Bridgeport Interact 2 Maintenance Manual Download Page 34

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Summary of Contents for Interact 2

Page 1: ...J I l 1 t t e PART NO 0596351 o...

Page 2: ...Ba TrFt tq v I 8 tz sS L 6 9 q...

Page 3: ...ard supplied as standard equipment with the Bridgeport Series ll lnteract 2 pictured above is made of a clear material Lexan or equivalent having high impact resistance to provide operator safety and...

Page 4: ...ments for a large number of applications However as the machine and attachments are designed for general engineering applications the guard supplied will not cover every possible requirement for effec...

Page 5: ...o Bridgeport Machines and its suppliers and is made available for the use and maintenance of our products Any use reproduction or disemination of this information for any other purpose wittrout writte...

Page 6: ...Disuibution CONTROL AND AXIS DRIVES Axis Drive Unit System Description Replacement of Axis Drive Unit Conuol System Description Fitting a New Controller Sofrware Limits Controller Buffer Battery Repl...

Page 7: ...l Limit Switches 8 5 Alignment of Quill Housing Assembly to Drive Motor Housing Assembly 8 6 Bdl Quill Extension Inspection SPARE PARTS LIST 9 1 Electrical Parts List 9 2 Mechanical Parts List PREVENT...

Page 8: ...t of Services Knee Lubrication System Saddle to l able Gib Setting Saddle to Knee Gib Setting Milling Head Assembly Special l ool 5 l 6921 Head Lift Bracket Z Axis Assembly Spindlc Brake antl Back Cea...

Page 9: ...sumed to have a fair knowledge of ttre equipment He is assumed to have a VOM spare fuses printed circuit boards etc Level2 maintenance consists of all level 1 procedures plus adjustment of power suppl...

Page 10: ...Figure 1 1 Series II Interact 2 Milling Machine 1 1...

Page 11: ...1 3 shows the necessary clearances around the machine for access door opening for maintenance and to continue the remainder of the installation 1 2 ELECTRICAL SERVICE 1 2 7 Referencelnformation The m...

Page 12: ...4 LEVELLING BOSSES ON BASE 108 mm 4ll 1180 mm 46 712 965 mm 39 LEVEL POSITION CROSS AND LENGTH WISE FOR 16 mm 5 8 BOLTS 660 mm 26 787 mm 31 Figure 1 2 Machine Base Layout t 3...

Page 13: ...20 mm DIA HOLE FOR 314 DIA CONDUIT FITTING 508 mm 20 1638 mm 64Y2 559 mm 279 mm 22 11 1194 mm 47 691 mm 27Y2 1346 mm 53 Figure 1 3 Installation Plan View 74 II...

Page 14: ...NS OR ANY OTHER INFLAM VIABLE OR TOXIC CLEANING AGENT Clean and lubricate all exposed sections of the table saddle and knee ways This includes the underside of all ways It also includes the possible n...

Page 15: ...nstalled and are secure c Check that the lubrication reservoir has been filled with the correcr grade of oil and operate the plunger to check that the system is pumping the lubricant 3 2 7 2 Wire Chec...

Page 16: ...Voltage reads volts D C c Measure the smoothed D C voltage terminals 65 and 90 and check that it falls within the range 22 volts D C to 26 volts D C Voltage reads volts D C 3 2 4 Pneumatics Set the r...

Page 17: ...that the following facilities are functional 3 2 6 1 MpI Check that the machine responds correcdy to MDI commands 3 2 6 2 Lube Check that the automatic centralised lubricating system is working corre...

Page 18: ...KNEE DRIVE 4 2 7 Raising and Lowering Knee The knee is elevated by an Acme screw A friction type dual dial calibrated in increments of 01 mm 001 is provided To change knee elevation push the knee eie...

