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OZGENC MAKINA OMRM 121 User Manual

Automatic end-milling machine
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USER'S GUIDE
AUTOMATIC END-MILLING MACHINE (EQUIPPED WITH A
SERIAL BLADE SYSTEM)
www.ozgencmakina.com.tr

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Summary of Contents for OZGENC MAKINA OMRM 121

  • Page 1 USER'S GUIDE AUTOMATIC END-MILLING MACHINE (EQUIPPED WITH A SERIAL BLADE SYSTEM) www.ozgencmakina.com.tr...

  • Page 2: Table Of Contents

    GENERAL INFORMATION Contents GENERAL INFORMATION ......................... 5 1. DOCUMENT ISSUING INFORMATION ....................5 1.1 After-sales Service ......................... 5 1.2 Certification Process ........................6 1.3 Procedures to Follow ........................7 2. SCOPE OF USER'S GUIDE ........................8 3. Machine Description ........................... 8 Options .............................
  • Page 3 GENERAL INFORMATION 7.3 Fault Control During Shipment ....................24 8. Machine Installation .......................... 25 8.1. Machine Placement ........................25 8.2 Fixing on Ground ......................... 25 8.3 Start-up Preparation ........................25 8.4 Electrical Connections ......................... 25 8.5 Electrical Panel Scheme and Equipment Structure ..............26 8.6 Pneumatic Connections .......................
  • Page 4 GENERAL INFORMATION 13.2 PNEUMATIC DIAGRAM ......................50 13.3 EXPLODED PICTURES AND LIST OF MATERIALS ..............50 13.4 LIST OF SPARE PARTS ......................50 P a g e...

  • Page 5: General Information

    GENERAL INFORMATION GENERAL INFORMATION Includes general topics related to the user’s guide. 1. DOCUMENT ISSUING INFORMATION REVISION 2016 1.1 After-sales Service Address: Nilüfer Organize Sanayi Bölgesi 113. Sk. No:23 Nilüfer BURSA/TURKEY 16250 Contact: TEL: +90 224 411 07 46 FAX: +90 224 411 07 49 E-mail: info@ozgencmakina.com.tr Note: Spare parts are supplied by our below-mentioned company.

  • Page 6: Certification Process

    1. DOCUMENT ISSUING INFORMATION 1.2 Certification Process The machine (OMRM 121) with the technical features described in the user's guide is compatible with CE norms. Safety measures are taken in line with CE norms. CE documents are provided upon request.

  • Page 7: Procedures To Follow

    1. DOCUMENT ISSUING INFORMATION 1. DOCUMENT ISSUING INFORMATION 1.3 Procedures to Follow Warning symbols and phrases in this document should be taken into consideration. Warning symbols and phrases in this document should be taken into consideration. Warning symbols and phrases in this document should be taken into consideration. These warning signs are intended to protect occupational health and avoid any hazard.

  • Page 8: Scope Of User's Guide

    2. SCOPE OF USER'S GUIDE 2. SCOPE OF USER'S GUIDE User’s guide is a document which must be read by the operating personnel before operating the machine. It covers all the required information for machine use. Information about how to provide long-term use of the machine and basic maintenance information is also contained in this document.

  • Page 9: Machine Description

    3.2 Machine Cutting Capacity OMRM 121 End milling machine can process profiles with max 90 mm height, profiles with 120 mm length for 90°cutting and profiles with 90 mm wide for 45° cutting process.
  • Page 10 3. Machine Description 10 | P a g e...

  • Page 11: Machine Specifications

    3. Machine Description 3.3 Machine Specifications 3.3 Machine Specifications Operating Voltage Volt (V) Total Force Drawn Kilowatt (Kw) Current Ampere (A) Operating Pressure Total Air Consumption L/Min Number of Engines Number Engine Power Kilowatt (Kw) Engine Speed 2810 Blade Sizes ØB ØA Max.

