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Emco Concept Mill 155PC-controlled milling machine for training

Machine DescriptionEmco Concept Mill 155Ref.-No. EN 2155 Edition A2003-10

3EMCO MAIER Gesellschaft m. b. H.Abteilung Technische DokumentationA-5400 Hallein, Austria

Introduction

All rights reserved, duplication only upon authorization of Messres. EMCO MAIER EMCO MAIER Gesellschaft m.b.H., Hallein/Taxach 2003

For more than five decades EMCO has been developing metal workingmachines and has also been successfully on the market since 1980 withcomputer controlled machine tools (CNC machines), particularly on thetraining sector.

This high degree of experience is a profit for the turning and millingmachines of the EMCO Concept Turn and EMCO Concept Mill modelseries.The newly designed compact machines meet entirely today's requirementsin construction and set up as well as safety.

The PC machines are operated via a conventional personal computer(PC). This kind of operation permits an efficient training of the most diffe-rent CNC controls (SIEMENS, FANUC, etc.) with one and the samemachine.The CNC monitor of the installed CNC control is simulated on the PCscreen, input of data is carried out via a control keyboard.

Due to the worldwide industrial use of our machines we dispose of aservice network wich covers all world areas.Immediately available service engineers, telephone service as well as a100% sparepart supply exceeding the 10-year obligatory provision issomething natural for us.

One of our more than 100 general representatives worldwide will informyou on particular new developments (e.g. clamping options for work piecesor tools, new softwares, etc.) and theire trafitting possibilities.

In the present operating instructions you will find a complete descriptionof safety hints, transport, set-up, operation and maintenance of themachine.Therfore read this instructions completely before machine start-up.

EC conformity

The CE mark certifies, together with the EC declaration ofconformity, that the machine and the guidelines are in conformitywith the regulations of the directives applicable to the products.

5Contents

Warranty conditions for new EMCO machines ........................... 7Adequate use ............................................................................. 7Safety recommendations ............................................................ 8Technical Data of the Machine .................................................. 10Techical Data of the PC-Control ............................................... 12Declaration of conformity .......................................................... 13

A Installation of the machineMachine acceptance ................................................................ 15

Machine number ................................................................... 15Electrics number ................................................................... 15

Scope of supply ........................................................................ 16Basic machine ...................................................................... 16Control Software ................................................................... 16Control Keyboard .................................................................. 16Modules/options ................................................................... 16

Transport of Machine ................................................................ 17Transport with pallet .............................................................. 17Transport without pallet ......................................................... 17Transport safety devices ....................................................... 18

Machine door .................................................................... 18Coolant device (accessory) .............................................. 18

Installation plan, dimensions of the machine ............................ 19Installation criteria .................................................................... 20

Requirements on installation surface .................................... 20Installation site ...................................................................... 20Ergonomy ............................................................................. 20Installation without anchoring ................................................ 20Additional criteria for installation ........................................... 21Anchoring on the ground ...................................................... 21

Electrical connection ................................................................ 22Control of the correct connection ...................................... 22

Mains connection data .......................................................... 23PC connection .......................................................................... 23Pneumatic connection (Option) ................................................ 24Initial start- up ........................................................................... 24Switch On/Off Sequence .......................................................... 25

Switch On the Machine ......................................................... 25Approach Reference Point ................................................ 25

Switching off the machine ..................................................... 26

B Description of the MachineMain elements- Survey ............................................................. 27

Machine zero point M ....................................................... 28Reference point R ............................................................. 28

Points at the Machine ............................................................... 28Workpiece zero point W .................................................... 28Toolholding-fixture reference point N (T) ........................... 28

Working area ............................................................................ 29Working area in X- and Y-axes .............................................. 29Working area in Z-axis .......................................................... 29Limitation of traversing paths ................................................ 29

Coordinate system ................................................................... 29Machine base ........................................................................... 30Slides ....................................................................................... 30Slide drives ............................................................................... 30

Milling spindle ........................................................................... 30Central lubrication .................................................................... 30Safety devices .......................................................................... 31

EMERGENCY-OFF key ....................................................... 31Door locking device .............................................................. 31Key switch ............................................................................ 32Consent key ......................................................................... 33

Pneumatic maintenance unit .................................................... 33Pneumatic scheme ................................................................... 34Automatic door mechanism (option) ......................................... 35Robotics interface (option) ........................................................ 35DNC-interface (option) .............................................................. 35Tool system .............................................................................. 36

Initialization of the tool turret ................................................. 37"7022 Initialize tool turret" ................................................. 37"6040 WZW - static interlock control" ................................ 37

Toolholder ................................................................................. 38Order numbers ..................................................................... 38Mounting the toolholder into the tool drum ............................ 39Dismounting the toolholder ................................................... 39Collet holders ....................................................................... 40

Maintenance of collets and collet holders ......................... 40Mounting the collets .......................................................... 40Dismounting the collets ..................................................... 40Clamping the tools into the collet holder ........................... 41Clamping ranges ............................................................... 41Working ranges of the tools .............................................. 42

Shell end mill arbor ............................................................... 43Clamping the tools in the shell end mill arbor .................... 43Working ranges of the tools .............................................. 44

Miller support ........................................................................ 45Clamping the tools into the miller support ......................... 45Working ranges of the tools .............................................. 46

Tap holder ............................................................................. 47Clamping the tools in the tap holder .................................. 47Working ranges of the tools .............................................. 48

Holder MT2 ........................................................................... 49Mounting the tools ............................................................ 49Dismounting the tools ....................................................... 49

Clamping devices for workpieces ............................................. 50Machine vice mechanic ........................................................ 50Machine vice with hydraulic support ..................................... 51

Mounting the machine vice ............................................... 51Rapid adjustment of the clamping range ........................... 51

Incremental straps ................................................................ 51Intermediate flange ............................................................... 52

Mounting the intermediate flange ...................................... 52Three-jaw chuck 125 mm ................................................... 52

Mounting the chuck ........................................................... 52Pneumatic vice (option) ............................................................ 53

Adjusting the clamping position ............................................ 53Setting the clamping device pressure ................................... 54Standard values for the clamping pressure ........................... 54

Determination of the tool length Z with the gauge ..................... 55Exchange of the control keyboard ............................................ 55Milling Tools .............................................................................. 56Characteristic curves at the milling spindle .............................. 57

Spindle 5000 ......................................................................... 57Spindle 10000 ....................................................................... 57

6C Control Panel EMCO-specificKey Description ........................................................................ 59

Skip ...................................................................................... 59Dryrun .................................................................................. 59Single Piece Mode ................................................................ 59Optional Stop ........................................................................ 59Reset Key ............................................................................. 60NC Stop ................................................................................ 60NC Start ............................................................................... 60Single Block .......................................................................... 60Reference Key ...................................................................... 60Direction Keys ...................................................................... 61Rapid .................................................................................... 61Feed Stop ............................................................................. 61Feed Start ............................................................................. 61Spindle Stop ......................................................................... 61Spindle Start ......................................................................... 61Spindle Override ................................................................... 61Coolant ................................................................................. 62Tool change manual .............................................................. 62

Swivelling in opposite direction ......................................... 62Auxiliary OFF ....................................................................... 63Auxiliary ON ......................................................................... 63Auxiliary ON ......................................................................... 63Clamping device (option) ...................................................... 63Swivel dividing device (option) .............................................. 63Machine door (option) ........................................................... 63Mode Selection Switch ......................................................... 64Feed Override Switch ........................................................... 65EMERGENCY OFF .............................................................. 65Key switch special operation ................................................. 65Additional Key Clamping Device ........................................... 66Consent key ......................................................................... 66Main Switch .......................................................................... 66

Serial Interface ......................................................................... 67Signal names ........................................................................ 67Maximum Cable Length ........................................................ 67

Standard Values ............................................................... 67Connection to PC ................................................................. 67

D Maintenance of the MachineSurvey ...................................................................................... 69Lubricant recommendations ..................................................... 70Filling Quantities ....................................................................... 70Chlorin-free coolants ................................................................ 71Central lubrication .................................................................... 72

Deaerating the lubricant lines ............................................... 72Tool magazine slide .................................................................. 73Milling spindle pressure piece .................................................. 73Indexing cams .......................................................................... 73Pneumatic vice (option) ............................................................ 74Pneumatic unit .......................................................................... 74

Water separator .................................................................... 74Coolant device .......................................................................... 75

Cooling lubricant level ........................................................... 75Cleaning the coolant tank ..................................................... 75

Filter cartridge for PC cooling device ........................................ 76

7

Adequate useThe machine is designed for milling and drilling of machinable metals and machinablesynthetic materials.Machining of other materials is not admitted and may be carried out in particular cases onlyafter consultation with the machine manufacturer.Adequate use also includes compliance with the operating and maintenance instructionsindicated by the manufacturer.The machine may exclusively be operated by persons familiar with operation, maintenanceand repair and who know about the hazards.All regulations for the prevention of accidents and safety instructions for work with machinetools have to be complied with at any time.In case of inadequate use of the machine the manufacturer renounces any liability and theresponsibility is transferred exclusively to the user.

