CE Safety Manual - Stone Machinery
704-0101-809
CE Safety Manual
Bedmills and Machining Centers
October, 2000 Revision A
CE Safety Manual
for
Hurco Bedmills and
Machining Centers
Hurco Manufacturing Company reserves the right to incorporate any
modifications or improvements in machines and machine specifications
which it considers necessary, and does not assume any obligation to make
any said changes in machines or equipment previously sold.
Hurco products and services are subject to Hurco’s then current prices,
terms, and conditions, which are subject to change without notice.
The information in this document is subject to change without notice and does not
represent a commitment on the part of Hurco Companies, Inc. (Hurco). The software
described in this document is furnished under the License Agreement to customers. It is
against the law to copy the software on any medium except as specifically allowed in the
license agreement. The purchaser may make copies of the software for backup purposes.
No part of this document may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, for any purpose without the express
written permission of Hurco.
 2000 Hurco Companies, Inc. All rights reserved.
Patents:
U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434;
Japanese Patents 1,649,006 and 1,375,124; other Patents pending.
Hurco and Ultimax are Registered Trademarks of Hurco Companies, Inc.
Many of the designations used by manufacturers and sellers to distinguish their products
are claimed as trademarks. Hurco has listed here all trademarks of which it is aware.
For more information on Hurco products and services, contact the corporate headquarters
in Indianapolis, Indiana or one of the subsidiaries listed below:
Hurco Companies, Inc.
One Technology Way
P.O. Box 68180
Indianapolis, IN 46268-0180
Autocon Technologies, Inc.
38455 Hills Tech Drive
Farmington Hills, MI
48331-5751
Hurco Southeast Asia Pte Ltd
27 Ubi Road 4 #01 01C
Fifth Avenue Building
Singapore 408618
TEL (317) 293 5309 (products)
(317) 298 2635 (service)
FAX (317) 328 2812 (service)
TEL (248) 488 0440
TEL (65) 742 6177
FAX (248) 488 0430
FAX (65) 745 7664
Hurco Europe Ltd.
Lincoln Road
Cressex Industrial Estates
High Wycombe
Buckinghamshire, England
HP12 3TH
Hurco S.a.r.l.
Centre Hurco
Belgique, Espagne, France,
Portugal
Parc d’activité Charles de Gaulle
4, rue Jean Monnet - BP 702
95197 Goussainville Cedex France
TEL 01494 442222
FAX 01494 444646
TEL
FAX
Hurco S.r.l.
Via C. Goldoni, 44
20090 Trezzano S/N (MI)
Italy
Hurco GmbH
85652 Landsham
Munich, Germany
TEL 02 4846 3781
FAX 02 4846 3157
TEL (089) 9050 94 0
FAX (089) 9050 9490
Hurco
(1) 39-88-64-00
(1) 39-92-94-83
October, 2000
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Using This Manual
The CE Safety Manual meets the requirements set forth by the European
Committee for Standardization, specifically those requirements found in
the document, “prEN 12417 Machine Tools—Safety—Machining
Centers,” item 7, and is published based on the requirements stated in the
document, “EN 292-2 : 1991,” item 5.
The sections in the following “CE Machine Standards” section ascertain
Hurco’s compliance to the CE requirements identified in section 7.2 of the
prEN12417 document.
This manual uses several conventions to explain the safety features and
emphasize key concepts. These conventions are described in this section.
Additional information is available in the following manuals, which are
available at all Hurco bedmills and machining centers:
•
Operator’s Manual (translated versions available from
Hurco)
•
Maintenance Manual
•
Parts Listings and Wiring Diagrams Manual
Style Guide
Indexed terms are italicized within the paragraphs that define them. Titles
of books also appear in italic print to meet the English language
convention for titles. References to chapter and section names are in
quotation marks for the same reason.
Screen titles, field names, key names and button names begin with capital
letters within the text and the index, to help the reader identify the
reference exactly as it appears on the system screen or console.
Hurco
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CE Safety Manual
Ultimax Screens
Hurco machining centers are operated using the Ultimax CNC. References
to CNC screens are made in this manual. Ultimax screens have three areas
of primary interest:
•
Softkeys with associated “F” keys on the right side of the
touch screen. Note that the softkeys may change even when
the text and data entry area does not.
•
Fields to the left of the softkeys. A field is an area that
displays information and may also receive information that
the operator enters by pressing console keys.
•
Prompt and error message area at the bottom of the screen.
For instance, the message area may contain an prompt such
as s, “Select softkey or press <Enter> to change part
program name.”
Standard Text Icons
This manual contains several icons to mark important sections:
Caution
A Caution message tells the operator that the machine may be
damaged or a part ruined if the described procedure is not followed.
Hints and Tricks
The light bulb icon marks useful suggestions for the machine tool
operator. These suggestions may show creative uses of the Ultimax
features or just helpful hints.
Important
The information marked with the arrow icon must be carefully
studied to ensure proper operation of the machine and/or the control.
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Using This Manual
HURCO
Troubleshooting
The toolbox icon indicates steps that can be taken to solve potential
problems. These sections contain information for Hurco Technical
Service representatives and customers.
Warning
A Warning message indicates that the operator may be
injured and the machine tool severely damaged if the
described procedure is not followed.
Hurco
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Table of Contents
CE Machine Standards
European Directives and Standards......................................................................... 1
Directives .................................................................................................... 1
Harmonized Standards ................................................................................ 2
Safety .......................................................................................... 2
EMC (Electromagnetic Compatibility) ........................................... 2
Other Standards ........................................................................................... 2
Safe Installation of Guarding System and Machine................................................ 3
Guarding System ......................................................................................... 3
Machine....................................................................................................... 4
Floor Conditions.............................................................................. 4
Electrical Service Requirements ..................................................... 4
Connecting Electrical Service ............................................. 4
Recommended Isolation Transformer Configuration ......... 6
Grounding Equipment ......................................................... 7
Compressed Air Requirements........................................................ 8
Specification........................................................................ 8
Connecting Compressed Air ............................................... 8
Anti-Vibration Mountings............................................................... 8
Initial Test and Examination ................................................................................... 9
Periodic Maintenance............................................................................................ 10
Cleaning the Machine................................................................................ 10
Equipment Maintenance............................................................................ 10
Recommended Routine Maintenance........................................................ 11
Daily
........................................................................................ 11
Weekly ........................................................................................ 12
Monthly ........................................................................................ 12
Quarterly........................................................................................ 12
Semi-Annually .............................................................................. 12
Annually ........................................................................................ 12
Safety Circuits ....................................................................................................... 13
Guidelines.................................................................................................. 13
CE Safety Circuits Commissioning Checklist .......................................... 15
Mode: Manual Setup ..................................................................... 15
Mode: Automatic Preparation ....................................................... 16
Mode: Automatic Production........................................................ 17
Hurco
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CE Safety Manual
Safe Operation, Setting, and Maintenance ............................................................ 18
Training for Operators............................................................................... 18
Setup.......................................................................................................... 19
Operation and Maintenance ...................................................................... 20
Safe Working Practices ............................................................................. 21
Responsible Conduct..................................................................... 21
Personal Care................................................................................. 22
Wearing Apparel ........................................................................... 22
Heavy Lifting ................................................................................ 22
Housekeeping ................................................................................ 23
Control Systems .................................................................................................... 24
Noise Levels.......................................................................................................... 24
Descriptions of Failure Modes .............................................................................. 25
Power-Up Troubleshooting ....................................................................... 25
No Response on the Console......................................................... 26
Initialization Error Messages .................................................................... 27
Error Messages on Input Screen................................................................ 28
Corrective Measures...................................................................... 28
Swap Out a Printed Circuit Board..................................... 28
Check Wiring .................................................................... 28
Perform a Reset ................................................................. 29
Emergency Stop Condition ........................................................... 29
Manual Safety Override Mode (BMC only) ................................. 29
Machine Diagnostics ..................................................................... 30
Common Problems.................................................................................... 31
Power-on Self Test ........................................................................ 31
Machine Voltages.......................................................................... 31
Coolant System ............................................................................. 33
Motion and Spindle Rotation ........................................................ 34
Environmental Conditions............................................................. 36
Fluid Specifications............................................................................................... 37
Lubrication ................................................................................................ 37
Autolube System ....................................................................................... 39
Check Filler Screen and Fluid Level............................................. 41
Activate System Manually ............................................................ 41
Adjust Autolube Discharge Rate................................................... 41
Replace Oil and Suction Filter ...................................................... 42
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Table of Contents
Automatic Tool Changer........................................................................... 43
ATC Oil Unit................................................................................. 43
Maintain the Oil Level ...................................................... 43
Replace the ATC Oil ......................................................... 43
ATC Hydraulic Unit...................................................................... 44
Maintain Fluid Level......................................................... 44
Replace Hydraulic Oil....................................................... 44
Pneumatic System FRL Unit..................................................................... 45
Set Air Pressure............................................................................. 46
Maintain Oil Level ........................................................................ 46
Adjust Drip Rate Screw................................................................. 46
Check and Replace Air Filter Element.......................................... 47
Check Auto Moisture Drain .......................................................... 47
Tool Release Cylinder Air/Oil Unit .......................................................... 48
Spindle Taper ............................................................................................ 48
Optional Spindle Oil Cooler...................................................................... 48
Maintain Oil Level in Spindle Oil Cooler Tank............................ 49
Inspect the Air Filter Screen.......................................................... 49
Maintain Oil in Cooling Tank ....................................................... 49
Persons Trapped in Machine ................................................................................. 50
Specifications for Table and ATC Tools............................................................... 50
Table Specifications .................................................................................. 50
ATC Tool Specifications........................................................................... 52
Part Replacement................................................................................................... 53
Replacing Tool Pots on the Swing Arm Tool Changer............................. 53
4Taper /24-Station Swing Arm ATC ............................................ 53
5Taper /32-Station and 4Taper /4Station Swing Arm ATC.......... 57
Index
Hurco
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Figure List
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Delta and Wye Transformer Configurations ................................................... 6
Autolube Pump and Tank Assembly ............................................................. 40
Filter, Regulator and Lubricator .................................................................... 45
Center Bolt and Tool Pot Bolt ....................................................................... 54
Correct Tool Pot Alignment .......................................................................... 55
Tool Pot Position for Replacement Procedure............................................... 57
Cotter Pin Location........................................................................................ 58
Tool Pot Retaining Shaft Removal ................................................................ 59
Table List
Table 1.
