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    2 - DMC 64V Linear (iTNC530) Machine Manual 2

    Uploaded by

    SVIATOSLAV

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    © All Rights Reserved
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    Machine Manual 2 Attachments & Accessories All about our range of attachments and accessories you can use on your machine DMC 64 V linear iTNC 530 DECKEL MAKM& Dear Customer: Your DMC 64 V linear may deviate in a few details from the illustrations shown in this manual, This s of no importance for the operation of the machine. Please specify the Stock No. shown at the top, right, of the label on the back of your documentation folder, adding MHB ~ 2: GB/04.2002, if you have any inquiries concerning this Operator's Manual or if you wish to obtain additional copies, A few remarks on the subject of safety: This manual is indispensable for safely operating your machine, Make sure it is always at hand for the operating personal No person is allowed to operate the machine ~ even for only a short time — without adequate training, either at your factory, at a qualified training institution or at one of our Training Centres. Make yourself familiar with all applicable industrial and local safety standards, laws and regulations. if they are not put up on a notice board, ask your safety engineer. Observe the notes on the prescribed end use of the machine on the following pages. Each Operator's Manual is accompanied by a brochure containing important instructions on operational safety and the prevention of accidents. Stucy these instructions carefully before you start working with your machine. Close the splashguard enclosure before beginning with a machining operation. All machines used for automated production must be equipped with a splashguard enclosure. ‘We wish you sinaoth and trouble-free operations with your DECKEL MAHO. machine. Sincerely, DECKEL MAHO Geretsried GmbH DECICS Prescribed end use of machine Basis: technology: Fields of application: Materials: Attachments and accessories: Personnel: Prescribed end use of DECKEL MAHO DMC-line machining centres. Your DECKEL MAHO machining centre was built using state-of-the-art technology and complies with all generally recognized safety regulations standards and specifications DECKEL MAHO machining centres are suitable for manual and automatic operation, Machining (as per DIN 8590, Part 0) by means of rotating tools with at least one geometrically defined cutting edge. Milling Drilling and boring {as per DIN 8589, Part 3): {as per DIN 8589, Part 2): * Surface milling * Spot facing * Circular milling * Drilling and boring + Helical milling * Tapping and threading + Hobbing + Profile drilling + Profile milling * Drilling of non-cylindrical holes * Form milling Metal, wood and plastics he machining of easily flammable and/or explosive materials (e.g magnesium, silicon) is not permissible except if suitable preca ions are taken, DECKEL MAHO provides a number of special attachments, accessories, add: on and optional equipment for extending the functional range of DECKEL MAHO machining centres to fulfil special applications. Only specially trained, authorized and reliable personnel may operate the machine, Persons without the necessary training are not allowed to work on the machine, not even for short periods of time. There must be clear rules to define the responsibilities of the persons entrusted with the tasks of transporting, installing, tooling, setting up, operating, servicing and maintaining the machine, and compliance with these rules must be ensured by regular spot checks. 2910 linear * TNC 530 ® mhb 2 FECHCIER RGALEECD ied cab Prescribed end use of machine Customer's obligations: Important: Environment, water conservation: Before the machine is put into operation, the customer must make sure that all persons responsible for the machine have read and understood the operating manual, and that particular attention has been given to the safety instructions. The customer is also obliged to keep a check on the general condition of the machine (externally visible defects or damage as well as changes in operating characteristics). Repairs may only be made by specially trained and qualified personnel, and must be made in conformity with the relevant maintenance and servicing structions. All the applicable safety regulations must be observed The following work methods are outside the scope of the prescribed end use of the machine. The manufacturer cannot be held liable if these structions are ignored: * Any use of the machine which deviates from, or exceeds, the applications described above, * Operating the machine when it is not in perfect working order and/or operating the machine without due regard to safety and possible hazards, observing all the instructions given in this operating manual * Failure to repair, before the machine is put into operation, any faults that, may put the safety of the machine operator at risk + Altering, bypassing or deactivating any equipment fitted to the machine to safeguard perfect functioning and unrestricted use of the machine and ensure active and passive safety. The operation of a machine may always involve unforeseeable risks, including * danger to life and limb of personnel, * damage to the machine and other assets of the company or user. The machine described in this manual is an installation for the manufacture, processing and use of potentially water-polluting substances within the meaning of the German Water Resources Act (Wasserhaushaltsgesetz) This means that the requirements of the Water Resources Act or similar legislation in the user's country must be observed whenever the machine, or any parts thereof, are operated, shut down or dismantled, Detailed information will be found in the applicable national or local regulations governing the use of potentially water-polluting substances. 2910 linear * iTNC 530 * mhb 2 03 BDECKEL MAIC» Warning notes, symbols used Gereteried Be sure to observe all warnings, labels and notes. Pass all warnings and safety instructions on to all persons doing any work on the machine. Note Special instructions on handling the machine, i machine reactions and the economic use of the machine Warning Special instructions on safety aspects and the F prevention of damage. f Danger Special instructions forthe prevention of accidents. A A or severe damage. & ‘Take particular care to avoid the risk of an accident. Caution — Warning of dangerously high electric voltage high voltage which may cause danger to life and limb, Take particular care to avoid any risk of accidents caused by electric current. Press key Key or key sequence, identified by symbol(s), to be cr 6 pressed for the operating step concerned | o4 2910 linear * (TNC 530 * mhb 2 Warning notes, symbols used Danger caused by high- intensity magnetic fields A 2910 linear # iTNC 530 * mhb 2 0-5 Your machine is equipped with linear synchronous motors. This requires the strict observance of the © ® © following general safety rules: The secondary parts of linear synchronous motors produce a high-intensity static magnetic field Persons with pacemakers, metal implants as well as pregnant women must not stay in the immediate vicinity (less than 0.5 m/2 ft) of such secondary parts. Moreover, secondary parts must not be moved into the vicinity of objects which might be impaired, damaged or destroyed by magnetic fields (e.g. watches, data carriers, credit cards etc.) Due to the marked effect of such secondary parts on ferromagnetic objects (including the primary parts and other secondary parts) whose movements may cause injuries or damage, the following safety measures shall be observed Always wear protective gloves when moving or installing secondary parts. Do not move, handle or install secondary parts unless they are fitted with the protective transport and assembly barrier guard. Do not remove such transport and assembly barrier guard before preassembly of the parts, i.e before the parts have been safely fitted to the machine. Without the safety barrier guard, such secondary parts may — unless firmly attached — be subject to uncontrolled movements or inadvertently attract ferromagnetic materials, such a iron, nickel, cobalt or the like. Do not move the secondary parts using a crane, since this may cause uncontrolled movements of the parts and thus lead to damage thereof. Linear motors may only be transported, installed and operated by specially trained, qualified personnel ‘All persons working with or on the equipment must be specially instructed at regular intervals, at least once a year DECKEL MARIO Overview of Operator's Manual geet Safety recom- This booklet contains important information on how you can mendations prevent added risks of personal injury or damage to the machine Accident by using our product solely within the scope of its prescribed prevention end use. Technical 1. Machine specification Fundamentals 2. Technical data Machine 3. Operation Manual 1 4, Tool