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XT series Heidenhain TNC640 Operating_1902623 B (CE) /56

Operating Manual

Heidenhain TNC 640

XT 630 5AX

XT 630 5F

XT 760

XT 1000

Original instructions (CE) Document Number 1902623

Issue B July 2016


CONTENTS Page

1.1 INTENDED USE 4

1.2 IMPORTANT SAFETY NOTICE WARNING! 5

1.3 SAFETY LISTS ALL COUNTRIES 6

1.4 GUARD WINDOW SAFETY 8

1.5 BEFORE SWITCHING ON 9

1.6 WARRANTY INFORMATION 10

1.7 ROUTINE INSPECTION 10

1.8 MAINTENANCE PROCEDURE 11

1.9 MACHINE WARM UP 12

1.10 ‘AUTOMATED’ SPINDLE WARM UP 14

1.11 SPINDLE OPERATING CONDITIONS 15

1.12 SPINDLE MAINTENANCE 15

1.13 SPINDLE TOOLING 16

1.14 INTERRUPTING MACHINING 17

1.15 COMPLETING A JOB 17

1.16 SAFETY DEVICES 18

2.1 TNC 640 VISUAL DISPLAY UNIT 20

2.2 KEYBOARD AND CONTROL PANEL 21

2.3 CONTROLS ON THE TNC 640 22

2.4 MODE SELECT SWITCH 24

2.5 MACHINE POWER ON AND REFERENCE 25

2.6 MACHINE POWER OFF 26

2.7 EMERGENCY STOP 27

2.8 SOFT KEY LAYOUT 28

2.9 MANUAL AXIS JOG 32

2.10 ELECTRONIC HANDWHEEL 34


2.11 MANUAL TOOL LOAD/UNLOAD 35

2.12 LOADING TOOL MAGAZINE VIA FRONT GUARD DOOR 36

2.13 TOOL TABLE 37

2.14 POCKET TABLE 38

2.15 ATC OPERATION IN MDI MODE 39

2.16 M-FUNCTION CODES 40

2.17 DATUM SETTING 42

2.18 PROGRAM RUN 43

2.19 MANUAL OPERATION OF SPINDLE 44

2.20 WASH DOWN GUN 45

2.21 USER PARAMETERS 46

2.22 SERVICE FUNCTION 47

2.23 ATC ARM RECOVERY 50

2.24 POCKET TABLE REFORMING 51

2.25 STACK LIGHTS 54

APPENDIX ONE: SPINDLE OUTPUT DIAGRAM 55


1.1 INTENDED USE

This 5 Axes Milling machining centre 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)


1.2 IMPORTANT SAFETY NOTICE WARNING!

It is the user’s responsibility to be acquainted with the legal obligations and requirements

in the use and application of the machine, particularly under the Health and Safety at

Work Act 1974 and in the British Standard document PD 5304:2005 Guidance on the Safe

Use of Machinery and other standards and safety codes applicable in the country of use.

SAFE INSTALLATION

It is the customer’s responsibility to ensure the machine is installed in a safe operating

position, with 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.

MACHINE GUARDING

The Hardinge Machining Center 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.

SOFTWARE

Unauthorised changing of machines software or control parameters is hazardous and is

not permitted. Hardinge will not accept any liability whatsoever for unauthorized changes

in this area.

AUTHORISED PERSONNEL AND TRAINING

Operating, service and maintenance engineers shall be authorised by the ‘User Company’

and properly trained in the use of the machine.

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 be carefully read and understood before use.

To prevent bodily injury, safe working practices should be employed when operating or

servicing the machine.

CONNECTING/DISCONNECTING ELECTRICAL CABLES FOR MACHINE

ACCESSARIES AND OPTIONAL EQUIPMENT

Machine power must be OFF before connecting/disconnecting terminals, adapters,

receptacles and cable connectors for any equipment, accessory or optional equipment

to/from the machine. This action will allow personnel to avoid accident electrical shock,

otherwise which could cause serious personal injury and machine damage.


1.3 SAFETY LISTS ALL COUNTRIES

• 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.

• Additional safety notices may exist for certain specific countries for which Hardinge may

be able to advise. Please ask.

• 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

removal 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 until you have read and understood all the machine and control

keys.

• DON’T run the machine for the first time without a qualified instructor. Ask your

supervisor for help when you need it.

• PROTECT your eyes. Wear safety glasses with side shields at all times.

• DON’T get caught in moving parts. Remove watches, rings, jewellery, neckties and

loose fitting clothes.

• PROTECT your head. Wear a safety helmet when working near overhead hazards.

• KEEP your hair away from moving parts.

• PROTECT your feet. Always wear safety shoes with steel toecaps and oil resistant soles.

• Gloves are easily caught in moving parts. TAKE THEM OFF before you turn on the

machine.

• Loose objects can become flying projectiles. REMOVE all loose items (wrenches, chuck

keys, rags etc.) from the machine before starting.

• 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.

• PROTECT your hands. Make sure the spindle is stopped before manually changing a tool

or 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 your hands.

