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Milltronics VM Series, Instruction Handbook Manual, Page: 18 / 56

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Milltronics VM Series Instruction Handbook Manual Download Page 18

Summary of Contents for VM Series

Page 1: ...Instruction Handbook for VM Series Machining Centers Milltronics Manufacturing Company 1400 Mill Lane Waconia MN 55387 USA Phone 952 442 1410 Fax 952 442 6457 www milltronics net Rev 9 17 2013 ...

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Page 3: ...cs Complete Specification Sheets 13 VM22 30 Machine Layout 14 VM15 20 Machine Layout 15 Item Identification 16 Retention Knob Chart 18 Torque specifications 19 Chapter 3 Site Preparation 21 Machine Placement Considerations 21 Power And Ground Requirements 22 Connecting a Transformer 23 Autotransformer Connection Diagram 24 Air Supply System 25 Lifting By forklift 26 Lifting By Crane or Hoist 27 Ch...

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Page 5: ...intenance 39 Periodic Maintenance Verification Of Safety Systems 39 Maintenance Schedule 39 Always 39 Daily 39 Weekly 40 Monthly 40 Annually 41 Safety Checks to be carried out monthly and after maintenance operations 41 Air System Maintenance 42 Way Lube Maintenance 43 Adjustment 43 On Off Timer Settings 43 Automatic Tool Changer ATC Maintenance 44 Drawbar cylinder Maintenance Inline spindle model...

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Page 7: ...ted If a particular operation is not documented in this or any other Milltronics manual as authorized usage for the particular equipment it should be assumed that this is an unauthorized or improper usage with potential danger and should be avoided A This machine is provided with various safety devices to protect the operator and the machine However these cannot cover all aspects of safety therefo...

Page 8: ...sons shall also be familiar with the proper use of any special precautionary techniques personal protective equipment including arc flash insulating and shielding materials and insulated tools and test equipment Basic Points Of Safety 1 DANGER There are high voltage terminals on the electrical panel transformer motors junction boxes and other equipment DO NOT touch the high voltage terminals or co...

Page 9: ...erials Never use flammable cutting fluids 3 CAUTION Do not subject the CNC control unit the operator s panel or the electrical control panel to strong voltage fluctuations Do not change any machine parameter values without consulting Milltronics service department If it becomes necessary to change a value first check if it is safe to do so then make a note of the original value so it can be reset ...

Page 10: ... to make sure they are properly fitted and not damaged Always obtain assistance when handling loads beyond your ability Do not adjust coolant nozzles while the machine is in operation Do not remove or interfere with any machine safety devices Do not wipe the work piece with a rag while the spindle is rotating or the machine is in motion Always stop the machine before removing or inspecting a tool ...

Page 11: ...limits Never machine flammable or explosive materials Never use flammable materials as cutting fluid 3 CAUTION Be sure the tool length is such that the tool will not interfere with any fixtures or other objects Perform test operations after mounting tools Safety Related To Machine Maintenance Maintenance should be performed only by qualified personnel as defined in the safety checklist on page 2 B...

Page 12: ...ve electrical terminals Remove jewelry while servicing the machine to avoid shorting any electrical circuits Always turn the main power off before servicing components within the electrical cabinet Allow all components to discharge before servicing them After removing power verify that the CHARGE LED indicator and 7 segment display on the spindle drive have turned OFF before servicing FAILURE TO F...

Page 13: ...sconnect switch on the door of the electrical cabinet at the rear of the machine When the machine is put into emergency stop mode the servo motors and the spindle motor are de energized If the machine has a horizontal tool change platter and the platter is under the spindle emergency stop causes the platter to withdraw from underneath the spindle When there is no power to the machine the ballscrew...

Page 14: ...p Auger Conveyor Hazard 9 4 Main Power hazard and Notice 10 5 ATC crush hazard 10 6 Auger warning 10 7 Warmup and daily checks 10 8 Spindle Operation and Precaution 10 9 Drawbar Maintenance if equipped For Inline spindle models only 10 10 Waylube maintenance 10 11 Air system maintenance 11 12 ATC maintenance 11 12 1 3 6 5 9 7 8 3 11 10 2 4 ...

