possible to perform multiple surface cutting with automatic tool changes The ZAT 650 requires a separate device to supply compressed air such as a compressor 6 Chapter 1 System Structure 1 2 Possible System Configurations Using the ZAT 650 Installable Combinations The ZAT 650 can be combined with the following products MODELA Pro series MDX 650A Yes MDX 650 No MDX 500 No Rotary axis units ZCL 650A Yes ZCL 650 No Use with the dedicated spindle packed with the ATC unit The ZS 650T ZS 500SH and the like cannot be used When the ZAT 650 is installed the following optional equipment cannot be used Vacuum adapters for chip cleaning ZAD 500 ZAD 500S etc table spacers ZA 500 series etc or a vacuum table ZV 500A Programs Compatible with ATC To perform automatic tool changes you need to use a program that supports ATC or to implement NC programming Even with a program that does not support ATC it s possible to perform cutting using a single tool but continuous cutting with automatic tool changes is not possible Check the compatibility of the program before you use it Chapter 1 System Structure 7 Chapter 2 Implementing the ATC Unit This chapter describes what you need to implement the ATC unit and how to install it 2 1 List of Included Items Items Nu
46. ol length offset After tool length offset Spindle unit nil J Reference position l L 5 a ki Offset Offset Offset value valueB value Aligned with the reference 1 position after correction Tool length B Tool length A Tool length C To perform tool length offset you must register save the offset amount in the machine You can register offset amounts from No 1 up through No 16 There are two registration methods one where the tool lengths are measured automati cally and one where you set the offset amounts manually Tool selections by M06 are not coordinated with offsets No 1 through No 16 in any way The program must specify the number of the offset amount to assign to a selected tool G43 This involves presetting the tool length offsets corre sponding to 16 tools in the machine Offset Amounts for Tool Selections Made Using Key Operations You can enable tool length offset even when you select tools manually using the procedures in 3 3 Selecting Tools Through Key Operations At the TOOL SELECT menu specifying a tool number and pressing the ENTER key dis TOOL OFFSET No lt gt plays a screen for selecting an offset number Selecting an offset number here achieves the same result as performing tool length offset using G43 The dis play shows
47. power is switched on while a tool is gripped the tool is released to ensure safety Pressing the ENTER key immediately performs a forced release and clears the error No operation to return the tool to the magazine is performed so support the tool with your hand as you perform this operation to keep the tool from being dropped 1 Press the ENTER key A forced release is performed and the message IF TOOL IS RELEASED THEN PUSH ENTER appears 2 If the tool was released then press the ENTER key to clear the error If the tool was not released then switch off the power Make sure the air pressure is within the specified range and that no air hoses of cables have come loose then switch on the power If the error message appears again press the ENTER key If this operation fails to release the tool then contact your Roland DG Corp service center If this message does not appear even though a tool is grasped then immediately switch off the power and contact your Roland DG Corp service center CAN T CATCH TOOL SET TOOL THEN ENTER The specified tool cannot be grasped Here indicates the stock number This appears when an attempt to get a tool fails because the tool is not loaded in the magazine or is not loaded at the appropriate location in the magazine or for similar reasons If the tool is not loaded in the magazine then load it and press the ENTER key The machine clears the error and again performs the operatio