Table 2.
Table 3.
Table 4.
Table 5.
Table 6.
Table 7.
Table 8.
Hurco
Missing or Faulty Connections ....................................................................... 31
Problems Due to Power Transients ................................................................. 32
Coolant System Problems ............................................................................... 33
Motion and Spindle Rotation Problems .......................................................... 35
Environmental Factors .................................................................................... 36
Lubrication for BMC Machines ...................................................................... 38
Table Specifications ........................................................................................ 51
ATC Tool Specifications................................................................................. 52
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CE Machine Standards
The information in this section ascertains Hurco’s compliance with the
European Community’s machine safety standards.
As defined in the Foreword of the “prEN 12417 Machine Tools—Safety—
Machining Centers” document, “…This European standard has been
prepared under a mandate given to CEN by the Commission of the
European Communities and the Secretariat of the European Free Trade
Association, and supports the essential safety requirements of the
Machinery Directive to determine safety for new machining centres.
“This standard has been prepared to provide one means of conforming
with the essential requirements of the Machinery Directive and associated
EFTA regulations.
“It was prepared by CEN/TC 143/WG4 – ‘Safety of Machining Centres’
under the direction of CEN Technical Committee 143 ‘ Safety of Machine
Tools.’…”
European Directives and Standards
Hurco machining centers installed in Europe must conform to the
directives and standards accepted by the European community. Consult
local authorities for additional safety directives and standards that may
apply in your country.
Directives
These directives apply to all machine tools sold in Europe:
Hurco
•
European Machinery Directive 98/37/EC
•
Electromagnetic Compatibility Directive 89/336/EEC
(amended by 91/263/EEC and 92/31/EEC)
•
European Low Voltage Directive 73/23/EEC
(amended by 93/68/EEC)
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CE Safety Manual
Harmonized Standards
These standards apply to all machine tools sold in Europe:
Safety
•
EN 292-1
•
EN 292-2
•
EN 294
•
EN 349
•
EN 418
•
EN 953
•
EN 954-1
•
EN 60204-1
•
EN 50082-2
EMC (Electromagnetic Compatibility)
•
EN 50081-2
•
BS 5378 Parts 1 and 3
Other Standards
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Bedmills and Machining Centers
CE Machine Standards
Safe Installation of Guarding System and Machine
Upon arrival, inspect the machine to ensure that all parts are included and
are in intact. This inspection should include all mechanical and electrical
parts in addition to the self-contained guarding system.
The owner is responsible for proper site preparation before the machine is
installed. A Hurco Field Service Engineer must install the machine in the
prepared location. This location must not subject the machine to
uncontrolled cabinet temperatures or unfavorable work environment
conditions that could cause electronic component failure.
If the owner decides later to move the machine tool from its
installed location, it is recommended that the owner call Hurco
for assistance. If this is not possible, Hurco recommends that
the owner use a competent rigger with the necessary equipment
to move the machine to the desired location.
Warning
Improper moving of the machine may result in personal
injury or damage to the machine.
Guarding System
Each machining center has a self-contained guarding system. Inspect the
machine to ensure the guarding system is intact.
Hurco
•
The chip doors on the front of the machine lock during
Automatic Run Mode to prevent access to the moving parts
of the machine.
•
The guards on each side of the machine are either movable
or fixed. The movable guards can be opened to access the
inside of the machine. A special key is required to open a
fixed guard.
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CE Safety Manual
Machine
Check these items before the machine is installed:
Floor Conditions
The foundation must be able to support the weight of the machine tool,
and should be constructed of continuous concrete (reinforced is best). The
thickness and consistency of the concrete must be compatible with
industry standards for supporting the machine’s weight. Actual
requirements will depend upon the physical properties of underlying soil.
A local civil engineer should be consulted if soil conditions are
questionable.
Rough level the machine by positioning it on foot pads, screwing each
leveling bolt down until it presses into the indentation of the footpad, and
torquing all bolts evenly so the machine does not move.
Electrical Service Requirements
Follow all requirements below to help ensure the safety of personnel and
prevent damage to equipment.
Warning
Always disconnect power before working with
electrical connections.
Connecting Electrical Service
Follow these guidelines:
4
•
On-site wiring, including grounding and protection of the
machine’s transformer, must comply with all established
directives and standards, including local electrical codes.
•
Clean power is essential for operation and reliability.
Dedicated, grounded 3 phase AC power for the machine is
required. This ensures that incoming AC is free from high
and/or low voltages, spikes, surges, and high frequency
noise caused by inductive loads.
Revision A
Bedmills and Machining Centers
CE Machine Standards
Hurco
•
Make certain that the AC power source matches the voltage
specifications on the machine’s electrical cabinet. This
information is listed on the machine’s data plate.
•
Wiring to the machine must be capable of supplying the
continuous specified amperage.
•
Failure to provide the required power parameters may affect
safety, machine performance and the warranty.
•
Do not make any electrical connections to the machine. Run
electrical power to the machine’s location, with adequate
cable length to reach the connections in the power cabinet.
Final connections must be supervised by a Hurco Certified
Service Engineer.
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CE Safety Manual
Recommended Isolation Transformer Configuration
If you decide to use a transformer not provided through Hurco, select a
transformer that meets Hurco’s machine operating voltage requirements.
Use one of the configurations shown in the figure below. Hurco
recommends the Wye system.
Figure 1..
6
Delta and Wye Transformer Configurations
Revision A
Bedmills and Machining Centers
CE Machine Standards
Grounding Equipment
The machine’s electrical and electronic control systems are
interconnected, terminating at the Protective Earth (PE) (i.e., ground)
point.
Hurco
•
This terminal, which is located inside of the machine’s
power cabinet, must be properly connected to the ground
circuit of the AC power source.
•
This single point ground provides only one conducting path
between the machine and external ground, preventing an
unwanted ground loop (ground differential voltage).
•
A ground loop can appear to the control as common mode
electrical transient. The grounding conductor must be sized
to conform to all applicable electrical codes. However,
Hurco recommends that the size of the neutral conductor
(when applicable) be at least the size of the phase (current
carrying) conductors.
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CE Safety Manual
Compressed Air Requirements
A continuous supply of clean and dry air is essential for proper machine
operation, and must be connected to the machine as described here.
Specification
Compressed air must conform to the specification: 5 CFM at 80-100 PSI
or 0.14 M3/min at 6-8 bar.
Connecting Compressed Air
Install the air supply line to the machine, meeting these requirements:
•
Connect the air supply line to the machine using an NPT
pipe fitting.
•
Install a regulator valve to control the air pressure into the
machine.
•
Install a factory-set pressure switch to shut off control
voltages if the air pressure falls below the pre-set level.
•
Use a minimum 1.27 cm diameter (trade size) pipe, or an
equivalent 1.99 cm diameter air hose supply line to the
machine. This will ensure adequate air volume for proper
machine operation.
•
Install a drip leg in the line ahead of the filter/regulator
assembly. The drip leg will help remove moisture
accumulation in the supply, making the filter last longer.
•
Do not use quick coupler type fittings at the connection to
the air filter/regulator, or within the supply line to the
machine. This is because of the restrictive nature of these
fittings.
Anti-Vibration Mountings
Anti-vibration mountings consisting of a spring-mounted ball bearing are
attached to each machine. Loose springs and balls are signs of excessive
vibration.
Check the mountings before uncrating the machine to ensure that the
machine has been handled properly prior to its arrival. Continue to inspect
the mountings on a regular basis.
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Bedmills and Machining Centers
CE Machine Standards
Initial Test and Examination
Follow the instructions below for performing the initial test and
examination of the machine and its guarding system before first use and
placing the machine into production.
Contact your Hurco Distributor to arrange for a Hurco Service Engineer to
perform the final leveling procedures. Complete these procedures prior to
the Service Engineer’s arrival:
•
Provide utilities such as electrical service and compressed
air.
•
Check all lubrication levels.
•
Place the flood coolant tank, tubing, and coolant pump
motor near the machine base.
The Hurco Service Engineer performs these tasks:
1.
Inspects the machine level and makes required adjustments.
2.
Checks and connects electrical service to the machine.
3.
Installs the control console.
4.
Measures voltages in the electrical cabinet and control
enclosure and makes adjustments if needed.
5.
Installs the flood coolant tank, tubing, and coolant pump
motor.
Caution
The motor encoder and cable assemblies are designed to resist
coolant and liquid contamination. However, Hurco will not be
responsible for failures due to abuse and direct spray of coolant
during cleaning, etc.
