TMC-1500 Instructions Manual

INSTRUCTIONS MANUAL
TMC 1500
• Chapter 1 – General Information….………………….………………………… 01
• 1.1 Manufacturer identification…………………………………………….……. 02
• 1.2 Machine identification…………………………………….. …..................... 03
• 1.3 Instruction manual…………………………….. ….. ……………….…….... 04
• Chapter 2 – Safety………………………………….…………………….………….. 05
• 2.1 General information about safety…………………..………….…………… 07
• 2.2 Precautions when using the machine………………………..…………..... 08
• 2.3 Operators and technicians……….……………………………….………… 10
• 2.4 Danger symbols………………..……….….………………………………… 11
• 2.5 Prohibition symbols……………………………….………………………..... 12
• 2.6 Obligation symbols………………………………………………………….. 13
• 2.7 Location of danger……………………………….…………..……………… 14
• 2.8 Hydraulic and pneumatic installations………..………..…………………. 15
• 2.9 Electrical installations……………………..….…………………………….. 16
• Chapter 3 – Transport and location - warning………………………...….. 17

• 3.1 Storage……………………………………………………………………..… 19
• 3.2 Transport…………………..…………....................................................... 20
• 3.3 Unpacking…………………………………………………………….……… 22
• 3.4 Sitting…………………….…………………………………………………… 23
• 3.5 Positioning…………………….……………………..……… ...................... 24
• 3.6 Levelling and fixing……………………………….……….……………….… 26
• Chapter 4 – Protections…….………………………………….……….……...….. 27
• 4.1 Drive head protection…………………………………….………………..… 29
• 4.2 Emergency stop………..……………........................................................ 30
• Chapter 5 – Preliminary installations & Putting into operation..…… 31
• 5.1 Pneumatic equipment - connection……………….……………………..… 33
• 5.2 Hydraulic equipment – adjustment ….............. …................................... 34
• 5.3 Electrical power – connection……………………………………….……… 35
• 5.4 Aspiration air – connection ………………………………………………… 36
• 5.5 Putting into operation…………….…. …..………………........................... 37
• Chapter 6 – Axes & strokes….……….……………………………………....….. 40

• 6.1 Axes………………………………………….……….……………………..… 41
• 6.2 Distances between axes......................................................................... 42
• 6.3 Electro spindle group strokes…………………………..……….….……… 44
• 6.4 Turning head group strokes (Y2 axis) ……….………….………………… 46
• 6.5 Shaping head group strokes (Y3 axis)…….….……..…........................... 47
• 6.6 Sanding head group strokes (Y4 axis) …………………………………… 48
• 6.7 Wood limits………….………………………….…………........................... 50
• Chapter 7 – Computer and operating panel….………………..….……….. 52

• 7.1 Computer and control panel………… …………………..………………… 53
• 7.2 Screen areas description……..………………………….………………..... 54
• 7.3 Home, Stop, Pause and Start keys……..…………….…………………… 55
• 7.4 Screens menu..……………..………….……………….…………………… 56
• 7.4.1 Automatic screen………………………………..………… ...…………… 57
• 7.4.2 Manual screens……………….………………………………………..…. 58
• 7.4.3 Timers screen………………………………..……………………………. 64
• 7.4.4 Offsets screen……………………………… ….……………………….. . 65
• 7.4.5 Emergency screen…………………………....….………….…….. …….. 69
• 7.5 Loading an ISO file for the mechanization…..……………...…………..... 71
• 7.6 Display of axes positions and access to manual movement.…………… 72
• 7.7 Password to access protected screens...............………………………… 75
• 7.8 Sliders for adjust the axes speed…..………………………..…………..... 76
• 7.9 Tools configuration..………………………………….……………………… 77
• Chapter 8 – Machine components………….…………..….………………….. 80
• 8.1 Drive head group……….……………...…………………..………………… 81
• 8.2 Tailstock group………….…………………….……………………………… 83
• 8.2.1 Eccentric tailstock blocker……………….………………………………… 87
• 8.3 Carriage group…………….…… .........……………..………….………..... 88
• 8.4 Electro spindle group………………..…………….………………………… 90
• 8.5 Turning head group (Y2 axis)….…………………………………………… 96
• 8.6 Shaping head group (Y3 axis)……………………………………………… 98
• 8.7 Sanding head group (Y4 axis) ……………………………………..………100
• 8.7.1 Change and adjustment of the sanding belt..……………………..………103
• 8.8 Feeder group…………………………………………………………………106
• 8.8.1 Feeder adjustment…………….…………………………….…………… 108
• Chapter 9 – Maintenance………...………………………..….…………………..110
• 9.1 Maintenance introduction……………..….……………..………………… 111
• 9.2 Guides maintenance.…………………...…………………………………. 112
• 9.3 Rack & Pinion maintenance..……….……………………….…………..... 116
• 9.4 Electro spindle maintenance……….……….….…………………………. 117
• 9.5 Filters maintenance………………….….………………………………… .118
• Chapter 10 – Greasing……………………………………...….…………………. 119

• 10.1 Linear guides sliders lubrication…………………………..……………… 120
• 10.2 Ball screws lubrication……………….…………………………………..… 124
• 10.3 Rack & pinion lubrication.……………………………..…….…………...... 126
• 10.4 Electro spindle lubrication……….…………….……….………………….. 128
• 10.5 Tailstock lubrication………………………..………………………………..129
• 10.6 Drive head lubrication……………… ………….….………..…………..... 130
• 10.7 Turning head lubrication………………………..…………………..………131
• 10.8 Shaping head group ……….……………………..…………………….. …132
• 10.9 Lubricated several…..……………… ..…………………………….………133
• 10.10 Hydraulic group lubrication….…….……………………………………..…134
• Chapter 11 – Hydraulic equipment…….……………...….…………………. 135
• Chapter 12 – Pneumatic equipment…………….……...…….…..…………. 139

• Chapter 13 – Electric equipment……….……….……...….…………………. 144
• 13.1 Control equipment…………………………………………..……………… 144
• 13.2 Electrical cabinet………….………….…………………………………..… 145
• 13.3 Inputs/outputs modules.…..…………………………..…….…………...... 153
Chapter
1
In this chapter:
• 1.1 Manufacturer identification

• 1.2 Machine identification
• 1.3 Instruction manual
1
1.1 Manufacturer identification
This machine was manufactured by:
Company: INTOREX,S A.
Address: Av. Camí de la Font Santa, s/n
City: SANT PERE DE TORELLÓ
P.C.: 08572
Country: Catalonia – Spain
Tel.: 34-93.858.44.53
Fax: 34-93.858.44.86
E-Mail: itx@ intorex.es

http://www.intorex.es
2
1.2 Machine identification
The machine is identified by a plate within its structure that bears the following data:
MACHINE MODEL
IDENTIFICATION NUMBER
YEAR OF MANUFACTURE
VOLTAGE
3
1.3 Instruction manual
The company, INTOREX, S.A., provides this instruction manual in order to achieve a correct and
safety use of the machine.
It is therefore essential that this manual has to be completely and carefully read by all the
operators who will use the machine and it should always be available to these persons so that they
may consult it whenever is necessary .
4
Chapter
In this chapter: 2
• 2 Safety
• 2.1 General information about safety
• 2.2 Precautions when using the machine
• 2.3 Operators and technicians
• 2.4 Danger symbols
• 2.5 Prohibition symbols
• 2.6 Obligation symbols
• 2.7 Location of danger
• 2.8 Hydraulic and pneumatic installations
• 2.9 Electrical installations
5
2 Safety
BEFORE BEGINNING ANY WORK, WHETHER INSTALLATION,

ADJUSTMENT OR MAINTENANCE OF THE MACHINE, IT IS ESSENTIAL
TO HAVE CAREFULLY READ THIS INSTRUCTION MANUAL AND
TO STRICTLY FOLLOW ALL THE GIVEN INDICATIONS
6
2.1 General Information about Safety
All the criteria necessary for complying with the machine safety legislation were followed during the
design phase of this machine.
The adopted measures were mainly focused on the reduction, as far as possible, of all risk to the
persons who work with the machine, including all types of protection in order to provide it with the
highest level of safety.
Moreover, this manual provides practical advice of how to best work with the machine.
INTOREX, S.A. recommends that general safety rules are adhered to, as well as any
indications that are made in this manual, always using equipment and tools that are
suitable for each operation.
7
2.2 Precautions when using the machine
The INTOREX company has placed a team of technicians at your disposal, to attend to any query
that you might have about the machine.
Below is a list of points that must necessarily be followed in order to use the machine correctly:
Suitable equipment and material must always be used when transporting the
machine and the presence of personnel within the whole of the manoeuvring area
should be completely avoided.
It is essential to disconnect the machine before any form of intervention,

whether electrical, hydraulic, pneumatic or mechanical. These tasks should be
performed only and exclusively by fully qualified personnel.
The area surrounding the machine must be kept both clean and well
illuminated.
The machine should only be operated by a single person, who must not be
distracted while actually operating it.
Hands or any other part of the body must not be brought near to any machine
component that is in motion or that could be in motion, without first having
disconnected the machine.
It is completely forbidden to disassemble, disconnect or manipulate any

original machine protection, whether mechanical, electrical or hydraulic.
8
(2.2)
The machine must never be put into operation without first having checked that all the covers and
protective parts are correctly mounted. It is also essential to check that all the blades and other
items are correctly fixed in place and are in perfect working order.
It is completely forbidden to wholly or partially use the machine for operations that are not specified
in the technical characteristics.
INTOREX, S.A. CANNOT BE HELD RESPONSIBLE FOR ANY POSSIBLE
INJURY TO PERSONS OR ANIMALS OR DAMAGE TO PROPERTY DUE TO
THE NON-COMPLIANCE OF THE GENERAL SAFETY RULES OR THE
RECOMMENDATIONS GIVEN IN THIS INSTRUCTION MANUAL
9
2.3 Operators and technicians
The following symbols have been drawn up to indicate the specialisation of the operators who are
to perform each task on the machine, they will be used repeatedly throughout these instructions:
OPERATOR
A person who is specialised in the preparation, programming and use
of the machine, and always with all the safety devices in operation.
MECHANICAL MAINTENANCE TECHNICIAN

A specialised, qualified technician for the installation, repair and
maintenance of all the mechanical mechanisms.
ELECTRICAL MAINTENANCE TECHNICIAN

A specialised, qualified technician for the installation, repair and
maintenance of the electrical equipment.
MANUFACTURER'S MECHANICAL TECHNICIAN

For carrying out special maintenance or repairs.
MANUFACTURER'S ELECTRICAL TECHNICIAN

For carrying out special maintenance or repairs.
10
2.4 Danger symbols
DANGER, PRESSURE IN THE HYDRAULIC SYSTEM
DANGER, HIGH VOLTAGE
DANGER, CUTTING TOOLS
11
2.5 Prohibition symbols
SMOKING NEXT TO THE MACHINE IS PROHIBITED
THE PRESENCE OF UNAUTHORISED PERSONS IN THE

WORKING AREA OF THE MACHINE IS PROHIBITED
MANIPULATION, CLEANING AND LUBRICATION IS PROHIBITED

WHILE THE MACHINE IS IN OPERATION
WORKING ON THE MACHINE WITHOUT ALL THE

PROTECTION AND SAFETY ELEMENTS IS PROHIBITED
12
2.6 Obligation symbols
GIVE IMMEDIATE WARNING, AND IF NECESSARY, STOP THE

MACHINE IN CASE OF ANY DANGEROUS SITUATION OR IF A FAULT
OR DEFECT IS DETECTED IN THE SAFETY ELEMENTS
SWITCH OFF THE MAIN ELECTRICAL POWER TO THE MACHINE

BEFORE HANDLING ANY OF THE CONNECTIONS
EYES MUST ALWAYS BE CORRECTLY PROTECTED
EARS MUST ALWAYS BE CORRECTLY PROTECTED
USE PROTECTION AGAINST BREATHING IN IMPURITIES
FEET SHOULD ALWAYS BE CORRECTLY PROTECTED WITH

SUITABLE FOOTWEAR
ALWAYS WEAR GLOVES WHEN NECESSARY
13
2.7 Location of danger
The machine has certain dangerous areas in case that the safety rules were not respected
09 05 01 02 03 04
06
07
01 - Electro spindle Unit.