magazine 5. Maintenance, lubrication 6. Transport 7. Installation 8. Connection, assembly Attachments & Accessories Machine Manual 2 1. Spiral-type swarf conveyor 2. Scraper-type swarf conveyor (option) 3. SPB 3-600 Lubricoolant cleaning system 4. Lubricoolant supply through tool 5. Flush cleaning unit 6. Flush gun 7. Cooling air 8. Inspection window 9. Oil mist separator 10. Active cooling unit 11, Control cabinet cooling unit 12. NC table 13. BLUM-MIN' tool scanner 14, MP 10 measuring probe TS 632 measuring probe 16. Portable control +6 2910 linear iTNC 530 ® mhb 2 DECC. MARES Gercteried GmbH Contents 1. Spiral-type Function 12 swarf conveyor — Technical data 1-2 Operation 13 Maintenance 15 2. Scraper-type. Function 22 swarf conveyor — Technical data 2-4 (option) Operation 25 Maintenance 27 Transport 2-12 Installation 2-12 Connection 2-13 3. SPB 3-600 Function 32 Lubricoolant Technical data 34 cleaning system Operation 3-5 Maintenance 3-6 Transport 3-12 Installation 3-12 Assembly 3-13 Connection 3-14 4. Lubricoolant Function supply through Technical data tool Operation Maintenance Transport Assembly Connection 5. Flush cleaning Function unit Technical data Operation 6. Flush gun Function Technical data Operation Connection 2910 linear # iTNC 530 * mh 2 DECKEL MAHO Contents Geretetied Gmbu 7. Cooling air Function 7-2 Technical data 72 Operation 72 8. Inspection Function 82 dow Technical data 82 Operation 83 Maintenance 83 9. Oil mist Function 9.2 separator Technical data 93 Operation 93 Maintenance 4 Installation 39 10. Active Function cooling unit Technical data 10:3 Operation 10-4 Maintenance 0-4 Installation 10-4 Connection 10-5 11. Control Function 11.2 cabinet cooling Technical data 113 unit Operation 113 Maintenance 13 12. NC table Function 122 Technical data 123 Operation 125 Maintenance 29 Transport 12-11 Assembly 12-12 Connection 12-12 2910 linear ® iTNC 530 * mhb 2 ( Contents 13. BLUM- MICRO Tool scanner 14, MP 10 Measuring probe 15. TS 632 Measuring probe 16. Portable control Function Technical data Operation - Calibration Operation - Too! breakage detector/tool scanning Operation ~ Reset tool scanner Maintenance Function Technical data Operation ~ Calibration and alignment Operation - Measuring procedure Maintenance Function Technical data Operation ~ Calibration and alignment Operation - Measuring procedure Maintenance Function Operation Connection 2910 linear # iTNC 530 * mhb 2 14-2 14:3 143 145 14-7 15-2 15-3 15-3 15-5 15-7 16-2 16-3 16-7 1 Spiral-type swarf conveyor 1. Spiral-type swarf conveyor Gere CaS Function Main components 1 Drive unit 2 Spiral 3. Discharge opening Application The swarf conveyor moves the cutting chips and swarf to the discharge point where they can be collected. The swarf conveyor is suitable for handling © metal chips, © plastics chips. When materials producing long cutting chips are machined, suitable measures have to be taken to break the chips. Description The cutting chips, swarf and lubricoolant flow from the working area into the discharge tube of the swarf conveyor where the rotary movement of the spiral moves them to the discharge opening and into the baskets of the swarf tray. (QWRizz2MM@ Technical data Data sheet Discharge height mm 380 (in) (15) 1-2 2910 linear iTNC 530 # mhb 2 ChE: MAHG caow 1. Spiral-type swarf conveyor Operation PF Obstructions resulting from intermittent £ operation. ntermittent operation of the swarf conveyor may lead to obstructions. DECKEL MAHO will not assume any liability for possibly resulting damage + To ensure continuous swarf removal, its essential that the swarf conveyor is constantly running while automatic machining is in progress. Only continuous operation of the ( swarf conveyor will ensure that the conveyor constantly discharges the chips and swarf. i Operation of the swarf conveyor is only possible when the door to the working area is closed The swarf conveyor is switched off when the door to the working area is opened, and switched on again when the door is closed. a Caution - avoid the risk of an accident: Be careful not to get trapped between machine parts and the rotating spiral. ( This may cause severe injuries on your hands. * Always switch the swarf conveyor off before starting any maintenance work on the lubricoolant unit. 2910 linear # iTNC 530 ® mhb 2 13 1. Spiral-type swarf conveyor DESKEL WVAHG To switch on/off Forward/reverse Continuous operation Run-on Intermittent operation To clear obstructions 14 1. Change over screen assignment: Press “Screen assignment" key. @i|" 2. Press function keys "OPTIONS FCT" and ELECT CHIP CONVEYOR ON/OFF" 3. Switch the swarf conveyor on/off using the function key "CHIP CONVEYOR ON/OFF" 4. Switch on forward/reverse rotation using the 1286 function key "CHIP CONVEYOR FORWARD/REVERSE" 5. Switch continuous operation on/off using the IESE function key "CHIP CONVEYOR CONTINUE" The time of "CHIP CONVEYOR TIME RUN’ can) JESSIE, be altered in the user parameters (see Supplement to Control Unit Manual). 7. Switch the run-on function of the conveyor on/off using the function key "CHIP CONVEYOR TIME RUN" The "CHIP CONVEYOR RUNNING TIME* canbe = JL altered in the user parameters (see Supplement ty Control Unit Manual). 9. The "CHIP CONVEYOR REST TIME" can be IIE altered in user the parameters (see Suaplement to Control Unit Manual) 10. Switch intermittent uperatiun un/offusiny the JEJE function key "CHIP CONVEYOR INTERVAL". « In the event of an obstruction caused by an excessive volume of cutting chips, switch back and forth several times between forward and reverse. 2910 linear ® iTNC 530 * mhb 2 DECKEL MAE + ied Gmbh 1. Spiral-type swarf conveyor (ares Maintenance Maintenance he schedule © 50 1 200 ARPA 400 $A 2000 “r2 Regular Point of intervention What to do maintenance 50 1 Swarf conveyor Clean thoroughly ( 50 2 Discharge tube Clean thoroughly Maintenance cause Point of intervention What to-do work as +12 | 1. Swart conveyor Clean thoroughly required +12 | 2. Discharge tube Clean thoroughly 1 Gross contamination and/or sludge deposits *2. When grey-cast iron is machined; cleaning intervals depend on the volume of cutting chips handled. 2910 linear * TNC 530 © mhb 2 15 1. Spiral-type swarf conveyor (5g Transport - not specified [§=E installation - not specified (72REME Assembly - not specified (SESS Connection — not specified 1-6 2910 linear # iTNC 530 * mhb 2 2 Scraper-type swarf conveyor (option) 2. Scraper-type swarf conveyor (option) DEKE hAHO (=a Function Main components Application 22 Discharge point Float switch Lubricoolant pumps Trough Scraper band Multiple-disk filter (underneath cover) Lubricoolant tank (option), net shown Noununa The swarf conveyor moves the swarf and chips to the gischarge point (1) where they can be collected An additional lubricoolant tank (option) serves to increase the volume of lubricoolant. The unit is suitable for handling - ‘+ metal chips, ‘short chips, needle chips, cast-iron chips. Not permissible is the use of the conveyor for ~ * plastics chips, # long cutting chips, When materials producing long cutting chips (100 mmn/4 in or longer) are machined, suitable measures have to be taken to break the chips, or else a slat-band chain conveyor has to be used. 2910 linear # iTNC 530 ® mhb 2 REGCKEIL MAHC . sail gow 2. Scraper-type swarf conveyor (option) Description Swarf, chips and the lubricoolant flow from the discharge opening of spiral-type swarf conveyor into the trough (4) of the scraper-type swarf conveyor. The lubricoolant is filtered by a multiple. disk filter (6) and fed by the lubricoolant pumps (3) to tool cooling, flush cleaning, to the flush gun and the SPB 3-600 lubricoolant cleaning unit (option). Scrapers (5) move the swarf and chips continuously from the bottom of the swarf conveyor to the discharge point (1). The multiple-disk filter (6) is continually cleaned by brush wipers attached to the conveyor chain, A fioat switch (2) on the swarf conveyor monitors the lubricoolant level in the tank 2910 linear # iTNC 530 ® mhb 2 2-3 2. Scraper-type swarf conveyor (option) Teraie DECKER MiAmIcD (QWizzzl_ Technical data Data sheet Lubricoolant volume Total system wart conveyor Lubricoolant tank Swart conveyor Dimensions Discharge height Liquid level, upper index mark Liquid level, lower index mark Chip length Delivery volume, tool cooling Delivery volume, flush cleaning Delivery volume, flush gun Running speed Multiple-disk filter fineness 24 approx. | 810 (imp/us (180/215) gal) approx \ 260 (imprus (60/70) gal) approx 550 (imprus (120/145) gal) LxWxH | mm — |3,130x 1,100x 1,550 (in) (123 x 43 x61) mm 1,250 (in) (50) max mm 205 (in) (8.0) min. mm 135 (in) (63) max. mm 100 (in) (4) Vin 50 (imp/us a3) gal) Yimin 90 (impius (20/24) gal) Vin 50 (imp/US (11/13) gal) mimin 20 (fpm) 6.5) mm os (in) (0.02) 2910 linear iTNC 530 ¢ mhb 2 2. Scraper-type swarf conveyor (option) Operation Obstructions resulting from intermittent operatic Intermittent operation of the swarf conveyor may lead to obstructions. DECKEL MAHO will not