Hurco
6.
Installs covers and enclosures as applicable.
7.
Checks fans and pumps for proper operation.
8.
Checks all axes for calibration and correct limit switch
operation.
9.
Tests the disk drive.
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CE Safety Manual
Periodic Maintenance
Follow this periodic maintenance schedule for machine, guards, and
protective devices, Refer to the Maintenance Manual for detailed
maintenance procedures.
Cleaning the Machine
The machine should be cleaned on a regular basis:
•
Machined and unpainted surfaces should be wiped clean
with a lint-free cloth dipped in a clean light machine oil.
•
The machine’s exterior painted surfaces may be cleaned
with a soft cloth dampened with water and a mild detergent.
•
The control console’s exterior surface may be cleaned with a
soft cloth moistened (not wet) with water and a mild
detergent.
•
The console screens may be wiped with a damp, soft, lintfree cloth.
Equipment Maintenance
Before any maintenance or repair operations are performed within the
electrical cabinet, the machinist or maintenance representative must verify
that the power switch has been turned to the Off position before the
electrical cabinet door is opened.
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Bedmills and Machining Centers
CE Machine Standards
Recommended Routine Maintenance
A regular schedule of lubrication and maintenance checks is required to
ensure continued dependable operation of the machine. It should be noted
that machine maintenance is dependent upon the amount of use, severity
of operation, and machine environment. Therefore, maintenance frequency
should also be determined on an individual basis and varied accordingly.
For more details about these procedures, refer to the Maintenance Manual.
Daily
Perform these maintenance checks on a daily basis:
Inspect and clean Coolant Tank or Chip Tray Filter Screens.
Hurco
^
Check all lubrication levels particularly in the Autolube
system and the air line lubricator.
^
Check air pressure at the Filter, Regulator, and Lubricator
(FRL) assembly in the pneumatic system.
^
Check coolant level(s).
^
Check the ways for proper lubrication and any scratches or
excessive wear. Be certain that the way wipers are not
damaged.
^
Check for and remove dirt, dust, fingerprints and other
materials from the touch screen that could degrade its
optical properties. The touch screen is abrasion-resistant.
However, contact with abrasive materials, such as metal
chips clinging to an oily glove, can scratch the front
surface. For best results, use a clean (damp) non-abrasive
cloth towel and any commercially available window
cleaner to regularly clean the surface. Apply the cleaning
solution to the towel rather than to the surface of the touch
screen.
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CE Safety Manual
Weekly
Perform these maintenance checks on a weekly basis:
^
Check the moisture drains from the FRL Unit and check
lube level.
^
Refill Autolube tank with proper lubricant.
^
Perform necessary cleaning of machine.
^
Check filter screen on the spindle oil cooler (if installed).
^
Inspect tools and tool holders and replace worn inserts,
shims, and clamp screws as needed. It is important to keep
the tools sharp since dull and damaged tools break easily
and impair part quality.
Monthly
Perform these maintenance checks on a monthly basis:
^
Check condition of tool holders.
^
Check the fasteners securing limit switches and the dogs to
be certain they are tight.
Quarterly
Perform these maintenance checks each quarter:
^
Clean and inspect flood coolant system.
^
Check ground impedance level on a quarterly basis during
the first year of installation.
Semi-Annually
Perform this maintenance check on a semi-annual basis:
^
Replace Autolube tank suction filter.
^
Replace Lube Metering filter.
Annually
Perform this maintenance check annually:
^
12
Check ground impedance level (resistance to true earth).
Revision A
Bedmills and Machining Centers
CE Machine Standards
Safety Circuits
If the owner or operator modifies the hardware or software by removing,
altering, disabling, or tampering with any safety circuit, safety switch, or
any safety operation and then continues to operate the machine with those
modifications, such operation is extremely hazardous, is also a foreseeable
misuse of the machine, and voids the Hurco warranty. If the owner or an
operator finds that such modifications have been made, that person must
immediately switch off the machine and prevent use of the machine until it
has been repaired. The owner must then contact a Hurco service
representative for assistance in restoring the machine to safe operation.
Important
In many locales, machine hardware or software modification to
override safety protections and continued operation of such a
modified machine is illegal and punishable with a fine and/or
imprisonment.
Guidelines
The machining center safety circuit is designed to provide safe and
reliable operation on Hurco products. The basic rules governing operation
are as follows:
Hurco
•
The spindle cannot operate unless all enclosure doors are
closed, not including doors that are fastened shut with bolts
or screws.
•
Enclosure doors must be closed, and locked, when initiating
or performing automatic motion. This includes part program
execution, warm-up cycle, calibration cycle, automatic tool
changes, probing cycles, etc., or when running the spindle
(excepting orient).
•
In the event that the enclosure door is opened during
automatic operation, or any time the doors are locked, an
immediate command to stop all motion will be executed and
control power will be removed.
October, 2000
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CE Safety Manual
•
Redundancy is included in electrical design to detect single
point failures (switch contact, relay coil, etc.)
•
Upon removal of control power, and a set time delay
(approximately 7 to 10 seconds to allow for deceleration),
the spindle drive will be removed from its source power
rendering it totally disabled.
•
ATC electrical circuits will be isolated from source power
when any door is open.
Tamper-resistant fasteners are used to hold combination door
lock/switches in place and to prevent access to internal wiring.
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Revision A
Bedmills and Machining Centers
CE Machine Standards
CE Safety Circuits Commissioning Checklist
Check the safety circuits after changing component parts and periodically.
Checklists are provided below for Manual Setup, Automatic Preparation,
and Automatic Production Modes:
Mode: Manual Setup
Door(s) Status: Open
Access code: Enabled (Limited operation)--- VMX/VSX only
A four-digit code is required for enabling limited safe operation such as
jogging axes with the chip doors open. The code is entered in the
CE Status & Diagnostics screen.
Safety Requirement
1. Control shall not allow “Spindle On”
to be selected.
2. Calibration cycle shall not be
initiated.
3. Control shall not allow tool change to
be initiated.
4. Axes may be jogged at maximum
feedrates of 2 M/min.
5. Chip auger shall not run.
6. Part program execution shall not be
initiated.
Verification
<Error message> displayed
when Spindle On key depressed.
<Error message> displayed
when softkey is depressed.
<Error message> displayed
when tool change cycle initiated.
Initiate jog cycle at maximum
allowable feedrate.
<Error message> displayed
when auger softkey depressed.
<Error message> displayed
when automatic mode enabled.
Hurco
October, 2000
Pass
Fail
15
CE Safety Manual
Mode: Automatic Preparation
Door(s) Status: Closed
Mode: Manual
Safety Requirement
1. The axes may be jogged at maximum
allowable without restriction
2. All tool change cycles shall be
permitted.
3. Chip auger functions shall be
permitted when function is selected.
16
Revision A
Verification
<Error message> displayed
when doors opened with jog key
depressed; all motion ceases
upon opening.
Verify all doors lock when tool
change key selected.
^)URQWHQFORVXUH
^6LGHHQFORVXUH
^$7&ORDGLQJ&$7
Verify all doors lock when
softkey function is selected.
^)URQWHQFORVXUH
^6LGHHQFORVXUH
^$7&ORDGLQJ&$7
Pass
Fail
Bedmills and Machining Centers
CE Machine Standards
Mode: Automatic Production
Door(s) Status: Closed.
Safety Requirement
1. Doors shall remain locked
throughout part program execution.
Verification
Verify all doors lock in auto
mode when “START CYCLE”
pushbutton is engaged.
^)URQWHQFORVXUH
^6LGHHQFORVXUH
^$7&ORDGLQJ
2. Doors shall unlock in auto mode only Verify doors unlock after axis
after all motion ceases.
and spindle stop with program
abort engaged (Stop Cycle
pushbutton or Interrupt Key)
3. Doors shall remain locked during an Verify all doors remain locked
ESTOP condition.
when ESTOP is engaged during
part program execution.
^)URQWHQFORVXUH
^6LGHHQFORVXUH
^$7&ORDGLQJ
4. Doors shall unlock only after the
Verify all doors unlock only
fault condition has been reset.
after control power is restored
(reset and Control On).
Hurco
October, 2000
Pass
Fail
17
CE Safety Manual
Safe Operation, Setting, and Maintenance
This section addresses the safety hazards encountered with the intended
use and the foreseeable misuse of the bedmill and BMC machine tools.
However, this information is not an exhaustive description of all of the
possible misuses of the machine nor is it a substitute for operator training,
skill, and good judgment. Hurco does not accept any liability for operator
error.
Training for Operators
All operators must be trained machinists. The machinists who run the
machine tool must be trained by Hurco or a Hurco authorized distributor.
Before attempting to operate the machine tool, study this manual and
become familiar with the machine functions and safety features.
While studying the manuals that accompany the product, make special
note of the caution and warning messages and all warning and instruction
plates or decals on the machine tool.
18
Revision A
Bedmills and Machining Centers
CE Machine Standards
Setup
Follow these precautions during machine and production setup:
Hurco
•
Perform all setup work with the ESTOP engaged. This
includes adjustments to the workpiece, fixture, and coolant
nozzles. Never put your hands near a part being machined.
•
Clamp the workpiece and fixtures securely before starting
the machine. Remember, loose objects such as wrenches and
chuck keys can become flying projectiles if not removed
before the machine is started.
•
Wear gloves or use a shop cloth when handling tooling.