• PROTECT your hands. Make sure the spindle is stopped before 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 hands. Beware of sharp edges on newly machined components wear

gloves when unloading.

• PROTECT your eyes and the machine. Never use a compressed air hose to remove swarf

or to clean out air vents.

• 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 objects from flying loose. Securely clamp and locate the workpiece.


SAFETY LISTS ALL COUNTRIES (Cont.)

• 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.

• 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 highly 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, with the EMERGENCY

STOP button depressed.

• 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.

• DON’T reach into any control or power case, unless electrical power is OFF.

• DON’T touch electrical equipment when hands are wet or when standing on a wet

surface.

• ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before

restarting the machine.

• This machine tool is a machining center, and is intended for the use in machining

materials with the work piece fixed to the table, and the cutting tool rotating in the

spindle. The machine should not be used for any other purpose.

• 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.

• This machine is intended for use in an industrial environment and must not be used in

the residential, commercial and light industrial environment.

• The windows fitted to Hardinge Machining Centers 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 conjunction with this machining center 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 GUARD WINDOW SAFETY

This Bridgeport Machining Centre is fitted with laminated vision panels to both provide

protection from ejected tool tips (or similar parts of the tool) and to prevent the harmful

effects of metalworking fluids reducing the effectiveness of the window.

Guidance on the replacement of windows is given in the Operators Safety Manual, section

1.7.


1.5 BEFORE SWITCHING ON

Training on all aspects of this machine tool is available from Hardinge. Please contact

your Hardinge representative for further details.

Cables, cords or electric wires of which insulation is damaged can produce current leaks

and electric shocks. Check their condition before connecting.

A qualified electrician should only carry out connection of the power cable to the machine.

Ensure the power 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 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.

Check the condition of the warning labels. If they are missing or become illegible, order

replacements from Hardinge 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.

Use recommended oil brands and appropriate levels for all lubricating systems. See the

instruction plate at the rear of the machine.

The coolant system comprises of a tank at the front of the machine and a set of coolant

pumps located towards the rear of the machine depending upon exact specification.

Whilst it is possible for a workpiece to be machined without the use of any the

coolant/lubricant on the short term application occasionally, it is strongly

recommended that the operator follow the steps outlined below:

1. Clean dirt and chips from the waycovers prior to commencing machining

each day.

2. Lubricate with oil the front edge area of the wiper's on the waycovers so

that the rubbing surface does not become dry from reduced service life.

If the workpiece always to be machined without the coolant/lubricant on the

application, it is strongly recommended that please select the special design

waycover assembly of Hardinge for this application whilst you put an order for a Hardinge machine.


1.6 WARRANTY INFORMATION

Hardinge warrants to the original purchaser only that all products manufactured by it will

be free from defects in materials or workmanship, such warranty to remain in effect if and

only if such products are used in accordance with all instructions as to maintenance and

operations set forth in manuals and instruction sheets furnished by Hardinge.

The machine manufacturer is not responsible for any danger or damage arising from

improper operation of the machine. Some examples of improper use are listed below.

1. Adding to or modifying the machine without consulting Hardinge.

2. Operating the machine outside the machining range.

3. Improper use of a workpiece holding or peripheral device.

4. Using the machine with interlocks or protection covers removed.

5. Carrying out machine operation, programming or maintenance and inspection work

without thoroughly understanding the caution information, i.e. without having read

the instruction manuals carefully.

1.7 ROUTINE INSPECTION

The schedules below are based on single shift operations using coolant at all times.

Daily

1. Check pressure gauge reading.

Air pressure 5.5bar (80psi)

2. Check that there is sufficient oil in the air lubricator.

3. Check motors and other parts for abnormal noises.

4. Check the lubrication of sliding parts for evidence of proper lubrication.

5. Check safety covers and safety devices for proper operation.

6. Check coolant level and fill as necessary.

7. Clean dirt and chips from the axes and empty the swarf trays.

Weekly (In addition to daily routine)

1. Clean chips and dirt from the entire machine and wipe down.

2. Check the air filter at the rear of the electrical cabinet. Replace the filter element

if it is contaminated.

3. Check all polycarbonate vision panels for signs of damage – crazing, cracking etc.

or reduced visibility and replace if necessary. Contact your Hardinge

representative for details.

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. Check lost motion.

4. Check the condition of the linear rail wipers.

5. Check the integrity of the electrical connections and inspect the condition of the

insulation.

6. Check condition of coolant filters and replace as necessary.


1.8 MAINTENANCE PROCEDURE

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 a semi-permanent means

with the printing clearly visible.

Only qualified and competent maintenance engineers should carry out machinery

maintenance work. Working on 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.


1.9 MACHINE WARM UP

We recommend that the machine is “Warmed up” prior to first operation by running all

axes for 10 to 20 minutes at about half or one third the maximum speed in the automatic

operation mode before actual cutting.

This automatic operation program should cause each machine component to operate.

During this cycle check the correct function of these operations.

Be particularly careful to warm up the spindle.

SPINDLE WARM UP

It is essential that the spindle in the machine is correctly warmed up before use.

