Content Preview
TB067 Rev1 Special Instructions for KOYO based ATCs
Overview
This document describes special procedures and instructions for setup and use of the Automatic Tool
Changers Included is a description of all special M codes used with the ATCs procedures to be used during
initial setup and when loading the tool carousel and notes about operating the ATC Â
Special M Codes for ATC
M5 Turns the spindle motor off even if in orientation mode
M6 The tool change process uses the other M functions It is littered with M1
commands which will
allow single stepping if optional stops are enabled Will unload tool in spindle and pick up tool
designated as M6T3
Use M20
if there is no tool in spindle
M15 Tool unclamp and air blow Be prepared to catch the tool from the spindle Will not operate if
spindle is turning Not to be used to manually change tools use clamp/unclamp button on head
M16 Tool clamp and air blow off turns off M15
request
M18 Reset tool counter to tool #1 ensure carousel is at position #1 before issuing
M19 Orient spindle for tool change and hold cannot be done if M15
is already active Note that it
turns on the spindle with zero speed
WARNING
If the spindle motor spindle encoder or spindle inverter is changed or if inverter encoder
parameters are changed the inverter parameters must be checked to ensure proper spindle
orientation to prevent a crash Follow the procedures in the Special Procedures for setting Fuji
Inverter parameters
section *
M20 Pick up a tool Useful when there is no tool left in the spindle Cannot be done if M15
is active
Will pick up the tool currently facing the spindle
M21 Move head up to Z Home position
M22 Move head to ATC level uses a G30
command that utilizes the G30
positioning parameters in
WCS configuration DO NOT
change the G30
parameters and DO NOT
use any codes in your
programs that will override these parameters
WARNING
If the Z axis motor has been reinstalled or Z Home has been changed in any way or if the
Motor revs/in mm in the machine configuration for the Z axis have been changed the G30
parameters must be reset to the correct value height to prevent a crash Follow the procedures in
the Special Procedures for setting G30 parameters
section
M80 Moves the carousel in regardless of Z axis positioning Will not accept command if spindle is
turning or orientation is started
WARNING
There is nothing to prevent the carousel from slamming into the head or tool Ensure
sufficient clearance before issuing command
M81 Moves the tool carousel out Turns off M80
request
WARNING
Be sure the tool is NOT
partially covered by the spindle or tool will be knocked out and
carousel fingers may be damaged Â
Initial Setup Procedures
Connect the air supply at the rear of the machine frame The air pressure gauge should read approximately 50
70 PSI If air pressure falls below approximately 40 PSI the warning message "*** Air Pressure Low ***" will
be displayed in the CNC7 message window and any running jobs will be canceled Once power has been
applied to the control and machine homing sequence completed ensure directional rotation of carousel is
correct When the Tool Index + or AUX1
key on the jog panel is pressed the carousel should rotate up in
number When the Tool Index or AUX3
key is pressed the carousel should rotate down in number If
rotation is incorrect two of the incoming 3 phase power lines will need to be switched by a qualified
electrician Once the carousel is rotating correctly use the Tool Index keys or AUX1/AUX3
to rotate the
carousel so the number one tool is positioned to be loaded into the spindle Once in position press F3 MDI
mode
and at the prompt type a M18
and press the CYCLE START key on the jog panel The message "
Tool 1 set in ATC " will be displayed in the CNC7 message window If the message does not appear there
is something wrong DO NOT operate the tool changer
Procedures for loading the Tool Carousel
1 Raise the head to the home position by issuing an M21
command at the MDI prompt and pressing CYCLE
START
2 Bring the carousel into the load position by issuing an M80
command at the MDI prompt and pressing
CYCLE START
3 Escape the MDI mode so the carousel can be rotated for loading multiple tools by using the Tool Index keys
or AUX1/AUX3
4 Once all tools are loaded rotate the carousel to the Tool#1 position and enter the MDI screen again
5 Issue an M81
command to move carousel back out and be sure there is no tool in the spindle
6 Issue an M18
command followed by an M20
command to pick up Tool #1
7 Press ESC
to exit MDI mode
General use and operation
The following guidelines should be considered when using the ATC
*DO NOT
change the Motor Revs/in or encoder counts in the Machine Configuration The ATC will not
function properly if these machine parameters are modified Doing so will cause misalignment resulting in a
crash or damaging the tool holder fingers
*DO NOT