•
Inspect tools and tool holders frequently. Use tools that are
properly sharpened and in good condition. Replace worn
inserts, shims, clamp screws (etc.) as needed. (Dull and
damaged tools break easily.)
•
Never start the machine when the cutter is in contact with
the workpiece. Make sure the direction of spindle rotation is
correct to prevent cutter breakage. (Rotate the spindle
clockwise for right-hand tools, and counterclockwise for
left-hand tools.)
•
Keep the work area well-lighted, using additional lights if
necessary. Adjust lamps so that light does not shine directly
into your eyes.
October, 2000
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CE Safety Manual
Operation and Maintenance
•
Know where the Emergency Stop pushbuttons are located.
•
Do not leave the machine unattended, but stand away while
it is running. Never lean on the machine.
•
Be aware of all pinch points caused by the motion of the
table, head and Automatic Tool Changer. Be aware of
protruding machine parts (such as hoses, piping, etc.).
•
Keep the electrical cabinet doors closed while power is on.
Before opening the electrical cabinet doors, verify that the
main disconnect switch has been turned Off.
Warning
High voltages present in the machine’s electrical
system can cause serious injury or even death.
20
•
Do not remove or bypass safety limit switches, interlocks
and other safeguards. Doing so (to obtain more travel, etc.)
can seriously damage the machine. If a job requires greater
range than the limit switches allow, for example, do the
work on a machine that has the necessary travel.
•
Do not start the machine unless all systems contain the
proper amount and type of lubricant.
•
Make certain that all necessary guards and protective
devices are in place before operating the machine.
•
Be aware of any unusual sounds, smoke, heat or damaged
parts. Turn off the machine immediately and report the
problem to a supervisor.
Revision A
Bedmills and Machining Centers
CE Machine Standards
Safe Working Practices
This product was intended to be used by trained machinists who create
part programs either on the machine tool console or an off-line system.
These machinists then run the part programs to shape materials into parts
or molds. While running the machines, the machinists must use their
experience and training to make any necessary adjustments and improve
the efficiency of their programs.
In order to ensure the safe operation of machinery, follow the correct
service and repair procedures. This reduces the likelihood of serious
injury. All service personnel must be careful that their actions will not
jeopardize the safety of others or damage the machine.
Safety precautions appear below. Observe these basic precautions when
working near a machine:
Responsible Conduct
Hurco
•
Follow the instructions provided when performing a
maintenance task.
•
Keep all parts of your body away from moving parts.
•
Be alert and keep safety in mind. Realize that the work you
are performing can be dangerous.
•
Never attempt to operate or repair a machine if you have
taken strong medication, used a prescription drug, or
consumed an alcoholic beverage.
•
Do not attempt to operate or repair a machine until you have
read and understood all information that pertains to the
machine. This includes all warning and instruction plates or
decals mounted on the machine.
•
Know how the machine functions, and understand its safety
features. Ask your supervisor for help if needed.
October, 2000
21
CE Safety Manual
Personal Care
Follow established working practices and personal hygiene standards. As
part of this effort, avoid frequent or prolonged skin contact with fresh or
used cutting fluids and oils. Some operators wear gloves or use a special
hand cream to protect their hands from these chemicals. If you get
machining chemicals on your hands, wash your hands immediately upon
leaving the machine and before taking a break. Change clothing that has
become contaminated with machining fluids and oils.
For complete information about handling industrial chemicals used in
machining, refer to the international Control of Substances Hazardous to
Health (COSHH) materials from the chemical suppliers.
Wearing Apparel
•
Any time you are in the work area, wear eye protection and
safety shoes. Safety glasses with side shields are
recommended. Safety shoes should be in good condition (no
holes), with steel toes and oil-resistant soles.
•
Remove items that could get caught in moving parts. This
includes watches, rings and other jewelry, and neckties. Do
not wear loose-fitting clothing or long shirt sleeves. Roll
long sleeves above the elbow.
•
Keep long hair tied-back so that vision is not obstructed and
hair cannot become caught in moving parts.
•
Remove your gloves before starting the machine.
Heavy Lifting
22
•
Do not attempt to lift more than you can safely handle. Keep
your back straight and use your legs.
•
Use a hoist for heavy lifting, making sure that the load is
evenly balanced and is raised slowly.
•
Do not raise the load over aisles and make certain that the
landing area is clear and level.
Revision A
Bedmills and Machining Centers
CE Machine Standards
Housekeeping
Hurco
•
Maintain a clean and orderly work space around the
machine. The floor must be free of coolant and oil spills. Do
not allow stacked cartons, supplies, etc. to obstruct the area.
•
Use only sturdy work platforms with anti-slip surfaces
around the machine.
•
Do not store tools, shop cloths, and miscellaneous parts on
the machine. Keep these items on workbenches, shelves, etc.
•
Dispose of chips properly. Do not use compressed air to
blow them from the spindle, table, controls, cabinet or floor.
Use a brush or chip scraper to remove chips. Do not remove
chips by hand, or while the spindle is turning. The cutter
must be completely stopped. Dispose of chips frequently.
October, 2000
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CE Safety Manual
Control Systems
Instructions on control systems including circuit diagrams for electrical,
hydraulic, and pneumatic systems are available in the accompanying Parts
Listings and Wiring Diagram Manual.
Noise Levels
The following noise level readings were taken in the vicinity of the
Ultimax CNC, 1.6 meters from the floor, 1 meter from the machine’s
enclosure. The maximum ambient noise level reading taken for each
machine at the time was 60 dB.
Measurements were made with background noise present using a dB meter
set on A-rated scale. The sensor head was placed vertical to the floor.
Readings Measured From CNC
Machine Type
dB Reading
VMX64
max 82 dB
VMX30
max 77 dB
VMX40
max 82 dB
VMX24
max 79 dB
HAWK30/40
max 75 dB
Note
The figures quoted above are emission levels and are not necessarily
safe working levels. While there is a correlation between the
emission and exposure levels, this cannot be used to determine
whether further precautions are required. Factors that influence the
actual level of exposure of the workforce include characteristics of
the workroom, other sources of noise, etc. i.e. the number of
machines and other adjacent processes. Also the permissible
exposure level can vary from country to country. This information,
however, will enable the user of the machine to make a better
evaluation of the hazard and risk.
24
Revision A
Bedmills and Machining Centers
CE Machine Standards
Descriptions of Failure Modes
Failure conditions can be evident during power up and operation.
Descriptions follow for detection and prevention.
Power-Up Troubleshooting
HURCO
Troubleshooting
If a problem occurs during power up, look for one of the following
symptoms:
•
No messages appear on the console screen. The system may
beep, but it does not start up.
•
Error messages appear during the initialization process
before the Input screen appears.
•
Error messages appear on the Input screen.
Warning
Before testing live circuits or attempting any repairs to
electrical connections, be certain that the power switch
on the electrical cabinet is in the Off position. Follow
all established safety practices. Remember that the
power line from the source to the machine may be live
even though the machine tool is not receiving power.
Hurco
October, 2000
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CE Safety Manual
No Response on the Console
If no messages appear on the text screen after switching on power, make
sure of the following:
•
Power supply cord on the Card Rack inside the Electrical
Cabinet is properly connected to the power source.
•
Power switch on the Card Rack inside the Electrical Cabinet
is in the On position.
•
No floppy disk is in the floppy drive.
If these conditions are met, but the control still does not respond, contact
the machine shop’s maintenance department or the machine
manufacturer’s technical services department.
26
Revision A
Bedmills and Machining Centers
CE Machine Standards
Initialization Error Messages
After power has been switched on, initialization messages appear on the
text screen. If an error message appears, there are many possible causes.
The error messages indicated below can be easily corrected by an
operator.
“Non-system disk detected.
Press any key.”
This message means there is a diskette
in the floppy drive. Remove the
diskette and turn the power off and
then back on.
“Security device is invalid or
has failed.”
The software security key has been
removed, is broken, or is not properly
connected. Switch off the control and
remove the security key. If the key is
damaged, replace it. Reconnect the key
and switch on power.
Other possible messages during initialization usually indicate missing or
corrupted files. The usual solution for such problems is to restore or delete
files. For help solving these problems, contact Hurco’s service department
or the distributor’s service department.
However, before asking for help, see the following important notice.
Important
Before calling a service representative for assistance, always switch
off the control at the power button, wait a few minutes, and then
power on again. If the problem continues, call the machine
manufacturer’s technical services department.
Hurco
October, 2000
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CE Safety Manual
Error Messages on Input Screen
Occasionally, the system will go through all of the initialization steps,
display the Input screen, and then refuse to respond when console keys are
pressed.
If this occurs, you should take careful note of any error messages on the
Input screen. If there are no error messages, the cable to the front panel
may be loose or defective. If the shop has a maintenance department that
repairs computers, a machine maintenance staff member may be able to
check the custom cable inside a conduit. If it needs to be replaced, call
technical services to perform the operation.
Corrective Measures
One or more of the following corrective measures may be necessary:
Swap Out a Printed Circuit Board
If a PC board is suspect and you can get a replacement, try swapping out
the board.
If swapping out a board corrects the error, one of the following problems
was the cause:
•
The original board is bad or has an intermittent
problem.
• The connector was not making good contact.
Install the original PC board to see whether the error returns. If not, the
connector probably was not seated properly or the contacts need cleaning.
Check Wiring
Perform these checks:
•
•
•
•
28
Trace the wiring as far as possible.
Wiggle connectors and ensure they are properly
seated.
Check the connections with an ohmmeter.
