Optimum Optimill F3 Operating Manual
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Optimum Optimill F3 Operating Manual

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OPTIMUM
M A S C H I N E N - G E R M A N Y
Operating manual
Version 1.0
CNC milling machine
GB

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Summary of Contents for Optimum Optimill F3

  • Page 1 OPTIMUM M A S C H I N E N - G E R M A N Y Operating manual Version 1.0 CNC milling machine...

  • Page 2: Table Of Contents

    OPTIMUM M A S C H I N E N - G E R M A N Y Table of contents Safety Type plate ..............................6 Glossary of symbols ..........................6 Safety instructions (warning notes)......................7 1.3.1 Classification of hazards...........................7 1.3.2 Other pictograms ............................7 Intended use .............................8...
  • Page 3 OPTIMUM M A S C H I N E N - G E R M A N Y 3.3.2 Installation plan F3 ..........................27 3.3.3 Machine mounting ..........................28 3.3.4 Corrosion protection ..........................28 3.3.5 Electrical connection ..........................29 3.3.6 Current in the Protective Earth Ground Wire..................30 3.3.7 Connection compressed air supply ......................
  • Page 4 OPTIMUM M A S C H I N E N - G E R M A N Y M - Code list, M functions M-function for milling machines according to PAL................153 G functions to PAL..........................155 Notes, messages and error messages...
  • Page 5 Dear customer, Thank you very much for purchasing a product made by OPTIMUM. OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee state-of-the-art products and safety at any time.

  • Page 6: Safety

    OPTIMUM M A S C H I N E N - G E R M A N Y Safety This part of the operating instructions explains the meaning and use of the warning notes included in these operating instructions, ...

  • Page 7: Safety Instructions (Warning Notes)

    OPTIMUM M A S C H I N E N - G E R M A N Y Safety instructions (warning notes) 1.3.1 Classification of hazards We classify the safety warnings into different categories. The table below gives an overview of the classification of symbols (ideogram) and the warning signs for each specific danger and its (possible) consequences.

  • Page 8: Intended Use

    If the CNC machine is used in any way other than described above, modified without the Intended use approval of the company Optimum Maschinen Germany GmbH then the CNC machine is being used improperly. We will not be held liable for any damages resulting from any operation which is not in accord- ance with the intended use.

  • Page 9: Reasonably Foreseeable Misuse

    OPTIMUM M A S C H I N E N - G E R M A N Y Reasonably foreseeable misuse Any other use other than that specified under "Intended use" or any use beyond the described use shall be deemed as non-intended use and is not permissible.

  • Page 10: Qualification Of Personnel

    OPTIMUM M A S C H I N E N - G E R M A N Y strictly follow these operating instructions.  In the event of improper use there may be a risk to personnel,  there may be a risk of damage to the CNC machine and other material values, ...

  • Page 11: Authorized Personnel

    OPTIMUM M A S C H I N E N - G E R M A N Y Qualified personnel Thanks to professional training, knowledge and experience as well as knowledge of relevant regulations the qualified personnel is able to perform the assigned tasks and to independently recognise and avoid any possible dangers themselves.

  • Page 12: Operator Positions

    OPTIMUM M A S C H I N E N - G E R M A N Y before taking the machine in operation  - have read and understood the operating manual, - be familiar with all safety devices and instructions.

  • Page 13: Emergency-Stop Button

    OPTIMUM M A S C H I N E N - G E R M A N Y Img.1-1: Main switch WARNING! Dangerous voltage even if the main switch is switched off. The areas marked by the pictogram might contain live parts, even if the main switch is switched off.

  • Page 14: Control Technical Protection

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.9.3 Control technical protection WARNING! If you bypass a controller you endanger yourself and other persons working on the CNC machine. injuries due to tools, workpieces or fragments hereof which are flying off at high ...

  • Page 15: Personal Protective Equipment

    OPTIMUM M A S C H I N E N - G E R M A N Y General check Equipment Check Protective housing Switching function, firmly bolted and not damaged Signs, Installed and legible Markers Sight window Check for mechanical damage (scratches, cracks).