Page 19: ...315 and Truslide 300 Oil Sinclair Factoray 5O Febis K 5 3 Mobil Vactra Oil No 2 Fina Artac EP 37 Tonna 68 See Atlantic Richfield Co Factoway 50 Sunoco Way Lubricant 80 D X Wayclingl32O Way Lubricant D...

Page 20: ...e spindle directly through the clutch Shifting into back gear low disengages the clutch and engages the bull gear The power travels through a toothed belt drive to a counter shaft and back to the spin...

Page 21: ...D MACHINE PERFORMANCE System resolution linear angular Display resolution Positioning repeatability Positioning accuracy Drilling capacity mild steel Milling capacity mild steel Boring max dia 760 mm...

Page 22: ...se distribution wiring Items connected to the 3 phase distribution wiring are 1 The spindle motor 2 Control voltage uansformer T1 3 Axis ririve power transformer T2 5 1 2 Single Phase Power The 110 vo...

Page 23: ...and 6 to close the velocity feedback loop 6 2 REPLACEMENT OF AXIS DRIVE UNIT 1 Switch off and isolate the machine 2 Remove the old drive unit after remorring the plug in terminal strip connector the p...

Page 24: ...ERMINALS Figure 6 1 Axis Drive Unit Connections and Adjustments MAIN ARMATURE TERMINALS CURRENT LIMIT POT TEST POINTS OFFSET POT COMPENSATION BOARD TACHOMETER GAIN POT t R30 1 2 3 5 14 15 76 GND R9 R2...

Page 25: ...s faciiities for automatic cycling of the machine from the stored programme and for interlocking of the power feed controls It is a closed loop feedback system This faciliry being achieved using a dig...

Page 26: ...h on the machine will now request Machine Parameters If not then input 95148 and press Eh l l lt 12 The control will then display machine Parameters 13 Enter the values as recorded on the Machine Soft...

Page 27: ...nd in the door pocket of the electrical cabinet 6 6 CONTROLLER BUFFER BATTERY REPLACEMENT When the dialogue display reads EXCHANGE BUFFER BATTERY the barteries should be replaced by new ones as soon a...

Page 28: ...o o o o rl z U o r z Ft C l Y x AXIS AXIS AXIS Z HANDWHEEL ENCODER VDU CABLE 110 V A C SUPPLY VOLTAGE SELECTOR SET TO 12OV TERMINAL STRIPS 5 PROGRAMME STORAGE INTERFACE SOCKET Figure 6 2 Rear of Contr...

Page 29: ...the saddle end cover and remove the cover continued in paragraph 4 If the belt is broken WARNING DISCONNECT THE POWER TO THE MACHINE BY THROWING THE MAIN CIRCUIT BREAKER TO THE OFF POSITION 1 Remove t...

Page 30: ...tor bracket above the motor flange 8 Support t le motor and remove the four screws securing the motor and remove the motor The dowel pin underneath the tension screw will be released so make sure this...

Page 31: ...BREAKER TO THE OFF POSITION BEFORE BEGINNING THIS PROCEDURE 1 Remove the two screws securing the motor bracket cover and remove the cover 2 Support t le motor and remove the four screws securing the m...

Page 32: ...597 36 r57 85 54 2159855 2159852 2L59851 21520t9 2152018 t57 7 59 1572493 r577592 2152002 2t52003 1700390 2159716 I r57799 879r8t4 879t877 t57 27 32 1702573 2t52t9t 2152045 700392 2t59853 1705558 2t52...

Page 33: ...1705559 o 2L52044 L700392 1720286 2152790 21597 40 2159868 2t52014 170257 3 1700335 L553359 2159863 2159864 t7L2t20 17t2077 1700754 2159862 rTtoooz L70to20 1700360 t577tt 2159867 1553590 t572733 Saddl...

Page 34: ...2Knee Arrangernent Sheet I of 2 7 5 215200r 2152070 I I I I 2150013 t700468 I I I I v o o 1540530 L700387 1705556 2150012 1720549 21500t4 1700372 t705625 t700497 1700837 879t8t5 215985 1572732 879t81...

