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Rottler S7AD, Operation And Maintenance Manual

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Rottler S7AD Operation And Maintenance Manual Download Page 5

Section 1 Introduction

S7AD / S8AD Manual

www.rottlermfg.com

1-1

INTRODUCTION

READ THE SAFETY CHAPTER BEFORE INSTALLING MACHINE. THOROUGHLY UNDERSTAND 

ALL SAFETY ISSUES BEFORE OPERATING MACHINE.

ATTENTION OWNER/BUSINESS MANAGER

To validate the warranty on your new Rottler machine, please be sure to sign 

and complete the “Installation Report” located in the Installation Chapter of this 

manual.

We suggest that the new user of the S7AD & S8AD read the CONTROL DEFINITIONS to get an idea 

how the machine operates.

The Operating Instructions chapter should be read in order to familiarize the user with the actual button 

pushing sequences required to carry out a job. These chapters in the manual should be considered 

an introduction. As the operators of the S7AD & S8AD series machines gain experience with using the 

different functions of the machine, complicated setups and programs will make more sense. 

The rest of the manual contains information and part number reference on fixtures, cutting tools, and 

machine maintenance. The operator should read and become familiar with these areas as well.

Summary of Contents for S7AD

Page 1: ...OPERATION AND MAINTENANCE MANUAL 8029 S 200th St Kent WA 98032 USA www rottlermfg com Ph 253 872 7050 Fax 253 395 0230 16 03 2017...

Page 2: ......

Page 3: ...model and serial number 6 Part number and description of what you want to order 7 Preferred method of shipment 8 You may also contact us via e mail with the above information Send e mail requests to p...

Page 4: ......

Page 5: ...he CONTROL DEFINITIONS to get an idea how the machine operates The Operating Instructions chapter should be read in order to familiarize the user with the actual button pushing sequences required to c...

Page 6: ...tal or lease without the prior express written consent of Rottler Manufacturing Rottler Manufacturing does not make any representations warranties or guarantees express or implied as to the accuracy o...

Page 7: ...d If merchandise is returned with shipping charges collect the actual amount of these charges may be deducted from any credit which may be due the customer The RGR assigned by the Order Department sho...

Page 8: ...Section 1 Introduction S7AD S8AD Manual www rottlermfg com 1 4...

Page 9: ...nual www rottlermfg com I INSTALLATION Contents ROTTLER S7 8AD SERIES INSTALLATION REPORT 2 2 Installation Procedure 2 6 Location 2 6 Unpacking 2 6 Shipping Hold Down Bolt 2 6 Leveling 2 6 Air Supply...

Page 10: ...ew Rottler machine please be sure to sign the installation report after the installation technician has installed the machine and verified the machine is operating correctly and given the operators op...

Page 11: ...e the best average flatness of the top table ______This machine requires 208 to 240V AC 1 phase 50 60HZ isolated power supply measured between L1 and L2 Current requirement is 15 amps When using two l...

Page 12: ...____________________________________________________ Signature Title ______Explain to the customer the importance of backing up the block profiles to a separate device Any computer failure or possible...

Page 13: ...ce ______Explain feed speed combinations for finish on cast iron and aluminum V6 8 BLOCK RESURFACING ______Assemble V block tooling in accordance with the manual diagram ______Demonstrate the convenie...

Page 14: ...______________________________________________ ____________________________________________________________________________________ ____________________________________________________________________...

Page 15: ...crate from the S7AD S8AD machine do not use force on any part of the spindle unit Remove the tool box parallels and optional tooling located at the lower portion of the machine and completely clean th...

Page 16: ...ight rear of machine base The connection point for power is located inside the enclosure The connection termination point is the breaker power switch Attach wire from the grounding rod to the ground b...

Page 17: ...I SAFETY Contents Safety Information 3 1 Safety Instructions for Machine Use 3 1 Electrical Power 3 3 Machine Operator 3 5 Emergency Procedure 3 6 Computer and Controller System Safety 3 6 Electrical...

Page 18: ...n which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damag...

Page 19: ...other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced NEVER OPERATE A MACHINE WHEN TIRED OR UNDER THE INFLUENCE OF DRUGS OR ALCO...

Page 20: ...uidelines can be complete Every piece of shop environment is different Always consider safety first as it applies to your individual working conditions Use this and other machinery with caution and re...

Page 21: ...eptible to extraneous electrical impulses internally for externally produced The machine may make moves out of the operator control at any time The operator should work in and around the machine with...

Page 22: ...Any operation involving hands in the cutter head area such as inspection or alignment of the cutter head or tools changing Centering Fingers tool insertion and removal cutter head changes and size che...

