cea] Operation Manual L210 L220/L/G/M/LM L300/M L2100A/LA/LMA/B/LB/LMB/C/LC/LMC/GA LEO160 LEO1600 Doosan Machine Tools ML00010PE181INTRODUCTION Thank you for choosing our machine tool. We are proud to have you among our machine tools family of users. Manuals contain concise information on the setup and operation of your machine tool. To make the most ofits outstanding performance over a long period, the machine must be properly installed, and operating and maintenance procedures must be clearly understood and caretully followed. This manual was considered complete and accurate at the time of publication, however, due to our desire lo constantly improve the quality and specification of all our products, it is subject to change or ‘modification. f you have any questions, please contact the nearest our machine tools Technical / Service cconter.CONTENTS Part1 MAIN OPERATION PANEL, 1. POWER SWITCHES 1.1 Layout of power switches.. 1.2 Operation of power switches. 2. MAIN OPERATION PANEL . 2.1 Layout of operation panel. 2.2 Operation panel switches ....n.ensonensnneen 2.3 Key selector switch... 2.4 Optional function switch 2.5 Foot switch operation 2.6 LED display. .. 27 Operation of HOTKEY Switch (Only some machine) .. “ 26 2.8 Other SWilch@s ecru 3. Sub operation panel (Only some machine). 3.1 Layout of sub operation panel 3.2 SPINDLE INCHING(JOGGING).... 3.3 Emergency stop switch 4. Portable MPG(Option)... 44 Layout of Portable MPG... 42 Type of switches ~ a a eee 29 Part2 OPERATION.. 1. POWER SUPPLY & BREAK 1.1 Power supply 2. EMERGENCY STOP & MACHINE READY.. 2.1 Emergency Stop2.2 Machine Ready.. Operation Mode selection.. 3.1 Operation Mode 34 sereennenee BO AXIS FEED OPERATION 4.1 Jog Travers 4.2 Rapid traverse during jog traversing 40 43 Handle feed 4 4.4 Manual REF. point return: 42 4.5 Automatic reference point return 47 4.6 Automatic axis feeding command... 48 C-AXIS CLAMP .. wi 5.1 Ceaxis operation 51 5.2 Axis traverse and restrictions in C-axis clamp status. SPINDLE.. eeesneeeeeee 5D. 61 Spindle operation... 53 62 — Main spindle selection 54 6.3 Rev. spindle selection MAIN SPINDLE OPERATION. 7.1. Main spindle introduction and the rotating condition .. 7.2 Main spindle manual operation 7.3 Main spindle automatic operation 63 7.4 Main spindle override operation...... 65 7.5 Main spindle operation 65 7.6 Main spindle output chanceover.... 67 7.1 Main Spindle Gear switching 70 REV. SPINDLE OPERATION 8.1 Rev. spindle introduction and rotating condition uF | n 82 Rev. spindle manual operation 75 76 83 Rev. spindle automatic operation... 84 Rev. spindle override operation 85 Rev. spindle orientation (option)... CHUCKING OPERATION 7910. 11. 12. 13. 9.1 Chuck operation : -80 9.2 Restrictions in machine operation according to the status of chucking 82 9.3. Chuck clamp/unclamp check 82 9.4 Chuck clamp/unclamp operation 86 9.5 Dual chucking (option) 88 90 9.6 Chucking operation on spindle rotating. 9.7 PMC alarm related to chucking 90 TOOL POST.. 91 10.1 The movement of tool post. 1 10.2 The operation of tool post .. 10.3 Tool life management (option) 94 10.4 Alarm related to tool COOLANT OPERATION 11.1 Connecting coolant motor and peripheral device 98 11.2 Standard coolant operation 11.3 Coolant flushing operation 11.4 Mutual operation between standard and optional coolant. 11.5 Cool jet coolant operation ..... 11.6 T.S.C (Through the spindle coolant) operation 11.7 Coolant Flushing... 11.8 Chuck coolant 11.9 Keep relay related to coolant 11.10 Alarm related to coolant . QUICK TOOL PRESETTER (OPTION)..... 12.1 Automatic type quick tool presetter operation 110 12.2 Manual type quick tool presetter operation 12.3 Incase of using quick presetter by manual operation 12.4 Keep relay and parameter related to quick tool presetter 12.5 Keep relay and parameter related to quick tool presetter PARTS CATCH(A) & CONVEYOR(OPTION)... 18.1. Parts catcher operation 13.2 Parts conveyor operation ... 13.3 Parts catcher(A) and conveyor operation. 11714. 15. 16. a 18. 19. 20. 13.4 Keep relay and parameter related to parts catcher and parts conveyor 17 13.5 Alarm related to parts catcher and parts conveyor 118 Tail stock. 14.1 Operation of tail stock traction bar 14.2 Tail stock quill operation 121 14.3 Tail stock operation on spindle rotating 124 14.4 Tail stock quill dual pressure operation 14.5 Keep relay related to tail stock. 