assume any liability for possibly resulting damage. * To ensure continuous swarf removal, itis essential that the swart conveyor is constantly running while automatic machining is in progress. Only continuous operation of the swarf conveyor will ensure that the brush wipers constantly clean the multiple-disk filter and discharge the chips and swarf Operation of the swarf conveyor is only possible when the door to the working area is closed. The swarf conveyor is switched off when the door to the working area is opened, and switched on again when the door is closed Caution ~ avoid the risk of an accident: Be careful not to get trapped between machine parts and the running chain! This may cause severe injuries on your hands. * Always switch the swarf conveyor off before starting any maintenance work on the lubricoolant unit, * Keep your hands off the conveyor chain and the discharge opening while the swarf conveyor is running * Do not remove the covers while the conveyor is in operation 2910 linear # iTNC 530 * mhb 2 25 DECKER MAE 2. Scraper-type swarf conveyor (option) To switch on/off 1. Change over screen assignment: Press "Screen assignment” key. 2. Press function keys "OPTIONS FCT" and "SELECT CHIP CONVEYOR ON/OFF" 3. Switch the swarf conveyor on/off using the IESE function key "CHIP CONVEYOR ON/OFF" Forward/reverse 4. Switch on forward/reverse rotation using the SLE function key "CHIP CONVEYOR FORWARD/REVERSE* ( Continuous 5. Switch continuous operation on/off using the = ILE ° operation function key “CHIP CONVEYOR CONTINUE" Run-on The time of “CHIP CONVEYCR TIME RUN" can 83] be altered in the user parameters (see Supplement to Control Unit Manual) 7. Switch the run-on function of the cunveyur IESE on/off using the function key "CHIP CONVEYOR TIME RUN* Intermittent 3. The "CHIP CONVEYOR RUNNING TIME" canbe JOE operation altered in the user parameters (see Sugalement to Control Unit Manual). 3. The "CHIP CONVEYOR REST TIME" can be altered in user the parameters (see Sujglement ty Cantrol Unit Manual). 19, Switch intermittent operation on/off using the function key *CHIP CONVEYOR INTERVAL". To clear In the event uf an ubstructiun caused by an obstructions excessive volume of cutting chips, switch back and forth several times between forward and reverse, 26 2910 linear * iTNC 530 ® mhb 2 DECKEL MAHIC 2. Scraper-type swarf conveyor (option) Maintenance schedule Maintenance Operational failure, damage to equipment due to neglected maintenance! * Observe the maintenance instructions of the equipment manufacturer. Operational failure, damage to equipment due to the use of unsuitable lubricoolant! Comply with the instructions on lubricoolant in Machine Manual 1 Always clean the swarf conveyor and the lubricoolant tank when changing the lubricoolant, 200 ————— t 1000 2000 “re 2910 linear # iTNC 530 * mhb 2 27 2. Scraper-type swarf conveyor (option) DECKEL MAHI Grretried Omen Regular maintenance work Maintenance work as required 28 200 200 200 200 200 cause “12 “2 Point of intervention 1/2 Swart conveyor/lubricoolant tank (option), not shown 3/2 Swart conveyor/lubricoolant tank (option), not shown 3/2 Swart conveyor/ubricoolant tank (option), not shown 4 Swarf conveyor 5 Swarf conveyor 6 Swart conveyor 7 Safety flap 8 Conveyor chain Point of intervention 3. Swarf conveyor 2. Lubricoolant tank (option), not shown What to do Check the lubricoolant level on the liquid level indicator, replenish if necessary. Check the condition of the emulsion, change the lubricoolant if necessary Check the tanks for contamination and sludge deposits, clean thoroughly if necessary Check the multiple-disk filter for contamination, remove and dean if necessary Check the pump ports and fittings for leakage Check the brush wipers for contamination and wear, remove and clean or replace them if necessary. Check the safety flap for proper function, clean if necessary Check the tension of the conveyor chain, re-tension if necessary. What to do Clean thoroughly Clean thoroughly 71. Gross contamination and/or sludge deposits *2_ When grey-cast iron is machined; cleaning intervals depend on the volume of cutting chips handled 2910 linear ® iTNC 530 ® mhb 2 DECKEL 2. Scraper-type swarf conveyor (option) Check 1. Check that lubricoolant does not fall below the lubricoolant minimum index mark (1) level, replenish lubricoolant 2. Fill the tank up to the upper index mark (1) of the level indicator. ‘Add diluted lubricoolant because the concentration tends to gradually increase due to evaporation. To fill tanks for Warning - dry running of the pumps may initial start-up __cause damage to the mechanical seals! or after long standstill * Pour lubricoolant into pumps before initial start- up or restarting the unit after iong periods of PF standstl 1. Fill the lubricoolant tank(s) with lubricoolant. 2. Open the filler neck (3) on the lubricoolant pumps. 3. Pour lubricoolant into the pumps through the filler neck (3) 4. Close the filler necks. 5. Start the lubricoolant pumps. If the pumps fail to deliver lubricoolant after approx. 10 minutes, stop the pumps and repeat items (2) to (4) above. Toclean system 1. Turn off the master switch and secure the Pp o switch in off position. 2. Suck off the Jubricoolant and dispose of it in compliance with pollution control legislation, 2910 linear * TNC 530 * mhb 2 29 DECKEL MAHE 2. Scraper-type swarf conveyor (option) reer can Pull out swarf conveyor Clean multiple- disk filter Clean swarf conveyor Clean/replace brush wipers Clean, replace 240 Pull out the swarf conveyor sideways from under the machine on the discharge side. Q Remove the cover (1). Open the multiple-disk filter: Remove the upper countersunk screw MS (metric thread, 5 mm dia) and the socket-head screws MS on the face sides of the multiple-disk filter and open the two-piece cover (2) of the filter. Clean the multiple-disk filter (2). tiple-disk filter (2). Close the mi Clean the swarf conveyor thoroughly, rinse it using a suitable system cleaner and remove the cleaner completely after rinsing. Push the swarf conveyor back underneath the machine. Turn off the master switch and secure the switch in off position Back off and remove the lock nut M8 (4) on both sides. Remove the hex head bolt M8 x 25 on both sides. Remove and clean the brush wiper (2) or replace if worn, 2910 linear # iTNC 530 ® mhb 2 RECKEL MAG 2. Scraper-type swarf conveyor (option) Reassemble parts F To re-tension conveyor chain 5, Attach the brush wiper (2) loosely, screwing in the hex head bolt M8 x 25 (2) finger-tight. 6, Back off the hex head bolt (1) about 1/ and hold it in this position, 7. Fit the lock nut M8 (4) and tighten it firmly. Do not lock the brush wiper (2) against the conveyor chain by tightening the hex head bolt (1) firmly. The brush wiper (2) must still be movable in the oblong holes. The lateral play (3) of the brush wiper (2) must not exceed 2 mm (0.08 in). Operational failure, damage to brush wiper if the wiper is not correctly installed! © Make sure the brush wiper is mounted in the correct position! 1. Turn off the master switch and secure the ~” switch in off position 2. Back off, but do not remove, the mounting screws on the driver casing (1) on both sides. 3. Back off the lock nuts of the tensioning screws on both sides 4. Turn the tensioning screws uniformly clockwise on both sides until the amount of slackness of the chain is approx. 10 mm (3/8 in) ‘Avoid canting the driver casing (1). Adjust the tensioning screws uniformly step by step on both sides, 5. Retighten the tensioning screws. 6. Retighten the lock nuts of the tensioning screws. 7. Retighten the mounting screws on the driver casing (1). 2910 linear # TNC 530 * mhb 2 an 2. Scraper-type swarf conveyor (option) BECKEL MAH (SMP Transport Attach 4 ring bolts M12 (metric thread, 12 mm dia) to the 4 lugs (1) provided for this purpose. 2. Use suitable hoisting gear to lift the swarf conveyor. 3. Put the swarf conveyor down along the right- hand side of the machine with the discharge opening pointing forward or the rear, a5 required (see Machine Manual 1, Chapter "Technical data" under the heading “installation diagram"). (=F installation 1. Push the scraper-type conveyor underneath the machine (see Machine Manual 1, Chapter "Technical data" under the heading “Installation diagram"). (WINER Assembly — not specified 2910 linear ® iTNC 530 * mhb 2 DREGE MARC 2. Scraper-type swarf conveyor (option) (GEASS Conne: Lubricoolant 1. Connect the three hose lines leading upwards connection, to the working area. machines with Watch for the identification markings on the external cooling fittings 403 (flush cleaning) to pump (1) 404 (flush gun) to pump (3) 407 (tool cooling) to pump (2) Lubricoolant Connection of the SPB 3-600 lubricoolant connection, cleaning unit (option) machines with Connect the lubricoolant supply line to the lubricoolant lubricooiant cleaning unit. supply through atch for the identification markings on the tool fittings: 409 (lubricoolant cleaning unit) to pump (1) 2. Connect the two hose lines leading upwards to the working area’ Watch for the identification markings on the fittings: 403 (flush cleaning) to pump (2) 404 (flush gun) to pump (3) Electrical 1. Connect the swarf conveyor: connection, Insert the plug B2-01-X 21 into the socket machines with B2-01-X 21 on the outside of the control external cooling cabinet, at the bottom, lower left. Lead the cable to the swarf conveyor and insert the plug into the receptacle of the swarf conveyor. 