Warranty conditions for new EMCO machines1. The warranty period for new EMCO machines is, without limitation of operating hours, 12

months after initial shipment of the machine from EMCO or its authorized representative.Should the installation be completed by EMCO or its authorized representative, thewarranty period begins with the completed installation of the machine.If a delay of installation occurs which is not caused by EMCO or its representative, thewarranty period becomes invalid 12 months after scheduled installation date.

2. The warranty extends to the elimination of all defects in material or workmanship whichaffect the regular function of the machine.

3. Occuring defects must be immediately reported to the EMCO respresentative or the nextEMCO service department with detailed description of the defect in written or oral form,followed by a written verification.

4. Defects which are correctly reported and under warranty will be corrected by eitherrepair or replacement delivery to the original buyer free-of-charge; defective parts are tobe returned to EMCO or the EMCO authorized respresentative, freight prepaid, ifrequested.

5. Warranty for spare parts: Emco guarantees to the original buyer that, only those partssold directly by Emco or through an authorized representative will be free from defects,which render part commercially unacceptable in material and workmanship, for a periodaccording to applicable national law, at least three (3) months, but not to exceed six (6)months from the date of initial shipment or installation by Emco or its representative.In the case of repeated claims for the same part: Warranty replacement does not extendthe period of the original warranty.

6. There is no claim of warranty for defects which occured by:Negligence of operating instruction manuals, safety and handling regulations or otherinstructions regarding delivery, installation, set-up or usage of the machine, incorrect set-up resp. installation, as well as, unauthorized, not expressed regulated or allowedalternations or modifications of the machine by the original buyer or third parties, naturalwear, improper or negligent handling, chemical, electro-chemical or electrical influences,inadequate energy supply or force majeure.

7. Any service performed by EMCO or its authorized representative beyond warranty willbe charged at EMCOs or its authorized representatives regular rates.

8SAFETY RECOMMENDATIONS

Safety recommendations

Read instructionsRead the instructions completely before you startup the machine.Prior to start of work get familiar with all functionsand operating elements. During the work it mightbe too late.

Electrical connectionElectrical connection of the machine must onlycarried out by an authorized electrics expert.Local protection measures have always to beborne in mind.

Observe local regulationsObserve your country's regulations for workinvolving machine tools and CNC machine tools

Authorized operationThe machine may only be operated by authorizedpersons.Authorized persons are exclusively personsfamiliar with operation, maintenance and repairand who are instructed on hazards.

Protect machineProtect the machine (main switch can be locked)during adjustment, maintenance and repair workagainst unauthorized start-up.

Start-upMake sure that prior to each start-up the machineis in perfect maintenance state and that no safetyfeatures have been removed.

No modifications on machineModifications on your own on safety features,bridgings of control features as well as anyinterference with the electric/electronic part of themachine are prohibited.

In case of hazards EMERGENCY-OFFIn case of hazards immediately stop machine withEMERGENCY-OFF.

Tool changeChange machining tools only during standstill ofmachine. Only use tools and sealing bolts with Oring on the shaft, always close all stations(otherwise danger of coolant and chip entry in theinternal area of the tool turret!). In case of toolchange always turn driven tool holder into lockingposition.

Personal protective equipmentDo not wear loose working clothes. Mind that theworking clothes are tight around the wrists andhips.Mind that your hair does not get caught in themachine (in such a case wear hair protection).Protect your eyes with safety-glasses.When removing chips use a chip hook and gloves.

Setting, maintenance and adjusting workAll setting, maintenance and adjusting work mustonly be carried out during standstill of machineand EMERGENCY-OFF key actuated.The inspection and maintenance instructions formachine and accessories are to be observed. Thissaves costs, excludes major standstills of themachine, reduces hazards and saves the environ-ment.

Tools, operating materials and spare partsOnly use tools, operating materials and originalspare parts recommended by EMCO.For parts not supplied by EMCO, EMCO does notassume liability.

Disposal of noxious materialsWhen handling auxiliary and operating materials(cooling lubricants, cleaning solutions, lubricatingoils, etc.) observe the safety regulations for thesematerials.Take adequate measures for the appropriatestorage and disposal of noxious materials.

ClaimIn the event of a collision or other instance ofdamage contact immediately the representativeor manufacturer.In case of complaints, damage, confusions andspare part orders always indicate the machinenumber, electric number and software version.

Machine supervisionNever leave running machine unattended.Before leaving the working place switch offmachine and protect against unauthorized start-up (lock main switch and remove key).

9SAFETY RECOMMENDATIONS

Danger, Attention, NotePlease always mind the regulations for preventionaccidents and safety rules indicated in theindividual chapters and the additional instructions.Important instructions concerning the technicalsafety and the staff protection are emphasizedparticularly:

Dangerrefers to possible danger to persons duringworking and operating procedures.

Attentionis indicated in working and operating pro-cedures which have to be observed exactly toavoid possible damage of the machine andslight danger of injury for operators.

Enviromental Protection Notesrefer to the avoidance of special waste,responsible handling of environmentallynoxious substances as well as possibilitiesfor saving auxiliary and operating materials.

Noteis indicated if something particular has to beobserved when an activity is carried out.

10

TECHNICAL DATA

Technical Data of the Machine

Subject to technical modifications!

Slideway longitudinal (X axis) [mm] 300Slideway cross (Y axis) [mm] 200Slideway vertical (Z axis) [mm] 300effective Z-stroke [mm] 200Distance spindle nose - table surface [mm] 285

Clamping surface (LD) [mm] 520180maximum table load [kg] 203 T-slots according to DIN 650, width [mm] 12Distance of T-slots [mm] 45

Spindle bearing [mm] 40Type of bearing rolling bearingToolholding fixture similar to DIN7920 - SK30 works standardTensioning bolt works standardTool clamping automatic

Power with 100/60% DC [kW] 1,7/2,5Speed range (infinitely variable) [min-1] 150-5000maximum torque at the milling spindle 60% DC [Nm] 24Drilling capacity in steel [mm] 16Threading capacity in steel [mm] M10

Step resolution [m] 1,5Max. feed force [N] 2500Working feed in X/Y/Z (inifinitely variable ) [m/min] 0 - 4Rapid traverse speed X/Y/Z [m/min] 7.5Medium positioning variation X/Y/Z according to DIN VDI 3441 [m] 3 / 3 / 4

10maximum tool diameter [mm] 70maximum tool length [mm] 200maximum tool weight [kg] 0.8Feeding force [N] 1100Tool change time T1 / 180 [s] 4.6Tool change time T2 and T3 / 36 [s] 4.0

Working area

Milling table

Milling spindle

Feed drivesAC step motors in X/Y/Z axis

Tool system Tool drum with direction logic

Milling spindle drive Rotary current motor AC

Number of tool stations

11

TECHICAL DATA


Guideways, feed spindle nutsMain spindle

Tank capacity [l] 140Max. conveying capacity [l/min] 20Max. conveying pressure [bar] 0.75

Supply pressure [bar] 6Hose connection [mm] 10

Supply pressure [bar] 6Hose connection [mm] 10

Opening capacity [mm] 125Jaw width [mm] 125

Power supply [V] 3/N/PE 400Max. voltage fluctuations [%] 10Frequency [Hz] 50/60Connected load of the machine [kVA] 5Max. preliminary fuse for the machine [A-slow] 20

Total height [mm] 1925Installation surface WxD [mm] 15021284Total weight of the machine [kg] 700

Medium sound pressure level [db(A)] 72With the following conditions:Masuring method: enveloping surface according to DIN 45635Operating mode: maximum speed during idle running

Pneumatic vice with final position control and blow-out device

Sound pressure level

Automatic clamping device (option)

Pneumatic unit (option)Pneumatic unit for the automatization accessories

Coolant device

autom. central oil lubrication

Dimensions, weight

Automatic door mechanism (option)pneumatically actuated, incl. final position controlElectrical connection

Pneumatics (standard design)Pneumatic maintenance unit for tool cone blow-out device (with filter)

life time lubrication

Lubrication system

12

TECHICAL DATA

Techical Data of the PC-Control


Separate set-up of machine operating board and replaceable control-specific keyboardControl display

Processor (min.)Main storage Disk drive CD-ROM driveHard disk memoryDisplay InterfaceKeyboardPC mouse

Interfaces

Operating system Windows 98SE

MF-2 (US-layout)

2 RS232, 1 USB,2 LAN-100Mbit

3"integrated

20 GBDVI

12" colour flat screen

Celeron 850 MHz128 MB RAM

PC control

PC configuration (PC integrated in the machine)

15

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Machine number and electrics number

A Installation of the machine

Machine acceptanceCheck the machine for any transport damage andcompleteness of the delivery.If you find any defects, please contact the dealeror the insurance company.In case of complaints always specify the exactdesignation of the machine and the machinenumber and the electric number.

