emco concept turn 60 pc-controlled lathe for...
TRANSCRIPT
EMCO Maier Ges.m.b.H.
P.O. Box 131
A-5400 Hallein-Taxach/Austria
Phone ++43-(0)62 45-891-0
Fax ++43-(0)62 45-869 65
Internet: www.emco-world.com
E-Mail: [email protected]
Translation of Original operating instructions
EMCO Concept Turn 60PC-controlled lathe for training
Description of the machineEMCO Concept Turn 60
Ref.-No. EN 1060Edition A2013-09
These instructions are also available at any time on request as electronic copy (.pdf).
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EMCO MAIER Gesellschaft m. b. H.Technical Documentation DepartmentA-5400 HALLEIN, Austria
Preface
All rights reserved. Copying only with permission from EMCO MAIER© EMCO MAIER Gesellschaft m. b. H., Hallein/Taxach - Austria
For over five decades, EMCO has been developing metal machining machines and has been a successful player since 1980 with computer-controlled machine tools (CNC machines), in particular in the training sector.
The lathes and milling machines in the EMCO Concept TURN and EMCO Concept MILL have profited from this immense body of experience.The newly designed compact machines comply totally both in design and construction and in safety with today's requirements.
Concept machines are controlled via a conventional Personal Computer (PC). This type of use facilitates efficient training on a wide variety of CNC controllers (Siemens, Fanuc, etc.) with but a single machine.The CNC monitor for the installed CNC controller is simulated on screen, with the data being entered via a keyboard, exchangeable depending on the controller in each case.
Because our machines are used in industry throughout the world, we have a comprehensive service network.Service technicians on call immediately, telephone service and a 100% spare part supply system, as well as a 10-year supply guarantee is something we perceive as obvious.
You can stay abreast of any special new developments (e.g. clamping options for workpieces or tools, new software applications, etc.) and determine whether they can be retrofitted from our distributors, of whom there over 100 throughout the world.
In these operating instructions are a complete description of safety rules, transport, instal-lation, handling and maintenance of the machine.Accordingly, read these instructions through completely before operating the machine.
EC compliance
The CE symbol, together with the EC compliance declaration, certifies that the machine and instructions comply with the directives under which the products are covered.
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Content
ContentAdequate use .............................................................................7
Warranty terms for new EMCO machines .................................8
Safety Regulations .....................................................................9Fire and explosion protection ...............................................11
Prevention ........................................................................11Firefighting measures .......................................................11
Awareness ............................................................................13
Technical Specification for the machine ..................................15PC configuration ...................................................................17
EC Declaration of Conformity ..................................................19
A Setting up the machineMachine takeover .....................................................................21
Machine number and electrics number ...............................21
Deliverables ............................................................................ 22Basic machine ..................................................................... 22Modules ............................................................................... 22Data medium ....................................................................... 22Packaging ............................................................................ 22
Transporting the machine ........................................................23Transport without machine base ..........................................23Transport with machine base (option) ..................................24
Set-up plan, machine dimensions ...........................................25Basic machine ......................................................................25Machine with base (option) ..................................................26
Set-up criteria ...........................................................................27Installation area ....................................................................27Ergonomics ..........................................................................27Machine without machine base ...........................................27Machine with machine base (option) ...................................28
Foundation requirements .................................................28Setting up with steel plates ..............................................28Setting up with levelling elements ....................................28
Additional Set-up Criteria .....................................................29
Electrical connection ............................................................... 30Set the mains voltage .......................................................... 30Mains connection specification ............................................31
Machine-PC connection ..........................................................31
Initial Start-up ...........................................................................32
Switching On/Off Process....................................................... 33Switch the machine on ........................................................ 33
Reference the axes individually ...................................... 33Reference automatically.................................................. 33
Switching the machine off ................................................... 34
B Machine DescriptionMachine Elements- Overview ................................................. 35
Points on the machine - coordinate system ........................... 36Machine zero point M ...................................................... 36Reference point R ........................................................... 36Workpiece zero point W .................................................. 36Workpiece housing reference point N (T) ....................... 36
Safety equipment .....................................................................37EMERGENCY-OFF key ........................................................37Door-locking system.............................................................37Key switch ........................................................................... 38
"Automatic" setting .......................................................... 38"Set-up mode" setting ..................................................... 38
Enable button ...................................................................... 39Functions of the Enable key ............................................ 39
Machine working area ............................................................. 40
Machine base ...........................................................................41
Machine bed .............................................................................41
Carriage ...................................................................................41
Carriage drives .........................................................................41
Main drive .................................................................................41
Main spindle .............................................................................42
Tool turret ................................................................................ 43Clamping the tools and aligning at tip height ...................... 43
Outer machining tools ..................................................... 43Inner machining tools ...................................................... 44
Tailstock (option) ..................................................................... 45
Clamping devices .....................................................................47Overview ..............................................................................47The 3-jaw turning chuck ...................................................... 48
Mounting the chuck ......................................................... 48Clamping ranges ............................................................. 48
The collet chuck device........................................................49Mounting the collet chuck device .....................................49Mounting collet chucks .....................................................49Removing the collet chuck ...............................................49Clamping workpieces .......................................................50Clamping ranges ..............................................................50
Tools and accessories .............................................................51Turning tools .........................................................................51HM cutting inserts ................................................................51Drilling tools ..........................................................................52Tailstock accessories ...........................................................52Accessories for tool turrets ..................................................52
Technological data .................................................................. 531. Cutting speed V ............................................................... 532. Speed S ........................................................................... 533. Feed F ............................................................................. 53Summary ............................................................................. 53Finding the speed ................................................................ 54Recalculating the feed ........................................................ 55
Speed-torque characteristic curve ..........................................56
C Machine maintenanceMaintenance overview - graphic illustration ........................... 58
Maintenance overview - Table .................................................59
Recommended lubricants ........................................................59
Unprotected parts ................................................................... 60
Hoses and lines....................................................................... 60
Clamps (option) ....................................................................... 60
Spindle nuts .............................................................................61
Roller guides ............................................................................61
Check the EMERGENCY OFF key ...........................................62
Tailstock (option) ......................................................................62
Main drive belt ......................................................................... 63Exchanging the main drive belt ........................................... 63
Pneumatic servicing unit (option) ........................................... 64water separator ................................................................... 64
Viewing plates ......................................................................... 65
Spare Parts List
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AdequAte use
Adequate use
The Concept Turn 60 machine is intended for turning machinable metals (alu-minium, brass, mild steel) and machinable plastics.Machining other materials is not permitted, or in special cases must take place only after consultation with the manufacturer.
Proper use also includes compliance with the operating and maintenance in-structions issued by the manufacturer.
The machine must be used only by those persons who have been entrusted with its operation, maintenance and repair and have been instructed in the dangers.
All accident prevention and safety instructions for working on machine tools must be obeyed at all times.
If the machine is used improperly, any liability on the part of the manufacturer will be inadmissible and the user alone will bear responsibility.
When installing the machine in a complete system, or if other changes are made to the machine, the system or machine is to be brought into compliance with CE regulations and their associated guidelines and instructions before start-up. Start-up before this is explicitly forbidden.
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WArrAnty terms
1. The warranty period for new EMCO machines is 12 months, with no limit on the hours run, from delivery of the machine by EMCO or its authorised dis-tributor. If EMCO or its authorised distributor also carries out the installation, the warranty begins to run from completion of the machine's installation.
If the installation is delayed for reasons for which EMCO or its distributor are not responsible, the warranty ends 12 months after the scheduled installation date.
2. The warranty includes the rectification of all material and design faults which impair the proper functioning of the machine.
3. Defects occurring are to be reported to the EMCO distributor or to the nearest EMCO service agency without delay, with a detailed description of the fault in writing or orally, with subsequent confirmation in writing.
