PROGRAM EQUIPMENT

MAINTENANCE
monitoring of execution of selected actions of regular
maintenance

for machine from WRD + i TNC530 series

January 2007
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MAINTENANCE

The operator can be notified about the necessity to carry out some operations of
routine maintenance by means of the control program. The program enables also
monitoring of the maintenance operation execution. So far fourteen places for the
routine maintenance operations have been selected. Advice before the announcement
of the maintenance itself is given in advance for the implementation of some more
complicated maintenance operations.
It is specified first of all for each maintenance place, by which control criteria the
place is controlled. Five control times and one control distance are operated by the
control program.
a) spindle running time that is displayed among others on the fourth line of times
(at the push of MOD and respective softkey)
b) machine running time that is displayed among others on the second line of times
(at the push of MOD and respective softkey)
c) time of "machine age" that is derived from UNIX time.
d) HUI50 head spindle running time that is displayed among others on the seventh
line of times (at the push of MOD and respective softkey)
e) HUR50 head spindle running time that is displayed among others on the tenth
line of times (at the push of MOD and respective softkey)
f) HF50 head spindle running time that is displayed among others on the thirteenth
line of times (at the push of MOD and respective softkey)
g) X group passed way that is derived form the control of lubrication of this group.

The following values are shown in the tables of the control program and they are
used for the control of the program equipment of the routine maintenance.
- period between the individual maintenance operations
- time of the advice announcement in advance
- execution of technical service of TOS Varnsdorf
- record of operations in the registration table.
The automatic evaluation of the routine maintenance execution, it means issuing of
advice and maintenance report is carried out always after the machine switch off and
after 12 hours of its continuous operation.

The following scale of the monitoring of the individual operations of the machine
maintenance is not definite and it can change during the machine development and
depending on its equipment and accessories.

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DESCRIPTION OF INDIVIDUAL PLACES OF ROUTINE MAINTENANCE

More demanding maintenance operations that are carried out by the

operators or machine producer and before which the advice is issued

1. Maintenance of bearings of the working spindle mounting is controlled by the

control time of the spindle running. The maintenance has the message M01 and
advice A01. The maintenance can be executed only by service personnel of TOS
Varnsdorf.
2. The maintenance of hydraulic devices is controlled by the control time of the
machine operation. The maintenance has the message M02 and advice A02.
3. The maintenance of the lubrication device of the spindle drives is controlled by the
time of the machine operation, the maintenance has got the message M03 and
advice A03.
4. The maintenance of the ball bolt with nut (lubricated by grease) of longitudinal feed
of S25 table is controlled by the control time of the table age, the maintenance has
got the message M04 and advice A04. This is valid only for the bolt that are not
lubricated by oil.
5. The maintenance of the S 25 turntable bearing is controlled by the time of the
machine age, the maintenance has got the message M05 and advice A05.
6. Maintenance of bearings of the HUI50 head is controlled by the control time of the
HUI50 head spindle running. The maintenance has the report M06 and advice
A06. The maintenance can be executed only by service personnel of TOS
Varnsdorf.
7. Maintenance of bearings of the HUR50 head is controlled by the control time of the
HUR50 head spindle running. The maintenance has the report M07 and advice
A07. The maintenance can be executed only by service personnel of TOS
Varnsdorf.
8. Maintenance of the bearings of the HF50 head is controlled by the control time of
the HF50 head spindle running. The maintenance has the report M08 and advice
A08. The maintenance can be executed only by service personnel of TOS
Varnsdorf.

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Simple maintenance operations executed by the machine operators without
any advice
11. The maintenance of conical cavity of the working spindle is controlled by the time
of spindle running, the maintenance has got the message M11.
12. The maintenance of the working spindle surface is controlled by the time of spindle
running, the maintenance has got the message M12.
13. The maintenance of the telescopic covers of X and V groups is controlled by the
machine age, the maintenance has the message M13.
14. The check of the filling pressure of the spindle balancing accumulators is controlled
by the machine age, the maintenance has the message M14.
15. The maintenance of X group drive is derived from the track of the X group, the
maintenance has the message M15.
16. The maintenance of conical cavity of the HUI50 head spindle is controlled by the
time of the head spindle running, the maintenance has got the message M16.
17. The maintenance of conical cavity of the HUR50 head spindle is controlled by the
time of the head spindle running, the maintenance has got the message M17.
18. The maintenance of conical cavity of the HF50 head spindle is controlled by the
time of the head spindle running, the maintenance has got the message M18.
This system of the service operation monitoring inform you, when and what
maintenance operation must be executed by the machine user, or it will give you an
information in advance about the necessity to order the visit of service personnel from
the machine producer company for the execution of the maintenance operation. The
procedure of the respective operation execution is described in the chapter EXECUTION
OF WRD MAINTENANCE.
The following instructions are valid as long as the "MAINTENANCE" screen is
displayed
- If some control criteria (for example machine running time) will reach the target
value of the advice of this maintenance (for example the maintenance of lubrication
device of main drive gearboxes, it means M03 maintenance), the advice will be
displayed(for example A03) that can be cancelled at the push of CE push-button.
The message will be displayed again after the next start of the machine, or after 12
hours of its continuous operation.
- The advice is issued in order to ensure that the customer will have enough time to
secure all respective personnel and material for the execution of the corresponding
maintenance, eventually to order the service execution from TOS Varnsdorf. If you
want to know, how much time you have before the maintenance, the operator can
display the MAINTENANCE table (its description is given in the next paragraph).
- If some control criteria (for example machine running time) will reach the target
value of the advice of the respective maintenance (for example the maintenance of
lubrication device of main drive gearboxes, it means M03 maintenance), the advice
will be displayed(for example M03). In order to enable the trouble-free finishing of
the running operation, the displayed message can be repeatedly and temporarily
cancelled at the push of the CE push-button. The message will be displayed again
after 1 hour (for example the M03 message).