Page 15: ...d with full enclosure Located around hazard areas on models equipped with chip conveyor Located around hazard areas on models equipped with chip auger Read and understand all Safety Operation and Maintenance labels affixed to the machine to ensure safety and reliability ...

Page 16: ...chip auger chute if equipped All models located near operator station Perform all checks to prevent damage and ensure reliable operation All models located near operator station Perform all checks to prevent damage and ensure reliable operation Maintenance labels located on machine near maintenance items Various labels are used depending on options equipment ...

Page 17: ...chine near maintenance items Various labels are used depending on options equipment Maintenance labels located on machine near maintenance items Various labels are used depending on options equipment Maintenance labels located on machine near maintenance items Various labels are used depending on options equipment ...

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Page 19: ...pockets All VM machine s 4 100 mm Maximum Tool Length Weight All VM Machines 9 15 lb 230 mm 7 kg STANDARD CURRENT VOLTAGE REQUIREMENTS 208 240 VAC 60 Amps 60 Amps 60 Amps 60 Amps 60 Amps 60 Amps Transformer 23 KVA 23 KVA 23 KVA 23 KVA 23 KVA 23 KVA OPTIONAL CURRENT VOLTAGE REQUIREMENTS 208 240 VAC 100 Amps 100 Amps 100 Amps 100 Amps 100 Amps 100 Amps Transformer 38 KVA 38 KVA 38 KVA 38 KVA 38 KVA ...

Page 20: ...14 VM22 30 Machine Layout ...

Page 21: ...CHAPTER 2 SPECIFICATION 15 VM15 20 Machine Layout ...

Page 22: ...16 Item Identification ...

Page 23: ...CHAPTER 2 SPECIFICATION 17 1 Operator panel 2 Spindle 3 ATC 4 Auger Chute 5 Electrical cabinet 6 Y axis cable track 7 Z axis cable track 8 Leveling pad 9 Waylube unit 10 Air system 11 Z axis motor ...

Page 24: ...18 Retention Knob Chart ...

Page 25: ...lb M8 SHCS EKL300 52 ft lb M10 SHCS Ballscrew support bearing mounting screws Size Torque M6 SHCS 12 ft lb M8 SHCS 30 ft lb Ballscrew bearing locknut setscrew Model Locknut Set screw ZM 20 13 ft lb 2 ft lb ZM 25 18 ft lb 4 ft lb ZM 40 40 ft lb 4 ft lb ZM 50 62 ft lb 4 ft lb Rail and bearing block mounting screws Bolt size Torque M8 SHCS 30 ft lbs M10 SHCS 61 ft lbs M12 SHCS 103 ft lbs Tollok keyle...

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Page 27: ...expansion joints Thickness for VM15 16 20 models must be at least 4 Thickness for VM22 25 30 models must be at least 6 Milltronics will not guarantee machine geometry unless this is adhered to 2 Ample ceiling height and clearance behind the machine to fully open the door of the electrical cabinet at the rear of the machine see machine dimensions drawing in Chapter 2 for distance 3 Do not subject t...

Page 28: ... our ground terminal and the main ground located at the electrical service box Also ensure that the electrical service box is tied to earth ground 4 Milltronics does not allow the use of a separate grounding rod 5 Milltronics does not allow conduit or wire raceways be used as a ground 6 If a transformer is used to step the voltage down to 220 refer to the transformer grounding procedures immediate...

Page 29: ...ely from power 3 Always measure voltage from line to line and from line to ground before applying power to the machine electrics Do this with or without the addition of a transformer 4 With or without a transformer any power leg of the three phase incoming power to the machine should not exceed 240 VAC to ground or from leg to leg At least two of the legs when measured between the leg and chassis ...

Page 30: ...er option an autotransformer is supplied The diagram below illustrates the various input voltage selections and proper ground wire connections Always call the factory if in doubt concerning transformer connections as serious damage can result if the machine or transformers are not properly connected ...