Page 23: ...g Rottler Software when not directed by Rottler personnel will result in a non operational machine The machine should be hooked up to the Internet anytime it is on The software on the machine will aut...

Page 24: ...rrent sensors in all motor control panels Electrical breakers to prevent voltage surges and spikes from reaching electrical system Electrical lockout on main electrical enclosure E Stop that shuts dow...

Page 25: ...Switch 4 2 Initialization Screen 4 3 General Information 4 3 Home 4 3 Rapid Travel Buttons 4 3 Feed Buttons 4 4 CW and CCW Buttons 4 4 Definitions of Control Buttons 4 4 Program Select 4 5 New 4 5 Op...

Page 26: ...Section 4 Control Definitions S7 8AD Manual www rottlermfg com II Spindle RPM 4 11 Operation Setup 4 11 START SPINDLE 4 12 START AUTOCYCLE 4 12...

Page 27: ...ware should ONLY be done when directed to do so by a Rottler service technician Updating Rottler Software when not directed by Rottler personnel could result in a non operational machine It is recomme...

Page 28: ...ain electrical control enclosure on back of the machine The switch must be in the off position before opening the rear enclosure door When first applying power to the machine the computer will need to...

Page 29: ...e Rottler software operates on a Block Model format You select or create the block you are working with Then select or create an operation to be performed on that block The following are descriptions...

Page 30: ...y the operator This button is a latching button and will remain activated until the end of travel is reached or the operator touches the button a second time Feed Down button moves the spindle down at...

Page 31: ...home screen is located above the spindle control buttons This is where you create programs for different type of blocks New Pressing this button will cause a dialog box to appear Here is where you nam...

Page 32: ...ermfg com 4 6 Options This will bring up the same dialog box as described above if any of the information needs to be changed Delete This will delete whatever block program is selected A dialog box wi...

Page 33: ...u first create a block You can create only certain modes you will use on a block or use a standard set up that inserts all modes available You can also create a new mode and rename if for a specific u...

Page 34: ...nd section automatically Delete Warning box will appear asking if you wish to delete all existing block data Options This button is not used on this machine Delete This will delete the selected Mode I...

Page 35: ...Section 4 Control Definitions S7 8AD Manual www rottlermfg com 4 9 Select Highlight the Mill Cycle function and then touch the Select button This will bring up the Set Zero screen...

Page 36: ...tes the tool to the desired index position always 6 o clock for normal operation and press the button to set that position as the tool index point Vertical Zero button is used to set the vertical zero...

Page 37: ...appear By selecting function a distance can be entered Press Enter to make spindle move the selected distance Spindle RPM Operator clicks the box to the right to enter desired spindle RPM Operation Se...

Page 38: ...ight position Start Cutting Height start spindle rotation feed down to the Finish Cutting Depth index the tool and move the spindle vertically up to the selected SET position The operator can press th...

Page 39: ...sition 5 3 Backing Up and Restoring Block Profiles 5 4 General Insert Information 5 11 Cutting Speed Calculation 5 11 Surfacing Inserts 5 12 6303B 5 12 6303M 5 12 6303U 5 12 6303K 5 12 RS322 5 12 6301...

Page 40: ...or other type of job For details of operating specific fixtures available on this machine refer to the Optional Surfacing Fixtures and Tooling section of this manual There are several ways to use the...

Page 41: ...Vertical and Horizontal Position When the machine has finished cutting press the Left travel button to stop the feed then the Spindle Start button to stop the spindle You must manually lift the cutter...

Page 42: ...o the last End of Cut set position If no End of Cut position has been set the automatic cycle will not start An End of Cut position must be set after every power up When the power is turned off to the...

Page 43: ...section will explain how to back up and restore the operator created block profiles for DM controlled machines for archival purposes or to transfer to a different machine First step is to open your fi...

Page 44: ...7AD S8AD Manual www rottlermfg com 5 5 The following pop up box will appear on your screen Click on the Open folder to view files option and the following screen will appear This is the contents of th...

Page 45: ...Section 5 Operating Instructions S7AD S8AD Manual www rottlermfg com 5 6 Next resize and arrange both file browsers so that they are side by side...

Page 46: ...with the current profiles being shown in the RottlerWPF folder All that needs to be done to back up the current profile is to simply drag it from the RottlerWPF folder to the flash drive folder A cop...

Page 47: ...D S8AD Manual www rottlermfg com 5 8 To restore or add block profiles go through the first 5 steps explained previously Highlight the block profiles file in the flash drive and drag it into the Rottle...

Page 48: ...tion 5 Operating Instructions S7AD S8AD Manual www rottlermfg com 5 9 You will get a pop up window about there being a file of the same name in the destination folder Click on the Copy and Replace opt...