4. Properly reported defects covered by the warranty will be resolved free of charge by rectification of the fault or delivery of a spare part for the customer; defective parts are to be returned to EMCO or its distributor on request. The customer is to bear the costs and risks of this despatch.
5. The warranty period for spare parts is six months from delivery or installa-tion, but in cases of repeated claims under this warranty only the deliverables provided for the first claim are covered.
6. Warranty claims are inadmissible for faults that are caused by: Failure to obey the operating instructions, safety and licensing regulations
or other instructions related to the delivery, set-up, commissioning or use of the machine, inappropriate or improper use, faulty installation or commis-sioning, as well as independent interventions or changes by the customer or by a third party that are not explicitly ordered or permitted, fair wear and tear, defective or negligent handling, chemical, electro-chemical or electrical factors, inadequate energy supplies and force majeure.
7. The customer is to bear the costs for services that are not provided under warranty.
Warranty terms for new EMCO machines
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sAfety regulAtions
Safety RegulationsRead instructionsRead the instructions through completely before operating the machine.Before beginning work, familiarise yourself with all functions and control elements.During work, it can be too late.
Set up and connect machineThe minimum set-up area (see set-up plan) as well as adequate access or escape routes for support in the event of unforeseen events must be available.The foundation requirements and the compressed air and electrical supply must be guaranteed in accordance with the operating instructions.Only a certified electrician should connect the machine to the mains.
Observe local regulationsAlways observe local regulations when connect-ing the machine to the mains and when working with machine tools and CNC machine tools.
Authorised UseThe machine may only be operated by authorised persons.Authorised persons are exclusively those who are entrusted with its operation, maintenance and re-pair and who have been instructed in the dangers.
Securing machinesSecure the machine against unauthorised start-ing, especially during adjustment, maintenance and repair work (lockable master switch).
Start-upBefore starting the machine, make certain that it is in a properly maintained condition, and that no safety devices have been altered or removed.
Tool change - working areaOnly change tools when the machine is off.Risk of injury - sharp tools.Do not use blunt or damaged tools!Use only tools and locking bolts with an O-ring on the shaft and always lock all stations (otherwise, there is a risk of coolant and chips penetrating into the tool turret).Always turn power tools into an engaged position when changing tools.
Do not change machineUnauthorised changes to safety devices, over-rides of monitoring equipment, as well as any interventions in the electrical/electronic area are forbidden.These devices have been installed for your own safety. By removing them you exposed yourself and others to a sharply increased risk of acci-dents.
CleanlinessAlways keep workplace and machine in a clean condition. Clear floors that are contaminated with oil and coolant. You could slip.Clear away parts that are lying around. You could stumble.
EMERGENCY SHUTDOWN in a danger situ-ationIn danger situations, the machine must be stopped immediately with the EMERGENCY SHUTDOWN switch.
It is mandatory to report failures caused by the control system which lead to personal injuryThe machine is fitted with electronic safety systems. These systems employ mature tech-nology. However, should errors occur, such as an axial drive or axial accelerations exceeding programmed speeds, these must be reported to the manufacturer in writing immediately.
Personal safety equipmentDo not wear loose work clothing. Take care that work clothing fits tightly around the hips and wrists.Ensure that your hair does not get caught in the machine (wear headdress).Protect your eyes with safety goggles.When removing chips, use a chip hook and pro-tective gloves.Wear protective gloves. Workpieces etc. may slip from the hand.Wear protective gloves; tools, workpieces and machine parts can become very hot.
No protruding partsTo keep the risk of injury as low as possible, clamped workpieces/bar materials should not protrude beyond the machine cladding.The prohibition plate on the machine must not be removed!
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sAfety regulAtions
Set-up, Maintenance and Adjustment WorkAny set-up, maintenance and adjustment work may only take place when the machine is switched off and the EMERGENCY SHUTDOWN switch thrown.Observe the inspection and maintenance regula-tions for the machine and its accessories.When using laser measuring equipment, it is essential to obey the manufacturer's regulations and instructions.Observing inspection intervals saves you money, prevents long outages, reduces the danger of ac-cidents and protects the environment.
Noise stressHigh frequency vibrations and therefore high noise stress (e.g. thin-walled workpieces) can oc-cur while machining workpieces - wear earmuffs.As a remedy, procure suitable clamping devices and/or change machining parameters.
Tools, Resources, Spare PartsOnly use tools, resources and original spare parts recommended by EMCO.EMCO assumes no liability for parts that it has not supplied.
Observe clamping pressuresToo high a clamping pressure damages work-piece and machine; if the pressure is too low, the workpiece is not clamped securely.This also increases the risk of injury for the user!
Disposal of Difficult WasteIn dealing with auxiliary and environmental resources (coolant lubricant agents, cleaning agents, lubricant oil, etc.), observe safety and disposal regulations for the difficult waste con-cerned.Take the relevant precautions for legitimate stor-age, labelling and disposal.
In case of damageIn the case of collision or other damage, contact your representative immediately.In the event of complaints, claims, if there are any ambiguities and when ordering spare parts, always quote the machine number, the electrics number and the software version.
Machine supervisionNever leave running machines unsupervised.Before leaving the workplace, switch the machine off and secure it against unauthorised starting (lock the master switch and remove the key).
Safety key for• Key Switch Special Operations Mode• Data protection key switch• Switchgear cabinet and terminal box• Padlock for master switchare only to be safeguarded by authorised persons who have appropriate training and the required knowledge of the dangers of such machines, and exercise appropriate caution.
Danger, Attention, NoteAlways observe the accident prevention and safety instructions mentioned in the individual chapters.Important information which concerns technical safety and operator protection is always specially highlighted:
Danger:relates to a possible risk to people during work and operational procedures.
Caution:appears next to work and operational pro-cedures which must be observed exactly in order to prevent possible damage to the ma-chine or minor injury to the operator.
Instructions:will be given if there are special precautions to be observed when carrying out a certain activity.
Environmental note:relates to the avoidance of hazardous waste, responsible handling of environmentally-damaging substances, as well as ways of economising on auxiliary and operational resources.
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sAfety regulAtions
Fire and explosion protection
Various greases, lubricants and coolants are required to operate the machine.
If these resources are used incorrectly or not in accordance with the regulations, these can catch fire.Fires or even explosions may occur, with serious injuries and damage to humans and the machine.In addition, toxic oxides of carbon, nitrogen, sul-phur and phosphorus, as well as toxic organic and inorganic substances are generated during combustion.
Prevention• In theory, you should use water-miscible cool-
ants in the right mixing ratio, because with these the risk of ignition is very low to negligible.
• When machining slightly inflammable materials with coolants that are immiscible with water, the machine is to be equipped with explosion valves and fire extinguishing systems (on request).
• Use all resources only in accordance with the manufacturer's instructions.
(operating area, mixing ratio, machining materi-als)
• Do not mix resources with each other. (physical and chemical properties may be
changed by this).
• Clean the machine regularly and thoroughly. (coolant and lubricant residues, etc.)
• Instruct users of the machine regularly in the risks.
Firefighting measures• Isolate the machine from the mains
• Individual protection equipment: Protective overalls and breathing apparatus
• Suitable fire extinguishers Foam, CO2, powder, no water
Ensure that there is an approved and checked fire extinguisher near the machine.
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sAfety regulAtions
InstructionsThe Safety Regulations chapter is to be presented to all those who are involved with the operation, servicing and repair of this machine. The regulations must be read, un-derstood and this confirmed in writing.The machine description must also have been read and understood.
