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Machine Description
Emco Concept Mill 155
Ref.-No. EN 2155
Edition A2003-10
Introduction
For more than five decades EMCO has been developing metal working
machines and has also been successfully on the market since 1980 with
computer controlled machine tools (CNC machines), particularly on the
training sector.
This high degree of experience is a profit for the turning and milling
machines of the EMCO Concept Turn and EMCO Concept Mill model
series.
The newly designed compact machines meet entirely today's requirements
in 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 different CNC controls (SIEMENS, FANUC, etc.) with one and the same
machine.
The CNC monitor of the installed CNC control is simulated on the PC
screen, input of data is carried out via a control keyboard.
Due to the worldwide industrial use of our machines we dispose of a
service network wich covers all world areas.
Immediately available service engineers, telephone service as well as a
100% sparepart supply exceeding the 10-year obligatory provision is
something natural for us.
One of our more than 100 general representatives worldwide will inform
you on particular new developments (e.g. clamping options for work pieces
or tools, new softwares, etc.) and theire trafitting possibilities.
In the present operating instructions you will find a complete description
of safety hints, transport, set-up, operation and maintenance of the
machine.
Therfore read this instructions completely before machine start-up.
EMCO MAIER Gesellschaft m. b. H.
Abteilung Technische Dokumentation
A-5400 Hallein, Austria
EC conformity
The CE mark certifies, together with the EC declaration of
conformity, that the machine and the guidelines are in conformity
with the regulations of the directives applicable to the products.
All rights reserved, duplication only upon authorization of Messres. EMCO MAIER
EMCO MAIER Gesellschaft m.b.H., Hallein/Taxach 2003
Contents
Warranty conditions for new EMCO machines ........................... 7
31
31
31
32
33
16
16
16
16
16
17
17
17
18
18
18
20
20
20
20
20
21
21
25
25
25
26
29
29
29
29
36
37
37
37
Toolholder .................................................................................
Order numbers .....................................................................
Mounting the toolholder into the tool drum ............................
Dismounting the toolholder ...................................................
Collet holders .......................................................................
Maintenance of collets and collet holders .........................
Mounting the collets ..........................................................
Dismounting the collets .....................................................
Clamping the tools into the collet holder ...........................
Clamping ranges ...............................................................
Working ranges of the tools ..............................................
Shell end mill arbor ...............................................................
Clamping the tools in the shell end mill arbor ....................
Working ranges of the tools ..............................................
Miller support ........................................................................
Clamping the tools into the miller support .........................
Working ranges of the tools ..............................................
Tap holder .............................................................................
Clamping the tools in the tap holder ..................................
Working ranges of the tools ..............................................
Holder MT2 ...........................................................................
Mounting the tools ............................................................
Dismounting the tools .......................................................
38
38
39
39
40
40
40
40
41
41
42
43
43
44
45
45
46
47
47
48
49
49
49
50
50
51
51
51
51
52
52
52
52
53
53
54
54
59
59
59
59
59
60
60
60
60
60
61
61
61
61
61
61
61
62
62
62
63
63
63
63
63
63
64
65
65
65
66
66
66
67
67
67
67
67
Survey ...................................................................................... 69
Lubricant recommendations ..................................................... 70
Filling Quantities ....................................................................... 70
Chlorin-free coolants ................................................................ 71
Central lubrication .................................................................... 72
Deaerating the lubricant lines ............................................... 72
Tool magazine slide .................................................................. 73
Milling spindle pressure piece .................................................. 73
Indexing cams .......................................................................... 73
Pneumatic vice (option) ............................................................ 74
Pneumatic unit .......................................................................... 74
Water separator .................................................................... 74
Coolant device .......................................................................... 75
Cooling lubricant level ........................................................... 75
Cleaning the coolant tank ..................................................... 75
Filter cartridge for PC cooling device ........................................ 76
ADEQUATE
USE/WARRANTY CONDITIONS
Adequate use
The machine is designed for milling and drilling of machinable metals and machinable
synthetic materials.
Machining of other materials is not admitted and may be carried out in particular cases only
after consultation with the machine manufacturer.
Adequate use also includes compliance with the operating and maintenance instructions
indicated by the manufacturer.
The machine may exclusively be operated by persons familiar with operation, maintenance
and repair and who know about the hazards.
All regulations for the prevention of accidents and safety instructions for work with machine
tools have to be complied with at any time.
In case of inadequate use of the machine the manufacturer renounces any liability and the
responsibility is transferred exclusively to the user.
SAFETY RECOMMENDATIONS
Safety recommendations
Personal protective equipment
Do not wear loose working clothes. Mind that the
working clothes are tight around the wrists and
hips.
Mind that your hair does not get caught in the
machine (in such a case wear hair protection).
Protect your eyes with safety-glasses.
