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tornos MultiAlpha 6x32 Safety Instructions

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SAFETY INSTRUCTIONS
MultiAlpha 6x32
English version translated from the original version
300940 en
Attention !
Document to be kept to refer to it later on.
Attention !
Before handling the machine, each user is held to read first this instruction !
TORNOS SA CH-2740 MOUTIER http://www.tornos.ch
Copyright ©1999-2011

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Summary of Contents for tornos MultiAlpha 6x32

  • Page 1 English version translated from the original version 300940 en Attention ! Document to be kept to refer to it later on. Attention ! Before handling the machine, each user is held to read first this instruction ! TORNOS SA CH-2740 MOUTIER http://www.tornos.ch Copyright ©1999-2011...
  • Page 3 MultiAlpha 6x32 Behaviour in the event of an emergency 1. Stay calm --> 2. Think --> 3. Act Raise the alarm Ambulance _____________________ Police _____________________ Fire brigade _____________________ Poisoning _____________________ Doctors _____________________ Hospital _____________________ Who? Person raising the alarm What happened?
  • Page 4 MultiAlpha 6x32 >>> 300940 en - 03/11...
  • Page 5 MultiAlpha 6x32 Identification I.1. Document Safety instructions MultiAlpha 6x32 No 300940 en Version Manager Version Date Description 03/11 31 March 2011 First version I.2. Manufacturer TORNOS SA Rue Industrielle 111 CH-2740 MOUTIER / SUISSE Tél. +41 (0)32 494 44 44 Fax +41 (0)32 494 49 03 contact@tornos.ch...
  • Page 6 MultiAlpha 6x32 >>> 300940 en - 03/11...
  • Page 7 MultiAlpha 6x32 " 3-1 Work environment " 4-1 Lubricants " 7-1 Fire prevention " 2-1 Individual protection " 8-1 Barfeeder " 5-1 Machine use " 6-1 Machine protection parts Fig. 1 300940 en - 03/11...
  • Page 8 MultiAlpha 6x32 >>> 300940 en - 03/11...

  • Page 9: Table Of Contents

    MultiAlpha 6x32 TABLE OF CONTENTS Generalities ...........
  • Page 10 MultiAlpha 6x32 Lubricants ........... . .
  • Page 11 MultiAlpha 6x32 Machine protection parts ........
  • Page 12 MultiAlpha 6x32 >>> 300940 en - 03/11...

  • Page 13: Generalities

    This document is written based on the information available at the moment of its publication. TORNOS SA may not be held responsible, however, in case of errors or omissions. The original language of this document is French. The information contained in this document is the property of TORNOS SA which is intended exclusively for internal customer usage, and may not be disclosed to or reproduced for third parties.

  • Page 14: Safety Principles

    Caution ! TORNOS SA shall not be held liable if these instructions are not followed. 1.5. Operating instructions and advice The operating instructions and advice provided by the supplier with the machine or after its delivery must be passed on to anyone handing and/or operating the machine or responsible for it in any way.

  • Page 15: Definition Of Pictograms

    Safety instructions MultiAlpha 6x32 - 1. Generalities 1.6. Definition of pictograms 1.6.1. General pictograms Note ! Warning and danger pictograms are used in this manual and on the machine. They indicate safety instructions, providing safety related information: -for the control and safe use of the machine by exposed persons, the operators, - as well as for the environment and the machine.
  • Page 16 1. Generalities - Safety instructions MultiAlpha 6x32 Danger Pictogram Definition Level Prohibition ! Prohibiting indication to be absolutely respect. Danger ! Indicates a direct serious warning. Indicates a serious danger of death or serious injury. Warning ! Indicates a machine element or action which may cause serious injury or affect health.

  • Page 17: Specific Pictograms

    Safety instructions MultiAlpha 6x32 - 1. Generalities 1.6.2. Specific pictograms Danger Pictogram Definition Level Prohibition ! Wearing loose clothing, long hair, necklaces, rings and all other objects exposes the operator to the risk of being drawn in or crushed. Prohibition ! Naked flames and smoking strictly prohibited.
  • Page 18 1. Generalities - Safety instructions MultiAlpha 6x32 Danger Pictogram Definition Level Danger ! Suspended load. Danger ! Exposure to magnetic field. When working on the spindle motors or quill drives, the operator is exposed to the significant magnetic field of the rotor.
  • Page 19 Safety instructions MultiAlpha 6x32 - 1. Generalities Danger Pictogram Definition Level Mandatory ! Goggles or eye protection devices are mandatory. Mandatory ! Wear safety shoes. Mandatory ! Perform all maintenance as described in the chapter entitled Maintenance. Mandatory ! Padlock mandatory.
  • Page 20 1. Generalities - Safety instructions MultiAlpha 6x32 >>> 300940 en - 03/11...