Page 35: ...Ir l J lll 2t52tO7 1700369 t572788 2152078 2152077 t700369 2L52070 2152074 2t52r72 1705086 2L5986t 2t52LO8 ll il I il JI I 5405 12 1700374 Figure 7 2 Knee Arrangement Sheet 2 of 2 7 6 I I 1 2152076 1...

Page 36: ...I 2t5027t 2t597 2 2r5 110 t7052AO 2L570L8 _l I Figure 7 3 Dtal Dial Layout 7 7...

Page 37: ...hould be replaced c The alignment of the ballscrew with the bedface and master guideway is critical and must be within 0 050 0 002 along the full length of the ballscrew When the screw alignment requi...

Page 38: ...knee Disassemble the ballscrew from the front bracket 1 3 To replace a new ballscrew reverse the disassembly procedurc paying particular attention to the following a The ballscrew assembly is supplie...

Page 39: ...aring and bearing retainer 5 Remove the two pedestal mounting screws and remove the pedestal from the base 7 5 2 linder Gasket Removal 1 Raise the knee to a position close to the topmost working posit...

Page 40: ...FITTING I5IO253 VINYL TUBING r579041 t700472 2152122 1540502 PIN 2159778 SPRING 2t52LL5 1722405 1722665 1722485 t700389 2t52tt8 1700792 2t 52117 1705556 2150013 2150554 21500t4 2159700 155210 2t552tt...

Page 41: ...software limits as per Section 7 6 3 7 6 2 X Axis Reference Dog The axis reference dog is used in conjunction with the encoder on the motor shaft to determine the machine datum following an intemrpti...

Page 42: ...mit switch located on the rear surface of the saddle turn off the power and proceed as follows 1 Remove the bottom cover plate from the limit switch 2 Unscrew the large hexagon nut s on the electrical...

Page 43: ...is reference points as normal 3 Place the control in reference mode by pressing the key and then 8EF REF 4 Re adjust the axis reference dog to operate the reference switch at between 1 0 mm and 1 5 mm...

Page 44: ...plate on the saddle Install the new limit switch by reversing the above procedure Adjustment of the limit switch may be achieved by slackening the two screws securing the mounting plate to the saddle...

Page 45: ...N SIDE OF KNEE I 2L52028 q 17034OO 3 lO 32 UNF x 5 8 HEX HD SCREWS t705603 3 16 WASHER 3 L7OO475 4 8791850 1700355 1 4 UNC x 314 SOCKET CAP SCREW 17005604 4 1 4 WASHER L70034 1 4 UNC x 518 SOCKET CAP...

Page 46: ...ITCH 1700 7 5 lO 32 UNFx 1 SOCKET CAP SCREW 879L85 STOP 3 2159859 Q t70560 1 4 WASHER 2 1705603 3 3 r6 WASHER 1703400 LO 32 UNF x 5 8 HEla D 3 2152045 2 2159858 1700355 1 4 UNC x 314 SOCKET CAP scREw...

Page 47: ...3605 r 5 10504 r570628 r570644 1 5 70800 2159894 1701597 t705039 156t77t r57 5246 1700353 2t59898 1 701038 17050 3 1705605 NOTE REGULATOR A TO BE SET AT 80 p s i g REGULATOR B TO BE SET AT 4O p s i g...

Page 48: ...8 8 30 3821 8303607 8303606 830361 3 METER UNIT FJB O METER UNIT FJB METER UNIT FJB 1 METER UNIT FJB 2 CLOSURE PLUG COMPRESSION BUSHING COMPRESSION SLEEVE DRIVE BUSHING I I _ I r I L l 1 t57 5297 8303...

Page 49: ...7 8 3 7 8 2 Saddle to Table Gib Setting see Figure 7 8 1 Set up indicators in position no 1 2 Push end of table and release pull end of table and release Note the total indicator reading less the spri...

