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Summary of Contents for Milltronics RH Series
- Page 1 Instruction Handbook for RH & RW Series Machining Centers Milltronics Manufacturing Company 1400 Mill Lane Waconia, MN 55387 USA Phone 952-442-1410 Fax 952-442-6457 www.milltronics.net Rev 9-17-2013...
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Page 3: Table Of Contents
NSTRUCTION ANDBOOK 1973 ERVING THE ETAL UTTING NDUSTRY INCE • W 1400 M , MN 55387 ACONIA : 952.442.6455 • F : 952.442.6457 Table Of Contents Chapter 1 - Safety ......................1 Safety Checklist......................2 Basic Points Of Safety....................2 Clothing and Personal Safety.................. - Page 5 Safety Checks, to be carried out monthly and after maintenance operations..... 38 Air System Maintenance .................... 39 Way Lube Maintenance....................40 Automatic Tool Changer (ATC) Maintenance............. 43 Chapter 7 – 8200 CNC Operation ................. 45 Milltronics 8200 CNC Front Panel ................45 Power ON........................45 Power OFF ......................... 45...
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Page 7: Chapter 1 - Safety
Chapter 1 - Safety The general principles for safe operation of Milltronics machines are outlined in this manual. Every Milltronics machine is engineered for safety. You will note, for example, that all rotating parts are protected by specially designed covers. On some models, the... -
Page 8: Safety Checklist
Safety Checklist • Always observe the safety instructions inscribed on the safety labels fixed onto the machine. Do not remove or alter these labels. • Do not attempt to operate this machine until you have read the manuals supplied with the machine and understand each of the functions and operation methods. •... -
Page 9: Clothing And Personal Safety
• Do not subject the CNC control unit, the operator’s panel, or the electrical control panel to strong voltage fluctuations. • Do not change any machine parameter values without consulting Milltronics service department. If it becomes necessary to change a value, first check if it is safe to do so, then make a note of the original value so it can be reset if necessary. - Page 10 • Always use safety shoes with steel toecaps and oil resistant soles. • Do not operate the machine while wearing loose or baggy clothes. • Always completely fasten buttons and hooks on the arms of clothing to avoid danger of entanglement in machine mechanisms. •...
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Page 11: Safety Related To Workpiece Machining And Tooling
1 - S HAPTER AFETY Safety Related to Workpiece Machining And Tooling 1. DANGER • Never operate the spindle above the rated speed of accessories mounted on it (chucks, tooling, etc). • Do not extend stock out of a lathe headstock without an appropriate bar feed or support. -
Page 12: Electrical Safety
Electrical Safety Read and understand the following list of cautions before attempting to perform service on this equipment. Failure to observe these rules can result in death or serious injury. 1. DANGER • Only qualified personnel should attempt to take current and voltage readings or perform service. -
Page 13: Machine Safety Labels
1 - S HAPTER AFETY enclosure, the machine should be put in an emergency stop condition, de-energizing the axis servo motors and spindle motor. Following these precautions prevents someone from becoming trapped or entangled in the machine. If a person should become trapped in the machine, the safest procedure is to put the machine in emergency stop by pressing the red EMERGENCY STOP button, then powering the machine down using the main disconnect switch on the door of the electrical cabinet at the rear of the machine. -
Page 14: Safety And Maintenance Label Locations And Descriptions
Safety and Maintenance Label Locations and Descriptions Item Description Page Danger and Safety Precaution Projectile Hazard Chip Auger/Conveyor Hazard Main Power hazard and Notice ATC crush hazard Auger warning Warmup and daily checks Spindle Operation and Precaution Drawbar Maintenance (if equipped) For Inline spindle models only Waylube maintenance Air system maintenance ATC maintenance... - Page 15 1 - S HAPTER AFETY Read and understand all Safety, Operation, and Maintenance labels affixed to the machine to ensure safety and reliability. Located near access doors on models equipped with full enclosure. Located around hazard areas on models equipped with chip conveyor. Located around hazard areas on models equipped with chip auger.
- Page 16 Located near main power disconnect switch on all models. Located near Automatic Tool Changers and other potential crush hazard areas. Located on chip auger chute if equipped. All models, located near operator station. Perform all checks to prevent damage and ensure reliable operation. All models, located near operator station.
