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MASTER

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Instruction Manual

Chap. 3
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INDEX

Machine description and technical data .................................................................................................... 1

3.1

Description of Operation ........................................................................................................... 4

3.2

Envisaged use ........................................................................................................................... 4

3.3

Characteristics of the materials to be machined ..................................................................... 4

3.4

Maximum loadable sizes ........................................................................................................... 5

3.5

Machining that may be carried out ........................................................................................... 7

3.5.1

Vertical and horizontal boring ..................................................................................................... 7

3.5.2

Vertical and horizontal milling ..................................................................................................... 7

3.5.3

Open flat milling ......................................................................................................................... 7

3.5.4

Vertical and horizontal milling ..................................................................................................... 8

3.5.5

Open milling 4/5 axes in space ................................................................................................... 8

3.5.6

Cutting ...................................................................................................................................... 8

3.6

Construction characteristics..................................................................................................... 9

3.7

Machine layout......................................................................................................................... 10

3.8

Description of main units ........................................................................................................ 11

3.8.1

Machine body and carriage 2 ................................................................................................... 11

3.8.2

Z axis carriage ......................................................................................................................... 11

3.8.3

Working head .......................................................................................................................... 12

3.8.4

Electrical cabinet ..................................................................................................................... 12

3.8.5

Numerical control ..................................................................................................................... 13

3.8.6

"TGV" variable geometry table ................................................................................................. 14

3.8.7

Centralised grease lubrication .................................................................................................. 15

3.8.8

Machine axes .......................................................................................................................... 16

3.8.9

Guards and safety devices ....................................................................................................... 17

3.8.10

Electrical board ........................................................................................................................ 17

3.9

Technical data.......................................................................................................................... 18

3.9.1

Technical data of the machine .................................................................................................. 18

3.9.2

Machine electrical system data................................................................................................. 19

3.9.3

Power and consumption ........................................................................................................... 19

3.9.4

Pneumatic system data (compressed air) ................................................................................. 20

3.9.5

Technical characteristics of the tools ........................................................................................ 20

3.9.6

Constant and impact loads ....................................................................................................... 21

3.9.7

Overall dimensions .................................................................................................................. 22

3.9.8

Overall dimensions .................................................................................................................. 23

3.9.9

Use and maintenance facilities ................................................................................................. 24

3.10

Identification of the machine................................................................................................... 25

3.11

EC declaration of conformity .................................................................................................. 26

Summary of Contents for MASTER

Page 1: ...Document Edition 01 2009 Revision 02 1 Date 16 03 2009 MACHINING CENTRE Mod MASTER Use and maintenance instruction manual translation of original instructions ...

Page 2: ... 0 3 0 0 0 0 4 0 0 0 0 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 9 0 0 0 0 MANUAL EDITION REVISION DATE 01 2009 2 0 14 01 2009 01 2009 2 1 16 03 2009 Instruction manual valid for machine models and versions specified in the table below MACHINE MODELS AND VERSIONS DESCRIBED IN THE MANUAL MODEL DESCRIPTION Master ...

Page 3: ...Chap 0 III 4 General index 0 Foreword 1 Safety information 2 Machine description and technical data 3 Installation 4 Controls and use 5 Maintenance 6 Messages Alarms 7 ...

Page 4: ...Chap 0 IV 4 Page intentionally left blank ...

Page 5: ...CHAPTER 1 Foreward Chap 1 1 16 1 Foreword CHAPTER ...

Page 6: ... Symbols adopted glossary of terms and illustrations 7 1 3 Glossary of safety terms 9 1 3 1 Description of the documentation provided with the machine 10 1 4 Use and conservation of documentation 12 1 5 Update of the manual 12 1 6 How to request additional copies 12 1 7 Manufacturer s Identification and Contact Details 13 1 8 Technical support 14 1 8 1 How to request spare parts 15 ...

Page 7: ...CHAPTER 1 Foreward Chap 1 3 16 Page intentionally left blank ...

Page 8: ...interventions Exclusively abide by the instructions provided and in case of doubt always contact the manufacturer This manual provides basic information that the user must know before using the machine Furthermore it contains information on machine maintenance needed to keep it efficient and safe in time To use the machine correctly it is necessary to consult the Manual for the software user and a...

Page 9: ...ctric electronic maintenance men Personnel with specific electrical skills capable of carrying out the tasks of the operators and work with the machine in standard operating conditions with disabled protection guards for maintenance and or repair work Not authorised to work on mechanical parts D Mechanical support technicians Qualified personnel with specific mechanical skills capable of carrying ...

Page 10: ...uthorised to operate on the machine but may be close to the premises for different reasons G Common Individual Non qualified individuals not suitable for carrying out any tasks intended for the professionals described at items A B C D E F and thus not authorised to operate the machine INFORMATION Remember that information training and supervision of common persons par G is up to the employer ...

Page 11: ...posed individual WARNING The information marked by the symbol on the left and this style denote situations that may damage the machine INFORMATION The information marked by the symbol on the left and this style denote useful suggestions and recommendations for the user ENVIRONMENTAL INFORMATION The information marked by the symbol on the left refer to environment related information such as handli...

Page 12: ... the safety of exposed persons If the illustrations of this manual are used to explain certain machine functions they could differ from the functions of your machine or they could be incomplete If necessary and in addition to the instructions of this manual it is advisable to consult the specific design of the component or unit on which intervention is required For the specific design e g installa...

Page 13: ...erials Portable devices for the identification and reporting of risks and harmful factors WORKER A person who is hired by an employer to perform labour save for people in charge of domestic and family services even with a special subordinate work relationship Partners of cooperatives or companies who perform their job on behalf of companies and organisations and users of school university and prof...

Page 14: ...ts motors pumps valves etc installed on the machine may be provided where available B EC DECLARATION OF CONFORMITY OR DECLARATION OF ASSOCIATION The EC Declaration of Conformity or declaration of association as per annex IIA or IIB of Machinery Directive No 2006 42 EC is supplied depending on the model only for machinery intended for the European market C WIRING DIAGRAM All the wiring diagrams for...

Page 15: ...e machine manual itself HAZARD If work needs to be carried out on the electrical or pneumatic circuits or on any component of either system please consult the attached diagrams N B INTERVENTIONS MUST BE CARRIED OUT ONLY BY QUALIFIED PERSONNEL HAZARD During component disassembly European Community Directive regarding worker safety must be abided by particularly as regards the use of personal protec...

Page 16: ...n intended for machinery users please send a request to Paolino Bacci S r L If doubts arise during consultation of this manual please contact Paolino Bacci S r L always before performing any operation Paolino Bacci S r L reserves the right to modify the characteristics of the product and content of this manual without prior notice Paolino Bacci S r L reserves the right to provide a soft copy of th...

Page 17: ... Company name PAOLINO BACCI S R L Address Viale Palermo 32 56021 CASCINA PI ITALY Tel 39 050 754 91 Fax 39 050 754 975 Fax assistance 39 050 975 E mail general information bacci info bacci com E mail assistance service bacci com E mail spare parts service bacci com Website www bacci com ...

Page 18: ... parts support office service provided by qualified operators which you may address to request spare parts of the machinery Support services are open during the working hours and days mentioned in the following tables The office hours referred to in the tables below are Italian based on the time zone of Rome GMT 1 00 h WEEKDAYS FROM MONDAY TO FRIDAY HOURS ACTIVE SERVICE 8 00 18 00 GMT 1 00h Custom...

Page 19: ...he machine Should these data not be available contact Paolino Bacci S r L DANGER You must use original spare parts The replacement of parts with non original parts or parts not authorised by Paolino Bacci S r L is up to the customer and shall lead to the immediate lapse of the warranty and of the certification as per applicable community directives Machine performance and correct safe operational ...

Page 20: ...MASTER Instruction Manual Chap 1 16 16 Page intentionally left blank ...

Page 21: ...CHAPTER 2 Safety information Chap 2 1 36 2 Safety information CHAPTER ...

Page 22: ...ion or reduction of risks during machine design 21 2 13 Guards and safety devices installed on the machine 22 2 14 Workstations 25 2 14 1 Identification of work areas 27 2 14 2 Responsibilities of the operator in charge of running the machine 27 2 14 3 Responsibilities of the operator in charge of loading unloading the machine 27 2 14 4 Warning for behaviour inside the safety enclosure 28 2 15 Saf...

Page 23: ...ntenance personnel and technicians for definitions see chapter 00 is exclusively made up of Expert Persons EXP and Informed Persons INFP and not Common Persons COMP INFORMATION Remember that it is up to the employer to inform and train the personnel who is going to run the machine this must be done on the basis of available knowledge information and instructions before working activities are assig...

Page 24: ...ings located next to the dangerous areas Use suitable clothing for the tasks to perform avoid clothing with flapping parts and do not use any hooking accessories to avoid entanglement and dragging Always use personal protective equipment PPE such as safety boots gloves googles etc if necessary in accordance with the specific instructions of the manual and company standards Before performing any op...

Page 25: ...tely replace parts that are worn or damaged Do not perform maintenance or lubrication operations while the machine is moving Perform all the operations foreseen for the machine to be safe Use appropriate tools to repair the machine Remove all tools used for maintenance from the work area Restore all protections and safety devices that have been removed and check they function correctly ...

Page 26: ...ctives 80 1107 EEC 82 605 EEC 73 477 EEC 86 188 EEC and 88 642 EEC The use of PPE is indicated in the manual and on the machine with the symbols listed below Symbol Explanation You are obliged to use protective clothing You are obliged to use PVC protective clothing You are obliged to use safety boots You are obliged to use protective gloves against general mechanical risks You are obliged to use ...

Page 27: ...nt PPE the employer is called upon to provide comprises the following devices Symbol Explanation You are obliged to wear safety clothing You are obliged to wear safety shoes You are obliged to wear safety gloves against general mechanical risks You are obliged to wear hearing protection or earmuffs It is indispensable as a minimum requirement that the operator uses the personal protective equipmen...