  • Page 16: Safety During Maintenance

    OPTIMUM M A S C H I N E N - G E R M A N Y Do not work on the CNC machine, if your concentration is reduced, for example, because  you are taking medication. Stay on the CNC machine until the program is termi- ...

  • Page 17: Disconnecting And Securing The Cnc Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.14 Disconnecting and securing the CNC machine Turn off the main switch of the CNC machine before starting any maintenance or repair work.

  • Page 18: Accident Report

    M A S C H I N E N - G E R M A N Y 1.16 Accident report Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of accidents, possible sources of danger and any actions which almost led to an accident (near misses).
  • Page 19 OPTIMUM M A S C H I N E N - G E R M A N Y Please follow the requirements of the Water Resources Law when operating, decommissioning or disassembling the CNC machine or parts hereof. Detailed information regarding this can be found in the Ordinance on Installations for the Handling of Substances Hazardous to Water (VAwS).

  • Page 20: Technical Data

    OPTIMUM M A S C H I N E N - G E R M A N Y Technical data The following information represents the dimensions and indications of weight and the manu- facturer‘s approved machine data. Electrical connection Total connection 3 x 400V ~ 50Hz 2.5 KW...

  • Page 21: Dimensions

    OPTIMUM M A S C H I N E N - G E R M A N Y Dimensions Height [mm]  Depth [mm] "Installation plan F3“ on page 27 Width [mm] Total weight [kg] 1400 Working area, traverse path...

  • Page 22: Environmental Conditions - Operation

    M A S C H I N E N - G E R M A N Y Environmental conditions - operation Temperature 19 - 21 °C (for an optimum milling result) 19 - 21 °C (for operation without malfunctions) Admissible relative humidity 5...80 % no condensation...

  • Page 23: Tools And Tool Holding Fixtures

    OPTIMUM M A S C H I N E N - G E R M A N Y 2.12 Tools and tool holding fixtures CAUTION ! When using tools with larger diameters or at higher speeds! The balancing of the tools has to amount to...
  • Page 24 OPTIMUM M A S C H I N E N - G E R M A N Y Technical data Page 24 Original operating instructions Version 1.0 dated 2015-05-27...

  • Page 25: Assembly And Commissioning

    OPTIMUM M A S C H I N E N - G E R M A N Y Assembly and commissioning INFORMATION The CNC-machine is delivered pre-assembled. It is delivered in a transport box. Scope of delivery Compare the delivery volume with the attached packing list.

  • Page 26: Installation And Assembly

    OPTIMUM M A S C H I N E N - G E R M A N Y  Lift the CNC machine carefully from the pallet of the transportation box by means of a crane  or a fork-lift truck.

  • Page 27: Installation Plan F3

    3.3.2 Installation plan F3 1600 1165 A-A ( 0,06 ) Connection compressed air Electrical connection Central lubrication system...

  • Page 28: Machine Mounting

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.3.3 Machine mounting Anchor-free assembly  Align the CNC machine with a machine spirit level. The slope deviation of all levels must not exceed 0.04/1000mm.

  • Page 29: Electrical Connection

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.3.5 Electrical connection  Check the fusing (fuse) of your electrical supply according to the technical instructions regarding the total connected power of the milling machine.

  • Page 30: Current In The Protective Earth Ground Wire

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.3.6 Current in the Protective Earth Ground Wire The degree of the leakage current in the protective earthing conductor depends on whether the internal EMC filter in the Emerson M200 frequency converter is used for spindle rotation speed control or not.

  • Page 31: Connection Compressed Air Supply

    Consider this fact when selecting your cool- ing lubricant. The company Optimum Maschinen Germany GmbH does not assume any guarantee for sub- sequent damages due to unsuitable cooling lubricants. The flashpoint of the emulsion must be higher than 140°C.
  • Page 32 OPTIMUM M A S C H I N E N - G E R M A N Y CAUTION! The cooling lubricant needs to be checked at least weekly, including during downtimes, with regard to its concentration, ph-value, bacteria and fungal decay.