ConfirmationsI hereby confirm that I have been briefed on the
• safety regulations for this machine• special safety regulations in the individual chapters of this machine description under
the heading "Danger, Caution, etc."• Proper use• special sources of risk on this machine (suspended loads, strong magnetic fields,
etc.)• duty to report to the manufacturer of the machine any kind of dangerous fault con-
nected with the control unit
and am aware of these.
Name Department Date Signature
_____________________ ___________________ _________ ________________________
_____________________ ___________________ _________ ________________________
_____________________ ___________________ _________ ________________________
_____________________ ___________________ _________ ________________________
_____________________ ___________________ _________ ________________________
_____________________ ___________________ _________ ________________________
_____________________ ___________________ _________ ________________________
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_____________________ ___________________ _________ ________________________
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teChniCAl speCifiCAtion
Technical Specification for the machine
We reserve the right to make technical changes!If information differs from the technical specification, the values given in it prevail!
Work areaRevolving diameter over bed [mm] ø130Revolving diameter over plane carriages [mm] ø60Maximum turning diameter [mm] ø60Maximum part length [mm] 215
Traversing rangesCarriage traverse X [mm] 60Carriage traverse Z [mm] 280
Main spindleSpindle connection according to the factory standardSpindle boring [mm] ø16Chuck diameter (manual chuck) [mm] ø74Penetration into chuck [mm] ø15Penetration into chuck [mm] ø15
Main spindle driveAC asynchronous motor, max. output (30% ED) [kW] 1,1Rated motor speed [rpm] 1400Spindle speed range [rpm] 300 – 4200Max. torque (30% ED) [Nm] 10
Feed drives3-phase stepped motor, resolution [µm] 0,5Task feed in X/Z, continuously variable [mm/min] 0 – 2000Rapid traverse speed in X/Z [mm/min] 3000max. feed force in X/Z [N] 1000average position variation range according to VDI 3441 in X/Z [µm] 8 / 8
Tool turretNumber of tool positions 8Tool housings inside/outside 4 / 4Max. tool cross-section [mm] 12 × 12Max. shaft diameter for drill rods [mm] ø10
Lubrication systemGuideways Greasing systemother lubrication points on the machine Greasing system
Hand-operated tailstock (option)Quill diameter [mm] ø22Quill travel [mm] 35Quill inner cone MK 1
Automatic tailstock (option)Electromechanical tailstock with end position monitoringQuill travel [mm] 15
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teChniCAl speCifiCAtion
We reserve the right to make technical changes!If information differs from the technical specification, the values given in it prevail!
Pneumatics unit (option)Basic pneumatics unit with filter and oiler for automatic clamp and automatic door systemSupply pressure [bar] 6Hose connection [mm] ø10Compressed air quality according to DIN ISO 8573-1, purity class 4
Automatic clamp (option)Pneumatic 3-jaw chuck with full clamping cylinder, pressure monitoring and blower deviceChuck diameter [mm] ø76
Automatic doors (Option)pneumatically operated, incl. end position monitoring
Operating conditionsrequired ambient temperature [°C] +10 to +35Atmospheric humidity [%] 40 to 70
Electrical connectionPower supply (plug-in) [V] 1/N/PE 115/230~Max. voltage fluctuations [%] ±10Frequency [Hz] 50/60Machine load connection value [kVA] 1,3Max. series fuse rating for the machine [A, gG] 13Short circuit resistance [kArms] 10Lead cross-section [mm²] min. 3 × 1.5
PaintworkLight grey RAL 7035Graphite grey RAL 7024Red RAL 3020Black RAL 9004
Dimensions/weightsHeight of rotating axis above hall (without machine base) [mm] 322Installation area W×D (without options) [mm] 895×745Height overall (with doors open) [mm] 600Total weight of the machine (without options) [kg] 150
Sound pressure levelaverage sound pressure level [db(A)] 65
under the following conditions:
Measuring procedure: Enveloping surface measurement procedure according to DIN 45 635Measuring point: 1 m distant and 1.6 m above the floorOperating status: Maximum speed under no load conditions
Declaration:The quoted figures are emission levels and not necessarily safe working levels. Although there is a correlation between the degree of noise emission and the degree of noise stress, this cannot be used reliably to decide whether further protective measures are required or not. Factors that affect the actual degree of stress on the occupants include the characteristics of the working area, other noise sources, etc., i.e. the number of machines and other processes running in the vicinity, as well as the duration for which an operator is exposed to the noise. The permitted stress level can also vary from country to country. However, this information should enable the user to make a better assessment of the dangers and risks.
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teChniCAl speCifiCAtion
We reserve the right to make technical changes!If information differs from the technical specification, the values given in it prevail!
PC configuration
Computer componentsConfiguration
minimum recommended
IBM or IBM-compatible processor 1 GHz 2 GHz
free hard disk space 400 MB
Working memory (RAM) 256 MB 32 bit - 1 GB64 bit - 2 GB
VGA graphics card, resolution min. 800×600
Operating system (32 or 64 bit) Windows XP (SP3)/ Vista/7/8 Windows 7/8
TCP/IP network card (machine connection to the PC) 10/100 MB, RJ45 plug
Screen 14" colour screen
Keyboard MF-2
2 USB interfaces for connecting the external keyboard (option
from USB 2.0 (2×) and higher
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Place, date:
Authorized person:
We hereby declare that the above mentioned product(s) is in accordance with the valid regulations of following terms:
- Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC;
- Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC;
Product: PC-controlled lathe for training
Machine data: Model Type No.EMCO CONCEPT TURN 60
Address of manufacturer: EMCO Maier GmbHSalzburger Strasse 80A-5400 Hallein
-
Bases of standards:
Name and address of the person authorised to compile the technical file:
EN ISO 14121-1:2007 EN ISO 13849-1:2008+AC:2009EN ISO 12100-1:2003+A1:2009 EN ISO 12100-2:2003+A1:2009EN 60204-1:2006+A1:2009 EN ISO 23125:2010+A1:2012
EC DECLARATION OF CONFORMITY REV.04en
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A Setting up the machine
Machine number (1) and electrics number (2)
Machine takeoverCheck the machine for any possible transport damage and for completeness of the delivery.If you detect a fault, please contact the dealer or insurance company immediately.
With complaints or repeat orders of replacement parts and accessories, the machine number, the electrical number, control console number and software version are always to be specified.
Machine number and electrics numberThe nameplate with the machine number (1) and the electrical number (2) are located on the side of the machine above the lockable master switch.The machine number is also stamped on the machine base.
Instructions:You will find the circuit diagrams applicable to your machine in the electrical documenta-tion, which is located in the machine switch-gear cabinet.An Electrical Documentation pack can also be purchased, quoting the following order num-bers and the EMCO electrical part number: ZVP 677 974
E-Doku.Ser.No.:Fabr.No.:Baujahr/Year of constr.:Made by EMCO MAIER Ges.m.b.H. Hallein/AUSTRIA
Concept Turn 60110/230VAC 1/N/PE 50/60HzImax=11 A Icw<=10 kArmsFuse for the supply lineFuse for the supply line 13A gG
A6D_V00
A6D 1336012013
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1
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set-updeliverAbles
DeliverablesBasic machineInclined bed lathe (1) with continuously variable main drive, 8x tool turret, ***chip bin***, chip guard cladding, safety package
ModulesGrab:
� USB stick with machine data (2) � Lathe tool documents: 8×0.2/4×0.5/4×1.0 (4) � Single open-ended wrench SW8 (3) � Allen key SW3, 4, 5, 8 (5) � Grease gun (6) � User handbook and electrical documentation (7)
Options: � Controller ..................................................... � Machine base � Swivelling table for machine base � Manual tailstock � Controller keypad with key module � 3-jaw manual chuck � Collet chuck � Electronic hand wheel
Automation: � I/O extension board � Pneumatics unit � Automatic doors � pneumatic power chuck � electromechanical tailstock � 5. Axis (rotary swivel unit) � Robotics interface � DNC interface
Data mediumA USB data stick with machine-specific data (MSD and PLC) is packed with the machine.It contains data specially for this machine and is needed for its configuration.This data must not be used on any other machine!