Page 28: ...and consequent dragging Follow the safety provisions Dragging Maintain a safe distance from the areas indicated so as to avoid dangers of dragging between rollers and rotating components Follow the safety provisions Snagging and dragging Keep at a safe distance from the indicated zones to prevent snagging and dragging with moving members or mechanical components Follow the safety provisions Crushi...

Page 29: ...ve In case of over ground work Comply with the safety dispositions and adopt the appropriate PPE safety belt Danger of falling due to height differences Be careful to the flooring and any presence of differences in the height of different machine zones Dangers of an electrical nature Be careful of the indicated zones Maintain a distance of safety in order to avoid dangers stemming from direct or i...

Page 30: ...es against acids irritating agents Flammable agents Be careful for any presence of flammable agents or products that may be present In the case of use refer to the warnings and instructions shown on the product sheets Follow the safety provisions Machine with automatic start up Always stay outside the protections which permit the start up of automatic cycles of the machine Radio controlled compone...

Page 31: ...gnetic fields Pay attention to the intense magnetic fields near the pictogram Persons wearing pacemakers must maintain a safe distance from the machine or parts of it when dismantled for eventual maintenance Suspended loads Check that there are no objects that could drop or cables that could become entangled Do not stand or move during the load lifting and handling steps Follow the safety provisio...

Page 32: ...x or adjust moving parts It is forbidden to execute repair operations and or adjustments with the machine or its components in motion Follow the safety provisions Prohibition to use water to extinguish fires No water should be used for extinguishing fires due to the presence of live components Use powder extinguishers or similar devices for the extinguishing operations in the event of a fire Follo...

Page 33: ... the machine Use instructions It is mandatory to refer to the instructions User s manual and Maintenance wiring diagrams etc provided with the machine before operating it Use of padlocks for the blocking of the supply or access to the machine It is mandatory to use personal locks to block the electrical pneumatic supplies etc or access to the machine in order to avoid untimely start ups during wor...

Page 34: ...STOM IMAGES 1 of 1 SYMBOL MEANING Machine barycentre Indication of the machine or its component barycentre This indication is essential to arrange proper machine or component lifting Lifting point Indication of the machine lifting point This indication is essential for proper machine or component lifting and transport ...

Page 35: ...OLO 2 Informazioni di sicurezza Chap 2 15 36 2 4 5 Location of symbols on the machine POS SYMBOL DESCRIPTION 1 Lifting point 2 Electrical hazard 3 Moving parts Danger of being snagged and dragged 3 4 2 2 2 1 ...

Page 36: ...CAPITOLO 2 Informazioni di sicurezza Chap 2 16 36 POS SYMBOL DESCRIPTION 1 Moving parts Danger of being snagged and dragged 2 Danger of being crushed 3 Lifting point 4 Electrical hazard 2 4 1 3 ...

Page 37: ...hine or create hazards for operators To avoid possible improper machine use we recommend you take into account the consistency of the material and relate it to the motor power at your disposal you are further advised not to use the machine to process pieces that exceed the maximum working strokes specified in the chapter Technical and Environmental Data Similar materials materials whose machining ...

Page 38: ...e not been preventively trained for machine operation and who are not informed on the possible risks or instructed as regards safety rules Use without proper personal protective equipment PPE as requested by the instructions on use and the current rules in the country of use Failure to comply with installation use and maintenance information contained in the instruction manual Unauthorised modific...

Page 39: ...ched to this manual 2 8 Illumination and aeration The areas in which the machine is installed must be adequately illuminated for the operations to be performed shadow areas disturbing glares and dangerous stroboscopic effects must be avoided Abide by the current standards on illumination of work environments Please note that the lack of adequante lighting could pose risks for exposed persons The m...

Page 40: ...hat are subject to transmitted or irradiated emissions The emission values meet the legal requirements thanks to the use of components that conform to the Electromagnetic Compatibility Directive appropriate connections and the installation of filters where necessary Therefore the machine complies with the European Electromagnetic Compatibility EMC Directive 2004 108 EC ...

Page 41: ... Measurement without dust removal system ACOUSTIC EMISSION VALUES Background noise 68 5 dB A Empty run 74 6 dB A Working run 78 8 dB A During machining especially when the tools enter the materials noise peaks up to 109 8 dB A were reached The above mentioned noise values are emission levels and are not necessarily safe work levels While there is a correlation between emission levels and exposure ...

Page 42: ...ts in an all around guard that protects the entire perimeter of the machine The inside of the enclosure may be accessed through doors fitted with interlocking micro switches for safe access 3 Micro switch with safety interlocking device The access doors are fitted with interlocking micro switches for safe access 4 Sliding doors with sensitive door edge The sliding doors are used to access the mach...

Page 43: ...n panel that separates the two loading areas 6 Partition This is a transparent Lexan panel that separates the loading area and the work area 7 Low pressure device The presses that block the piece close at low pressure The pressure increases to full pressure value when the access door is closed 3 1 2 1 4 5 4 1 1 6 7 ...

Page 44: ...CRIPTION 8 Two hand control The portable pushbutton panel has an operator Present switch Life Man Switch Press this pushbutton to confirm enabling of the portable pushbutton panel When the pushbutton is released the portable pushbutton panel is disabled ...

Page 45: ...areas INFORMATION During normal operating mode the operator must occupy the areas indicated below INFORMATION The work area mush be free of obstacles and nothing should obstruct the operator s freedom of movement In case of emergency immediate access to the machine by qualified staff must be guaranteed Pos Name Location 1 Left loading unloading area In front of the work bench for loading unloading...

Page 46: ...MASTER Instruction Manual Chap 2 26 36 Pos Name Location 3 Control and programming area In front of the main pushbutton panel to operate the controls and monitor correct machine operation ...

Page 47: ... function of all the controls and characteristics of the machine The machine must be used exclusively by operators who have been trained on machine use and have read the instructions contained in this manual Instructions warnings and general accident prevention rules contained in this manual must be abided by 2 14 3 Responsibilities of the operator in charge of loading unloading the machine Before...

Page 48: ...NTENANCE IN PROGRESS sign During interventions inside the safety enclosure open the doors and keep them open Before entering inside the safety enclosure remove the key from the Mode of use selector switch Keep the key on your person during intervention In the event of an Emergency press one of the Emergency pushbuttons or touch the sensitised edge of the loading unloading doors and exit the enclos...

Page 49: ...osed and that no one is inside the enclosure Check the condition of the tools and make sure that there are no chips or deformed parts that may compromise balance Make sure that the tools spacers and tool holder shafts meet the requirements specified in the machine instruction manual Before accelerating the spindle to the programmed speed of rotation start the spindle rotating at slow speed and mak...

Page 50: ...y programme including automatic resetting we recommend making sure that the portable key pad is enabled so as to reduce speed and if necessary stop machine movements When launching a programme for the first time disable spindle start up using all the precautions specified in the respective paragraph and run the machine a slow speed using the potentiometer on the keypad Abide by the technological p...

Page 51: ...is supplied The yellow green ground protection wire cannot be disconnected removed or used for other purposes Upon completion of the intervention make sure it has been performed properly Use original spare parts only P Bacci S r l declines any responsibility for the installation of non original electrical components In case of replacement of components check that protection and control devices of ...

Page 52: ...m by enabling the pneumatic switch pos 1 for EMERGENCY STOP and discharging all residual compressed air from the circuit For correct disassembly and assembly use appropriate tools and equipment Use only suitable hoisting means Before hoisting the load verify the weight the location of the barycentre and the location of the hoisting points For hoisting please consult the specific instruction contai...

Page 53: ...red PREVENTION MEASURE NAME DESCRIPTION estimate if measured Manual handling of loads Hoisting panels Muscular and skeletal injuries discopathy Subjective disorders Dorsal lumbar pain Use of compressed air pushers and or other devices Inserting tool holder tool Handling sharp tools with a cutting edge Cutting hands and fingers Use of protective gloves ...

Page 54: ...ses vibrations The vibrations may increase and involve the entire machine The force of the vibrations may exceed the blocking force Gradual tool wear The cutting force increases with tool wear The greater cutting force causes greater wear of the electro spindle Sudden tool damage Large variations in the hardness of the material being machined may damage the tool a plate chips or breaks off the sup...

Page 55: ...g ordinary machine operation PRECAUTIONS SAFETY MEASURES Operators are required to wear hearing protections plugs or earmuffs PPE SYMBOL 2 23 3 Crushing of upper limbs SOURCE OF RISK Crushing POSSIBLE CAUSES While blocking the piece to be machined the operator activates closing of the vices The vices close at reduced pressure OPERATION PROCEDURE This risk is present during normal machine operation...

Page 56: ...MASTER Instruction Manual Chap 2 36 36 Page left intentionally blank ...

Page 57: ...Chap 3 1 27 CHAPTER 3 Machine description and technical data 3 Machine description and technical data CHAPTER ...

Page 58: ... units 11 3 8 1 Machine body and carriage 2 11 3 8 2 Z axis carriage 11 3 8 3 Working head 12 3 8 4 Electrical cabinet 12 3 8 5 Numerical control 13 3 8 6 TGV variable geometry table 14 3 8 7 Centralised grease lubrication 15 3 8 8 Machine axes 16 3 8 9 Guards and safety devices 17 3 8 10 Electrical board 17 3 9 Technical data 18 3 9 1 Technical data of the machine 18 3 9 2 Machine electrical syst...

Page 59: ...Chap 3 3 27 CHAPTER 3 Page intentionally left blank ...

Page 60: ...achined must be loaded and unloaded manually by the operator on and off the machine the work bench The piece if permitted by the length of the piece along the Cartesian X axis see paragraph Characteristics and sizes of materials to be machined may be loaded an unloaded on one part of the work bench while the machining unit machines the opposite side so as to reduce production times pedant use 3 3 ...

Page 61: ...en space between columns 2750 mm L3 bench length 2200 mm S1 maximum thickness 750 mm Values L1 and L3 correspond to the resting surface of the piece on the work bench in the direction of the Cartesian X and Y axes Value L2 corresponds to the open space between the columns of the portal from the X axes Value S1 corresponds to the maximum thickness that the piece may have to avoid interfering with t...