Machine numberThe adhesive plate with the machine number (1)is to be found laterally on the machine above thelockable main switch.The machine numer is also stamped into themachine bed.

Electrics numberThe adhesive plate with the electrics number ismounted on the right side of the machine belowthe main switch.The electrics number consists of a 9-digit number(2) followed by the version number (3).

Example of a complete electrics number:Q1F 101 000 V1.30 (see illustration)

Note:The wiring diagrams valid for your machineare to be found in the electrical documen-tation which is in the switch cabinet of themachine.An electrical documentation can also beobtained under order number ZVP 677 916andindicating the version number (e.g. V1.30)from EMCO.

INSTALLATION

16

Control Software (8) Siemens 810/820 Siemens 810D/840D GE Fanuc Series 0 GE Fanuc Series 21 Emcotronic TM02 Heidenhain TNC 355

Control Keyboard (9) Siemens 810 Siemens 820 Siemens 810D/840D GE Fanuc Series 0 GE Fanuc Series 21

9

1

SCOPE OF SUPPLY

Scope of supplyBasic machine (1)(1) PC-controlled CNC-machining center PC-Mill

155 with:- full shell with chip tray- safety devices according to CE-standard- machine lamp- central lubrification- integrated PC with keyboard and PC mouse- 12" colour flat display

(2) 1 reference tool (clamped in tool drum)(3) machine supports (4pcs.)(4) 5 pcs. filter cartridges for PC cooling device(5) double-ended spanner SW810(6) oil press(7) machine description, software description and

electrical documentation

Modules/options speed up to 5 000 rpm (2.5 kW-drive) speed up to 10 000 rpm (4 kW-drive) machine vice - mechanic machine vice - hydraulic machine vice - pneumatic NC-dividing device tailstock for NC dividing device coolant device workpiece collection device automatic door mechanism robotic interface DNC interface

Scope of supply

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INSTALLATION

17

Transport of Machine

1

Dimensions by transport of machine

800 kg

700 kg

TRANSPORT

transport with pallet

transport without pallet

Transport with pallet

Lifting capacity ................................... min. 800 kgFork width ................................. 1 000 - 1 200 mmFork length ....................................min. 1 300 mm

Attention:The machine may only be transported on thepallet if the machine is fixed on the pallet bymeans of anchor bolts.

Lifting capacity ................................... min. 700 kgFork width .................................... 700 - 1 000 mmFork length ....................................min. 1 300 mm

Attention: The lifting points and the fork widths have

to be adhered to exactly so that there is nodeformation at the machine base.

The foot panel (1) and/or coolant tray(accessories) must be removed duringtransport.Furthermore, the coolant pump must beswivelled out (see "transport safety devices"in this chapter).

Transport without pallet

INSTALLATION

18

1 2

Transport safety devices

Attention: Prior to start-up of the machine all transport

devices have to be removed. Keep the transport safety devices and

remount them when transporting the ma-chine again.

TRANSPORT SAFETY DEVICES

Machine doorThe machine door is fixed by a securing screw(2) at the left machine panelling - remove screw(2).

Coolant device (accessory)If the machine is equipped with the "coolantdevice" accessory, the transport safety device forthe coolant pump must be removed:Screw out securing screws (1).Now the coolant pump can be swivelled outlaterally.

Transport safety devices at the machine

INSTALLATION

19

DIMENSIONS, INSTALLATION PLAN

Installation plan, dimensions of the machine

Space for operation

Space for maintenance

A Setting screws (8) resp. levelling elements (4)(see "Installation criteria" in this chapter)

B Bores 18120 for anchor bolts

INSTALLATION

20

18-35CrH 40-70%

1 2 3 4

0

INSTALLATION CRITERIA

Aligning the machine

Installation criteriaRequirements on installationsurfaceThe machine is to be installed on a pavement ashorizontal as possible with adequate carryingpower and vibration stability.When screwing down the machine bores for theanchor bolts have to be mounted.

ErgonomyDue to its ergonomic design the machine providesoptimum operation.However, when choosing the installation site payattention to sufficient lighting.

Installation siteMind that the selected installation site is ade-quately clean (free of excessive dust exposureetc.) to take care of the machine as well as thePC and the peripheral devices.

Furthermore, the following requirements mustbe met:Room temperatue ....................................18-35CAtmospheric moisture .............................. 40-70%

Installation without anchoringIn general, screwing down the machine on thefloor is not necessary.However, anchoring is possible.Use the supports supplied with the machine (2)

as a base. Align the machine horizontally at the setting

screws (3). Fix alignment by tightening the counter nuts (1).

Note: This kind of installation is the easiest one,

however, there is no vibration damping. As a remedy you can use also vibration

damping levelling elements (4) instead ofthe supports (2).Levelling element ............ order no. 881 500(4 pcs. necessary)

Room climate at installation site

Installation without anchoring

INSTALLATION

21

1 2 3

3 4

80 Nm

30 Nm

INSTALLATION CRITERIA

Anchoring on the ground

Anchoring on the ground

Required accessories (order no.):4 pcs. levelling elements ......................... 881 5004 pcs. anchor bolts FHA 1860 B ............. 573 045

Drill 4 anchor bolts 18 120 in a distance of1368 704 mm (see installation plan).

Place the machine above the bores. Insert levelling elements (1) and align machine

horizontally. Thread in achor bolts (3) and push them into

the anchor bore until the distance between thewasher of the anchor bolt and the setting angle(2) is approx. 5 mm (see sketch - distance X).

Pretension anchor bolts (3) with 80 Nm.(anchorage in the ground)

Reloosen hexagon nuts of the anchor bolts andattach insulating disk (4).

Tighten anchor bolts with 30 Nm (holding downthe machine).

Additional criteria for installationIn addition to the required capacity and vibrationstability further requirements are to be met bythe installation surface and the installation site: The installation site has to comply with

building authority regulations so that in caseof possible leakage of cooling lubricant,lubricating and hydraulic oil, the environmentis not burdened.An ideal situation would be provided if theinstalltion site at the same time fulfilled thefunction of a collecting tray.

Vibration-proof features as favourable aspossible to avoid a transmission of vibrations(particularly when working in the upper speedrange, with bar work, when machining heavilyunbalanced workpieces, with interrupted cut,when using driven tools etc.) to nearbyobjects.

Good and sufficient lighting of the workingspace facilitates operation of the machine andincreases quality and security of work.

The specific noise load of a machine operatoris to be noted.

It has to be taken into account that in accordancewith the operating situation a highly qualifiedoperator works on the lathes who has to carryout exacting programming and supervisingactivities.

Sometimes the situation can be improved bysound insulation walls.From studies we know that the double distanceto a nearby source of noise decreases thesound level by 3 to 5 dB(A).When doubling the number of similar sourcesof noise the level is increased by 3 dB(A).

Heat sources with inconstant temperaturenear the machine as well as air drafts willinfluence the quality of the place of work aswell as the operating position of the machine.If necessary, adequate measures for pro-tection are to be taken.

INSTALLATION

22

3

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1

ELECTRICAL CONNECTION

Electrical connection

Danger:The electrical connection of the machine andits accessories may only be established byan electrics expert.Feed cables must be idle during the connec-tion.

Thread feed cable through the cable screwedjoint (2) laterally at the electrical cabinet (1).

Connect the three phases L1, L2 and L3 to theterminal strip +1FL1-X1 (3)(connecting termi-nals L1, L2 and L3).

Connect zero conductor to terminal N of theterminal strip +1FL1-X1 (3).

Connect earth contact (yellow/green core) tothe connecting terminal PE of the terminal strip(3).

Control of the correct connectionControl the connection by checking the rotarydirection of the main motor fan.The rotary direction of the fan is marked on thefan cover.In case of wrong rotary direction switch offmachine immediately and interchange two phasesof the main connection.

Cable screwed joint at the machine

E-cabinet and connecting terminal

Attention:Connecting this machine to a mains protectedby leakage current circuit breaker is admittableonly with using an all-current-sensitiveleakage current breaker.Reason:The drives used for this machine can causeDC leakage currents which will impair theprotective function of the leakage currentbreaker (no release).Type of the all-current-sensitive leakagecurrent breaker tested by EMCO:SIEMENS 5 SZ6 468 - OKG00EMCO-Order-No.: ZME 280 720Alternative:ABB F804 - 63/0,3

INSTALLATION

23

ELECTRICAL CONNECTION

Attention:A preliminary fuse is ordered forcible!The specified value of the fuse has to be keptstrictly.