2910 linear # iTNC 530 ® mhb 2 213 2. Scraper-type swarf conveyor (option) DECKEL MAHO Electrical connection, machines with lubricoolant supply through tool F 214 Connect the swarf conveyor and the SPB 3-600 lubriccolant cleaning unit (option): Connect the signal line for pumping over between the swarf conveyor and the lubricoolant cleaning unit to the swarf conveyor and the lubricoolant cleaning unit. Operational failure, damage to equipment due to wrong connections! + Watch for identification markings and consult the fluidics diagram! 2910 linear # iTNC 530 © mhb 2 3 SPB 3-600 Lubricoolant cleaning unit 3. SPB 3-600 Lubricoolant cleaning unit BECKEL MAM C= Function Main components Application 32 Transport belt Web advance switch End-of-web switch Web feed roll Belt drive motor Float switch, lubricoolant level Lubricoolant pumps Contro! cabinet Sludge box © Lubricoolant tank Bemis anwn Lubricoolant supply through the cutting tool requires a high degree of purity of the lubricoolant. The lubricoolant cleaning unit serves to clean the lubricoolant of even very fine particles of solid matter, such as metal or dust particles, which are not filtered out and removed by the screens and filters of the upstream swarf disposal equipment (eg. the swarf conveyor) 2910 linear # iTNC 530 * mhb 2 DECKEL MAC 3. SPB 3-600 Lubricoolant cleaning unit Description The lubricoolant, which is prefittered in an upstream swart disposal unit (e.g. swarf conveyor), flows via the intake distributor of the lubricoolant cleaning unit into the filtering trough formed by a filter web resting on an transport belt. The filter web retains the particles of solid matter and the filtered lubricoolant flows downwards into the lubricoolant tank. The solid particles form a filter cake on the web which has an additional fine filtration effect The more solid particles are separated from the ubricoolant, the less fluid will pass through the filter cake. As a result, the liquid level in the ( filtering trough rises until the web advance switch {float switch) starts the drive motor of the transport belt. The latter moves the used-up filter web into the sludge box and pulls unused web from the web feed roll into the filtering trough. This make the liquid level in the trough go down until the web advance switch turns off the belt drive motor. The lubricoolant pumps feed the filtered ubricoolant from the iubricoolant tank to flush cleaning, too! cooling and the lubricoolant supply through the cutting tool 2910 linear # TNC 530 * mhb 2 33 3. SPB 3-600 Lubricoolant cleaning unit DECKEL MAH® al data (27MM Tech Data sheet Dimensions Lubricoolant cooling unit Tank capacities Total system Swarf conveyor Lubricoolant cleaning unit Pump capacities Delivery volume, flush cleaning Pressure, flush cleaning Delivery volume, tool cooling Pressure, tool cooling Delivery volume, flush gun Pressure, flush gun Delivery volume, lubricoolant supply through tool Pressure, lubricoolant supply through too! 34 LxWxH approx, approx, approx. mm (in) (imp/US gal) ' (Imp/Us, gal | (imp/us gal) Vmin (imp/us gal) bar (psig) Vin (imprus gal) bar psig Vein (imp/us gal) bar (psig) Vin (Imp/US gal) bar (psig) 1,820 x 850 x 1,330 (71.6 x 33.5 x 52.4) 1,000 (220/265) 260 (57/69) 600 (132/159) 50 (11/13) 42 (60) 40 (88/106) 2 (28) 25 (5.5/6.6) 46 (65) 30 (6.5/8) 16 (227) 2910 linear # iTNC 530 ® mhb 2 _ 3. SPB 3-600 Lubricoolant cleaning unit (Gzzz Filter Filter surface | Web feed roll Min. width min Max. permissible width max Diameter max. Operation Please refer to the manufacturer's instructions on the operation of the unit! Avoid spill-over of the system! * Do not start the upstream swarf disposal equipment (e. g. swart conveyor) before starting the lubricoolant cleaning unit. Caution - avoid the risk of an accident: Be careful not to get trapped between the drive chain and the sprockets and between the drive belt and the belt drum! This may lead to severe injuries on your hands. * Do not remove the chain case while the lubricoolant cleaning unit is running 2910 linear # iTNC 530 ® mhb 2 m2 (sq ft) (in) 07 (7.5) 700 (27.6) 1,000 (39.4) 250 (9.8) 35 3. SPB 3-600 Lubricoolant cleaning unit DECKEL MAC To switch on To switch off 36 1. Switch the machine and control unit on: Tum the master switch (Q1) on the control cabinet of the machine to "1" 1, Turn the master switch (Q1) on the control cabinet of the machine to "0" Maintenance Operational failure, damage to equipment due to neglected maintenance! © Observe the maintenance instructions of the equipment manufacturer. Operational failure, damage to equipment due to the use of unsuitable lubricoolant! © Comply with the instructions on lubricoolant in Machine Manual 1 Always clean the upstream swarf disposal equipment (e. g. swarf conveyor) as well as the lubricoolant tank, the filter trough and the sludge tank of the lubricoolant cleaning unit when changing the lubricoolant. 2910 linear # iTNC 530 © mhb 2 DECKER NUANCE ied Gmb 3. SPB 3-600 Lubricoolant cleaning unit Maintenance schedule Regular maintenance work 2910 linear # iTNC 530 ® mhb 2 O ooo 50 50 200 200 Point of intervention 4 Filter web Sludge tank 3. Web advance switch 2. Lubricoolant tank 5. Lubricoolant tank 5. Lubricoolant tank 6 Drive chain of belt drum 6 Drive chain of belt drum What to do Check, fit new roll if necessary. Empty out Check for proper function, clean if necessary. ‘Check the lubricoolant level on the liquid level indicator, replenish if necessary. Check the condition of the emulsion, change the lubricoolant if necessary. Check for contamination and sludge deposits, clean thoroughly if necessary. Check the chain tension, re-tension the chain if necessary. Check the chain lubricoolant, lubricate if necessary. 37 3. SPB 3-600 Lubricoolant cleaning unit Maintenance work as required To fill tank for initial start-up or after long standstill Check lubricoolant level, replenish lubricoolant To empty out sludge box 38 Cause Point of intervention What to do 4 7 End-of-web switch Check the switching point. *1 when a new web roll is mounted Quantity of lubricoolant required to fill the unit up to the float switch *Max. Iubricoolant level” approx. 600 | (132 Imp/160 US gal) For quantities required to fill the entire system including upstream swarf disposal equipment (e. g swarf conveyor) see Machine Manual 1, Chapter “Technical data”) 1. Check whether the lubricoolant has fallen below the "min." mark when the float switch is tripped. 2, fill the tank until the float switch on the lubricoolant tank is closed ‘Add diluted lubricoolant because the concentration tends to gradually increase due to evaporation Avoid spill-over caused by checking the lubricoolant level too early! * Do not check the lubricoolant level and pour in lubricoolant before all the liquid has flown back to the lubricoolant tank. 1. Use a knife or scissors to cut off the used filter web, 2. Dispose of the used web with the filter cake in compliance with applicable pollution contro! legislation. 2910 linear # iTNC 530 ® mhb 2 To clean web 1. Turn off the master switch and secure the p* advance switch switch in off position 2. Clean the web advance switch (1). To check web 3. Switch the lubricoolant cleaning unit on. advance switch Caution — avoid the risk of an accident: Be careful not to get trapped between the drive chain and the sprockets and between the drive belt and the belt drum! This may lead to severe injuries on your hands. ‘© Keep your fingers off when the unit is running 4, Watch for the switching point of web advance, Readjust the potentiometer of the web advance switch if necessary i The drive belt must be switched on when the lubricoolant level has risen to approx. 10 cm (4 in) below the upper rim of the filter trough. 10mm Belt drum drive 1. Turn off the master switch and secure the ~ chain switch in off position, 2910 linear ® iTNC 530 ¢ mh 2 3-9 cI mee 3. SPB 3-600 Lubricoolant cleaning unit nineteen To check chain 2. Measure the slackness of the belt drum drive tension chain Max. amount of slackness: 2 mm (0.08 in) Vv, ye [ia Tore-tension 3. Back off the mounting screws (1) of the drum chain bearings. 4, Adjust the drum to reduce the chain slackness. 5. Retighten the mounting screws. To lubricate 6. Check the chain lubrication, relubricate if chain necessary. To mount filter 1. Turn off the master switch and secure the web feed roll switch in off position. 2, Insert the filter web feed roll (1) with support roll (2) into the holder. 