PackagingThe machine will be delivered bolted to awooden pallet (4 mushroom head bolts). The external packaging varies according to country of delivery and contractual agreement.After removing the 4 M12/SW 19 hexagonal nuts, the machine can be lifted from the pallet.
Machine with options, deliverables
1
2
3
4
7
5
6
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set-up trAnsport
Transport with lifting bars
Position of the forks (1) while transporting the machine
Transporting the machineTransport without machine base
Transport with pallet
1
2 3approx.
1200 mm
Caution:The machine should be transported on the pallet only if it is fastened to the pallet with all the anchor bolts.Also note the positions of the forks (1).
Caution:Ensure that the lifting angle is bolted firmly to the machine!
Lifting capacity ................................ min. 230 kgFork width ................................. 800 - 1 000 mmFork length ..................................min. 1 200 mm
Transport without palletThe machine is transported with suitable lifting bars (2), which are pushed through the lifting angles (3) on both sides of the machine.
Lifting capacity .................................min. 150 kgLifting bars ................... ø35 × approx. 1 200 mm
~230 kgwith pallet
kg ~150 kgwithout palletkg
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set-uptrAnsport
1
Transport with machine base (option)
Position of the forks (1) while transporting the machine with base (option)
Transport with pallet
Caution:The machine should be transported on the pallet only if it is fastened to the pallet with the anchor bolts.
Caution:The lifting points and fork dimensions must be observed, so that no distortion is caused to the machine pillars.
Lifting capacity .................................min. 310 kgFork width ................................. 800 - 1 000 mmFork length ..................................min. 1 200 mm
Transport without pallet
Lifting capacity ................................ min. 230 kgFork width .................................... 700 - 800 mmFork length ..................................min. 1 200 mm
Transport with forklift
~310 kgwith pallet
kg ~230 kgwithout pallet
kg
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set-up set-up plAn
Set-up plan, machine dimensionsBasic machine
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set-upset-up plAn
Machine with base (option)
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set-up set-up CriteriA
Set-up criteriaInstallation areaEnsure that the selected installation area is thor-oughly clean (free from excessive dust and similar contamination), in order to protect the machine, as well as the PC and peripherals.
The following criteria must also be met:
Room temperature ................................ 12-35°CAtmospheric humidity ............................ 40-70%
ErgonomicsThe machine facilitates ideal operation through its ergonomic design.However, ensure that there is adequate lighting when choosing the installation site.
Machine without machine baseThe machine must be installed on a stable base.Weight of the machine ............................. 150 kgIdeal table height ....................... approx. 750 mmInstallation width × installation depth .................1200 × 1200 mm
Climatic conditions at the installation site
Alignment of the machine
Danger:Ensure the load capacity of the table is com-patible with the weight of the machine!
1200×1200 mm
ca. 7
50 m
m
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set-upset-up CriteriA
±0°
Alignment of the machine
Setting up with steel plates or levelling elements
Machine with machine base (option)Order no. A7Z 210
Foundation requirementsThe machine should be set up on a base that is level as far as possible, with the corresponding load-bearing capacity and vibration stability.
Setting up with steel plates• Use the supports (2) enclosed with the machine
as a base.
• Align the machine horizontally on the setting screws (3).
• Fix the alignment by tightening the locknuts (1).
Setting up with levelling elements
To achieve a degree of vibration damping, we recommend the use of levelling elements (4).Order number (4 units required) .............F3Z 150
• Screw the setting screws (5) and locknuts (6) delivered with the elements into the machine pillars from beneath.
• Place the machine with the setting screws on the levelling elements (4) and align the machine horizontally.
• Fix the alignment by tightening the locknuts (6).
1 42 53 6
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set-up set-up CriteriA
Additional Set-up CriteriaAs well as the required load-bearing capacity and vibration stability, the set-up surface or place should fulfil some other requirements.
• The set-up area must comply with building regulations, so that any possible leakages of coolant, lubricating oil or hydraulic oil will not harm the environment.Ideally, the set-up area should also fulfil the function of a catch basin.
• Furthermore, the set-up area should be el-evated and well-aired.Observe workplace safety guidelines (permit-ted Maximum Workplace Exposure and TRK limit values should not be exceeded)
• The best possible vibration damping proper-ties, to limit the transfer of vibrations to neigh-bouring objects (especially with high speed work, bar work, work on workpieces that are seriously out of balance, for interrupted cut-ting, use of power tools, etc.).
• Good and adequate lighting in the workplace facilitates working with the machine and im-proves quality.
• Inconvenient light or sunshine can lead to reflections on the control screen and thus influence the visibility of the information.
• Attention should be paid to the special noise stress faced by those working on the ma-chine.
• It should be considered that, depending on the operational situation, a highly qualified techni-cian may be working at the machine, who will be required to carry out sophisticated program-ming and monitoring tasks.
Sometimes sound-absorbing walls can bring about an improvement in the situation.
Tests have shown that doubling the distance from a nearby sound source produces an at-tenuation of between 3 and 5 dB(A).
Doubling the number of equivalent sound sources leads to an increase in the level of 3 dB(A).
• Heat sources with fluctuating temperature close to the machine, as well as draughts, influence both the quality of the workplace and the working accuracy of the machine.If necessary, appropriate protective meas-ures should be taken.
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set-upeleCtriCAl ConneCtion
L1 1 2 3N NPE
=1+L1-X0 =1+L1-X1
230V~ 115V~
-X0
-X1
L N PE
1 2 3 1 2 3
Electrical connection
PG union on the machine
Switchgear cabinet and terminals
Danger:Only a trained electrician should connect the mains power to the machine and its acces-sories.The supply cable must be de-energised on connection.
Caution:It is essential to set the mains voltage before the machine is connected to the power supply so as to avoid damage to the machine!
Power supply Terminal strip = 1+L1-X1
230 V ~ Jumper (5) across terminals 1 and 2
115 V ~ Jumper (5) across terminals 2 and 3
• Thread the mains lead (3×1.5 mm², not included in the machine as delivered) (6) through the PG union (2) on the side of the switchgear cabinet (1).
• Connect the Live phase to the terminal strip = 1+L1-X0 (3) (terminal L1)
• Connect the neutral lead to the terminal N of the terminal strip +=1+L1-X0 (3).
• Connect earth wire (yellow/green wire) to the equipotential terminal on the terminal strip (3).
Set the mains voltage
The machine can be operated with 2 voltages - 115 V and 230 V.The setting is made with a bridge (jumper) on the terminal strip =1+L1-X1 (4):
5
3
4
5
6
1
2
1
2
31
set-up eleCtriCAl ConneCtion / ConneCtion With pC
Mains connection specification
Caution:A series fuse is mandatory for the machine!It is essential to obey the given fuse rating.
Power supply ............................. 1/N/PE ~ 230 V 1/N/PE ~ 115 VFrequency ........................................... 50/60 HzMax. voltage fluctuations .......................... ±10%Rated output ...........................................1.3 kVAMax. series fuse ................................... 13 A gGLead cross-section ................... min. 3 × 1.5 mm²
Instructions:Detailed information on the electrical con-nection is in the electrical documentation for your machine.If any information differs, the information from the electrical documentation is to be deemed correct.
Instructions:To connect the machine with the PC, a net-work card must be inserted into the PC and installed correctly.For insertion, installation and network set-tings, see WinNC controller description, "In-stallation" chapter.Card type: ............... Ethernet network card
Machine-PC connectionThe machine is controlled from a PC.Either the PC keyboard, or the keypad controller available from EMCO as an accessory can be used as the data entry device.