Page 31: ...just the air purge regulator unless instructed to do so by an authorized Milltronics Representative Set the drop rate on the lubricator to approximately 1 drop per every 1 2 tool changes Spindle air pressure gauge Do not alter from factory setting Maintain fill levels weekly using specified air tool oil Main air pressure gauge Adjust using knob A 90 PSI A B Water trap is self draining No need to d...

Page 32: ...er hardware Raise machine only as far as needed to move Small frames up to 20 Y travel Use minimum 5 foot forks with capacity of 15 000 Lbs Large frames over 20 Y travel Use minimum 6 foot forks with capacity of 20 000 Lbs This machine should only be moved loaded unloaded or skidded unskidded by a trained and certified machine mover ...

Page 33: ...CHAPTER 4 INSTALLATION 27 Lifting By Crane or Hoist This machine should only be moved loaded unloaded or skidded unskidded by a trained and certified machine mover ...

Page 34: ...pping purposes Qualified personnel See the safety checklist on page 2 for qualifications should install and adjust as necessary according to the photos and descriptions Locate the leveling pads and then thread them into the machine base before setting the machine on the floor Loosen and remove the mounting hardware for the shipping bracket Remove the bracket if it slides out easily It the bracket ...

Page 35: ...n many cases this track is loosened or removed for shipping If the Y axis cable track was removed for shipping attach it as shown Connect the remote hand controller if equipped cable into the 25 pin D sub connector to the right side of the operator panel Connect all remaining cables to their respective plugs on the machine Enclosure end Piece Each side ...

Page 36: ... page 2 for qualifications Level the machine rough level in both side to side and front to back directions Install the auger chute if equipped 1 Remove the screws holding the auger in to the coolant tank 2 Raise the end of the auger so the chute can be installed 3 Install the chute then replace auger hardware Slide the flood coolant tank under from the front of the machine ...

Page 37: ...s it may have changed while adjusting front to back Repeat steps 6 7 until the machine is level in both directions 6 Using a magnetic base with a dial indicator sweep the table to check tram The tram should sweep within 001 over a 10 diameter sweep Adjust leveling pads if necessary At this stage it is more important to be level to tram and NOT level to the precision level 7 Extend the center pads ...

Page 38: ...ening electrical cabinet or performing adjustments or diagnostic measurements while energized Only qualified personnel should attempt to take current and voltage readings or perform service See the safety checklist on page 2 for qualifications Always turn the main power off before servicing components within the electrical cabinet Always keep hands and fingers away from live electrical terminals R...

Page 39: ...machine Close and lock the door of the electrical cabinet Visually Check That Guards Are In Place Required Guards for Mills Milling machines and machining centers should have way covers on all three axes closing off the pinch points associated with machine axis motion All machining centers by definition have a full enclosure around the machining area Check that the enclosure door operates smoothly...

Page 40: ...LE START Start the Spindle Operate only within proper startup break in limits outlined on page 36 During the sequence outlined below the spindle will rotate If there is a tool in the spindle make sure it is not going to hit anything when the spindle turns If the machine has an enclosure close the door From the main menu Press F5 MDI Key in S code for RPM followed by RPM value Example S500 500 RPM ...

Page 41: ...uding conveyor remote hand controller etc Test the enclosure safety circuit CE machines only If the machine is still in emergency stop mode from the previous test then twist the red EMERGENCY STOP button clockwise to release it Press the RESET button to re energize the axis motors and the spindle motor Follow the directions in the previous sequence for starting the spindle for manual use Now hold ...

Page 42: ... to room temperature Resume the procedure at the point it was halted The temperature can be measured with a pyrometer If a pyrometer is not available a good indication of excessive temperature is if you cannot hold your hand on the spindle cartridge for more than 5 seconds Warning Do not put your hand on the rotating spindle only on the fixed spindle cartridge 4 If the temperature is within normal...