15,000rpm DDS Spindle

Short Term Spindle Warm up

If the machine has been idle for over 24 hours, run the spindle at 25%, 50%, 75% &

100% of the maximum spindle speed individually for 5 minutes. Once this has been

completed, the machine is ready for operation.

If the machine has been idle for within one week, run the spindle at 25%, 50%, 75% &

90% of the maximum spindle speed individually for 10 minutes and 100% of the

maximum spindle speed for 30 minutes. Once this has been completed, the machine is

ready for operation.

Long Term Spindle Warm up

If the machine has been idle for over one week, run the spindle at 25%, 50%, 75% &

90% of the maximum spindle speed individually for 30 minutes and 100% of the

maximum spindle speed for 120 minutes. Once this has been completed, the machine is

ready for operation.

18,000rpm Built-in Spindle

Daily Spindle Warm up

The spindle should execute a daily pre-lubrication procedure before start the warm up

procedure, i.e. turn ON the air/oil lubrication system and the air purge system

simultaneously at least 20 minutes. If the machine has been idle for over eight hours and/or

warm up the machine for start operating every day, the control will proceed a warm up cycle

automatically before normal machine operation can be run. The CNC will display the

message "160 Warm up is required!". Then the spindle warm up procedure will be executed

after the pre-lubrication procedure has finished, which consist with 4 steps running (i.e.

25%, 50%, 75% and full speed of the maximum spindle speed, each step running for 5

minutes). Once this has been completed, the machine is ready for operation.

If the machine is used to produce components

immediately after being started, following a long idle

period, sliding parts may be worn due to lack of oil and

thermal expansion of the machine can jeopardize

machining accuracy. To prevent this condition, always

warm the machine up.

Never start the spindle without a tool holder in place and

tooling with a balance level of G2.5 or better should always be used.


Short Term Spindle Warm up

If the machine has been idle for over one weeks, automated run the spindle for 60 minutes

after the CNC displayed the message "160 Warm up is required!".

Long Term Spindle Warm up

If the machine has been idle for two weeks or more, automated run the spindle at the run-in

procedure for 500 minutes after the CNC displayed the message "160 Warm up is required!".

Once this has been completed, the machine is ready for operation.

Caution: The balanced tool needs to be used on the spindle in the above operating

procedure.

Note: There is a risk of grease deterioration and ‘standstill corrosion’ in spindles that

have been idle for long periods which can reduce the life of the spindle. To

prevent this, the spindle should be rotated manually, 5 to 10 times by hand

every 2 months. This action should be performed with the power removed from

the machine at the main isolator.


1.10 ‘AUTOMATED’ SPINDLE WARM UP

In order to prolong the life of the spindle it is essential to follow a warm up procedure

after the machine has been idle for an extended period of time.

When the spindle has not been used for more than 8 hours, the control will require a

warm up cycle to be run before normal machine operation can continue. The NC will

display the following message at the top of the screen display:

When this message is displayed, the only automatic function permitted is a ‘TOOL CALL’

in MDI mode, allowing a balanced tool to be loaded if necessary.

Activating Spindle Warm-up

1. Select Manual or Hand wheel mode: or

2. Close guard doors. Press and hold the ‘Spindle Start’ key for approximately 5 seconds,

the NC will prompt to confirm if a suitable balanced tool assembly is in the spindle:

3. If a balanced tool is already in the spindle, press NC Start to continue. If the tool

assembly is not balanced, or there is no tool present, cancel warm-up with NC Stop,

load a suitable tool in the spindle, and return to step 1.

4. When NC start is pressed, the machine will begin spindle warm-up, and the following

information will be displayed:

5. When the warm up is completed, the message ‘Warm Up Successful’ will be

displayed.


1.11 SPINDLE OPERATING CONDITIONS

It is recommended that the spindle is not run continuously at high speed (above 10,000

rpm) for more than 12 hours. Instead reduce the speed to 500 rpm for 5 minutes before

resuming high speed operation.

Use coolant appropriate to the cutting process. Do not aim coolant directly at the spindle

nose or submerge the spindle nose in coolant.

The spindle is provided with an air purge system. Continue to run the air purge for 15 to

30 minutes after the spindle has stopped. Only then should the emergency stop button be

pressed.

Oil Chiller Unit OPTION – Certain alarms within the oil chiller will protect the machine

from further damage. Refer to the original manual supplied by the manufacturer.

1.12 SPINDLE MAINTENANCE Daily Maintenance.

Clean the front nose of the spindle with dummy toolholder and a lint-free cloth but do not

use compressed air.

Check the taper for dirt. If necessary - use a cleaning arbor.

Check coolant level in spindle chiller and top up if necessary.

Check air supply.

Check if spindle rotates easily and smoothly when turned by hand.

Check if abnormal sound is generated.

Check if excess heat is generated.

Check if excess vibration is generated.

Monthly Maintenance.

Test tool change function.

Check the spindle knock out distance. Activate the tool un-clamp pushbutton to check

that the knock out distance is as specified in the maintenance manual.

Note: prior to inserting a toolholder: ensure that the spindle taper is clean.