• Plug the machine's mains cable with the plug (2) into the corresponding connection on the network card (1).
Machine-PC network card connection
1 2
32
set-upinitiAl stArt-up
Initial Start-up• All uncoated parts are to be cleaned of rust
protection agents with a clean cloth.
• Check all connections to the machine.
• Degrease the machine before starting up (see machine maintenance).
• Open the air supply at the valve (2) (option).
• Tool and workpiece must be tightly and securely clamped.
• Switch on machine at the master switch (1).
• See the switching on and off procedure for the machine, as well as the software description, for further use.
Master switch on the machine
Pneumatics unit (option) on the machine
Instructions:If the machine is no longer in use:
• Clean the machine thoroughly• Lightly oil uncoated parts.• Secure the machine against unauthorised
access (key switch on the control console, lockable master switch).
• Place a dust guard (packaging) over the machine.
After the machine is switched off for a long period, all activities that are described under "Starting up for the first time" must be carried out.
2
1
33
set-up sWitChing on
Switching On/Off ProcessSwitch the machine onOpen the air supply (option).
Switch on the master switch (1) at the switchgear cabinet.
Open and close the chip guard door to check each of the door limit switches once and close again.
Hold down the "AUX ON" key for approx. 1 sec-ond.Pressing the "AUX ON" keys powers up all the drives.
Reference the axes individually
Pressing the +Z keyCarriage moves to the reference point in the Z axis
Pressing the +X keyCarriage moves to the reference point in the X axis(Only after the collision-free space in the Z axis has been reached).
Reference automatically
Pressing the "Reference point" key moves the axes automatically to their reference points one after another.
For further use of the machine, refer to your "Soft-ware Description".
Master switch
1
Instructions:After reaching the reference points the soft-ware limit switches are active.
"Alt + M" or
"6" or
"8" or
"5" or
34
set-upsWitChing off
Master switch
1
Switching the machine off
Press the AUX OFF key.
Ending the controller software (WinNC).
Ending Windows
Switch off the master switch (1)
Shut off the air supply.
Instructions:• The machine is switched off with the master
switch. � It is recommended that the machine is
switched off only with the tool turret idle.• Operations can be interrupted with the
Reset key. � RESET interrupts all running machine func-
tions.
"Alt + N" or
"0" or
35
B Machine Description1 2 3 4 15
7
8
9
6
5
10
1617
19
11
18
12
20
13
14
Machine Elements- Overview1. Chip guard doors2. 8x tool turret3. X carriage4. Z carriage5. Switchgear cabinet6. Machine nameplate7. Door opening button8. EMERGENCY SHUTDOWN button9. Key switch10. Machine master switch (lockable)11. Door-locking system
12. Spindle head13. Machine base14. Chip bin
Accessories/options15. Tailstock16. Easy Cycle comfort package17. Machine base with tool drawer and PC shelf18. Pneumatics, maintenance unit and valves19. Optical tool preset device20. Collet chuck
36
desCriptionpoints of the mAChine / CoordinAte system
Points on the machine - coordinate system
Machine zero point M The machine null point M is in the rotating axis on the front of the spindle nose.The machine null point is the origin of the coor-dinates system.
Reference point R The reference point is a specified fixed point on the machine. It is used to calibrate the measure-ment system.The reference point must be approached each time after the machine is switched on, in order to make the distance between the points M and N (T) known to the control system.
Workpiece zero point W The workpiece zero point W can be freely pro-grammed by the user.By programming a workpiece zero point, the ori-gin of the coordinate system will be shifted from the machine zero point M to the workpiece zero point W.
Workpiece housing reference point N (T)Distances to the tool tip are measured from this point.
The tool housing reference point N (T) is precisely on the front of the tool turret disk in the axis of the housing boring for inside machining tools.However, the housing boring must be swivelled.
Coordinates system
Points on the machine
M
RN(T)
W +Z
+X
+X
+Z
–S1
37
desCription sAfety equipment
Safety equipmentSafety equipment is built into the basic machine, meaning that its operation is free from risk to a considerable degree.
EMERGENCY-OFF keyThe EMERGENCY-OFF key (2) should be pressed immediately in a danger situation.On pressing the key (2), the power supply to the main drive, the feed motors and the auxiliary drives will be cut off immediately.To unlock the EMERGENCY-OFF key, turn the button clockwise.
Door-locking systemA door-locking mechanism (1) is built into the ma-chine, which only permits the chip guard doors to be opened if the main drive has stopped.A program cannot be started if a door is open.
Open the chip guard doors by pressing the Con-firm key "T" (4).
Danger:Safety devices must never be removed from the machine.Mechanical or electrical bypassing of the safety devices are also forbidden.
Instructions:After pressing the EMERGENCY-OFF key, the reference point must be approached again.
1
2 34
38
desCriptionsAfety equipment
Key switchThe key switch (3) can be switched to the posi-tions "Automatic" and "Set-up mode."
"Automatic" settingThe "Automatic" switch setting is the working setting of the machine in which all safety devices are enabled.
"Set-up mode" setting
Danger:• In the "Set-up mode" switch setting, there
is an increased risk of accidents.• In set-up mode, keep the machine door
closed insofar as the work process permits this.
• After conclusion of the set-up work, switch the key switch immediately to "Automatic" again and remove the key.
• The key should only be given to people who have the required knowledge of the dangers that exist and are familiar with the machine.
With the switch in this position, the carriages can be moved by hand with the chip guard doors open (for two-handed operation in conjunction with the Enable key - see next page).
Instructions:The carriage can only be moved by hand with the chip guard doors closed if:• the reference point was approachedor• if the key switch is in the "Setup mode"
position.
39
desCription sAfety equipment
Instructions:If the Enable key is held down for more than 40 seconds, then the function of this key is interrupted. The Enable key must then be released and pressed again.
Enable buttonThe function of the Enable key depends on the position of the key switch.
Position of the Enable key
Functions of the Enable keyKey switch position on "Automatic"
• Loosen the locking bolts of the chip guard doors with the main spindle stationary.
The machine doors can be opened.
Key switch position at "Set-up mode"
• Move the carriage in JOG mode with the un-reached reference point and the machine doors open.
• Manual movement of the carriage with the chip guard doors open.
• Swivelling the tool turret with the chip guard doors open (swivelling by one position respec-tively).
40
desCriptionWorking AreA
Machine working area
Turning circle at thetool turret
41
desCription mAChine Components
Machine baseThe machine base is a massive welded con-struction for housing the machine bed and all the electrical equipment.
Machine bedThe machine bed is manufactured from grey cast iron, extremely resistant to torsion and vibration-damping.Spindle stock, carriage unit and tailstock (option) are built on to the machine bed.
CarriageAll guides are formed as high quality precision roller guides, with high feed forces and high traverse speeds.Lubrication is via grease nipples with long-life grease.
Carriage drivesCarriages are moved with step motors via recir-culating ball spindles.Spindles of large dimensions, rigid spindle nuts and zero-play axial bearings produce high posi-tioning and working accuracy.
Feed speed ............................... 0-2000 mm/minRapid traverse speed.................... 3000 mm/minLongitudinal carriage travel ....................290 mmTransverse carriage travel .......................60 mmIncremental resolution .............................0.5 µmmax. longitudinal carriage feed force ...... 1000 Nmax. transverse carriage feed force ........ 1000 N
Main driveThe main spindle is driven by an asynchronous AC motor.