Unplug and reseat circuit boards; sometimes
connectors become tarnished and do not conduct
well. If the contact points on a PCB are dull
looking, polish them with a common rubber pencil
eraser.
Revision A
Bedmills and Machining Centers
CE Machine Standards
Perform a Reset
Technical assistance personnel may ask you to reset a circuit board or the
machine.
•
•
To reset a PC board, press the board’s reset button.
To reset the machine, switch the main power off
and then back on.
Emergency Stop Condition
While troubleshooting, you may encounter the Emergency Stop condition
or instructions to go to the Machine Diagnostics screen. An error condition
occurs if the Emergency Stop button is depressed, or a machine system
needs service. These conditions are easily corrected.
Pressing the Emergency Stop button removes all servo power and power
to the way lubrication pumps. The current program resets to the beginning.
A message on the screen indicates the Emergency Stop condition. To
remove the Emergency Stop condition, execute these steps:
1.
If the Emergency Stop button is depressed, twist and lift it.
2.
Press these console buttons in this order:
a.
Manual
b.
Power On
c.
Start Cycle
Manual Safety Override Mode (BMC only)
A Safety switch is installed on the chip doors and is operated with a key.
This switch has a Safety Override position that permits opening the
enclosure doors when the system is in the manual mode. With the doors
open, manual functions such as adjusting the fixture can be performed.
However, the jog feed and spindle are restricted. The Safety Override is
cancelled when the chip doors are closed and one of the following console
keys is pressed: Input, Single, Auxiliary, Test, Auto and Review.
When the key is turned to the Protected Operation position, all movement
is prohibited when the chip doors are opened. Removing the key from the
switch locks the machine into protected operation (see Conversational Part
Programming in the Condensed Operator’s Manual).
Hurco
October, 2000
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CE Safety Manual
Machine Diagnostics
Several error messages direct you to the Machine Diagnostics screen. The
control detects the status of various machine components, and presents
this information on the diagnostics screen. For example, the status of the
Autolube level will be either OK or Low Level.
The ATC and Machine Diagnostics screen shows the current status of the
machine tool limit switches. To reach the Machine Diagnostics screen,
follow these steps:
1.
Press the console Manual key.
2.
Select Machine Diagnostics (F2)
3.
Select ATC and Machine Diagnostics (F7)
If an error condition is displayed, follow these steps:
1.
Correct the problem and view the diagnostics screen again.
2.
Once the error status is corrected, exit the screen.
3.
Restart and calibrate the machine.
Bedmills sold in Europe have a Chip Enclosure and a limit switch to
indicate whether or not the enclosure doors are open or closed. If the doors
are not completely closed, the Door Open field will be highlighted. Press
the enclosure doors together to clear the error and begin machining.
30
Revision A
Bedmills and Machining Centers
CE Machine Standards
Common Problems
Possible problems are listed below, with causes and solutions. These
problems are usually noticeable without the help of error messages,
although error messages may occur. More than one problem can result
from a single cause.
Power-on Self Test
When you turn on the machine, the control performs a self test. If an error
in the control circuitry is detected, a pattern of beeps may sound instead of
the normal start-up beep. A screen error message may appear. Do not
ignore these indications. Write down all messages.
Machine Voltages
Missing or faulty connections can cause a combination of problems. High
impedance conductors to Ground (PE) or to Neutral can also interrupt
voltages to machine systems.
Connections
Missing
Improper
Loose
Table 1.
Hurco
Description
Open grounds
Open neutrals
Open phase connections
Missing neutral-to-ground strap at main
source
Phase and neutral reversed
Phase and ground reversed
Ground and neutral reversed
Ground and neutral shorted at panel
At main panels
At equipment
At other equipment in system
At service entrance
Missing or Faulty Connections
October, 2000
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CE Safety Manual
Fluctuating voltages to the machine can create problems. Power transients
can come from inside or outside of your facility. They often occur when
power usage in your region is high (typically on a very hot or cold day).
Problems
Fuse blows
Power is lost.
Causes
Power
sag
Solutions
Repair faulty in-plant wiring.
Move any other machines on the
circuit to separate circuits.
Motor(s) overheat
Control PC boards
and/or
microprocessor fail
Power
spike
Move any nearby high current
switching devices (arc welders,
inductive motors) away from the
machine.
Properly ground equipment and
install surge protection to insulate
against lightning strikes.
Machine stops
Data is lost.
Table 2.
Problems Due to Power Transients
If a machine malfunction occurs, consider the following issues:
•
Is another machine that uses high current connected to the
AC distribution power supply line?
•
Is the ground impedance of the AC distribution power
supply line sufficient?
•
Are there fluctuations in the input voltage to the machine?
•
Is there a source of “noise” nearby (crane, welder, etc.)?
•
If other CNC or NC machines are connected to the same
group of circuits, do any of those machines demonstrate
similar problems?
•
Was another machine being operated at the same time the
problem occurred?
•
Does the problem occur mainly at a certain time of day
(such as, start of work shift, noon, etc.)?
Note
Power surges can occur when large loads are suddenly placed on, or
removed from, an electrical system.
32
Revision A
Bedmills and Machining Centers
CE Machine Standards
Coolant System
If a problem occurs with the coolant system, check these possibilities:
Problems
Coolant flows
slowly or stops.
Causes
Clogging due to dirty
coolant
Pump is not working
properly
Solutions
Flush lines, clean filters, drain and
refill the system with fresh coolant.
Check and service the pump. For
mist system, check shop air
pressure.
No liquid (only
air) comes from
mist nozzle
Coolant tank is empty
There is too much air
in the system.
Coolant valve is not
turned On
Coolant is not
programmed to be
On.
Incorrect program
parameters
Fill coolant tank with fresh coolant
Close off valve, then slowly open
again to get desired flow
Turn on the valve (via the control).
Coolant fails to
start when head
lowers to Z up
level or below
Coolant fails to
stop when head
is up to Z retract
level
Table 3.
Check the operating mode (auto or
manual) or programming.
Check parameters and correct the
setting.
Coolant System Problems
Machine operation failures, such as a coolant valve not opening, can be a
programming or hardware problem. Hardware includes electronic
components, wiring, and electro-mechanical devices.
Hurco
October, 2000
33
CE Safety Manual
Motion and Spindle Rotation
If the spindle or an axis does not move the way it was programmed to,
moves without being instructed to, or spindle rotation is incorrect, refer to
the following table.
Problems
Spindle does
not turn.
The machine’s
control power
is Off and the
screen shows a
Motion Error
message.
Causes
Program might
not have proper
RPM setting
Spindle drive
breaker is
tripped
Actual collision
or binding
occurs between
machine parts
and product
fixtures.
Chip buildup
causes a Motion
Error
The X, Y and Z
axes ballscrews
are not well
lubricated.
Servo cable
connections are
not making good
contact.
Error LED is On
servo(s)
Servo encoder or
decoder not
working properly
Continued on next page.
34
Revision A
Solutions
Check the RPM setting in the program. If
this setting is wrong, check and correct
the entire program.
Power down the machine, reset the
breaker on the spindle amp and turn on
power.
Examine the path, parts and fixtures for
evidence of collision or rubbing.
Look under chip covers for excessive chip
buildup. Clean and maintain to avoid
reoccurrence.
Check the lube oil level, lubrication to the
way ballscrews, and lube pump operation.
Correct as needed.
Check each connector (by hand, visual
check is not enough). Clean, press
together and wiggle. Replace the
connection if it is intermittent during
wiggling.
Note the location of lighted LED(s).
Phone for technical assistance.
Jog the machine while watching position
numbers on the screen.
Bedmills and Machining Centers
CE Machine Standards
Continued from previous page.
Problems
The machine
chatters while
machining or
cutting
Causes
Machine feeds
too fast
Wrong tool, tool
is damaged, or
tool is not sharp
Fixture is not
rigid enough
Tool is not held
perfectly straight
Small errors in
dimensions
show up
occasionally
Table 4.
Hurco
Temperature
fluctuates as the
part is machined.
Solutions
Check the program settings for Feed and
Speed – reprogram if they are wrong
Make sure that the actual speed matches
the programmed speed.
Make sure the right tool is being used for
the application.
Make sure the tool shaft is clean and not
bent.
Verify that the tool is sharp.
Check the fixture. Tighten or reinforce it
if needed.
Check the spindle taper for foreign
material. Clean the taper if necessary.
Check the tool holder to see that the tool
is inserted straight. Reinsert the tool if
needed.
Check tool retention force on the draw
bar.
Stabilize the temperature of the blank by
providing enough coolant while
machining.
Motion and Spindle Rotation Problems
October, 2000
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CE Safety Manual
Environmental Conditions
When the electrical cabinet overheats, this causes the machine to shut
down until the cabinet’s temperature sensor registers that the temperature
has dropped to an acceptable level. If this error occurs, check the
temperature around the electrical cabinet to be certain the cabinet is not
subjected to an additional heat source such as a space heater or bright
sunlight from a nearby window.
Temperature and other environmental variables can cause problems which
might otherwise be attributed to the machine.
Problems
Relatively small
dimensional
problems occur
in the product.
Dust, debris,
rust or
discoloration
accumulates on
work surfaces.
Table 5.
36
Causes
Metal blanks stored in
temperatures much higher
or lower than the
temperature of the
machining area can expand
or contract during and after
machining.
Extreme temperatures are
typical, and/or the
environment is too humid or
dusty.