Page 50: ...E POSITION NO 1 INDICATOR SET UP INDICATOR ON TABLE BASE ON SADDLE 330 mm 13 13 Figure 7 8 Saddl able Gib Setting fa r PUSH PULL FORCE ON TABLE SADDLE KNEE POSITION NO 2 SADDLE IN FULL FRONT POSITION...

Page 51: ...ingbas been acbieoed Lost rnotion should be less tban 025 mm 001 if tbis fiyrt is exceeded slacken the gib strtp btt one quarter of a rurn and recbeck It sbould also be noted tbat lost motion may be p...

Page 52: ...pensation facility built into the control To compensate for backlash proceed as follows 1 Measure lost motion as per Section 7 9 1above 2 In manual mode key in 95748 and ENTER Screen displays Machine...

Page 53: ...control snugly against the high speed stop 3750 readingon dial Loosen the jam nut 8300351 and turn the adjusting screw 8025526 at the top of the head Using a tachometer set the spindle speed at 3750 r...

Page 54: ...ity of the head 10 Support the head by an overhead hoist through the loop of the lifting tool 11 Remove the remaining four bolts that secure the head to the ram 12 After reassembly trammel the spindle...

Page 55: ...3 COPPER 7 UPIN 83O36IO AA sr soo B rr c s 8ioo566 METER UNI I 830360T CCMP NUT 830J506 sT 157 S H C S 2 83oot57 7 7 1A2 ItIIACKET 8050i82 N swt rcH 8o758o9 sT l r4r R H M S 2 8101941 r 1 i961 WASHER...

Page 56: ...cation of tbis part 83 mm 3 281 H DRILL 3 10 mm 3 8 1 WELD 96 mm 3 789 32 mm oc r t o co t J A a o F l o o u L I o o fJ o F o t Fb d EE rl F n 7f o 7 t 4 6mm t 121 mm 4 3t 48 mm 1 995 mm 44 mm 7 3 4 1...

Page 57: ...be belt as far forward towards tbe cente of tbe drioen pulleys 5025533 and 8025534 as possible Next work tbe belt as far as possible towards tbe peripbery of tbe driae pulleys 7012642 and 7012643 Witb...

Page 58: ...stop in the speed changer is reached This adjustment may be made in either the high or low speed range 2 Shut down the motor 3 Lower the quill 4 Disconnect power to the machine 5 Remove the motor pul...

Page 59: ...EF 8050187 s f I57 SHCS REF 8300157 t IYIf 553589 JOYSTICK VIEW C Z AXIS ASSEMBLY 77 0184 ADJ SCREW 8050180 J r44 GEAR REF 8007t44 1 i I 8780063 COVEE J477 TAPER PrN 4 8025677 co I El oa d t o oo I N...

Page 60: ...our screws holding the drive motor to the motor mounting housing 3 Slide ttre timing belt 8800072 off the motor pulley 4 Remove the drive pulley 8791808 and fit to new motor 5 Remove the rear cover fr...

Page 61: ...the drive motor to the motor mounting housing 4 Slide the timing belt 8800012 off the motor pulley 8050142 5 Loosen the four screws and pull the motor pulley 879180S off the motor shaft 6 Lift the dri...

Page 62: ...4 2 znd rcset Z a is software limits as per Section 8 4 3 8 3 4 BaIl Quill Extension Removal Figure 8 1 Special tools 3T 6927 Figure 8 2 2 adjustable spanner wrench 3 l 2 diameter adjustable hook span...

Page 63: ...8025604 sr I53 s H c s 2 8300153 2l s2 77 Or9l SLEEVE 8050r93 4J 3O2 HANDLE 8303953 t7 2J szz ausurNc so2s5z2 2l 579 CAM 8Ot4699 sT 22 PtN A300022 sT 22 PtN 8300648 2J 556 SNAP RING 8025556 2J 556 SN...