When removing chips use a chip hook and gloves.
Read instructions
Read the instructions completely before you start
up the machine.
Prior to start of work get familiar with all functions
and operating elements. During the work it might
be too late.
Electrical connection
Electrical connection of the machine must only
carried out by an authorized electrics expert.
Local protection measures have always to be
borne in mind.
Protect machine
Protect the machine (main switch can be locked)
during adjustment, maintenance and repair work
against unauthorized start-up.
Start-up
Make sure that prior to each start-up the machine
is in perfect maintenance state and that no safety
features have been removed.
Claim
In the event of a collision or other instance of
damage contact immediately the representative
or manufacturer.
In case of complaints, damage, confusions and
spare part orders always indicate the machine
number, electric number and software version.
No modifications on machine
Modifications on your own on safety features,
bridgings of control features as well as any
interference with the electric/electronic part of the
machine are prohibited.
In case of hazards EMERGENCY-OFF
In case of hazards immediately stop machine with
EMERGENCY-OFF.
Machine supervision
Never leave running machine unattended.
Before leaving the working place switch off
machine and protect against unauthorized startup (lock main switch and remove key).
Tool change
Change machining tools only during standstill of
machine. Only use tools and sealing bolts with O
ring on the shaft, always close all stations
(otherwise danger of coolant and chip entry in the
internal area of the tool turret!). In case of tool
change always turn driven tool holder into locking
position.
SAFETY RECOMMENDATIONS
Danger
refers to possible danger to persons during
working and operating procedures.
Attention
is indicated in working and operating procedures which have to be observed exactly to
avoid possible damage of the machine and
slight danger of injury for operators.
Note
is indicated if something particular has to be
observed when an activity is carried out.
TECHNICAL DATA
[mm]
[mm]
[mm]
[mm]
[mm]
300
200
300
200
285
[mm]
[kg]
[mm]
[mm]
520180
20
12
45
Spindle bearing
Type of bearing
Toolholding fixture similar to DIN7920 - SK30
Tensioning bolt
Tool clamping
Milling spindle drive
Rotary current motor AC
[mm]
40
rolling bearing
works standard
works standard
automatic
[kW]
[min ]
[Nm]
[mm]
[mm]
1,7/2,5
150-5000
24
16
M10
[m]
[N]
[m/min]
[m/min]
[m]
1,5
2500
0-4
7.5
3/3/4
-1
Step resolution
Max. feed force
Working feed in X/Y/Z (inifinitely variable )
Rapid traverse speed X/Y/Z
Medium positioning variation X/Y/Z according to DIN VDI 3441
Tool system
Tool drum with direction logic
Number of tool stations
maximum tool diameter
maximum tool length
maximum tool weight
Feeding force
Tool change time T1 / 180
Tool change time T2 and T3 / 36
[mm]
[mm]
[kg]
[N]
[s]
[s]
10
10
70
200
0.8
1100
4.6
4.0
TECHICAL DATA
Lubrication system
autom. central oil lubrication
life time lubrication
[l]
[l/min]
[bar]
140
20
0.75
Supply pressure
Hose connection
Pneumatic unit (option)
Pneumatic unit for the automatization accessories
[bar]
[mm]
6
10
Supply pressure
Hose connection
Automatic clamping device (option)
Pneumatic vice with final position control and blow-out device
[bar]
[mm]
6
10
Opening capacity
Jaw width
Automatic door mechanism (option)
pneumatically actuated, incl. final position control
Electrical connection
[mm]
[mm]
125
125
Power supply
Max. voltage fluctuations
Frequency
Connected load of the machine
Max. preliminary fuse for the machine
Dimensions, weight
[V]
[%]
[Hz]
[kVA]
[A-slow]
Total height
Installation surface WxD
Total weight of the machine
Sound pressure level
[mm]
[mm]
[kg]
11
[db(A)]
3/N/PE 400a
10
50/60
5
20
1925
15021284
700
72
TECHICAL DATA
Processor (min.)
Main storage
Disk drive
CD-ROM drive
Hard disk memory
Display Interface
Keyboard
PC mouse
2 RS232, 1 USB,
2 LAN-100Mbit
Windows 98SE
Interfaces
Operating system
12
Machine number
The adhesive plate with the machine number (1)
is to be found laterally on the machine above the
lockable main switch.
The machine numer is also stamped into the
machine bed.
Electrics number
S6-60%
400V~
3/N/PE
('RNX6HU1R
)DEU1R
%DXMDKU<HDURIFRQVWU
50/60Hz
0DGHE\(PFR0$,(5*HVPE++DOOHLQ$8675,$
1
Example of a complete electrics number:
Q1F 101 000 V1.30 (see illustration)
Q1F101000
G. E-Kasten PCM155
Auftrag:
VERSION
3005381/
20
01.30
BAW
Note:
The wiring diagrams valid for your machine
are to be found in the electrical documentation which is in the switch cabinet of the
machine.
