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OPTIMUM Maschinen BF 30 Vario Modification Instruction

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OPTIMUM
M A S C H I N E N - G E R M A N Y
Modification instruction
Version 1.0.2
BF46 /BF 30 Vario CNC
Fig.0-1: BF 46 Vario with CNC modification
Keep for future reference!
23. Oktober 2008
Add-on kit BF 46 / BF30 Vario CNC ; Version 1.0.2
Page 1

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  • Page 1 M A S C H I N E N - G E R M A N Y Modification instruction Version 1.0.2 BF46 /BF 30 Vario CNC Fig.0-1: BF 46 Vario with CNC modification Keep for future reference! 23. Oktober 2008 Add-on kit BF 46 / BF30 Vario CNC ;...

  • Page 2: Table Of Contents

    Safety warnings (warning notes) ................3 Classification of hazards ......................3 Proper use ..........................4 Required auxiliary material...................... 4 Packing list BF 30 Vario..................5 Packliste BF 46 Vario..................... 7 Assembly CNC kit....................9 Assembly X-axis........................9 Assembly Y-axis........................13 Assembly Z-axis........................

  • Page 3: Safety Warnings (Warning Notes)

    OPTIMUM Safety warnings (warning notes) M A S C H I N E N - G E R M A N Y Safety warnings (warning notes) Classification of hazards We classify the safety warnings into various levels. The table below gives an overview of the classification of symbols (pictograms) and warnings for the specific danger and its (possible) consequences.

  • Page 4: Proper Use

    If the adapter kit is used in any way other than described above or modified without approval of the company Optimum Maschinen Germany GmbH the adapter kit is no longer properly used. We do not take any liability for damages caused by improper use.

  • Page 5: Packing List Bf 30 Vario

    Hülse für Handrad X- und Y-Achse Bushing for the handwheel on the X- and Y- 0 3570030 08 BF3CNC-08 axis 23. Oktober 2008 Packing list BF 30 Vario Add-on kit BF 46 / BF30 Vario CNC ; Version 1.0 Page 5...
  • Page 6 DIN 4762 M8x15 Screw Schraube DIN 4762 M8x40 Screw Kabel 4 x 0,75mm Wire cord Datum: Prüfer: Verified by: Date: Page 6 Packing list BF 30 Vario Add-on kit BF 46 / BF30 Vario CNC ; Version 1.0 23. Oktober 2008...

  • Page 7: Packliste Bf 46 Vario

    OPTIMUM Packliste BF 46 Vario M A S C H I N E N - G E R M A N Y Packliste BF 46 Vario CNC - Anbausatz MK F46DP Bezeichnung Designation BF 46 CNC Artikelnummer Anbausatz 3570046 Item no. mounting set Netto Gewicht 6,3 kg Net Weight...
  • Page 8 OPTIMUM Packliste BF 46 Vario M A S C H I N E N - G E R M A N Y Bezeichnung Artikelnummer Teile Nr. Grösse Abbildung Stck. Description Article no. Part no. Size Picture Qty. Schrittmotor für X-, Y- und Z-Achse 34 H2160-02IP Step motor for X-, Y- and Z-axis 357 3314...

  • Page 9: Assembly Cnc Kit

    OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y Assembly CNC kit CNC conversion kit Assembly X-axis 4.1.1 Disassemble the self-locking nut and the shim of the left handwheel of the X- axis.
  • Page 10 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.1.5 Fix the distance ring (No 6) on the plate of the X-axis. Distance ring Fig.4-4: Screw the distance ring 4.1.6 Screw the housing (Nr.
  • Page 11 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.1.8 Screw the nut on the shaft (beforehand apply some Loctite). Hexagon nut Slightly hold on the handwheel at the right side and slightly tighten the hexa- gon nut using a fork wrench.
  • Page 12 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.1.11 Attach the motor on the housing. Motor Fig.4-10: Attach the motor 4.1.12 Fix the motor on the housing using the four screws.