3. Pull the filter web (5) around the guide roll (6) and all along the drive belt (4) until the front end (3) of the web extends into the sludge box. 3-10 2910 linear * iTNC 530 ® mhb 2 3. SPB 3-600 Lubricoolant cleaning unit End of web 1, Tur off the master switch and secure the switch in off position. To check end-of- 2. Check the switching point of the end-of-web web switch switch, The switch must be tripped when the web thickness on the feed roll has decreased to. approx. 3 mm (0.12 in), To change feed 3. Remove the support roll (2) with the roll remainder of the used web from the holder. 4, Insert a new feed roll (1) with support roll (2) into the holder. 5. Pull the filter web (5) around the guide roll (6) and all along the drive belt (4) until the front end (3) of the web extends into the sludge box. 2910 linear # iTNC 530 ¢ mhb 2 ” 3. SPB 3-600 Lubricoolant cleaning unit BECKS ARG (5PM Transport To lift unit 1. Attach suitable hoisting gear to the four lifting eyes at the four upper comers of the lubricoalant cleaning unit. A Caution - avoid the risk of an accident that may be caused by the lubricoolant cleaning unit tipping over or falling down! * Drain the lubricoolant tank completely befure moving the unit. © Never walk under a suspended load ~ keep at a safe distance ( (§2=H installation Installation 1. Place the lubricoolant unit adjacent to the diagram machine as shown in the installation diagram (see Machine Manual 1, Chapter "Technical data") 312 2910 linear # iTNC 530 ® mhb 2 3. SPB 3-600 Lubricoolant cleaning unit (Ze 2EE Assembly 1. Remove the shipping fixtures and locks which are conspicuously marked, 2. Place the sludge box underneath the discharge opening 2910 linear # iTNC 530 * mhb 2 3-13 i | i i | | 3. SPB 3-600 Lubricoolant cleaning unit (8EZ2=S3H Connection To connect 1. Connect the return line from the scraper-type lubricoolant swarf conveyor. lines Watch for the identification markings on the fittings Connect the hose line 409 (return line from swarf conveyor) to the intake distributor fitting () 2. Connect the hose lines leading to the machine Watch for the identification markings on the fittings: Connect the hose line 410 (overflow to swarf conveyor) to fitting (2) Connect the hose line 407 (external cooling) to fitting (3) Connect the hose line 408 (/ubricoolant supply through tool) to fitting (4) 314 2910 linear * TNC 530 ¢ mhb 2 DEGIKEL Rf ce x ‘, + bi 3. SPB 3-600 Lubricoolant cleaning unit F Electrical connection A Operational failure, damage to equipment by wrong connections! © Watch for identification markings and consult the fluidics diagram! 3. Lead the two cables to the lubricoolant cleaning unit and insert the plugs 3X S2 and 5X S1 into the sockets on the control cabinet of the lubricoolant cleaning unit. Caution — avoid the risk of an accident caused by high voltage! * The machine must be electrically connected by @ qualified electrician Be sure to give priority to compliance with al applicable local standards, laws and regulations Operational failure, damage to equipment due to wrong or improper electrical connection! This may cause damage by short circuits and/or damage to electronic components. * Be sure to observe and follow the instructions in the electric wiring diagrams! 2910 linear # iTNC 530 © mhb 2 3-15 4 Lubricoolant supply through tool SCKEL MARIcD 2 Gmbn 4. Lubricoolant supply through tool Ce Function Main 1 23 4 components \ \ \ Upstream swarf disposal equipment and lubricoolant cleaning unit (diagrammatic view) including - Prefilter Microfilter Lubricoolant tank High-pressure pump Spindle with cutting tool designed for lubricoolant supply through tool wR wna Application Lubricoolant supply through the tool is used to feed the lubricoolant to a point as close as possible to the cutting edge. This ensures adequate lubrication of the cutting edge(s) and efficient heat dissipation even in cutting operations involving a high rate of stock removal. Description Swarf, chips and lubricoolant flow from the working area of the machine into the swarf disposal unit and the lubricoolant cleaning unit. In these units, the lubricoolant is passed through several filters (1, 2), where it is cleaned of chips, swarf and even very minute particles of solid matter, such as metal or dust particles, and is then collected in the lubricoolant tank (3) The high-pressure pump (4) on the lubricoolant tank feeds the cleaned lubricoolant via a rotating union and a bore through the tool (5) to the cutting edge. A flow monitor in the high-pressure pump line monitors the minimum rate of flow and ‘riggers off an alarm in the event of a malfunction 42 2910 linear * iTNC 530 * mhb 2 ECE. MABEC 4. Lubricoolant supply through tool (Qiizz2M Technical data Data sheet Tool design Pump delivery for lubricoalant supply through tool Delivery volume Ymin (imp/US gal) Pressure bar (psig) For details, such as quantity of lubricant or filter fineness see "Technical data" of the swarf disposal and lubricoulant cleaning equioment installed on your machine. Tools with a central bare through the tool shank Operational failure, damage to equipment due to the use of unsuitable tools! * Only use tools adequately dimensioned for the high lubricoolant pressure, the desired cutting speed and stack removal rate * Avoid damage to the cutter spindle. * Only use tool shanks provided with a central through bore. 2910 linear # iTNC 530 © mhb 2 30 (6.5/8) 16 (227) 43 SCKEL MANG 4. Lubricoolant supply through tool Tr eeretsries omen (3EEZZZZ2M Operation Entry in tool list Each tool to be used for lubricoolant supply through the cutting tool must be marked in the too! list. 1. Call the tool list (see Control Unit Manual). 2. Identify the tool suitable for lubricoolant supply through the tool Enter the appropriate code in column “PLC Bit 1 % 00000010 Lubricoolant supply through the tool is enabled ( for the tools) concerned. 3. Identify the tool not suitable for lubricoolant supply through the tool. Enter the appropriate code in column “PLC Bit 1 = "0" % 00000090 Lubricoolant supply through tool is inhibited for the tool(s) concerned. To switch on/off Press “Lubricoolant supply through tool ON/OFF" manually Program The control unit offers several commands (M commands functions) for switching the lubricoolant supply on and off, You can choose between working with lubricoolant supply through the tool and using the standard lubricooiant system of the machine. To switch on Command "M07" ™o7 lubricoolant supply through —* Lubricoolant supply through tool ON tool 44 2910 linear * TNC 530 ¢ mhb 2 UG 28. IMAG 4. Lubricoolant supply through tool To switch off lubricoolant supply through tool Standard lubricoolant system To switch off lubricoolant 2910 linear * TNC 530 © mhb 2 45 Lubricuulant is only supplied while the suindle is running. Since the machine does not wait until the lubricoolant actually arrives at the tool tip or spray nozzles, the starting command (MQ7 or M08) should preferably be programmed in the preceding positioning block, or else a dwell should be programmed The command “TOOL CALL" suppresses lubricoolant supply through the tool. The spindle and cutting tool are released by compressed air for automatic tool change. Command "MOS" mos ‘Standard lubricoolant system ON | Command "M09" switches the lubricuolant unit off: Mog ‘* Lubricavlant supply through tool OFF ‘* Standard lubricoclant supply OFF Maintenance Operational failure, damage to equipment due to neglected maintenance. © Observe and follow the maintenance instructions given for the swarf disposal and lubricoolant cleaning equipment supplied with your machine i Operational failure, damage to equipment due to the use of unsuitable lubricoolant | ‘© Comply with the instructions on lubricoolant in Machine Manual 1 4. Lubricoolant supply through tool DE See ene i Always replace the rotating union far lubricoolant supply to the tool when changing the spindle. Transport i Observe and follow the instructions on transport given for the swart disposal and lubricoolant cleaning equipment supplied with your machine (§==E installation - not specified (72S Assembly i Observe and follow the instructions on assembly given for the swarf disposal and lubricoolant cleaning equipment supplied with your machine ($EZ=S3—9 Connection i Observe and follow the instructions on connection given for the swarf disposal and lubricoolant cleaning equipment supplied with your machine. 46 2910 linear * iTNC 530 ® mhb 2 | | | \ | | | | i t i | | | { } | Flush cleaning unit + DESCKEL MAH 5. Flush cleaning unit eerie ea Cia Function Main 1 components 3 Lubricoolant nozzles 2. Lubricoolant distributor line Application Flush cleaning serves to flush off the cutting chips and swarf from the working area and to flush- clean the swart disposal and lubricooiant cleaning equipment supplied with your machine. 