An electrical documentation can also be
obtained under order number ZVP 677 916and
indicating the version number (e.g. V1.30)
from EMCO.
15
SCOPE OF SUPPLY
INSTALLATION
Scope of supply
Basic 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
Siemens 810/820
Siemens 810D/840D
GE Fanuc Series 0
GE Fanuc Series 21
Emcotronic TM02
Heidenhain TNC 355
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o
o
o
o
6
8
Siemens 810
Siemens 820
Siemens 810D/840D
GE Fanuc Series 0
GE Fanuc Series 21
LQQRY
DWLYH
PDFK
LQGXV
LQHWR
WULDOWU
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Modules/options
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Scope of supply
16
TRANSPORT
INSTALLATION
Transport of Machine
800 kg
Attention:
The lifting points and the fork widths have
to be adhered to exactly so that there is no
deformation at the machine base.
The foot panel (1) and/or coolant tray
(accessories) must be removed during
transport.
Furthermore, the coolant pump must be
swivelled out (see "transport safety devices"
in this chapter).
700 kg
17
INSTALLATION
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 machine again.
Machine door
The machine door is fixed by a securing screw
(2) at the left machine panelling - remove screw
(2).
18
INSTALLATION
19
INSTALLATION CRITERIA
INSTALLATION
Installation criteria
Requirements on installation
surface
The machine is to be installed on a pavement as
horizontal as possible with adequate carrying
power and vibration stability.
When screwing down the machine bores for the
anchor bolts have to be mounted.
Installation site
Mind that the selected installation site is adequately clean (free of excessive dust exposure
etc.) to take care of the machine as well as the
PC and the peripheral devices.
Ergonomy
Due to its ergonomic design the machine provides
optimum operation.
However, when choosing the installation site pay
attention to sufficient lighting.
18-35C
rH 40-70%
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 of
the supports (2).
Levelling element ............ order no. 881 500
(4 pcs. necessary)
1 2 3
4
Installation without anchoring
20
INSTALLATION
INSTALLATION CRITERIA
80 Nm
30 Nm
21
ELECTRICAL CONNECTION
INSTALLATION
Electrical connection
1
Danger:
The electrical connection of the machine and
its accessories may only be established by
an electrics expert.
Feed cables must be idle during the connection.
/ / / 1 3(
Attention:
Connecting this machine to a mains protected
by leakage current circuit breaker is admittable
only with using an all-current-sensitive
leakage current breaker.
+1FL1-X1
Reason:
The drives used for this machine can cause
DC leakage currents which will impair the
protective function of the leakage current
breaker (no release).
9RUVLFKW
6SDQQXQJ
/ / / 1 3( 3( 3( 3(
22
INSTALLATION
ELECTRICAL CONNECTION
Note:
Further information about electrical connection is to be found in the electrical documentation of your machine.
In case of different specifications the data in
the electrical documentation are valid.
PC connection
Opening the PC compartment
4
5
23
INSTALLATION
Pneumatic connection
(Option)
By machines with automatization (pneumatic
chuck, automatic tailstock, ...) lateral on the
machine there is a pneumatic connection device.
Working pressure .................... min.4 max.6 bar
4
5
CLOSE
Initial start- up
All blank parts are to be cleaned from rust
preventive agent with a clean cloth.
24
INSTALLATION
SWITCH-ON / SWITCH-OFF
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Main switch
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Control panel
Note:
After reaching the reference points the
software limit switches are active.
Possibility B:
Automatic referencing
Press the key "reference". The axes traverse to
the reference point one after the other.
25
SWITCH-ON / SWITCH-OFF
INSTALLATION
Notes
The machine is switched off by means of
the main switch.
We recommend to switch off the machine
only in inoperative position of the tool turret.
Operation is interrupted by means of the
Reset key.
All current machine functions are interrupted
with RESET.
26
11
12
13
14
15
10
9
10
11
12
13
14
Coolant tray
Coolant pump (swivelling)
Main switch
E-cabinet
Control-specific keyboard (exchangeable)
PC keyboard drawer (folding, with integrated
mouse tray)
15 Machine base with chip area
27
REFERENCE POINTS
DESCRIPTION
17
:
5
Reference point R
28
DESCRIPTION
Working area
Working area in X- and Y-axes
Traversing path X-axis ............................ 300 mm
Traversing path Y-axis ............................ 200 mm
Note:
Mind that the clamped workpieces in the
traversing area of the milling cutters are
clamped at the milling table.
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Coordinate system
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Coordinate system
29
MAIN ELEMENTS
DESCRIPTION
Machine base
The machine base is of solid welded design, for
supporting the machine bed, the control with the
PC as well as the whole electrical equipment.