  • Page 13: Assembly Y-Axis

    OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.1.14 Detach the right handwheel of the X- axis and plug the bushing (No 8) on the X-axis. Bushing X-axis Fig.4-13: Mount the bushing 4.1.15...
  • Page 14 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.2.3 Disassemble the cover at the rear side of the Y-axis. Cover Fig.4-16: Disassemble the cover 4.2.4 Unscrew the three screws from the plate.
  • Page 15 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.2.6 Drill the three core holes for M8 at the marked positions in the plate using an Drill appropriate drill. Then deburr the drills using a countersink.
  • Page 16 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.2.9 Put the pulley (No 3) on the motor shaft (beforehand apply some Loctite on the motor shaft). Mount the pulley shaft aligned with the Pulley shaft end of the motor.
  • Page 17 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.2.12 Screw the step motor to the housing using the four hexagon socket screws. Hexagon socket screw Motor Fig.4-25: Screw the motor 4.2.13 Screw the lid of the housing (No 2) to the housing using the hexagon socket...

  • Page 18: Assembly Z-Axis

    OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y Assembly Z-axis 4.3.1 Remove the three screws of the spindle cover of the Z-axis and take off the cover. Spindle cover Z-axis Fig.4-28: Remove spindle cover...
  • Page 19 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.3.4 Mount the pulley (No 4) on the shaft of the Z-axis (beforehand apply some Loc- Pulley tite on the motor shaft) and lock it with the nut (No 5).
  • Page 20 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.3.7 Put the belt on the pulley in the hou- sing. Belt Fig.4-34: Attach the belt 4.3.8 Attach the motor (No 9) to the housing. Motor Fig.4-35: Attach the motor 4.3.9...
  • Page 21 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.3.10 Tighten the lid (No 2) on the housing using the four hexagon socket screws. Mount the lid Fig.4-37: Mount the lid of the Z-axis 4.3.11 Unscrew the complete handwheel of the Z-axis and take it off .
  • Page 22 OPTIMUM Assembly CNC kit M A S C H I N E N - G E R M A N Y 4.3.13 Dress the spindle cover of the Z-axis to the appropriate diameter and screw it to the column. Column Z-axis Spindle cover Fig.4-40: Screw on the cover Page 22...

  • Page 23: Assembly Notes

    OPTIMUM Assembly notes M A S C H I N E N - G E R M A N Y Assembly notes Assembly and disassembly of ball bearing spindles Please observe the following assembly and maintenance instructions. If such instructions are ATTEN- not obeyed, the warranty for those components will become null and void TION!

  • Page 24: Maintenance Instruction Ball Bearing Spindle

    OPTIMUM Assembly notes M A S C H I N E N - G E R M A N Y Maintenance instruction ball bearing spindle Page 24 Assembly notes Add-on kit BF 46 / BF30 Vario CNC ; Version 1.0.2 23.

  • Page 25: Assembly Ball Bearing Spindles

    OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y Assembly ball bearing spindles Ball bearing spindles Disassembly of all axes 6.1.1 Disassemble the chuck protection and the handle at the head. 6.1.2 Lift the head from the head carrier using an appropriate lifting gear.
  • Page 26 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.1.5 Disassemble the cover of the Z-axis. Cover Fig.6-4: Unscrew the lid 6.1.6 Unscrew the fixing screws of the spindle block at the head carrier.
  • Page 27 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.1.8 Unscrew the cover of the Z-column. Then remove the V-ledge of the Z-axis. Cover Z-axis Fig.6-7: Loosen the cover 6.1.9 Shift the head carrier from the column to the top and take it off.
  • Page 28 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.1.11 Unscrew the stopper in the center and at the left and right ruler stopper on the table. Stopper Fig.6-10: Disassemble stopper 6.1.12...
  • Page 29 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.1.14 Disassemble the bearing lid of the X- and Z-axis. Also remove the V-ledges of the X- and Y-axis. Bearing lid Fig.6-13: Take off the bearing lid 6.1.15...
  • Page 30 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.1.17 Loosen the nut holder of the Y-axis. Unscrew the screws from the plate Fig.6-16: Remove the screws for the holder 6.1.18 Take off the carriage of the Y-axis.

