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Chapter 5 - Failure Modes, Detection and Prevention

Minimizing Wear and Tear

•

The effects of everyday wear and tear may be minimized by good maintenance

practice. Items high on the maintenance list include keeping the machine clean,

providing clean dry compressed air with the correct oil drip into the air stream,

and continuous application of the correct way oil through the automatic oiler.

•

Machine failure is most likely to be caused by everyday wear and tear.

•

The effects of everyday wear and tear may be minimized by good installation

practice, including a flat and stable foundation and clean input power at the

correct voltage with a good ground.

•

Please refer to Chapter 4 of this manual for installation guidelines.

•

Please refer to Chapter 6 of this manual for a periodic maintenance checklist.

Clearing Faults in Electrical Components

•

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 its rated power for a prolonged period. The machine can operate

outside its ratings for a short period, but eventually under these conditions a drive

will overload. In these and other failure modes caused by electrical components,

cycling power is the best way to clear the fault.

•

Press the red EMERGENCY STOP button to de-energize the drives (if the

machine is not already in emergency stop mode), then turn off power to the

machine using the main switch on the door of the electrical cabinet at the rear of

the machine. Wait a minute. Turn the power to the machine back on. Wait for

the CNC software to boot up. Enable and home the machine.

•

When an electrical component needs to be replaced, follow the guidelines in this

manual describing safe maintenance practice.

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Содержание SL12 OPT

Страница 1: ...Instruction Handbook for SL12 Lathes Milltronics Manufacturing Company 1400 Mill Lane Waconia MN 55387 USA Phone 952 442 1410 Fax 952 442 6457 www milltronics net Rev 1 10 2 2013 ...

Страница 2: ...ii ...

Страница 3: ...tion 11 Hydraulic Fluid Tank Capacity 11 Control Instructions Schematics and Mechanical Parts list 11 Tooling Specifications 12 Tool shank size SL12 12 Boring bar size SL12 12 SL12 Series Machine Layout 13 Chapter 3 Site Preparation 17 Machine Placement Considerations 17 Power And Ground Requirements 18 Connecting a Transformer 19 Autotransformer Connection Diagram 20 Air Supply System if equipped...

Страница 4: ...iv ...

Страница 5: ...Of Safety Systems 33 Maintenance Schedule 33 Always 33 Daily 33 Weekly 34 Monthly 34 Annually 35 Safety Checks to be carried out monthly and after maintenance operations 35 Air System Maintenance if equipped 36 Way Lube Maintenance 37 Adjustment 37 On Off Timer Settings 37 Tool Turret Maintenance LS 200 if equipped 38 Hydraulic System Maintenance 38 Hydraulic Tailstock and chuck pressure adjustmen...

Страница 6: ......

Страница 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...

Страница 8: ...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 components under any circumstances when the power ...

Страница 9: ...l 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 if necessary Do not open any doors or remove any safety covers while the machine is under operation Stop al...

Страница 10: ...in 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 Tools and tooling can be very sharp Take care when handling Never ...

Страница 11: ...e beyond its specified power 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...

Страница 12: ...he machine to avoid shorting any electrical circuits 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 FOLLOW THESE RULES CAN RESULT IN SERIOUS INJURY OR DEATH Neither the manufacturer nor the manufacturers representatives or dealers can assume resp...

Страница 13: ...n powering the machine down using the main disconnect 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 t...

Страница 14: ... Danger and Safety Precaution 9 2 Extended Material Stock Danger 9 3 Chip Auger Conveyor Hazard 9 4 Main Power Hazard and Notice 10 5 Lathe Safety Operation Instructions 10 6 Warmup and daily checks 10 7 Hydraulic Oil Maintenance Notice 10 8 Waylube maintenance 10 7 9 5 1 3 6 2 4 3 ...

Страница 15: ...ed at headstock end near spindle through hole Located around hazard areas on models equipped with chip conveyor Read and understand all Safety Operation and Maintenance labels affixed to the machine to ensure safety and reliability ...

Страница 16: ... visible Important safety guidelines that must be observed All models located near operator station Perform all checks to prevent damage and ensure reliable operation Perform maintenance to prevent damage and ensure reliable operation Ensure waylube pump is operating and oil is being dispensed regularly Use only proper lubrication type ...

Страница 17: ...t 1 x 6 32 x 150 mm Boring Bar Capacity Standard 8 Station Turret 2 50 mm Current Voltage requirements STD OPT Voltage 208 240 VAC 208 240 VAC Current 60 Amps 100 Amps Transformer 23 KVA 38 KVA Coolant Capacity Gallons 48 Liters 185 Coolant Recommendation Consult with a reputable coolant supplier in your area You should use non toxic non corrosive and non flammable coolant Avoid chlorine and sulfu...

Страница 18: ...vided separately Tooling Specifications Milltronics SL series lathes come equipped for various tooling sizes depending on machine model and turret size selected Please refer to your machine order or dealer to find out what tooling is required for your particular machine Tool shank size SL12 1 1 4 x 6 32mm x 150mm 8 position Boring bar size SL12 2 50mm boring bar holders ...

Страница 19: ...CHAPTER 2 SPECIFICATION 13 SL12 Series Machine Layout 168 4 122 23 74 81 ...

Страница 20: ...14 Item Identification SL10 shown 1 Worklight 2 Tool Turret and Tailstock 3 Operator panels 4 Setup door switch 5 Waylube unit and hydraulic fluid level indicator 9 8 6 5 3 2 1 4 7 10 ...