02 - Turning Head Unit.
03 - Shaping Head Unit.

04 - Sanding Head Unit. 08
05 - Drive Head.
06 - Tailstock.
07 - Automatic Feeder.
08 - Hydraulic Unit.
09 - Electrical Cabinet
14
2.8 Hydraulic and pneumatic installations
All the equipment that is under pressure may be dangerous if the necessary precautions are not
taken. For this reason, the person responsible for the maintenance and adjustment of these
installations must have a suitable degree of specialisation and training and must also have access
to, and knowledge of, the contents of this instruction manual.
Before any intervention or handling of the installation, it is very important to ensure that there is no
direct or residual pressure coming from any of the accumulators.
The pneumatic circuits must never be subjected to a pressure greater than that indicated by the
machine’s technical characteristics.
If, during maintenance operations, the skin comes into frequent contact with the oil, then it is
essential that this part of the body is carefully washed with soap and water, and that gloves are
worn whenever possible.
15
2.9 Electrical installations
As has already been mentioned, any maintenance or handling of the electrical installations must be
done solely and exclusively by specialised personnel who are fully aware of the risks involved if the
work is not correctly performed.
The machine’s electrical installations have been designed according to current safety legislation,
which does not exclude the possibility of accidental contact with high voltage elements if the safety
rules explained in this instruction manual are not followed.
The opening of the electrical cabinet or the handling of any electrical installation element is totally
prohibited unless the machine’s electrical power input has been previously switched off. Once the
machine has been switched off, a prudent time of several minutes must be allowed to elapse
before attempting any manipulation.
16
Chapter
3
In this chapter:
• 3 Transport and location - warning

• 3.1 Storage
• 3.2 Transport
• 3.3 Unpacking
• 3.4 Siting
• 3.5 Positioning
• 3.6 Levelling and fixing
17
3 Transport and location
WARNING:
ALL TRANSPORT AND LOCATION OPERATIONS FOR THE MACHINE, MUST BE
PERFORMED BY SPECIALISED PERSONNEL WITH EXPERIENCE IN EACH ONE
OF THE SPECIALITIES THAT THEY TAKE PART IN
18
3.1 Storage
The place chosen to store the machine must always be closed and covered, so that it is completely
protected from atmospheric effects and any others that could affect it.
The floor on which the machine is to stand must be perfectly flat and strong and the machine itself
must always be well supported by the floor.
Sufficient space must be left around the machine so that the workers are able to move around and
perform handling operations in complete safety.
19
3.2 Transport
WARNING: During handling operations, loading or unloading, nobody should remain

within in the radius of action.
The machine is supplied on a wooden base and protected by a plastic cover and in some cases, it
is supplied in a wooden crate.
The loading and unloading operations should be performed with a crane or a forklift, always
ensuring that these items possess sufficient load capacity and are in perfect working order.
20
21
3.3 Unpacking
The first operation will be to remove the wooden box or crate if the machine has been packed in
this manner and then the plastic wrapping should be removed.
The machine is supplied with anti-rust protection, which should be carefully removed once it is free
of all the packing material. A degreasing product should be used for this cleaning operation,
ensuring that it is not aggressive to paint or plastic and synthetic material.
Once it has been cleaned, the machine will require a general lubrication.
22
3.4 Siting
The machine must be installed on premises that comply with the following conditions:
- An absence of all types of animals.
- A working room temperature of between 15 and 35 degrees centigrade. Working in

temperatures outside these limits could make the use of air conditioning necessary for
the hydraulic and electrical equipment.
- The relative air humidity must be between 40% and 65% in relation to a reference
temperature of 20 degrees centigrade.
- The machine must be protected against dirt, humidity and vibrations.
23
3.5 Positioning
The internal transport of the machine should be performed with a crane or a forklift, always
ensuring that these items possess sufficient load capacity and are in perfect working order.
The machine must be positioned so that there is adequate free space all around it.
The working area must be perfectly illuminated and have the necessary connections for vacuum,
air and electricity. The latter must be equipped with an automatic circuit breaker.
The paving on which the machine is installed must provide guarantees of good stability and
strength, since not only must it support the weight of the machine, but it must also allow the
machine to be correctly fixed to the floor.
24
UNITS: meters
25
3.6 Levelling and Fixing
Before fixing the machine to the floor, it must first be levelled with the base screws. A precision
level must be used and the references taken from the machined flat surfaces.
Once the machine is levelled, it must be fixed to the floor through the holes provided in the base.
LEVEL
26
Chapter
4
In this chapter:
• 4 Protections and emergency stops.
• 4.1 Drive head protection.
• 4.2 Emergency stop.
27
4 Protections and emergency stops
The machine is provided with all the covers, protection and emergency stops that allow work to be
carried out with complete safety, always respecting the indications that are given in this instruction
manual and that the work is performed with all this protection mounted and functioning.
05 03 04
01
02 06
01- Front protection.

02- Front sliding doors
03- Behind protection.
04- Behind sliding doors.
05- Drive head protection.
06- Closed door safety switches.
28
4.1 Drive head protection
01
01- Drive head upper pulley protective cover
29
4.2 Emergency stop
01 02
01- General emergency pushbutton.

Once it has been activated, this pushbutton is locked in position and is necessary
make a slight turn to unlock it.
02- Hydraulic start button.
TO RESTART THE SYSTEM AFTER AN EMERGENCY STOP, IT MUST OPERATE THE

HYDRAULIC START BUTTON LOCATED IN THE CONTROL PANEL.
30
Chapter
5
In this chapter:
• 5 Preliminary installations
• 5.1 Pneumatic equipment - connection
• 5.2 Hydraulic equipment - adjustment
• 5.3 Electrical power - connection
• 5.4 Aspiration air – connection
• 5.5 Putting into operation
31
5 Preliminary installations
The machine is supplied completely assembled and with all its equipment and pneumatic,
hydraulic and electrical installations
32
5.1 Pneumatic equipment - connection
The air input connection to the machine is made via the connector 01.
Before the air enters the filter group, it passes through the discharge valve 02, this allows the air to
be cut off from the machine’s circuit, thus completely cutting off the pressure to the machine.
Once the air input has been connected and valve 02 opened, the minimum air pressure arriving at
the input must be checked and it should be 7 Kg/cm². The regulating handle 03 is used to regulate
it to 7 Kg/cm², which is the normal working pressure.
In order to carry out this regulation, pull handle 03 upwards. Once in this position, the pressure can
be changed.
Once the pressure has been regulated, the handle should be returned to the original downwards
setting and will remain locked in this position.
Finally there is a depuration filter 04

03 7Kg/cm2
01
04 02
The air that comes to the connection of the machine must be completely dry, filtered
and free of impurities. Otherwise it can cause problems with the electro valves.
33
5.2 Hydraulic equipment - adjustment
A drum of hydraulic oil, which is required for machine operation, is supplied with the accessories.
Before continuing with the start-up, the hydraulic oil tank 02 must be filled to the maximum level 01.
01
02
34
5.3 Electric energy - connection
The machine must be connected to the mains power supply with cables of cross-section suitable
for the total power (35 mm2) and this must be equipped with an automatic breaker and a correct
earth connection for all the machine’s earth points.
The cables used to connect the machine must be completely protected within metal tubes and
perfectly insulated.
Before carrying out the definitive mains power connection, the line voltage must be checked with
that for which the machine has been prepared, and in no case may this exceed ±10% of the
voltage indicated on the characteristics plate.
The machine must be connected to the mains power supply via the R-S-T connector terminals
inside the electrical cabinet, without forgetting to connect the earth to its terminal.
R-S-T + Ground
35
5.4 Aspiration air - connection
The machine is supplied with aspiration pipes for shavings and dust, but not the flexible tubes or
other material required for the connection.
The connection must be made with pipes of Ø120 mm.
The aspiration system must always be working at the same time as the machine and should be
efficient and correct. Any deficiencies in the aspiration system could cause risk to both the operator
and the machine.
36
5.5 Putting into operation
The machine is controlled and programmed via the operating panel keyboard. All
the data and menus are shown on the screen.
When the general switch is turned on and power is supplied to the machine, the
system takes a few seconds to verify and load all the system files.
When the system is operational, is necessary to open the general menu by making
double-click on the machine’s program icon (01). Once the principal screen is
ready, the hydraulic unit start button (02) must be pushed.
01
02
37
Checking the turning direction of the hydraulic group motor
If the turning direction is not correct, then it will be necessary to invert one phase of
the main power supply power input.
38
The general pressure of the hydraulic group normally comes with a factory setting
of some 40 Kg/cm². This pressure can be checked in manometer 01 after selecting
the position and pressing selector 02 of the manometer.
The general pressure can be checked in the manometer 01 selecting position #1 in
the selector 02.
The Tailstock pressure can be checked in the manometer 01 selecting position #3
in the selector 02.
02 01
Pressure limiter 03 is used to vary and adjust the general pressure.
03
39
Chapter
6
In this chapter:
• 6.1 Axes.
• 6.2 Distances between axes.
• 6.3 Electro Spindle Group Strokes.
• 6.4 Turning Head Group Strokes (axis Y2).
• 6.5 Shaping Head Group Strokes (axis Y3).
• 6.6 Sanding Head Group Strokes (axis Y4).
• 6.7 Wood Limits.
40
6.1 Axes
The machine is equipped with 8 axes controlled by CNC.
A AXIS. Rotary movement of the headstock.