126 14.6 Alarm related to tail stock. 14.7 Programmable Tailstock Auto moving function (G460) Alte CNC Tailstock. 15.1 Operation 15.2 Method for Setting-up Position 131 15.3 Related Alarms .. Steady rest (OPTION) 16.1 Steady rest gripper operation 16.2 Programmable steady rest operation (Option) 16.3 Keep relay and parameter related to steady rest 16.4 Alarm related to steady rest 16.5 Programmable Steady rest Auto moving function (M513). 139 16.6 Automatic Steady rest arm Clamp/Unclamp function. Air Blow (OPTION, 17.4 Air blow operation SIGNAL TOWER & LIGHT (OPTION) .. 18.1 The machine status according to the light color of signal tower... 143 PARTS COUNT (OPTION) .. a Parts count function by means of NC function 144 19.2. Parts count function by attaching external counter 19.3 Alarm related to parts counter... AUTO POWER OFF(OPTION)... 20.1 The sequence of auto power OFF21. =. 23. 24. a. 26. 27. 28. Part3) PROGRAMMING... AUTO DOOR(OPTION).... 244 Auto door operation 148 21.2 Alarm related to auto door. re ones soon sa 149 21.3 Keep relay related to auto door.... CHIP CONVEYOR(OPTION).. 22.1 Chip conveyor operation... ct = cae 0 22.2 Chip Conveyor Alarm. 152 22.3 Chip Conveyor Keep Relay. 152 Periodic maintenance function... Manual Handle Interrupt (Option) 241 Manual Handle Interrupt operatic 164 24.2 Manual Handle Interrupt Alarm Auto Power Saving (Power Saving Function). 25.1 Auto Power Saving Operation a a vee 165 Manual Handle Retrace(OPTION).. 26.1 Manual Handle Retrace Operation...sousnmsninnnnnnenn 166 26.2 PARAMETER for Manual Handle Retrace a wn 166 Arbitrary Speed Threading (OPTION)... 27.1 Operation for Arbitrary Speed Threading 27.2 Re-machining PMC Data Reading Function... 167 AUTOMATIC RE-CYCLE START... 1.4 Function description 170 1.2 M-code. 170 1.3 How to use (Sample program 170 RIGID TAPPING... 2.1 Function description... oe cee TA 2.2 Synchronous tapping command M-code & G-code.... eo AT2.3. Example of the rigid tapping .. 2.4 — Cautions in the rigid tapping 2.5 Alarm & remedy related to the rigid tapping... 7” 174 3. Polygon turning function (option). 3.1 Command method related to polygon turning 3.2 Example of polygon turning program. 3.3 Alarm & remedy related to polygon turing... 3.4 Restrictions in polygon turning mode. 4. Processing macro statements... Part4 AUTOMATIC OPERATION... 1. AUTOMATIC OPERATION.. 1.1 Program make & modify 1.2 Automatic operation TUM .vacsotrneseneee 1.3. Auxiliary functions in automatic operation 1.4 Automatic operation stop 1.5 Multi M-code function. Part5 APPENDIX... 1. M-CODE LIST.. Part6 MACHINE ALARM. 1. OVERVIEW... 2. Alarm levels. 3. Alarm detail contents...Part 1 MAIN OPERATION PANEL 1 POWER SWITCHES 44 Layout of power switches Located in the rear of machine aT hsnicr Horr emicn ‘Tum on the power according to power ON procedure after being fully understood the safety precautions for power ON. 1.2 Operation of power switches This switch is for supplying the main power of turning center, itis possible to turn ON/OFF the main power by MCCB handle allached to the door of control panel. MCCB used in machine has been solected by the power capacity for each models of turning ‘center. Regarding the power capacity for each models of turning ‘center, refer tothe electric circuit diagram A\GAUTION BBe sure not to open the door under the state of ON, OFF and TRIP of MCCB. 2 | PartiMAIN OPERATION PANEL Layout of operation panel Devised by the company under the operation panel adopted a Membrane Switch, our machine tools only. The operation panel is unique. Membrane switch to switch all existing Discrete form of improved Push butlon, and all the action on the PCB is fixed. No matter which type model, easy access to unified operation panel. | adopt the button on the removable system, additional changes of options depending on the needs of the usor is easy. 1 has improved the operation of the application of the hotkey, visbilly is excellent and equipped with an LED to all funetion buttons, Operation panel > MAIN OPERATION PANEL | 3a) MCCB handle deseription MCCB handle description is as follows. ‘Switch position Description Trihe door of control panel s closed and the handle position is ON ON stata, the power is suppliad to the machine. I Note) Compulsory force may break the handle if MCCB is not correctly assembled with handle. OFF o Ifthe door of control panel s closed and the handle position is OFF slate, the power stale of machine is cutoff TRIP if the handle is in current position, MCCB performs the power breaking lunction according to the folowing reasons. 