1.13 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 void the machine warranty.

Do not use broken or worn tools.

Avoid chatter and excessive vibration (do not exceed 4 mm/s).

If using a tool with a length to diameter ratio of more than 5:1, limit the speed so that the

vibration level does not exceed 1 mm/s.

For safe operation, refer to the informative tag and make sure the tool holder and pull

stud combination meet the standard as specified in the relevant Pre Delivery &

Installation Guide.


1.14 INTERRUPTING MACHINING

WARNING!

When leaving the machine temporarily after completing a job, turn off the power on the

operator panel with the Emergency Stop button and turn off the main isolator.

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.

1.15 COMPLETING A JOB

Always clean the machine and supporting equipment down after use. Remove and

dispose of chips and clean the covers and windows etc.

Return each machine component to its initial condition.

Check the wipers of axes waycovers for damage and replace if necessary.

Check coolants, hydraulic oils and lubricants for level & 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 end of the shift.


1.16 SAFETY DEVICES

Make yourself aware of the locations 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 are located on the main operator panel, ATC load door,

chip conveyor (if fitted) and remote hand wheel (if fitted).

Further safety devices are located at the following points around the machine:

The front door and ATC load door have safety interlock switches with guard door locking.

Stored stroke limit (Parameter setting): The control system will recognize when a move

is requested that will take the motion beyond the end of the machine stroke. This move

will not be allowed to start.

Functional Explanation

Emergency Stop Circuit

A safety circuit is fitted in the machine through which the Emergency Stop Buttons are

wired. If any one of Emergency Stop button is pressed, the machine will stop immediately

and go into an Emergency Stop condition.

CAUTION!

Once the emergency condition has been safely resolved and the emergency stop buttons

are released, the “Power On” button on the operator panel must be pressed to reset the

safety relay into its normal condition. The “CE” button should then be pressed to clear

any error messages within the control system.

Servo & Spindle Power Disconnect

Once the Emergency Stop button is pressed, the machine will stop and the power supply

to the drives is removed.

Door Safety Function

The machine has interlocked doors, the main access door at the front of the machine and

the toolchanger load station door at the left hand side of the machine. Both doors are

shot bolted shut and 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 either

door is open)

Limited machine functionality is available to the operator whilst either door is open. The

handwheel and jog keys are able to move the machine axes at feed rates of 2m/min and

less when the mode select key switch is in the ‘manual’ position. Selection of automatic

program running is prohibited until the doors are shut and the mode select key switch is

returned to the ‘auto’ position. Rotation of the tool magazine is also prohibited until the

doors are shut.


Door Interlock of Electrical Cabinet Safety Circuit

When door interlock switch is in the ‘0’ position and the cabinet doors are open, the power

to the machine will be turned OFF. When door interlock switch is in the ‘1’ position and the

cabinet doors are open, the power to the machine will be kept ON

WARNING: Only trained, skilled personnel should use this functionality.


2.1 TNC 640 VISUAL DISPLAY UNIT

1. Header

When the TNC is on, the current operating mode is shown in the header.

Messages to the operator are also shown in this area.

2. Softkeys

Various TNC functions are indicated on these soft keys. The displayed

functions can be selected by pressing the keys directly below them.

3. Softkey selector keys.

4. Switch softkey rows.

5. Select screen layout.

6. Shift key to switch display between machining and programming modes.

7. Softkey selector keys for machine specific functions e.g. Toolchanger

8. Softkeys for various machine specific functions. The displayed functions

can be selected by pressing the keys directly to the right.

Further information on the use of and programming the Heidenhain control can be found

at the following website address:

http://content.heidenhain.de/doku/tnc_guide/html/en/index/1242135142456/1242135142456.html

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2.2 KEYBOARD AND CONTROL PANEL

M/C power on

Spindle speed override knob

Feedrate override knob

Mode select switch

Emergency stop button

Axis jog keys

Program start

Program stop

Washdown on/off

Standard coolant on/off

Spindle on/off


2.3 CONTROLS ON THE TNC 640

Mode select switch

Program Management

Program/file management

Subprogram call

MOD functions

Help functions

Pocket calculator

Typewriter keyboard for entering letters and symbols

Tool Functions

Load tool offsets and activate ATC

Machine operating modes

Manual operation

Electronic Handwheel

Positioning with MDI

Program run, single block

Program run, full sequence

Programming path movements

Approach/depart contour

Flexi Curve programming

Linear move

Circle centre/pole

Circle move around CC

Circle with radius

Tangential circle

Chamfer

Corner rounding

Programming modes

Test run

Programming and editing

Moving the highlight, going directly to

blocks, Cycles and parameter functions

Move high-light

Go directly to blocks, cycles and

parameter functions

Controls on the visual display unit

Split screen layout

Switch between machining or programming modes

Softkeys for selecting

functions in screen

Switching for softkey rows

Switching for softkey columns


CONTROLS ON THE TNC 640 (cont.)