B AXIS. Rotary movement of the electro spindle.
X AXIS. Lateral movement of the carriage.
Z AXIS. Vertical movement of the electro spindle.
Y AXIS. Horizontal movement of the electro spindle.
Y2 AXIS. Horizontal movement of the turning head.
Y3 AXIS. Horizontal movement of the shaping head.
Y4 AXIS. Horizontal movement of the sanding head.
The axes Y, Y2, Y3, and Y4 are activated when in the iso program the tool for each case is
selected.
41
6.2 Distances between Axes
It is necessary to know the distances between Y, Y2, Y3 and Y4 axis. These distances are
known by the machine in the CNC configuration.
In the Y4 axis a change between the turning sanding group and the shaping sanding group is
possible and the distance between axes doesn’t change.
6.2.1 AXES DISTANCE WITH SHAPING SANDING GROUP
162.5 258.5 202.5
42
6.2.2 AXES DISTANCE WITH TURNING SANDING GROUP (OPTIONAL)
162.5 258.5 202.5
43
6.3 Electro Spindle Group Stroke
It is important to know the stroke of the machine’s axes to have no problems with the emergency
micro contacts.
Y axis stroke 460mm.

Z axis stroke 455mm.
B axis stroke + - 90º
72.5
230mm -230mm
510mm Max. Z axis
55 mm Min. Z axis
44
-90º
190 mm Min. Z axis
90º
645 mm Max. Z axis
45
6.4 Turning Head Group Stroke (Y2 axis)
It is important to know the stroke of the machine’s axis to have no problems with the emergency
micro contacts.
Y2 axis stroke 350mm.
-355mm Max.
-5 mm Min.
46
6.5 Shaping Head Group Stroke (Y3 axis)
micro contacts.
-340mm Max.
20mm Min
47
6.6 Sanding Head Group Stroke (Y4 axis)
micro contacts.
-340mm Max.
20mm Min
48
-340mm Max.
20mm Min.
49
6.7 Wood Limits
The maximum length of the wood is 1500mm.

The minimum length of the wood is 120mm.
The maximum square wood is 140mm.
The minimum square wood is 30mm.
120mm Min. / 1500mm Max.
50
140mm
30mm
51
Chapter
7
In this chapter:
• 7.1 Computer and control panel

• 7.2 Screen areas description
• 7.3 Home, Stop, Pause and Start keys
• 7.4 Screens Menu
• 7.4.1 Automatic Screen
• 7.4.2 Manual Screens
• 7.4.3 Timers Screen
• 7.4.4 Offset Screen
• 7.4.5 Emergency Screen
• 7.5 Loading an ISO file for the mechanization.
• 7.6 Display of axes positions and access to manual movement.
• 7.7 Password to access protected screens
• 7.8 Sliders for adjust the axes Speed.
• 7.9 Tools configuration
52
7.1 – Computer and control panel
1. Computer with OS Windows XP Pro, CD

2 Room, Floppy Disk, USB and Network
1 connection.
2. Access to CD Room, Floppy and USB.
5 3. Keyboard and Mouse.
4. Emergency pushbutton. It stops completely

the machine. After push, remains locked in
4 position and it must be given a slight turn to
unlock it.
5. First start pushbutton. It activates the

3 Hydraulic motor and enables the Axes Servo
Drives.
6. Main power switch
7. Light of Power ON.
8. BYPASS: At position 0 the limit switches of

the axes are active and it will stop the
7 machine when one of these limit switches are
pressed. At position I, disables the limit
switch and the operator can move manually
6 the axes.
9. DOORS: At position 0 the switches of the

safety doors are active and the machine
stops when one door is opened. At position I,
the switches of the safety doors are disabled,
and is possible to open the safety doors
without stop the machine. In this case all the
9 motors, except the motors of the AXES, will
8
stop. We use this option for simulation.
The two selectors (8 and 9) must always be in

the position 0 for the normal work cycle of the
machine. Can only be activated when
absolutely necessary and always under the
responsibility of the operator.
53
7.2 – Screen areas description
7.6
7.5 7.7
7.8
7.4
7.3
7.3 - Home, Start and Stop keys.
7.4 - Screens menu: Automatic, Manual, Timers, Offsets and Emergency.
7.5 - Area for load the ISO file model.
7.6 - Position axes display and access to manual movement of the axes.
7.7 - Password access key.
7.8 - Sliders for adjust the axes Speed.
54
7.3 – Home, Start, Pause and Stop keys
START PAUSE STOP HOME
HOME
Key to find the HOME position of the machine’s axes. This operation has to be operated always after
start the computer, after an emergency or after to modify the tailstock position.
START
Key to start the machining cycle. This key is enabled after doing home and when an ISO machining
program is loaded on window 7.5.
STOP
Key to stop the cycle. The machine will stop when the current cycle will be finished.
PAUSE
Making one click on this key cancels the current cycle and stops the machine immediately. Then press
the Stop key and Home key to return the machine to home position.
55
7.4 – Screens Menu
2 3 4 5
1 6
1. Keys to open the different screens
2. Screen area where appears the active inputs information. When the green button appears means
that the input is active.
3. Screen area where appear the outputs. When the red button appears means that the output is
active and clicking on the button activates or deactivates manually the output. Care, provided that
we have an output to activate and another to disable the same function, we click first to the active
before activating the opposite. The manual activation of these outputs is responsibility of the
operator.
4. Screen area where appear the machine functions that the operator can manually activate. The
yellow button shows that the function is active. Making one click on the button activates the
function and another click on it disables the function. The manual activation of these functions
is responsibility of the operator.
5. Screen area where the operator can write values of different functions. These functions and
values are explained on the following paragraphs. Whenever that we write a new value should be
confirmed with the enter key.
6. Keys to change the screen up and down to find more buttons of the same menu.
56
7.4.1 – Automatic Screen
Belt ON. The red led ON indicates that the extraction belt is moving.
57
7.4.2 – Manual Screens
First Standard MANUAL screen.
The machine has more buttons in the manual screen, but they are protected by a password. Look at the
following paragraphs for the PASSWORD explanation.
Second Standard MANUAL screen.
58
First MANUAL screen with Password.
Second MANUAL screen with Password.
59
INPUTS DESCRIPTION.
The GREEN led ON confirms that the corresponding input is activated
Feeder Back. The Feeder Unit is on back position with the switch activated.
Feeder Forward. The Feeder Unit is on front position with the switch activated.
Tailstock Back. The Tailstock is on back position with the switch activated.
Tailstock Forward. The Tailstock is on front position with the switch activated.
Router Tool OK. The TOOL is correctly installed and fixed on the ElectroSpindle motor.
Tool Magazine Closed. The tool magazine door is closed with the sensor activated.
Tool Magazine Open. The tool magazine door is open with the sensor activated.
Tool Magazine Back. The tool magazine is on back position with the sensor activated.
Tool Magazine Frwd. The tool magazine is on front position with the sensor activated.
Tool Clamp Open. The ElectroSpindle tool clamp is open.
Tool Clamp Closed. The ElectroSpindle tool clamp is closed.
60
OUTPUTS DESCRIPTION
The RED led ON confirms that the corresponding output is activated. The manual activation of
these outputs is responsibility of the operator.
Belt ON. The extraction belt is moving.
Finger. The output of the electro-valve to move UP the finger installed on the feeder unit is active.
Dosage. The output of the electro-valve to move forward the wood dispenser installed on the feeder unit
is active.
Dosage V. The output of the electro-valve to move UP the wood vertical dispenser installed on the
feeder unit is active
Water Cooling ON. The water cooler for the ElectroSpindle is working. This function starts automatically
when the ElectroSpindle starts working.
Hydraulic ON. The hydraulic motor is working.
Feeder move back. The output of the electro-valve to move the feeder unit back is active.
Feeder move Fwrd. The output of the electro-valve to move the feeder unit forward is active.
Tailstock move back. The output of the electro-valve to move the tailstock back is active.
Tailstock move Fwrd. The output of the electro-valve to move the tailstock forward is active.
Tool Magazine Open. The output of the electro-valve to open the tool magazine door is active.
Tool Magazine Out. The output of the electro-valve to move the tool magazine forward is active.
Tool Clamp OP1. For safety, the Electro Spindle’s tool clamp is controlled by two electro-valves. The
red led ON indicates that the first electro-valve (1) is open, and if we active the number 2, the tool will
drop.
Tool Clamp OP2. For safety, the Electro Spindle’s tool clamp is controlled by two electro-valves. The
red led ON indicates that the second electro-valve (2) is open, and if we active the number 1, the tool will
drop.
Tailstock block. The output of the electro-valve to move forward the eccentric tailstock blocker is active.
Sander Oscillation. The oscillation of the sander belt of the axis Y4 is active.
61
FUNCTIONS DESCRIPTION
The Yellow led ON confirms that the corresponding function or movement is activated. One click
on the button activates the function and clicking again disables the function. The manual
activation of these functions or movements is responsibility of the operator.
Feeder F/R. Function to move the Feeder unit forward and back. If the Tailstock is on forward position,
the Feeder can’t move forward.
Tailstock F/R. Function to move the Tailstock forward and back.
Tool Change. Function to activate manually the tool change cycle. The window “Active Tool” shows the
tool number currently fixed on the ElectroSpindle. And the window “New Tool” shows the number of the
new tool to load.
Tool Magazine O/C. Function to open and close manually the Tool Magazine Door.
Tool Magazine F/R. Function to move forward and back the Tool Magazine.
Load Piece. Function to make the piece loading cycle: load a piece of wood on the machine, take back
the feeder and prepare to load a new piece.
Y3 – Shaping Tool Rv. Start manually the reverse rotation of the Y3 - Shaping Tool.
Y3 – Shaping Tool Fw. Start manually the forward rotation of the Y3 - Shaping Tool.
Y4 – Sander Belt. Start manually the Y4 - Sander Belt rotation.
Axe A Free. After the machine has searched the HOME position, the A AXIS (headstock) position is
locked and controlled for the CNC at 0 degrees position, and we can’t turn manually the A Axis. Clicking
on this function unlocks the A Axis and then the operator can turn manually the wood to find the desired
position. Clicking again on the function will lock again the Axis, and on the display will change the degree
position to the angle value written on the “Pos Fix A” value.
Turning Tool Fw. Start manually the forward rotation of the Y2 - Turning Tool (saw blade).
Turning Tool Rv. Start manually the reverse rotation of the Y2 - Turning Tool (saw blade).
Y – ElectroSpindle Rv. Start manually the reverse rotation of the Y - ElectroSpindle. The RPM value will
be written on the ElectSpindle [rpm].
Y – ElectroSpindle Fw. Start manually the forward rotation of the Y - ElectroSpindle. The RPM value
will be written on the ElectSpindle [rpm].
62
FUNCTION VALUES DESCRIPTION
Screen area where the operator can write values of different functions. Whenever that we write a
new value should be confirmed with the enter key.
New Tool. Tool number of the new tool that will be loaded manually with the Tool Change Function. See
the Tool Change paragraph.
Active Tool. Tool number of the current tool fixed on the ElectroSpindle. See the Tool Change
paragraph.
Pos Fix A. Value of the angle position where will be positioned the “A” Axis when the operator use the
“Free Axe A” function. See the Free Axe A paragraph.
ElectSpindle [rpm]. RPM value of the ElectroSpindle rotation. Only for manually starting with
Y- ElectroSpindle Fw. or Y- ElectroSpindle Rv.
63
7.4.3 – Timers Screen
Tailstock [s]. Delay time for the tailstock’s forward movement, once the feeder has loaded the piece.
Time in seconds.
Finger [s]. Delay time for the fingers opening movement, once the feeder has loaded the piece. Time in
seconds.
Feed back [s]. Delay time for the feeder’s back movement, once the piece has been fixed by the
tailstock. Time in seconds.
Sander Oscillation [s]. Time for adjust the Sander belt oscillation. Time in seconds.
64
7.4.4 – Offsets Screen
The Offsets Screen is protected under Password, and is used to adjust the position of the axes.
Before adjusting the Offsets and axes positions is essential making HOME in the machine.
Keys to confirm and save the Windows for write the Offset
axes position distance
PRELIMINARY INSTRUCTIONS BEFORE ADJUSTING THE OFFSETS AND AXES POSITIONS
For adjusting the Axes X – Z and Y is necessary:
• On the ElectroSpindle we advise to use a blank shaft of 20mm of diameter. Use the Tool 109
and write the length and diameter on tools configuration (see the paragraph 7.9).
• Write manually the tool number on “Active Tool” window; in this example is number 109 (see
the paragraph 7.4.2).
For adjusting the Axis Y2 is necessary:
• Check on Y2 tool configuration if the tool diameter is coincident with (2 x radius) of the tip of the
Saw blade (see the paragraph 7.9).
• Check on Y3 shaping tool configuration if the tool diameter is coincident with the assembled
shaping tool (see the paragraph 7.9).
• Check on Y4 sanding belt configuration if the tool diameter is coincident with the assembled
sanding tool (see the paragraph 7.9).
65
ADJUSTING AXIS X POSITION
On the X axis, the machine has four different machining axes with tool (Y – Y2 – Y3 – Y4).
The position of the X axis should be adjusted with the Y tool (ElectroSpindle).
In the CNC configuration have the distance between the tools axes:
• Between tools centre assembled on Y and Y2
1. Move the ElectroSpindle to the position shown on the attached drawing.
2. Write -10 (Tool Radius) in the window “Offset MX”.
3. Click on “Save Position X” key.
Diameter 20mm
-10
ADJUSTING AXIS Y POSITION
Move the ElectroSpindle to the position shown on the attached drawing.
1. Write 7.5 (Tailstock Radius) in the window “Offset MY”.
2. Click on “Save Position Y” key.
Tool Diameter
20mm
17.5
7.5
Tailstock Diameter
15mm
66
ADJUSTING AXIS Z POSITION
1. Move the ElectroSpindle to the position shown on the