A coolant tray (accessory) can be inserted at the
lower part of the base.
Slides
The slides run in precisely ground dove-tail
guides.
The clearance of the slides can be readjusted via
tapered gibs.
The slides are supplied with oil via the central oil
lubrication so that all sliding surfaces are always
dampened with oil.
Slide drives
The slides are traversed with step motors via
recirculating ball screw spindles.
The amply dimensioned spindles, the rigid spindle
nuts and the axial bearings without backlash
provide high positioning and working accuracy.
Feed speed .................................. 0-4000 mm/min
Rapid motion speed ........................ 7500 mm/min
Step resolution ........................................... 1.5 m
max. feed force X-/Y-/Z-slides ................. 2500 N
Milling spindle
The milling spindle is mounted in rolling bearings
in the milling head. The drive is carried out via a
three-phase A.C. motor, the spindle speed is
infinitely variable via the control.
Speed ............................................. 150-5000 rpm
maximum torque ........................................ 24 Nm
Central lubrication
The slides are supplied with glideway oil via the
central lubrication.
The pump is automatically switched on after a
slide traversing path of 16 m.
Central lubrication
30
DESCRIPTION
SAFETY DEVICES
Safety devices
The safety devices are contained in the base
machine and facilitate generally risk-free operation of the machine.
Danger:
The safety devices must never be removed
from the machine.
Also mechanic or electric bridgings of the
safety devices are prohibited.
EMERGENCY-OFF key
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Note:
After pressing the EMERGENCY-OFF KEY
the reference point must be reapproached.
31
".
SAFETY DEVICES
DESCRIPTION
Key switch
The key switch can be switched in 2 different
positions:
Position "automatic"
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Note:
Manual traversing of the slide is only possible
with closed chip guard door as soon as the
reference point has been approached, or the
key switch is in position "setting operation".
32
DESCRIPTION
Consent key
The function of the consent key depends on the
position of the key switch.
Note:
If the consent key is pressed for more than
40 s the function of this key is interrupted, the
consent key must be released and pressed
again.
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Pneumatic
maintenance unit
The basic equipment of the pneumatic maintenance unit contains valves and switches for the
blow-out device of the tool system.
The maintenance unit available as option for the
automatization of the machine contains additionally all connections, push switches, pressure
regulators and valves to trigger the automatic door
mechanism and the pneumatic vice with the blowout device as well as the dividing axis.
Supply pressure ........................................ 4-6 bar
Pneumatic connection ............................. 10 mm
33
Dividing axis
45-stroke 1
3
Pneum. vice
50/30-4-fold stroke 5
4
Blow-out device
4 internal
Blow-out device
milling spindle
4 internal
only together
6
Automatic door
mechanism
32/12-stroke
620
PNEUMATIC SCHEME
DESCRIPTION
Pneumatic scheme
34
DESCRIPTION
AUTOMATIZATION
Automatic door
mechanism (option)
Upon order the automatic door mechanism can
be mounted as option at the manufacturer.
The chip guard door can be opened and/or closed
by the program or by pressing a key via a
pneumatic cylinder (1).
Monitoring of the door position is carried out via 3
limit switches.
Robotics interface
(option)
With the robotics interface in addition to the
general triggering of the periphery (such as
automatic door mechanism) the machine can also
be connected with further machines or devices
(e.g. loading and unloading robot).
DNC-interface
(option)
Via the DNC-interface the machine can be
operated via a host. In contrast to the robotics
interface, in addition to standard functions, e.g.
programs can be transmitted or started from the
host.
The DNC-interface is mainly used for the set-up
of an FMS.
35
TOOL
DESCRIPTION
SYSTEM
Tool system
All tools are mounted on the toolholders.
The toolholders with the premounted drilling and
milling tools are mounted on the tool drum (1).
Note:
Due to the safety devices of the machine a
tool change procedure is only possible with
closed chip guard door.
36
DESCRIPTION
TOOL SYSTEM
Alarm message
"7022 Initialize tool turret"
The interrupted tool change procedure is
terminated by pressing the tool turret key.
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Alarm message
"6040 WZW - static interlock control"
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37
TOOLHOLDER
DESCRIPTION
Collet holder
Toolholder
Miller support
Order numbers
Tap holder
Toolholder
Collet holder
Shell end mill arbor
Miller support
5 mm
Tap holder
MT2 holder
Holder MT2
MT2
Toolholder
38
Order no.
ESX 16
16
10
12
16
M2
M3
M4
M5-M8
M10
Q1Z 910
Q1Z 860
Q1Z 830
Q1Z 840
Q1Z 850
Q1Z 760
Q1Z 870
Q1Z 880
Q1Z 890
Q1Z 900
Q1Z 780
DESCRIPTION
TOOLHOLDER
Tool drum
Attention:
While tightening the clamping screws (4) mind
that the flat parts (B) of the screws are
directed away from the the tool support.