1) Automatic power breaking due to over-current in the machine. 2) Automatic power breaking according to Auto power ON/ OFF function (option). For supplying the power again under current position, tum OFF the handle and then turn it ON. RESET This is lever for separating between the door of control panel and MCCB. When opening‘closing the door of electric control cabinet under tho position ON of handle, turn to the reset position using scrow driver @ @ CNC Switch ONT ‘This switeh is for power ON of CNC controler. OFFS This switch is for power OFF of CNC controler. Th order to turn OFF the ONO power aller operaling the machine, ‘change the state to emergence stop by pressing the emergency slop switch and thon turn OFF the power. Emergency stop switch Emergency stop switch is for stopping the machine immediately when the machine has been an emergency state or damaged by wrong operation, And its also used before pressing the OFF switch of CNC power in the machine, When pressing the emergency stop switch, cul off the circult that conirois axis feeding and spindle rotation, the machine stops as soon as it pressed. And all the power of control valves are cut off simultanoously. When releasing the emergency stop state, return to the original position by turning the emergency stop switch to the 4 Part 1right direction, then operate the machine by pressing Machine ready switch (4) RS-2920 & Someco plug receptacio ‘The service plug receptacle and D-SUB connector for interfacing RS-232C and external input/output device are located on the right side of operation panel in the machine. Some of CNC models are equipped with 10-BASE-T Ethernet socket MAIN OPERATION PANEL | 522 Operation panel switches (1) Mode selection switch Mode selection switch is the basic operating switch to select he operation type of turning contr Each mode selection switch can be classified ino 3 kinds of operation according to the operation characteristics [Automatic Operation} MEM mode, MOI m lf lim 10de, MDI mode c = Program Edit) @ Ihe Edit mode re || <0 [Manual Operating } Handle mode, Jog mode, Reference point retumn mode Note) When supplying the power at the first time, MDI mode will be selected automatically When pressing the Edit mode switch, white LED in switen Js ON and the machine will bo changed to Et modo, corr Eek made can input the CNC program and save no the feornesy tervaries. Andis also posse to may / delle the program ane oad he program which akoady saved *»> ‘The lunetone related tothe program eat determine ~~ whether the program can be edited or not according to Y the slecton of Program Protectan Key Switch. For more ata, rfr tote programprotectn ste desertion Progra When pressing the MEM mode switch, LED in switch is (ON and the machine will be changed to MEM mode. MEM Mode can load the machining program which is saved inlo memory and run the automatic operation of loaded program. Itis a'so possible to edit in back ground during MEM operation. Back Ground Edit is the function [MEM MODE] that edits another program on display monitor during the automatic operation. For more details, refer to the CNC. Manual 6 | PartiDB Mol [MDI MODE} [REFMODE] When pressing the MDI mode switch, LED in switch is (ON and tne machine will be changed to MDI mode. MDI Mode can input and execute a simple program. The program made by MDI mode will be doleted on display ‘monitor after executing one cycle, And program under writing will be also deleted in spite of pressing the reset button on MDI panel. MDI mode can input the parameter related to CNC and ‘each kinds of data, When pressing the Reference Point Return Switch, LED in switch is ON and the machine will be changed to Reference Point Return mode. Reference point return made can move each axis to the ‘machine reference point by manual operation. When pressing the Jog Mode Switch, LED in switch is, ‘ON and the machine will be changed to jog mode. Jog mode can operate the Jog feed of each axis. During pressing the manual axis feed switchi((4) rofer to the dog feed switch) of each axis, each axis will be moved toward the selected direction