  • Page 12: Machine Layout And Unit Structure

    4. Machine Layout and Unit Structure 4. Machine Layout and Unit Structure A- User Control Panel B- Protection Cover C- Pressure/Fixing Pistons D- Profile Support Lever E- Electrical Panel Board F- Blade Group Storage Container G- Profile Lateral Support Square 12 | P a g e...
  • Page 13 4. Machine Layout and Unit Structure A- Blade Group B- Tray C- Blade Replacement Button 13 | P a g e...

  • Page 14: General Machine Size

    4. Machine Layout and Unit Structure 4.1 General Machine Size 14 | P a g e...

  • Page 15: Machine Placement

    4. Machine Layout and Unit Structure 4.2. Machine Placement While placing the machine, take the range of motion into account to operate the machine. In addition, allow for a certain distance for the machine's panel doors to open when necessary. Take following sizes into account for safe operation.

  • Page 16: Occupational Safety And Measures

    Operator is responsible for use, cleaning, adjustment, operation, maintenance etc. 5.3 Machine Usage and Misuse OMRM 121 machine is designed for end-milling profile cutting. Any machine fault and occupational safety gap that may caused by machining non-PVC materials shall lie with the user’s responsibility.

  • Page 17: General Safety Rules

    5. OCCUPATIONAL SAFETY and MEASURES 5.4 General Safety Rules OMRM 121 end-milling machine is suitable for only one single operator. Operator must not operate the machine in case of any lack of attention caused by drugs, alcohol or medication. Operator must check the machine and components prior to operation. It should be ensured that the main switch is turned off during routine maintenance.

  • Page 18: Connections

    5. OCCUPATIONAL SAFETY and MEASURES 5.8 Connections All necessary connections must be prepared at the layout site in line with the machine. Electrical power, pneumatics or similar demands must be at values meeting requirements, and compatible equipment must be kept available at the layout site. Take IEC 64-8 norm into consideration for the installation of electrical equipment.

  • Page 19: Safety Equipment

    6. Safety Equipment 6. Safety Equipment DANGER! It is not permitted to remove or deactivate safety measures taken for the machine and equipment. 19 | P a g e...
  • Page 20 6. Safety Equipment 20 | P a g e...

  • Page 21: Risky Areas And Warnings

    6. Safety Equipment 6.1 Risky Areas and Warnings 6.1 Risky Areas and Warnings Safety measures are taken on the machine through equipment, but it is also required to comply Safety measures are taken on the machine through equipment, but it is also required to comply Safety measures are taken on the machine through equipment, but it is also required to comply with additional visual safety measures at the operating site.

  • Page 22: Noise Emission

    6.2 Noise Emission There is no noise emitted by machine units with an impact on occupational health. 6.3 Disposal of Hazardous Substances If the user uses lubrication and cooling equipment, then apply the methods indicated on respective labels. 7. Machine Start-up 7.1 Domestic Shipping Our machines are specially packed in accordance with the size and weight criteria.
  • Page 23 7. Machine Start-up Important NOTE: Remember to take off the protective wedge which is put to use during shipment, once you are done with placing the machine! A- Forklift B- Machine C- Shipment Vehicle Take necessary precautions during the machine is being taken off the vehicle. Take action to avoid any skid.

  • Page 24: International Shipping

    7. Machine Start-up 7.2 International Shipping Any machine to be shipped abroad is packed in wooden boxes according to its size. Some environmental equipment with a risk of damage during packaging procedures must be demounted and separately packed. 7.3 Fault Control During Shipment Check the machine for any fault and damage that may arise during shipment and report to the shipping company in case you encounter a problem.

  • Page 25: Machine Installation

    8. Machine Installation 8. Machine Installation Expert M.S.K. personnel will carry out all procedures with regard to loading and unloading and conduct performance tests for assembly, mounting and start-up, if necessary. These procedures are evaluated on machine basis and carried out for products deemed necessary. Setting up of parts and equipment which should be prepared prior to machine use must be performed.