Power supply .............................. 3/N/PE 400 VFrequency ............................................... 50/60 HzMax. voltage fluctuations ............................. 10%Connected load ........................................... 5 kVAMax. preliminary fuse ........................... 20 A/slowRequired short circuit power ................ 1100 kVAFeed cross section .......... acc.to local regulations

Mains connection data

Note:Further information about electrical con-nection is to be found in the electrical docu-mentation of your machine.In case of different specifications the data inthe electrical documentation are valid.

The PC is already installed and cabled in themachine by the manufacturer. Access to the PC keyboard (3) by opening the

cover (1). To use the PC mouse swivel out integrated

mouse tray (2) laterally. Floppy (5) and CD-drive (4) are above the PC-

keyboard.

PC connectionOpening the PC compartment

1

2

3

4

5

PC with floppy - and CD-drive

INSTALLATION

24

4

5

5

6

PNEUMATIC CONNECTION, INITIAL START-UP

OPEN

CLOSE

Pneumatic connection of the machine

Pneumatic connection(Option)By machines with automatization (pneumaticchuck, automatic tailstock, ...) lateral on themachine there is a pneumatic connection device.Working pressure .................... min.4 max.6 bar

Connect air supply at the connection piece (6)of the pneumatic unit laterally at the machine(compressed air hose 10 mm).

The set pressure can be read at the manometer(4) at the rear side of the machine.

By pushing the manual slide (5) upwards thefilter and the valves are supplied with com-pressed air.

Initial start- up All blank parts are to be cleaned from rust

preventive agent with a clean cloth. Prior to start-up grease the machine (see

maintenance of the machine). Check oil level of central lubrication, if necessary

refill oil (see maintenance of the machine). Tool and workpiece must be clamped tightly and

safely. For further operation please see switch-on and

switch-off procedure of the machine as well assoftware description.

Note:

If the machine is not used for a major period: Clean machine carefully Slightly oil blank parts. Protect machine against unauthorized start-

up (key switch at the operating panel,lockable main switch).

Cover machine with dust protection (packing).After a major standstill of the machine alloperations as describerd under "Initial start-up" are to be carried out.

INSTALLATION

25

Approach Reference PointPossibility A:Referencing axis by axisPress the +Z keyThe slide traverses to the reference point in Z.Press the +X keyThe slide traverses to the reference point in X.(Only after the collision-free area was reached inZ)Press the +Y keyThe slide traverses to the reference point in Y.(Only after the collision-free area was reached inZ)If the dividing device is active, it must be alsoreferenced.By pressing the key "+4" the dividing deviceapproaches the reference point.

Open air supply (option).Switch on main switch at the electrical cabinet(cabinet fan runs).Open and close the chip guard door once forchecking the door safety switch.After a major standstill of the machine press "AUXON" key for approx. 1 minute.By pressing the "AUX ON" key all drives aresupplied with current. With a steady pressure onthe key also the central lubrication is activatedapprox. every 6 seconds in order to lubricate theslide guides.

Main switch

Control panel

SWITCH-ON / SWITCH-OFF

Switch On/Off SequenceSwitch On the Machine

Note:After reaching the reference points thesoftware limit switches are active.

Possibility B:Automatic referencingPress the key "reference". The axes traverse tothe reference point one after the other.

For further operation of the machine please seeyour "Software description" .

INSTALLATION

26

Switching off the machine

Press key AUX OFF.

Terminate control software (WinNC).

Terminate Windows.

Switch off main switch

Lock air supply.

Notes The machine is switched off by means of

the main switch.We recommend to switch off the machineonly in inoperative position of the tool turret.

Operation is interrupted by means of theReset key.All current machine functions are interruptedwith RESET.

SWITCH-ON / SWITCH-OFF

27

B Description of the Machine

Main elements- Survey

1

11

2 3 4 5 6

7 8 9 10

12

13

14

15

1 Milling table with X/Z slide systems2 Working area3 Machine lamp4 Chip guard door5 Milling spindle with tool drum6 EMERGENCY-OFF key button7 Chip tray (to be pulled out)8 Chip screen

9 Coolant tray10 Coolant pump (swivelling)11 Main switch12 E-cabinet13 Control-specific keyboard (exchangeable)14 PC keyboard drawer (folding, with integrated

mouse tray)15 Machine base with chip area

DESCRIPTION

28

REFERENCE POINTS

Points at the Machine

Machine zero point M The machine zero point M lies on the surface ofthe milling table on the left front corner.The machine zero point M is the origin of thecoordinate system.

Reference point R The reference point R is a fixed point at themachine. It serves for the calibration of themeasuring system.The reference point R must be approached aftereach switch-on of the machine to communicatethe exact distance between the points M and N(T)to the control.

Workpiece zero point W The workpiece zero point W can be freelyprogrammed by the user.By programming a workpiece zero point the originof the coordinate system is displaced from themachine zero point M into the workpiece zeropoint W.

Toolholding-fixture reference point N(T) The toolholding-fixture reference point N (T) liesexactly in the rotary axis of the milling spindle, ina distance of 30 mm in Z-direction from theshoulder of the ball bearing of the toolholder.The tool lengths are described starting from thispoint.

Points at the machine

DESCRIPTION

29

WORKING AREA, COORDINATE SYSTEM

M

Working area

Working area in X- and Y-axesTraversing path X-axis ............................ 300 mmTraversing path Y-axis ............................ 200 mm

Traversing paths of the X- and Y-slides

Coordinate system

Coordinate systemThe coordinate system is turning in clockwisedirection. The origin lies in the machine zero pointM or in the workpiece zero point W.

Limitation of traversing pathsThe traversing paths of the slides are limited bysoftware limit switches.When reaching a software limit switch therespective feed motor stops and a message isindicated at the monitor of the control.By means of the software limit switches amechanical overload of the axis spindles due tofixed stops is avoided.

Working area in Z-axisThe working area in Z-direction depends on thelength of the clamped workpiece.Further details are to be found at the respectiveclamping device.effective Z-stroke ..................................... 200 mm

Note:Mind that the clamped workpieces in thetraversing area of the milling cutters areclamped at the milling table.

DESCRIPTION

30

MAIN ELEMENTS

Central lubrication

Slide system and milling spindle

Machine baseThe machine base is of solid welded design, forsupporting the machine bed, the control with thePC as well as the whole electrical equipment.A coolant tray (accessory) can be inserted at thelower part of the base.

Central lubricationThe slides are supplied with glideway oil via thecentral lubrication.The pump is automatically switched on after aslide traversing path of 16 m.

Milling spindleThe milling spindle is mounted in rolling bearingsin the milling head. The drive is carried out via athree-phase A.C. motor, the spindle speed isinfinitely variable via the control.Speed ............................................. 150-5000 rpmmaximum torque ........................................ 24 Nm

Slide drivesThe slides are traversed with step motors viarecirculating ball screw spindles.The amply dimensioned spindles, the rigid spindlenuts and the axial bearings without backlashprovide high positioning and working accuracy.Feed speed.................................. 0-4000 mm/minRapid motion speed ........................ 7500 mm/minStep resolution ........................................... 1.5 mmax. feed force X-/Y-/Z-slides ................. 2500 N

SlidesThe slides run in precisely ground dove-tailguides.The clearance of the slides can be readjusted viatapered gibs.The slides are supplied with oil via the central oillubrication so that all sliding surfaces are alwaysdampened with oil.

DESCRIPTION

31

2

1

Door locking deviceIn the machine a door locking device (2) isinstalled with which the chip guard door can beopened only during standstill of the main drive.A program start with an open door is not possible.

Opening the door by pressing the key" ".

EMERGENCY-OFF key at the machine

Door locking device

SAFETY DEVICES

Safety devicesThe safety devices are contained in the basemachine and facilitate generally risk-free opera-tion of the machine.

EMERGENCY-OFF keyIn case of any hazard the EMERGENCY-OFF key(1) is to be pressed immediately.By pressing the key (1) the power supply to themain drive, the feed motors as well as the toolturret is interrupted immediately.For unlocking the EMERGENCY-OFF key turnknob in clockwise direction.

Note:After pressing the EMERGENCY-OFF KEYthe reference point must be reapproached.

Danger:The safety devices must never be removedfrom the machine.Also mechanic or electric bridgings of thesafety devices are prohibited.