Page 62: ...nd the space required by other groups present on the operating unit Before starting machining always make sure that the piece is properly supported and blocked Minimum working sizes are not easily defined in that the intensity of the action of the blocking system which is vacuum operated depends on the porosity thickness and size of the piece Furthermore the minimum blocking intensity differs for ...

Page 63: ...ing operations that may be performed by the machine are described and illustrated below Some of these operations may be carried out only with the addition of optional units 3 5 1 Vertical and horizontal boring 3 5 2 Vertical and horizontal milling 3 5 3 Open flat milling ...

Page 64: ...MASTER Instruction Manual Chap 3 8 27 3 5 4 Vertical and horizontal milling 3 5 5 Open milling 4 5 axes in space 3 5 6 Cutting ...

Page 65: ... TGV variable geometry bench Piece resting system The following optional units may be installed even subsequently on the machine Blocking devices sometimes requires modifying the systems Boring head unit to be blocked onto the electro spindle Angular heads units to be blocked onto the electro spindle PITAGORA programming software intelligent user friendly CAM software system to programme and optim...

Page 66: ...at closes off the entire machine Access inside the enclosure may be gained through door fitted with micro switches for safe access 4 Lubrication system Autonomously distributes lubricant to all points connected by the system axis skids and re circulating ball bearing screws 5 Electrical cabinet Contains the main controls and electronic equipment needed to run the machine including numerical contro...

Page 67: ...on the machine body 3 8 2 Z axis carriage The Z axis carriage is the assembly of devices that allow the tools to machine the piece The Z axis carriage consists in the X axis carriage and the working head pos 1 The two balancing cylinders pos 2 compensate the weight of the Z axis carriage to reduce stress on moving organs The working head holds the electro spindles pos 3 onto which the tools are fi...

Page 68: ...e working head is held by a 2 arm fork The fork allows using tools up to 140mm long as well as circular blades with diameters of up to 200mm 3 8 4 Electrical cabinet The electrical cabinet contains the main controls and electronic equipped required to run the machine including the CN numerical control pos 1 and the operator panel pos 2 The electrical panel is equipped with an air conditioning syst...

Page 69: ...e features standard with which it is equipped ISO programming system RTCP automatic tool verticality with respect to the surface to be machined UPR programming on tilted surfaces VFF high precision contouring USB USB port HDU hard disk to memorise programmes TEACH PENDANT portable pushbutton panel for self learning programming and manual operation of the machine ...

Page 70: ...along the X axis is 200mm and the maximum value is 1170 mm Each shelf holds a resting bar pos 1 that is 900 mm which serves to anchor the piece by pressing it The shelf therefore is chequered 50 x 50 mm The flat surface of the resting bars for piece loading unloading is 850 mm from the ground Two dovetail millings are located on both long sides of the bar pos 4 that allow anchoring the pneumatic p...

Page 71: ...quency with the grease contained in the grease tank pos 1 POS NAME 1 Grease tank 2 Grease pump 3 Pressure gauge for operating pressure The pump pos 2 is positioned at the bottom of the tank and is controlled by a single acting piston powered by compressed air The pressure is adjusted to bar pos 3 Return to the starting position is spring controlled A compression spring with a pressing disk is inse...

Page 72: ...udinal X axis of the head Transversal Y1 and Y2 axes of the 2 TGV tables Vertical Z axis of the Z axis carriage Rotating B axis of the working head Rotating C axis of the working head Each axis has a positive and a negative direction The drawing indicates the positive direction of each axis Y2 Z X Y1 C A ...

Page 73: ... efficiency of the guards and safety devices must be evaluated after having installed the machine in the final user s plant at which point the risks related to inter connection with other machines present in the plant may be assessed and any additional guards and or safety devices deemed necessary may be provided for 3 8 10 Electrical board The machine is equipped with a main electrical board loca...

Page 74: ...6 Axis strokes Longitudinal X axis of the head 3000 mm Transversal Y axis of the 2 tables 1800 mm Vertical Z axis of the head 750 mm Rotating A axis Unlimited Rotating C axis 200 200 Speed X Y Z axes 1 m s A C axes 12 000 min Electro spindles Rated power S1 7 5 kW Rotating speed 0 24 000 1 min Direction of rotation Clockwise and counter clockwise Working tables Number of tables 2 Height of the wor...

Page 75: ...ON Electrical tension in volts See machine plate Electrical frequency in Hz See machine plate Electrical absorption in kW See machine plate Contemporaneity factor 0 7 Connection type 3 phases 1 earth Star connection TT TN C TN S Max earth resistance 2 Ohm Max power See machine plate Protection B type device Delayed action 0 3 sec With 0 3A of adjustable differential current 3 9 3 Power and consump...

Page 76: ...nd oil may damage the electro spindle Use only clean non lubricated filtered dry air free of condensation 3 9 5 Technical characteristics of the tools Use only tools with diameters and weights that correspond to those specified in the table below TECHNICAL DATA OF THE TOOLS 1 of 1 SIZE OF COUPLING MAX DIAMETER OF TOOL SHAFT MM ROTATING SPEED RPM MAX TOOL DIAMETER MM MAX TOOL WIEGHT KG ER40 25 6000...

Page 77: ...Chap 3 21 27 CHAPTER 3 3 9 6 Constant and impact loads Constant and impact machine loads are specified in the civil works installation layout ...

Page 78: ... shows the main overall dimensions For measurements and percentages not illustrated in the figure please refer to the installation general layout VARIABLE MEASUREMENT VARIABLE MEASUREMENT L1 5000 mm L5 1300 mm L2 4500 mm L6 1050 mm L3 600 mm L7 700 mm L4 560 mm L1 L4 L6 L5 L3 L7 L2 ...

Page 79: ...rall dimensions The figure below shows the main overall dimensions For measurements and percentages not illustrated in the figure please refer to the installation general layout VARIABLE MEASUREMENT L 3650 mm H 3300 mm W 2700 mm W L H ...

Page 80: ...e of structural elements such as walls columns etc or work equipment in the area where the machine will be used and serviced may result in incorrect machine assembly users may thus be asked to take measures to adapt the workplace before installing and starting the machine Use and maintenance facilities and possible adaptation requirements are contained in the general installation layout of the mac...

Page 81: ... and only on machines marketed within the borders of the European Community accompanied by the related EC declaration of conformity as per annex II A of Machinery Directive 2006 42 EC symbol is not present on machines marketed in non EU member countries INFORMATION Do not remove or replace the identification plate of the machine or the electrical system If it is damaged please contact the manufact...

Page 82: ...e is to be sold on the European market it will be accompanied by the relative EC declaration of conformity as per Annex II A of Machinery Directive 2006 42 EC The signed EC declaration of conformity is provided upon delivery of the machine please see a facsimile of said declaration below ...

Page 83: ...Chap 3 27 27 CHAPTER 3 ...

Page 84: ...CHAPTER 4 Installation Chap 4 1 32 4 Installation CHAPTER ...

Page 85: ...2 Disassembly of balancing cylinders and X axis cable holder chain 12 4 3 3 Moving the Z axis 14 4 3 4 Safety devices for transport 15 4 4 Identification and handling of freight components and units 16 4 4 1 Machine hoisting diagram 18 4 4 2 Hoisting procedure for the electrical cabinet 19 4 4 3 Hoisting procedure for the tables 20 4 5 Installation site requirements 21 4 5 1 Flooring specification...

Page 86: ...s all the necessary information on the installation phase of the machine This phase includes the preparation loading and unloading of the machine for transport purposes Furthermore it describes the positioning of the machine components and its fastening to the floor Finally it illustrates how to assemble the components removed in order to facilitate transport and connect the machine to the electri...

Page 87: ...s otherwise agreed all the material must be available in the installation site LOAD HANDLING EQUIPMENT 1 of 1 EQUIPMENT Crane Stacker Rocker arm Galvanised screw pin shackles Hoisting accessories e g chains belts lashing ropes INFORMATION The choice of the means to use for handling loads must be based on the evaluation of the mass to hoist and the existence of environmental limitations such as the...

Page 88: ...chine 4 1 1 Installation arrangements care of the customer The installation site must be equipped with the following 220 volt power supply points close to the machine assembly site to which the different work equipment drills welding machine etc can be connected A telephone line with access to the Internet Any necessary civil works must be implemented and the foundations and or installation site m...

Page 89: ...d hoisting and handling it is OBLIGATORY to abide by the following rules It is OBLIGATORY that all hoisting and load handling operations are performed only by qualified and authorised personnel It is OBLIGATORY to use personal protective equipment PPE such as safety boots work clothing crush protection gloves safety helmet and safety slings if aerial work is foreseen It is OBLIGATORY that only the...

Page 90: ...damage to machinery when possible place the machinery on the side frames The machine and or devices and components must be placed on the ground slowly and carefully to avoid damage Carefully inspect load hoisting accessories hooks slings chains eyebolts shackles before use If defects are detected replace accessories with new ones and make sure the components replaced are off The defects that may a...

Page 91: ...causes corrosion On the basis of the type of transport the entire electrical switchboard can be further wrapped in a barrier bag to prevent humidity from entering To hoist and handle freight units it is OBLIGATORY to consult the related specifications in this manual Upon machine delivery check that the package has not been damaged during transport and the product is in line with the specifications...

Page 92: ... painted parts The film also partly protects the machine from gentle atmospheric phenomena and prevents foreign material dirt from depositing on the machine Structure Control panels Grease The application of grease on surfaces or machine components aims to protect the components from atmospheric agents and prevent accumulation of foreign material on the machine Joints Articulations Guides Bearings...

Page 93: ...Wooden crates are normally used to ship the machine or other disassembled machine parts equipment or spare parts of the machine equipment or material for assembly purposes Miscellaneou s Barrier bag Should the machine be shipped inside a container all the material in the container is contained inside the barrier bag and is hermetically sealed The barrier bag aims to protect components from atmosph...

Page 94: ... is warned and informed of the work to be carried out Make sure that all operators are in a safe position and have been warned of the work about to be performed 2 Warnings Precautions Risk of bumping into the structure or parts of the machine Use caution during inspection operations Risk of slipping tripping and falling inside the machine Move with caution during operations 2 Electrical disconnect...