Speed range (continuous) ...........300 - 4200 rpmmax. output ............................................. 1.1 kWmax. torque ............................................. 10 Nm
1 2 3 4 5
6 7 8 9 10
Pos. Pos.1 Main spindle 6 Drive belt2 Z carriage 7 Main drive3 X carriage 8 Machine bed4 X spindle 9 Z spindle5 X drive 10 Z drive
42
desCriptionmAin spindle
Connection mass at the spindle nose (factory standard)
Main spindleThe main spindle is driven by an AC motor via a V-belt.It is mounted in sealed for life lubricated roller bearings and is therefore zero maintenance.
The clamp is tightened at the tapped borings provided for this purpose, according to the type of clamp.Clamps must have a centring flange.
Spindle connection ..................Factory standardMax. chuck size ........................................... ø74Speed range ...............................300 - 4200 rpmPower: ............................................ max. 1.1 kWTorque .............................................max. 10 Nm
43
desCription tool turret
Tool turretNumber of tool housings .................................. 8(4 outer and 4 inner machine tools in each case)
Maximum turning circle diameter
Turning tools ..................................... ø129.5 mmCutting tool ....................................... ø140.0 mm
Clamping the tools and aligning at tip heightBefore you clamp a tool, read in the WinNC soft-ware about using the tool turret via the PC.
Outer machining tools
tool turret
Clamping outer machining tools
Set tip height and tool protrusion
Instructions:Aids to setting the tip height are the dimen-sion "30 mm" between tool cutting edge and transverse carriage surface, or the centring tip in the main spindle or tailstock, or a clamped centring drill in the fitted triple-jaw chuck.
Danger:Tools should only be clamped with the ma-chine stationary.
A maximum of 4 outer machining tools can be clamped.
• Set the desired tool turret position.
• Place the tool (4) in the housing (1) and set the tool protrusion. The protrusion should be approx. 13.5 mm, and for cutting tools approx. 22 mm.
• Insert spacers (3) to set the tool at tip height.
• The tool is clamped by tightening the two lock-ing screws (2) with an Allen key SW3.
30
13,5-22
140
129.5
1 2 3 4
44
desCriptiontool turret
Inner machining tools1. Inner turning chisel
A maximum of 4 inner machining tools can be clamped.Required shaft diameter ........................ ø10 mm
• Push the inner chisel (1) into the housing boring (2) on the tool turret.
• Turn the chisel (1) so that the cutting edge of the turning chisel is exactly at turning axis height.
• Clamp the chisel (1) by tightening both locking screws (3) with an Allen key SW3.
2. Drilling tools
Maximum shaft diameter ....................... ø10 mm
• Push the clamping sleeve (5) with the corre-sponding interior diameter on to the borer (4).
• Plug the borer (4) with the clamping sleeve (5) into the tool turret housing boring (2).
• Clamp the borer and clamping sleeve by tight-ening both locking screws (3) with an Allen key SW3.
Should the tip height not match, then proceed as follows:
• Loosen the four Allen screws SW5 (6).
• Turn the tool turret disk (7) until the tip height of the boring tool corresponds.
• Retighten the four Allen screws (6).
• After setting the boring tools to tip height, all other clamped tools must be reset to the tip height.
Clamping the inner turning chisel
Clamping boring tools
Instructions:Aids to setting the tip height are the dimen-sion "30 mm" between tool cutting edge and transverse carriage surface, or the centring tip in the main spindle or tailstock, or a clamped centring drill in the fitted triple-jaw chuck.
1 2 3
4 5 2 3
6
7
45
desCription tAilstoCk
Tailstock
Tailstock (option)The tailstock is used to counter-support work-pieces with rolling particles and for boring and centring tasks.
Quill diameter ......................................... 22 mmQuill inner cone .......................................... MK1Quill travel ...................................... max. 35 mmQuill travel for 1 turn of the handwheel ......1 mm
The quill is moved via the handwheel (3). On the side at the quill is a millimetre scale (1) for setting the quill travel. The tailstock is clamped at the clamping lever (4) and the quill at the clamping lever (2).The quill inner cone houses the tailstock acces-sories, which are simply pushed into the cone. When the quill is turned back to the stop, the tool housed by the cone is ejected automatically.
Instructions:Always swivel the convertible clamping lever (2) after clamping the tailstock to the right, to avoid a collision with the tool turret.
1 2 43
46
Blank page
47
desCription ClAmping deviCes
Clamping devicesAll clamps given here are available as accesso-ries from EMCO.
Overview
Main spindle
The main spindle is manufactured in accordance with the factory standard. The chuck is mounted with 3 fixing screws on the housing threads (1) at the spindle nose, the chuck being mounted with 4 fixing screws on the housing threads (2).
Triple-jaw chuck ø74 mmMain spindle spindle nose
Triple-jaw chuck A6Z 630
Collet chuck A5Z 040
Order no. ............................................. A6Z 630It is used for central clamping of circular, hexago-nal and dodecagonal workpieces.
Collet chuck
Order no. ............................................. A5Z 040Collet chucks can clamp circular workpieces with maximum revolving accuracy. Collet chucks do not leave behind any clamping marks on the workpiece.
1
2
48
desCriptionClAmping deviCes
The 3-jaw turning chuckAlso, observe the instructions enclosed with the chuck.
Mounting the chuck
Danger:• The chuck should only be fitted when the
machine is stationary.• To mount the flange, only M5×12 screws to
DIN 912 should be used; the chuck should only be tightened with M5×35 screws.
� If the screws are longer, the chuck could not lie flush on the spindle nose and if the screws are too short these could tear out.
Danger:• The maximum permitted clamping ranges
must never be exceeded. Exceeding this can lead to the jaws breaking.
• The jaw protrusion must never be more than 7 mm, otherwise there is a risk of the jaws breaking.
• After clamping workpieces, pull out the chuck key.
• The spindle nose (1) and borings on the flange (2) and chuck (4) must be free from dirt.
• Screw the flange (2) with the three M5×12 cylin-drical screws (3) to the spindle nose and tighten the screws.
• Mount the chuck (4) with the M5×35 cylindrical screws (5) on the flange (2).
Clamping ranges
Mounting the chuck
Maximum clamping range of the 3-jaw turning chuck (data in [mm])
1 2 3 4 5
d5
d6
d7
d8
d9
d10
d11
d12
d13
d min.5 d max.6 d min.7 d max.8 d max.9 d min.10 d min.11 d max.12 d max.13
2 24 23 68 88 2 23 68 88
49
desCription sWitChing on
Mounting the collet chuck device
Mounting collet chucks
The collet chuck deviceAlso, observe the instructions enclosed with the collet chuck device.
Collet chucks can clamp circular workpieces with maximum revolving accuracy. Collet chucks do not leave behind any clamping marks on the workpiece.
Clamping range ............................. 1.5 to 16 mmCollet chuck type ...................................ESX 25
Mounting the collet chuck device
Danger:• The chuck should only be fitted when the
machine is stationary.• Only M5x10 screws to DIN 933 should be
used to fit the chuck. � If the screws are longer, the chuck could
not lie flush on the spindle nose and if the screws are too short these could tear out.
• The spindle nose (1) and the chuck boring (3) must be free from dirt.
• Screw the collet chuck device (3) with the three M5×10 cylindrical screws (2) to the spindle nose and tighten the screws.
Mounting collet chucks• Unscrew the locknut (5).
• Insert the collet chuck (4) in the clamp housing (5) at an angle, so that the eccentric ring (6) engages in the collet chuck groove.
• Screw the collet chuck with its clamping nut on to its holder.
Removing the collet chuck• Tighten the locknut (5).
• If the locknut is unscrewed, the eccentric ring (6) in the locknut presses out the collet chuck (4).
1 2 3
4
5
6
50
desCriptionClAmping deviCes
Clamping workpieces• Fit the appropriate collet chuck.
• Push the workpiece (5) into the collet chuck. Ensure that the workpiece is pushed far enough
into the collet chuck. If the clamping is too short, the workpiece can
be flung out of the device.