DESCRIPTION

32

SAFETY DEVICES

Key switchThe key switch can be switched in 2 differentpositions:

Position of the key switch

Key switch in position "automatic operation"

Key switch in position "setting operation"

Position "automatic"The switch position "automatic" is the workingposition of the machine in which all safety devicesare active.

Danger: With switch position "setting operation" there

is an increased danger of hazards. During setting operation keep the chip guard

door closed as far as the working procedurepermits.

After termination of the setting work imme-diately switch the key switch to position"automatic" and take off the key.

The key may be handed only to thosepersons who know about the hazards andtake adequate precaution measures.

Position "Setting operation"In this switch position it is possible to to traversethe slides manually by opened machine door(Two-hand mode in connection with the consentkey - see next page).

Note:Manual traversing of the slide is only possiblewith closed chip guard door as soon as thereference point has been approached, or thekey switch is in position "setting operation".

DESCRIPTION

33

Consent keyThe function of the consent key depends on theposition of the key switch.

Position of the consent key at the operating panel

SAFETY DEVICES, PNEUMATIC

Note:If the consent key is pressed for more than40 s the function of this key is interrupted, theconsent key must be released and pressedagain.

Functions of the consent key

Key switch in "automatic" position Releasing the interlocking bolt of the chip guard

door with main spindle out of operation.The machine door is to be opened.

Traversing of slides in the JOG-manual, withnon activated reference point and openedmachine door.

Key switch in "setting" position Releasing the interlocking bolt of the chip guard

door with main spindle out of operation.The machine door is to be opened.

Manual traversing of the slide with open chipguard door.

Swivelling the tool drum with open chip guarddoor (swivelling by one position respectively)

Traversing the pneumatic tailstock quill withopend machine door.

Pneumaticmaintenance unitThe basic equipment of the pneumatic mainte-nance unit contains valves and switches for theblow-out device of the tool system.The maintenance unit available as option for theautomatization of the machine contains additio-nally all connections, push switches, pressureregulators and valves to trigger the automatic doormechanism and the pneumatic vice with the blow-out device as well as the dividing axis.Supply pressure ........................................ 4-6 barPneumatic connection .............................10 mm

Pneumatic maintenance unit

DESCRIPTION

34

PNEUMATIC SCHEME

Pneumatic scheme

Blo

w-o

ut d

evic

em

illin

g sp

indl

e

4 in

tern

al

1D

ivid

ing

axis

45

-stro

ke 1

23

Pneu

m. v

ice

50

/30-

4-fo

ld s

troke

5

4B

low

-out

dev

ice

4

inte

rnal

5A

utom

atic

doo

rm

ec

hani

sm

32/1

2-st

roke

6206

on

ly to

geth

er

DESCRIPTION

35

AUTOMATIZATION

DNC-interface(option)Via the DNC-interface the machine can beoperated via a host. In contrast to the roboticsinterface, in addition to standard functions, e.g.programs can be transmitted or started from thehost.The DNC-interface is mainly used for the set-upof an FMS.

Automatic doormechanism (option)Upon order the automatic door mechanism canbe mounted as option at the manufacturer.The chip guard door can be opened and/or closedby the program or by pressing a key via apneumatic cylinder (1).Monitoring of the door position is carried out via 3limit switches.

Robotics interface(option)With the robotics interface in addition to thegeneral triggering of the periphery (such asautomatic door mechanism) the machine can alsobe connected with further machines or devices(e.g. loading and unloading robot).

DESCRIPTION

36

1

TOOL SYSTEM

Tool system

Tool drum for 10 tools

All tools are mounted on the toolholders.The toolholders with the premounted drilling andmilling tools are mounted on the tool drum (1).

The tool change is carried out manually or duringa CNC-program automatically.The tool drum (1) is provided with a directionlogic, i.e. always the shortest way for swivellingthe drum is selected. Thus the time for the toolchange procedure is reduced to the minimum.Number of tool supports ............................... 10

Note:Due to the safety devices of the machine atool change procedure is only possible withclosed chip guard door.

During tool change tool drum and milling headtraverse upward.The milling head continues to traverse when thetool drum has reached the end position. Thus,the toolholder in the milling head is released.Now the tool drum is swivelled into the desiredposition (direction logic).The milling head traverses downward again, thus,the toolholder with the new tool is released.The whole tool change procedure is controlledvia limit switches (proximity detectors).

DESCRIPTION

37

1

Switch the mode selection switch to "JOGoperation".

Acknowledge alarm message by pressing thekey " ".

Start manual tool change procedure to swivelout the tool not correctly clamped.

Release and check tool.(For tool change see the following pages).Check also the indexing cam (1) for smoothrunning.

Clamp tool again and retry to clamp the toolagain.

If the alarm message is displayed again, contactthe EMCO service department.

TOOL SYSTEM

Initialization of the tool turret

After the interruption of a tool change procedure(current interrupted, EMERGENCY-OFF KEY,interruption key) the tool turret must be initializedto adjust the control to the position of the toolturret.

Alarm message"7022 Initialize tool turret" The interrupted tool change procedure is

terminated by pressing the tool turret key.

Initialization of the tool turret

Alarm message"6040 WZW - static interlock control"If this alarm message is displayed on the screenthe tool turret is in a position not identified by thecontrol.The tool has not been clamped correctly after atool change procedure.

Attention:To avoid a damage at the machine the mainspindle must not be started on any account ifthis alarm message is displayed !

Indexing cam at the tool drum

DESCRIPTION

38

5

mm

ESX 16

MT2

TOOLHOLDER

Toolholder

Tool support similar to DIN 2079 ............... SK 30Clamping bolt ............................... works standard

Miller support Tap holder

Toolholder

Collet holder Shell end mill arbor

The machining tools are mounted on the tool-holder.Drills, end-milling cutters and profile cutters areclamped by means of collets into the collet hol-der, shell end mills and disk milling cutters aremounted on the shell end mill arbor.Taps are clamped in special tap holders with lon-gitudinal compensation.All toolholders are available as accessory atEMCO.A special miller support is availabe for the end-milling cutters 10, 12 and 16 mm.

Order numbers

Holder MT2

Order no.Collet holder ESX 16 Q1Z 910Shell end mill arbor 16 Q1Z 860

10 Q1Z 83012 Q1Z 84016 Q1Z 850M2 Q1Z 760M3 Q1Z 870M4 Q1Z 880

M5-M8 Q1Z 890M10 Q1Z 900

Q1Z 780

Toolholder

MT2 holder

Miller support

Tap holder

DESCRIPTION

39

X1 2

1 3 A 2 4 B

TOOLHOLDER

Tool drum

Detail X - mounting the toolholder

Mounting the toolholder into thetool drum

Danger: Due to the modified DIN tool support only

toolholders bought particularly for thismachine from EMCO may be clamped.

Wear protection gloves during mounting anddismounting the tools to avoid injuries atthe hands.

Twist the clamping screws (4) in such a way atthe tool drum (1) so that the flat part (B) of thescrews shows in the direction of the tool support.Thus, it is possible to insert the tool into thesupport.

Insert toolholder (2) with mounted tool into thesupport of the tool drum (1).

Twist the toolholder in such a way that therecess (A) at the toolholder engages in theindexing cam (3).

Push toolholder entirely to the top. Tighten clamping screws (4) so that the tool-

holder sticks safely in the support.

Attention:While tightening the clamping screws (4) mindthat the flat parts (B) of the screws aredirected away from the the tool support.Thus, it is assured that the toolholder cannotfall out from the support.

Swivel tool drum by one position to mount nexttool.

Dismounting the toolholder Swivel in tool. Loosen clamping screws (4) so that the tool-

holder (2) can be removed.Hold the toolholder tight so that the toolholderdoes not fall down and the tool is not damaged.

Remove dirt and chips from the released tooland oil the tool shank slightly with oil.

DESCRIPTION

40

1 2 3

ESX 16

TOOLHOLDER

Collet holders

Drills, end-milling cutters and profile cutters areclamped in the collet holder.

Order no. ................................................. Q1Z 910Clamping range .......................... 0.5 up to 10 mmCollet type .................................................ESX 16

Maintenance of collets and colletholders

Note:In case of insufficient maintenance dirt andchips may damage the collet holders and thecollets.Thus, the round-run accuracy of the tool mightbe impaired.

Dismounting the collets Loosen clamping nut (1). Via the eccentric ring (3) in the clamping nut

the collet (2) is pressed out when screwing offthe clamping nut.

Danger:When the collet holder is clamped in the tooldrum of the machine, mounting and dis-mounting of the collet holders may only becarried out during machine standstill.

Mounting the collets Unscrew clamping nuts (1). Insert collet (2) obliquely into the clamping nut

(1) so that the eccentric ring (3) engages in thegroove of the collet.