  • Page 26: Electrical Panel Scheme And Equipment Structure

    8. Machine Installation 8.5 Electrical Panel Scheme and Equipment Structure This electrical panel scheme is provided solely for placement of components within the panel. See ANNEXES for an in-depth electrical scheme. A- Electric Terminal Group B- Power Supply C- Double Relay D- Contactor E- Motor Protection F- 6A Fuse...

  • Page 27: Pneumatic Connections

    8. Machine Installation 8.6 Pneumatic Connections Ideal air pressure for the machine to properly function is 6 bar. Check the manometer. Attach the air hose from the compressor to this inlet. Caution: Make sure that your air supply is dry! Solenoid Valve group controls the motion of current pneumatic equipment.

  • Page 28: Machine Use

    9. Machine Use 9. Machine Use 9.1 Machine Start/Stop Make sure that there are no foreign objects on machine prior to operation. 9.2 Turning on Machine MAIN SWITCH Rotate the main switch clockwise until it slots into place. Check whether the EMERGENCY/STOP button on the manual control panel is rearward. (EMERGENCY STOP BUTTON MUST BE REARWARD!!) 28 | P a g e...

  • Page 29: Control List

    9. Machine Use 9.3 Control List Main Switch: It completely cuts off the power supply from mains. The emergency stop button on the operator's panel solely stops the operation. Contact with moving parts may lead to electric shock. Do not use sharp objects on protective isolation equipment as they may do harm. Do not use pointed objects that can penetrate into the protective isolation equipment.

  • Page 30: Control Panel And Features

    9. Machine Use 9.4 Control Panel and Features 9.4 Control Panel and Features A- Main Switch B- Pres/Fixing piston profile clamping button C- Pres/Fixing piston profile release button D- Button to start engine E- EMERGENCY STOP button 30 | P a g e...

  • Page 31: Moving Equipment On Machine

    9. Machine Use 9.5 Moving Equipment on Machine A- Pressure/Fixing Pistons B- Blade Group C- Multi-stage Profile Shield D- Lateral Support Square E- Blade Group Movement Lever F- Motor Shaft Piston 31 | P a g e...

  • Page 32: Automatic End Milling Procedure And Machine Settings

    9. Machine Use 9.6 Automatic End Milling Procedure and Machine Settings Rotating adjustment system Profile support Multi-stage Profile loading location profile support Operations During Usage • Turn on main switch • A suitable setting is selected on the rotating adjustment system depending on the profile to be machined •...

  • Page 33: Replacement Of Cutting Blades

    9. Machine Use 9.7 Replacement of Cutting Blades 1- Blade Group Replacement Button 2- Blade Engine Mill 3- Clamp 4- Blade Group 33 | P a g e...
  • Page 34 9. Machine Use Process Steps • Hold the blade group replacement button • The engine mill will go up • Take off the clamp on the top of the blade group • Pull up and take off the blade group •...
  • Page 35 9. Machine Use Once you hold the blade group replacement button, the engine mill goes up Remove the collar after the shaft is moved to the top 35 | P a g e...
  • Page 36 9. Machine Use After taking off the clamp, place the new blade group After fitting the new blade group press and hold the blade group replacement button and refit the collar. 36 | P a g e...

  • Page 37: Adjusting The Multi-Stage Profile Support To The Desired Angle

    9. Machine Use 9.8 Adjusting the Multi-stage Profile Support to the Desired Angle 1. Multi-stage Profile support 2. Fixing Screw 3. Clamping Springs 37 | P a g e...
  • Page 38 9. Machine Use Loosen the fixing screw with a wrench Remove the clamping springs 38 | P a g e...
  • Page 39 9. Machine Use • After adjusting the multi-stage profile support angle install the clamping springs and then tighten the loose fixing screws with a wrench Adjust the multi-stage profile support to the desired cutting angle. 39 | P a g e...
  • Page 40 9. Machine Use 9.9 Adjusting the Rotating Adjustment System Profile support arm Rotating adjustment system for 4 types of profiles. 40 | P a g e...