Page 95: ...rried out in complete safety and verifying the proper working order and positioning of safety devices also making sure that all personnel in the vicinity is warned and informed of the work to be carried out Make sure that all operators are in a safe position and have been warned of the work about to be performed 2 Warnings Precautions Risk of bumping into the structure or parts of the machine Use ...

Page 96: ...ap 4 13 32 PREPARING MACHINE FOR SHIPMENT BALANCING CYLINDERS AND X AXIS CABLE HOLDER CHAIN 2 of 2 STEP ACTION DESCRIPTION 5 Remove the four anchoring screws Remove the four anchoring screws 3 4 on the X axis cable holder chain ...

Page 97: ...ity is warned and informed of the work to be carried out Make sure that all operators are in a safe position and have been warned of the work about to be performed 2 Warnings Precautions Risk of bumping into the structure or parts of the machine Use caution during inspection operations Risk of slipping tripping and falling inside the machine Move with caution during operations 3 Fasten the pipes F...

Page 98: ...r and positioning of safety devices also making sure that all personnel in the vicinity is warned and informed of the work to be carried out Make sure that all operators are in a safe position and have been warned of the work about to be performed 2 Warnings Precautions Risk of bumping into the structure or parts of the machine Use caution during inspection operations Risk of slipping tripping and...

Page 99: ...all equipment used The two ropes anchored to the two pipes at the rear of the base side opposite to the spindle holder head must be brought near to the base itself while on the front side they must be positioned about 400 mm from the base so as to balance the momentum caused by the distribution of the machine weight FREIGHT UNITS AND COMPONENTS 1 of 2 UNIT HANDLING Handling Hoisting components 1 c...

Page 100: ... FREIGHT UNITS AND COMPONENTS 1 of 2 UNIT HANDLING Handling using lift trucks The alternative machine positioning using two lift trucks 4 should be used only for small movements The diameter of the holes for the hoisting pipes 3 is 80 mm ...

Page 101: ...1 Machine hoisting diagram The table below illustrates the machine hoisting diagram for shipment the hoisting points and types and the weight of the load to be hoisted HOISTING POINTS 1 of 1 UNIT HANDLING Machine body MACHINE WEIGHT 4000 Kg 400 ...

Page 102: ...t allow lifting the cabinet using a single hoisting means for example a crane 1 and four ropes 2 The electrical cabinet weighs approximately 400 kg If the electrical cabinet has been packaged in a protective bag for shipment 3 it may be moved using a lift truck 5 Once the protective case 4 has been removed the electrical cabinet may be handled using a crane 1 with the four ropes 2 and the four eye...

Page 103: ...k To hoist using a crane fasten the ropes 1 around the ends of the table Position the ropes on the external part of the transport beams 5 The rope on the cable holder chain side 3 must be positioned between the table structure 4 and the cable holder chain 2 to keep it from being crushed TABLE HOISTING POINTS 1 of 1 UNIT HANDLING Tables WEIGHT OF THE TABLES 900 Kg ...

Page 104: ... maximum acceptable inclination 2 1000 If steel grating is used to reinforce concrete it must be at a sufficient distance from the ground given that the machine could be fastened using anchorage screws reaching a depth of 15 cm Any ditches for the removal of dust and chips must be at a distance of at least 10 cm from the machine support feet FLOORING SPECIFICATIONS 1 of 1 TYPE DESCRIPTION Type of ...

Page 105: ...ises are well ventilated to protect the operator s health 4 5 4 Vacuum system The vacuum system is not supplied with the machine For proper and safe machine use the machine must be connected to a vacuum system with the specifications indicated in the table below VACUUM SYSTEM SPECIFICATIONS 1 of 1 TYPE DESCRIPTION Number of mouths 2 Mouth diameter 120 160 mm Suction speed 20 25 m s Total min flow ...

Page 106: ...orms to meet the 4 metre limitation Pay attention to machines shipped in OPEN TOP type containers with an extra height In such cases Paolino Bacci Srl guarantees transport up to the ship Unless otherwise agreed upon the customer is responsible for arranging for suitable means of road haulage from the destination harbour to the installation site Inspection upon arrival Visually inspect the cargo an...

Page 107: ... STEP ACTION DESCRIPTION 1 Safety checks Before acting on any circuit or machine components it is OBLIGATORY to always check for the absence of residual tension or pressure on the machine ensuring that operations may be carried out in complete safety and verifying the proper working order and positioning of safety devices also making sure that all personnel in the vicinity is warned and informed o...

Page 108: ...at the extremities of the machine body Always tighten or loosen one pair of opposite screws by 1 4 turn at a time 7 Position the disks Act on the adjustment screws 2 to rest all the other disks uniformly on the ground Always tighten or loosen one pair of opposite screws by 1 4 turn at a time 8 Check levelling Check the levelling of the X axis and of the Y axis 9 Block the screws Block the adjustme...

Page 109: ...sion or pressure on the machine ensuring that operations may be carried out in complete safety and verifying the proper working order and positioning of safety devices also making sure that all personnel in the vicinity is warned and informed of the work to be carried out Make sure that all operators are in a safe position and have been warned of the work about to be performed 2 Warnings Precautio...

Page 110: ...CHAPTER 4 Installation Chap 4 27 32 ANCHORING THE TGV TABLES 2 of 3 STEP ACTION DESCRIPTION 3 Positioning diagram ...

Page 111: ...re that the table is perfectly levelled along Y 7 Check levelling Check levelling along the X axis by resting the precision level along the shelf s linear guides 8 Level Act on the four adjustment screws 2 located at the extremities of the table Always tighten or loosen one pair of opposite screws by 1 4 turn at a time 9 Anchor the screws Check levelling along the X axis to make sure that the tabl...

Page 112: ...achine ensuring that operations may be carried out in complete safety and verifying the proper working order and positioning of safety devices also making sure that all personnel in the vicinity is warned and informed of the work to be carried out Make sure that all operators are in a safe position and have been warned of the work about to be performed 2 Warnings Precautions Risk of bumping into t...

Page 113: ...lectrical cabinet following the electrical wiring diagram LOCATION OF POWER SUPPLY POINTS ON THE MACHINE 1 of 1 STEP ACTION DESCRIPTION Key 1 Compressed air connection point 2 Electrical power connection point DANGER The customer is liable for any damage deriving from the connection of the machine to power supply and or compressed air systems that do not meet the requirements herein specified 1 2 ...

Page 114: ... 2 Ohm for maximum earth resistance ELECTRICAL CIRCUIT DATA 1 of 1 CRITERION SPECIFICATION Electrical tension in Volts See machine plate Electrical frequency in Hz See machine plate Electrical absorption in kW See machine plate Contemporaneity factor 0 7 Connection type 3 phases 1 earth Star connection TT TN C TN S Max earth resistance 2 Ohm Max power See machine plate Protection B type device wit...

Page 115: ...IFICATION Recommended diameter for the compressed air pipe 1 2 Coupling diameter for rubber pipes 25 mm external 17 mm internal Air consumption at 6 bar 200 L min for 2 spindle version 360 L min for 4 spindle version Optimal line pressure 6 5 bar DANGER Danger of electro spindle breaking Dust condensation and oil may damage the electro spindle Use only clean and dry air filtered non lubricated con...

Page 116: ...CHAPTER 5 Controls and Use of the machine Chap 5 1 62 5 Controls and use of the machine CHAPTER ...

Page 117: ...s 33 5 7 2 Operating mode Manual 34 5 7 3 Operating mode Automatic 36 5 7 4 Work cycles 37 5 8 Equipping the machine 39 5 9 Tools 40 5 9 1 General information regarding machine tools 40 5 9 2 Machine tool diameter and weight 41 5 9 3 Sharpening machine tools 41 5 9 4 Machine tool assembly information 42 5 9 5 Balancing machine tools 43 5 9 6 Cleaning machine tools 44 5 10 Tool load and presetting ...

Page 118: ...hine must be operated by qualified and authorised personnel who has read and understood the instructions contained in this manual and who is familiar with the machine s safety devices In the event of serious or unidentified malfunctions stop the machine and wait for servicing on behalf of qualified technicians LOCATION OF THE CONTROL PANELS 1 of 1 1 5 2 3 4 5 6 1 Main switch 2 Main pushbutton pane...

Page 119: ...MASTER Instruction manual Chap 5 4 62 5 2 Machine controls MACHINE CONTROLS 1 of 2 POS CONTROL IDENTIFICATION 1 Main switch 2 Main pushbutton panel 3 Industrial PC keyboard ...

Page 120: ...CHAPTER 5 Controls and Use of the machine Chap 5 5 62 MACHINE CONTROLS 2 of 2 POS CONTROL IDENTIFICATION 4 Portable pushbutton panel 5 Right and left bench pushbutton panel 6 Right and left bench pedals ...

Page 121: ...SCRIPTION OF CONTROLS POS CONTROL DESCRIPTION 1 Main switch Two position main switch 0 1 Turn the main switch to turn the machine on and off Turned to position 0 the machine is off Turned to position 1 the machine is on The electrical cabinet is powered by the main power grid 1 ...

Page 122: ...m pump LEFT bench start When the pushbutton is lit the vacuum pump is on Press the pushbutton to turn off the pump and enable blocking the pieces with the presses 3 Backlit control pushbutton Vacuum pump RIGHT bench start When the pushbutton is lit the vacuum pump is on Press the pushbutton to turn off the pump and enable blocking the pieces with the presses 4 Backlit control pushbutton Stop vacuu...

Page 123: ...ne Equipping the machine machining trials maintenance etc Select Automatic mode to carry out regular piece machining 6 Return from extra run mode selector switch When an axis has exceeded its stroke this selector is used to return the axis within operating limits Only the machine operator is authorised to use this selector Remove the key and keep it in a safe place to avoid unauthorised use 7 Norm...

Page 124: ...pushbutton to start the machining programme 11 Pushbutton not present 12 Emergency stop pushbutton Stops the machine in emergency mode and turns off the machine Disconnects power to the axes and spindles 1 The pushbutton has a mechanical block that ensures that it remains in position it may be reset by turning it to the left Use the emergency stop pushbutton in case of imminent danger for the oper...