Screw collet with clamping nut onto collet hol-der.

Collet holder

Mounting the collets

The collet holders and the collets have to becleaned carefully and oiled slightly before andafter use.

DESCRIPTION

41

TOOLHOLDER

1 2 3 4 5 6

Clamping the tools into thecollet holder

Mount adequate collet (4). Insert tool (5) into the collet (4). Mind that the

tool is pushed in far enough into the collet. Whenclamping too short the tool may be ejected fromthe device.

Tighten clamping nut (3) with supplied pinwrench (6).Countertighten the collet holder (2) with the se-cond pin wrench (1).

Danger: With mounted collet holder, mounting and

dismounting the tools may only be carriedout during machine standstill.

The values indicated in the table "clampingranges" must always be complied with,otherwise the tools cannot be clampedsafely.

Clamping rangesThe clamping ranges are engraved in the collets.

Clamping the tools into the collet holder

[mm] [inch]1,0 0,5-1,0 1/64-1/32 152 7101,5 1,0-1,5 3/64 152 7152,0 1,5-2,0 1/16-5/64 152 7202,5 2,0-2,5 3/32 152 7253,0 2,5-3,0 7/64 152 7304,0 3,0-4,0 1/8-9/64-5/32 152 7405,0 4,0-5,0 11/64-3/16 152 7506,0 5,0-6,0 13/64-7/32-15/64 152 7607,0 6,0-7,0 1/4-17/64 152 7708,0 7,0-8,0 9/32-19/64-5/16 152 7809,0 8,0-9,0 21/64-11/32 152 79010,0 9,0-10,0 23/64-3/8-25/64 152 800

152 700

Nominal diameter of the collet

Order no.

Clamping range

Set of collets (1,0 - 10,0)

DESCRIPTION

42

TOOLHOLDER

Working ranges of the tools

Working ranges with the collet holder

200

effe

ctiv

e st

roke

in Z

-axi

s

twis

t dril

le

xtra

sho

rt ac

c.to

DIN

1897

en

d-m

illin

g cu

tter

acc

. to

DIN

844

shap

e A

radi

us c

utte

r

slo

ttin

g en

d m

illa

cc.

to D

IN32

7 sh

ape

B

DESCRIPTION

43

TOOLHOLDER

1

2

3

4

5

6

7

4 mm

12 mm8 mm6 mm

Shell end mill arbor

Clamping the tools into the shell end mill arbor

Clamping the tools in the shell endmill arbor

In the shell end mill arbor shell end mills and diskmilling cutters are clamped.Collars are supplied with the milling spindle forcompensating the milling cutter width and awrench for tightening the clamping screw.

Order no. ................................................. Q1Z 860Tool support shaft ....................................16 mm

Shell end mill arbor

Unscrew clamping screw (6). If necessary, mount adequate collar (4) onto

the collar shaft (2). Mount tool (5) onto the shaft (square key). Screw clamping screw (6) into the shaft and

tighten with the wrench (7).Countertighten the shell end mill arbor (1).The clamping screw must lean on the tool (5)and not on the end face of the shell end millarbor.

Danger: With clamped shell end mill arbor in the tool

drum, clamping and unclamping the toolmay only be carried out during machinestandstill.

Only tools with a bore of 16 mm and squarekey groove may be clamped.

DESCRIPTION

44

TOOLHOLDER


200

effe

ctiv

e st

roke

in

Z-ax

is

Working ranges with the shell end mill arbor

she

ll en

d m

ill

40 x

20

mm

, fo

r alu

min

ium

DESCRIPTION

45

TOOLHOLDER

1 2 3

Miller support

The miller support serves for the support of end-milling cutters which cannot be clamped any morewith the collet holder.Due to the support diameter we distinguishbetween 3 miller supports.

Order number:miller support 10 mm ............................ Q1Z 830miller support 12 mm ............................ Q1Z 840miller support 16 mm ............................ Q1Z 850

Clamping the tools into the miller support

Clamping the tools into themiller support

Danger: With clamped miller support in the tool drum

of the machine, clamping and unclampingof the tools may only be carried out duringmachine standstill.

Only tools with the nominal diameter fittingthe miller support may be clamped.

Insert tool (2) into support shaft of the millersupport (1).

Tighten both set screws (3) with an Allan keySW3.Mind that the tool (2) is held by both set screws(3).

DESCRIPTION

46

TOOLHOLDER


200

effe

ctiv

e st

roke

in Z

-axi

s

NCs

tart

dril

l 10

twis

t dril

l 10

DIN

1897

ext

ra s

hort

slo

ttin

g en

d m

illD

IN32

7 sh

ape

Be

nd-

mill

ing

cutt

er f

or T

-s

lots

(12

,5x6,

shaft

10

)

en

d-m

illin

g cu

tter

for

T-

slo

ts (

16x

6, sh

aft

10)

twis

t dril

l 1

2D

IN18

97 e

xtra

sho

rt

an

gle

cutte

r 16

x4D

IN18

33 s

hape

A a

nd B

en

d-m

illin

g cu

tter

16D

IN84

4

Miller support10

Millersupport

12

Millersupport

16

Working ranges with the miller supports

DESCRIPTION

47

TOOLHOLDER

1 2 3

Tap holder

Clamping of tap holders

Danger: With clamped tap holder in the tool drum of

the machine the tap may only be clampedand unclamped during machine standstill.

Only the taps allocated to the tap holdermay be clamped.

Clamping the tools in the tap holder

Taps are not clamped in the collet holder but inthe tap holder.The tap holder has a length compensation of10 mm (5 mm).We distinguish between 4 tap holders accordingto the thread size.

Order numbers:

tap holder M2 .......................................... Q1Z 760tap holder M3 .......................................... Q1Z 870tap holder M4 .......................................... Q1Z 880tap holder M5-M8 .................................... Q1Z 890tap holder M10 ........................................ Q1Z 900

Loosen thread pin (3) with the hexagonal key(wrench size 2,5).

Put in tap (2) into the seat of the holder (1) andturn it in a way, that the square of the tap gearsinto the square of the holder

Tighten thread pin (3) to fix the tap (2).

DESCRIPTION

48

HolderM10

TOOLHOLDER

shor

tene

d


200

effe

ctiv

e st

roke

in Z

-axi

sHoldersM5-M8

Working range with the tap holder

HolderM2

shor

tene

d

shor

tene

d

stan

dard

leng

th

stan

dard

leng

th

stan

dard

leng

th

HolderM3

HolderM4

DESCRIPTION

49

TOOLHOLDER

1

2

3

Holder MT2

Mounting the tools

Mounting the tools

The holder MT2 with reduced support serves formounting tools with cone support.

Order n ................................................... Q1Z 780

Insert tool (3) into the support of the holder (2). Fix tool in the cone by a slight beat with the

slight hammer (in direction of the arrow - seesketch).

Danger:Tool support and tool must be free of dustand grease so that the tool fits safely in thecone!

Dismounting the tools Insert the expulsion wedge (1) into the expulsion

opening on the toolholder (2). The tool is released in the toolholder by means

of a slight beat on the wedge.Take care that the tool does not fall on theground.

DESCRIPTION

50

1 5 4 6 7

1 2 3 4 2

CLAMPING DEVICES FOR WORKPIECES

Clamping devices forworkpiecesThe listed clamping devices for workpieces canbe obtained as accessory from EMCO.

Danger: To avoid accidents and for correct operation

also read the instructions attached to theaccessories.

Always take care that clamping device andworkpiece are clamped tightly and safelybefore you start machining!

The clamping device may only be operatedduring standstill of the machine!

Machine vicemechanicThe mechanic machine vice is equipped withexchangeable clamping jaws (6).The width of the jaws and clamping capacity differaccording to the construction size of the vice:

Construction size AWidth of jaws .............................................. 90 mmClamping capacity ..................................... 90 mmOrder n ................................................... 781 000

Construction size BWidth of jaws ............................................ 110 mmClamping capacity ................................... 125 mmOrder n ................................................... 781 010

Mounting the machine vice Mount firm sliding blocks (2) by means of the

hexagon socket screws M610 (3) on the lowerside of the machine vice (1).The vice is aligned on the milling table (7) bymeans of these sliding blocks.

Clamping on the milling table (7) is carried outvia the T-nut screws (4) by tightening the nuts(5).

Machine vice on the milling table

Mounting the firm sliding blocks

DESCRIPTION

51

1 2 3 4 2 5 6

1 7 4 8 6 5

Incremental strapsIncremental straps are suitable for clampingirregular and high workpieces.For clamping a workpiece at least 2 incrementalstraps are required.Clamping height ................................... 15-58 mmOrder no. ................................................ F3Z 210

Clamping height ................................. 50-125 mmOrder no. ................................................ F3Z 220

Machine vice withhydraulic supportClamping of the workpiece in the vice is carriedout with hydraulic support to increase theclamping force.The clamping range is rapidly adjustable.