Solutions
Before machining, move the
blanks to the machine area
and allow the blanks time to
reach ambient temperature.
Improve the machine’s
environment. (For example,
close the machining area to
outside dust, etc., and install
air conditioning to lower
room temperatures and
humidity.)
Environmental Factors
Revision A
Bedmills and Machining Centers
CE Machine Standards
Fluid Specifications
Although lubrication procedures have been performed at the factory and
during final installation, check all lubrication levels. This not only
familiarizes you with the lubrication points, but further guarantees safe
operation of the machine. In order to keep the machine in good operating
condition, the operator must periodically check and maintain all lubricant
levels.
Lubrication
Lubrication points and recommended lubricants appear in the table below.
This is not a complete list of lubricants. Lubricants that meet the same
specifications as those listed below may be substituted. It is the customer's
responsibility to ensure that the lubricant used is an equivalent of the
recommended type. Local suppliers should be able to cross reference
recommended lubricants.
Lubricant
Lubricant and
Lube Point
Fill Level or Condition
Type
Manufacturer
ATC Oil Unit
Maintain reservoir at 1/3 full. I.S.O. V.G. 32 Teresso 32
(Esso),
40-Taper 24-station
Swing Arm ATC
DTE Oil Light
(Mobil),
Hydraulic Power
Top of the tank’s sight gauge
Unit
Tellus Oil 32
40-Taper 40-station
(Shell),
and 50-Taper Swing
Turbo 32
Arm ATC
(Shell),
FRL Unit
Between the high and low
Magnus Oil 32
(Filter, Regulator,
marks on the plastic bowl
(Phillips),
Lubricator)
Hyken Golden
Optional High Speed Midway on the sight gauge
(Kendall)
Machining Spindle
Oil Cooler
Continued on next page.
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October, 2000
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CE Safety Manual
Continued from previous page.
Lube Point
Tool Release
Cylinder
Fill Level or Condition
Maintain at 1/3 full, not to
exceed 1/2 full. Otherwise,
oil will flow out during
pumping of cylinder.
Autolube
Linear Way
Ballscrew
Between the high and low
marks on the reservoir. If
machine will be idle for 30
days or more, use rust
protection additive.
If machine will be idle for 30
days or more, clean the taper
and wrap it in a cloth soaked
with this lubricant and rust
protection additive
Spindle Taper
Table 6.
38
Lubricant
Lubricant and
Type
Manufacturer
I.S.O. V.G. 32 Teresso 32
(Esso),
DTE Oil Light
(Mobil),
Tellus Oil 32
(Shell),
Turbo 32
(Shell),
Magnus Oil 32
(Phillips),
Hyken Golden
(Kendall)
I.S.O. V.G. 68 Febis K68
(Esso),
Vactra No. 2
(Mobil),
Tonna Oil T68
(Shell)
Lubrication for BMC Machines
Revision A
Bedmills and Machining Centers
CE Machine Standards
Autolube System
The Autolube system automatically lubricates the slideways and
ballscrews. If the axes are idle for 30 days or more and a rust preventative
is added, initiate a manual lube cycle and move all axes for full travel
several times. Pump flow is delivered to main oil manifolds, where it is
sent through fixed metering fittings and tubing for delivery throughout the
system. The discharge rate of the meter fittings is not adjustable.
To prevent contamination from entering the lines and fixed metering
fittings, the system lines contain lube metering filters. These filters must
be checked periodically, and replaced if they become plugged.
Perform maintenance according to the schedule in the “Periodic
Maintenance—Equipment Maintenance” section earlier in this manual.
System lubrication is a timed cycle. The pump will cycle once every 15
minutes to send the preset discharge rate of lube oil through the system
when servos are On. The preset discharge rate, which is 3.0 cc per pump
cycle, is adjustable. The cycle time and discharge rate are the same for
bedmills.
Note
Excess servo On time without table or head movement may cause oil
to accumulate on the table and the slideways. This is normal since
automatic lubrication operates at predetermined time intervals while
the axis servo motors are energized. Control has a Power Off Timer
that automatically shuts off Control Power after the machine is idle
for a specified time. This prevents the Lube Pump from cycling and
causing excess lubrication and spills.
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October, 2000
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CE Safety Manual
Here is a diagram of an Autolube system.
1 Set screw
2 Discharge plunger
3 Indicator rod
4 Electric motor
9
10
11
12
5 Strainer, oil filter
13
6 Reservoir worm
and gear lube
7 Screw, cover
mounting
8 Screw, reservoir
mounting
14
Figure 2.
40
15
16
Retaining ring
Reservoir
Screw
Float switch
assembly
O-ring
17
18
19
20
Motor cover
Grommet
“Thru” coupling
Reservoir gasket
21
Suction filter
group
Screw, cover
mounting
Gasket, motor
cover
22
Mounting bracket,
reservoir
Reservoir gasket
23
Outlet tube assembly
24
Outlet check valve
assembly
Autolube Pump and Tank Assembly
Revision A
Bedmills and Machining Centers
CE Machine Standards
Check Filler Screen and Fluid Level
Maintain the fluid level and check the filler screen:
1.
Lift the oil filler cap and check that the screen is clean.
•
•
2.
If it is dirty, remove and clean it using a suitable
solvent.
Dry the screen before reinstalling it.
If needed, add oil to the tank. The level should be between
the high and low marks (about ½" or 1.27 cm from top cover
of tank). Return the fill cap into place.
Activate System Manually
If the machine has been idle for a long time before powering up, or if the
oil has just been replaced, follow these steps to activate the system
manually:
1.
Pull upward on the discharge plunger, then release it.
2.
Stroke the plunger in this manner three to six times.
Adjust Autolube Discharge Rate
The scale graduations on the flat surface of the indicator rod indicate the
discharge rate in cubic centimeters (cc) per pump cycle. This rod is
located in the discharge plunger. To adjust the discharge rate of the
Autolube system, follow these steps:
Hurco
1.
Loosen (but do not remove) the set screw in the center of the
discharge plunger body.
2.
Turn the plunger body clockwise to increase, or
counterclockwise to decrease the pump discharge rate.
3.
Once the required discharge rate is obtained, align the set
screw with the flat surface on the rod. Tighten the set screw
to secure the rod position.
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CE Safety Manual
Replace Oil and Suction Filter
To drain the tank and replace the oil and suction filter, follow these steps:
1.
Shut off power to the machine.
2.
Loosen and remove the two thumb screws that secure the
tank to its mounting bracket.
3.
Lower the tank downward from the threaded spacers.
4.
Remove the suction filter group by first carefully prying out
the retaining ring.
5.
Remove the filter discs and screws. Note their order of
assembly.
6.
Insert the new coarse screen (filter disc support), fine screen
(screen disc, filter disc), filter clamp ring and retaining ring.
7.
Clean any contaminates from inside of the tank. Dry the
inside with a clean, lint-free cloth.
8.
Check that the strainer in the filler opening is clean and not
damaged (i.e., there are no holes, etc.).
9.
Make certain that the gasket is installed and is in good
condition.
10.
Place the tank on its mounting bracket, guiding it over the
threaded spacers.
11.
Carefully tighten the two thumb screws that secure the tank
to its mounting bracket.
Caution
Over-tightening these thumb screws can damage the tank.
42
12.
Check that the screen is installed in the filler opening.
13.
Fill the tank with the recommended oil.
14.
Manually activate the system.
Revision A
Bedmills and Machining Centers
CE Machine Standards
Automatic Tool Changer
The lubrication required depends upon the type of ATC.
ATC Oil Unit
This procedure is for the 40-Taper tool changer that has a 24-station
magazine. If the tool magazine has more than 24 tool pockets, see the
“Hydraulic Unit” section that follows.
This 40-Taper tool changer with 24-station magazine has an enclosed oil
lubrication system. The tool changer housing holds the oil, some of which
is displaced into a small oil reservoir during the tool change cycle.
Maintain the Oil Level
Follow these steps to maintain the oil level:
1.
Check the level – the reservoir cup should be 1/3 full. The
reservoir is located on the front of the tool changer (viewed
from front of machine).
2.
If the oil is low, add the recommended type. (See the table at
the start of this chapter.)
Replace the ATC Oil
To replace the ATC oil, follow these steps:
Hurco
1.
Open the drain plug located near the bottom of the swing
arm transmission casting. Drain the oil.
2.
Flush the system. Use a non-volatile flushing agent that is
suitable for a mineral-type lubricating system.
3.
Replace the drain plug.
4.
Add the suggested oil until the reservoir cup is 1/3 full.
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CE Safety Manual
ATC Hydraulic Unit
This free-standing hydraulic unit runs the rotation of the tool magazine,
the magazine locking cylinder and the tool pot up and down cylinder. The
hydraulic unit also runs the unclamp cylinder for the tool in the spindle.
The following Automatic Tool Changers operate using a hydraulic unit:
•
50-Taper Swing Arm
•
40-Taper Swing Arm with a 40-station tool magazine
The hydraulic oil tank is located at the rear of the machine. The system
holds 80 liters (21 gal.) of oil (50-Taper and 40-Taper machines).
Perform the following service according to the recommended maintenance
schedule in the “Periodic Maintenance—Equipment Maintenance” section
earlier in this manual.
Maintain Fluid Level
Maintain the fluid level in the tank:
1.
Check the tank sight gauge.
2.
If the level is low, add the recommended oil type. For the
correct lubricant type, see the table at the beginning of this
section.
Replace Hydraulic Oil
To replace the hydraulic oil, follow these steps:
44
1.