Page 125: ...otentiometer is enabled in Manual and Automatic modes 3 Operator present pushbutton Life Man Switch Press this pushbutton to confirm the operations of the portable pushbutton panel Hen the pushbutton is released portable pushbutton panel operation terminates Collision risk For all manual movements Observe axis orientation The speed of all movements is reduced to a maximum value of 2 m min Manual m...

Page 126: ...Press this control to turn the magazine to a forward position 9 Axis position digitalisation control pushbutton Use this control in Programming for self learning mode To be used to zero set the axes in JOG mode or to BLOCK UNBLOCK execution of the programmes in MEM mode 10 Stop pushbutton Press this control to stop the axes and spindles Pressing the STOP pushbutton does not turn off the machine 11...

Page 127: ...ment of the X axis in the negative direction 15 A axis movement control pushbutton Press this control to allow manual movement of the A axis in the positive direction 16 A axis movement control pushbutton Press this control to allow manual movement of the A axis in the negative direction 17 Y2 axis movement control pushbutton Press this control to allow manual movement of the Y2 axis in the positi...

Page 128: ...he sliding loading doors Automatic Mode Closes the sliding loading doors 2 Not present Free for future installations 3 Emergency stop pushbutton Stops the machine in emergency mode and turns off the machine Disconnects power to the axes and spindles 1 The pushbutton has a mechanical block that ensures that it remains in position it may be reset by turning it to the left Use the emergency stop push...

Page 129: ...pressure On machines with T G V benches vacuum surface or suction cup system The piece is vacuum blocked Press the pedal again to release the piece Note the loading door is open Automatic mode The piece is blocked On machines with T G V tables with press units The piece is blocked at low pressure On machines with T G V benches vacuum surface or suction cup system The piece is vacuum blocked Press ...

Page 130: ... due training and qualification for initial start up operations The first start up may be carried out without products to be machined to verify the proper working order of machine units subsequently the machine may be started with product to be machined in order to verify the efficiency of the machine and of the piece gripping devices Machine output and production is defined with the exception of ...

Page 131: ...the machine and function properly It is MANDATORY to check that all persons exposed to risks deriving from the movement of mechanical organs are outside the machine in a safe place and have been warned of impending machine start up 2 Warnings Precautions Risk of colliding with the structure and parts of the machine Use caution during machine start up operations Danger of slipping stumbling and fal...

Page 132: ...rking pressure use the balancing cylinder pressure regulator 1 to increase or decrease the pressure Check that the pressure gauge for door closing piece blocking 5 indicates a working pressure of 6 bar If the pressure shown is not the proper working pressure use the door closing piece blocking pressure regulator 4 to increase or decrease the pressure Check that the spindle cooling pressure gauge i...

Page 133: ...correctly assembled on the machine and function properly It is MANDATORY to check that all persons exposed to risks deriving from the movement of mechanical organs are outside the machine in a safe place and have been warned of impending machine start up 2 Warnings Precautions Risk of colliding with the structure and parts of the machine Use caution during machine start up operations Danger of sli...

Page 134: ...ched The login window will appear on the monitor for password entry 6 Reset emergency pushbuttons Release any Emergency pushbuttons that may have been pressed by re pressing and rotating to the left 7 RESET Press the Reset pushbutton 8 Start auxiliary functions Press the Start auxiliary 8 pushbutton The Grid connected pilot light 1 turns on indicating that the machine is energised ...

Page 135: ...tection devices are correctly assembled on the machine and function properly It is MANDATORY to check that all persons exposed to risks deriving from the movement of mechanical organs are outside the machine in a safe place and have been warned of impending machine start up 2 Warnings Precautions Risk of colliding with the structure and parts of the machine Use caution during machine start up oper...

Page 136: ...O 2 of 3 STEP ACTION DESCRIPTION 4 Enable the portable pushbutton panel Enable the portable pushbutton panel from the main Menu The softkey changes colour The LED 1 on the portable pushbutton turns on 5 Resetting the potentiometer to zero Gradually turn the Overdrive 2 potentiometer to 0 ...

Page 137: ...P PROCEDURE RESET TO ZERO 3 of 3 STEP ACTION DESCRIPTION 6 Resetting the axes to zero Reset the axes to zero through the Panel From the main Menu press the Softkey F ZEROING 7 Set the potentiometer Gradually turn the Overdrive potentiometer to 100 ...

Page 138: ...ectro spindles must perform a brief heating cycles to allow the bearings to gradually reach a uniform operating temperature To this end a programme must be created in which each electro spindle is used as follows SPINDLE PREHEATING PROCEDURE 1 of 1 STEP ROTATING SPEED CYCLE TIME 1 50 of max speed 12 000 1 min 5 min 2 75 of max speed 18 000 1 min 3 min 3 100 of max speed 24 000 1 min 3 min ...

Page 139: ... 1 Machine Reset Press the Reset pushbutton 2 Emergency pushbutton Press on of the Emergency pushbuttons located on the pushbutton panels 3 Exit submenus Exit the submenus on the Interface panel and return to the main page 4 Turn off Windows Turn off the Windows operating system Click on START Click on CLOSE SESSION Click on STOP SYSTEM Click on OK The message now the machine may be turned off app...

Page 140: ...CHAPTER 5 Controls and Use of the machine Chap 5 25 62 PROCEDURE TO TURN OFF THE MACHINE 2 of 2 STEP ACTION DESCRIPTION 4 Disconnect machine from electric power supply Turn the main switch to 0 ...

Page 141: ...TION 1 Disconnect machine from pneumatic power supply Close the master shut off valve turn the knob counter clockwise and lock as required The pneumatic system is cut off from the pneumatic supply The filters discharge any impurities that may be present in the system 2 Safety warning DANGER The balancing cylinders remain pressurised even after the main shut off valve has been enabled Do not tamper...

Page 142: ... a stop at the maximum deceleration permitted electrical energy is cut off and therefore the auxiliary systems are turned off The normal Stop is used to stop the programme being carried out without completely stopping all machine functions This stop is operated by pressing the STOP pushbutton located on the main panel The programme being run is immediately interrupted all movements are brought to ...

Page 143: ...volved must locate and become familiar with all the emergency stop pushbuttons on the machine control panels shown in the photographs that follow INFORMATION Pressing an emergency pushbutton 12 stops the machine in emergency mode and transmits the stop signal Moreover pressing an emergency pushbutton disconnects the power supply to the axes and spindles 2 Restart procedure To restart the machine C...

Page 144: ...bling the control If a person is in danger press the emergency stop pushbutton located on any control panel The emergency stop is a safety function and has priority over all the controls and is not synchronised with the forward travel of the machined product which may therefore become jammed at one or more machine points after the emergency stop ...

Page 145: ...ed Proceed as described following STOP AND RESTART PROCEDURE FOR CONTROLLED STOP INTERVENTION STOP 1 of 1 STEP ACTION DESCRIPTION 1 Press the STOP pushbutton Before using the machine all persons involved must locate and become familiar with all the STOP pushbuttons on the machine control panels 2 Restart procedure To restart the machine Clear the cause for stopping the machine Press the Reset push...

Page 146: ...en stopped Proceed as described following STOP AND RESTART PROCEDURE FOR CONTROLLED STOP RESET 1 of 1 STEP ACTION DESCRIPTION 1 Press the STOP pushbutton Before using the machine all persons involved must locate and become familiar with all the STOP pushbuttons on the machine control panels 2 Restart procedure To restart the machine Clear the cause for stopping the machine Press the Reset pushbutt...

Page 147: ...ust extract the electro spindle from the piece NOTE Safety warning DANGER Danger of collision between the electro spindle and the piece The system of coordinates may be turned with respect to the machine axes The direction to extract the tool from the piece is always Z Extract the electro spindle from the piece using the Z axis movement pushbutton ...

Page 148: ...n Please read and understand the instruction manual especially the operating and safety instructions 5 7 1 Operating modes The machine may run in two operating modes Manual Automatic The two modes differ from one another in terms of the level of safety The safety level in manual mode is lower than that in automatic mode Only the operator is authorised to change the operating mode ...

Page 149: ... in addition to the specific pushbutton on the portable pushbutton panel the operator must also press the Operator present pushbutton and keep it pressed until the desired position is reached When the pushbutton is released the movement stops The rotation of the electro spindle is not enabled in manual mode NOTE Safety warning DANGER Crushing risk The operating head moves in all directions Hold th...

Page 150: ...ING MODE 1 of 1 USER DESCRIPTION Maintenance technician The operations that may be carried out with the machine in manual mode are the following Machine equipping Machine cleaning Machine maintenance INFORMATION Any other work on the machine in manual mode is forbidden ...

Page 151: ...an and by the machine operator for normal machining operations on consented materials AUTOMATIC OPERATING MODE 1 of 1 USER DESCRIPTION Operator Maintenance technician The operations that may be carried out with the machine in manual mode are the following Work cycles INFORMATION Any other work on the machine in automatic mode is forbidden ...

Page 152: ...k cycles STOP AND RESTART PROCEDURE FOR CONTROLLED STOP INTERVENTION RESET 1 of 2 ACTION DESCRIPTION 1 Load the piece programme 2 Press the Start cycle pushbutton 3 Load the piece on the table 4 Block the piece press the Piece blocking pedal 5 Exit the loading area ...

Page 153: ...ESTART PROCEDURE FOR CONTROLLED STOP INTERVENTION RESET 2 of 2 ACTION DESCRIPTION 6 Close the door press the DOOR pushbutton 3 The loading unloading operator must carry out only steps 3 to 6 The operator running the machine may carry out all the steps ...

Page 154: ...ified to carry out the operations described in this section This section contains all the information pertaining to equipping the machine The section is divided in two parts The first part regards the tool including the safety instruction tool choice maintenance and presetting The second part regards blocking the piece Topics ...

Page 155: ...mation on the tool Tool marking Manufacturer name Maximum number of revolutions Measurements diameter length Tools must be marked Work cycles INFORMATION Tools must be marked and must comply with European Community directives Verify the data on the tool plate 1 NOTE Safety warning DANGER Cutting hazard The cutting edges of the tools are sharp and may cause Cut wounds Punctures Handle the tools wit...