Width of jaws ............................................ 113 mmClamping capacity ..........................max. 170 mmOrder n ................................................... 781 080

Mounting the machine vice Mount firm sliding blocks (2) by means of the

hexagon socket screws (3) on the lower side ofthe machine vice (1).The vice is aligned on the milling table (5) bymeans of these sliding blocks.

Clamping on the milling table (5) is carried outvia the T-nut screws (4) by tightening the nuts(7).

Machine vice at the milling table

Mounting the firm sliding blocks


Rapid adjustment of the clampingrange Release vice.

Pull out indexing bolt (6) laterally. Shift moveable jaw (8) into the desired position

and fix it with the indexing bolt (6).

Incremental strap

DESCRIPTION

52

1 2 3 4 5

1 6 7


Intermediate flangeThe intermediate flange is used for the support ofthe three-jaw chuck.It is mounted on the milling table.Order no. ................................................ F3Z 230

Mounting the intermediate flange

Put the intermediate flange (1) with the centeringbolt (2) into the groove at the milling table (3).

Thread T-nut screws (4) into the intermediateflange and fix flange by tightening the nuts (5).



Three-jaw chuck 125 mmThe three-jaw chuck is clamped on the inter-mediate flange.Order no. ............................................. V1D 106R

Note:Also mind the instructions enclosed in therespective chuck.

Mounting the chuck

Danger: For mounting the chuck only the enclosed

screws may be used. With longer screwsthe chuck might not fit tightly on the inter-mediate flange, in case of too short screwsthey might tear out.

The maximum admissible clamping rangesmust never be exceeded. Exceeding themmay lead to to jaw fracture.

After clamping of workpieces take off thechuck key.

Intermediate flange (1) and centering flange ofthe chuck (6) must be free of dirt.

Screw the chuck (6) by means of the threecheese head screws (7) on the intermediateflange and tighten screws (7).

DESCRIPTION

53

1 2 4 53 6


Pneumatic vice (option)

pneumatic vice

The pneumatic vice is mounted as option by themanufacturer.A prerequisite is a pneumatic maintenance unitavailable as option.The vice is supplied with an Allan key SW5 and afork wrench SW 10/13.In the scope of supply also a blow-out device isincluded.To enable an efficient blow-out of the vice themounted copper tube can be easily adjusted tothe desired position by bending it with caution.When adjusting the copper tube mind that thetools clamped in the tool drum can be swivelledthrough without collision.During the adjustment of the copper tube mindthat the tools clamped in the tool drum can swivelthrough without collision.

Adjusting the clamping positionFor easier clamping of cylindrical workpiecesprisms are installed in the clamping jaws of thevice in horizontal and vertical direction.

Distance of jaws ..............................max. 130 mmWidth of jaws ............................................ 125 mmJaw stroke .................................................... 5 mmClamping force ................................. max. 5500 NOrder no. ................................................ Q1Z 520 Set clamping device state of the control on "Re-

lease" (message "7054 Vice open!" is displayedon the screen).

Place workpiece on vice against the clampingjaw (3) of the vice.

Approach clamping jaw (4) of the vice by turningthe knurling wheel (5) up to a distance of approx.2 mm from the workpiece (adjust jaw distancevia the workpiece length to be clamped).When turning the knurling wheel mind that thesliding valve (6) does not turn with the wheel(counterhold).

Laterally at the vice a stop is mounted on theclamping jaw (4) which has to be adjusted bytwisting the hexagon screw M640, SW10 (1).The adjustment is fixed by means of the counternut SW10 (2).A second setting screw (1) M620 is containedin the scope of supply of the vice. It should beused for wider workpieces to avoid a collisionof the milling head with the setting screw.

When closing the vice via the control theworkpiece is clamped with the set pressure (thejaw stroke of the clamping jaw (4) is 5 mm).

DESCRIPTION

54

1 2 3 4


Setting the clamping devicepressure

Close clamping device.

Set clamping device pressure 0,5 bar.Set pressure which lies about 0.5 bar below thedesired clamping device pressure by means ofthe turning knob (4) at the pressure control unit.The set pressure can be read at the manometer(3).

Loosen fixation screw (2) at the press switch.

Turn setting screw (1) at the press switch untilthe message "Vice not ready" is displayed onthe screen.

Increase pressure ... turn in clockwise directionReduce pressure ....... turn in counter-clockwise

direction

Tighten fixation screw (2) with caution.

Set desired clamping device pressure at theturning knob (4) of the pressure control unit.

Acknowledge the alarm message on the screen.If the workpiece is clamped again no alarmmessage must be displayed on the screen.

Setting the clamping device pressure

Clamping force diagram for vice

Pneumatic pressure p [bar]

Clam

ping

forc

e F

[N]

The clamping force of the vice can be regulatedby changing the air pressure at the pneumaticmaintenance unit.Additionally a press switch is mounted whichcontrols the pressure set at the manometer.If the set pressure is not achieved an alarmmessage is displayed on the screen.

Minimum clamping pressure ........................ 2 barMaximum clamping pressure ....................... 6 bar

The clamping forces with set clamping pressureare to be seen at the opposite diagram.

Standard values for theclamping pressure

DESCRIPTION

55

Z=L30

1 2 3 4

DETERMINATION OF THE TOOL LENGTH, EXCHANGE OF CONTROL KEYBOARD

Determination of the toollength Z with the gauge

Determination of the tool length Z

Note: Mind the negative sign for the tool lengths. This is not a very exact method. You will

have to carry out tool length corrections afterthe first sample workpiece.

The toolholding-fixture reference point N (T) is tobe found in a distance of 30 mm from the shoulderof the ball bearing of the toolholder (see "Pointsat the machine").Measure the entire length from the ball bearingshoulder to the tool tip and deduct 30 mm fromthis value.The calculated value is the Z-dimension whichhas to be entered into the tool register of yourcontrol.

Exchange of the controlkeyboardBy exchanging the control keyboard it is possibleto operate the machine fast and without largerresetting effort with another control.

Untwist knurled screws (2) at the key modules(1 and 3).

Take off key modules (1 and 3). Insert new key modules from above into the

recesses at the operating panel (4) and thenswivel them to the operating panel.

Fasten the newly inserted key modules with the4 knurled screws (2) at the operating panel (4).

Now install the corresponding software for yournew control at your PC (see software descrip-tion).

Change of the key modules

Note:Wrap up well the key modules not neededand keep them in a protected and clean placeto avoid damage.

DESCRIPTION

56

Milling Tools

MILLING TOOLS

Order no.

NC start drill (HSS)acute angle 120, shaft 10mm 771 010Edge tracer4/10mm, shaft 10mm F1Z 090

Slot milling cutter HSS, DIN 327-shape Bmilling cutter 3 mm (shaft 6 mm)milling cutter 4 mm (shaft 6 mm)milling cutter 5 mm (shaft 6 mm)milling cutter 6 mm (shaft 6 mm)milling cutter 8 mm (shaft 8 mm)milling cutter 10 mm (shaft 10 mm)milling cutter 12 mm (shaft 12 mm)milling cutter 16 mm (shaft 16 mm

764 301764 302764 303764 304764 306764 308773 100773 105

Heavy-duty shank end mill HSS, DIN 844-shape Amilling cutter 8 mm (shaft 8 mm)milling cutter 10 mm (schaft 10 mm)milling cutter 12 mm (shaft 12 mm)milling cutter 16 mm (shaft 16 mm)

764 200781 152781 151771 020

Radius cutter HSSshaft 6 mmshaft 8 mm

771 030771 040

Angle cutter HSS, DIN 1833, shape A-60milling cutter 16 mm, shaft 12 mm 764 400Angle cutter HSS, DIN 1833, shape B-45milling cutter 164 mm, shaft 12 mm 771 050Shell end mill HSSfinishing and roughing teeth4020 mm, boring hole 16 mm 764 410Set of twist drills HSS25 twist drills 1-13 mm (in increments of 0.5 mm)9 twist drills 2-10 (in increments of 1 mm)

781 280260 628

Set of core hole drills HSS6 core hole drills 2.5-8.5 mm 271 230

Centre drill HSS6.8 mmA8, DIN333

573 770271 220

Set of taps HSS, DIN 352/3715 taps M3-M8 781 300

Taps HSS, DIN 352/371M3 (shaft 3.5 mm)M4 (shaft 4.5 mm)M5 (shaft 6 mm)M6 (shaft 6 mm)M8 (shaft 8 mm)M10 (shaft 10 mm)

781 301781 302781 303781 304781 305781 306

Description

DESCRIPTION

57

Characteristic curves atthe milling spindle

speed

Torq

ue

Pow

er

CHARACTERISTIC CURVES

Spindle 5000

speed

Torq

ue

Pow

erSpindle 10000

59

C Control PanelEMCO-specific

Key Description

SkipIn skip operation the program blocks that aremarked with a slash "/" before the block number,will not be executed in program run (e.g.: /N100).

