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Ver 1.0 CM SERIES FRYER / SIEMENS 828 CONTROL MAINTENANCE MANUAL 70 Jon Barrett Road, Patterson, NY 12563, USA | www.fryermachine.com | v: 845.878.2500 | f: 845.878.2525...
......................22 4.3 REVERT TO THE FACTORY SET PASSWORD ....................22 4.4 ADJUSTING INPUT VOLTAGE PARAMETERS ....................23 4.5 M- CODES .................................. 24 4.6 ALARMS 4.61 Siemens Alarms............................25 4.62 Fryer PLC Alarms and Descriptions......................25 4.63 Clearing an Alarm............................26...
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4.7 WORKING WITH FILES 4.71 File Types..............................26 4.72 Back-Up An 828 Archive File to A USB Stick....................26 4.73 Reloading an Archive File ........................... 27 4.74 Backing Up Tool Data on the 828 Control....................27 4.8 ADDING A SOFTWARE OPTION TO AN 828 CONTROL ................
Only Fryer factory-trained service personnel should troubleshoot and repair the equipment. Do not modify or alter this equipment in any way without first consulting Fryer Machine. Any modification or alteration of this equipment could lead to personal injury and/or mechanical damage and could void your warranty.
5. Always wear safety shoes with steel toes and oil-resistant soles. 6. Do not paint, alter, deface, or remove any warning plates from the machine. Replacement plates are available from Fryer Machine Systems. 7. Keep flammable liquids and materials away from the work area and hot chips.
10. Never clean up chips while the machine is running or is in automatic mode. 11. Do not file workpieces being rotated under power. 12. At the end of the workday the machine should be placed in "EMERGENCY STOP MODE" 13.
Pictures should be sent to service@fryermachine.com. 2. Place the machine in its location and complete inspection. If there is any damage to your machine, Fryer should be notified immediately. This will enable us to provide replacement parts before the service technician arrives install the machine.
To make certain that your machine installation goes smoothly, it is important that the following items are completed prior to the arrival of the Fryer authorized service technician. This will ensure that our technician is able to provide you with the maximum amount of training during his allocated time with you.
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You should always refer to your local electrical code to be sure you are grounding to code. Generally, use a grounding wire with a cross section of more than 14 mm and a resistance to ground of less than 100 ohms. This wire size should be greater than AWG (American Wire Gauge) No.
2.6 LEVELING THE MACHINE Before attempting to use the machine, it will be necessary to accurately level it. • Screw the leveling bolts (with nut) into the holes in the base of the machine. Set a leveling pad under. • Please prepare the following tools to adjust machine level: •...
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Step 3 • Adjust the center leveling studs until they are just touching. • Again, verify the machine is level with the level parallel to both axes without further adjustment. Step 4 • With the level parallel to the X-axis, slowly move the table back and forth over full Y-axis travel check to see that the level does not change.
3.0 GENERAL INFORMATION 3.1 MAINTENANCE SCHEDULE CHART *FOR FURTHER MAINTENANCE DETAIL, REFER TO THE MACHINE COMPONENT SECTIONS IN THE MANUAL LISTED BELOW. CAUTION! Always follow all Lock Out / Tag Out procedures before performing any maintenance MAINTENANCE ITEM RECOMMENDED Daily Weekly 6 Mo Required...
3.2 MACHINE COMPONENTS 3.21 Axis Lubrication System • The automatic way lube system is controlled by the PLC in the control. The system only pumps way oil when the spindle and axes are moving. If there is no machine movement the pump will not pump unnecessary oil. This method greatly reduces way lube usage and keeps oil out of the machine coolant sump and prevents fouling.
3.23 Pneumatic System • Schematic – See Pneumatic Schematic in electrical cabinet (see previous page) • Pneumatic List / Pressure Settings • Main Supply – 90-125 PSI at 5 CFM • Air Gun • Tool changer – Carousel In • Tool changer –...
• If it is required for the spindle to run at maximum RPM, the spindle must not run more than 2 hours straight. After 2 hours of run time at maximum RPM, the spindle must be slowed down to 50% of the maximum RPM for at least 30 minutes before running at the maximum RPM again.
3.27 Fryer Tool Setter (Tool Probe) The Fryer Tool Probe can only be used to automatically measure tool length. It cannot be used to measure tool diameter or radius. Optional tool setting probes are available to perform length and diameter or radius measurements.
Fryer Part Probe Calibration 1. To set up a new FRYER probe in the tool table. it needs to be in the manual tool location in the library. It is important to remember your probe is wired which is manually inserted and removed the tool from the spindle.
3.3 BASIC MACHINE PROCEDURES 3.31 Setting Axes Home Positions PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY The 828 control comes standard with absolute encoders which generally do not require homing. However, if you have an issue with the battery or the machine is not turned on for an extended length of time the machine may need to be re- homed according to the following procedure.
When done make sure parameter 34210 [0] shows 2 for all axes (axis with motor encoder) When done make sure parameter 34210 [0] and parameter 34210 [1] shows 2 for all axes (axis with scale) 3.32 Check Axis Backlash Tools Required: 0.0001” resolution dial indicator, remote handwheel (manual pulse generator) •...