Page 156: ... 7 12000 15000 110 5 15000 18000 80 5 ER32 20 6000 9000 140 4 9000 12000 130 4 12000 15000 110 2 5 15000 18000 80 2 5 5 9 3 Sharpening machine tools MAINTENANCE NOTE Machine maintenance information INFORMATION The tools must be kept sharp to reduce cutting stress and electro spindle operating temperature The heat generated by the electro spindle itself may overheat the bearings and the lubricant I...

Page 157: ...MASTER Instruction manual Chap 5 42 62 5 9 4 Machine tool assembly information MAINTENANCE NOTE Machine maintenance information INFORMATION Use only spacers that correspond to the drawing below ...

Page 158: ... tool is sharpened Improper tool balancing may result in The tool breaking The tool coming free of the electro spindle Balance the tools and the tool holder in G1 Rebalance the tools whenever they are sharpened in G1 NOTE Safety warning DANGER Danger of flying tool parts Use the following personal protection equipment PPE wire mesh gloves a when replacing and or handling tools Use the following pe...

Page 159: ...utely clean Cones Shafts Tool gripping pincers DANGER Danger of tool holder group breakage The presence of dust deposits on the tool stem may cause Tool misalignment Ineffective tool blocking If the operator tightens the pincer holder ring nut with excessive tightening torque the shaft or tool holder threading may be damaged Clean tools thoroughly Do not tighten the ring nut with torque greater th...

Page 160: ...t using the manual controls Portable pushbutton panel A axis movement pushbutton 15 A axis movement pushbutton 16 The spindle to be equipped is positioned facing upwards 2 Unscrew ring nut Unscrew the blocking ring nut 1 3 Select pincer Select the pincer with the proper diameter for the tool Insert the pincer in the cone 4 Insert tool Insert the tool in the pincer and after having positioned it in...

Page 161: ...button panel A axis movement pushbutton 15 A axis movement pushbutton 16 The equipped spindle is positioned facing towards the work surface 6 Measure the tool Using an appropriate instrument measure the tool length 7 Update parameters Enter the tool length datum in the software 8 Repeat steps described above starting from step 1 for all the other spindles present on the head ...

Page 162: ...e performed by means of pneumatic presses and or suction created by the vacuum pump POS NAME 1 Connection for vacuum pump 2 50mm x 50mm chequering For vacuum blocking 3 Metric ruler Y axis 4 18 holes with 2 purposes Fastening holes for templates Holes for passage of the vacuum blocking air 5 4 fastening screws to anchor the resting table on the shelf 6 Dovetail milling 7 Shelf steel support 8 4 fa...

Page 163: ... the piece blocking requirements L direction Release the take up levers 8 and move the shelf to the desired position P direction The pneumatic presses move inside the dovetail milling system 6 along the bar 5 11 3 Joining the 2 variable geometry tables To machine large pieces the tables may be joined in the CN programme Table movement is therefore synchronised P L ...

Page 164: ...urfaces may be rotated by 90 to adapt the TGV table to blocking requirements 5 11 5 Using vacuum modules Templates are not supplied with the machine The example below serves only for information purposes POS NAME 1 Holes to fasten the template to the surface 2 Piece blocking presses 3 Piece stopping guides ...

Page 165: ...king Templates are not supplied with the machine The example below serves only for information purposes NOTE Safety warning DANGER Danger of flying pieces or tool parts Inadequate blocking with respect to machining force may result in Piece flying free Tool breaking and consequently flying free Make sure that the piece has been blocked properly before starting the work cycle After having assembled...

Page 166: ...the machining programme before starting production After the machine has been equipped the operator running the machine must check that the work cycle proceeds correctly Usually verification in original conditions is the most efficient The only difference with respect to the definitive cycle is that the operator holds the portable pushbutton panel in his her hand and reduces machining speed using ...

Page 167: ...chine All the information pertaining to these customisations are contained in this chapter For details regarding general CN programming please consult the CN manual Self learning system included in standard machine configuration This system also uses all the parametric programmes MACRO created by BACCI tenon execution mortising boring parting boring parting milling boring etc For details regarding...

Page 168: ... the tools and the piece zero position This programming stage is described in the paragraph Managing piece programmes and Softkey MICROSCRIBE optional This system traces paths and surfaces from an existing piece For use instructions please consult the MICROSCRIBE manual 3 Master Programme The operator coordinates management of piece blocking and door opening according to the machine work mode pend...

Page 169: ... The CNC OSAI Series10 has a platform for piece programme management To launch the programme click on the ProVideo icon on the WINDOWS desktop The programme has 5 modes N MODE 1 Select 2 Set UP 3 Origin Tool 4 Part Programme 5 Utility Further explanations are provided in the CN manual ...

Page 170: ...y SOFTKEY FUNCTION COPY Copies the piece programmes part programme hereinafter PP name in another with a different name DELETE Erases the selected part programme PP RENAME Renames the selected part programme PP BACCI UPR Enables the utility programme HELP Enables the help file for the corresponding menu EDIT Enables the programme editor on the PP If the specified PP does not exist the system creat...

Page 171: ...NE SEARCH INCLUDE SEQUENCE GEOMETRY CYCLE EXIT F5 F6 F7 F8 F9 Key SOFTKEY FUNCTION CONFIG Changes the Editor configuration CYCLE MODIFY do not use CUT PASTE Allows selecting a group of lines and therefore erasing moving and copying them HELP Displays help information DEL LINE Erases the highlighted line OLD LINE Retrieves the line erased using DEL LINE SEARCH Word and number search INCLUDE Inserts...

Page 172: ...lows running an automatic lubrication cycle ROT MANDRINO Allows rotating a spindle after having pressed the ABILITA MANDR Softkey Specify the parameters Spindle number optional specify the number of the spindle to be activated 1 4 Enter 1 if there is only one spindle Number of revolutions specify the number of rpm Direction of rotation 1 forwards 1 reverse In Manual mode spindle rotation is disabl...

Page 173: ...r l authorised personnel and is password protected This function cuts out spindle operation even if they are programmed in a piece programme This SK works only in combination with the enabled ABILITA MANDR Softkey BLOCCAGGI OFF This function may be used only by Paolino Bacci S r l authorised personnel and is password protected ...

Page 174: ...SPB OK_SPC OK_SPD SPEED REACHED AND SPINDLE w ROTATING G231 SBL_DX SBLDX_OK RIGHT BENCH UNBLOCK REQUEST G232 SBL_SX SBLSX_OK LEFT BENCH UNBLOCK REQUEST G281 SPA_FW SPAFW_OK SPINDLE 1 FORWARD default G282 SPB_FW SPBFW_OK SPINDLE 2 FORWARD default G283 SPC_FW SPCFW_OK SPINDLE 3 FORWARD G284 SPD_FW SPDFW_OK SPINDLE 4 FORWARD G285 SPA_RV SPARV_OK SPINDLE 1 REVERSE G285 SPB_RV SPBRV_OK SPINDLE 2 REVERS...

Page 175: ...e 1 2 3 4 speed of rotation 5 14 3 The MASTER programme A piece programme PP requires a series of commands and controls to work properly and coordinate the opening of the doors and the work centre All these functions are entrusted to a master programme within which the name of the programme to be executed must be entered MASTERPEND to use the left and right benches alternately MASTERAND to use bot...

Page 176: ... G291 w2 r1 S0 G291 w3 r1 S0 G291 w4 r1 S0 G601 AUTO UNBLOCKING TABLE RH G231 OPEN DOOR RH GTO START Spindle enabled Safety positioning preliminary see above see above cycle start label resets origin resets dual axes resets axis name renames Y with P redefines interpolation plan uses P axis in TCP compensation TCP disables 5 axis compensation disables tool corrector table waits for blocking and LH...

Page 177: ...increases from 2 to 6 bar for safety reasons Furthermore low pressure may be adjusted by means of two pressure regulators right and left located in the pneumatic box Note When the loading door is closed the blocking unblocking pedal is disabled To use vacuum blocking just turn on the vacuum pump using the respective pushbuttons on the operator panel and follow the same blocking procedure with the ...

Page 178: ...CHAPTER 6 Maintenance Chap 6 1 30 6 Maintenance CHAPTER ...

Page 179: ... of machining 9 6 4 2 Cleaning the FRL unit Filter regulator lubricator 11 6 4 3 Recommended oils 12 6 4 4 Cleaning tools and tool holders 13 6 4 5 Recommended lubricant 14 6 5 Weekly machine maintenance 15 6 6 Monthly machine maintenance 17 6 6 1 Recommended greases 18 6 7 Maintenance to the lubrication system 19 6 7 1 Checking and filling the automatic system 20 6 7 2 Recommended greases 22 6 8 ...

Page 180: ...es of operations that must be performed to keep a product effective functional and capable of fulfilling the purpose for which it was designed product stands for a building machine system or road Maintenance activities comprise a series of operations such as tests repairs parts replacement etc INFORMATION Lubrication maintenance operations may be performed either independently by operators who int...

Page 181: ...ne must be switched off before performing maintenance Live mains voltage parts or parts under pneumatic pressure may cause extremely serious injuries Switch off the machine and cut off pneumatic supply to the machine Lock the main switch and the main disconnecting valve with a padlock NOTE Safety warning DANGER Crushing hazard The balancing cylinders remain pressurised even after the main shut off...

Page 182: ...r Use ONLY original spare parts Spare parts that are not original parts may be incompatible and may damage the machine All servicing must be compatible with and comply with safety regulations regarding operator health and safety 6 2 1 Other interventions If the machine requires maintenance or repairs not described in this manual during machine use please contact the Paolino Bacci S r L Customer Se...

Page 183: ...AN 1 of 2 Machine part component Employee qualification Mechanical maintenance technician Frequency Hours Product 1st level machine cleaning Work surface Cylinders and templates Microswitches and cams Bellows 8 h FRL unit Inspect clean and if required top up 8 h See oil table Centralised lubrication system Check level Visual inspection Check pressure 8 h 1000 h 1000 h NLGI 0 NLGI 1 2nd level machi...