Thus, it is assured that the toolholder cannot
fall out from the support.
Swivel tool drum by one position to mount next
tool.
Swivel in tool.
Loosen clamping screws (4) so that the toolholder (2) can be removed.
Hold the toolholder tight so that the toolholder
does not fall down and the tool is not damaged.
Remove dirt and chips from the released tool
and oil the tool shank slightly with oil.
39
TOOLHOLDER
DESCRIPTION
Collet holders
Drills, end-milling cutters and profile cutters are
clamped in the collet holder.
Order no. ................................................. Q1Z 910
Clamping range .......................... 0.5 up to 10 mm
Collet type ................................................. ESX 16
ESX 16
Collet holder
Danger:
When the collet holder is clamped in the tool
drum of the machine, mounting and dismounting of the collet holders may only be
carried out during machine standstill.
40
DESCRIPTION
TOOLHOLDER
Danger:
With mounted collet holder, mounting and
dismounting the tools may only be carried
out during machine standstill.
The values indicated in the table "clamping
ranges" must always be complied with,
otherwise the tools cannot be clamped
safely.
Clamping ranges
1
Nominal
diameter of
the collet
Clamping range
[mm]
[inch]
1,0
0,5-1,0
1/64-1/32
1,5
1,0-1,5
3/64
2,0
1,5-2,0
1/16-5/64
2,5
2,0-2,5
3/32
3,0
2,5-3,0
7/64
4,0
3,0-4,0
1/8-9/64-5/32
5,0
4,0-5,0
11/64-3/16
6,0
5,0-6,0 13/64-7/32-15/64
7,0
6,0-7,0
1/4-17/64
8,0
7,0-8,0 9/32-19/64-5/16
9,0
8,0-9,0
21/64-11/32
10,0
9,0-10,0 23/64-3/8-25/64
Set of collets (1,0 - 10,0)
41
Order
no.
152 710
152 715
152 720
152 725
152 730
152 740
152 750
152 760
152 770
152 780
152 790
152 800
152 700
TOOLHOLDER
DESCRIPTION
end-milling cutter
acc. to DIN 844 shape A
radius cutter
twist drill
extra short acc.to DIN 1897
42
DESCRIPTION
TOOLHOLDER
In the shell end mill arbor shell end mills and disk
milling cutters are clamped.
Collars are supplied with the milling spindle for
compensating the milling cutter width and a
wrench for tightening the clamping screw.
4 mm
6 mm
8 mm
12 mm
1
Danger:
With clamped shell end mill arbor in the tool
drum, clamping and unclamping the tool
may only be carried out during machine
standstill.
Only tools with a bore of 16 mm and square
key groove may be clamped.
2
3
4
5
43
TOOLHOLDER
DESCRIPTION
PP
PP
PP
PP
1
44
DESCRIPTION
TOOLHOLDER
Miller support
The miller support serves for the support of endmilling cutters which cannot be clamped any more
with the collet holder.
Due to the support diameter we distinguish
between 3 miller supports.
Order number:
miller support 10 mm ............................ Q1Z 830
miller support 12 mm ............................ Q1Z 840
miller support 16 mm ............................ Q1Z 850
Danger:
With clamped miller support in the tool drum
of the machine, clamping and unclamping
of the tools may only be carried out during
machine standstill.
Only tools with the nominal diameter fitting
the miller support may be clamped.
45
46
Miller
support
12
end-milling cutter 16
DIN 844
Miller support
10
twist drill 12
DIN 1897 extra short
twist drill 10
DIN 1897 extra short
NCstart drill 10
TOOLHOLDER
DESCRIPTION
Miller
support
16
1
DESCRIPTION
TOOLHOLDER
Tap holder
Taps are not clamped in the collet holder but in
the tap holder.
The tap holder has a length compensation of
10 mm (5 mm).
We distinguish between 4 tap holders according
to the thread size.
Order numbers:
tap
tap
tap
tap
tap
holder
holder
holder
holder
holder
Danger:
With clamped tap holder in the tool drum of
the machine the tap may only be clamped
and unclamped during machine standstill.
Only the taps allocated to the tap holder
may be clamped.
Put in tap (2) into the seat of the holder (1) and
turn it in a way, that the square of the tap gears
into the square of the holder
47
TOOLHOLDER
DESCRIPTION
0
0
Holder
M10
shortened
standard
length
standard
length
0
shortened
0
0
Holders
M5-M8
shortened
standard
length
0
48
DESCRIPTION
TOOLHOLDER
Holder MT2
The holder MT2 with reduced support serves for
mounting tools with cone support.
Order n ................................................... Q1Z 780
Danger:
Tool support and tool must be free of dust
and grease so that the tool fits safely in the
cone!