2Qiizz7ae Refer to the technical data of the lubricoolant cleaning unit supplied with your machine. (322277 Operation To switch on/off 1. Chanye aver screen assignment: Press "Screen assignment” key. er 2. Press function keys "PLC" and "MACHINE" IMIDE 3. Switch the flush cleaning function on/off using = JIE the function key "RINSING ON/OFF" Unless * Lubricoolant supply with door unlocked" has been sgectfically activated, flush cleaning will automatically be switched off when the door to the working area is unlocked. 5-2 2910 linear * TNC 530 © mhb 2 DECKEL MAH 5. Flush cleaning unit (5 “Transport - not specified (6H Installation - not specified ({2INE Assembly - not specified (8EZ==S39H_ Connection - not specified 2910 linear # iTNC 530 # mhb 2 Maintenance - not specified 53 Flush gun DIECHEL Nis 6. Flush gun Gereteried Enbe! ( a a Function Main components 1 Hand lever 2 Valve 3 Lubricoolant line 4 Lubricoolant nozzle Application The flush gun serves to clean the workpiece and the set-up station. (QW Technical data Refer to the technical data of the lubricoolant system provided on your machine. 62 2910 linear ® iTNC 530 # mhb 2 6. Flush gun Gazz To switch on/off, alternative 1 To switch on/off, alternative 2 5a = aa Operation 1. Change over screen assignment: Press “Screen assignment" key. 2. Call PLC range: Press function keys "PROGRAM + PLC* or "PLC" 3. Change over softkey strip. 4, Press function key "OPTIONS FCT" 5. Switch the flush gun on/off using the function key "SPRAYER ON/OFF" 1. Press *FCT" ey. 2. Switch the flush gun on/off using the function key "SPRAYER ON/OFF" Lubricoolant supply is not activated until after the door to the working area has been unlocked. Maintenance - not specified Transport — not specified Installation - not specified Assembly — not specified 2910 linear * TNC 530 ® mhb 2 DESIE or ILE wy IEE 6-3 DEGCKEL MAHO 6. Flush gun ata ( (SES Connection Connecting 1. Connect the flush gun to the fitting provided on point the side of the machine ded, at the lawer left. ( ( 6-4 2910 linear * TNC 530 ¢ mhb 2 / | Cooling air 7. Cooling air ECHEL MAM Cres Main components Application Description Data sheet Gazz Safety circuit 72 Cooling air nozzles Cooling air is used if dry machining is required for certain tools (e. g. carbide-tipped tools) or certain materials (e. g. graphite. Air nozzles (1) provided at the lower left of the spindle head produce a blast of cold air to cool the workpiece and the cutting tool Technical data Pressure at air nozzles bar (psig) Operation The cooling air supply is automatically shut off When the door to the working area is unlocked and switched on again when the door has been locked 55 (78) 2910 linear © iTNC 530 ¢ mhb 2 7. Cooling air To switch on/off manually, alternative 1 To switch on/off manually, alternative 2 To switch on/off manually, alternative 3 To switch on/off in program 1. Change over screen assignment Press “Screen assignment™ key. 2. Call PLC range Press function key "POSITION + PLC" or "PGM. + PLC" or "PLC* 3. Change over softkey strip. 4. Press function key "OPTIONS FCT" 5. Switch the cooling air on/off using the function key "M25 AIR COOLING" 1. Press "FCT" key. 2. Switch the cooling air on/off using the function key "M25 AIR COOLING" 1. Press function key "M", enter the desired command and start the function by pressing “Program start" ‘Command for cooling air ON: *M25* Command for cooling air off: “M03" Check the direction of the air stream If necessary, shut off the cooling air and adjust the air nozzles as required 1, Cooling air ON: Command "M25" 2. Cooling air OFF Command "M09" 2910 linear # iTNC 530 ® mhb 2 M25 mg 73 7. Cooling air (2) Maintenance — not specified (SE «Transport - not specified (§=2 Installation — not specified (72IRHE Assembly - not specified (8EZ=S3™ Connection - not specified 74 2910 linear © iTNC 530 © mhb 2 8 Inspection window 8. Inspection window DEGKEL Manca a Main components Application Description (iii Data sheet 82 Function Ct. 1. Rotating window 2 Electric cable The inspection window permits the close observation of the cutting process even if a large volume of lubricoolant is used. The rotating disk (1) of the inspection window, which is inserted into the window on the door to the working area, rotates at high speed and thus throws off splashed-on lubricoolant by centrifugal force to provide a clear view of the working area Technical data Window diameter (in) 215 (8.5) 2910 linear # iTNC 530 * mhb 2 DECKEL MAHO 8. Inspection window (312220 Operation 1. The window is switched on and off using the toggle switch (3) provided on the door to the working area Switch the inspection window on before starting the lubricoolant flow. (4G Maintenance Maintenance as —_ Use a commercia! bathroom cleaner to remove required lime deposits when the rotating disk (1) tends to become clouded Transport - not specified Installation - not specified (70273 Assembly — not specified [$EZ==SSM_ Connection - not specified 2910 linear * iTNC 530 « mhb 2 83 | 9 Oil mist separator 9. Oil mist separator DECKEL MANHG embn CSS Function Main components Application Description 9.2 Fan wheel Filters Discharge lines Siphons Suction line wen The oil mist separator provided on top of the machine enclosure serves to exhaust and extract noxious oil and emulsion vapours that may be set free when lubricoolant is used in machining operations. ‘A fan wheel (1) sucks off the contaminated air from the working area of the machine. The dirt and dust particles and the oil mist contained in the contaminated air precipitate on the webs and inserts of the filters (2). The condensed oil mist flows back to the lubricoolant unit through the discharge lines (3), 2910 linear * TNC 530 « mhb 2 DECKE!. 9. Oil mist separator (2fizz2M@ Technical data Data sheet Fan data Throughput Motor power Run-on time after switching off approx. Installation dimensions Mounting height of oil mist separator Height of celling to ensure proper min operation of unit (312222 Operation To switch on/off The oil mist separator is switched off automatically when - * the lubricoolant unit is switched on, * lubricoolant supply through the tool is started. The oil mist separator is switched off when the lubricoolant unit switched off. 2910 linear # ITNC 530 * mhb 2 mh 600 (cu ftvh) (21,200) kw 05 (hp) (0.7) min 1 m 23 (vin) (7/6) m 31 (fvin) (10/2) 93 . + DECKEL RAAH® 9. Oil mist separator eerste Gb (QQ Maintenance Cleaning The cleaning intervals of the four filters of the oil intervals mist separator depend on ~ # the frequency of use of the unit, * the degree of contamination of the cil mist processed. To gain experience, start off by checking the prefilter, intermediate filter, main filter and exhaust filter for contamination at least at monthly intervals Maintenance schedule 9-4 2910 linear * iTNC 530 ® mhb 2 DECKER WLC 9. Oil mist separator Regular a) Point of intervention What to do maintenance 299 1 Prefilter Check for contamination, wash out if work necessary 200 2 Intermediate filter Same 200 3. Main fiter same 200 4 Exhaust filter Check for contamination, replace if necessary 200 5 Suction line Check for leaks 200 6 Discharge lines same 200 7 Seals at discharge fittings Same 200 8 Siphons Check for clogging, clean if necessary 200 9. Fan wheel Check for contamination, clean if necessary 200 10 Exhaust opening Same Maintenance Cause Point of intervention What to do work as 4 11 Housing Clean inside and outside required 2 9 Fan motor bearings Replace *1_ In the event of dirt and dust deposits *2. When service life of greased-for-life bearing has expired (approx. 30,000 hours of operation) To clean, 1. Turn off the master switch and secure the go replace filters switch in off position = A Caution - risk of injuries caused by the rotating fan wheel, health hazard due to residual oil dripping off. This may lead to bruises or irritation of the eyes. ‘© Wait until the unit has come to a standstill Wear eye protection. Keep your hands off the rotating fan wheel 2. Open the maintenance ports 2910 linear # iTNC 530 # mhb 2 95 9. Oil mist separator BECKEL MAHS Clean prefilter Clean intermediate filter Clean main filter 96 Pull out the prefilter (1) sideways from its channel-section mount and clean the wire netting (hot water, fat dissolving-cleaning agents, steam-jet cleaners, industrial washing machine). 4, Refit the prefilter to the channel-section mount, 5. Remove the intermediate filter (2), clean (hot water, fat dissolving cleaning agents) and refit the filter. 6. Pull the main filter with frame (3) sideways out of its channel-section mount. 7. Open the frame and remove the filter plates. 8. Clean the filter plates (hot water, fat dissolving cleaning agents, steam-jet cleaners) Avoid damage due to chemical reaction with the solvent This may iead to the decomposition of the filter plates Only use non-organic solvents. 9. Re-install the filter plates and reassemble the frame. 