Page 184: ...METABLE ELECTRICAL ELECTRONIC MAINTENANCE TECHNICIAN 1 of 1 Machine part component Employee qualification Electrical maintenance technician Frequency Hours Product Electrical system Visual inspection wires and connections Inspect the safety devices 1000 h ORDINARY MAINTENANCE TIMETABLE MECHANICAL MAINTENANCE TECHNICIAN 1 of 1 Machine part component Employee qualification Mechanical maintenance tec...

Page 185: ...arding maintenance frequency refer to use of the machine for one work shift per day If the machine is used for more than one work shift per day the maintenance frequency must be increased accordingly Every 8h of operation that is after every shift every day for only one shift Every 40 of operation that is every 5 shifts every week for only one shift Every 160 of operation that is every 20 shifts e...

Page 186: ... 2 STEP ACTION DESCRIPTION 1 Removal of chips Remove all chips and other machining waste Suction all chips with an appropriate industrial suction fan 2 Machine cleaning It is not allowed to clean by blowing compressed air as chips could enter in between the gears and jeopardise normal machine operation During cleaning operations use the following PPE ...

Page 187: ...ch 3 the X axis micro switch 5 and the X and Z axis cams 4 The TGV variable geometry table TGV piece support system 7 including the support surface 6 and any cylinders and templates MAINTENANCE NOTE Machine maintenance information INFORMATION Risk of machine damage Do not use compressed air to clean the machine Jets of air may push dust and machining chips inside the dust proof guards Use and indu...

Page 188: ...king efficiency of the balancing cylinder lubricator 1 and the regulator lubricator for door closing piece blocking 3 Check the oil level in the balancing cylinder oil tank 2 and the door closing piece blocking oil tank 4 2 Check condensate Check and empty the spindle cooling condensate 5 the condensate tank for door closing piece blocking 6 and the condensate tank for the balancing cylinders 7 ...

Page 189: ...No 4 Q8 Puccini 4P TEXACO 300 Oil 5 TOTAL Azolla ZS 15 MAINTENANCE NOTE Machine maintenance note INFORMATION Risk of machine damage Use only one of the above mentioned oils Other products may be incompatible with the oil used by the manufacturer for initial filling Oils that are not cross compatible if mixed or used on after the other may form substances that can compromise machine efficiency with...

Page 190: ...pply a light layer of lubricant on the conical seat of the spindle Check the conditions of the tool cutting edges Replace the tool if a cutting edge is damaged or blunt Use only tools tool holders balanced in G1 Rebalance the tool each time it is sharpened NOTE Safety warning DANGER Danger of flying tool parts Negligence when cleaning tools represents one of the major causes of on the job accident...

Page 191: ...MASTER Instruction Manual Chap 6 14 30 6 4 5 Recommended lubricant Use only the product specified in the table below BRAND TYPE OF LUBRICANTE METAFLUX Paste spray 70 81 ...

Page 192: ...making sure that interventions are always carried out in safe conditions Risk of colliding with the machine structure or parts Move with caution during maintenance Risk of slipping tripping and falling on machining residues Move with caution Risk of dust and materials flying or being suctioned According to the operation being carried out in addition to standard PPE also use the following PPE PVC o...

Page 193: ...he electric components in the electrical cabinet Clean the machine and inside the electrical cabinet using an industrial vacuum NOTE Safety warning DANGER Electrocution hazard Never use compressed air to clean the machine Jets of air may push machining chips and dust inside the milling unit or under the contacts of the electric components in the electrical cabinet Clean the machine and inside the ...

Page 194: ...ircuits making sure that interventions are always carried out in safe conditions Risk of colliding with the machine structure or parts Move with caution during maintenance Risk of slipping tripping and falling on machining residues Move with caution Risk of dust and materials flying or being suctioned According to the operation being carried out in addition to standard PPE also use the following P...

Page 195: ...grease resistant to high pressures Otherwise if the oil soaps separate inside the lubricant grease the soaps may solidify and obstruct the pneumatic circuit Use only one of the greases recommended above Other products may be incompatible with that used by the manufacturer for initial greasing Greases that are not cross compatible if mixed or used one after another may form substances that can comp...

Page 196: ...Maintenance to the lubrication system NOTE Safety warning DANGER Danger of the spring flying loose A strongly wound spring 1 is located inside the tank see plate 2 Do not open the lubricant tank Top up the tank using the nipple see procedure ...

Page 197: ...ing suctioned According to the operation being carried out in addition to standard PPE also use the following PPE PVC overalls 2 Inspection Check the lubricant grease level in the tank Keep the tank full minimum level electric signal A pump that works with an empty tank may pump air into the circuit resulting in difficulty in reaching the pressure required or preventing the pump itself from primin...

Page 198: ...RED MACHINE STATE Inspection Operators 1 one MACHINE DISCONNECTED MAINTENANCE TOOLS AND MATERIALS lubricant pneumatic filling pump ACTIVITY STEP STEP STEP 4 Top up the tank Use clean lubricant as foreign matter may obstruct the pump filling filter 5 Connect the system Connect the pneumatic topping up system to the centralized system nipple 6 Top up the tank Top up the tank to the maximum level ...

Page 199: ...aintenance information INFORMATION Risk of machine damage Check system pressure Follow the procedure described in the attached manual 6 7 2 Recommended greases Use one of the products listed in the table below TYPE OF GREASE NLGI 0 or equivalent NLGI 1 or equivalent MAINTENANCE NOTE Machine maintenance information INFORMATION Risk of machine damage Use only grease resistant to high pressures Other...

Page 200: ...ing sure that interventions are always carried out in safe conditions Risk of colliding with the machine structure or parts Move with caution during maintenance Risk of slipping tripping and falling on machining residues Move with caution Risk of dust and materials flying or being suctioned According to the operation being carried out in addition to standard PPE also use the following PPE PVC over...

Page 201: ...k that all mechanical safety devices are in place and efficient Enclosure pos 2 Partition pos 5 and pos 6 Check that the pneumatic safety devices are efficient Low pressure device pos 7 Check that the electromechanical safety devices are efficient Emergency pushbuttons pos 1 Sensitive edges on doors pos 4 Interlocking device on the supplementary door pos 3 Two hand control on the portable pushbutt...

Page 202: ...OLS AND MATERIALS ACTIVITY STEP ACTION DESCRIPTION 4 Inspect the pneumatic circuit Visually inspect that the pneumatic pipes are not damaged Check that the pneumatic connections are firmly fastened 5 Inspect the mechanical components Visually check that the mechanical components that are in continuous movement and subject to wear are not damaged Guides skids and re circulating ball bearing screws ...

Page 203: ...ND TYPE Automatic lubrication system guides axes re circulation screws NLGI 0 or equivalent NLGI 1 or equivalent Pneumatic system FRL Units AGIP Oso 10 ESSO Nuto H 5 MOBIL Velocite Oil No 4 Q8 Puccini 4P TEXACO 300 Oil 5 TOTAL Azolla ZS 15 Tool holders METAFLUX Paste spray 70 81 ...

Page 204: ... r l Pneumatic circuit Check functioning of solenoid valves overheating and jams and as required check the FRL groups and replacement as required Electrical circuit Electrical electronic and electromechanical components Check the electrical header of the operating head and replace brushes Electrical cabinet air conditioner fan Overhaul the electrical cabinet air conditioner Mechanical Check proper...

Page 205: ... the machine has reached the end of its service life it must be shut down and must not be used again for the purposes for which it was originally designed and manufactured however the parts and raw materials making up the machine may be re used Machine parts may be re used for purposes and functions different from those for which the separate machine parts and the machine as a whole were designed ...

Page 206: ... CEE 75 439 dated 16 July 1975 In accordance to this directive all companies disposing of used oil are obliged to provide the competent authorities with information pertaining to the elimination and disposal of used oil and oil residues Please note that according to Presidential Decree DPR N 691 of 23 August 1982 it is obligatory to address the CONSORTIUM OF USED OIL ...

Page 207: ...MASTER Instruction Manual Chap 6 30 30 Page left intentionally blank ...

Page 208: ...CHAPTER 7 Messages Alarms Chap 7 1 31 7 Messages Alarms CHAPTER ...

Page 209: ...6 Alarm 34 ATTIVA BANCO SX O DX 14 7 2 27 Alarm 36 LH TOUCH SENSITIVE EDGE INTERVENTION 15 7 2 28 Alarm 37 RH TOUCH SENSITIVE EDGE INTERVENTION 15 7 2 29 Alarm 38 LH DOOR CLOSING TIMEOUT 16 7 2 30 Alarm 39 RH DOOR CLOSING TIMEOUT 16 7 2 31 Alarm 42 LH DOOR OPENING TIMEOUT 17 7 2 32 Alarm 43 RH DOOR OPENING TIMEOUT 17 7 2 33 Alarm 45 SW OVER STROKE AXIS C 18 7 2 34 Alarm 46 SPINDLE 1 DRIVE NOT OK 1...

Page 210: ...ION Machine logic not initialised correctly POSSIBLE CAUSE There are two possible causes Specifically CN malfunction Corrupted PLC software SOLUTION Contact customer service technician 7 2 2 Alarm 02 Reset axes to zero ALARM 02 RESET AXES TO ZERO 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION At least one axis has not been reset to zero POSSIBLE CAUSE There is one possible cause Specifically The m...

Page 211: ...read the relative description and measures to be adopted Check that the emergency mushroom pushbuttons red have not been pushed Only for qualified technicians Check that the automatic switches in the electrical cabinet are connected Check the position of the red selector switch cabinet door open bypass inside the electrical cabinet 7 2 4 Alarm 04 Mode change not permitted in Homing ALARM 04 MODE C...

Page 212: ...2 6 Alarm 08 Spindle reference timeout ALARM 08 SPINDLE REFERENCE TIMEOUT 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Inverter serial malfunction POSSIBLE CAUSE There are various possible causes CN Serial Port not working Inverter serial port not working Connection cable error or damage SOLUTION Check connections between the CN serial port COM2 and the inverter Check CN status CN errors or othe...