  • Page 31: Assembly On The X- And Y-Axis

    OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.1.20 Completely clean the machine. Cleaner Fig.6-19: Clean the machine Assembly on the X- and Y-axis 6.2.1 Disassemble the nut of the Y-axis. Nut of the Y-axis Fig.6-20: Disassemble the nut 6.2.2...
  • Page 32 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.2.3 Check the assembly surface at the bot- tom of the Y-axis carriage. The surface has to be free from color remnants. Assembly surface at the carriage of the Y- axis...
  • Page 33 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.2.6 Assemble the bearing plate of the Y- axis. Bearing plate Fig.6-25: Screw on the bearing plate 6.2.7 Assemble the distance ring and the feather key of the Y-axis.
  • Page 34 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.2.9 Assemble the distance bushings on the spindle and adjust the bearing clea- rance using the nut. Distance piece Fig.6-28: Adjust the clearance of the bearing 6.2.10...
  • Page 35 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.2.12 Assemble the two bearing plates of the X-axis and readjust the V-ledge once again. Bearing plate Fig.6-31: Put on the bearing plate 6.2.13 Mount the distance ring on the right side of the X-axis using the feather key...

  • Page 36: Assembly On The Z-Axis

    OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y Assembly on the Z-axis 6.3.1 Mount the spindle holder for the Z-spindle. In doing so, drill the holes to fix the nut, if necessary.
  • Page 37 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.3.4 Insert the spindle with the holder into the column from the top. Then put the Spindle spindle into the column. Fig.6-36: Insert the spindle 6.3.5 Mount the head carrier, build in the...
  • Page 38 OPTIMUM Assembly ball bearing spindles M A S C H I N E N - G E R M A N Y 6.3.7 Screw the head carrier to the Z-axes holder. Head carrier Fig.6-39: Mount head carrier 6.3.8 Put the bearing plate on the column and tighten the screws.

  • Page 39: Installation Of Step Motors

    OPTIMUM Installation of step motors M A S C H I N E N - G E R M A N Y Installation of step motors Wiring X-, Y- and Z-axis 7.1.1 Open the lid of the step motor using a crosstip screwdriver.
  • Page 40 OPTIMUM Installation of step motors M A S C H I N E N - G E R M A N Y 7.1.4 Peel off the cables at a length of about 5 mm using insulation stripping tongs. 7.1.5 Plug and press wire terminations on the ends of the cables. 7.1.6 Plug the strain relief over the cable.

  • Page 41: Plug Assembly For X-, Y- And Z-Axis

    OPTIMUM Installation of step motors M A S C H I N E N - G E R M A N Y Plug assembly for X-, Y- and Z-axis 7.2.1 Remove about 3cm of the isolation at the other end of the motor cable. Twist the shielding to a connectable Shielding conductor bunch.
  • Page 42 OPTIMUM Installation of step motors M A S C H I N E N - G E R M A N Y 7.2.4 Slide the plug together with the table clamping from the rear into the housing. Beforehand slide the color Cable clamping marking over the cable.

  • Page 43: Appendix

    OPTIMUM Appendix M A S C H I N E N - G E R M A N Y Appendix Copyright © 2008 The documentation is copyright. All derived rights are also reserved, especially those of transla- tion, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, neither partial nor total.

  • Page 44: Liability Claims For Defects / Warranty

    OPTIMUM Appendix M A S C H I N E N - G E R M A N Y Liability claims for defects / warranty Beside the legal liability claims for defects of the customer towards the seller the manufacturer of the product, OPTIMUM GmbH, Robert-Pfleger-Straße 26, D-96103 Hallstadt, does not grant any further warranties unless they are listed below or had been promised in the frame of a single contractual agreement.