48. r T code in the same block Also specifying M06 alone or a T code alone results in an error Specify M06 and a code together as a pair Any command to get or change a tool that is already grasped is ignored Chapter 6 NC Code Reference 43 44 Chapter 7 Menu Reference This chapter describes in detail the extended menus codes that be come available through the addition of the ATC unit 45 7 1 RML 1 Menu Flowchart Main menu 13 ATC 13 1 TOOL SELECT 13 gt 1 TOOL SELECT 13 1 gt 1 TOOL 1 2 OFFSET NUMBER 2 TOOL 2 3 LENGTH SCAN 3 TOOL 3 4 TOOL LENGTH 4 TOOL 4 5 AIR PRESS 5 RETURN 6 MAGAZINE SETUP 6 RELEASE 7 NO OF STOCKS 7 To Main Menu 8 To Main Menu lt END gt 13 2 OFFSET NUMBER 13 2 gt 1 STOCK 1 gt 1 2 STOCK 2 gt 2 3 STOCK 3 gt 3 4 STOCK 4 gt 4 13 2 gt 2 STOCK 2 5 To ATC Menu OFFSET NUMBER lt 2 gt lt END gt 13 2 gt 1 STOCK 1 OFFSET NUMBER lt 1 gt 13 2 gt 3 STOCK 3 OFFSET NUMBER lt 3 gt 13 2 gt 4 STOCK 4 OFFSET NUMBER lt 4 gt 13 3 LENGTH SCAN NOW SCANNING TOOL LENGTH 13 4 TOOL LENGTH 13 4 gt 1 OFFSET NO 1 2 OFFSET NO 2 3 OFFSET NO 3 13 4 gt 1 OFFSET NO 1 lt 0 00mm 13 4 gt 2 OFFSET NO 2 lt 0 00mm gt 16 OFFSET NO 16 17 To ATC Menu lt END gt 13 4 gt 16 OFFSET NO 16 Next page lt 0 00mm gt 46 Chapter 7 Menu Reference 7 1 RML 1 Menu Flowchart Previous page 13 5 AIR
49. rogram expects then set the workpiece origin point 8 Point There are a wide variety of ways to get the workpiece origin depending on the program but one example follows 1 Move the tool to the lower left area of the workpiece 2 Lower the tool and align the tool tip with the surface of the workpiece 3 Use G54 EXOFS or the like to set the workpiece origin the origin point for the X and Y axes and for the Z axis at this location 4 Return the grasped tool to the magazine Step 3 Make the Preparations in the Program In the program specify the tool number you want to select M06 Also specify the offset number corresponding to the tool in the program G43 For example if you want to use tool A for rough cutting and tool B for finishing specify offset No 1 for the rough cutting and offset No 2 for the finishing This completes the preparations When you send the program to the machine the specified tool is automatically grasped and cutting starts The tool length offsets of the specified offset numbers are applied and so even when one tool is changed for another the position of the tip remains uniform Chapter 5 Operation in the NC Code Mode 39 5 3 Tool length Adjustment and Manual Setting Tool length Adjustment You can adjust the results of the automatic measurement you carried out earlier in Step 1 Perform Automatic Measure ment of Tool Length Procedure 1 Display the main menu Use the dia
50. sing the ENTER key moves the spindle to the VIEW position 2 4 Installing the ATC Unit Datum plane L shaped hexagonal wrench Calibration location 1 Calibration surface Magazine If a gap is produced with the spindle press the key PUSH ENTER TO SET X OFFSET 0 0mm PUSH ENTER TO MOVE TO NEXT CHECK POS PUSH ENTER TO SET X OFFSET 0 0mm PUSH ENTER TO MOVE TO NEXT CHECK POS PUSH ENTER TO SET Y OFFSET 0 0mm PUSH ENTER TO MOVE TO VIEW POSITION If the difference between the adjustment values for calibration location 1 and cali bration location 2 is 0 5 mm or more the message shown at right appears If this happens press the ENTER key then redo the operation from step 4 on page 19 TILTED TOO MUCH TRY TO SET AGAIN Chapter 2 Implementing the ATC Unit 21 2 4 Installing the ATC Unit 22 When Using in Combination with a Rotary Axis Unit Spindle gt Datum f lane Calibration the unit Calibration p lt location 1 location 2 Calibrati Calibration a 5 surface Q 2 efe a AN eli location 3 me Og For calibration location 1 2 Completely Completely flush flush Ensure that the L shaped hexago nal wrench is completely flush with the spindle and the tool
51. sure to release the This makes the lowering speed faster Release the Z key before contact is made key before contact is made with the sensor When all the tools have been measured and operation stops the procedure has ended Remove the ZO sensor Alternatively attach the sensor cover If necessary replace the tools in the magazine with other tools and repeat steps 4 through 6 You can register a total of 16 offset amounts Chapter 5 Operation in the NC Code Mode 5 2 Preparations for Tool length Offset Step 2 Make the Settings for the Workpiece Coordinate System Load the magazine with tools that have already been measured and set the workpiece origin point the cutting start location Procedure 1 Load the magazine with tools whose offset amounts have Offset No 1 No 2 No 3 No 4 been registered fi In this example tools A through D that you measured in Step 1 loaded B D 2 Perform key operations to grasp any tool then select the SELECT AND ENTER corresponding offset number TOOL OFFSET No lt gt In this example tool A is grasped The tool length of tool A is registered as offset No 1 so here you select offset No 1 3 Move the tool to the cutting start location that the p