Page 213: ...ntify and remove the cause Press RESET Press the AUXILIARY START pushbutton Check presence of other error messages 7 2 8 Alarm 10 Skew error ALARM 10 SKEW ERROR 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Position error of a slave axis with respect to the master dual axes exceeds the limit value set in the CN parameters CN EE002 error POSSIBLE CAUSE There are various possible causes A collision...

Page 214: ...ion cables between motor encoder and drive Check the status of the motor and motor encoder 7 2 10 Alarm 12 Tolerance error ALARM 12 TOLLERANCE ERROR 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Axis requested position not reached within maximum foreseen time CN EE004 error POSSIBLE CAUSE There are various possible causes A collision an obstacle to movement Excessive friction during a movement SO...

Page 215: ...e selector switch inside the switchboard is turned to the left to work with the door open red light on if the door is closed POSSIBLE CAUSE There are various possible causes An emergency pushbutton has been pressed Interruptions or short circuits on the emergency line SOLUTION Check that all emergency pushbuttons have been released Check that the selector Disable door micros is turned to the left ...

Page 216: ...FUNCTION The spindle is subjected to an over torque for a prolonged period of time POSSIBLE CAUSE There are various possible causes The machining parameters are excessive The material has an excessive resistance SOLUTION Reduce the feeding speed or Reduce the material to be removed Increase the number of revolutions of the tool if provided for by the manufacturer of the tool itself 7 2 15 Alarm 19...

Page 217: ...VEL ALARM 20 LOW LUBRICANT LEVEL 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION The oil level in the lubrication pump tank is at minimum level POSSIBLE CAUSE Automatic or manual lubrication request SOLUTION Top up the tank Consult the Maintenance chapter 7 2 18 Alarm 22 SPINDLE MANAGEMENT ERROR ALARM 22 SPINDLE MANAGEMENT ERROR 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Two directions of rotat...

Page 218: ...button turn the pushbutton counter clockwise Press Reset Check wiring 7 2 20 Alarm 25 ENCLOSURE DOOR OPEN ALARM 25 ENCLOSURE DOOR OPEN 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION There is a door micro switch at each of the side sliding doors that give access to the machine cabin One of the micros signals that one of the doors is open POSSIBLE CAUSE There are various possible causes One of the d...

Page 219: ...N input If the error persists contact service technician COMPONENT CODE BP5 7 2 22 Alarm 28 AXIS DRIVE NOT OK ALARM 28 AXIS DRIVE NOT OK 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION One of the motor drives is in alarm state POSSIBLE CAUSE There are various possible causes An overload An encoder malfunction A motor malfunction A malfunction of the drive itself A malfunction of the electric circui...

Page 220: ...sure gauge If necessary replace the pressure gauge COMPONENT CODE In the upper section of the pneumatic box BP1D right loader Q axis 7 2 24 Alarm 30 LH BLOCKING MALFUNCTION ALARM 30 LH BLOCKING MALFUNCTION 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION One of the piece blocking pressure gauges signals a pressure drop POSSIBLE CAUSE There are various possible causes Pneumatic supply has been interr...

Page 221: ...pply has been interrupted The pressure gauge is not correctly calibrated The pressure gauge is defective False contact with the CN 7 2 26 Alarm 34 ATTIVA BANCO SX O DX ALARM 34 ENABLE LH OR RH BENCH 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION TCP enabling has been requested using the TOOL POINT softkey without having previously specified the reference bench POSSIBLE CAUSE SK pressed There are v...

Page 222: ... the CN input card and the touch sensitive edge SOLUTION Remove the obstacle Only for qualified technicians Check wiring 7 2 28 Alarm 37 RH TOUCH SENSITIVE EDGE INTERVENTION ALARM 37 RH TOUCH SENSITIVE EDGE INTERVENTION 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION The loading door was closing The touch sensitive edge has detected an obstacle Therefore the door has reopened POSSIBLE CAUSE There a...

Page 223: ...ck for possible compressed air leaks Check the solenoid valve for door opening and closing and the electrical connection 7 2 30 Alarm 39 RH DOOR CLOSING TIMEOUT ALARM 39 RH DOOR CLOSING TIMEOUT 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION The loading door did not close within the expected time lapse POSSIBLE CAUSE There are various possible causes Mechanical obstacle in the movement of the cylin...

Page 224: ...libration Check the electrical connections COMPONENT CODE In the upper part of the pneumatic box BP1S left loader P axis 7 2 32 Alarm 43 RH DOOR OPENING TIMEOUT ALARM 42 RH DOOT OPENING TIMEOUT 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Piece blocking pressure gauge malfunction POSSIBLE CAUSE There are various possible causes Pneumatic supply has been interrupted The pressure gauge is not corr...

Page 225: ...able EXCSW_C to zero from VARIABLES PLUS VARIABLES then press RESET and reset the axis Subsequently reset the variable EXCSW_C to 1 only qualified technician 7 2 34 Alarm 46 SPINDLE 1 DRIVE NOT OK ALARM 46 SPINDLE 1 DRIVE NOT OK 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION The spindle drive inverter signals a malfunction POSSIBLE CAUSE There are various possible causes Inverter off or in alarm s...

Page 226: ...rgise the machine before enabling the spindles 7 2 36 Alarm 48 SPINDLE 2 DRIVE NOT OK ALARM 48 SPINDLE 2 DRIVE NOTOK 1 OF 1 CONDITION CHECK DESCRIPTION MALFUNCTION The spindle drive inverter signals a malfunction POSSIBLE CAUSE There are various possible causes Inverter off or in alarm state Spindle inverter connection problem Inverter PLC input connection problem SOLUTION Only for qualified techn...

Page 227: ...MALFUNCTION Spindle start up attempt not activated POSSIBLE CAUSE There are various possible causes Inverter off or in alarm state Spindle inverter connection problem Inverter PLC input connection problem SOLUTION Enable the ENABLE SPINDLE SK In automatic from programme check the presence of the M3 code in the piece programme or in the MASTER ...

Page 228: ...ed technicians Remove chips Check efficiency of limit stops Check wiring PROCEDURE FOR RETURN FROM OVER STROKE 1 of 1 ACTION DESCRIPTION 1 Identify which axis is in over stroke 2 Turn the Return from over stroke selector to the right 3 Press Reset 4 Turn on the machine again using the Auxiliary Start pushbutton The Grid connected light turns on 5 Turn the Automatic Manual selector to the right 6 W...

Page 229: ... Defective solenoid valve Pneumatic problem crushed pipe Defective sensor Defective electrical connection between the solenoid valve and the CN I O cards Movement obstacle SOLUTION Only for qualified technicians Periodically unblock the gripper to keep the surfaces from sticking together Use the appropriate grease to keep the surfaces from sticking together Check the solenoid valve and the electri...

Page 230: ... solenoid valve and the CN I O cards Movement obstacle SOLUTION Only for qualified technicians Check the solenoid valve and the electrical wiring Check the pneumatic system Check sensors and connections Clean the tool change Contact service technician 7 2 41 Alarm 54 TOOL CHANGE SPINDLE ROTATION NOT PERMITTED ALARM 53 TOOL CHANGE SPINDLE ROTATION NOT PERMITTED 1 of 1 CONDITION CHECK DESCRIPTION MA...

Page 231: ...ressure gauge is defective False contact with the CN SOLUTION Check the pneumatic pipes and couplings Check the pressure gauge and calibration Check the electrical connections 7 2 43 Alarm 59 DISCONNECT OVER STROKE RETURN ALARM 59 DISCONNECT OVER STROKE RETURN 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION No axis in over stroke POSSIBLE CAUSE The over stroke selector is in the return position but...

Page 232: ...LUTION Select MANUAL mode from the CN Mode selector in MANUAL mode 7 2 45 Alarm 61 LH DOOR 2 OPENING TIMEOUT ALARM 61 LH DOOR 2 OPENING TIMEOUT 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Malfunction of pressure gauge 2 for piece blocking POSSIBLE CAUSE There are various possible causes Pneumatic supply has been interrupted The pressure gauge is not correctly calibrated The pressure gauge is de...

Page 233: ...e direction for return from over stroke Check zero position micro and wiring qualified technician 7 2 47 Alarm 68 CANBUS NODO N ALARM ALARM 68 CANBUS NODO N ALARM 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION CANBUS I O card system alarm POSSIBLE CAUSE There are various possible causes Connection problem on CAN cable Power supply problem to CAN cards or node CANBUS CN card malfunction Module conn...

Page 234: ...drive temperature Check air conditioner electrical cabinet temperature Check drive alarm Check CN drive motor connections 7 2 49 Alarm 71 INVERTER 1 OVER TORQUE ALARM 71 INVERTER 1 OVER TORQUE 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION Inverter over torque POSSIBLE CAUSE There are various possible causes Excessive tool machining stress Spindle rotation problems Problem with over torque input c...

Page 235: ... if allowed tool revolutions Reduce amount of material removed by machining Only for qualified technicians Check spindle rotation Check inverter over torque connections Contact service technician 7 2 51 Alarm 74 RESET ALARM 74 RESET 1 of 1 CONDITION CHECK DESCRIPTION MALFUNCTION CN reset in progress POSSIBLE CAUSE There are various possible causes Excessive tool machining stress Spindle rotation p...

Page 236: ...are limit POSSIBLE CAUSE There are various possible causes Axis in over stroke PLC memory error SOLUTION In manual mode bring the A axis back within normal stroke so that the zero setting stroke does not damage the machine In the event of a PLC memory error reset the variable EXCSW_A to zero from VARIABLES PLUS VARIABLES then press RESET and reset the axis Subsequently reset the variable EXCSW_A t...

Page 237: ...arms 7 3 1 Drive Alarms DRIVE ALARMS 1 of 1 SOLUTION Only for authorised qualified technicians Consult the drive user manual 7 3 2 Inverter Alarms INVERTER ALARMS 1 of 1 SOLUTION Only for authorised qualified technicians Consult the inverter user manual ...

Page 238: ...CHAPTER 7 Messages Alarms Chap 7 31 31 Page left intentionally blank ...

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