attached drawing.
2. Write 7.5 (Tailstock Radius) in the window “Offset MZ”.
3. Click on “Save Position Z” key. Tool

Length
7.5
ADJUSTING AXIS Y2 POSITION
. 1. Move the Axis Y2 to the position shown on the attached

drawing.
Diameter of the tip 2. Write 7.5 (Tailstock Radius) in the window “Offset MY2”
D=2xR
3. Click on “Save Position Y2” key.
7.5
ADJUSTING AXIS Y3 POSITION
1. Move the Axis Y3 to the position shown on

the attached drawing.
2. Write 7.5 in the window “Offset MY3”. Diameter =125

7.5
67
ADJUSTING AXIS Y4 POSITION with the SHAPING belt group
Important notice: It is necessary to check the diameter in the setup of the tools
1. Move the Axis Y4 to the position shown on

the attached drawing.
2. Write 7.5 in the window “Offset MY4”.

Diameter =125
7.5
ADJUSTING AXIS Y4 POSITION with the TURNING belt group
1. Move the Axis Y4 to the position shown

on the attached drawing.
2. Write 7.5 in the window “Offset MY4”.
7.5
68
7.4.6 – Emergency Screen
Limit X OK. Green led ON means that the limit switches of the X axis are OK.
Limit Y OK. Green led ON means that the limit switches of the Y axis are OK.
Limit Y2 OK. Green led ON means that the limit switches of the Y2 axis are OK.
Limit Z OK. Green led ON means that the limit switches of the Z axis are OK.
Limit B OK. Green led ON means that the limit switches of the B axis are OK.
SetPoint X. Green led will be activated when the HOME switch of the X Axis is pressed.
SetPoint Y. Green led will be activated when the HOME switch of the Y Axis is pressed.
SetPoint Y2. Green led will be activated when the HOME switch of the Y2 Axis is pressed.
SetPoint Z. Green led will be activated when the HOME switch of the Z Axis is pressed.
´
SetPoint B. Green led will be activated when the HOME switch of the B Axis is pressed.
ByPass ON. Green led will be activated when the ByPass key is turned to the ON position. The ByPass
key cancels the Limit Switches of all axes.
Power OK. Green led ON means that the Power Supply of the 24V Dc line is OK.
Safety Mod OK. Green led ON means that the Safety module in the electrical cabinet is OK.
Hydraulic OK. Green led ON means that the Hydraulic line is OK.
69
Not Brake Z. Red led ON means that the mechanical brake of the Z axis doesn’t work. Led OFF means
that the mechanical brake works.
HW enable X. Red led ON means that the X Axis Servo Drive is Enabled.
HW enable Y. Red led ON means that the Y Axis Servo Drive is Enabled.
HW enable Y2. Red led ON means that the Y2 Axis Servo Drive is Enabled.
HW enable Z. Red led ON means that the Z Axis Servo Drive is Enabled.
HW enable A. Red led ON means that the A Axis Servo Drive is Enabled.
HW enable B. Red led ON means that the B Axis Servo Drive is Enabled.
70
7.5 – Loading an ISO file for mechanization.
All the machining files must have the extension *.iso, and is possible to edit this type of files with
Notepad but should never change the extension.
Double click for load a new ISO file
1. Double click on the Name window to access to the ISO folder.
2. Find and select the file name, then click on open key.
3. The selected file will be loaded on the Name window.
The path to the ISO folder in the machine’s computer is: C: \ Program Files \ Intorex TMC \ ISO \
71
7.6 – Display of axes positions and access to manual movement.
On this area of the screen, the current position of all the axes is displayed, and with double clicking on
the window of each axis, will access to independent movement in manual mode.
72
Movement on manual mode of the X axis.
This example can be applied also on the axis Y – Y2 – Y3 – Y4 and Z. These six axes have a linear
movement. The values are in millimetres and the speed in meters/minute.
Jog movement.
Available before and after doing the machine HOME
1. Write the Speed on m/min on the screen.
2. Push the positive or negative key depending

on the direction you want to move the axis.
The axis will move while you have the key
pressed.
Absolute movement
Available only after doing the machine HOME
2. Write the new position where you want to

move the axis.
3. Push the negative key, the axis will move to

the new position written on Negative point
window. Push the positive key, the axis will
move to the new position written on Positive
point window.
Incremental movement
Available only after doing the machine HOME
2. Write the millimetres, on negative or positive

window, you want to move the axis.
3. Push the negative or positive key depending

on the window where have written the value.
The axis will move, on positive or negative,
the millimetres we have written.
73
Movement on manual mode of the A axis.
This example can be applied also on the B axis. The A and B axes have a circular movement. The
values are in degrees and the speed in degrees/second.
On the A and B axes also is possible to use Jog, Absolute and Incremental movement. And the process
is the same as described on the previous page.
New axis position (90 degrees) where we want to

move and speed (10 degrees/second).
After pushing the positive key the axis moves and

reaches the new position.
74
7.7 – Password to access protected screens
intorex
To enter password
1. Click on Password with the mouse and will appear the Password screen.
2. Write the word password: intorex
3. Click the enter key on the computer keyboard.
To return back with the password protection
4. Click on Password with the mouse and will appear the Password screen.
5. Don’t write any password
6. Click the enter key on the computer keyboard.
75
7.8 – Sliders to adjust the axes Speed.
In the ISO program we have programmed the machining with different speed values F or S. The Sliders
can be used, when an ISO machining program is running, for increase or decrease in percentage the
programmed values.
G0 Slider. Is for decrease in percentage the programmed F speed of the G0 movements.
G1 Slider. Is for increase or decrease in percentage the programmed F speed of the interpolate G1,
G2 and G3 movements.
PW slider. Is for increase or decrease in percentage the S speed of the A Axis during the turning
operation, and for increase or decrease the ElectroSpindle S speed during the milling
operation.
You can move and adjust up and down the Sliders with the mouse or first click on the slider with the
mouse and then adjust up and down with the keyboard arrows.
76
7.9 – Tools configuration
For access to the tool configuration screen, follow the following steps:
2
3
4
1. Click on “Interpret CNC” icon.
2. Click on “Tool” icon
3. Click on “+ (1) Tools List” and will

appear the Tools List n.4.
4. Click on each tool to open the tool

configuration window
(1) Tool 1. Tool number 1 for the ElectroSpindle installed on Tools Magazine.
(7) Tool 7. Not used.
(122) Turning Saw, Y2 Axis. Saw blade for turning installed on Y2 Axis.
(123) Shaping Tool, Y3 Axis. Shaping tool installed on Y3 Axis.
(124) Sanding Tool, Y4 Axis. Sanding belt installed on Y4 Axis.
77
Is essential that the dimensions of the tools installed on the machine are exactly equal to the
dimensions introduced in the tools configuration menu. And exactly like those programmed into
the IntorEdit CAM software.
ElectroSpindle Configuration Tool 1 to Tool 6
Length
Diameter
1. On the ElectroSpindle tools

configuration should write the values of
the Length and Diameter.
2. To save the new values Click on “OK”

then click on “Salva” and “Chiudi”.
Turning saw blade Tool configuration (Tool 122)
Radius Radius x 2 =Diameter
1. On the Turning Saw blade tool configuration installed on the Y2 axis, should write the Diameter of
the tip of the saw blade. (Radiusx2=Diameter).
2. To save the new value Click on “OK”, then click on “Salva” and “Chiudi”
78
Shaping Tool configuration (Tool 123)
Diameter
1. On the Shaping tool configuration installed on the Y3 axis should write the tool Diameter.
2. To save the new value Click on “OK”, then click on “Salva” and “Chiudi”
Sanding belt Tool configuration (Tool 124)

Diameter
In the configuration of the Sanding belt for shaped parts installed on the Y4 axis should write the
Diameter.
Diameter
In the configuration of the Sanding belt for turned parts (OPTIONAL) installed on the Y4 axis should write
the thickness of the sander belt.
79
Chapter
8
In this chapter:
• 8.1 Drive head group

• 8.2 Tailstock group
• 8.2.1 Eccentric Tailstock Blocker (Optional)
• 8.3 Carriage group

• 8.4 Electro spindle group
• 8.5 Turning head group (Y2 axis)
• 8.6 Shaping head group (Y3 axis)
• 8.7 Sanding head group (Y4 axis)
• 8.7.1 Change and adjustment of the sanding belt
• 8.8 Feeder group

• 8.8.1 Feeder adjustment
80
8.1 Drive Head Group
01 02
04 03
01- Encoder to control the drive head.