  • Page 21: Individual Protection

    Safety instructions MultiAlpha 6x32 - 2. Individual protection Individual protection Fig. 2 300940 en - 03/11...

  • Page 22: General Rules

    The use of air blasts or any other compressed air device is strictly prohibited. Mandatory ! The user must read the contents of this instruction before handling the machine. TORNOS SA will not be held responsible if the user disregards this obligation. Mandatory ! Read and observe the instructions provided with the machine.

  • Page 23: Safety To Observe During Production

    Safety instructions MultiAlpha 6x32 - 2. Individual protection 2.2. Safety to observe during production Danger ! Never insert your hands or other parts of your body inside or near the operating and moving area of mechanical parts; danger of being snatched.

  • Page 24: Safety To Observe During Maintenance

    2. Individual protection - Safety instructions MultiAlpha 6x32 2.3. Safety to observe during maintenance Caution ! Certain maintenance operations are absolutely necessary to ensure good oper­ ation of the machine. They are given in the maintenance schedule on the machine.

  • Page 25: Operator Maintenance

    Safety instructions MultiAlpha 6x32 - 2. Individual protection 2.3.1. Operator maintenance Danger ! Stop and disconnect the machine from the power supply before performing any work on it ! If electricity is required to perform certain maintenance tasks, only a qualified and trained person is authorised to work on the machine whose main QS0 switch is on! "...

  • Page 26: Technician Maintenance

    The maintenance must be performed by a specialist who has taken a TORNOS SA training course. Danger ! The replacement of a spindle belt or axis must be performed by a TORNOS SA technician. Danger ! Only a qualified person is authorised to work inside the electrical cabinets or on electrical parts.

  • Page 27: Safety Precautions To Take During Maintenance Work

    Safety instructions MultiAlpha 6x32 - 2. Individual protection 2.3.2.3 Safety precautions to take during maintenance work Warning ! Starting conditions before any intervention: - Machine power off, main electrical switch locked. - Wear gloves to avoid all risks of getting cut by chips or sheet metal working.

  • Page 28: Safety In The Event Of A Fault

    2. Individual protection - Safety instructions MultiAlpha 6x32 2.4. Safety in the event of a fault 2.4.1. Skills Warning ! All repairs following a fault must be performed by a specialist who has attended a TORNOS SA maintenance training course.

  • Page 29: Work Environment

    Safety instructions MultiAlpha 6x32 - 3. Work environment Work environment " 3-2 Conditions of use of the machine " 3-6 Noise " 3-2 Oil spray and fume extraction " 3-2 Order and cleanliness " 3-5 Quality of the floor "...

  • Page 30: Order And Cleanliness

    3. Work environment - Safety instructions MultiAlpha 6x32 3.1. Order and cleanliness Warning ! Order and cleanliness around the machine are key factors for safety. Danger of slipping, falling and injury. clean the floor around the machine regularly; remove all grease spots, oil stains, etc...;...

  • Page 31: Oil Spray And Fume Extractor

    It is highly recommended in all cases to install a fume and oil spray extraction system. All TORNOS SA machines are equipped with a connection for a fume and vapour extractor or collector. Caution ! Despite installation of the fume extractor, the treatment system may be insuffi­...
  • Page 32 3. Work environment - Safety instructions MultiAlpha 6x32 CHARACTERISTICS OF OIL SPRAY EXTRACTION Name Unit Value ø minimum extraction Volume of machining area Extraction rate 1700 Fig. 4 300940 en - 03/11...

  • Page 33: Quality Of The Floor

    The floor needs to be sufficiently resistant to support the weight of the machine and all its components. TORNOS SA recommends a nonslip surface. We do not recommend the use of non-slip mats in other places. This could cause people to trip and fall.

  • Page 34: Noise

    Any measurement results obtained on a particular production site will obviously differ from those measured by TORNOS SA at its plants. Warning ! If for any reason the sound load at workplace (Leq) is 85 dB(A) or more, the employer must inform the personnel concerned about the noise.

  • Page 35: Lubricants

    Safety instructions MultiAlpha 6x32 - 4. Lubricants Lubricants " 4-4 High pressure unit " 4-4 Cutting liquid cooling system " 4-2 Lubricating " 4-2 Cutting liquid Fig. 5 300940 en - 03/11...

  • Page 36: Restrictions

    Restrictions Prohibition ! Lubricants : TORNOS SA prohibits the use of all lubricants (grease, oil) with chlorin­ ated and/or active sulphurous and heavy metal additives. Moreover, the degree of copper corrosion, in accordance with European standard EN ISO 2160 must not be greater than 1.