52. the coordinate values after tool length offset Selecting offset No 0 at this screen causes no tool length offset to be applied here Offset number 36 Chapter 5 Operation in the NC Code Mode 5 2 Preparations for Tool length Offset This section describes the preparations up to performing cutting using tool length offset There are tasks that you per form on the machine and specifications you make in the programming Step 1 Perform Automatic Measurement of Tool Length This section explains the basic operations of how to perform automatic measurement of tool length The procedures are different depending on whether you are using the unit in combination with a rotary axis unit Procedure 1 Load the tools you want to measure into the Stock No 1 No 2 No 3 No 4 magazine fi fi In this example the tools are A through D RR Tool A B D When using with no rotary axis unit When using in combination with a rotary axis unit Connect the ZO sensor included with the main unit and Detach the sensor cover on the rotary axis unit then place the ZO sensor on the sensor base Display the main menu Use the dial to select then S13 ATC press the ENTERI key 14 To Coordinate 4 Use the dial to select
53. to select MAGAZINE SETUP then press the ENTER key 3 Turn the dial to select MAGAZINE POS2 then press the ENTER key 4 Make sure no tools are in the tool magazine then press the ENTER key 5 When the screen shown at right appears open the spindle cover again AFTER MAGAZINE2 SET PUSH ENTER KEY 6 Secure the added tool magazine in place Install the positioner perform positioning then tighten the cap screws Then correct the positioning of the tool magazine and the spindle When doing this go to 2 4 Installing the ATC Unit find Step 3 Install the Tool Magazine and refer to steps 4 through 9 in that section 7 Mount the ZO sensor base on the added tool magazine When doing this go to 2 4 Installing the ATC Unit find Step 3 Install the Tool Magazine and refer to step 10 in that section Chapter 8 Other Information 8 5 Extended RML 1 Commands Installing the ATC unit extends RML 1 command set as follows Mode 1 Command J Tool change Format Jt J Parameter t Tool number Range 0 through 4 or 0 through 8 when expansion magazine is installed Mode 2 Command SP Tool change Format SPt SP Parameter t Tool number Range 0 through 4 or 0 through 8 when expansion magazine is installed Chapter 8 Other Information 63 8 6 Specifications ZAT 650 Number of tools housed 4 or 8 when optional expansion magazine is installed Maximum tool length 110 mm 4 5
54. tool is performed immediately without returning the tool to the magazine Inadvertent operation while in this state may result in the tool being dropped so be sure to give attention to this point This operation is employed when it is necessary to detach a tool manually for some reason Carry out this operation while securely supporting the tool by hand to keep it from being dropped 28 Chapter 3 Basic Operation 3 4 Important Notes on Prolonged Continuous Cutting When the Tool Holder Fails to Come Loose Performing continuous cutting with a single tool for an extended time may make the tool holder fail to come loose from the spindle unit interrupting cutting This phenomenon is prone to happen when the following three conditions occur at the same time e When the cutting load is large such as when cutting light metal e When the end mill is comparatively thick around 8 mm or larger e When cutting is continued for a prolonged period around 24 hours or longer How to Prevent the Problem Make sure that the continuous cutting time using a single tool does not exceed 24 hours How to Correct the Problem If It Occurs If the tool holder does not come loose the MOTOR LOCK error is displayed and the machine stops If this happens follow the procedure below to recover from the error Procedure 1 Switch the power to the machine off and then on again 2 Make sure the screen shown in the figure is displayed ENTER TO RE

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