Drain the oil using the plug at the bottom of the tank.
2.
Flush the system. Use a non-volatile flushing agent that is
suitable for use in a mineral-type hydraulic system.
3.
Check the filter. If necessary, replace it.
4.
Replace the drain plug.
5.
Add the recommended oil type to the tank, checking the
sight gauge on the tank. For the correct oil type, see the
table at the beginning of this section.
Revision A
Bedmills and Machining Centers
CE Machine Standards
Pneumatic System FRL Unit
The pneumatic system includes a Filter, Regulator and Lubricator (FRL)
Unit. The filter cleans incoming compressed air and expels accumulated
moisture through a drain. The lubricator meters oil into the air stream to
lubricate cylinders and valves. The rate at which lubricant is released into
the pneumatic system (i.e., drip rate) is adjustable.
Important
The air supply requirement for the machine is a continuous 5 CFM
of clean, dry compressed air at 80-100 PSI (0.14 M3/min at 6-8 bar).
1
2
3
4
Figure 3..
Lubricator unit
Fill/Oil drip viewer
Drip rate adjust
Air pressure adjust
5 Air pressure gauge
6 Filter unit
7 Auto moisture drain
Filter, Regulator and Lubricator
Maintain the FRL according to the schedule in the “Periodic
Maintenance—Equipment Maintenance” section earlier is this manual.
Hurco
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CE Safety Manual
Set Air Pressure
If the air pressure reading on the gauge does not meet the required
specification, adjust the knob on top of the filter unit to set the correct
system pressure.
Maintain Oil Level
Maintain the oil level between the low and high marks on the lubricator
unit. If oil must be added, do not overfill.
Important
Shut off the compressed air supply before adding lubricant or
removing one of the housings. Use only a recommended oil or an
equivalent. Refer to the table in the “Lubrication” section for
recommended lubricant types. Other lubricants can damage
components in the pneumatic system, including the polycarbonate
housings. If the lubricant becomes contaminated, it can clog the
lubricator element and prevent the necessary oil drip.
Adjust Drip Rate Screw
The oil drip rate was factory-set and should not require adjustment.
However, if the oil drip is not visible at the top of the lubricator unit, turn
the drip rate adjustment screw to obtain one drop of lubricant for every
second tool change.
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Revision A
Bedmills and Machining Centers
CE Machine Standards
Check and Replace Air Filter Element
Check the air filter element in the filter unit regularly and replace it when
necessary. If the filter becomes clogged, the air pressure may still measure
as acceptable, but air flow to the pneumatic system will be restricted.
Caution
When you remove the bowl to access the filter element, clean the
bowl using a soft, lint-free cloth dabbed with the recommended FRL
Unit lubricant. Do not use any type of cleaning fluid.
Before connecting the air supply, install the metal bowl guard.
Check Auto Moisture Drain
Make sure the auto moisture drain is not stuck open and leaking air. If the
drain is stuck open, follow these steps:
Hurco
1.
Shut off the compressed air supply to the machine.
2.
Using a crescent wrench, turn the auto drain nut at the filter
unit bottom counter-clockwise one turn.
3.
Press upward on the nut to release any foreign material that
may be lodged, and to reseat the drain valve.
4.
Tighten the nut clockwise.
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CE Safety Manual
Tool Release Cylinder Air/Oil Unit
An air/oil unit lubricates the tool release cylinder. This applies to
machines equipped with a Swing-in position ATC, and not to machines
equipped with a Swing Arm Random Pocket tool changer.
Maintain the oil level, checking it more often if the ATC is used
frequently:
1.
Remove the set screw.
2.
The oil level should be 1/3 full ideally, up to 1/2 full. If
needed, add oil. Do not fill above 1/2 full, which will cause
oil to flow out of the cylinder when it cycles.
3.
When finished, insert the set screw. Tighten the screw and
then back it out slightly so air can vent.
Spindle Taper
When the spindle is unclamped, air blows from the spindle taper hole. Any
moisture in the air system will be detrimental to the taper, especially when
the machine is stopped for an extended time. If the machine will be idle,
wrap the spindle taper in a cloth soaked with clean Autolube oil.
Optional Spindle Oil Cooler
The optional spindle oil cooler is used to maintain the temperature of
cooling oil that is force-circulated around the spindle cartridge. This action
cools the head and helps stabilize its operating temperature. This cooling
effect reduces thermal growth, which improves machining accuracy.
If the oil level in the tank is not maintained at or above the low mark,
foaming could result and damage the system’s pump. Additionally,
spindle cooling would be impaired.
Service the spindle oil cooler according to the schedule in the “Periodic
Maintenance—Equipment Maintenance” section earlier is this manual.
48
Revision A
Bedmills and Machining Centers
CE Machine Standards
Maintain Oil Level in Spindle Oil Cooler Tank
To maintain the oil level in the spindle oil cooler tank, follow these steps:
1.
Check the level. Units typically have a sight gauge.
2.
If the level is low, shut off the oil cooler.
3.
Add the recommended oil to the tank. Leave space at the top
to allow for hot oil expansion. Do not overfill.
Inspect the Air Filter Screen
To inspect the air filter screen, follow these steps:
1.
Shut off the spindle oil cooler.
2.
Clean the air filter screen if it is dirty.
Maintain Oil in Cooling Tank
To drain, flush and refill the cooling tank yearly, and any time the oil
shows signs of contamination or overheating, follow these steps:
Hurco
1.
Shut off the spindle oil cooler.
2.
Drain and flush the tank. Use a non-volatile flushing agent
suitable for use in a mineral-type hydraulic system. This
agent must be compatible with the oil.
3.
Add the recommended oil to the tank. Leave space at the top
for hot oil expansion. Be careful not to overfill.
October, 2000
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CE Safety Manual
Persons Trapped in Machine
Provided that all safety circuits are intact, it is not possible to run a
bedmill or machining center while making direct contact with any axis, the
tool changer, chip conveyor, or chip auger.
Pressing the Emergency Stop push button releases all energy and stops
movement. Once this occurs, mechanically disassemble the machine to
remove tooling.
Specifications for Table and ATC Tools
The tables below contain table and ATC tool specifications for each
machine.
Table Specifications
Machine Type
Table
Specifications
Working Surface
(No Skirt)
Number of T-Slots
T-slots Width and
Spacing
Load Capacity
Stainless Steel Cap
in Front
Floor to Table
Surface
VMX 24
76.2 cm x 50.8 cm
VMX 30
101.6 cm x
50.8 cm
HSMC
150 cm ×
65.0 cm
5
18mm/
100mm
1335kg
NA
VMX 40
121.92 cm
x
50.8 cm
5
18mm/
100mm/
1350kg
NA
5
18mm/
100mm
1335kg
NA
87.38 cm
88.90 cm
88.90 cm
84.5 cm
9
14mm/
63mm
1350kg
NA
Table continued on next page.
50
Revision A
Bedmills and Machining Centers
CE Machine Standards
Table continued from previous page.
Machine Type
VMX 50
Table
Specifications
Working
Surface
(No Skirt)
Number of
T-Slots
T-Slots Width
and Spacing
Load Capacity
Stainless Steel
Cap in Front
Floor to Table
Surface
VMX64
40T
40 Station
167.64 cm
x
88.9 cm
7
50T
167.64 cm
x
88.9 cm
7
40T
149.86 cm
x
66.04 cm
6
50T
149.86 cm
x
66.04 cm
6
40T
24 Station
167.64 cm
x
88.9 cm
7
18mm/
100mm
1335kg
Yes
18mm/
100mm
1500kg
Yes
18mm/
125mm/
2670kg
NA
18mm/
125mm/
2670kg
NA
18mm/
125mm/
2670kg
NA
91.44 cm
91.44 cm
101.60 cm
101.60 cm
101.60 cm
Machine Type
Table
Specifications
Working Surface
(No Skirt)
Number of T-Slots
T-slots Width and
Spacing
Load Capacity
Stainless Steel Cap
in Front
Floor to Table
Surface
Table 7.
Hurco
HAWK 30
132.08 cm x
27.94 cm
3
16mm/
80mm
350kg
NA
HAWK 40
147.32 cm x
33.02 cm
4
18mm/
82mm
450kg
NA
93.5 cm
95.5 cm
Table Specifications
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CE Safety Manual
Type
Swing
Arm/
Drum
Swing
Arm/
Drum
Swing
Arm/
Drum
Swing
Arm/
Drum
Number of Tools
Maximum Tool
Diameter with
Adjacent Tools
Maximum Tool
Diameter without
Adjacent Tools
Maximum Tool
Length
Maximum Tool
Weight
Maximum Tool
Carousel Weight
Magazine Driving
24
81 mm
24
81 mm
24
81 mm
20
125 mm
Double
Gripper
Robotic
Arm
30
80 mm
120 mm
120 mm
120 mm
150 mm
130 mm
300 mm
300 mm
300 mm
300 mm
250 mm
7 kg
7 kg
7 kg
15 kg
8 kg
82 kg
82 kg
82 kg
82 kg
200 kg
Electric
motor
NA
Electric
Motor
NA
Electric
Motor
NA
NA
Robot Gripper Tool
Position
Robot Arm Rotation
Electric
motor
NA
NA
NA
NA
NA
Robot Arm Position
NA
NA
NA
NA
Chip Guard
Standard
Standard
Standard
Standard
Table 8.