  • Page 33: Refill Central Lubrication System

    OPTIMUM M A S C H I N E N - G E R M A N Y Refill central lubrication system The CNC machine is equipped with a central lubrication system. INFORMATION The CNC milling machine is delivered without lubricating oil. The central lubricating system is located on the left-hand side of the machine housing.
  • Page 34 OPTIMUM M A S C H I N E N - G E R M A N Y Choke manifold system Central lubrication system Reducing the discharge volume per cycle: To reduce oil delivery, remove lock screw, measure “A”, turn adjusting screw clockwise, increasing “A”by “B”...

  • Page 35: Functional Test And Controls

    OPTIMUM M A S C H I N E N - G E R M A N Y Functional test and controls Rotation coolant pump  Check the direction of rotation of the CNC machine. There must be a right-handed rotating field.

  • Page 36: General Information About Cnc

    OPTIMUM M A S C H I N E N - G E R M A N Y General information about CNC Compensation of geometry It is necessary to be able to measure any currently actual position of the CNC-controlled axis in order to perform tool moves on workpieces.The measured value is related to a machine fixed...

  • Page 37: Polar Coordinate System

    OPTIMUM M A S C H I N E N - G E R M A N Y 4.2.2 Polar coordinate system In the Cartesian coordinate system a point is described by e.g. its X- and Y-coordinate. For rotation-symmetric outlines, e.g. circular drilling images the required coordinates can only be calculated with considerable effort.

  • Page 38: Rotary Axes And Secondary Axes

    OPTIMUM M A S C H I N E N - G E R M A N Y 4.2.5 Rotary axes and secondary axes NC machines with rotary table or swivel head Rotary axis: A B C Positive turn around X, Y, Z (right- hand-rule)

  • Page 39: Trigonometric Functions

    OPTIMUM M A S C H I N E N - G E R M A N Y The Greek Pythagoras (from about 580 to 496 before Jesus Christ) had been the first person to prove the following mathematic relation which had later on been named the Pythagorean the- orem.

  • Page 40: User Interface, Machine Control Panel

    OPTIMUM M A S C H I N E N - G E R M A N Y User interface, machine control panel Screen arrangement Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Img.5-1: Screen arrangement...

  • Page 41: Elements On The Ppu(Panel Processing Unit) Front

    OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the PPU(Panel Processing Unit) front Img.5-2: Panel Processing Unit Elements on the PPU Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation"...
  • Page 42 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the PPU Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Description Control keys Shift key...
  • Page 43 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the PPU Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Description Menu function key Opens the wizard main screen.
  • Page 44 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the PPU Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Description Operating area keys Opens the "Machine" operating area Opens the "Program"...

  • Page 45: Key Combination

    OPTIMUM M A S C H I N E N - G E R M A N Y 5.2.1 Key combination Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Opera- tion" Element Description <ALT> + <X>...

  • Page 46: Controls On The Machine Control Panel

    OPTIMUM M A S C H I N E N - G E R M A N Y Controls on the machine control panel Img.5-3: Machine control panel Controls on the machine control panel Element Function Drive voltage Push button with indicator light •...
  • Page 47 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Element Description Handwheel key (with an LED status indicator) Controls the axis movement with external handwheels.
  • Page 48 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Element Description Machine luminaire control key Pressing this in any operating mode switches on/off the machine luminaire.
  • Page 49 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Element Description Forward rotation of the chip conveyor (active only in JOG mode) Pressing this key in any operating mode starts the forward rotation of the chip conveyor.
  • Page 50 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Element Description Y axis key Traverses the Y axis in the positive direction.

  • Page 51: Protection Levels

    OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 808D OPM Operation" Element Description Cycle stop key Stops the execution of NC programs...

  • Page 52: Passwords

    OPTIMUM M A S C H I N E N - G E R M A N Y Protection level 1 Protection level 1 requires a manufacturer password. With this password entry, you can per- form the following operations: Entering or changing all machine data ...

  • Page 53: Operation

    OPTIMUM M A S C H I N E N - G E R M A N Y Operation Safety Commission the CNC machine only under the following conditions: The CNC machine is in proper working order.  The CNC machine is used as intended.