• Tighten the locknut (4) with the clamping pin (2). Resist the collet chuck holder (3) with the sec-
ond clamping pin (1).
Clamping ranges
Danger:The clamping ranges given in the table must always be observed.If collet chucks are too large, workpieces can-not be clamped securely.
1 2 3 4 5
Clamping workpieces
Nominal ø Collet chuck
Clamping range Order no.[mm] [inches
2.0 1,5-2,0 1/16-5/64 225 0202.5 2.0-2.5 3/32 225 0253.0 2.5-3.0 7/64 225 0304.0 3.0-4.0 1/8-9/64-5/32 225 0405.0 4,0-5,0 11/64-3/16 225 0506.0 5.0-6.0 13/64-7/32-15/64 225 0607.0 6.0-7.0 1/4-17/64 225 0708,0 7.0-8.0 9/32-19/64-5/16 225 0809.0 8.0-9.0 21/64-11/32 225 09010.0 9.0-10.0 23/64-3/8-25/64 225 10011.0 10.0-11.0 13/32-27/64 225 11012.0 11.0-12.0 7/16-29/64-15/32 225 12013.0 12.0-13.0 31/64-1/2 225 13014.0 13.0-14.0 33/64-17/32-35/64 225 14015.0 14.0-15.0 9/16-19/32 225 15016.0 15.0-16.0 10/16-5/8 225 160Complete set of collet chucks 225 000
51
desCription tools
Tools and accessories
Turning tools
HM cutting inserts
Tool no. Order no. Description
1 271 070 Side cutting tool right
2 271 050 Side cutting tool left
3 271 060 Side cutting tool neutral
4 260 630 Outer thread cutter maximum pitch 1.5 mm
5 271 170 Inner thread cutter ø10x60 mm maximum pitch 1.5 mm
6 271 140 Boring bar ø10x60 mm
7 264 020 Cutting mount
HM plate Order no. Description matching tool no.
260 610271 056
Set of 10 HM cutting inserts for steel Set of 10 HM cutting inserts for aluminium 1, 2, 3, 6
260 631 Set of 5 HM cutting inserts for outer threads, maximum pitch 1.5 mm 4
271 175 Set of 5 HM cutting inserts for inner threads, maximum pitch 1.5 mm 5
271 086 Set of 5 HM cutting inserts for cutting mount 7
52
desCriptiontools / ACCessories
Description Order no.
Set of HSS [high-speed steel] spiral drills9 spiral drills ø2-10 (1 mm steps) 260 628
HSS spiral drillsø12 mm, extra short A6Z 050
HSS centring drillsø6.8 mmA8, DIN333
573 770 271 220
Description Order no.
Reducing sleeves8 reducing sleeves ø2 to ø9 mm for clamping drills. A6Z 270
Drilling tools
Tailstock accessories
Accessories for tool turrets
Description Order no.
Rolling particles MK1Rolling particles 3x mounted to counterbalance longer workpieces.
A5Z 260
53
desCription teChnologiCAl dAtA
Technological data
D [mm] · π · S [rpm]1000V [m/min]=
V [m/min] .......... Cutting speedD [mm].............. Workpiece diameterS [rpm] ............. Main spindle speed
The maximum permitted cutting speed is depend-ent on:
• Workpiece material The higher the material rigidity, the lower the
cutting speed.
• Turning chisel material Hard metal tools allow higher cutting speeds
than HSS tools.
• Feed size The larger the feed, the lower the cutting speed.
• Chip depth The higher the chip depth, the lower the cutting
speed.
Cutting speed for programming exercises on
V [m/min] · 1000D [mm] · πS [rpm]=
The main spindle speed can be calculated from the cutting speed and the workpiece diameter.
the EMCO Concept Turn 60:
Workpiece material: ..... ***Automat aluminium***Turning chisel: ..................................Hard metalCutting speed - turning: ..............150-200 m/minCutting speed - cutting: ................. 60-80 m/minFeed size - turning: ................... 0.02-0.1 mm/revFeed size - cutting: ................. 0.01-0.02 mm/rev
3. Feed FThe feed F is programmed on the EMCO Concept Turn 60 in [mm/min].
F [mm/min] = S [rpm] · F [mm/rev]
F [mm/min] ....... Feed in [mm/min]F [mm/rev] ........ Feed in [mm/rev]S [rpm] ............. Main spindle speed
Summary
Cutting speed
Speed calculation
Feed calculation
The tables on the next page will save you a cal-culation task.
1. Cutting speed V 2. Speed S
54
desCriptionteChnologiCAl dAtA
5 10 20 30 40 50 100 2003
5
10
20
30
40
50
100
200
300
400
500
1000
4000
300025002000
1500
1000
750
500
350
200
150
100
60
Finding the speed
π⋅⋅
=d
v1000n
n [rpm] ......................rpmv [m/min] ......................Cutting speedd [mm] ......................Turning diameter
Speed n [r
pm]
Turning diameter d [mm]
Cut
ting
spee
d v
[m/m
in]
55
desCription teChnologiCAl dAtA
200 500 1000 2000 30001000,01
0.02
0.05
0.1
0.15
0.2
4000
10
30 50 70 100 20
150 200
300 400
Feed speed FV n [mm
/min]
Speed n [rpm]
Feed
F [m
m/r
ev]
Recalculating the feed
ExampleGiven:
• Main spindle speed ....................... n=1700 rpm• Feed ........................................ F=0.06 mm/rev
Wanted:
• Feed speed.................FV= approx.100 mm/min
56
desCriptionteChnologiCAl dAtA
Speed-torque characteristic curve
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
9,0
10,0
11,0
12,0
0 500
n [min-1]
M [Nm]
1000 1500 2000 2500 3000 3500 4000 4500
rpm
Torq
ue
57
C Machine maintenance
Danger:• All repair and maintenance tasks may only be carried out with the machine
switched off.• Ensure that while this is in progress the machine is secured against start-
ing, e.g. the master switch is barred with a personal padlock.• After repairs and servicing, the machine should only then be switched on
if all cladding plates are fitted.• Never clean the machine with compressed air, as chips may penetrate the
guide rails and damage these!
• Maintenance overview - graphic illustration ............................ 58
• Maintenance overview - Table ................................................ 59
• Recommended lubricants ...................................................... 59
• Unprotected parts .................................................................. 60
• Hoses and lines ..................................................................... 60
• Clamps (option) ..................................................................... 60
• Spindle nuts .......................................................................... 61
• Roller guides ......................................................................... 61
• Check the EMERGENCY OFF key ......................................... 62
• Tailstock (option) ................................................................... 62
• Main drive belt ....................................................................... 63
• Pneumatic servicing unit (option) ........................................... 64
• Viewing plates ....................................................................... 65
58
mAintenAnCeovervieW
4 2
76
11
8
109
9 10
13
5
12 5 years
500 hours
500 hours
8 hours
8 hours
40 hours
40 hours
Cleaning,exchange if necessary
grease (via grease nipples)
exchangecheck,exchange if necessary
oil
59
mAintenAnCe overvieW/reCommended lubriCAnts
Observe the maintenance notes in the manufacturer's instructions enclosed with the individual machine components and the safety data sheets for the resources. These are enclosed with the machine.