and the speed which is sot in Feodrate switch When pressing the Handle mode switch of each corresponding axis, LED in switch is ON and the handle mode of corresponding axis will be selected. If rotating MPG(Manual Pulse Generator) in Handle ‘mode of selected axis, axis feed can be activated at the solected ratio of the Incremental Feed. Note) 8 axis, C axis, Y axis and axis is adcitional mode according to machine type. MAIN OPERATION PANEL | 7(2) Machine ready, Emergency stop release and Alarm release Itis the functional switch to release the emergency stop and to start up the initial operation fof the machine after turning on the power of the machine. 1) Machine ready switch me When pressing this switch under the slate of being not activated the emergency slop switch and electrical torque || limiter, LED is flickering under the basic condon for machine ready, and if Servo Ready Signal in CNC is ON, then green agin LED is ON. - (a) Machine Ready Relay is ON. (LED flickering) (0) Electric contactor of CNG power supply circuit is ON, and the power will be supplied to PSM in CNC. When CNC. bocomes Servo Ready stato, LED is ON (c) When CNG becomes Servo Ready stale normally, X axis brake will be released. Note) Be sure to check whether the emergency stop switch is released or not before pressing the machine ready switch. Without releasing the emergency stop switch, Machine ready can't be done. 2) Alarm Reset & Emergency Stop Release Switch There are some possibiilies that the machine can be an ‘emergency stop slate by electrical torque limiter due to the increasing of load by the interference with workpiece or mechanical interference during the axis jogging or automatic, ‘operation of the machine. In this case, in order to release the emergency stop state, press the Machine Ready switch simultaneously during pressing the emergency stop release switch. And when ‘emergency stop state is occurred owing to over travel of axis, press the Machine ready switch simultaneously during pressing the emergency stop release switch. it makes the machine to Machine Ready Stale and then move the axis to the inside of travel stroke using feeding handle. Normally alarm reset can not be released by the above mentioned operation of these switch until all of the alarm causes are completely removed. In order to reset the alarm, be sure to 8 | Partremove all of the alarm causes first. In case of occurring the problem about the auto quick too! presetter, I can use for solving problem, Ax pressing i, the drive of the auto quick tool presetter is reset and it makes the state of the auto quick tool resettor to bo good. (3) Automatic operation & Cycle stop switch ‘This is the switch that performs the automatic operation in MEM mode for CNC program (or holds the axis feed during automatic operation, 1) Cycle start switeh CYCLE START AXGAUTION| gf The available mode of cycle start is || MEM It can be used to start the automatic operation in MEM mode regarding CNC machining program called by operator. The called program will be run automatically 2s soon as roleasing the cycle start switch during pressing it under the condition of satisfying for automatic operation ‘And this switch make it possible to the Reference point return of each axis according to the setting of Koop Relay in reference point retun made. Light : in case of Automation Operation of CNC Flicker : on the way to the Reference Point Return in Reference point return mode. Be careful that program will be activated to cycle start as soon as releasing this switch during pressing it undor the state of satisfying the condition for automatic operation. Before cycle slart, be sure to check the axis stroke ele, for preventing Irom unexpected human accident and the machine damage. In order to satisfy the condition for the automatic operation, refer to chapter 4-1(the ‘condition for performing the automatic operation) MAIN OPERATION PANEL | 92) Cycle stop switch This switch is used to hold the axis feed temporarily during DQ __attomatic operaion. When pressing tis switch, the auiiay CYCLE STOP functions(M, S, T) during program execution will stop after its completion. And axis feed and D wel also stop. At that time, the selection of Keep Relay determines whether spindle and coolant slop of not. In order to release the hold state and restart auto- ‘matic operation, press