Page 64: ...or installation notes and settings see Section 8 3 4 steps 7 and 8 CA ITION Tbe only occasion on wbicb a quill sbould be remoaed is in tbe eoent of seoere damage by scoring tbrougb lack of lubrication...

Page 65: ...of rotation for unlocking This is usually the hole closest to a locking ear 5 Rotate nut back to load position This is when locking ears and keys are in line KEYS LOCKING EARS ___ t ROTATE TO UNLOCK...

Page 66: ...97 TRrP DOG 8050187 LIMIT SWITCH 8075 1 o5 SWITCH ADJUSTMENT LOCKING SCREWS 2 8301941 QUILL REFERENCE SWITCH SWITCH ADJUSTMENT QUILL HOUSING TRrP DOG 8050187 LIMIT SWITCH 8075 10s LOCKING SCREWS 2 830...

Page 67: ...the top of the trip stop 8050179 in the quill housing slot and up to the quill 6 Carefully use rhe handwheel to raise the quill until a slight resistance is felt on the shim 7 Turn the positive stop s...

Page 68: ...om the positive software limit figure to obtain the negative software limit figuie 6 Enter these values as foiiows Machine paranreter 35 I ositive sofrware limit Z a xis Machine paramei cr 3fi J egati...

Page 69: ...spindle S050109 or gear hub 8025998 8 Install four screws S300499 but leave them loose 9 Repeat step 2 ro float motor mounting housing 3050161 into place Tighten the four screws 8300499 10 Repeat ste...

Page 70: ...UP 510 g 18 ozs MAX DOWN 510 g 18 ozs MAX QUILL THREAD UPWARD NUT TRAVEL BALL QUILL EXTENSION ASSEMBLY 878046s PULL SCALE fO ROTA fE NUT SCALE STRING WRAPPEI AROUND NUT Figure 8 7 Ball Quill Extensio...

Page 71: ...orizontal position and place over a flushing tank per Figure 8 9 2 Pour an oil dissolving solvent over the ball threads and ballnut This will remove any contam inated oil chips or foreign material fro...

Page 72: ...N SOLVENT OVER BALL QUILL EXTENSION EXTERIOR CLEAN SOLVENT BALL QUILL EXTENSION ASSEMBLY 8780465 rN HORIZONTAL POSITION Figure 8 9 Ball Quill Extension Flushing 8 20 FLUSHING TANK ililil uuul i tiil f...

Page 73: ...8 q PrtvtXY FN t rt A a o C aJr E rl v g r t I I D s3s s3 t 1 2z I la uo I l lri i rZ t is...

Page 74: ...e ZO 3 7 A Overload ZO 6 7AOverload Axis Drive Unit Bosch Auto Transformer Bosch Choke Bosch Resistor 3R3 12W Transformer Rectifier Capacitor 0 1 Microfarad Resistor 10 OHM Resistor 1 2 KOHM Capacitor...

Page 75: ...Off Bulb Axis Drive Motor SEM MT30R4 58 Encoder Coolant Pump Spindle Motor 2h p 21597 t6 7579779 2759760 1577994 1572 93 1705558 1577 592 Ballscrew Driven Pulley Motor Pulley Belt Bearing PR Bearing...

Page 76: ...M9308 PP TR25O J7O2 2 Bearing M203 NPP 2 Where Used Elevating straft assembly Knee pedestal location Secured to front of saddle Secured between column and table rear One shot lubrication One shot lubr...

Page 77: ...ly Hi Lo assembly Lifting bull gear Speed change Vari drive assembly MISCELLANEOUS Variable Drive Belt Timing Belt Adj Driven Vari Disc Stat Driven Vari Disc Adj Motor Vari Disc Stat Motor Vari Disc B...

Page 78: ...of tbe lubrication sJlstem 2 Clean dirt and chips from ways DO NOT USE AN AIR HOSE 70 2 2 Weekly Maintenance MAINTENANCE LEVEL I In addition to daily maintenance l Clean chips and dirt from the entire...