Page 49: ...5 Operating Instructions S7AD S8AD Manual www rottlermfg com 5 10 The archived block profiles will now be installed Close both browser windows and remove the flash drive The restore process is now co...

Page 50: ...ip when cutting too slow Interrupted cuts can cause an insert to break as well When making a heavy sleeve cut in a cylinder that has been cracked it is often required to slow the RPM down to 1 2 the n...

Page 51: ...on heads and blocks often found in the performance industry RPM speeds with a 14 cutter range from 650 750 RPM 6303K A round 3 8 IC single sided coated carbide insert This is a very economical general...

Page 52: ...rs and Aluminum Blocks with Hard Sleeves Cylinder heads with pre combustion chambers or aluminum engine blocks with cast iron or steel cylinder sleeves are a challenge to cut and most often require a...

Page 53: ...igh Performance Resurfacing Spray RPM speeds with a 14 cutter range from 650 750 RPM 6303U A round 3 8 IC single sided CBN Insert This insert does an excellent job when cutting hard cast iron blocks a...

Page 54: ...aluminum cylinder heads with pre combustion chamber and cast iron heads with soft pre combustion chambers like Land Rover Use in 7202X tool holder only RPM speeds with 14 cutter range from 450 550 RPM...

Page 55: ...6 4 Production Cutting 6 4 Aluminum Cast Iron 6 4 Dial Indicator Setting 6 5 Vertical Travel Belt Removal Replacement and Adjustment 6 6 Vertical Travel Belt 6 7 Drive Belt Replacement 6 8 Drive Sproc...

Page 56: ...ar Bearings and Belleville Washers 6 23 Bearing Alignment 6 23 Belleville Washer Alignment 6 23 Z Axis Vertical Ballscrew Lower Bearing Stacking Order 6 24 Z Axis Vertical Ballscrew Lower Bearing Sect...

Page 57: ...he cutterhead Every 40 hours Add 2 or 3 drops of ISO VG 32 Hydraulic Oil Every 175 hours Add one shot of NLGI 2 White Lithium Grease Run the spindle down near the lower limit and you will see a flush...

Page 58: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 2 S7AD S8AD Machine Lubrication Illustration...

Page 59: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 3 2 Axis Universal Machine Table 7119Q Lubrication Illustration...

Page 60: ...w the pin will pop out and hit the back of the slot Tighten the set screw This way when a tool holder is removed and then replaced it will be located very nearly where it was Insert height will still...

Page 61: ...whenever handling the cutter head Touch off surface by turning hand wheel clockwise until cutter insert just touches test piece surface when rotated back and forth Note Do not lower the cutter head d...

Page 62: ...cover and lift it off Remove the access panel at the rear of the machine shroud Remove the six screws mounting the shroud to the machine Four screws are located inside the enclosure and are accessed t...

Page 63: ...mounting bolts Loosen the locking Jam nut Turn the Belt Tension adjustment bolt CW until you can slide the mounting bracket all the way forward Remove belt Follow this procedure in reverse order to i...

Page 64: ...ght side from the outside Lift cover off the machine carefully As cover is lifted slide forward and up to clear motor and belt case Remove the four screws holding the upper cover Lift cover off Loosen...

Page 65: ...three screws located on the bottom of the sprocket bushing between the bushing and the motor Use three screws in the threaded holes in the bushing to loosen the bushing from the sprocket Lift off spr...

Page 66: ...low the index bushing Replacement of Driven Sprocket Clean bushing and sprocket Do not use any lubrication on bushing sprocket or screws Assemble the sprocket back onto the index bushing Slide the ind...

Page 67: ...chine before continuing Mark cutterhead and spindle so they can be reassembled in the same position Remove cutterhead by removing its four 3 8 16 screws Remove chip guard by removing its two 1 4 20 se...

Page 68: ...r housing Compress the air cylinder and lay it out of the way Remove the screw holding the top of the Linear Scale on to the Upper Housing Remove the four 4 bolts holding the vertical ballscrew nut to...

Page 69: ...adjusting nut back onto inner spindle to keep the spindle from falling out after throwback nut is unthreaded Take a rod or punch and insert it into one of the holes in the outside of the throwback nu...

Page 70: ...s on the Horizontal Motor Mount Plate Remove the belt Loosen the four mounting bolts on both of the ballscrew supports one at each end Move the machine to the home position all the way right Tighten t...

Page 71: ...r Adjustment of the S7AD S8AD Machine The Regulator for the counter balance air cylinder is located in the Spindle Base Remove the rear cover to access the regulator This pressure should be approximat...

Page 72: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 16 Pneumatic Control Diagram...