  • Page 54: Operational Modes

    OPTIMUM M A S C H I N E N - G E R M A N Y Signal lamp Pos. Colour Meaning Lights up when activity the EMERGENCY STOP push button Lights up when a disturbance or in set-up operation such as...

  • Page 55: Operation Of The Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y Operation of the machine 6.5.1 Turning on the CNC- machine   Switch on the main switch. "Lockable main switch“ on page 12 ...

  • Page 56: Reference Point Approach After Turning On

    OPTIMUM M A S C H I N E N - G E R M A N Y 6.5.2 Reference point approach after turning on INFORMATION If your machine is configure with ABS encoder (808D ADVANCED), you do not need to reference the axis of the machine.
  • Page 57 OPTIMUM M A S C H I N E N - G E R M A N Y  Traverse each axis to the machine zero point until the referenced sym- bol is shown on the respective axis. Once the axis approaches the refer- ence point, the referenced symbol must shown next to the axis.

  • Page 58: Using The Electronic Handwheel

    OPTIMUM M A S C H I N E N - G E R M A N Y 6.5.3 Using the electronic handwheel The electronic handwheel can always be used when the CNC- machine is referenced,  the sliding door is opened, ...

  • Page 59: Manual Tool Change

    OPTIMUM M A S C H I N E N - G E R M A N Y 6.5.5 Manual tool change ATTENTION! Hold your tool if there is a tool inserted in the spindle.  Press the push button "Open/Close door" and open the sliding door.

  • Page 60: Turning Off The Cnc- Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y 6.5.7 Turning off the CNC- machine  Push the EMERGENCY stop push button. For a long-term standstill of the CNC machine switch it off at the main switch.

  • Page 61: Central Lubrication System

    The optimum cutting speed mainly depends on the material and on the material of the tool. With tools (milling cutters) made of hard metal or ceramic insert it is possible to work with higher speeds than with tools made of high-alloy high speed steel (HSS).