  • Page 37: Precautions To Take During Handling

    Fig. 6 4.2.5. Emulsion 4.2.5.1 Restrictions Prohibition ! Emulsion: TORNOS SA do not authorises the use of aqueous cut-off liquid (emul­ sion) on MultiAlpha 6x32 type machines. Mandatory ! Read the Fire prevention section. " See page 7-2. 300940 en - 03/11...

  • Page 38: High Pressure Unit

    4. Lubricants - Safety instructions MultiAlpha 6x32 4.2.6. High pressure unit Danger ! The operator must be aware of the existing danger at the tip of the tool, if the high pressure drilling system is operating at high pressure. The ”thread” of oil is very fine and barely visible. If a hand passes near the outlet of the drill bit, the part exposed will be pierced through.

  • Page 39: Machine Use

    Safety instructions MultiAlpha 6x32 - 5. Machine use Machine Use " 5-7 Emergency stops " 5-3 Handling the machine safely " 5-8 Opening/closing the electrical cabinet " 5-5 Stopping the machine without turning it off " 5-16 Opening/closing machining doors "...
  • Page 40 5. Machine use - Safety instructions MultiAlpha 6x32 5.1. General rules Danger ! The machine must not operate with the doors and guards open. Before powering or starting the machine, the user should make sure that all doors, access hatches and other mobile and fixed guards have been closed properly.

  • Page 41: Machine Power On

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.2. Handling the machine safely 5.2.1. Machine power on Danger ! Before starting the machine, always check no one is servicing any invisible parts of the machine. Initial condition - The machine's main switch is set to power off.

  • Page 42: Turning The Machine Off

    5. Machine use - Safety instructions MultiAlpha 6x32 5.2.2. Turning the machine off Action Notes Press the “End of part” key. Wait until the program stops. Attention ! If you turn the power off during machining, you could damage the machined part and the tools.

  • Page 43: Stopping The Machine Without Turning It Off

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.3. Stopping the machine without turning it off Info ! For certain maintenance operations, reserved for specialists trained by TORNOS SA, it is necessary to work with the machine powered. Follow the procedures below. 5.3.1.

  • Page 44: Locking The Machine Energy Sources For Maintenance Tasks

    5. Machine use - Safety instructions MultiAlpha 6x32 5.4. Locking the machine energy sources for maintenance tasks Mandatory ! Before carrying out a repair, maintenance work or any other tasks requiring access to the interior of the machine, set the QS0 switch to the off position and lock it with your own personal padlock.

  • Page 45: Emergency Stop

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.5. Emergency stop Note ! When one of the 3 emergency push-buttons is activated, all the machine parts are immediately stopped and the controls are immediately inoperative. Location of parts Function “Punch” emergency stop button with locking device.

  • Page 46: Opening/Closing The Electrical Cabinet

    5. Machine use - Safety instructions MultiAlpha 6x32 5.6. Opening/closing the electrical cabinet Danger ! Only a qualified person is authorised to work inside the electrical cabinets or on electrical parts. Info ! The QS0 switch is fitted with a locking system that prevents the door from opening when it is set to 1.

  • Page 47: Opening The Door On The Cnc Ap3 Plate

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.6.2. Opening the door on the CNC AP3 plate Fig. 11 300940 en - 03/11...

  • Page 48: Opening The Rear Door

    5. Machine use - Safety instructions MultiAlpha 6x32 5.6.3. Opening the rear door Fig. 12 300940 en - 03/11 5-10...

  • Page 49: Moving Back The Cabinet

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.6.4. Moving back the cabinet Action Notes Set the switch to 0. Fit the padlock. In the specially-provided slot. Open the conveyor doors. Unscrew the upper fixations. 2 screws (1). Unscrew the lower fixations.

  • Page 50: Opening The Access Panel To The Entry Transformer

    5. Machine use - Safety instructions MultiAlpha 6x32 5.6.5. Opening the access panel to the entry transformer Fig. 14 Fig. 15 300940 en - 03/11 5-12...

  • Page 51: Opening/Closing Of Doors In Loading And Unloading Zones

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.7. Opening/closing of doors in loading and unloading zones Warning ! Do not open a door without first turning off the power. Info ! The doors are fitted with a safety lock allowing you to fix them in the open position.

  • Page 52: Opening Procedure

    5. Machine use - Safety instructions MultiAlpha 6x32 5.7.1. Opening procedure Action Notes Press the POWER OFF key. Push the door up against the top. Until the safety lock Using the handle. catches. Danger ! Do not keep the door open with a wedge. Risk of door closing suddenly involun­...
  • Page 53 Safety instructions MultiAlpha 6x32 - 5. Machine use Fig. 16 300940 en - 03/11 5-15...