Cycles, subprograms and program section repeats

Define and call cycles

Enter and call labels for

Sub-programming and section

repeats

Program stop in a program

Enter touch probe functions

Co-ordinate axes and numbers:

Entering and editing

Select co-ordinate axes

Numbers

Decimal point

Change arithmetic sign

Incremental co-ordinates

Q parameter programming

Actual position capture

Skip dialog questions, delete words

Polar co-ordinates

Abort dialog, delete program section

Clear numerical entry, or error message

End block

Confirm entry and resume dialog


2.4 MODE SELECT SWITCH

‘MODE-key’ set to MSO1

This is the normal operating condition which allows full machine functionality with all

guard doors closed and locked shut. The general requirements of this manual and the

Safety manual must be followed.

Provided guard door is closed, any program can be started via CYCLE START when key is

set in this mode.

The key can be removed in this position by a Supervisor.

When guard door is opened. All axes and spindle movement is disabled.

‘MODE-key’ set to MSO2

This allows limited movement of the machine axes (<2m/min) with the main guard door

open either by the hold-to-run jog keys on the main operating panel or the hold-to-run

jog keys or electronic handwheel on the remote MPG in conjunction with the permissive

keys for adjustment and/or setting purposes.

There is a higher level of risk associated with any movement of the machine with the

main guard door open (eg. crushing, shearing, cutting, ejection of material or mists etc)

which could result in serious injuries or even death so, only specifically trained and

authorised personnel are permitted to operate the machine in this condition and have

access to the key switch which permits this mode.

During any movement, all parts of the body should be kept away from the moving

elements.

The final responsibility for ensuring the safety of the operator in this mode of operation

lies with the machine owner.

If the operation can be carried out in MSO 1 with the main guard door closed, then that

route should be selected in preference.

MSO1 should be re-selected and the key switch removed as soon as all setting actions

have been completed.

The key should be kept in a safe place by the person authorised to use it.

Machining is not permitted in MSO2 (Setting Mode).


2.5 MACHINE POWER ON AND REFERENCE Turn on Machine at the Isolator

The isolator is located on the side of the machine. Turn the isolator switch "I" to the “ON”

position, Figure A below.

Rotate valve “J” of the main air switch, Figure B below, to the vertical position to turn the

machine air supply ON.

The machine will begin to power up, and the message “Power Interrupted” will be

displayed.

Press the key to clear this message and conclude boot-up sequence.

Reference Machine

1. Ensure all Emergency stop buttons are out.

2. Press the Power ON button.

Note: Due to safety checks it may be necessary to press the “power on”

button twice.

3. Ensure that the feedrate override knob is set to 100%.

4. Press the Cycle Start button.

5. The machine will automatically Magazine reference out.

6. The ATC chain would rotate, but the other axes would be stationary.


2.6 MACHINE POWER OFF In order to prevent loss of data, the machine should be powered off using the following

procedure:

Press or to enter either Manual or Handwheel mode.

Press key once to alter softkey display.

Press softkey.

The message “What would you like to proceed?” will be displayed. Confirm this by

pressing the “Shut down” softkey. The machine will then power down.

Note: It is also possible to set the machine to power off at the end of the program

via the “END PGM OFF” softkey (See softkey operation section) Turn the main isolator switch “I”, Figure A, OFF. The main air switch valve “J”, Figure B, rotate the switch valve to horizontal position to

turn the machine air supply OFF.

Figure A - Main Disconnect Switch

I

Figure B - Main Air Valve

OFF

ON

J


2.7 EMERGENCY STOP Pressing any Emergency stop button will cut the power supply to the axis drives, spindle

drive and any other equipment on the machine (e.g. swarf conveyor).

Emergency stop buttons are located in the following areas:

Machine operator panel

ATC manual operation panel (on side machine guard)

Chip conveyor (if fitted)

Remote MPG (if fitted)

Power on Machine

After an Emergency stop, the machine must be “powered on” before normal use can

resume:

Ensure all Emergency stop buttons are out.

Press the Power ON button.

Note: Due to safety checks it may be necessary to press and hold the

“power on” button for a few seconds.

Press the key to clear the emergency stop message.


2.8 SOFT KEY LAYOUT The machine functions accessible via softkey are split into 3 groups:

Machine functions: e.g. coolant

Spindle functions: e.g. rotation

Toolchange functions: e.g. magazine loading

The following pages contain an explanation of the functions available:


SOFT KEY LAYOUT (cont.)

Machine Functions

Return to Main Menu

End of program power off

Cycle start

Feed hold

Axis positive move

Axis negative

move

Axis negative

move

Swarf conveyor

on/off

Swarf conveyor reverse

(whilst key is pushed)

Return to Main Menu



Spindle Functions

Start spindle (cw)

Spindle stop

Jog spindle (cw)

Jog spindle (ccw)

Orientate spindle to

tool change position

Return to Main Menu

Return to Main Menu

Through spindle coolant on/off

(optional)

Standard coolant on/off

Washgun on/off

(optional)

DRY RUN on/off



Toolchange Functions

Enable tool changer

magazine loading

Jog tool changer

magazine cw

Jog tool changer

magazine ccw

Return to Main Menu

Manual tool load/unload function

Tool unclamp

Return to Main Menu


2.9 MANUAL AXIS JOG

Manual Axis jog via operator panel keys

The Machine axes can be moved manually with the axis jog keys in either Manual

Operation or Electronic Handwheel modes.