Страница 21: ...ssure switches and gauges 6 Conveyor Chute and chip bucket option 7 Leveling bolt and pad Coolant tank with level indicator 8 Coolant pump facing rear of machine 9 Spindle chuck and parts catcher Main power disconnect switch Located at rear of machine ...

Страница 22: ......

Страница 23: ...t 4 thick concrete slab free of cracks and not crossing any expansion joints 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 section 2 for distance 3 Do not subject the machine to direct sunlight 4 Do not all...

Страница 24: ... 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...

Страница 25: ...etely 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 chassi...

Страница 26: ...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 ...

Страница 27: ...ssure in order to perform optimally 90 110 PSI at 10 CFM is required Adjustments Set the main air regulator to 90 PSI Air pressure switch adjusted to trip at 75 PSI Main air pressure gauge Adjust using knob A to 90 PSI Water trap is self draining No need to drain manually Weekly fill with Marvel No 085 Mobil Velocite No 10 or equivalent ...

Страница 28: ... be lifted using a special lifting pallet and spreader bar along with straps rated to handle the weight of the machine See Chapter 2 Notes 1 Use extreme caution whenever moving lifting equipment 2 Be sure the straps and other rigging equipment are all appropriately rated to handle the weight being lifted 3 Always keep the machine well balanced and as close to the ground as possible when moving lif...

Страница 29: ... or adjusted for shipping 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 and install the conveyor wheel assemblies in the conveyor support legs Locate the leveling bolts 1 and install on the machine Place the leveling pads 3 under the bolts Remove the various shipping hold dow...

Страница 30: ...slide then level the machine head to tail using the outer most footpads 4 corners 3 Adjust the remaining footpads to contact the floor 4 Place the level on the ground surface of the saddle running perpendicular to the Z axis way surface 5 Move the Z axis the full length of the travel while adjusting the footpads to eliminate any twist in the bed 6 Check that all footpads have full contact on the f...

Страница 31: ... it concentric Quality of the cut and tooling pressure can have an effect on the measurements however and need to be minimized for an accurate reading By inserting a ground bar into the chuck of the lathe and check along its length with an indicator The bar must be dialed in for concentricity to the spindle on both ends before checking for taper This may prove difficult with a three jaw chuck By i...

Страница 32: ...ning 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 Re...

Страница 33: ...tween and V pins on the 5 VDC power supply if present C Check 110VAC on the secondary side of the 110 Volt transformer or between terminal blocks 1 2 The AC voltage must be between 110 and 125VAC Turn the main disconnect switch to the OFF position powering down the machine Close and lock the door of the electrical cabinet Visually Check That Guards Are In Place Required Guards for Lathes All lathe...

Страница 34: ...sequence outlined below the spindle will rotate If there is a tool in the spindle for mills or if there is a workpiece in the spindle for lathes make sure it is not going to hit anything when the spindle rotates For lathes the chuck guard must be down 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 Key ...

Страница 35: ...e machine should not be operated until the emergency stop circuit is operating correctly Repeat the same tests using all emergency stop buttons including conveyor remote hand controller etc Test the enclosure safety circuit 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 ENABLE button to re energize th...

Страница 36: ......

Страница 37: ...mponent 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 its rated power for a prolonged period The machine can operate...

Страница 38: ...re 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 Regular maintenance is a good way of detecting mechanical faults before they occur Inspection of covers belts and wear surfaces...

Страница 39: ... 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 as described in Chapter 1 Electrical Safety Rules should be observed Maintenance Schedule Always Remove chips as necessary from the chip pan area Daily Ensure the air lubr...

Страница 40: ...grease to each grease zerk on the chuck itself Monthly Inspect ballscrews and way surfaces Inspect all oil lines and repair or replace as necessary Inspect all belts for excess wear damage and proper tension 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 flas...

Страница 41: ...orrect 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 Power up the machine enable the drives close the enclosure door and start the spindle Hol...

Страница 42: ...l further details about lubrication type can be found in the mechanical manual Ensure the automatic water trap drain is working Adjustments Set the air regulator to 90 PSI Air pressure switch adjusted to trip at 75 PSI Main air pressure gauge Adjust using knob A to 90 PSI Water trap is self draining No need to drain manually Weekly fill with Marvel No 085 Mobil Velocite No 10 or equivalent ...

Страница 43: ...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...

Страница 44: ...TE24 or equivalent if necessary Replace the hydraulic oil annually with Mobil DTE24 or equivalent Tank capacity is 10 5 Gallons or 40 Liters Monitor sight glass to ensure fluid level remains topped off Lubrication is supplied by hydraulic system See LS 200 turret manual if troubleshooting information is required Filler vent cap Drain Site Glass ...

Страница 45: ...pressure switches are located behind the left hinged side panel of the machine Each pressure switch is factory set to trip at 100 psi The machine will e stop if chuck pressure drops below 100 psi Adjust as necessary for the application The proximity switches are used to detect the end of the drawbar stroke The switches should be set to sense only if a part is not clamped Pressure adjustments ...

Страница 46: ......

Страница 47: ... 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 ...

Страница 48: ...l 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 Re...

Страница 49: ...ble and axis waylube oiler Emergency stop buttons lock down when pressed and must be rotated to release 10 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 11 Alphanumeric keypads used to enter characters in MDI mode or program mode 12 Function keypad used to select machine functions that are show...

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