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"MAINTENANCE" SCREEN
The confirmation and postponement of the maintenance operations and more detailed data
about their dates are available at the MAINTENANCE screen that has the following three pages
in its last version. The MAINTENANCE screen can be activated by the following procedure:

1. Push the softkey 2. Push the push 3. Push the

SERVICE on the vertical button for the MAINTENANC
bar and the 1st softkey switch-over of the E softkey
bar of the SERVICE will vertical softkey
be accessed bar

CAUTION: Numerical data on the following pictures are used only for the
illustration purposes

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The following display of the first page of the tables will be accessed at the push of
the MAINTENANCE softkey:
column column column column column
1 2 3 4 5

Push of the cursor buttons ↓ or ↑ will cause that the green cursor displayed in
the fourth column will move in the vertical direction and it will cause the display of
the second and third pages.

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column column column column column
1 2 3 4 5

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DESCRIPTION AND CONTROL
Variable data are displayed colourfully in the columns No. 1 up to 5 on the
MAINTENANCE screens in addition to the information texts. The data has the following
meanings:
Column 1 checking control criteria in blue colour (times and tracks)
Column 2 Up number of maintenance in green colour (for example M11), if
the maintenance of the machine producer is cancelled, off is
displayed instead of this and the variable data is zero
yellow R character means that the evaluation of this
maintenance is registered in LOGBOOK file of the
maintenance
down programmed period of maintenance in blue colour
Column 3 Up target data of the control time (track) of the closest
maintenance in blue colour
down positive number in blue colour - time (track) till the execution of
this maintenance
negative number in blue colour - time (track) of the exceeding
of this maintenance
Column 4 Up orange number of the evaluated advice within the range from
A01 up to A08 (deleted by CE)
down red number of the evaluated maintenance within the range
M01 up to M18, the message can be temporarily cancelled by
postponing, or it can be cancelled by the confirmation of the
required maintenance
Column 5 softkey bar
The green cursor moves in the vertical direction only in the fourth column in the
positions, beside which the number of the maintenance can be displayed.
If the MAINTENANCE screen is displayed, then the operator will decide in case of the
error message display:
• whether the execution of the required operations will be implemented immediately
• or if he /she will postpone the operations because of the technical or organisation
reasons.
In the first case the operator will push the sofkey with the text "IMPLEMENTED" as the
confirmation of the service operation execution. Adding up of the programmed
maintenance period and immediate condition of the control criteria are carried out. The
result is written down into the target value and new automatic evaluation of the
calculations is carried out automatically. The maintenance can be executed only by
service personnel of TOS Varnsdorf. The machine information text informs the operator
about this requirement. The confirmation of their execution will require the password
enter. If the password is not entered, the error message is displayed for a short time.
IMPOSSIBLE! ONLY TOS SERVICE!
In the second case, when the execution of the required operation must be postponed,
the operator will push down the softkey with the text "POSTPONED" and the displayed
message will disappear till the moment of the new evaluation of the maintenance data
that will be carried out always after
• new start of the control system
• every 12 hours after its switch-on
• the push of the NEW softkey.

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REGISTRATION MAINTENANCE FILE
The execution of the routine maintenance according to the instructions of PLC program
for the maintenance is obligatory for the operators. Some of the regular operations
(especially those ones with a longer execution period) are very important and therefore
its implementation is registered in table file. The choice of the registration is defined by
the machine producer and it is displayed as yellow R in the second column of the
maintenance table. The maintenances M01 - M08 and M13 - M15 are registered as
standard.
The operator cannot change the content of the registration file, but he can display it
anytime at the push of the softkey with the LOGBOOK text that is displayed on the
vertical bar of the MAINTENANCE screen.
The displayed table can have for example the following content:

It is quite
obvious
that it
contains:
• date of record
• report with the name of the maintenance
• status of postponing or execution of the maintenance
• immediate condition of the evaluated date (the number from the third down
column is displayed), positive number = number of hours (meters) to the
maintenance date
negative number = number of hours (meters) of the maintenance date exceeding
• If the page is full, the text "page" will be displayed on the lowest line and it is
possible to browse at the push of the cursor push-buttons↓ or ↑.
The MAINTENANCE tables will be displayed again after the pushing of the
softkey with the text TABLE.

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