Press or to enter the desired mode. A diagram of the axis jog keys is shown below:

Press jog key relating to the desired axis and direction. The feedrate can be controlled

using the feed override knob.

To traverse at rapid feed press and the desired axis direction key.

Note: The rapid jog feed will be reduced to 2m/min maximum when attempting

to jog an axis with the guard door open, and it is only possible to move the

axis individually. The mode select switch must be in the position.


HR 410 Permissive Buttons


2.10 ELECTRONIC HANDWHEEL The Machine axes can also be moved using the Manual Pulse generator (See Illustration)

in Electronic Handwheel mode.

Moving an Axis using Electronic Handwheel Press to enter Electronic Handwheel mode.

Select the desired axis by pressing the relevant orange Axis key.

Turn the Handwheel to move the axis.

Setting the Interpolation factor

Pressing the switch for handwheel.

Selecting one of the three factor "SLOW" , "MEDIUM" ,"FAST" .

Note: The rapid jog feed will be reduced to 2m/min maximum when attempting to move

an axis with the guard door open, and it is only possible to move the axis

individually. The mode select switch must be in the position.


2.11 MANUAL TOOL LOAD/UNLOAD

Press to enter manual mode.

Press softkey to activate manual tool load/unload function.

The message “Tool Unclamping Please” will appear.

Open guard door of machine

Close guard door of machine

The message “TC quit, Please !” will appear

Press softkey to complete the manual tool load/unload function.

WARNING Ensure adequate protection is used to

prevent injury from sharp cutting tools.

!

XT 630 5AX machine:

Note: Whilst the ‘TOOL RELEASE’ button on the

machine head is pressed the tool in spindle is

unclamped – release button to clamp tool.

While holding the tool, press the ‘TOOL RELEASE’

button to release the tool in spindle.

Replace tool then release the ‘TOOL RELEASE’ button to clamp the tool in spindle


2.12 LOADING TOOL MAGAZINE VIA FRONT GUARD DOOR

Press to enter manual mode.

Press softkey to access toolchange menu.

Press softkey to access load menu.

Insert/remove tools from the carousel pockets, ensuring that they are correctly located.

Press softkey to disable tool magazine loading. Press key to

complete the operation.

Press softkey to exit toolchange menu.

Note: After manually changing the contents of the ATC magazine, check

the pocket table to ensure the correct positioning.

To rotate the ATC magazine, press and hold

the desired direction button until the

magazine is in the required position

(see picture).

(Note: the magazine can only be rotated if the guard door is closed)


2.13 TOOL TABLE Tool data, such as length, radius etc is stored in a centralised tool file. This file can be

accessed from the following modes

Manual Operation

Electronic Handwheel

Manual data input (MDI)

Program run single block

Program run full sequence

In all modes, the tool table is accessed using the softkey.

The tool table display is shown as below:

Typical tool table fields are shown below.

NAME Tool name.

L Tool length offset.

R Tool radius offset.

R2 Tool corner radius.

DL Delta (wear adjustment) length offset.

DR Delta (wear adjustment) radius offset.

PLC PLC information regarding the tool. There are four possible settings:

00000000 - Tool pocket will stay down after toolchange

00000010 - Tool pocket will retract after toolchange

Editing tool table

Press “EDIT ON/OFF” softkey so that “ON” is highlighted:

Using cursor keys, highlight the desired field. Enter the new value.

Exit tool table using the “END” soft-key or key.


2.14 POCKET TABLE The pocket table can be accessed from the tool table page using the softkey.

The tool table display is shown below:

The pocket table fields are shown below:

Abbreviation Input Dialogue

P Pocket number of the tool in the tool

magazine (0 denotes spindle)

POCKET NUMBER ?

T Tool number TOOL NUMBER ?

RSV Pocket reserved Pocket reserv.: Yes

= ENT / No = NOENT

ST Special tool with a large radius requiring

several pockets in the tool magazine. If your

special tool takes up pockets in front of and

behind its actual pocket, these additional

pockets need to be emptied and locked

(status L).

SPECIALTOOL ?

F Fixed tool number. The tool is always

returned to the same pocket.

Fixed pocket? Yes

=ENT / No = NO ENT L Locked pocket Pocket locked? Yes

=ENT / No = NO ENT

DOC Display of the comment to the tool from

TOOL.T

Editing pocket table

Press “EDIT ON/OFF” softkey so that “ON” is highlighted:

Using cursor key, highlight the desired field. Enter the new value.

Exit tool table using the “END” softkey or key.

The pocket table can also be reset using the softkey. This will set the tool and

pocket numbers the same, and remove any ST, F, L, DOC status. This should only be

used if the magazine and spindle are empty.


2.15 ATC OPERATION IN MDI MODE Press key to enter MDI mode. Cursor to the end of the program using keys.

Press key to begin a tool call line. Enter the new tool number using keys and press .