  • Page 41: General Maintenance Issues

    10. General Maintenance Issues 10. General Maintenance Issues 10.1 General Maintenance REMARKS DAILY WEEKLY MONTHLY Cleaning top and surroundings of machine Cleaning of oil and other wastes Cleaning of moving parts Cleaning of slides and threaded rods Conditioner control (water, oil) Lubrication points Weekly maintenance Adjust the profile support arm as per the...

  • Page 42: Coolant Control

    10. General Maintenance Issues 10.4 Coolant Control A coolant is put to use in case OMRM 121 Automatic end milling machine is purchased with an aluminum cutting option. 10.5 Conditioner Water Level Control There must be no water in the glass tube on the left side of conditioner (reservoir no. 1). Any accumulated water should be discharged.

  • Page 43: Cylinder Settings

    10. General Maintenance Issues 10.7 Cylinder Settings Loosen nut no. (1). Tighten or loosen bolt no. (2).
This helps to adjust the pressure on the piston (6) within the cylinder (5) and to determine the speed of the cylinder to drive the engine. Loosening screw no.

  • Page 44: Filter Maintenance

    10. General Maintenance Issues Note: In normal standby position of the machine, backward and forward sensors of LED lights in relation to the cylinder position should be lit. You can adjust sensor settings using the special allen key located in the spare part box. 10.9 Filter Maintenance For pressure settings: Pull up the regulator cap "1".

  • Page 45: Ergonomics

    10. General Maintenance Issues 10.10 Ergonomics The machine is compliant with operating ergonomics. Operator's panel height and access to manually adjusted equipment are compliant. Electric and pneumatic panel access is viable. Ergonomic conditions for sampling, loading and pre-preparation are suitable. 45 | P a g e...

  • Page 46: Problem Detection Chart

    11. Problem Detection Chart 11. Problem Detection Chart FAILURE CAUSE SOLUTION Machine Fails to Draw • Main board switch Power Turned off • Turn on main switch Pneumatic Equipment Do • Machine fails to Not Operate draw air • Check the compressor line Pistons Do Not Mangle •...
  • Page 47 • Valve coil may • Remount the coil In case valve is broken have been • Tighten or replace dislocated cables • Coil cables may be • Oil the valve loose or burnt • Check hose • Valve may have •...

  • Page 48: Warranty Disclaimer

    12. Warranty Disclaimer The term of warranty starts as of the invoice date and it is 2 years. The machine is under our company's warranty for any manufacturing and material-related defects. If the machine breaks down within the term of warranty, the period of time spent to repair is added to the term of warranty.

  • Page 49: Out Of Warranty Situations

    12. Warranty Disclaimer 12.1 Out of Warranty Situations Consumables (milling, drilling bits, saws, teflon, etc.) are out of warranty. Damages to arise during shipment. Defects resulting from use of non-original parts. Defects resulting from user's lack of attention or knowledge. The machine must be initially started up by the service officer.

  • Page 50: Annexes

    13. Annexes 13. Annexes 13.1 ELECTRIC CIRCUIT DIAGRAM 13.2 PNEUMATIC DIAGRAM 13.3 EXPLODED PICTURES AND LIST OF MATERIALS 13.4 LIST OF SPARE PARTS 50 | P a g e...
  • Page 51 13. Annexes 51 | P a g e...
  • Page 52 13. Annexes 52 | P a g e...
  • Page 53 13. Annexes 53 | P a g e...
  • Page 54 13. Annexes 54 | P a g e...
  • Page 55 13. Annexes 55 | P a g e...
  • Page 56 13. Annexes 56 | P a g e...
  • Page 57 13. Annexes 57 | P a g e...
  • Page 58 13. Annexes 58 | P a g e...
  • Page 59 13. Annexes 59 | P a g e...
  • Page 60 13. Annexes 60 | P a g e...
  • Page 61 13. Annexes 61 | P a g e...

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