- Page 17 1 - S HAPTER AFETY Maintenance labels located on machine near maintenance items. Various labels are used depending on options/equipment. Maintenance labels located on machine near maintenance items. Various labels are used depending on options/equipment. Maintenance labels located on machine near maintenance items.
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Page 19: Chapter 2 - Specification
Chapter 2 - Specification Basic Machine Specifications Machine Model RW15 RH20 RH30 750 lb 2500 lb 3000 lb Maximum Table Load 340 kg 1130 kg 1360 kg 6500 lb 8000 lb 11,000 lb Machine Weight 2950 kg 3628 kg 5000 kg 4"... -
Page 20: Rh20 & 30 Machine Layout
RH20 & 30 Machine Layout... -
Page 21: Rw15 Machine Layout
2 - S HAPTER PECIFICATION RW15 Machine Layout... -
Page 22: Item Identification
Item Identification... - Page 23 2 - S HAPTER PECIFICATION Operator panel Spindle ATC, Carousel and ARM types Auger Chute Electrical cabinet Y-axis cable track Z-axis cable track Leveling pad Waylube unit Air system Z-axis motor...
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Page 24: Retention Knob Chart
Retention Knob Chart... -
Page 25: Chapter 3 - Site Preparation
1. At least 4” thick concrete slab free of cracks and not crossing any expansion joints. Milltronics will not guarantee machine geometry unless this is adhered to. 2. Ample ceiling height, and clearance behind the machine to fully open the door of the electrical cabinet at the rear of the machine. -
Page 26: Power And Ground Requirements
4. Milltronics does not allow the use of a separate grounding rod. 5. Milltronics does not allow conduit or wire raceways be used as a ground. 6. If a transformer is used to step the voltage down to 220 refer to the transformer grounding procedures immediately following this page. -
Page 27: Connecting A Transformer
3 – S HAPTER REPARATION Connecting a Transformer It is important that proper grounding procedures be followed when hooking up machines to power. Please review the following pages. They explain proper transformer connections and checks to ensure proper connections. Refer to the autotransformer diagram provided to verify that your connections are suitable. -
Page 28: Autotransformer Connection Diagram
Autotransformer Connection Diagram If your machine was ordered from Milltronics with a transformer option an autotransformer is supplied. The diagram below illustrates the various input voltage selections and proper ground wire connections. Always call the factory if in doubt concerning transformer connections as serious... -
Page 29: Air Supply System
3 – S HAPTER REPARATION Air Supply System Milltronics machining centers require a constant supply of quality air pressure in order to perform optimally. 90-110 PSI at 10 CFM is required for RW15-20 and RH19-30 models. Adjustments • Do not adjust the air purge regulator unless instructed to do so by an authorized Milltronics Representative. -
Page 30: Lifting By Crane Or Hoist
This machine should only be moved, loaded/unloaded, or skidded/unskidded by a Lifting By Crane or Hoist trained and certified machine mover. -
Page 31: Chapter 4 - Installation
Startup checklist The enclosed startup checklist guides the process of the machine installation and checkout. The startup checklist forms must be completed and sent to Milltronics Mfg. to activate the machine warranty. Use the startup checklist in conjunction with the following outline when installing and setting up the machine. - Page 32 Install or adjust the Z-axis cable track as shown (if applicable). In many cases this track is loosened or removed for shipping. Connect the remote hand controller (if equipped) cable into the 25-pin “D-sub” connector to the right side of the operator panel.