No. Object of inspections and maintenance Activity Interval [h]
1 Clean chip area and chip bin
82 Door plate: check for damage
3 Clean clamp
4 Pneumatics option: Check the condensate separator
5 Check all hoses and lines
406 Clean and oil unprotected parts on the machine
7 EMERGENCY SHUTDOWN button: Check function
8 Option: Oil tailstock quill
9 Roller guides (X/Z spindles): Grease grease nipples
50010 Spindle nuts (X/Z spindles): Grease grease nipples
11 Main drive: Check belt
12 Door plate exchange 5 years
Recommended lubricants
Use Designation according to DIN Recommendation
• unprotected parts• Collet chuck• Tailstock
Slideway oil:CGLP DIN 51502 ISO VG 68
BPCASTROLJOKISCHKLÜBERMOBILOMVSHELLTRIBOL
Maccurat D 68Magnaglide D 68BBÖ 68Lamora D 68Vactra 2Glide 68Tonna S681060/68
• Spindle nuts• 3-jaw chuck
Grease:DIN 51804/T1 NLGI 2DIN 51807-1
EMCOHAINBUCHKLÜBERMOLUB ALLOYOMVRÖHMSHELLTRIBOL
Slide pasteUniversal grease 2085/0003Altemp Q NB 50Topfit 3284Signum LMF 80Retinax HDX 24020/460-2
• Roller guidesGrease:on lithium soap baseNLGI 2
CASTROL Spheerol EPL 2
• Compressed air oiler Pneumatic oil:DIN 51524 ISO VG32
CASTROLMOBIL
Magnaglide D 32HLP 32
60
mAintenAnCeunproteCted pArts / lines / ClAmps
Unprotected parts such as cover plates and fin coverings are to be cleaned weekly.Then oil the parts lightly with slideway oil.
Unprotected parts
Clamps (option)Clamps (collet chucks, jaw chucks) are to be cleaned daily of chips and other dirt, in order to guarantee ease of access and thus secure clamping.
Hoses and linesTo improve operating safety, a visual check for leaks should be made at regular intervals (roughly every six months) of the hose surfaces for all pneumatic lines, as well as all electrical power lines.To do this, remove the corresponding cladding plates and check whether a hose/line has failed or is moist or damaged anywhere.
Danger:Parts in the working area of the machine should only be cleaned and oiled if the ma-chine is idle.
Danger:• Damaged lines/hoses are to be replaced
immediately by authorised technicians!• Ensure that pneumatic lines are depressu-
rized (bleeding)• Work on the electrical system is allowed
only when the machine has been switched off and isolated from the mains!
• Lightly oil unprotected parts• Check hoses and lines
Clean
Machine working area
Instructions:Also observe the instructions enclosed with the relevant clamp!
61
mAintenAnCe spindle nuts / guides
Spindle nutsLongitudinal and transverse spindles are recir-culating ball spindles produced to the highest standards.Accordingly, ensure that spindle nuts are greased regularly to avoid damage.
Lubrication interval .........................500 hoursLubrication .................via grease nipples (2, 3)Grease ............. see lubricant recommendations
• Remove carriage cover (1).
• Greasing the X spindle nuts via the grease nip-ples (2)
• Greasing the Z spindle nuts via the grease nip-ples (3)
• Refit the carriage cover (1).
Roller guidesLongitudinal and transverse carriages run in pre-cision roller guides.These must be greased at regular intervals
Lubrication interval .........................500 hoursGreasing ..............................via grease nipplesGrease ............. see lubricant recommendations
• Remove carriage cover (1).
• Greasing the X guide via the grease nipples (4)
• Greasing the Z guide via the grease nipples (5)
Grease nipples for spindle nuts
Grease nipples for roller guides
Machine working area
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2
3
4
5
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mAintenAnCeemergenCy off key / tAilstoCk
Check the EMERGENCY OFF keyFor safety reasons, you must check the function-ing of the emergency shutdown button monthly:To do this, press the EMERGENCY OFF key and then clear the EMERGENCY OFF condition in each case.If an alarm is triggered when an EMERGENCY OFF state is induced, the machine safety is no longer guaranteed.No further work can be performed with this machine until it has been repaired by a service engineer.
Example:
- Press the EMERGENCY OFF key- Unlock the EMERGENCY OFF key- RESET- AUX ON- Open and close the machine door . . .
Tailstock (option)• Clean the tailstock quill (2) regularly and mois-
ten lightly with slideway oil.
• Clean the quill inner cone (1) thoroughly.
EMERGENCY OFF key on the machine
Tailstock
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mAintenAnCe mAin drive belt
Cover for spindle stock and belt
Main drive beltThe main drive belt should be checked at least every six months for condition and tension.If there are signs of wear, the belt should be changed immediately.
Belt ................................ Poly-V belt 864 PJ4Order no. .....................................ZRM 800 864
Exchanging the main drive belt• Remove the left machine cover (1).
• Loosen all 4 locking screws (2).
• Loosen the setting screw SW17 (4) to a point where the drive belt (3) can be removed.
• Replace the drive belt (3) with a new belt.
• Tension the belt using the setting screw (4). The tension must be set so that the belt can
be depressed between the two belt disks by approx. 10 mm under a testing force of 66 N (≈ 6.6 kg).
• Lock the belt setting by tightening all 4 locking screws (2).
• Fit the machine cover (1).
Danger:The main drive belt should only be changed when the machine is stationary.
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Changing and tensioning the drive belt
Fp=66 NE=10 mm
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mAintenAnCepneumAtiCs
Pneumatic servicing unit (option)The oil level of the compressed air oiler must be checked daily at the servicing unit tank (3).If necessary, it must be topped up with an ap-propriate oil.A sensor monitors the oiler level. If it falls below the danger level, an alarm message pops up on the controller screen.
• Unscrew the filler screw (2) and fill with oil up to the "max" mark on the tank (3).
• The controller (1) is used to set the air/oil mix-ture ratio.
This is preset in the factory and should not be changed.
See lubricant recommendations for oil type
water separatorTo keep the compressed air free of water as far as possible, a water separator is built into the servicing unit.The separator tank (4) is drained by loosening the locking screw (5) on the tank.
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2
1
4
5
Pneumatics unit on the machine (option)
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mAintenAnCe door plAte
Viewing platesThe machine door has a polycarbonate safety window
The polycarbonate viewing disk (PC disk) offers penetration safety against flying parts such as chuck jaws or broken tool tips.
Cleaning recommendationsDusty PC plates must be wiped with water, a soft cloth or sponge - never rub dry! Electrostatically charged PC plates attract dust and must therefore be blown clean with ionised air.We recommend that you do not use a harsh cleaner for basic cleaning. Razor blades or other sharp tools, corrosive or strongly alkaline clean-ers, solvents, petrol containing lead and tetrachlo-ride must not be used.A microfibre cloth moistened simply with water has a good and broadly smear-free cleaning effect. For more severe, in particularly greasy contamination, benzole-free pure petrol (washing petrol, light petrol) can also be used for PC.Paint sprays, grease, sealant residues, etc. can be removed before hardening by light rubbing with a soft cloth soaked in ethyl alcohol, isopropyl-alcohol or ether. Rust spots can be removed with a 10% oxalic acid solution.All mechanical systems, e.g. with rotating brush-es, strippers, etc. are unsuitable for PC, even if the brushes are fed with copious quantities of run-ning water, as the plate surface can be scratched.Minor, shallow scratches can be repaired or made invisible by hot air polishing.
Danger:Viewing disk ageing:The door plate must be exchanged at least every 3-5 years or exchanged immediately if there is visible damage!Reason:Through contact with coolant, the polycar-bonate viewing disk undergoes an ageing process (embrittlement), in which the ability to retain flying parts is lost within a few years.
Servicing the viewing diskThe safety-critical retention capability of the PC disk is lost after a few years through the effect of coolant.This ageing or brittleness of the PC disk cannot be detected by visual examination, and therefore the door plate must be renewed in principle at least every 5 years.
In addition, the PC disk must be inspected visu-ally at regular intervals so as to exchange it im-mediately if the following damage occurs:
• plastic distortion (buckling) through past impact stresses
• Cracks• Damage to the surrounding seal
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