74
XYZ Machine Tools Ltd
TRAK
2
OP
Installation, Maintenance, Service & Part List Manual
5.9
Pneumatic Diagnostics
Air is a vital component to the operation of the 2 OP machine and is used to run many key components on
the machine. Air is used to run the tool change carriage cylinder, clamp and unclamp tools in the spindle,
and to clean the spindle taper during a tool change.
The following is a brief description of the pneumatic components used on the 2 OP machine. Please refer
to drawing 27563-2 at the rear of the manual for a schematic of the pneumatic system.
5.9.1
Supply Air Line to Machine
In order to provide the proper pressure and volume of air necessary to run the 2 OP you must use an air
supply line with a minimum bore of 10mm, we recommend a 13mm supply line. The main air line is
connected to the machine at the rear.
5.9.2
Air regulator (main)
The air regulator allows you to adjust the air pressure supplied to all the major components of the
pneumatic system. It is set to 90 psi from the factory and should not need to be adjusted. The air
pressure can be adjusted by lifting up on the cap at the top and rotated clockwise to increase the air
pressure and anti-clockwise to decrease the air pressure. A separator is used to remove water and oil
which is collected in the bottom of the bowl. The bowl empties automatically. A 40µm filter removes solid
contaminants.
5.9.3
Air regulator (door)
A 2nd air regulator is used to control the air pressure to the door open cylinder. This regulator is set so
that the door requires around 4 to 5kgs of force to lift, which equates to a pressure setting of 70 to 75 psi.
5.9.4
Air regulator (spindle)
A 3rd air regulator is used to provide pressurised air to the spindle cartridge. This helps prevent debris
from getting inside. It is set between 7 and 10 psi. In addition to this, a spindle ring is mounted to the
dogs of the spindle as an extra measure to prevent coolant from getting inside the spindle.
5.9.5
Air Pressure Switch
The 2 OP is equipped with an air pressure switch that monitors the air pressure supplied to the machine. It
is set at the factory to 60 psi. When the pressure falls below this level, a low air pressure flashing message
will appear on the screen. This message will go away automatically when the air pressure rises above this
value. The low pressure setting on this switch is factory set on the “RANGE” scale to 60 psi (4 kg/cm² ),
and the differential pressure setting is factory set on the “DIFF” scale to ~22 psi (1.5 kg/cm2). These values
should not need to be adjusted in the field. If necessary, the low pressure setting “Range” can be adjusted
by turning the right hand screw on the top of the switch. Clockwise adjustment will reduce this setting and
anti-clockwise; will increase it. The differential pressure setting “DIFF” is adjusted by turning the left hand
screw on the top of the switch. Clockwise adjustment will increase the value and anti-clockwaise; will
reduce it.
Note - The “Range” is the system pressure at which the switch will operate. The “Diff” setting is for setting
the maximum pressure difference between the input and output. If this difference is exceeded the switch
will also trip.
5.9.6
Solenoids Valves
The 2 OP Mill has 2 solenoid valves as seen on the drawing 27563-2. These valves are designed to control
various functions of the pneumatic system:
1.
Valve labeled “1” (controls the flow of air to the clamp/unclamp air cylinder) – this valve allows air to
flow to the air cylinder found on top of the spindle which allows tools to be clamped and unclamped
from the spindle. It also provides air to blow down the centre of the spindle when changing tools.
This helps blow swarf or debris off the spindle taper and tool holder during a tool change.
2.
Valve labeled “2” – this is a dual solenoid, 4 Way valve and designed to control the direction of flow of
air to the ATC carriage cylinder and the ATC door lift cylinder. It moves the ATC front and back
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