cycle start switch once. Light : In case that the automatic operation stops and the hold signal output comes out. However, in case of hold during M.S, ‘and T code execution, LED is ON and then automatically OFF by the completion of motion. (4) Jog teod switch The following switches are provided for jog feed of axis in the machine. @ || ao Jog feed switch of each axis is available only In. _rer_||_ 30s According to the machine type, jog feed switches are as follows 1) dag feed switch Se | © Standard 2-axis machine @ additional miling and B-axis mode. - PUMA - Standard 2-axes wD PUMAM Type 12 In jog mode, jog feed switch can be used to the following manual axis operation. Part 1(a) Jog food operation of each axis: (b) Rapid traverse operation of each axis (c) Reference point return operation of each axis in reference point made (8) Rapid & rapid override switch Rapid override switch is for controlling the rapid specs. Available mode: [2] [2] RAPID OVERRIDE, Rapid speed will be set in CNC parameter for every axis. Itis available for rapid moving using Jog switch in manual operation or when selecting the Jog mode. Operation is only available during pressing this button. Manual rapid speed al the 100% of rapid override has been set fo parameter (No. 1424) 3-step override can be selected by rapid select button on the let figure, Rogarding the related paramoter, refer to CNC parameter manual This rapid override switch can be selected individually (Once pressing the button, LED is ON and corresponding override is selected. The selected feed maintains just before off slate even power ON after power OFF. = Fo LED of Fo button is ON. = 25% LED of 25% button is ON ‘The setting speed in parameter(No. 1421) is FO under the state that the solection switch of FO. Rapid override will be selected to 25% Note1) In case that the body fixing pin of steady rest and programmable tail stock is gone back and then feeding is possible, In case of selected Ref, retum mode F25% LED is tlickering MAIN OPERATION PANEL | 11Ww LED of 100% button is ON (6) Feedrate override (7) Handle incremental feed & MPG 200 8 FEEDRATE OVERRIDE. @ # INCREMENTAL FEED Rapid override will be selected to 100% Using this switch, axis food speed can be adjusted between 0% and 200% at the amount of 10% except the rapid traverse and handle feed in MDI, MEM and Jog mode. But this select function will be ignored at the thread ccuting or tapping operation. Automatic operation can be changed by 10% feedrate(F) which is commanded in program to 100. Ii feedrate is set 10 0%, axis feed is stopped and alarm will be occurred. It foodrate is sot to 100%, LED Lamp is ON. ‘This switch & MPG are available in handle mode. Aitor selecting the handle axis by pressing the handle mode switch of corresponding axis, select the incremental feed switch. When pressing incremental food switch X100, LED is ON and feedrate of corresponding axis will be 0.1mm selected, When pressing incremental feed switch X10, LED is ON and foodrato of corresponding axis will bo 0.01mm. X1 and X10, X100 switches will be alternative type that cone is selected, LED is ON, but the other LED is OFF. ‘Tho selected handle incremental feed maintains just before OFF state even power ON after power OFF. Incremental feed LED state of switch MPG x100 wit 0.1mm (moti unit) guaergN 0.01 inch {inch unit) 12 | Part 1Ineremental feed LED state of switch MPG = x10 0.01mm (metric unit) x10 3} Sertch ON 0.001 inch finch unit) = xt 0.001mm (metric unit) x” 4 Switch ON (0.0001 inch (inch unit) This is Manual Pulse Generator(MPG) to traverse axis you want after selecting Incremental feed switch. After selecting mode for axis feed, if MPG is rotated, the selected axis of handle mode moves as the amount of constant step(0.tmm, 0.1mm, 0.001 mm) according to the selection of incremental feed switch AXCAUTION| For safo axis food, be sure to check the interference between axis and device before rotating the handle, then operate the axis. (8) Spindle selection switch Itis the function switch to select spindle in manual operation of the machine. ‘Available mode for spindle solection switch is [PIPE Use this switch to select spindle when operating the machine. Please keep in mind that there are no selection switches as follows in standard 2-axes machine, Spindle rotation (FWOIREV), jog operation and spindle