49
CLAMPING
DESCRIPTION
Danger:
To avoid accidents and for correct operation
also read the instructions attached to the
accessories.
Always take care that clamping device and
workpiece are clamped tightly and safely
before you start machining!
The clamping device may only be operated
during standstill of the machine!
Machine vice
mechanic
1
Construction size A
Width of jaws .............................................. 90 mm
Clamping capacity ..................................... 90 mm
Order n ................................................... 781 000
Construction size B
Width of jaws ............................................ 110 mm
Clamping capacity ................................... 125 mm
Order n ................................................... 781 010
50
DESCRIPTION
CLAMPING
Incremental straps
Incremental straps are suitable for clamping
irregular and high workpieces.
For clamping a workpiece at least 2 incremental
straps are required.
Clamping height ................................... 15-58 mm
Order no. ................................................ F3Z 210
Clamping height ................................. 50-125 mm
Order no. ................................................ F3Z 220
Incremental strap
51
CLAMPING
DESCRIPTION
Intermediate flange
The intermediate flange is used for the support of
the three-jaw chuck.
It is mounted on the milling table.
Order no. ................................................ F3Z 230
Danger:
For mounting the chuck only the enclosed
screws may be used. With longer screws
the chuck might not fit tightly on the intermediate flange, in case of too short screws
they might tear out.
The maximum admissible clamping ranges
must never be exceeded. Exceeding them
may lead to to jaw fracture.
After clamping of workpieces take off the
chuck key.
52
DESCRIPTION
CLAMPING
Set clamping device state of the control on "Release" (message "7054 Vice open!" is displayed
on the screen).
Place workpiece on vice against the clamping
jaw (3) of the vice.
Approach clamping jaw (4) of the vice by turning
the knurling wheel (5) up to a distance of approx.
2 mm from the workpiece (adjust jaw distance
via the workpiece length to be clamped).
When turning the knurling wheel mind that the
sliding valve (6) does not turn with the wheel
(counterhold).
Laterally at the vice a stop is mounted on the
clamping jaw (4) which has to be adjusted by
twisting the hexagon screw M640, SW10 (1).
The adjustment is fixed by means of the counter
nut SW10 (2).
A second setting screw (1) M620 is contained
in the scope of supply of the vice. It should be
used for wider workpieces to avoid a collision
of the milling head with the setting screw.
When closing the vice via the control the
workpiece is clamped with the set pressure (the
jaw stroke of the clamping jaw (4) is 5 mm).
pneumatic vice
53
CLAMPING
DESCRIPTION
54
DESCRIPTION
DETERMINATION OF
THE
Z=L30
1
=
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 after
the first sample workpiece.
=
Determination of the tool length Z
;
=
&
56
&
=
(',7
;
$8;
$8;
Note:
Wrap up well the key modules not needed
and keep them in a protected and clean place
to avoid damage.
55
MILLING TOOLS
DESCRIPTION
Milling Tools
Description
NC start drill (HSS)
acute angle 120, shaft 10mm
Edge tracer
4/10mm, shaft 10mm
Slot milling cutter HSS, DIN 327-shape B
milling 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
Heavy-duty shank end mill HSS, DIN 844-shape A
milling 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)
Radius cutter HSS
shaft 6 mm
shaft 8 mm
Order no.
771 010
F1Z 090
764 301
764 302
764 303
764 304
764 306
764 308
773 100
773 105
764 200
781 152
781 151
771 020
771 030
771 040
764 400
771 050
764 410
781 280
260 628
56
271 230
573 770
271 220
781 300
781 301
781 302
781 303
781 304
781 305
781 306
DESCRIPTION
CHARACTERISTIC CURVES
Characteristic curves at
the milling spindle
Spindle 5000
0
>1P@
3
0
Power
Torque
3
>N:@
Q>PLQ @
speed
Spindle 10000
0
>1P@
3
>N:@
0
Power
Torque
3
speed
57
Q>PLQ @
58
C Control Panel
EMCO-specific
6.,3 '5<
581
237
[ 6723
;
6%/
<
=
<
;
=
(',7
$8;
$8;
Key Description
Skip
In skip operation the program blocks that are
marked with a slash "/" before the block number,
will not be executed in program run (e.g.: /N100).
6.,3
Dryrun
In dryrun operation the traversing movements will
be executed with the feed set in setting data
"dryrun-feed" .
The dryrun feed works instead of the programmed
feed.
'5<
581
[
Optional Stop
At active function (key was pressed) the program
run will be stopped at blocks that contain the
command M01.
The screen shows "Halt: M00/M01 active". Continue the program with the key NC Start.
When the function is not active, M01 (in the part
program) will be ignored.