02 - Encoder transmission belt (ref. TCO-AT05545-010).
03 - Transmission belt for the headstock (ref. TCO-L1562-20)
04 - Drive head motor.
81
05
06
05 - Drive Head.
06 - Headstock. It’s possible to change the dimensions of the headstock. The
appropriate headstock to be used in the machine depends of the diameter of the
piece to be mechanized, ensuring at all times that it is the largest diameter point
possible.
This headstock is compound by two different parts:
- The headstock Base TP10.0.Lt.040
- The interchangeable headstock points
REF. ØD Lt
Lt TP10.0.093.040 Ø40 093
TP10.0.093.040 Ø40 133
63
REF. Ød
TP21.0.020 Ø20
TP21.0.030 Ø30
TP21.0.040 Ø40
Ød TP21.0.050 Ø50
TP21.0.060 Ø60
ØD TP21.0.070 Ø70
TP10.0.Lt.040
TP_ _.0._ _ _ X100.1.002
82
8.2 Tailstock Group
03
01
04
02 07 02
05 06
02
Automatic
position
02
83
01- Tailstock. These points are secured to the tailstock shaft by a thread. And, as
headstock points, are available in different diameters. Always ensure that you use
the largest.
Lt
REF. ØD Lt
X1690008 Ø08 115
X1690012 Ø12 115
X1690015 Ø15 115
X1690018 Ø18 115
X1690040 Ø40 115
Ød
X169.0.0 _ _
X100.1.007
Optionally there is also the possibility of mounting eccentric points, this requires
mounting the eccentric counterpoint blocker (see section 8.2.1)
Lt
REF. Ød A Lt
Ød TP61.0.05.015 Ø15 05 115
TP61.0.10.015 Ø15 10 115
TP61.0.15.015 Ø15 15 115
TP61.0.20.015 Ø15 20 115
TP61.0.25.015 Ø15 25 115
X100.1.007 TP61.0. _ _.015
02- Nuts for fixing the tailstock to the linear guides.

03- Cylinder and manual tailstock control valve group. When working in the automatic
cycle, the manual lever must be in the advance position.
04- Regulator to control the advance speed of Tailstock (ref. HCC3 in the hydraulics
diagram).
05- Inductive sensor which is active while the tailstock is located in front
(microprocessor input i:5 module MI.4)
06- Inductive sensor which is active while the tailstock is back. In automatic cycle, when
the tailstock advances and this sensor is disabled, the feeder moves backwards
(microprocessor input i:4 module MI.4).
84
07- Tailstock’s position indicator.
07.1
07.2 07.3
07.1- Battery power.
07.2- F+SET Sets display to datum value (0mm in this case).
07.3- Incr/Abs Alternately selects Absolute or Incremental mode of the display. In

incremental mode, “INC” is displayed in the right-hand digit of the display. At all
times the internal counter retains the absolute value.
It is Important to Work in Absolute mode.
POSITIONING THE TAILSTOCK’S POSITION INDICATOR TO 0 POSITION.
In case you lose the 0 position follow the next steps:
Move the tailstock until it touches the “0” position screw. (07.4)
Tighten the F+SET buttons simultaneously and automatically will appear the 0.0 value on
the display.
07.4
85
HOW TO CHANGE THE BATTERY?
Loosen the 4 screws at rear and remove the rear panel.
Now the battery (1.5 V/8 Ah) can be changed.
All data (except the actual position) will be stored in the data memory.
86
8.2.1 – Eccentric Tailstock Blocker (OPTIONAL)
There is the possibility of mounting eccentric points for a specific type of pieces. When
using these points, it is absolutely necessary to mount the tailstock blocker to never lose
the position.
To mount the blocker (01) should follow the following steps:
02 03 02
01 Black Red
- Loosen the screws (02) and mount the blocker on the axis of the tailstock as
shown in the picture.
- Level the blocker with the help of the piece (03)
- Tighten the screws (02)
- Connect the pneumatic tubes of the blocker to the base of the tailstock, the red
tube with the red fitting and black tube with black fitting.
87
8.3 Carriage Group
04
01 02 05 06 07 03
01- Servomotor for the carriage group movement X axis.

This movement is performed through a rack and pinion. This pinion is fixed to a
Planetary Gearhead and to the servomotor.
02- Micro-contact positive point for X axis.
02.1
02.1 Emergency micro contact for the position of X Axis in a positive direction
(Headstock Limit of X axis in the electrics diagram). When this signal is
activated, the machine comes to a complete stop. To start it up again, turn
the Bypass key to position I (Chapter 7), this cancels the safety measure.
Doing this restarts the machine and the appropriate buttons can be used to
move X carriage until the micro contact is released. Once it has been
released, turn the Bypass key to the initial position 0.
88
03- Micro-contacts points and starting point of X axis
03.1
03.2
03.1- Emergency micro contact for the position of X axis in negative direction
(Tailstock Limit of X axis in the electrics diagram). When this signal is
move carriage X until the micro contact is released. Once it has been
03.2- Micro contact for the starting point of X axis (Microprocessor input I:3 module
MI.1)
04- Electro spindle group (Chapter 8.4)
05- Turning head group (Chapter 8.5)
06- Shaping head group (Chapter 8.6)
07- Sanding head group (Chapter 8.7)
89
8.4 Electro Spindle Group
05
10
04
06
03
02
12
11 01
09
14
08
13
07
90
01- Electro spindle HSK F63 Tool holder.
REF. d
TH000.32.03 03
TH000.32.04 04
TH000.32.05 05
TH000.32.06 06
TH000.32.07 07
TH000.32.08 08
TH000.32.09 09
TH000.32.10 10
TH000.32.11 11
TH000.32.12 12
TH000.32.13 13
TH000.32.14 14
TH001.32.1 TH000.32.15 15
TH000.32.16 16
TH000.32.17 17
TH000.32.18 18
REF. Lt TH000.32.19 19
TH001.63.60.32 60 TH000.32.20 20
The electro head must be connected to the coolant circuit to dissipate the heat generated
by the electro-spindle during machining. The coolant must be: water with 10% ethylene
glycol.
01.1
01.1 The cooler has to operate correctly. The set temperature is +20ºC (+68ºF).
91
01 02 03
02- Micro-contacts points and starting point of B axis
02.1
02.2
02.1- Emergency micro contact for the position of B axis in negative and positive
direction. (Limit B axis in the electrics diagram). When this signal is activated,
the machine comes to a complete stop. To start it up again, turn the Bypass
key to position I (Chapter 7), this cancels the safety measure. Doing this
restarts the machine and the appropriate buttons can be used to move
carriage B until the micro contact is released. Once it has been released,
turn the Bypass key to the initial position 0.
02.2- Micro contact for the starting point of B axis (Microprocessor input I:1 module
MI.2)
03- Hollow-shaft Servo Actuator for the movement of the B axis.
92
04- Servomotor for the carriage group movement Z axis.
This movement is performed through a rack and pinion. This pinion is fixed to a
Planetary Gearhead and to the servomotor.
05- Micro-contacts points and starting point of Z axis
05.1
05.2
05.1- Emergency micro contact for the position of Z axis in negative and positive
direction. (Limit Z axis in the electrics diagram). When this signal is activated,
carriage Z until the micro contact is released. Once it has been released,
05.2- Micro contact for the starting point of Z axis (Microprocessor input I:5
module MI.1)
06- Circulating ball screw and nut for the Y axis movement transmission.
07- Servomotor for the carriage group movement Y axis.
08- Toothed belt for the transmission of the shaft that moves the carriage (ref. TCO-
AT10610-032 GENIII).
09- Screws and grooves for fitting the Y motor and tensioning the belt.
93
10- Micro-contacts points and starting point of Y axis
10.1
10.2
10.1- Emergency micro contact for the position of Y axis in negative and positive
direction. (Limit Y axis in the electrics diagram). When this signal is activated,
carriage Y until the micro contact is released. Once it has been released,
10.2- Micro contact for the starting point of Y axis (Microprocessor input I:7 module
MI.1).
11- Linear tools changer of 6 positions. Cone type HSK-F63.
12- Rotary actuator to open the door of the tools changer.
12.1- Mechanical stroke adjustment.

12.2 12.2- Flow Regulator to control the
12.3 speed for open the door of the

12.1 tools changer (ref. PCC 03 in
the pneumatic diagram).
12.3- Flow Regulator to control the
12.4 speed for close the door of the
tools changer (ref. PCC04 in
12.5 the pneumatic diagram).
12.4- Magnetic sensor which is
activated while the door is
opened (microprocessor input
i:8 module MI.5)
12.5- Magnetic sensor which is activated while the door is closed (microprocessor
input i:7 module MI.5)
94
13- Cylinder to move the linear tools changer, to make the tool change.
13.3 13.4
13.1 13.2
13.1- Flow regulator to control the speed for the lineal tools changer advance (ref.
PCC02 in the pneumatic diagram).
13.2- Flow regulator to control the speed for the lineal tools changer setback (ref.
PCC01 in the pneumatic diagram).
13.3- Magnetic sensor which is activated while the lineal tools changer is in
forward position (microprocessor input i:6 module MI.5).
13.4- Magnetic sensor which is activated while the lineal tools changer is in back
position (microprocessor input i:5 module MI.5).
14- Manually tool change push button.

Press the button once to open the Electro spindle cone and remove the tool. Push
again to close the cone and to fix the tool.
95
8.5 Turning Head Group Y2
01
05
04
02
03
09
08
06
07
96
01- Motor turning head group.
02- Transmission belt (ref. TCO-K1795-10)
03- Bearings head turning group.
04- Turning disk saw D-350 d60 Z-90 (ref. T800.350.090.60)
05- Suction pipe.
06- Servomotor for the carriage group movement Y2 axis.
07- Screws and grooves for fitting the motor and tensioning the belt.
08- Toothed belt for the transmission of the Y2 axis movement (ref. TCO-AT05450-032-
GENIII).
09- Micro-contacts points and starting point of Y2 axis
09.1
09.2
09.1- Emergency micro contact for the position of Y2 axis in negative and positive
direction. (Limit Y2 axis in the electrics diagram). When this signal is
move Y2 carriage until the micro contact is released. Once it has been
09.2 Micro contact for the starting point of Y2 axis (Microprocessor input I:3
module MI.2).
97
8.6 Shaping Head Group Y3
01
02
03
05
04
09
08
06
07
98
01- Motor Shaping head group.
02- Transmission belt (ref. TCO-K1194-08)
03- Bearings head Shaping group.
04- Milling tool for the shaping headstock (ref. T502._ _ _._ _ _.040)
REF. ØD Ød BU BT
T502.080.105.40 Ø80 Ø40 105.6 114.1
T502.080.131.40 Ø80 Ø40 131.1 139.6
T502.125.080.40 Ø125 Ø40 80.1 88.6
T502.125.105.40 Ø125 Ø40 105.6 114.1
T502.125.131.40 Ø125 Ø40 131.1 139.6
05- Suction pipe.

06- Servomotor for the carriage group movement Y3 Axis.
GENIII).
09.1
09.2
released turn the key to the initial position 0.
09.2- Micro contact for the starting point of Y3 axis (Microprocessor input I:5
module MI.2).
99
8.7 Sanding Head Group Y4
The standard sanding Head group (Y4) is to sand shaped pieces. Also, optionally, there’s another
group to sand the turned pieces, and can either be used interchangeably depending on whether
you want sand turned or shaped pieces.
Sanding Head Group

For
Shaping Group
04
05
03
02 01
Sanding Head Group 07

For 06
Turning Group
08
100
01- Motor Sanding head group for shaping.
02- Transmission belt (ref. TCO-J0914-10)
03- Cylinder for the swing band.
04- Suction pipe.
05- Sanding bands of 170x1500
REF. WIDTH DEVELOPMENT GRAIN

X7214100 170 1500 100
X7214120 170 1500 120
X7214150 170 1500 150
06- Motor Sanding head group for turning.