change the machine home position for the Z axis; this includes changes to the G30
Z axis value
the G28
Z axis return point or using an M26/Z command Doing so will cause misalignment resulting in a
crash or damaging the tool holder fingers
*The default mode for the ATC is automatic mode To change the mode of operation to manual choose F5
CAM
to access the F4 ATC
option The utility that is run will allow a choice between automatic and manual
modes of operation The tool changer control will respond to a tool change request for tools numbered one to
the total number of stations Trying to change to a tool number outside this range will result in an Emergency
Stop condition before the tool change cycle finishes
General tool changer behavior
A tool change process always places the tool in the spindle back into the tool station from which it was picked
up Manually placing a tool into an empty station from which a tool was picked up from will most likely result in
a tool changer crash unless the mistake is realized and the Emergency Stop ESC or CANCEL key is
pressed If this happens follow the procedure outlined below in emergency conditions The only time that the
tool changer will not place a tool back into the currently aligned tool station is when the Tool Index auxiliary
keys are used to manually rotate the carousel out of position
Emergency conditions
The following conditions require special attention
1 The "*** Air Pressure Low ***" message or other fault message is displayed
2 The Emergency Stop ESC key or CANCEL
key on the jog panel is pressed when a tool change is in
action
3 A loss of power occurs unexpectedly while a tool change is in progress
If any of these conditions occur or if there is a possibility that a tool change was in progress and did not finish
normally the correct procedure to follow is to rotate the tool carousel to Tool #1 position and issue an M18
command If there is no tool in the spindle use an M20
to pick up Tool#1 If there is a tool in the spindle and
also one in the Tool#1 carousel position use the manual unclamp to remove the tool from the spindle and
follow the steps in the Procedures for loading the Tool Carousel
section
Special Procedures for setting Fuji Inverter parameters
Refer to the Fuji inverter manual on how to set parameters all parameters should be set to the original factory
defaults except as listed below
Parameter Value
P001 Motor Maximum Speed 4500 or 6000 depends on motor
P002 Acceleration Time 2 0 for most motors
P003 Deceleration Time 2 0 for most motors
P038 DC Injection Time 0 0 sec
P053 Motor Code 105 or 107 depends on motor
P078 PE Feedback Control 1 Use
P079 NTC Thermister 1 Use
P106 ASRP Gain 30
P115 ASR Integration Time 0
P201 Spindle/PE ratio 1 1 1
P202 A/B Phase Select 1 Phase B leading in forward direction
P203 Pulse Select 0 encoder lines 1024 default
P204 Acc/Dec Mode 1 Use
P217 ARP P Gain 30
P221 Completion Range 48 pulses
P225 Re ORT Mode 1 after one revolution
After setting all parameters in the previous table shut off the machine at the disconnect switch and wait 15
minutes for the inverter to reinitialize
1 Perform machine startup and complete the Homing sequence
2 Press F3 MDI
mode
WARNING DO NOT leave the MDI screen until instructed to do so You could cause a tool crash and
you will have to restart the procedure from step 1
WARNING Before completing the next step be sure there is clearance for the tool carousel to be
moved into the tool change position so the carousel will not slam into the head when you perform the
M80 command
3 Type M80
at the MDI prompt and press CYCLE START
This should move the carousel into the tool
change position
4 Remove the retention knob from the tool in the carousel directly below the spindle or else the spindle will
not be able to be lowered over the tool completely and it will be hard to line up the spindle accurately
5 Using the Jog buttons carefully move the Z axis down over the tool in the carousel Rotate the spindle by
hand until the spindle dog's lineup with the notches in the tool Be sure the vertically shorter of the two dogs is
facing the carousel The long vertical dog must face away from the carousel to allow clearance for the spindle
to come down close enough for clamp to grab the tool
6 Carefully jog down the spindle so the spindle dog and tool notch match and the taper is fully covered The
spindle should almost but not quite touch the tool If you didn't remove the retention knob as previously
instructed you will not be able to fit the dog into the notch
7 Manually rotate the spindle so the dog is centered approximately in the notch
8 At the Fuji inverter change parameter 206 to a 1 and save This will set the current spindle position into
parameter 205
9 Raise the Z axis to home Press TOOL CHECK
10 Type M19
at the MDI prompt and press CYCLE START
The spindle should spin momentarily and stop in