override selection ‘switch on operation panel can be activated effectively only when the selected spindle ‘changes to speed control mode. p When selecting the main spindle selection switch, the state of 1st spindle in system 1 will be set to speed control mode. white LED is Main spindie turned on after completion of selecting spindle. Selection MAIN OPERATION PANEL | 13When selecting C-axis selection switch, the state of main spindle will be changed to Contouring control mode, the 2nd spindle( milling too)) willbe changed lo speed contral mode. According to the turning center type, it is available only for the c-axe selection Machine that has milling function. After change the contouring control mode axis (C-axis), LED will be ON. AXCAUTION| If spindle selection switch is selected, spindle rotation command can not be activated bocause spindle(Main, Sub) xcept miling tool is changed into contouring contro! mode. @) Spindie control Switeh 1) Spindle rotating direction selection & Jog switch = “en This switch is used to select the rotation direction of spindle. Be sure to FWD determine the rolation direction alter selecting the spindle selection switch in 2.28, Spindle rotation CW =_ IW looking to main spindle in back view, clockwise rotation direction is he FWD (forward). rotation. And in case of milling tool(the 2nd spindle), also me. clockwise rotation direction is FWD. rotation, On the contrary, counter Spindle clockwise rotation direction is RVS (reverse) rotation, rotation COW ‘Spindle FWD. switch LED ON: indicates to solect the FWD. rotation of tho selected spindle Spindle FWD. switch LED flicker: indicates to select the spinale Jog. Spindle REV. switch LED : indicates to select the RVS. rotation of the solacted spindle Spindle Jog switch LED ON : indicates to select the spindle Jog operation. Using Jog switch of spindle, itis possible to operate Jog operation at 50 rpm. under the following condition. 1. In ¢ase of opening the door without releasing the door interlock. 2. Koop Relay (K10.0) is sot 10 0 in automatic mode, When manual jog operation is selected, LED of FWD, rolation switch is flickering, at this time, spindle will be rotated as long as pressing the spindle rotation starl switch. Spindle jog 14 | Part 12) Spindle rotation start & stop switch This button is used to start and stop the spindle rotation, In manual mode, select the spindle to rotate and select direction. When pressing this switch, spindie will start to rotate. However, in jog Spindle operation, spindle can be rotated only es long as this switch is pressed. rotation stant In manual mode, press the spindle rotation stop switch for stopping the rotating spindle. Note) It is impossible lo rotale spindle by manual until S-code is ‘commanded in automatic mode. Therefore, in order to rotate the spindle by manual, command certain Suxx of S-code in MDI Spindie rotation stop mods. (10) Spindle winding change over switch / Gear charge switch Considering the electrical characteristics of spindle motor in some machine, itis possible to select the motor winding change over (Y-Y, Y-/) manually according to motor type. Winding selection such as high speed or low speed depends on the state of electric contactor, Normally maximum r.p.m. for low speed and high speed winding wil be fixed individually according to the characteristics of spindle motor. Referring to the electrical diagram related 10 spindle of the machine which is required winding change over, the electric contactor for low speed or high speed winding can be seen, Note) The winding change over can be changed regardless of the state of rotation/stop ‘of general spindle. But in state of Cs contouring control mode, can not do the winding change over. 1) Winding change over switch / Gear charge switch If this switch is used for gear change, any gear type is not ssolected when turning on NG first. And at this time, the stato of LED is flickering, This switch can be used for two purposes (winging chage’ gear change). And both mode can not be used al the same time. This switch can be used for two purposes Main spindle change switch "9 (winding chage’ gear change). And both mode can not be used at the same time. According to the selection of winding selection ‘switch for main, high speed winding and low speed winding are selected respectively. MAIN OPERATION PANEL | 15