Page 43: ...onents A wide variety of failure modes caused by electrical component faults are possible for the machine An accidental crash between tool and workpiece even if it does not do mechanical damage will likely cause an axis drive fault putting the machine into emergency stop mode Even without a crash a drive fault might be caused by machining conditions where the machine is asked to deliver more than ...

Page 44: ... modes also are possible even without a crash A careful inspection of the parts involved in a mechanical fault is the best way to assess its extent When a mechanical component needs to be replaced follow the guidelines in this manual describing safe maintenance practice Ensure all hardware is tight and properly torqued after performing maintenance operations See torque specifications in chapter 2 ...

Page 45: ...intenance activity on each machine WARNING Due to the hazard of live power special caution should be taken with electrical repairs or electrical component replacement Electrical maintenance should only be performed by qualified personnel Electrical Safety Rules should be observed Maintenance Schedule Always Remove chips as necessary from the chip pan area Daily Ensure the air lubrication unit disp...

Page 46: ...damage and proper tension Check drawbar cylinder hydraulic fluids reservoir Top off with recommended hydraulic oil if necessary Check operation of low air pressure switch if equipped Remove compressed air source from the machine and verify that a red alarm message box appears at the front panel display WARNING Arc flash and shock hazard Follow ALL requirements in NFPA 70E for safe work practices a...

Page 47: ...nd after maintenance operations Repeat the checks for correct operation of the emergency stop circuit and of the safety enclosure circuit outlined in Chapter 4 of this manual In brief power up the machine enable the drives and start the spindle Verify that pushing the red Emergency Stop button makes the spindle brake rapidly to a stop and machine motion is halted For CE compliant machines power up...

Page 48: ...the main air regulator to 90 PSI Do not adjust the air purge regulator unless instructed to do so by an authorized Milltronics Representative Set the drop rate on the lubricator to approximately 1 drop per every 1 2 tool changes Spindle air pressure gauge Do not alter from factory setting Maintain fill levels weekly using specified air tool oil Main air pressure gauge Adjust using knob A 90 PSI A ...

Page 49: ...rease the OFF time without first consulting the factory On Off Timer Settings Model Series On Time Seconds Off Time Minutes BR VM HM20 MM18 TT 5 60 HM35 7 45 MB VK RH RW 8 28 ML SL 7 30 There are two types of oiler timers in use as shown below CESD Type MA 219 Set the built in timer controls for Seconds ON and Minutes OFF operation per the table above CEN01 Type MA 458 Set the CNC parameters for S...

Page 50: ...ight glass to ensure fluid level remains topped off Replace oil annually with Mobilgear ISO 150 or equivalent gear oil 16 or 24 Pocket carousel style ATC Lubrication is automatic via the lubrication system on the machine No scheduled maintenance is required but the area should remain free of chips and coolant overspray ...

Page 51: ...enance Inline spindle models only Check fluid level here 3 4 full Fluid reservoir Inline spindle drawbar cylinder Monitor fluid reservoir to ensure fluid level remains topped off Top off to full if necessary with ISO VG32 hydraulic oil or equivalent ...

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Page 53: ... Panel Power ON The main power switch is located on the electrical cabinet at the back of the machine When main power is switched on the power to the CNC is also applied Power OFF Before switching off the main power press the E Stop button to ensure the machine is in emergency stop mode ...

Page 54: ... vary by machine type and options o SINGLE BLOCK Single block program execution on off o OPTIONAL STOP Optional stop M01 on off o BLOCK SKIP Block skip function on off o AIR Air blast function on off o FLOOD COOLANT Flood coolant function on off o MIST COOLANT Mist coolant function on off o AUGER Auger or Conveyor chip removal function on off o WASHDOWN COOLANT Washdown function on off o SETUP Rel...

Page 55: ...able and axis waylube oiler Emergency stop buttons lock down when pressed and must be rotated to release 9 ENABLE button When pressed and released it enables axis and spindle drives All Emergency stop and limit switches must be released for drives to enable 10 Alphanumeric keypads used to enter characters in MDI mode or program mode 11 Function keypad used to select machine functions that are show...

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