Enter spindle axis as “Z” using orange key and press . Enter spindle rpm using keys and press . Conclude Tool Call line by pressing key. Ensure Tool Call line is highlighted using keys. Activate ATC cycle by pressing the green cycle start button.


2.16 M-FUNCTION CODES

Function

Effective at

Beginning

of Block

End of

Block

M00 Stop program run/stop spindle •

M01 Optional program stop •

M02 Stop program run/stop spindle/return to

program block 1 •

M03 Spindle on clockwise •

M04 Spindle on counter-clockwise •

M05 Spindle stop •

M07 Through spindle coolant on (where fitted) •

M08 Standard Coolant on •

M09 All Coolants off •

M10 Clamp axis •

M11 Unclamp axis •

M13 Spindle on CW and standard coolant on •

M14 Spindle on CCW and standard coolant on •

M19 Spindle orientation 0 degree •

M20 Spindle orientation selectable via Parameter •

M21 Spindle orientation cycle 13 •

M30 Stop program run/stop spindle/return to

program block 1 •

M31 Working without M3/M4 •

M41 Wash down (chip-flush) coolant on •

M42 Wash down (chip-flush) coolant off •

M44 Unclamp axis 4 •

M45 Unclamp axis 5 •

M50 Chip conveyor stop •

M51 Chip conveyor forward •

M52 Chip conveyor reverse •

M56 Workpiece air-blast on •

M58 ATLM air-blast on

M64 Clamp axis 4 •

M65 Clamp axis 5 •

M71 Axis limit 1 •



Notes:

• Certain M-codes are specific to a machine or Option fitted to machine.

• ‘TOOL CALL’ must be used for toolchange command (M06* verifies without action)

• A comprehensive M-function list can be found in the Heidenhain TNC 640 manual

supplied with the machine.


M76 Workpiece air-blast off •

M78 ATLM air-blast off

M80 Parts counter reset =0 •

M81 Parts counter +1 •

M82 Tool specific torque monitoring off •

M83 Tool specific torque monitoring on •

M180 Spare M-code 1 on •

M181 Spare M-code 1 off •
















2.17 DATUM SETTING Preparation

� Clamp and align the workpiece.

� Load a tool of known radius and length into spindle.

� Ensure that the control is displaying actual (ACTL) position values. (to do this see the

Heidenhain TNC 640 manual supplied with the m/c)

For X and Y axis datum setting

In manual operation or electronic handwheel mode, carefully move the tool

until it touches the workpiece surface using the jog keys and the electronic handwheel.

Press the softkey, and select the required axis using the orange axis keys.

Enter the datum co-ordinates (taking tool radius in account where necessary) and

confirm with the key.

Repeat as necessary for other axis.

For Z axis datum setting

In manual operation or electronic handwheel mode, carefully move the tool

until it touches the workpiece surface using the jog keys and the electronic handwheel.

Press the softkey, and select the required axis using the orange axis keys.

Enter the surface co-ordinate and confirm with the key.

Please consult the supplied Heidenhain manual for information regarding this setting

before use.


2.18 PROGRAM RUN Methods of program run

Program run, single block - Each block of the program must be started individually

with the Program start button. Used for program proving.

Program run, full sequence- The program will run through automatically after the

Program start button is pressed. Ensure workpiece is securely clamped and the datum and tools have been set.

Enter the desired mode. (Note you can switch between modes during program execution)

Select program to run

Press to enter program management screen.

Select the required program using the cursor keys and confirm with .

The display will return to program run mode.

Select block 0 by pressing .

Begin program run by pressing the program start button.

The program can be interrupted at any time by pressing the program stop (Feed hold)

button. Program run can be resumed using the program start button, or ended by

pressing the “Internal Stop” softkey. In addition, the machine can be manually moved

via jog keys/handwheel by pressing the “Manual Traverse” soft key. Machining can be

resumed by pressing the “Restore Position” soft key, followed by “Cycle Start”.

Note: During program run, the spindle rpm and feedrate can be altered using

the override knobs. When overriding spindle speed there may be a short

feedrate hold to allow the spindle to alter speed.


2.19 MANUAL OPERATION OF SPINDLE The machine spindle can be manually activated in both manual operation and electronic

handwheel mode:

Press or to enter the desired mode. Ensure guard door is closed

Activate Spindle Press softkey, and enter the desired spindle RPM.

Confirm Spindle RPM by pressing the green cycle start key . Press softkey, and enter “3” (spindle on CW M code). Confirm spindle activation by pressing the green cycle start key .

The Spindle will now begin to rotate at the programmed RPM.

Deactivate spindle Press softkey, and enter “5” (spindle off M code). Confirm spindle deactivation by pressing the green cycle start key .

The Spindle will now stop. Note: After loading the spindle RPM as described above, it is also

possible to activate/deactivate the spindle using the spindle

on/off buttons or the spindle on/off key


2.20 WASH GUN

The machine is fitted with a manually operated coolant wash gun.

To operate the wash gun:

Ensure that the machine is stopped and the front guard door is open.