the proper orientation to load a tool If the carousel retracts use the M80
command to bring it back in
11 Replace the retention knob that was removed Type M15
at the MDI prompt and press CYCLE START
12 Carefully lower the spindle around the tool and check for dog to notch alignment If it is aligned the
procedure is complete If not you must repeat the entire procedure
13 If alignment is complete raise the Z axis to home Press TOOL CHECK
14 Enter the following commands at the MDI prompt and press CYCLE START
after each M function
M16 To clamp the tool and turn off the air blow
M81 To retract the tool carousel
M5 To disengage the spindle orientation
15 If necessary continue with the procedure to set G30
parameters
Â
Special Procedures for setting G30 parameters
1 Perform machine startup and complete the Homing sequence
2 Press F3 MDI
WARNING DO NOT leave the MDI screen until instructed to do so You could cause a tool crash and
you will have to restart procedure from step 1
3 Type M19
at the MDI prompt and press CYCLE START
The spindle should spin momentarily and stop in
the proper orientation to load a tool If this does not happen follow the steps in Special Procedures for
setting Fuji Inverter parameters
WARNING Before completing next step be sure there is no tool loaded in the spindle If there is a tool
in the spindle unload it using the Clamp/Unclamp button on the head If the tool remains in the
spindle it will be dropped when you perform the M15 command
4 Type M15
at the MDI prompt and press CYCLE START
This should unclamp the spindle to prepare for tool
loading
WARNING Before completing the next step be sure there is clearance for the tool carousel to be
moved into the tool change position so the carousel will not slam into the head when you perform the
M80 command
5 Type M80
at the MDI prompt and press CYCLE START
This should move the carousel into the tool
change position
6 Use the Jog buttons to carefully move the Z axis down over the tool in the carousel Make sure the spindle
dogs lineup with the notches in the tool If they don't follow the steps in Special Procedures for setting Fuji
Inverter parameters
7 Jog the spindle down so the spindle dog and tool notch match and the taper is fully covered The spindle
face should just barely touch the tool The spindle should not be pushing the tool down through the carousel
fingers or they may be damaged
8 Set the Jog panel to Incremental mode and carefully jog the Z axis up and down to ensure there is no
pressure being applied to the tool but that the spindle is positioned so that the tool can be clamped
WARNING If the spindle is not positioned properly the next step could damage the tool carousel or
tool holding fingers
9 Issue an M16
at the MDI prompt and press CYCLE START
The tool should be pulled up into the spindle
but the tool should only slightly pull the tool holding fingers upward If the fingers are pulled up too much
release the tool with an M15
command and try repositioning Z axis again DO NOT
try to move Z axis while
the tool is clamped into the spindle
10 Once the tool can be clamped and unclamped with only slight movement of the fingers continue to the
next step
11 Issue an M16
command and press CYCLE START
to clamp the tool
12 Issue an M81
at the MDI prompt and press CYCLE START
The carousel should retract to the parked
position and the tool should remain clamped into the spindle
WARNING If the preceding steps were not performed correctly the following step could cause a tool
crash and this procedure will need to be restarted from step 1 Be prepared to abort the next move
by pressing the E STOP button if the fingers do not align properly with the tool holding groove as the
carousel moves in
13 Issue an M80
at the MDI prompt and press CYCLE START
The carousel should move into the tool
change position The fingers should align with the groove in the tool to properly hold the tool If further Z axis
adjustments are needed repeat steps 9 12
14 Once you are fully satisfied with the positioning of Z axis be sure the tool is clamped into the spindle and
use the M81 command to retract the carousel
15 Press ESC
to exit the MDI screen and return to the Main Menu screen
16 From the Main Menu press F1 Setup
F1 Part
and F9 WCS
17 From the WCS Menu press F1 Return
to change the G30 Z axis return position to the number displayed
in the Z axis DRO digital read out Make sure you include the negative sign
18 Press F10 Save
to save the changes
19 Repeatedly press ESC
until the Main Menu screen appears
The Z axis level is now properly set to change tools
WARNING If Z axis motor is removed and reinstalled or position altered Z Home is changed in any
way Motor revs/in mm in the machine configuration is changed or any parameter is changed that
will affect positioning of the Z axis the G30 parameters must be reset to the correct height to prevent
a crash
Document History
Rev1 Created on 1999 07 08