Page 79: ...r the equipment in the belt housing and exhausts around the motor shroud THE AIR INLET SHOULD BE FILTERED FOR PUNITIVE ENVIRONMENTS 2 Specially designed vacuum systems at the cutting tool are recommen...

Page 80: ...lean as necessary 10 3 5 6 Monthly Maintenance MAINTENANCE LEVEL 2 In addition to weekly inaintenance 1 Remove automauc lubricator filter and clean 2 Check spindle speed and adjust as per Section 8 2...

Page 81: ...m ways x x x x x x x Clean and apply oil to ways x x x x Clean entire machine x x x x x Check that oil is reaching slideways x x x x Check and apply oil to sliding guards x x x x x Clean spindle motor...

Page 82: ...individually in this chapter The procedure has been written in a logical sequence which must be followed from the beginning The results of this procedure will also be most useful in any further dialog...

Page 83: ...of control Also check 11Ov AC supply to control between wire 8 and 9 efi rrt brightness contrasr on display Check lead between control VDU connected If display still not wo pking then faulty VDU E on...

Page 84: ...cking 24v t 2v berween earth terminal block 65 Switch off at isolator and resta rt if fault clears then carry on otherwise faulty control unit i c Check for 11Ov A C benveen earth and the following te...

Page 85: ...al rs t ffr tr t and terminal 22 t I t HoId POWER ENABLE pushbutrcn IN and check 11Or A C between earth and the following termind block numberq 27 rlt YES 28 lr r Thermal overloadjnside X axis Motor a...

Page 86: ...f if I I I Does Contactor 5FC pull IN Faulty POWER ENABLE bulb END OF CHECKS f t YES t 77 5...

Page 87: ...nguish on being released One of the three otes is on an AXIS LIMIT SWITCH With POWER ENABLE button pressed drive off a cis limit by using electronic handwheel or joysticks or reference Turn to the nex...

Page 88: ...d REF PASS OVER REFERENCE POINTS when pushbutton Pressed Does control display read MACHINE PARAMETER O Input machine parameter into control unit Machine parameter for machine are inside electrical pan...

Page 89: ...7 Are the t uyo small green LED s marked BTB illuminated at the top right hand corner of the feed drive card z Does the Y axis x 14 relay 13 CR pull IN 12 Turn to the next page but one Check lubricati...

Page 90: ...z Does the Y Axis drive green x LED s marked FG illuminate Faulty drive Faulty drive Faulty drive motor Faulry control END OF CHECKS YES 7t 9...

Page 91: ...read GROSS POSITIONING ERROR Do the joysticks controls operate correctly in the rapid mode Turn to the next page Faulty encoder or associated cable on the indicated aris Faulty control unit Axis slide...

Page 92: ...Joystick rapid pushbutton faulty Joyitick directional microswitches faulty END OF CHECKS t J 11 1 1...

Page 93: ...ITCH Programming error Feedrate override control atzero Miscellaneous function in programme block not completed e g M03 spindle start M51 indexer if fitted Tool length or diameter compensation in oper...

Page 94: ...0 OFF 0 150 rr 34 AcT 2 S 5o ou og 0 1 2 3 4 5 6 7 I 9 10 11 L2 13 L4 15 16 L7 18 19 20 2L 22 23 MP t t l 9 0 0 2 1 0 0 0 0 0 0 0 2000 5 ON ON ON ON OFF ON OFF OFF ON 0 0 0 022 0r045 o 005 1 1 1 2 0 0...

Page 95: ...s O Bridg port Machines Diiision of Textron Limited t P O BAX 22 FOREST ROAD LEICESTER Lfr Telephone 0533 531 122 r t Bridgeport Texnon reseroe tbe igbt to amepd specification witbou notbe 1 i Prlnted...

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Bridgeport Interact 2, Maintenance Manual

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