2 ( A P ( ( 2910 linear * iTNC 530 ¢ mhb 2 o 2 mist separator Watch for the correct position of the filter plates. The bores of adjacent filter plates must be staggered (as shown). The projecting ends of the bores (1) must point in the direction against the air flow (2). =e 10. Refit the main filter to its channel-section mount, Replace exhaust 11. Back off the mounting screws (2) on the filter exhaust filter and pull the filter out of its guide rails ( 12. Insert a new filter, j Check the filter for correct position. The rubber sealing strip must be located on the intake side The filter pockets in the filter must be vertical Clean exhaust Avoid damage to bearings due to unbalance. opening, fan Dirt deposits on the fan wheel may cause bearing wheel damage on the fan drive motor. f ‘© When dirt deposits are found, clean the fan wheel and the exhaust opening 1. Turn off the master switch and secure the Pp * switch in off position. 2910 linear * iTNC 530 ® mhb 2 97 9. Oil mist separator a Caution - risk of injuries caused by the rotating fan wheel, health hazard due to residual oil dripping off. This may lead to bruises or irritation of the eyes. ‘© Wait until the unit has come to a standstill Wear eye protection. * Keep off the rotating fan wheel Open oil mist 2. Open the maintenance port in the machine F separator enclosure, above the tool magazine. ( 3. Open the maintenance port on the oil mist separator. 4. Clean the exhaust opening (2) and the fan wheel (3) using a brush or a vacuum cleaner. Lf F Avoid damage to bearings due to unbalance. . Unbalance caused by a distorted fan wheel may cause bearing damage on the fan drive motor. + Do not distort the fan wheel blades. * Do not remove the fan wheel from the motor shaft. + Never use any high-pressure equipment (steam jet cleaner) for cleaning Clean siphons, 1. Should the discharge line become clogged, discharge lines clean the siphons (1) and the discharge lines (2). 9-8 2910 linear * iTNC 530 ® mhb 2 BECKEL MAG 9. Oil mist separator (aa =a Access is through the sliding window on the tool magazine Fill the siphons with lubricoolant before initial operation, after cleaning or after long periods of non-use of the unit, otherwise the oil mist separator is not likely to operate properly. Transport — not spee Installation Operational failure due to insufficient height of room! ‘+ Make sure there is enough room above the oil mist separator to ensure proper operation of the unit (see "Technical data"). Assembly - not specified Conne In — not specified 2910 linear # iTNC 530 # mhb 2 9-9 10 Active cooling unit . . DECKEL MAG 10. Active cooling unit eeretvried Gwen Cea Func Main components 1* Evaporator 2* Coolant reservoir 3* Compressor 4* Condenser 5 Operator terminal * Main components behind the enclosure Application The active cooling unit for the motor spindle and the linear drives is provided in substitution for the standard cooling unit if a high refrigerating capacity is required. Description The motor spindle and the linear drives are cooled by a refrigerant. The waste heat is eliminated via this refrigerant and dissipated to ambient air 10-2 2910 linear * iTNC 530 ¢ mhb 2 BEDCKEL MAHG 10. Active cooling unit (2QWFizzz@ Technical data Data sheet Cooling circuit, linear drives Cooling capacity * Cooling temperature * Cooling circuit, motor spindle Cooling capacity * Cooling temperature * Cooling circuit, cooling unit Cooling capacity * Delivery volume Operating pressure Coolant Glysantin G48, Water Rust preventive agent * at 25 °C (77 °F) ambient temperature 2910 linear # iTNC 530 # mhb 2 Product name kw (hp) kw (hp) Vmin (imp/us gal) bar (psig) 4) 26 (79) 25 (3.3) (8) 7 (3.7/4.5) 0.8 to 4.4 (11 to 62) 40 % 60 % Varidos 10-3 . . . DECKEL MAHC 10. Active cooling unit _eerenried emo Operation (F/_2eerational failure, damage to equipment £ due to inappropriate operation. Observe the manufacturer's instructions on the operation ofthe unit. To switch on/off 1. Set the master switch (Q1) on the operator p * minal of the active cooling unit to "1" or as the case may be. (QQ Maintenance Regular © 50h maintenance Coolant reservoir: Check the liquid level on the level indicator (2). Replenish coolant through the filler neck (3) if necessary Transport - not specified (= Installation 1. Install the active cooling unit in level position adjacent to the machine (see "Installation diagram" in Machine Manual 1, Chapter “Technical data"). 10-4 2910 linear # iTNC 530 ® mhb 2 PECKHEL MAH 10. Active cooling unit [7A Assembly - not specified ({S5S88 Connection Connect cooling 1. Connect the feed lines to the cooling circuits. circuits Watch for the identification markings on the fittings: Connect the hose line 502 (feed line to motor 2 spindle) to fitting 502 (1) a 1 Connect the hose line 504 (feed line to linear drives) to fitting 504 (2) 2. Connect the return lines from the cooling circuits Watch for the identification markings on the | fittings: | Connect the hose line 501 (return line from motor spindle) to fitting 501 (3) Connect the hose line 503 (return line from linear drives) to fitting 503 (4) Electrical 1. Insert the mains voltage plug into the socket (5) connection (on the active cooling unit. 290 linear ® iTNC 530 ¢ mhb 2 10-5 11 Control cabinet cooling unit 11. Control cabinet cooling unit CS Function Main components Internal fan Heat exchanger (evaporator) External fan Heat exchanger (condenser) Compressor wR uno Application The control cabinet cooling unit serves to dissipate the waste heat produced by the electrical equipment inside the control cabinet. Description The waste heat in the control cabinet is given off via an internal fan and a heat exchanger (evaporator) to a refrigerant. The refrigerant ( dissipates the heat to ambient via a further heat exchanger (condenser) and an external fan provided on the outside of the control cabinet. 11-2 2910 linear * TNC 530 « mhb 2 DECKEL MARC 11. Control cabinet cooling unit (2WRizzz@ Technical data Data sheet Temperature difference Ambient temperature °C cer Cooling temperature, adjustable °C er Fan capacity Flow volume, internal fan mh (uf) Flow volume, external fan mh (cu ft) i For further technical data refer to the manufacturer's manual (3EXZZZNM_ Operation Automatic No operator intervention or handling required. operation Maintenance FF Operational failure, damage to equipment due to neglected maintenance! ‘© Observe and follow the maintenance instructions of the equipment manufacturer. Regular © 200h maintenance Check the filter web for contamination 2910 linear ® iTNC 530 ¢ mhb 2 #10 t0 +55 (50 to 130) +30/+35/440 (85/95/105) 250 (8,825) 350 (12,355) 11. Control cabinet cooling unit Maintenance as required Sa ae CS Replace the filter web. *1 The maintenance intervals are deoendent on the degree of contamination of the ambient air and should be based on the experience gained in the course of time. Transport - not specified Installation - not specified Assembly — not specified Connection - not specified 2910 linear * iTNC 530 ® mhb 2 12 EA-410 NC table _ 12. EA-410 NC table C= Function Main components 1. Spindle head 2. Drive unit Application With the NC table you can rotate the workpiece about the A axis either manually or by program- control — * to any desired angular position, © for rotary milling, The torque of the drive motor is transmitted to the spindle via a belt drive and a worm gearing i ‘An upgraded version of the machine is required for using the NC table. 12-2 2910 linear * TNC 530 ¢ mhb 2 12. EA-410 NC table (2Q6izzzl Technical data Collision range Front view 1134, 149.35, 276_(520) 244 8 1 2 wy - ol - - wal g i - 2 Rat N is 3 a aa T e ¢ Collision range Plan view 2910 linear # iTNC 530 # mhb 2 123 12. EA-410 NC table Data sheet Spindle headstock (external) Tool mount (internal) (option) Centre height Workpiece diameter Speed Load data Workpiece weight Workpiece with tailstock Tipping moment Machining moment (dynamic) Tangential moment (static) Weight NC table Tailstock * HST = hollow steep taper 12-4 Dia x W mm (in) DIN 69063-1 mm (in) max. mm (in) max. ‘min rpm max, kg (lb) max kg (ib) max, Nm (lof ft) max, Nm (ibf ft) max. Nm (ibf ft) kg (tb) kg (lb) 3x5 (3.15x 9.2) HSK AS3* 159 (5.9) 300 (11.8) 20 20 35 (187) ( 140 (303) 1,000 (735) 170 (125) 750 (552) 50 (110) 3 (68) 2910 linear # iTNC 530 ¢ mhb 2 12. EA-410 NC table (3222 Operation Manual work damping To clamp workpiece To move to reference point 1. Attach the required accessory item(s) to the spindle head of the NC table and secure them with screws. 2. Either: Clamp the workpiece on the table top or in a jaw chuck. or Insert the workpiece into the manually clamped internal taper HST A63 (option) and clamp firmly. Caution — avoid the risk of an accident that may be caused by the clamping key. if you leave the key in the jaw chuck, it will be thrown out when the spindle is started. * Remove the key immediately after clamping ‘© Never leave the key in the unit. ‘The reference point of the A axis must be approached: © each time the A axis is activated, © when the A axis is already activated: each time the machine is restarted (when the master switch Q1 is turned ON). 