3.33 Adjusting Backlash Compensation PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY • Refer to Section 4.1 for directions to access parameter screens. • Press MENU SELECT • Select SETUP • Select MACHINE DATA • Select AXIS MD • Using AXIS+ AND AXIS-, select the correct axis •...
3.35 Check / Adjusting Ballscrew Endplay * It is important to read and understand the procedure 3.34 Working with Waycovers, before executing this procedure. • Tools Required: 0.0001” resolution dial indicator, remote handwheel (manual pulse generator), metric allen key set, spanner wrench. •...
4.0 828 CONTROL 4.1 ACCESSING MACHINE PARAMETERS PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY Press MENU SELECT Select SETUP Select MACHINE DATA Available folders: GENERAL MD / CHANNEL MD / AXIS MD 4.2 ACCESSING THE SOFTWARE VERSION To find out the version of the software you are running on your 828 control: 1.
4.4 ADJUSTING INPUT VOLTAGE PARAMETERS PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY The Siemens control will shut itself off if the line voltage is more than 10% different than the voltage set in the control. You must adjust the parameter to match your line voltage to the machine. The first step to accurately measure your line voltage.
4.5 M-CODES An M code in CNC programming controls miscellaneous machine functions, including starting and stopping specific actions or programs. PROGRAM STOP OPTIONAL PROGRAM STOP END OF PROGRAM SPINDLE CLOCKWISE SPINDLE COUNTERCLOCKWISE SPINDLE STOP TOOL CHANGE REQUESTED MIST COOLANT / AIR BLAST ON FLOOD COOLANT COOLANT (FLOOD AND MIST / AIR BLAST) OFF INDEXER CYCLE START WAIT FOR COMPLETION...
4.62 Fryer PLC Alarms and Descriptions There are certain PLC alarms in the 700000 range which are not in the HELP screen. These are FRYER Machine specific alarms that are for optional equipment installed on the machine. The alarms are listed below:...
700042 Y AXIS MOTION AND ATC ARM NOT AT HOME POSITION 700043 DRAWBAR FAILURE 700044 QUILL SCALE POSITION UPDATE ON PRESS BUTTON AGAIN TO TURN OFF 4.63 Clearing an Alarm Carefully check the machine according to the description given in the alarm. Clarification of the alarm codes can be found by using the HELP as described above.
4.73 Reloading an Archive File PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY NOTE: Set the password protection to “Current Access Level: Manufacturer”. Refer to Section 4.3 above. 1. Select the PROGRAM MANAGER key. 2. Press the ARCHIVE and READ IN ARCHIVE keys. 3.
4.8 ADDING A SOFTWARE OPTION ON THE 828 CONTROL When you receive your machine all license numbers applicable to your order are activated prior to the machine leaving the factory. If you purchase a control option after the machine arrives at your facility you will receive a license number to active on your control.
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9. Follow step 1 to get to the license screen. Type in (overwriting old license key) current license key and press input. The field is highlighted, make sure to enter correctly. Figure 3 10. Press all options soft key 11. Search for the particular option you want to activate. Set the box with the select key. See figure 4. Figure 4 12.
4.9 SET UP THE NETWORK DRIVE IN THE 828 NOTE: It is recommended that this procedure be performed by an experienced network administrator. The transfer of programs can be achieved by mapping a soft- key to a networked computer. The soft key will appear in the Program Manager screen of the controller.
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8. Press the OK key. The entries are checked. A window with the appropriate message opens if the data is incomplete or incorrect. Acknowledge the message with OK key. If you press the CANCEL key, then all of the data that has not been activated is rejected. 9.
5.0 ATC OPERATION 5.1 CAROUSEL TYPE ATC OPERATION 5.11 Safety Rules -- READ BEFORE OPERATING ATC CAUTION! Always follow all Lock Out Tag Out procedures before performing any maintenance • Due to the complexity and timing of the ATC, it should only be operated with the M6 command. •...
5.13 Setting Tool Change Height PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY The proper tool change height must be set for the ATC to perform correctly. The tool change height (machine coordinates from home position) is stored in parameter MD30600. NOTE: To manually get the tool grab fingers of a carousel style ATC under the spindle you will need to disconnect the air from the machine and manually push the carousel toward the spindle.
5.14 Recovering from a Tool Change Failure PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY If the tool changer fails, you may get an alarm. This means that after 30 seconds of waiting, a function did not receive its proper finish signal. At this point, do not E-stop or hit reset. This can cause a tool to drop and possibly cause an injury to the operator.
5.16 Spindle Orient Adjustment PROCEDURE TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY This procedure will outline how to adjust the spindle orient position when an M19 is commanded to perform a tool change. Read all instructions carefully and do not skip steps. 1.
> 14. Press AXIS SD ( you may have to press “ ” to show additional buttons) 15. Use Axis+ until spindle axis is displayed. 16. Scroll down to parameter 43240 $SA_M19_SPOS, this is the current orient position. Add the value you obtained in step 10 and input into this field.