237
6723
59
KEY DESCRIPTION
CONTROL PANEL
Reset Key
Actuating Reset causes:
Stop of working off the actual part program.
Alarms and messages are cleared with the exception of Power On or Recall alarms.
The channel will be set to the reset status, that
means:
- The NC control stays synchronous to the machine.
- All intermediate and working memory is
cleared (the contents of the part program
memory stays resident).
- The control is in basic setting and ready for
program run.
NC Stop
After pressing the NC Stop key and takeover of
the function by the control, working off of the
running part program will be stopped.
You can continue working off by pressing NC
Start.
NC Start
After pressing the NC Start key the selected part
program will be started with the actual block.
Single Block
This function allows to work off a part program
block by block.
The function single block can be activated in AUTOMATIC mode.
6%/
Reference Key
Pressing this key causes approaching the reference point in all axes.
Initialization of the tool drum after an alarm.
60
CONTROL PANEL
KEY DESCRIPTION
; &
=
&
Direction Keys
Use this keys to traverse the NC-axes in the JOG
mode.
The keys "+4" and "4" are for the control of the
fourth axis in "+" and ""-direction.
=
;
Rapid
If this key is pressed simultaneous to a direction
key the responding axis traverses in rapid feed.
Feed Stop
This key stops slide movements in AUTOMATIC
mode (not for threads).
Feed Start
This key continues programmed, interrupted slide
movements.
When spindle run was interrupted additionally first
the spindle run must be continued.
Spindle Stop
This key stops the running of the main spindle
and driven tools.
Before stopping the spindle you must stop the
slides.
Spindle Start
By means of this key the programmed spindle
run can be continued again.
Programming
WinNC software description
Directions of rotation
see "Coordinate system" in chapter "B Description".
Spindle Override
The actual spindle speed S is shown at the screen
as absolute value and in percent.
Valid for main spindle and driven tools.
Setting range:
Step width:
100% spindle speed:
61
KEY DESCRIPTION
CONTROL PANEL
Coolant
The coolant device can be switched on and/or off
with this key.
Programming
M9, M2, M30, Reset key: coolant off
M8: coolant on
Note:
This function gets active only if after switching
on the machine, the tool position 1 was
surpassed in standard swivelling direction.
62
CONTROL PANEL
KEY DESCRIPTION
Auxiliary OFF
$8;
Auxiliary ON
This key switches the auxiliary drives of the machine to ready status (hydraulics, feed drives,
spindle drives, lubrication, chip conveyor, coolant).
The key must be pressed for approx. 1 second.
Short pressing the AUX ON key is a quit function
and effects a lubrication impulse.
$8;
without function
63
KEY DESCRIPTION
CONTROL PANEL
(',7
Ref
Approaching the reference point (Ref) in JOG
mode.
Automatic
Control of the machine by automatic working off
of programs.
(',7
Edit
With the Sinumerik-control this key is without any
function.
MDA - Manual Data Automatic
Control of the machine by working off one block
or a sentence of blocks. The input of the blocks
occurs via operation panel.
Jog - Manual traverse
Conventional traversing of the machine by continuous moving of the axes via direction keys or
via incremental moving of the axes via direction
keys or via handwheel.
Teach In
With the Sinumerik-control this key is without any
function.
64
CONTROL PANEL
KEY DESCRIPTION
Setting range:
0 % to 120 % of the programmed feed.
In rapid feed 100 % will not be exceeded.
EMERGENCY OFF
Actuate the red button only in emergency situations.
Effects:
Normally all drives are stopped with maximum
deceleration by EMERGENCY OFF.
Unlock: Pull out button
To continue press the following keys:
RESET, AUX ON, OPEN and CLOSE door.
Danger:
Active special operation increases the danger of accidents.
The key must be used only by authorized
persons, who have the knowledge about the
dangers and are careful in operation.
Keep the chip guard door closed also during
setup operation.
Take off key always after working in special
operation (danger of accidents).
Observe the local safety regulations (e.g.:
SUVA, BG, UVV ....).
65
KEY DESCRIPTION
CONTROL PANEL
Consent key
Opening the chip guard door
Axis movements via direction keys and tool
turret movements with open door are admitted
by pressing the consent key (prerequisite key
switch in position SET UP).
Main Switch
Function:
0 - OFF
1 - ON
The main switch has no emergency off function,
that means the drives run out (unbreaked).
The main switch can be locked (unauthorized
operation of the machine).
no function
66
CONTROL PANEL
SERIAL INTERFACE
Serial Interface
The 25-pin sub-D-jack ist mounted laterally on
the operatiom panel.
Pin occupation: identical with system Sinumerik
800
SH
TXD
RXD
Signal names
RTS
SH
TXD
RXD
RTS
CTS
DSR
GND
CD
DTR
RI
CTS
DSR
GND
DTR
CD
RI
Schielding
Transmit data
Receive data
Request to send
Clear to send
Data send ready
Ground
Carier identification
Data terminal ready
Ring indicator
Standard Values
machine side
PC-side
Attention:
Don't overshoot maximum cable length!