2910 linear # iTNC 530 « mhb 2 12-5 | DECIER MAHG 12. EA-410 NC table Cavotsrlea mbH 1. Clase and lock the door to the working area. 2. Tum the keylock switch to "Machining" mode. 3. Move to the reference points of the axes shawn an the display screen (2, Y, X, A): Press “Program start" for each axis, The axis concernad moves beyond the reference point, The A axis is positioned to O* when the reference point is reached. ( i“ Caution — avoid the risk of collision with a d workpiece or fixture in the working area. * Select the sequence of the axis movements in such @ way that collisions are excluded. To set A-axis To set the A-axis zero point, proceed in the same zero point way as for the X, Y and Z axes (see Contro! Unit Manual). To rotate A axis The rotary A axis is controlled in the same way as A 5 within program the three linear axes X, Y and Z. _-=- _. a Cc ( To rotate the table in program-controlled operation, proceed as if you were moving the machine slides in program-controlled machining operations. The A axis must be activated, A linear movement of 0.001 mm corresponds to a rotary movement of 0.001° about the A axis. 12-6 2910 linear * TNC 530 * mhb 2 12. EA-410 NC table To rotate A axis by manual control You can rotate and position the A axis in the same manner as you mave and position the X, ¥ or Z axis (see Machine Manual 1 under the heading “Operation"). 1. Either: Call “Manual" mode: Press the "Manual mode" key. or Call “Electronic handwheel" made’ Press the " Electranic handwheel" key. 2. Set the keyluck switch If the duor to the working area is closed, select ° os "Machining" mode, © 9 If the door to the working area is open, select ~ "Set-up" mode or "Manual intervention* (option) ‘or "Extended manual intervention" (option). 3. Press the axis key for the desired direction of the rotary movement in the A axis. 2910 linear # iTNC 530 © mhb 2 12-7 12. EA-410 NC table DECHKEL MAHCG A-axis clamp To prepare A- axis clamping To activate damp, alternative 1 To activate damp, alternative 2 12-8 if the A axis was clamped via the M function "M10", the clamp is released and the A axis keeps moving as long as the key is held down. After the movernent, the axis clamp is epplied again. The movement is carried out at the previously set, feedrate in degrees per minute. Jepending on the operating mode selected, the “Enable” key may have to be pressed and held down as well The A axis is clamped or released (as the case may be) automatically for each rotary movement, Call "Manual" mode: Press "Manual mode” key. 1. Press function key "M", key in "10" and enter by pressing "Program start” The A-axis clamp is activated 1, Press "FCT" 2. Activate clamp: Press function key "TABLE CLMP CLOSE" On machines with an NC table mounted on each of the two sides of the rotary table: The clamping command only applies to the NC table positioned in the working area of the machine. 2910 linear # iTNC 530 « mhb 2 12. EA-410 NC table damp, alternative 1 To deat clamp, alternative 2 ate Clamping within program Ar 1. Press function key *M", key in "11" and enter by pressing "Program start" ‘The A-axis clamp is deactivated 41. Press "FCT" 2. Deactivate clamp Press function key "TABLE CLMP OPEN" Activate clamp: Command "M10" 2. Deactivate clamp’ Command "M11" Maintenance Operational failure, damage to equipment due to neglected maintenance Observe the maintenance instructions of the equipment manufacturer. * Observe the maintenance instructions in Machine Manual 1, Chapter "Maintenance, lubrication «In the event of any queries concerning maintenance or in the event of malfunctions, please contact our Technical Service or call your nearest DECKEL MAHO agent. 2910 linear # iTNC 530 © mhb 2 rae) J Be IESE M10 m1 12-9 12. EA-410 NC table DEGCKEL MAHO Maintenance schedule Regular maintenance work Maintenance work as required 12-10 50 eg) SSS SS 200 41000 ——$£_—_——_—____| 2000, Point of intervention 27 Filter/regulator unit Compensation system cause —_| Point of intervention *1 27 Filter/regulator unit Compensation system Hydraulic system (not shown) (6 months) What to do Check liquid level What to do Check liquid level Bleed hydraulic oil lines Applicable in the case of restarting the machine after a long period of standstill 2910 linear * iTNC 530 © mhb 2 DECKEL MANG 12. EA-410 NC table Samm Transport Insert two lifting eyebolts into the tapped holes ‘on top of the NC table. 2. Attach the ropes (straps, chains) to the lifting eyebolts and the crane hook Caution — avoid the risk of an accident caused by material failure, slipping off or tipping over of the NC table. © Screw in the lifting-eye bolts all the way. © Only use suitable and fully operative slinging and hoisting equipment of adequate load capacity. 3. Lift the NC table with the crane and move carefully 4. Deposit the NC table on a suitable support. Operational failure, damage to equipment due to inappropriate transport and storage. ‘* Keep the mounting surface of the NC table clean and protect the table against corrosion and mechanical damage ‘* Avoid bumping the NC table when putting it down, ‘Attach the ropes or chains to the lifting eyebolts only ‘Never use the work mount for transporting the unit 2910 linear ® iTNC 530 © mhb 2 12-11 12. EA-410 NC table DEC TEL RLAHIC? ha Electrical connection Pneumatic and hydraulic connection 12-12 Installation - not specified Assembly Turn off the master switch and secure the switch in off position 2. Carefully place the NC table on the table, making sure that the keys on the NC table engage the keyway in the table slide 3. Secure the NC table to the table with four T-slot bolts. 4, Remove the lifting eyebolts after mounting the NC table. 5. Place the tailstock on the table, if required, and secure it with four T-slot bolts. Connection 1. Insert the plugs for the control signals and the feed motor into the sockets provided at the rear, left, in the working area 2. Fit the compressed-air and hydraulic oil fittings to their counterparts at the rear, left, in the working area The hydraulic and pneumatic lines can only be connected or disconnected when they are in depressurized condition. 2910 linear # iTNC 530 ® mhb 2 DECKEL MAHI 12. EA-410 NC table — To activate NC table To prepare A- axis activation-/ deactivation Operational failure, damage to connecting lines due to inappropriate installation of cables, oil and air lines. © Do not twist or cross the connection lines, Certain additional functions, such as drive, clamping, display etc., are necessary for the attachment "NC table" * Upon mounting the table, call the adcitional axis to activate such function, otherwise the axis will not be operative * Before removal, deactivate the additional axis, otherwise a faulverror message will be produced Switch off the control unit: Press "EMERGENCY STOP" and reset the button, " 2. Call "Manual" mode. 3. Change over screen assignment: Press "Screen assignment” key. 4, Call PLC range: Press function key "PROGRAM + PLC" or ILE "PLC" 5. Change over softkey strip. Dy" 6. Press function key "CONFIG" SESE The softkey “CONFIG" will only appear on screen @ ‘ when the control unit has been switched off. 2910 linear ® iTNC 530 ® mhb 2 12-13 12. EA-410 NC table DECKEL MAH Gereteried Emon To activate Aaxis To deactivate A axis 12-14 1. On machines with only one NC table Activate the A axis using the function key “4-AXIS NCT" On machines with two NC tables: Activate the A axis using the function key "S-AXIS 2AT", This will set the parameters for operations with the Aaxis. The control unit will be restarted 2. Press “Machine ON" 1, Deactivate the A axis using the function key AXIS" This will reset the parameters to operations without the A axis. The control unit will be restarted, 2. Press "Machine ON" ‘The activated (or deactivated, as the case may be) ‘A axis remains stored when the machine is switched off, so there is no need to repeat the procedure when the master switch is switched on again os ISIE os 2910 linear # iTNC 530 © mhb 2 13 BLUM-MICRO Tool scanner 13. BLUM-MICRO Tool scanner CSS Function Main components 1 The main components of the unit are located on the right-hand side of the working area, adjacent to the door to the tool magazine. Laser beam light barrier Application The BLUM-MICRO automatic tool scanner can be used — * for determining the tool length, tool radius and the size of the individual cutting edges, and transferring these data to the tool list; ‘for detecting any changes in length, such as may be caused by tool breakage, wrapped- around chips or loosening of the too! in the chuck. 13-2 2910 linear # iTNC 530 ® mhb 2 DEGKEL iMAC Coreterioa © 13. BLUM-MICRO Tool scanner Description Tool scanning is initiated by moving a laser beam light barrier (1) towards the cutting tool (either rotating or standing still) from above and from the rear. Changes in length, e.g. tool breakage, are then detected by comparison with the too! length compensation value entered in the tool list. The process is controlled by DECKEL MAHO cycles. 2910 linear # iTNC 530 ® mhb 2 13-3 i EC 13. BLUM-MICRO Tool scanner Se (QI Technical data 235 Collision range re a c tt 4 (UE 4 art

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