DryrunIn dryrun operation the traversing movements willbe executed with the feed set in setting data"dryrun-feed" .The dryrun feed works instead of the programmedfeed.

Single Piece ModeWith this key you can select single piece mode orcontinuous operation in connection with anautomatic loading device.Power-on status is single piece operation.

Optional StopAt active function (key was pressed) the programrun will be stopped at blocks that contain thecommand M01.The screen shows "Halt: M00/M01 active". Con-tinue the program with the key NC Start.When the function is not active, M01 (in the partprogram) will be ignored.

CONTROL PANEL

60

KEY DESCRIPTION

Reference Key Pressing this key causes approaching the ref-

erence point in all axes. Initialization of the tool drum after an alarm.

NC StopAfter pressing the NC Stop key and takeover ofthe function by the control, working off of therunning part program will be stopped.You can continue working off by pressing NCStart.

Single BlockThis function allows to work off a part programblock by block.The function single block can be activated in AU-TOMATIC mode.Active single block mode causes: Display SBL1 at the screen (in the line channel). Display of "Hold: Single block mode" in the

message line (in interruption status). The actual block of the part program will be

worked off after pressing NC Start. Working off will be stopped after each block. The following block will be worked off after

pressing NC Start.Deselect the function by pressing again on thesingle block key.

Reset KeyActuating Reset causes: Stop of working off the actual part program. Alarms and messages are cleared with the ex-

ception of Power On or Recall alarms. The channel will be set to the reset status, that

means:- The NC control stays synchronous to the ma-

chine.- All intermediate and working memory is

cleared (the contents of the part programmemory stays resident).

- The control is in basic setting and ready forprogram run.

NC StartAfter pressing the NC Start key the selected partprogram will be started with the actual block.

CONTROL PANEL

61

KEY DESCRIPTION

Spindle StartBy means of this key the programmed spindlerun can be continued again.ProgrammingWinNC software descriptionDirections of rotationsee "Coordinate system" in chapter "B Des-cription".

Direction KeysUse this keys to traverse the NC-axes in the JOGmode.The keys "+4" and "4" are for the control of thefourth axis in "+" and ""-direction.

Feed StopThis key stops slide movements in AUTOMATICmode (not for threads).

RapidIf this key is pressed simultaneous to a directionkey the responding axis traverses in rapid feed.

Spindle StopThis key stops the running of the main spindleand driven tools.Before stopping the spindle you must stop theslides.

Feed StartThis key continues programmed, interrupted slidemovements.When spindle run was interrupted additionally firstthe spindle run must be continued.

Spindle OverrideThe actual spindle speed S is shown at the screenas absolute value and in percent.Valid for main spindle and driven tools.Setting range: 50 - 120 % of the pro-

grammed spindle speedStep width: 5 % per key touch100% spindle speed: 100% key.

CONTROL PANEL

62

KEY DESCRIPTION

Tool change manualOperating mode JOGThe drum turns on by one position.

CoolantThe coolant device can be switched on and/or offwith this key.ProgrammingM9, M2, M30, Reset key: coolant offM8: coolant on

Application of the coolant key Unless a coolant is programmed, coolant 1 is

switched on- Machine door closed:

permanent running of the coolant pump- Machine door open:

coolant pump runs until the key is pressed If the key is pressed during a program in

operation and with closed machine door (coolantpump runs), the run of the respective coolantpump is interrupted (control of machining).

With programmed coolant and open machinedoor (pump switched off) the respective coolantpump is switched on by pressing the key aslong as the key is being pressed (adjustment ofthe coolant nozzles).

Swivelling in opposite directionKeep key below the tool turret key pressed andadditionally press the tool turret key.The drum swivels from e.g. position 9 to position8.

Note:This function gets active only if after switchingon the machine, the tool position 1 wassurpassed in standard swivelling direction.

CONTROL PANEL

63

KEY DESCRIPTION

Clamping device (option)The machine vice is opened/closed with thesekeys.Via NC programFor M-commands see software description.

Swivel dividing device (option)This key permits manual swivelling of the dividingdevice in operation mode JOG.The dividing device swivels on by one position.Via NC programFor M-commands see software description.

Machine door (option)The chip guard door can be opened/closed withthese keys.Via NC program Closing the machine door is not possible via

the NC program. Opening is carried out automatically by pro-

gramming M00, M01, M30.

without function

Auxiliary OFFThis key switches off the auxiliary drives of themachine. Effective only at spindle and programstop.

Auxiliary ONThis key switches the auxiliary drives of the ma-chine to ready status (hydraulics, feed drives,spindle drives, lubrication, chip conveyor, cool-ant).The key must be pressed for approx. 1 second.Short pressing the AUX ON key is a quit functionand effects a lubrication impulse.

CONTROL PANEL

64

KEY DESCRIPTION

Mode Selection Switch

RefApproaching the reference point (Ref) in JOGmode.

AutomaticControl of the machine by automatic working offof programs.

EditWith the Sinumerik-control this key is without anyfunction.

MDA - Manual Data AutomaticControl of the machine by working off one blockor a sentence of blocks. The input of the blocksoccurs via operation panel.

Jog - Manual traverseConventional traversing of the machine by con-tinuous moving of the axes via direction keys orvia incremental moving of the axes via directionkeys or via handwheel.

Teach InWith the Sinumerik-control this key is without anyfunction.

Inc 1 - Incremental FeedTraverse incremental value with fix step width of1 increment.

Inc 10 - Incremental FeedTraverse incremental value with fix step width of10 increments.




ReposNo function

CONTROL PANEL

65

KEY DESCRIPTION

Key switch special operationFor the function of the key switch see chapter "BDescription" under "Safety devices".

Feed Override SwitchThe rotary switch with engaging-positions allowsto alter the programmed feed F (meets 100 %).The selected feed value F in % is displayed atthe screen.

Setting range:0 % to 120 % of the programmed feed.In rapid feed 100 % will not be exceeded.

EMERGENCY OFFActuate the red button only in emergency situa-tions.

Effects:Normally all drives are stopped with maximumdeceleration by EMERGENCY OFF.Unlock: Pull out buttonTo continue press the following keys:RESET, AUX ON, OPEN and CLOSE door.

Danger:Active special operation increases the dan-ger of accidents.The key must be used only by authorizedpersons, who have the knowledge about thedangers and are careful in operation.Keep the chip guard door closed also duringsetup operation.

Take off key always after working in specialoperation (danger of accidents).

Observe the local safety regulations (e.g.:SUVA, BG, UVV ....).

CONTROL PANEL

66

KEY DESCRIPTION

Consent key Opening the chip guard door Axis movements via direction keys and tool

turret movements with open door are admittedby pressing the consent key (prerequisite keyswitch in position SET UP).

no function

Additional Key Clamping DeviceThis key has the same function as on the machinecontrol panel.(Double equipment for better comfort).

Main SwitchFunction:0 - OFF1 - ON

The main switch has no emergency off function,that means the drives run out (unbreaked).The main switch can be locked (unauthorizedoperation of the machine).

CONTROL PANEL

67

TXDRXD

GNDDSRCTSRTS

RI

DTR

SH

CD

SERIAL INTERFACE

Maximum Cable LengthThe maximum cable length depends the bit rate.

Standard Values9 600 bd ................................................ max. 10 m19 200 bd ................................................ max. 7 m38 400 bd ................................................ max. 5 m

Attention: Don't overshoot maximum cable length! Don`t use schield for signal ground GDN!

Connection to PCThe plug load you see in the plot beside.

plug connection25-poles

female connection,9 poles

machine side PC-side

Cable connection machine-PC

Serial interface - occupation

Signal namesSH SchieldingTXD Transmit dataRXD Receive dataRTS Request to sendCTS Clear to sendDSR Data send readyGND GroundCD Carier identificationDTR Data terminal readyRI Ring indicator

Serial InterfaceThe 25-pin sub-D-jack ist mounted laterally onthe operatiom panel.Pin occupation: identical with system Sinumerik800

69

D Maintenance of the MachineSurvey

Danger: All maintenance work may only be carried

out with the machine switched off. Pay attention to the maintenace instructions

in the enclosed manuals in chapter "E Addi-tional Instructions"!

central lubrication

manual lubricat

concept mill 155 en beschr a

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