  • Page 45: Product Follow-Up

    We would be grateful if you could send us the following information: modified settings experiences with the BF 46 / BF30 Vario CNC, which could be important to other users Repeated failures Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D-96103 Hallstadt Phone +49 (0) 951 - 96 822 - 0 Fax +49 (0) 951 - 96 822 - 22 E-Mail: info@optimum-maschinen.de...
  • Page 46 OPTIMUM M A S C H I N E N - G E R M A N Y Mounting examples Version 1.0 Universal reference switch kit 23. Oktober 2008 Reference switch Universal mounting kit ; Version1.0 Page 1...
  • Page 47 OPTIMUM Packing list M A S C H I N E N - G E R M A N Y Packing list CNC reference switch with universal mounting parts Bezeichnung Designation Artikelnummer Anbausatz 357 1980 Item no. mounting set Netto Gewicht 0,7 kg Net Weight Brutto Gewicht...
  • Page 48 OPTIMUM Mounting examples reference switch BF30 Vario/ BF46 Va- M A S C H I N E N - G E R M A N Y Mounting examples reference switch BF30 Vario/ BF46 Vario Y-axis X-axis Z-axis 23. Oktober 2008 Anbaubeispiel Referenzschalter BF30 Vario/ BF46 Vario ;...
  • Page 50 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y The necessary adjustments for the start-up of the milling machine can be done in the menu "Control", sub-menu "Settings" (please note marking in Picture 3). Abb.0-4: Description of setting This menu (Picture 4) contains several sub-menu-cards in which the settings have to be inser- ted.
  • Page 51 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Abb.0-5: Description of setting 4. The fourth sub-menu-card "Tool change" is not relevant for the use of the milling machine BF 20 Vario.
  • Page 52 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Abb.0-7: Description of setting In Picture 7 are shown example settings for the X-axis of the BF 20 Vario. Due to the fact that at all milling machines the names of the three main axes are standardized it is not possible to insert different names to the section "Axis"...
  • Page 53 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Abb.0-8: NCdrive diagnostics Here can be selected e.g. the X-axis in section "Axis test" (Detail "A" in Picture 8). Then the axis can be moved back and forth with manually pre-set speeds and accelerations.
  • Page 54 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Configuration of optional accessories 0.5.1 Circular dividing table (4th axis) If a circular dividing table (e.g. RT 100 or RT 150 of OPTIMUM) is connected to the CNC-Con- troller by use of our add-on kit CNC MK RT1 (art.-no.
  • Page 55 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Abb.0-10: Inputs Additionally you have to do several settings for each axis (which has got a switch) at section "Referencing" (Picture11). Abb.0-11: Referencing First you have to assign the sequence of axis movements at reference point run of the machine (Detail "A"...
  • Page 56 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y the correct algebraic sign so that the switch can be surely reached. Consequently you have to insert a positive value for the Z-axis because the sensor usually is mounted to the upper area of the column.
  • Page 57 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y 0.5.3 Actuating of main drive spindle The software NCdrive is able to actuate relays at the CNC-Controller. With these relays can be switched the main drive spindle of the milling machine as well as other devices (e.g.
  • Page 58 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y In the software have to be done following settings for the control of the relays: At the sub-menu-card "Interfaces" you have to insert hooks in section "Control outputs" as shown for relay 1 and 2 to pin 1 and 14 (Detail "A"...
  • Page 59 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y First machine movements Abb.0-19: First machine movements When you have done all the above described connections and adjustments, you can already run the milling machine BF 20 Vario in manual operation mode by NCdrive.
  • Page 60 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Automatic mode and NC-programs Abb.0-20: Automatic mode and NC-programs NC-drive is designed for reading and executing NC-programs which are created according to standard DIN 66025.
  • Page 61 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Simulation of the progam run Abb.0-21: Simulation of the progam run Before a NC-program is running at the milling machine the first time, you should check it by a simulation in all cases.
  • Page 62 OPTIMUM Manual NCdrive M A S C H I N E N - G E R M A N Y Data back-up of the settings We highly recommend that you do a data back-up of the parameter settings after you have made all settings and first test run.

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