Page 73: ...leading edge of the cutterhead should be 0025 to 004 inch lower than the right trailing edge of the cutterhead If the tilt is not within this tolerance it will need to be adjusted Loosen the six allen...

Page 74: ...lear position making sure the spindle can travel its full vertical length Thoroughly clean and lightly oil the Outer Spindle before adjustment Remove the lower wiper retainer ring along with the wiper...

Page 75: ...adjustment rod should be 1 4 5 16 inch diameter and 8 to 10 inches long Carefully rotate the cutterhead counter clockwise looking from above the cutterhead letting the adjustment rod move against the...

Page 76: ...computer fails to boot up and you get a CMOS error message on the screen then the battery on the computer motherboard has failed and needs to be replaced The following is the procedure for replacing t...

Page 77: ...check to see that the power light is not on If it is on turn off the power switch Note On some machines it may be necessary to unbolt the computer from the enclosure in order to gain access to the co...

Page 78: ...battery When the clip is released the battery will pop up Remove the battery and place new battery in the battery holder Using your finger tip push down on the battery until the retention clip is in i...

Page 79: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 23 Alignment Definitions for Angular Bearings and Belleville Washers Bearing Alignment Belleville Washer Alignment...

Page 80: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 24 Z Axis Vertical Ballscrew Lower Bearing Stacking Order Z Axis Vertical Ballscrew Lower Bearing Section View...

Page 81: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 25 Inner Spindle Upper Section Belleville Washer Stacking Order Inner Spindle Upper Section Belleville Washer Section View...

Page 82: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 26 Inner Spindle Lower Section Bearing Stacking Order...

Page 83: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 27 Inner Spindle Lower Section Bearing Section View...

Page 84: ...Section 6 Maintenance S7AD S8AD Manual www rottlermfg com 6 28...

Page 85: ...all icons 2 Touch and release the upper left target the target should jump to the lower right 3 Touch and release the lower right target the target should jump to the upper right 4 Touch and release t...

Page 86: ...Section 7 Troubleshooting S7AD S8AD Manual www rottlermfg com 7 2...

Page 87: ...8 4 650 7 1 Computer Assembly 8 5 Upper Housing 8 6 Spindle Base Front Section 8 7 Inner Outer Spindle Assembly 8 8 Spindle Base Bushings 8 9 Spindle Base Assembly 8 10 Left Ballscrew Support 8 11 Ri...

Page 88: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 1 Machine Parts Front Right Side View S7AD S8AD...

Page 89: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 2 Pneumatic Assembly...

Page 90: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 3 Electrical Enclosure...

Page 91: ...V W 8 7 22 23 U U V V W W GND GND THL SW THL SW 0V 0V KTY KTY THL SW 0V KTY GN GN GN YL YL YL 2 1 T1 T2 T3 T1 T2 T3 6 5 0 1 2 3 1 0 IN IN A A B B 31 30 BN WH C31 DC IN 32 33 BK BK BK RD WH GN GN BK GN...

Page 92: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 5 650 7 1 Computer Assembly...

Page 93: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 6 Upper Housing...

Page 94: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 7 Spindle Base Front Section...

Page 95: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 8 Inner Outer Spindle Assembly...

Page 96: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 9 Spindle Base Bushings...

Page 97: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 10 Spindle Base Assembly...

Page 98: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 11 Left Ballscrew Support...

Page 99: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 12 Right Ballscrew Support...

Page 100: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 13 Home and Limit Switches...

Page 101: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 14 Pendant Assembly...

Page 102: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 15 Spindle Base...

Page 103: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 16 Chip Shield...

Page 104: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 17 14 Fly Cutter...

Page 105: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 18 Chip Chute...

Page 106: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 19 Waycovers and Optional Chip Catcher Assembly...

Page 107: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 20 Riser Set...

Page 108: ...Section 8 Machine Parts S7AD S8AD Manual www rottlermfg com 8 21...

Page 109: ...Section 9 Options S7AD S8AD Manual www rottlermfg com 9 1 Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine OPTIONS...

Page 110: ...Section 9 Options S7AD S8AD Manual www rottlermfg com 9 2...

Page 111: ...chine Other substances and materials are used in the manufacture testing and shipping of this machine A complete list of the Material Data Safety Sheets of substances and materials used by Rottler Man...

Page 112: ...Section 10 Material Data Safety Sheets S7AD S8AD Manual www rottlermfg com 10 2...

Page 113: ...Section 10 Material Data Safety Sheets S7AD S8AD Manual www rottlermfg com 10 3...

Page 114: ...Section 10 Material Data Safety Sheets S7AD S8AD Manual www rottlermfg com 10 4...

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