07- Suction pipe.
08- Sanding bands of 40x2215
REF. WIDTH DEVELOPMENT GRAIN

X7238060 40 2215 60
X7238080 40 2215 80
X7238100 40 2215 100
101
14
11 12 13
09- Servomotor for the carriage group movement Y4 Axis.

GENIII).
14.1
14.2
released turn the key to the initial position 0.
14.2- Micro contact for the starting point of Y4 axis (Microprocessor input I:7
module MI.2).
102
8.7.1 – Change and adjustment of the sanding belt
In order to change and adjust he sanding belt follow the next steps:
1- Unscrew the 4 screws (A) and remove the cover (B).
2- With the help of the rod (C), loosen the springs and remove the old belt.
103
3- With the same rod (C) loosen the springs again and install the new belt, is necessary to
look at the direction of rotation of the belt.
Direction of rotation
4- Leave the sanding belt about 10 mm over the drive wheel.

Loosen the nut (D) to adjust the oscillating movement of the sanding belt.
10 mm
104
5- Ensure that the slack in the back of the cylinder is approximately 2mm when it is in the
back position.
6- Start the sanding belt motor (Y4 sander belt on the screen) and adjust the oscillation of
the belt.
Adjust the oscillation time of the sanding belt on the Timers screen. The recommended
time is between 0.5 and 1.5 seconds.
2mm
Adjusting nut
a. When turning the back nut of the cylinder counterclockwise – the belt will go
down.
b. When turning the back nut of the cylinder clockwise – the belt will go up.
Counterclockwise. Clockwise.
Belt go down Belt go up
7- Stop the motor, tighten the nut (D) and place the cover (B).
105
8.8 Feeder Group
01 03
05 05
06 06
07 07
04 04
02
01- Left side vertical guides: Almost always have to stay in the same position in order to
allow the entrance of the wood between the headstock and the tailstock without touch
none of them. Should be adjusted to the width of the wood to work with the help of
the millimeter ruler
02- Feeder: it’s possible to move the feeder along the base guides in order to put it
centered with the wood. It contains the clamping fingers and the centering guides.
03- Right side vertical guides: must be moved along the base guides and separate
enough from the left vertical guide to fit the wood between both guides. Should be
adjusted to the width of the wood to work with the help of the millimeter ruler
04- Feeder centering guides: They should be adjusted to the width and the height of the
wood with the help of the millimeter ruler.
05- Vertical dispenser: cylinder to leave the wood in a controlled way on the centering
guides.
06- Horizontal dispenser: the function of this cylinder is to hold the next piece until the
vertical dispenser picks it up.
07- Clamping fingers: pneumatically-activated clamps to attach the wood in the feeder.
106
09 08 10 12
08- Hydraulic cylinder to control the advance of the feeder.

09- Regulator to control the advance speed of the Feeder (ref. HCC2 in the hydraulics
diagram).
10- Regulator to control the reverse speed of the Feeder (ref. HCC1 in the hydraulics
diagram).
11- Micro contact for the feeder group.
11.1
11.2
11.1- Micro contact that detects when the feeder is in front (Microprocessor input
I:6 module MI.4).
11.2- Micro contact that detects when the feeder is back (Microprocessor input I:7
module MI.4)
12- Manual clamping levers for fix the feeder group.
The Feeder is prepared to load woods of □30 minimum and □140 maximum.
107
8.8.1 Feeder adjustment
- must first adjust the vertical guides to the length of the wood, leaving a clearance between
4 and 6 mm.
- The next step is to adjust the centering guides to the width and height of the timber with the
help of the millimeter ruler.
- Then you must adjust the vertical guides to the width of the timber with the help of the
millimeter ruler
108
- After that, put the horizontal dispenser (06) approximately in the centre from the second
piece of wood.
- Then, adjust the two stops of the dispenser 3 to 5 millimeters above the base of the second
piece.
3 mm
02
- Finally, it should adjust the stops of the vertical dispenser. To do this, place the piece in the
feeder and adjust the top stop nut so that it is a clearance of about 3 or 4 mm between timber
and dispenser.
Top stop
nut
A 3 mm
3 mm
Bottom
stop nut
- Then adjust the bottom stop nut to a distance (A) equal to the height of the piece. Thus,
when the dispenser rises, will be positioned just below the next piece without actually
touching it.
109
Chapter
9
In this chapter:
• 9.1 Maintenance Introduction.

• 9.2 Guides Maintenance.
• 9.3 Rack & Pinion Maintenance.
• 9.4 Electro Spindle Maintenance.
• 9.5 Filters Maintenance.
110
9.1 Maintenance Introduction
Read this section carefully before carrying out any maintenance operation on the machine.
Maintenance operations must only be carried out by trained and qualified personnel, duly
authorised by the technical management of the plant, in accordance with the safety directives and
standards in force, using tools, intruments and products suitable for this work.
During maintenance work, it is obligatory to wear suitable clothing, such as close-fitting overalls,
safety shoes, strictly avoiding wide garments or items with protruding parts.
During any mantenance operations, disconnect the electric power supply.
The machine generates shavings and dust. It must be cleaned daily for the correct operation of
the machine.
At the end of the working day, clean correctly the machine and check that all machine parts
are ok.
It is the responsibility of the operator that the machine is kept clean for proper functioning.
The cleaning frequency has been calculated on the basis of a working week of 5 days, 8 working
hours each, under normal environmental working conditions.
111
9.2 Guides Maintenance
Need to clean weekly the different guides and sliders of the different axes of the machine for his
correct operation.
Use a vacuum cleaner to remove the shavings and dust.
To make the maintenance of the guides, follow these steps:

- Remove the upper covers (01) of the carriage loosening the indicated screws (02).
- Separate the covers from the end of the carriage for proper cleaning.
- Clean the guides and the bottom of the carriage.
This cleaning needs to be made at the following carriage axes:
9.2.1 X AXIS CARRIAGE
01 02 02 02 02 01
112
9.2.2 Y AXIS CARRIAGE
02
02
02
02
113
9.2.3 Y2, Y3, Y4 AXIS CARRIAGE
02 02 02 02 02 02
114
9.2.3 FEEDER GUIDES MAINTENANCE
Daily clean the guides of the feeder for his correct work.
03 - Areas that need to be cleaned
03
03
03
03
115
9.3 Rack and pinion Maintenance
It is necessary make a maintenance of the rack and pinion of the X axis and Z axis. Check the
gear reducer by a visual inspection, looking for exterior damage and lubricant leakage.
Clean weekly all the racks of the machine for its correct operation.
116
9.4 Electro Spindle Maintenance
Daily, check and clean the tool holder seat and the tool holder cone.
The contact surfaces between the tool holder and tool holder seat must be kept clean in order to
guarantee a safe coupling.
At the start of the work day, check that the surfaces shown in the drawing are thoroughly clean,
with no traces of dust, grease, cooling liquid, oil, wood particles or machining residues, nor signs of
oxidisation or scale. If necessary, wipe with a soft, clean cloth.
01 02 01
01- Conical surfaces
02- Stop surfaces
02
For cleaning the surfaces indicated, use soft, clean cloths. NEVER USE abrasive
instruments such as wire wool, metal scrapers, emery cloth, acids or other aggressive
elements.
At the end of the working day, clean the surfaces shown in the drawing with a soft, clean
cloth. Inadequate cleaning may result in serious consequences for the operator’s safety,
for the wear of the electrospindle and tool holder, for the precision and efficiency of the
machining operation.
Do not direct jets of compressed air inside the tool holder set if the tool holder cone is
missing, or if the tool holder cone fitted has through bores.
117
9.5 Filters Maintenance
The machine has some filters that is necessary to clean for his correct operation.
9.5.1 CONTROL PANEL FILTER.

The control panel has two filters. Is necessary clean these filters and check that the control panel
cabinet is clean.
118
Chapter
10
In this chapter:
• 10.1 Linear Guides Sliders Lubrication.

• 10.2 Ball Screws Lubrication.
• 10.3 Rack & Pinion Lubrication.
• 10.4 Electro Spindle Lubrication.
• 10.5 Tailstock Lubrication.
• 10.6 Drive Head Lubrication.
• 10.7 Turning Head Lubrication.
• 10.8 Shaping Head Lubrication.
• 10.9 Lubricated Several.
• 10.10 Hydraulic Group Lubrication.
119
10.1 Linear Guides Sliders Lubrication
The machine has diferents Linear Guides with sliders for the diferent movements.
The Linear Guides and Sliders must also be kept clean, not allowing the accumulation of
waste wood around.
These sliders feature a special sealing system and don’t require any regular greasing, so the
original lubrication is sufficient.
However, it can be greased again every 8000 working hours using:
SHELL ALVANIA GREASE or equivalent

Physical state at 20º Doughy
Metal contents Lithium < 0,5%
Sodium < 0,5%
Drop point, ºC (ASTM D-566) >180
Penetration, grade NLGI 2
Density at 15ºC, Kg/m3 0,900
10.1.1 X Axis Lubrication Points of Linear Guides Sliders
10.1.1 10.1.1
120
10.1.2 Y2 Axis Lubrication Points of Linear Guides Sliders
10.1.2
10.1.3 10.1.3
10.1.4 10.1.4
121
10.1.5 Y Axis Lubrication Points of Linear Guides Sliders
10.1.5
10.1.5
10.1.6 Z Axis Lubrication Points of Linear Guides Sliders
10.1.6
10.1.6
10.1.6
10.1.6
122
10.1.7 Feeder Lubrication Points of Linear Guides Sliders
10.1.7 10.1.7 10.1.7 10.1.7
10.1.8 Tools Change Magazine Lubrication Points of Linear Guide Slider
10.1.8
123
10.2 Ball Screw Lubrication
The machine has diferent Rolled Ball Screws to control the movement of the Y, Y2, Y3 and Y4
Axes.
The spindle and the nut must be kept clean, ensuring that scrap wood is not collected around
them.
The greasing needs to be done approximately once every three months using:
SHELL ALVANIA GREASE or equivalent

Physical state at 20º Doughy
Metal contents Lithium < 0,5%
Sodium < 0,5%
Drop point, ºC (ASTM D-566) >180
Penetration, grade NLGI 2
Density at 15ºC, Kg/m3 0,900
10.2.1 Lubrication Point of the Ball nut in Y Axis
10.2.1
124
10.2.2 Lubrication Point of the Ball nut in Y2 Axis
10.2.2
10.2.3 Lubrication Point of the Ball nut in Y3 and Y4 Axis
10.2.3
125
10.3 Rack & Pinion Lubrication
The machine has two rack & pinion systems to control the movement of the X and Z Axes.
Efficient lubrication systems are essential in guaranteeing a long service life for our pinon and
rack systems.
The machine has installed a complete lubrication set for each movement. The lubricator
supplies a preset amount of grease to the felt pinion and ensures a constant lubrication film in
the rack and pinion.
When the machine runs, a microswitch starts the required dose. Nitrogen generated
continuously moves the piston. A discharge time of 1, 2, 3, 6, 12 or 18 months, and individual
quantities of lubricant can be selected.
The machine goes out of manufactures with the emptying option of 18 months .
18 MONTH ON
The used grease is Klüber Microlube GB0.