  • Page 54: Opening/Closing Machining Doors

    5. Machine use - Safety instructions MultiAlpha 6x32 5.8. Opening/closing machining doors Danger ! The fire-fighting system is deactivated when the doors are opened. If a fire breaks out while an operator is working in the machining area, the oper­...
  • Page 55 Safety instructions MultiAlpha 6x32 - 5. Machine use Warning ! Doors open, safety key on SETTING mode and mode selector on JOG, mode or reference mode for an axis, all movements and all axis rotations are authorised in certain conditions: - movement of the linear axes is limited to 2m/min with operator hold to run action.

  • Page 56: Definition Of Continuous Cycle And Setting Mode

    5. Machine use - Safety instructions MultiAlpha 6x32 5.8.1. Definition of CONTINUOUS CYCLE and SETTING mode Item Function When the selector is set to CONTINUOUS CYCLE, the program is performed with the doors closed. When the selector is set to SETTING, you can work with the doors open and the axis feed and spindle rotation at reduced speed.

  • Page 57: Unlocking In Setting Mode

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.8.3.2 Unlocking in SETTING mode Initiale condition the machine power is on. Action Notes Turn the key to SETTING mode. Press the F1 key. Unlocks the machining doors. Open the door(s) Info ! The doors remain unlocked for 15 seconds.
  • Page 58 5. Machine use - Safety instructions MultiAlpha 6x32 START Starting conditions: Power on. Select the "CONTINUOUS CYCLE" mode or "SETTING" mode. SETTING CONTINUOUS CYCLE If you open the doors in that instant, the Opening of power is immediately disconnected. doors in loading...
  • Page 59 Safety instructions MultiAlpha 6x32 - 5. Machine use Automatic modes Automatic Select automatic mode to Select the "MDI" mode to run the program. perform one or more controls entered on the keyboard. Press the "CYCLE" key. Hold the keys “Cycle Feed” and “F2” down Keep the key "Cycle Feed"...
  • Page 60 5. Machine use - Safety instructions MultiAlpha 6x32 Manual modes Incremental References Select the "JOG" mode Select the "Incremental" to feed the axes at the mode to feed the axis maximum speed of 2 step by step. m/min. Keep the key "Cycle Feed" + or - pressed.
  • Page 61 Safety instructions MultiAlpha 6x32 - 5. Machine use Reference for Reference for 1 axis Select the "Reference Select the "Reference for all the axes for all the axes" mode. 1 axis" mode. Disabled Keep the key "Cycle Feed" + or - pressed.
  • Page 62 5. Machine use - Safety instructions MultiAlpha 6x32 CONTINUOUS Close the CYCLE machining doors Doors closed Press the F1 key. It The power is goes on and the disconnected doors lock. Close the doors CONTINUOUS CYCLE TURNED ON The power is...

  • Page 63: Signal Lamp

    Safety instructions MultiAlpha 6x32 - 5. Machine use 5.9. Signal lamp Item Function Yellow lamp on: message operator enabled. Flashing red lamp: machine not in cycle, without alarm. Red lamp on: class 2, 3 or 4 “PMC” alarm, NC alarm or power off.
  • Page 64 5. Machine use - Safety instructions MultiAlpha 6x32 >>> 300940 en - 03/11 5-26...

  • Page 65: Machine Protection Parts

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts Machine protection parts " 6-12 Machine protection components " 6-20 Pneumatic protection parts " 6-15 Electrical protection parts Fig. 22 300940 en - 03/11...

  • Page 66: General Rules

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.1. General rules Prohibition ! Never disable the safety devices. 6.1.1. Safety device check Danger ! Before starting the machine, always check no one is servicing any invisible parts of the machine.

  • Page 67: Cleaning The Machining Areas

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts 6.1.2. Cleaning the machining areas Fig. 23 300940 en - 03/11...

  • Page 68: Removable Chip Tank

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.1.3. Removable chip tank Caution ! You must install a retention tank when using a removable chip collection pan, fit­ ted underneath the latter. Mandatory ! Check the level of oil retained in the chip pan every 4 hours.

  • Page 69: Danger In The Loading Zone

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts 6.1.4. Danger in the loading zone Fig. 25 300940 en - 03/11...
  • Page 70 6. Machine protection parts - Safety instructions MultiAlpha 6x32 Fig. 26 300940 en - 03/11...
  • Page 71 Safety instructions MultiAlpha 6x32 - 6. Machine protection parts Fig. 27 300940 en - 03/11...