52
Electric
Motor
Pneumatic
Motor
Pneumatic
Cylinder
NA
ATC Tool Specifications
Revision A
Bedmills and Machining Centers
CE Machine Standards
Part Replacement
Replacing Tool Pots on the Swing Arm Tool Changer
Warning
Only Hurco authorized service personnel are authorized
to make the repairs described below.
40-Taper /24-Station Swing Arm ATC
Follow these steps to replace a tool pot for this type of ATC. Only one tool
pot can be changed at a time.
Note
To replace a tool pot on the 40-station magazine, see the next
procedure.
1.
Tag and remove all tooling.
2.
Rotate the tool magazine so that the defective tool pot is in
the 6 o’clock position.
3.
Press the ESTOP push button.
Warning
You must engage the ESTOP push button before going
to the next step. Failure to do so could result in injury.
Hurco
October, 2000
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CE Safety Manual
Figure 4.
4.
Remove the fiberglass magazine cover.
5.
Loosen the M6 SHCS bolt in the tool pot to be removed.
Center Bolt and Tool Pot Bolt
6.
Loosen the tool magazine’s 16mm M6 center bolt. This bolt
must stay threaded into the center hub 2 to 3 turns.
Warning
Do not completely remove the bolt in the center of the magazine.
Do not pull the magazine too far from the main casting. If the
magazine is pulled too far, the tool pots and magazine will fall off
the center hub, damaging the equipment and possibly causing injury.
If tool pots disengage from the magazine, the magazine will have to
be removed and all tool pots unbolted from the magazine. The empty
magazine must then be installed onto the hub, and the tool pots
installed one at a time onto the magazine.
54
Revision A
Bedmills and Machining Centers
CE Machine Standards
7.
Pull the magazine out and away from the casting until it hits
the center bolt.
8.
Remove the M6 SHCS from the tool pot and push the tool
pot straight back.
9.
Figure 5.
Hurco
a.
Grab the tool pot by the tool opening in the pot and
pull down and back towards the casting.
b.
The tool pot should pop out. If not, loosen the
center bolt just a little more and try again. Do not
pull the magazine out too far.
Put a small amount of grease on the top and bottom of the
new tool pot’s cam piece to prevent wear. The cam piece of
the new tool pot should have the larger side facing down.
See the figure below.
Correct Tool Pot Alignment
October, 2000
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CE Safety Manual
10. Install the new tool pot.
a.
Grab the pot by the tool opening in the pot.
b.
Push up and forward away from the casting.
11. Use 242 Blue loctite on the tool pot’s M6 bolt and torque to
12 ft-lbf (1.659 kgf-m). It may be necessary to use a small
allen wrench, coming in from the backside of the tool pot, to
index the threaded bar into location so the bolt can be
installed.
Caution
The tool pot is not installed correctly if one of these conditions exist:
^
After being tightened, the tool pot is not in
alignment with the adjacent tools
^
The tool pot has a small amount of up and down
travel. A properly installed tool pot will not have
up and down movement. Re-install, making sure
that the cam on the tool pot is oriented properly, as
shown in the previous figure.
12. If you have more than one tool pot to replace, push the
magazine back against the casting, snug the center M6 bolt,
and rotate the magazine to the next defective tool pot.
Repeat the steps above.
13. When you are finished replacing tool pots, push the
magazine back against the casting.
14. Remove the M6 bolt and apply 242 Blue loctite.
15. Re-install the M6 bolt and torque to 12 to 14 ft-lbf (1.659 to
1.936 kgf-m).
16. Rotate the magazine one full revolution clockwise, and then
one revolution counter-clockwise. Rotation should be
smooth in both directions.
17. Calibrate the magazine and install the magazine cover. Tool
pot 1 must be in the 6 o-clock position.
56
Revision A
Bedmills and Machining Centers
CE Machine Standards
50-Taper /32-Station and 40-Taper /40-Station Swing Arm ATC
Follow these steps to replace a tool pot for this type of ATC:
Note
To replace a tool pocket on the 24-station magazine, see the
previous procedure.
1.
Rotate the magazine so that the tool pocket is at one end of
the magazine (see the figure below). The front of the tool
magazine is the best place to perform this procedure.
Figure 6..
2.
Tool Pot Position for Replacement Procedure
Press the ESTOP push button.
Warning
You must engage the ESTOP push button before going
to the next step. Failure to do so could result in injury.
Hurco
October, 2000
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CE Safety Manual
3.
Figure 7.
58
Locate the cotter pin that holds the retaining shaft in place
(see the figure below).
Cotter Pin Location
Revision A
Bedmills and Machining Centers
CE Machine Standards
Figure 8.
4.
Straighten the cotter pin and remove it from the end of the
retaining shaft.
5.
Pull out the tool pot retaining shaft, from the side indicated
in the figure. Do not lose the two washers located on each
end of the shaft.
Tool Pot Retaining Shaft Removal
6.
Take the broken tool pot out of its bracket. The tool pot will
pull straight out.
7.
Put the new tool pot into the empty tool pot bracket.
8.
Make sure that one washer is still affixed to the retaining
shaft before installing the shaft in the next step.
9.
Insert the retaining shaft through the tool pot bracket and
tool pot.
10. Once the shaft end with the cotter pin hole is through, put a
washer over the end.
11. Insert the cotter pin through the hole in the shaft end. Bend
the two ends of the cotter pin to secure it.
12. Check that the tool pot is secured in place.
Hurco
October, 2000
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Revision A
Bedmills and Machining Centers
Index
A
Autolube
adjusting discharge rate, 41
lubrication cycle, 39
system maintenance, 39, 42
Automatic Tool Changer
lubrication (see Lubrication), 43
replacing tool pots (see
Maintenance), 53
Equipment
electrical grounding, 7
Error messages
corrective measures, 28
initialization, 27
Machine Configuration, 28
F
C
Capacities
hydraulic oil tank, 44
tool release cylinder air/oil unit, 48
Chip enclosure (Europe only)
limit switch, 30
Cleaning, 10
Compressed air
installation requirements, 8
requirements, 45
specifications, 8
Coolant
system
troubleshooting, 33
Corrective measures, 28
D
Diagnostics screen, 30
E
H
Hydraulic unit
maintenance, 44
I
Installation
transformer, 4
Isolation transformer, 4, 6
recommended configuration, 6
L
Electrical
codes, 4
hookup, 4
problems (see Troubleshooting), 31
requirements
connecting, 4
grounding, 7
isolation transformer, 4, 6
safety, 20
Electrical cabinet, 10
over temperature, 36
Emergency Stop, 20, 29
Hurco
Floppy drive
errors at start-up, 27
Foreseeable misuse, 18
from operator error, 18
tampering with safety devices, 13
Foundation
construction requirements, 4
FRL Unit, 45, 46, 47
October, 2000
Limit switches, 20
Lubrication, 11
autolube, 41, 42
adjusting discharge rate, 41
Automatic Tool Changer, 43
fill levels, 37
hydraulic unit, 44
pneumatic system, 45
points, 37
recommended lubricants, 37
61
CE Safety Manual
O
spindle
oil cooler, 48
taper, 48
tool release air/oil unit, 48
Lubrication cycle, 39
Operating
error conditions, 29
error, 18
personal care, 22
P
M
Machine
basic error conditions, 29
cleaning, 10
common problems, 31
Diagnostics screen, 30
Emergency Stop, 29
foundation, 4
FRL Unit, 45, 46, 47
isolation transformer, 4, 6
malfunction, 32
power-on self test, 31
problems (see Troubleshooting), 31
tool
foreseeable misuse, 18
troubleshooting
coolant system, 33
electrical connections, 31
environmental conditions, 36
machine voltages, 32
motion, 34
spindle rotation, 34
Machine Configuration
screen
error messages on, 28
Machine tool
maintenance, 10
Maintenance
cleaning the machine, 10
hydraulic unit, 44
pneumatic system, 45
safety, 20
spindle (see Lubrication), 48
tool release cylinder air/oil unit, 48
Manual Safety Override Mode, 29
62
Revision A
Pneumatic system
maintenance, 45
requirements, 45
Power
problems, 26
Power (see Electrical), 4, 6, 32
Power cabinet
over temperature, 36
Problems (see Troubleshooting), 33
R
Requirements
compressed air installation, 8
foundation, 4
Routine maintenance, 10
S
Safety
clean up, 23
decals, 18
electrical cabinet, 25
fixturing, 19
guards and protective devices, 20
heavy lifting, 22
high voltages, 20
limit switches, 20
maintenance, 20
setup, 19
tools, 19
Safety switch, 29
Bedmills and Machining Centers
CE Machine Standards
Screens
Machine Configuration, 28
Security key
initialization error, 27
Service (also see Maintenance), 10
Site
foundation, 4
Specifications
compressed air, 8
lubricants, 37
Spindle
oil cooler, 48
maintenance, 48
taper
maintenance, 48
W
Ways
maintenance, 11
Weight
machine
and supporting foundation, 4
T
Technical services
preparation for call, 27
Tool
maintenance, 12
release cylinder air/oil unit
maintenance, 48
Touch screen
maintenance, 11
Transformer, 4, 6
Troubleshooting
basic error conditions, 29
common problems, 31
coolant system, 33
electrical connections, 31
Emergency Stop, 29
environmental conditions, 36
Machine Diagnostics screen, 30
machine voltages, 32
motion, 34
power up problems, 25
power-on self test, 31
spindle rotation, 34
Hurco
October, 2000
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Revision A
Bedmills and Machining Centers
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