The lubrication kit’s reference for replacement is GCR-BC021555
126
10.3.1 X Axis Lubrication Kit
10.3.1
10.3.2 Z Axis Lubrication Kit
10.3.2
127
10.4 Electro Spindle Lubrication
In order to maintain the proper efficiency of the HSK collet over a long period of time, it must be
lubricated every month with grease:
METAFLUX-Fett-Paste No. 70-8508

or alternatively
METAFLUX-Molyt-Spraye No. 70-82
USE ONLY THE GREASES INDICATED ABOVE

Greases that are incompatible mixed or used successively on the same collet form substances
harmful to the functioning of the collet, with serious consequences for safety.
Spread the grease in the gap between the segments of the collet and the ejector using a clean, thin,
plastic tool.
Carry out roughly ten tool changes to distribute the grease uniformly.
Remove the tool holder from the spindle shaft and remove any visible remains of grease with a clean
cloth.
Excessive grease is harmful as it cans collet chips or other machining residues, soiling the collet,
the tapered surfaces and the stop surfaces. These areas must be kept as clean as possible in order
to guarantee the safety of the operator, the precision of the machining operation, and to reduce wear
on the spindle and tool holder cone.
01
02
01- Segments
02- Ejector
128
10.5 Tailstock Lubrication
02 01
01- Greasing points for the tailstock spindle. This part needs to be lubricated once a day
using general lubrication oil:
SHELL TONA T-68 OIL or equivalent
Aspect Liquid clean
Density at 15.5ºC 0,890gr/cm3
Viscosity at 20ºC 198cst
Index of viscosity 100
02- Tailstock bearing group.

These bearings are lubricated for life with a grease for high speed and require no
further lubrications. Although we indicate some steps for lubricate them if necessary.
To grease the bearings, the tailstock must first be dismantled. Then the bearings need
to be fully cleaned, and then reassembled with fresh lubrication (approximately 0.7 cm3
of lubricant for each of the four bearings).
This greasing operation needs to be done approximately once every 8000 working
hours using:
ISOFLEX NBU 15 made by KLÜBER or equivalent.

Density at 20ºC 0,99gr/cm3
Base oil Semisynthetic
Soap Barium complex
Drop point
DIN-ISO 2176 > 220º
Dynamic viscosity At 25ºc 5500mPa.s
Speed factor 1.000.000
Consistence NLGI(DIN 51818) 2
129
10.6 Drive Head Lubrication
01
These bearings are lubricated for life with a grease for high speed and require no
further lubrications. Although we indicate some steps for lubricate them if necessary.
01- Headstock bearing group

To grease the bearings, the headstock must first be dismantled. Then the bearings
need to be fully cleaned, and then reassembled with fresh lubrication (approximately
0.7 cm3 of lubricant for each of the four bearings).
This greasing operation needs to be done approximately once every 8000 working hours using
Soap Barium complex
Drop point
DIN-ISO 2176 > 220º
Dynamic viscosity At 25ºC 5500mPa.s
Consistence NLGI (DIN 51818) 2
130
10.7 Turning Head Lubrication
01
These bearings are lubricated for life with a grease for high speed and require no further
lubrications. Although we indicate some steps for lubricate them if necessary.
Soap Barium complex
Drop point
DIN-ISO 2176 > 220º
131
10.8 Shaping Head Lubrication
01
These bearings are lubricated for life with a grease for high speed and require no further
lubrications. Although we indicate some steps for lubricate them if necessary..
Soap Barium complex
Drop point
DIN-ISO 2176 > 220º
132
10.9 Lubricated Several
The machine must be cleaned regularly for correct operation (Chapter 9).
Once you have cleaned it, is necessary lubricate axes and parts not painted for a long
conservation of the machine.
For these cases use a general lubricant:

SHELL TONA T-68 OIL or equivalent is to be used
Aspect Liquid clean
Density at 15.5ºC 0,890gr/cm3
Viscosity at 20ºC 198cst
Index of viscosity 100
133
10.10 Hydraulic Group Lubrication
01 Hydraulic Oil Level
01- Oil tank for the hydraulic group.

It is important to keep the oil for the hydraulic group at the level indicated in the
window. Do not allow dust or other impurities, which may contaminate the oil, entering
the tank.
The oil can be changed every 5000 working hours. The tank should be completely
emptied and cleaned before being refilled.
The oil to be used is:
Hydraulic oil HM
Grade ISO 32
Viscosity ºEngler 50ºC = 3,0
134
Chapter
11
In this chapter:
• 11 Hydraulic equipment
135
11 Hydraulic equipment
01 02 03 04
05 06
01- Manometer selector. Each pressure value must be selected by means of this
selector in order to view it. The following table details each of the possibilities:
POSITION SELECTOR PRESSURE SELECTED APPROXIMATE VALUE

1 General Pressure 40 Kg/cm2
3 Tailstock Pressure 40 Kg/cm2
02- Manometer where you can view the selected pressure.

03- Hydraulic pump.
04- Oil aspiration filter.
05- Hydraulic group motor.
06- Hydraulic oil level
136
07- Hydraulic valve base plate.
08- General pressure restrictor valve (ref. HCP.0 in the hydraulics diagram). This can be
viewed on the manometer with the selector in position 1.
11 10 9
12
13
12
07
07
08
08
137
9- Electro-valve to control the Tailstock (ref. HCD2 in the hydraulics diagram).
9.1 9.2
9.1 Electromagnet for the Tailstock forward advance (microprocessor output Q:5
module MO.3).
9.2 Electromagnet for the Tailstock reverse movement (microprocessor output Q:6
module MO.3).
10- Non Return valve for the Tailstock line (ref. HAT2 in the hydraulics diagram).
11- Pressure reducer valve for the Tailstock line (ref. HCP2 in the hydraulics diagram).
This pressure can be viewed on the manometer with the selector in position 3.
12- Electro-valve to control the Feeder (ref. HCD1 in the hydraulics diagram).
12.1 12.2
12.1 Electromagnet for the Feeder Reverse (microprocessor output Q:8 module
MO.3).
12.2 Electromagnet for the Feeder Advance (microprocessor output Q:7 module
MO.3).
13- Non Return valve for the Feeder Line (ref. HAT1 in the hydraulics diagram).
138
Chapter
12
In this chapter:
• 12 Pneumatic equipment
139
12 Pneumatic equipment
The air inlet connection to the machine shall be as indicated in Chapter 5 (paragraph 5.1).
Below are all the elements making up the pneumatic equipment:
02 7Kg/cm2
01
04
03
01 - Discharge valve to cut off air pressure in the circuit.

02 - Knob for adjusting pressure in the pneumatic group.
03 - Cock for emptying water that has been accumulated from air humidity.
04 - Depuration filter compressed air filtration/drying group with automatic condensate
drain: first stage 5µ and second stage 0.1µ.
The air that comes to the connection of the machine must be completely dry, filtered
and free of impurities. Otherwise it can cause problems with the electro valves.
140
06
05
05 - Electro-valve to control the Belt oscillation cylinder. Microprocessor output Q:8

module MO.6 (ref. PCD 08 in the pneumatics diagram).
06 - Electro-valve to control the eccentric tailstock blocker (OPTIONAL). Microprocessor
output Q:8 module MO.4 (ref. PCD 09 in the pneumatics diagram).
Feeder
07 08 09
07 - Electro-valve to control the vertical dispenser of the Feeder. Microprocessor output

Q:7 module MO.6 (ref. PCD 05 in the pneumatics diagram).
08 - Electro-valve to control the horizontal dispenser of the Feeder. Microprocessor
output Q:2 module MO.4 (ref. PCD 06 in the pneumatics diagram).
09 - Electro-valve to control the finger clamps in the Feeder. Microprocessor output Q:1
141
15
13
14
12 10 11
10 - Electro-valve to control the storage tool cylinder. Microprocessor output Q:5 module
MO.4 (ref. PCD 01 in the pneumatics diagram).
11 - Electro-valve to control the storage tool gate cylinder. Microprocessor output Q:6
12 - Pressure regulator for air hole, 4 bar. (ref. PCP 02 in the pneumatics diagram).
13 - Pressure switch. (ref. PGF 02 in the pneumatics diagram).
14 - Pressure regulator in the intensifier for the tool holder, 6bar. (ref. PCP01 diagram).
15 - Pressure intensifier for the tool holder cylinder, 12bar. (ref PMP01 in the diagram).
142
16
17
16 - Electro-valve to control unfreezing motor cone tool. Microprocessor output Q:3

17 - Electro-valve to control unfreezing motor cone tool. Microprocessor output Q:4
143
Chapter
13
In this chapter:
• 13.1 Control equipment

(See chapter 7)
• 13.2 Electrical cabinet

• 13.3 Inputs/Outputs Modules
144
13.2 Electrical Cabinet
3 4
1. Main power switch
2. Light of Power ON.
3. DOORS: At position 0 the switches of the safety doors are active and the machine stops
when one door is opened. At position I, the switches of the safety doors are disabled, and is
possible to open the safety doors without stop the machine. In this case all the motors,
except the motors of the AXES, will stop. We use this option for simulation.
4. BYPASS: At position 0 the limit switches of the axes are active and it will stop the machine
when one of these limit switches are pressed. At position I, disables the limit switch and the
operator can move manually the axes.
5. Heat exchanger.
The two selectors (3 and 4) must always be in the position 0 for the normal work cycle of
the machine. Can only be activated when absolutely necessary and always under the
responsibility of the operator.
145
7 6
KM1 KM2 QF2.X QF2.Y QF2.Y2 QF2.Y4 MN3
QF1 MN1 QF2.Z QF2.B QF2.Y3 MN2 MN4
6. Cabinet lighting
7. Suppressor filter for the axes.
QF1. Circuit breaker for the A axis inverter
KM1. Power contactor for the A axis inverter
MN1. Thermal magnetic for the power supply of the inverters of the axes.
KM2. Contactor for the inverters of the axes.
QF2.X Circuit breaker for the inverter of the X axis servo motor
QF2.Z Circuit breaker for the inverter of the Z axis servo motor
QF2.Y Circuit breaker for the inverter of the Y axis servo motor
QF2.B Circuit breaker for the inverter of the B axis servo motor
QF2.Y2 Circuit breaker for the inverter of the Y2 axis servo motor
MN2 Thermal magnetic for the power supply of the manoeuvre’s transformer.
MN3 Thermal magnetic for the power supply of the transformer for the electro spindle
cooler.
MN4 Thermal magnetic for the power supply of the electro spindle cooler.
146
KM4.1 QF5 KM5.2 KM6.1 KM7 KM8 KM9 KM11
QF4 KM4.2 KM5.1 QF6 KM6.2 QF7 QF8 QF9 KM10
QF4. Circuit breaker for the inverter of the electro spindle motor.
KM4.1. Contactor of the inverter of the electro spindle motor.
KM4.2. Contactor of the inverter of the electro spindle motor
QF5. Circuit breaker for the inverter of the milling motor
KM5.1. Contactor of the inverter of the milling motor
KM5.2. Contactor of the inverter of the milling motor
QF6. Circuit breaker for the inverter of the disc motor
KM6.1. Contactor of the inverter of the disc motor
KM6.2. Contactor of the inverter of the disc motor
QF7. Circuit breaker for the hydraulic motor
KM7. Contactor for the hydraulic motor
QF8. Circuit breaker for the sanding unit motor
KM8. Contactor for the sanding unit motor
QF9. Circuit breaker for the conveyor belt motor
KM9. Contactor for the conveyor belt motor
KM10. Contactor for the fan motor of the drive head A
KM11. Contactor for the electro spindle cooler
147
9 11
8 10 12 13
8. Power supply 24VDC

9. Power supply 12VDC (analogical module).
10. Power supply 5VDC (drive head encoder)
11. Fuses
12. Trailing socket
13. Power distributor
KS1 KAS1 KAS2 KAS3 KAS4 14
KS1. Security module

KAS1. Auxiliary contact of the safety module
KAS4. Auxiliary contact of the safety module (simulation switch)
14. Manoeuvre relays.
148
18 20 22
15 16 17 19 21 23
15. Suppressor filter for the drive head inverter.