- Page 33 4 - I HAPTER NSTALLATION Slide the flood coolant tank under from the front of the machine (if equipped). Install the auger chute (if equipped)
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Page 34: Finish Level And Tram The Machine
Note: This procedure is duplicated as part of the startup checklist enclosed. Please make note of the final tram readings on the startup checklist forms to be returned to Milltronics. 1. Center the table in the travels of both the X and the Y-axes. -
Page 35: Initial Checks Of The Machine, Its Guards And Safety Systems
4 - I HAPTER NSTALLATION Initial Checks of the Machine, its Guards and Safety Systems General Checks 1. Check for missing parts. Do not operate the machine if parts are missing. 2. Visually check for damage outside of machine and inside. Do not operate the machine if there has been shipping damage. -
Page 36: Visually Check That Guards Are In Place
WARNING: DANGEROUS VOLTAGES EXIST FOR THE VOLTAGE LEVEL CHECKS! 2. Check voltage levels. As stated in the Electrical Safety Rules, only qualified personnel (as described in chapter 1) should attempt to take these measurements. With the electrical cabinet door open, turn on the main power at the disconnect switch. -
Page 37: Safety Checks
4 - I HAPTER NSTALLATION Safety Checks Follow the sequences outlined below for Milltronics control. Home the Machine During this operation, the machine will move. Before starting the operation, make sure any shipping clamps that might impede machine movement have been removed and nothing else remains to interfere with machine motion. -
Page 38: Test The Enclosure Safety Circuit (Ce Machines Only)
Spindle rotation should stop. The emergency stop button is the most important safety switch on the machine. It stops and then de-energizes the spindle motor. (At the same time, it stops and de-energizes the axis servo motors, although they are not running for this test.) When the red emergency stop button is pushed, the spindle should brake to a rapid stop. -
Page 39: Spindle Start Up Procedure
4 - I HAPTER NSTALLATION Spindle Start up Procedure Daily Run-in procedure 1. Start the flood pump or chiller unit (if equipped) and run coolant through coolant passages until the temperature stabilizes. 2. Clamp a tool holder into the spindle. Never operate the spindle without a tool holder installed. -
Page 41: Chapter 5 - Failure Modes, Detection And Prevention
Chapter 5 - Failure Modes, Detection and Prevention Minimizing Wear and Tear • The effects of everyday wear and tear may be minimized by good maintenance practice. Items high on the maintenance list include keeping the machine clean, providing clean dry compressed air with the correct oil drip into the air stream, and continuous application of the correct way oil through the automatic oiler. -
Page 42: Diagnosing Mechanical Faults
Diagnosing Mechanical Faults • Eyes, ears and hands are the best tools for detecting mechanical failure modes. As is the case for electrical faults, an accidental crash between tool and workpiece is a likely way to cause mechanical damage. A wide variety of mechanical failure modes also are possible even without a crash. -
Page 43: Chapter 6 - Maintenance
Chapter 6 – Maintenance Periodic Maintenance; Verification Of Safety Systems Note: Before performing any of the procedures in this section, please read and follow the directions in this manual covering safe practices for operation, setting and maintenance. Maintenance operations should only be performed by qualified personnel as described in chapter 1. -
Page 44: Monthly
Monthly • Lubricate the counterweight chains (if applicable). • Inspect ballscrews and way surfaces. Adjust gibs if necessary. • Visually inspect all oil lines, and repair or replace as necessary. • Inspect all belts for excess wear, damage, and proper tension. •... -
Page 45: Air System Maintenance
• Ensure the automatic water trap drain is working. Adjustments • Do not adjust the air purge regulator unless instructed to do so by an authorized Milltronics Representative. • Set the drop rate on the lubricator to approximately 1 drop per every 1-2 tool changes... -
Page 46: Way Lube Maintenance
Way Lube Maintenance • Ensure the way lube reservoir level is maintained (if equipped). (Use Mobil Vactra No. 02, Amoco Waytec No 68, Sunoco Sunwaylube No1180, or equivalent oil, more details found in mechanical manual). • Clean the intake filter screen annually. •... -
Page 47: Automatic Tool Changer (Atc) Maintenance
Automatic Tool Changer (ATC) Maintenance 16 or 24 Pocket carousel style ATC Lubrication is automatic via the lubrication system on the machine. No scheduled maintenance is required, but the area should remain free of chips and coolant overspray. Drawbar cylinder lubrication Fluid level should be approximately 1/3 of the way to the top when the drawbar cylinder is in the normal... -
Page 49: Chapter 7 - 8200 Cnc Operation
Chapter 7 – 8200 CNC Operation Milltronics 8200 CNC Front Panel 3 4 5 Power ON The main power switch is located on the electrical cabinet at the back of the machine. When main power is switched on, the power to the CNC is also applied. - Page 50 1) Manual Pulse Generator (HANDWHEEL) - rotate this wheel to control axis feed while in HDW mode. 2) FEEDRATE override rotary switch - labeled in percentages. Controls the feedrate and rapid traverse (Exception - see #3) of the machine axes. Also affects handwheel rate.
- Page 51 8) SPINDLE CW/STOP/CCW o Spindle CW button – starts spindle in clockwise direction provided there is a programmed spindle rpm. o Spindle CCW button – starts spindle in counter-clockwise direction provided there is a programmed spindle rpm. o Spindle STOP button – stops spindle rotation. 9) EMERGENCY STOP button –...
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