6.0 – MECHANICAL DRAWINGS 6.1 828 CONTROL ELECTRICAL PANEL LAYOUT 828 CONTROL ELECTRICAL PANEL – PARTS PART NO. DESCRIPTION PARTS NAME SWT-5064 Main Disconnect MSE-1912 Fuse Block Motor Controller Overloads Line Choke MSE-2940 24 VDC POWER SUPPLY MSE-1410 MC1 Magnetic Contactor MSE-1610 Transformer Fuse Panel...
6.2 828 FRONT CONTROL PANEL LAYOUT PART NO. DESCRIPTION PARTS NAME MON-4378 Siemens Monitor NCU CMB-3202 Siemens Control Panel MSM-8210 Keys (3) 1 set SWT-6210 E-Stop w/ Contact Block...
6.9 CM-15 MACHINE ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION SPECIFICATION 253002F Base HD673 Oil pipe Coupler HW104 Spring Washer HS231 Hex. Socket Head Screw M6*P1*L25 253011F Y Ballscrews 253007J Motor Bracket Y HW105 Spring Washer HS244 Hex. Socket Head Screw M8*P1.25*L30 ø...
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253034 Bearing Seat 253117B Bull block X HS220 Hex. Socket Head Screw M5*P0.8*L20 HCS06 C-Retainer Ring CA6003ZZ Ball Bearing 6003ZZ 253003B Center Base 253091D Switch bracket HW004 Washer M6* ø 13*T1 HS230 Hex. Socket Head Screw M6*P1*L20 HW004 Washer M6* ø 13*T1 HS229 Hex.
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øø 253061 Retractable sheath Y 253065A Sheath holder HT001 Cross Round Head Screw M5*P0.8*L10 HT004 Cross Round Head Screw M6*P1*L16 253029A Oil Distributor set. HW104 Spring Washer HS230 Hex. Socket Head Screw M6*P1*L20 253031A Oil Distributor CAB-6-0.16CC HW104 Spring Washer HS231 Hex.
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HS231 Hex. Socket Head Screw M6*P1*L25 HW004 Washer M6* ø 13*IT HN004 Hex. Nut HW104 Spring Washer HS230 Hex. Socket Head Screw M6*P1*L20 HT003 Cross Round Head Screw M6*P1*L10 253063A Retractable sheath (Z) HT003 Cross Round Head Screw M6*P1*L10 HS222 Hex.
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Air hose ø10 Air hose ø10 Connector ø10 Air hose ø10 HS511 Cross Round Head Screw M4*P0.7*20L HS220 Hex. Socket Head Screw M5*P0.8*L20 253153 Wedge HS231 Hex. Socket Head Screw M6*P1*L25 253152B Z axle Linear recirculating HS230 Hex. Socket Head Screw M6*P1*L20 Oil pipe Coupler...
6.15 CM-20 MACHINE ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION SPECIFICATION 151141 Leveling Pads HN009 Hex. Nut M20*P2.5 255103 Hex. Head Screw M20*P2.5*L80 255002A Base HD673 Oil pipe Coupler 1/8"×90° HS231 Hex. Socket Head Screw M6*P1*L25 HW104 Spring Washer 255011B Y Ballscrew 255007C Y Motor Housing...
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253153 Linear Rail Clips HS220 Hex. Socket Head Screw M5*P0.8*L20 Oil pipe HW104 Spring Washer HS230 Hex. Socket Head Screw M6*P1*L20 255402B Plate 253010A YSF-M20xP1.0 CA7204 Thrust Bearing 7204-P5 255401B Bearing Seat HS230 Hex. Socket Head Screw M6*P1*L20 HW104 Spring Washer ø25*40ø*7t Oil Seal 255117...
HW105 Spring Washer HS243 Hex. Socket Head Screw M8*P1.25*L25 Oil Seal ø32*ø50*10t CA25BSB62 Bearing B14008Q-1 P4 255006 Interval Ring Oil Seal ø35*ø50*7t 255010 YSF-M25xP1.5 255405B Bearing Retainer HW104 Spring Washer HS231 Hex. Socket Head Screw M6*P1*L25 25532A Motor Coupling SQR-55C(ø20ø24) 249-1 255380 Z-Axis Motor Plate...
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HS243 Hex. Socket Head Screw M8*P1.25*25L 255001F Head Casting Nozzle 3/8"PT*100L Valve 3/8"PT HS231 Hex. Socket Head Screw M6*P1*L25 255165A Coolant Manifold 181980A Coupler 1/4"PT*3/8 HD681 Hose Clip 5/8" 255031 Oil Manifold HW104 Spring Washer HS230 Hex. Socket Head Screw M6*P1*L20 Oil pipe Oil pipe...
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330- Coupler 1/4"*#8-90° 330- ø8 Air hose 330- Flow Control Valve HW106 Spring Washer HS264 Hex. Socket Head Screw M10*P1.5*50L HT003 Cross Round Head Screw M6*P1*L10 255021A Head Sheet Metal 255023 Cover HT003 Cross Round Head Screw M6*P1*L10 Tool In/Out Plate HT001 Cross Round Head Screw M5*P0.8*L10...
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