Press the ‘WASHGUN’ softkey.

This will enable the wash gun and also activate the base wash down for a time period set

in a parameter.

The wash gun can now be operated by pulling the trigger on the gun body.

If time out occurs to de-activate the wash gun – press the ‘WASHGUN’ softkey again

Press the ‘WASHGUN’ softkey again or close the front guard door to disable the wash gun.


2.21 USER PARAMETERS Some machine functions can be altered via the "OPTION BIT SETTING PAGE".

Entering password "531122" can enter option bit setting page.

Care should be used when altering these settings and it is recommended that the original

values are noted before any alteration takes place.

"OPTION BIT SETTING" page


2.22 SERVICE FUNCTION Activate SERVICE Function

Ensure the all Machine guard doors are closed.

Press the softkey after the "Jog" mode has been selected. [However this

softkey will be turn to deactivate status (shading) when operating in the

other modes.]

Press the softkey and then the "SERVICE" function will be active.

Using HELP Function

Using the key of switching for softkey columns to select the desired

function softkey e.g. : “S TO TOOLCHANGE POSITION”.

Press the cycle start button to perform selected softkey function. When the function has

been performed, the message ‘209 Function OK’ will be displayed. (A list of the softkey

service functions available is shown on the next page.)

When the maintain has been finished, press the softkey to exit the service

function.

(Note: It may be necessary to check the pocket table after service function about

ATC arm exchange. See supplied Heidenhain TNC 640 manual.)


SERVICE FUNCTION (cont.) Service functions available:

1. The machine ‘service softkey’ below is for a ‘Double arm cam driven’ type ATC:


- Orientate the spindle to toolchange position

- Move Z to Safety position

- Move A to toolchange position

- Move Z to toolchange position

- Move Y to toolchange position

- Move X to toolchange position

- Unclamp tool in spindle

- Swarf door open

- Swarf door close

- Clamp tool in spindle

- Tool-pot down (towards spindle)

- Tool-pot in (towards Mag.)

- Move swing-arm to spindle

- Move swing-arm to change tool

- Move swing-arm to basic (home)

- ATC recovery

- Move magazine cw (right)

- Move magazine ccw (left)

- Move magazine to pocket 1

- Set spindle-tool status to tool 0 (DO NOT

USE).

- Move swing-arm to spindle

- Move swing-arm to change tool

- Move swing-arm to basic (home)


2.23 ATC ARM RECOVERY

WARNING: Please contact your local Hardinge Service Representative

before using the toolchange recovery function.

WARNING: Before executing ATC ARM RECOVERY procedure, check the

spindle and Z axis tool change position.

In the event of a toolchange error mid-toolchange, the ATC ARM RECOVERY function can

be used to manually recover the machine.

The machine happened E.M stop or power failed when ATC arm running. ATC ARM

RECOVERY can make arm go to original.

After machine power on, the alarm "88 ATC not on 0 degree position" will display on

screen.

Press → → →

ATC ARM go reference automatically


2.24 POCKET TABLE REFORMING

WARNING: Please contact your local Hardinge Service Representative

before using the pocket table reforming.

PRESSING "TOOL TABLE" →"POCKET TABLE" →"EDIT ON" (highlighted) →

"RESET POCKET TABLE" →"OK"


Note: There are some steps need you to pay attention after finished the tool recovery

procedure as below:

Step 1: Check what number of tool package is displayed on the main screen.

Step 2: Setting the RSV value of this tool package to be "R" when you get the

number of tool package from the main screen. (Example as Figure shown

below: the number of tool package is "9" was shown up, then setting the


RSV value is "R" on the row of "1.9" tool package.)

Step 3: Access to the "package table editing" mode screen and then setting the

number of tool package to be "0" that you got from the main screen.

(Example as Figure shown below: the number of tool package is "9" was

shown up, then setting the number of tool package value is "9" on the row

of tool package "0.0".)


2.25 STACK LIGHTS

The stack lights will be flicking when power ON the machine firstly that allow the operator

to carry on the stack lights checking as Figure at right-side shown.

The colors and definitions are listed below:

RED

Emergency Stop or alarm condition. Automatic cycle is stopped.

AMBER

The machine is in Automatic mode, but automatic cycle is not

active.

GREEN

Automatic cycle active. Normal operation.


APPENDIX ONE

SPINDLE OUTPUT DIAGRAM

6000

60

0

40

20

20000 4000

TORQUENm

200

180

120

140

160

100

80

9

120008000 10000 14000

0

6

3

18

12

15

21

24

kW

30

27

POWER

16000 18000

220

240

260

280

300

33

36

39

42

45

87.9Nm(S1)

123.8Nm(S6~40%)

30kW(S1)

38kW(S6~40%)

29303260 Spindle Speed (RPM)

GTW 18,000rpm Built-in Spindle Motor for XT 630 5AX


Heidenhain QAN200UH / 15,000rpm DDS Spindle Motor for XT 630 5AX

operating manual heidenhain tnc 640 xt 630 5ax xt 630 5f ...hardingeservice.com/usr/xt series/op...

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