Don`t use schield for signal ground GDN!
female connection,
9 poles
Connection to PC
The plug load you see in the plot beside.
plug connection
25-poles
67
68
200 h
10
8h
1
machinery
8h
40 h
1000 h
11
central lubrication
Danger:
All maintenance work may only be carried
out with the machine switched off.
69
SURVEY
No.
1
2
3
4
5
6
7
8
9
10
11
MAINTENANCE
Lubrication point
X/Y slide, guideway and spindle nut
Z slide, guideway and spindle nut
Chip drawer
Coolant level
Coolant container
Central lubrication
Pneumatic maintenance unit
Filter cartridge for PC cooling device
Tool magazine slide
Milling spindle pressure piece
Tool drum indexing cams (10 pcs.)
Coolant
Activity/lubrication
central oil lubrication
central oil lubrication
clean
check
clean
check oil level
check oil level
clean / exchange
oil (slideway oil)
oil (slideway oil)
oil (slideway oil)
change
Interval [h]
adjusted by
manufacturer
8
8
40
40
40
200
200
200
200
1000
Filling Quantities
Container
Central lubrication
Pneumatic oiler
Coolant tank
Quantity
0,7 l
4,5 cl
140 l
Lubricant
recommendations
Application
Central lubrication
Tool drum
Tool turret slide
Slideway oil:
CGLP DIN 51502 ISO VG 68
Compressed-air oiler
Pneumatic oil:
DIN 51524 ISO VG32
70
CASTROL
KLBER
MOBIL
OMV
TRIBOL
CASTROL
MOBIL
Recommendation
Magnaglide D 68
Lamora Super Pollad 68
Vactra 2
Glide 68
1060/68
Magnaglide D 32
HLP 32
MAINTENANCE
SURVEY
Chlorin-free coolants
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71
CENTRAL LUBRICATION
MAINTENANCE
Central lubrication
Longitudinal and cross slides are supplied with
glideway oil via the central oil lubrication.
The distribution elements (4) distribute the
glideway oil evenly to the lubricating points.
As soon as the slide has passed a travel path of
16 m the pump (2) is switched on automatically.
The central lubrication can also be activated
manually by means of the "
$8;
" key.
$8;
72
MAINTENANCE
TOOL
CHANGE SYSTEM
Note:
Instead of the oil-press you also may use an
aerosol container with lubricant.
But be careful, that no lubricant may be
sprayed at the driving belts.
Indexing cams
To avoid "seizure" of the indexing cams they must
be cleaned and oiled regularly.
Lubrication interval ................ every 200 hours
Lubricant ........................................... slideway oil
73
MAINTENANCE
Pneumatic unit
The oil level of the compressed-air oiler has to be
controlled daily at the tank (7) of the maintenance
unit.
If necessary an adequate oil has to be refilled
(see lubricant recommendations).
Screw off filling screw (8) and fill in oil up to the
"max" mark at the tank (7).
The control knob (6) serves for setting the
mixture ratio air/oil.
It is preset by the manufacturer and should not
be changed.
Oil quality for compressed-air oiler
Pneumatic oil DIN 51 524 ISO VG 32
e.g. CASTROL Magnaglide D 32
MOBIL
HLP 32
Water separator
10
74
MAINTENANCE
COOLANT DEVICE
Coolant device
Cooling lubricant level
Check interval .................................................. 8 h
Exchange of the coolant ............................ 1000 h
The cooling lubricant level is checked at the front
side of the machine on the display (4) of the
cooling lubricant tank(1).
When refilling the cooling lubricant observe the
composition and the miscibility of the existing liquid (also see cooling lubricant recommendations).
Attention:
For a regular function of the coolant pump
the coolant level must be at least 45 mm.
In general only use chlorine-free coolants.
The chlorine part in the coolant is responsible for the rust on bright parts.
Notes:
Dispose cooling lubricants acc. to environmental requirements (special waste!).
Do not use fluorine chlorinated hydrocarbons (e.g. trichloroethylene, trichlorethane etc.) for cleaning the tank!
During cleaning mind complete elimination
without residues of deposits! Remaining
contaminations are sites of growth for
bacteria which attack the newly filled emulsion and reduce its service life.
Dirty cleaning rags (cleaning paper) have to
disposed of as special waste.
75
FILTER CARTRIDGE
MAINTENANCE
1
2
3
Open PC load.
Dismount guard rail (2) with the two knurled
screws (3) and exchange filter cartridge (1).
Mount guard reil (2).
Caution:
For protection of the PC, the machine may
not be operated without mounted filter
cartridge!
76