16. Inverter for the A head motor
17. Inverter for the X axis servo motor
18. Inverter for the Z axis servo motor
19. Inverter for the Y axis servo motor
20. Inverter for the B axis servo motor
21. Inverter for the Y2 axis servo motor
The Unidrive SP Drives trigger and control the movement of the axes, and operates from the data
that supplied by the control.
These drives have a factory setting which must not be changed.
149
24 25 26 27 28 29
24. Suppressor filter for the inverter of the electro spindle motor.
25. Inverter of the electro spindle motor.
26. Suppressor filter for the inverter of the milling motor
27. Inverter of the milling motor
28. Suppressor filter for the inverter of the disc motor
29. Inverter of the disc motor
150
30 31
32 33 34 37
35 36
30. Motor Power trailing socket

31. Outputs trailing socket
32. Inputs trailing socket
33. Security-emergency trailing socket
34. Transformers trailing socket
35. Manoeuvre’s transformer 400V-220V/110V
36. Cooler transformer 400V-220V
37. Terminal socket.
151
38
39 40
41 42
43 44
38. Emergency pushbutton. It stops completely the machine. After push, remains locked
in position and it must be given a slight turn to unlock it.
39. Braking resistors (R6) for the disc motor.
40. Braking resistors (R1) for the drive head motor.
41. Braking resistors (R2) for the X axis servo motor.
42. Braking resistors (R3) for the Z axis servo motor.
43. Braking resistors (R4) for the electro spindle.
44. Braking resistors (R5) for the milling motor.
152
13.3 Inputs/Outputs Modules
07
09
01
08
10
02
15
11
03
12
04
13
05
14
06
01- Input module MI.1 02- Input module MI.2

I:1 A axis A I:1 B axis Origen
I:2 X axis Status I:2 Y2 axis Status
I:3 X axis Origin I:3 Y2 axis Origin
I:4 Z axis Status I:4 Y3 axis Status
I:5 Z axis Origin I:5 Y3 axis Origin
I:6 Y axis Status I:6 Y4 axis Status
I:7 Y axis Origin I:7 Y4 axis Origin
I:8 B axis Status I:8 Electro spindle Status
153
03- Input module MI.3 06- Input module MI.6
I:1 Moulding motor Status I:1 Limit X axis (tailstock.) OK +
I:2 Hydraulic thermal OK limit X axis (headstock) OK.
I:3 Belt motor thermal OK I:2 Limit Z axis OK.
I:4 Tool change Push-button I:3 Limit Y axis OK.
I:5 Start Push-button I:4 Limit B axis OK.
I:6 ---- Reserved I:5 Limit Y2 axis OK
I:7 Safety Bypass I:6 Limit Y3 axis OK
I:8 Servos ON I:7 Limit Y4 axis OK
I:8 Safety doors switch
04- Input module MI.4 07- Inputs/Outputs module MI/O7

I:1 ---- Reserved I:1 Safety module OK
I:2 Electro spindle coolant I:2 Air pressure OK.
circulation NO OK Q:3 Tool holder 2 cover 2 (optional)
I:3 Z axis lubrication level. I:4 ---- Reserved
I:4 Tailstock back. I:5 ---- Reserved
I:5 Tailstock in front I:6 Conveyor motor thermal.
I:6 Feeder forward I:7 Saw blade Status
I:7 Feeder back I:8 X axis lubrication level
I:8 24 VDC
05- Input module MI.5 08- Inputs/Outputs module MI/O8

I:1 N=0 electro spindle I:1 ---- Reserved
I:2 sensor S1 collet chuck holder I:2 ---- Reserved.
closed I:3 ---- Reserved
I:3 sensor S2 collet chuck holder I:4 Boring motor Status (optional)
opened I:5 Boring unit/back (optional)
I:4 sensor S1+S4 collet chuck I:6 Boring unit/forward (optional)
holder closed, working position. I:7 Tool holder 2 cover/closed (optional)
I:5 Saddle tools/back I:8 Tool holder 2 cover/opened(optional)
I:6 Saddle tools/forward
I:7 Saddle tools/closed
I:8 Saddle tools /open
154
09- Output module MO.1 12- Output module MO.4
Q:1 A axis enable Q:1 Feeder finger.
Q:2 X axis enable Q:2 Feeder dosage.
Q:3 Z axis enable Q:3 1 unfreezing motor cone tool.
Q:4 Y axis enable Q:4 2 unfreezing motor cone tool.
Q:5 B axis enable Q:5 Tool changer advance
Q:6 Y2 axis enable Q:6 Tool changer opening
Q:7 Y3 axis enable Q:7 Z axis motor off-brake
Q:8 Y4 axis enable Q:8 Cyl. Tailstock blocker
Q:1 Electro spindle enable Q:1 Saw blade motor enable
Q:2 Electro spindle Start clockwise Q:2 Saw blade motor start
Q:3 Electro spindle Start counterclockwise.
clockwise Q:3 Saw blade motor start counter-
Q:4 Y3 axis moulding enable. clockwise.
Q:5 Y3 axis moulding Start Q:4 ---- Reserved
clockwise Q:5 ---- Reserved
Q:6 Y3 axis moulding Start counter- Q:6 ---- Reserved
clockwise Q:7 ---- Reserved
Q:7 Hydraulic Start Q:8 ---- Reserved.
Q:8 Y4 axis sanding motor start
Q:1 Soft OK Q:1 ---- Reserved
Q:2 CNC OK. Q:2 Cyl. Thin sanding belt (optional)
Q:3 Conveyor belt Start. Q:3 Boring motor enable (optional)
Q:4 Cooler start. Q:5 Boring motor start (optional)
Q:5 Tailstock advance Q:6 Boring unit advance (optional)
Q:6 Tailstock return Q:7 Feeder piece descend
Q:7 Feeder advance Q:8 Cyl. Belt oscillator
Q:8 Feeder return

15- Analogical module
155

TMC-1500 Instructions Manual

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TMC-1500 Instructions Manual

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INSTRUCTIONS MANUAL

• Chapter 3 – Transport and location - warning………………………...….. 17

• Chapter 6 – Axes & strokes….……….……………………………………....….. 40

• Chapter 7 – Computer and operating panel….………………..….……….. 52

• Chapter 10 – Greasing……………………………………...….…………………. 119

• Chapter 11 – Hydraulic equipment…….……………...….…………………. 135

• Chapter 12 – Pneumatic equipment…………….……...…….…..…………. 139

• 1.1 Manufacturer identification

This machine was manufactured by:

Address: Av. Camí de la Font Santa, s/n

City: SANT PERE DE TORELLÓ

Country: Catalonia – Spain

E-Mail: itx@ intorex.es

BEFORE BEGINNING ANY WORK, WHETHER INSTALLATION,

It is essential to disconnect the machine before any form of intervention,

It is completely forbidden to disassemble, disconnect or manipulate any

INTOREX, S.A. CANNOT BE HELD RESPONSIBLE FOR ANY POSSIBLE

INJURY TO PERSONS OR ANIMALS OR DAMAGE TO PROPERTY DUE TO

THE NON-COMPLIANCE OF THE GENERAL SAFETY RULES OR THE

RECOMMENDATIONS GIVEN IN THIS INSTRUCTION MANUAL

MECHANICAL MAINTENANCE TECHNICIAN

ELECTRICAL MAINTENANCE TECHNICIAN

MANUFACTURER'S MECHANICAL TECHNICIAN

MANUFACTURER'S ELECTRICAL TECHNICIAN

DANGER, PRESSURE IN THE HYDRAULIC SYSTEM

DANGER, HIGH VOLTAGE

DANGER, CUTTING TOOLS

SMOKING NEXT TO THE MACHINE IS PROHIBITED

THE PRESENCE OF UNAUTHORISED PERSONS IN THE

MANIPULATION, CLEANING AND LUBRICATION IS PROHIBITED

WORKING ON THE MACHINE WITHOUT ALL THE

GIVE IMMEDIATE WARNING, AND IF NECESSARY, STOP THE

SWITCH OFF THE MAIN ELECTRICAL POWER TO THE MACHINE

EYES MUST ALWAYS BE CORRECTLY PROTECTED

EARS MUST ALWAYS BE CORRECTLY PROTECTED

USE PROTECTION AGAINST BREATHING IN IMPURITIES

FEET SHOULD ALWAYS BE CORRECTLY PROTECTED WITH

ALWAYS WEAR GLOVES WHEN NECESSARY

01 - Electro spindle Unit.

03 - Shaping Head Unit.

• 3 Transport and location - warning

WARNING: During handling operations, loading or unloading, nobody should remain

- An absence of all types of animals.

- A working room temperature of between 15 and 35 degrees centigrade. Working in

- The machine must be protected against dirt, humidity and vibrations.

• 4 Protections and emergency stops.

• 4.1 Drive head protection.

• 4.2 Emergency stop.

01- Front protection.

01- Drive head upper pulley protective cover

01- General emergency pushbutton.

02- Hydraulic start button.

TO RESTART THE SYSTEM AFTER AN EMERGENCY STOP, IT MUST OPERATE THE

Finally there is a depuration filter 04

The connection must be made with pipes of Ø120 mm.

Pressure limiter 03 is used to vary and adjust the general pressure.

A AXIS. Rotary movement of the headstock.

6.2.1 AXES DISTANCE WITH SHAPING SANDING GROUP

162.5 258.5 202.5

162.5 258.5 202.5

Y axis stroke 460mm.

Y2 axis stroke 350mm.

Y3 axis stroke 360mm.

Y4 axis stroke 360mm.