  • Page 72: Danger In The Machining Area

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.1.5. Danger in the machining area Fig. 28 300940 en - 03/11...
  • Page 73 Safety instructions MultiAlpha 6x32 - 6. Machine protection parts Fig. 29 300940 en - 03/11...

  • Page 74: Danger In The Controlled Parts Unloading Zone

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.1.6. Danger in the controlled parts unloading zone Fig. 30 300940 en - 03/11 6-10...

  • Page 75: Danger In The Palletising Zone

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts 6.1.7. Danger in the palletising zone Fig. 31 300940 en - 03/11 6-11...

  • Page 76: Machine Protection Components

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.2. Machine protection components The removable guards such as the motor cowl, belt guard, cable way and the like must be fitted so as: to ensure the correct operation of the equipment;...
  • Page 77 Safety instructions MultiAlpha 6x32 - 6. Machine protection parts Fig. 32 300940 en - 03/11 6-13...

  • Page 78: Detection And Locking Of Closed Doors

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.2.2. Detection and locking of closed doors Info ! The doors in the loading and unloading zones are controlled in a closed position via a magnetic presence detection system (1-2). The locking of each door in the machining zone is guaranteed by an electromag­...

  • Page 79: Electrical Protection Parts

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts 6.3. Electrical protection parts Prohibition ! Do not remove the Plexiglas safety guards covering all electrical parts. Info ! All potentially dangerous electrical areas are signalled by an electrical danger pictogram.

  • Page 80: Electrical Connection

    Caution ! TORNOS SA guarantees the correct operation of its products provided the elec­ tricity mains supplies a stable voltage without any micro power cuts. The customer must ensure the power supply voltage to the machine does not vary by more than +/- 5%.

  • Page 81: Earthing

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts 6.3.2. Earthing Info ! Each device is earthed by connecting it to one of the 4 copper bars (PE/RAIL). Info ! See the wiring diagram available in the control cabinet. Fig. 34...

  • Page 82: Earthing Of Doors

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.3.3. Earthing of doors Info ! The cabinet doors are earthed by means of a cable (2) crimped with two lugs on the two copper rods (1) and (3) welded on the door and cabinet. A cable (4) connects it al to one of the copper bars (PE/RAIL).

  • Page 83: Circuit Breaker

    Safety instructions MultiAlpha 6x32 - 6. Machine protection parts 6.3.4. Circuit breaker Info ! From the XT10 terminal board, all the electrical lines are protected against short- circuits via circuit breakers upstream. Some lines are protected by a default current circuit breaker, for the protection of people.

  • Page 84: Pneumatic Protection Part

    6. Machine protection parts - Safety instructions MultiAlpha 6x32 6.4. Pneumatic protection part Mandatory ! Cut off the compressed air supply at the mains before disconnecting the machine's pneumatic connection. 6.4.1. Pneumatic connection Characteristics Name Unit Value Compressed air Minimum - maximum operating pressure...

  • Page 85: Fire Prevention

    Safety instructions MultiAlpha 6x32 - 7. Fire prevention Fire prevention " 7-4 Fire prevention device " 7-2 Fire prevention " 7-4 Minimum room volume " 7-4 Ventilation of premises Fig. 37 300940 en - 03/11...
  • Page 86 If cutting oils are used and/or if the machine operates under high inflammability risk conditions, the user shall be solely responsible, or if the machine operates unattended, TORNOS SA strongly recommends equipping it with an automatic fire extinguishing system. Warning ! Materials...
  • Page 87 Safety instructions MultiAlpha 6x32 - 7. Fire prevention Info ! On order, TORNOS SA will install a fire extinguishing system on all its products (refe­ rence 5480). Warning ! Machining Conditions Machining generates a potentially hot heat source ; the presence of oil mists or vapors, use of inappropriate cutting oil, insufficient lubrication or cooling, inad­...
  • Page 88 Info ! Under certain machine operating conditions, TORNOS SA recommends the use of a fire-fighting system. TORNOS SA can install to order on all its products a system to protect them against fire (product no. 5480) Mandatory ! Read the Fire prevention section.

  • Page 89: Barfeeder

    Safety instructions MultiAlpha 6x32 - 8. Barfeeder Barfeeder " 8-2 Barfeeder Fig. 39 300940 en - 03/11...

  • Page 90: Barfeeder

    8. Barfeeder - Safety instructions MultiAlpha 6x32 Danger ! The space between the machine and the barfeeder should not allow a hand to pass through, in order to avoid any accidents. Danger ! Risk of bar feeding. Do not place your hand or any other part of your body in front of the spindle collet when it is open.

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