  • Page 62: Standard Values For Speeds With Hss - Eco - Twist Drilling

    OPTIMUM M A S C H I N E N - G E R M A N Y Inserted -tooth cutter with SS [ m/min ] 15 - 30 12 - 25 200 - 300 Inserted-tooth cutter with HM [ m/min ]...
  • Page 63 OPTIMUM M A S C H I N E N - G E R M A N Y The above mentioned indications are standard values. In some cases it may be advanta-  geous to increase or decrease these values.
  • Page 64 OPTIMUM Preparation Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Brief instruction 808D Milling Basic Theory Basic knowledge of programming for milling is required, before operating of a machine !
  • Page 65 OPTIMUM Preparation Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y User interface Moving axis Axis movement The 808D machine control panel (MCP) is used to control manual operation of the axis.
  • Page 66 OPTIMUM Preparation Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Machine coordinate Passwords at the control are used to set the user’s right to Passwords system access the system.
  • Page 67 OPTIMUM Switch On and Referencing Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Switch On and Referencing SEQUENCE Description Switch on Switch on This unit describes how to switch the machine on and reference it.
  • Page 68 OPTIMUM Switch On and Referencing Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE MCP mode Reference If your machine is configure with ABS encoder, you Changing After completing the referencing procedure for do not need to reference the axis of the machine.
  • Page 69 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Tool Setup SEQUENCE Description Create This unit describes how to create and set up tools. A tool must have been created and measured tool before executing the program.
  • Page 70 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Create tool edge A tool must have been created and selected Step 2 The range of tool numbers which can be created before creating a tool edge! by this system is 1 ~32000.
  • Page 71 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Load tool into Step 2 A tool must have been created in the system Spindle before it can be loaded into the active position.
  • Page 72 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Select the required override increment The tool are usually loaded manually into the spindle. according to the buttons on the right(this selection fits all axes) The tool will be automatically loaded into the spindle with an automatic tool changer.
  • Page 73 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE OPTIMUM Start spindle A tool must have been loaded and rotated to the position. Start the spindle before adjusting tools as follows: Press the “Machine”...
  • Page 74 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Use “SELECT” key to set the reference point as “workpiece” (In real measurement, the reference point can be set as either “workpiece”...
  • Page 75 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Enter “0” at “X0” Enter “0” at “Y0” (This is the value of the width of a setting block if it is used.Select one of X0/Y0 according to...
  • Page 76 OPTIMUM Tool Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE User Execute M Please make sure all the machine axes are in interface function Machine...
  • Page 77 OPTIMUM Workpiece Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Workpiece Setup SEQUENCE Description Manual This unit describes how to set the workpiece offset and test the tool results.
  • Page 78 OPTIMUM Workpiece Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Create workpiece A tool must have be created and measured offset before it can be used to set the workpiece offset.
  • Page 79 OPTIMUM Workpiece Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE This method is normally for setting the zero point of the workpiece at the Method 1 Press the “Handwheel”...
  • Page 80 OPTIMUM Workpiece Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE This method is normally used for setting the zero points at the center Method 3 This method is normally used for setting the workpiece zero point at the point of a circular workpiece.
  • Page 81 OPTIMUM Workpiece Setup Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Test tool The tool setup and workpiece setup must have offset results been performed correctly so that it can be...
  • Page 82 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Create Part Program Part 1 Basic Theory A standard program structure is not needed but is...
  • Page 83 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Step 4 The following sequence should be followed to create a part...
  • Page 84 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Inches and Edit program Header N5 G17 G90 G54 With G71 at the header,...
  • Page 85 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y N5 G17 G54 G71 Machine Definition of coordinate target Absolute positioning; with G90 at the...
  • Page 86 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y User Rapid interface motion N5 G17 G90 G54 G71 Feedrate  Spindle speed ...
  • Page 87 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory When traversing circular Contour feedrate with contours with cutter radius User...
  • Page 88 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Determine tool radius of T1 D1 Milling circles and arcs N5 G17 G90...
  • Page 89 OPTIMUM Create Part Program Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Machine Controlling the coordinate Moving to a spindle system fixed position...
  • Page 90 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Create Part Program Part 2 Basic Theory Description Radius and This unit describes how to create a part program, edit the part program and get to know chamfers the most important CNC commands required to produce a workpiece.
  • Page 91 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory With the “OK” SK, the values and cycle Modal call call will be transferred to the part Hole program as shown below.
  • Page 92 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory With the “OK” SK, the values and cycle Modal call call will be transferred to the part Drilling program as shown below.
  • Page 93 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory DAM parameter ① DAM≠0, the first drilling operation (FDPR) cannot exceed the drilling depth. As of the...
  • Page 94 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory With the “OK” SK, the values and cycle Modal call call will be transferred to the part Tapping program as shown below.
  • Page 95 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory For descriptions of RTP, RFP, SDIS and DP,  please see...
  • Page 96 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory With the “OK” SK, the values and cycle call will be transferred to the...
  • Page 97 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory By selecting the “New file” SK, the contour turning data can be inserted into file Sub Program File (.SPF).
  • Page 98 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory After opening the contour data setting window, please make the following settings:...
  • Page 99 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory  For descriptions of RTP, RFP, SDIS and DP, please see Page 91 With the “OK”...
  • Page 100 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory With the “OK” SK, the values and cycle call will be transferred to the part program as shown below.
  • Page 101 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Parameters Meanings Remarks NUM=3 Three slots on the circle AFSL=30 Angle slot length is 30º...
  • Page 102 OPTIMUM Create Part Program Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y 808D Page 102 Operating and Programming — Milling...
  • Page 103 OPTIMUM Simulate Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Simulate Program Simulate A part program must have been created before program (Axis Description it can be tested using “Simulation”.
  • Page 104 OPTIMUM Simulate Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Step 3 Step 2 Press the “CYCLE START” key on the MCP. Press the “Simu.” SK on the PPU.
  • Page 105 OPTIMUM Test Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Test Program Basic Theory Description Program Before the part program can be loaded and executed This unit describes how to simulate a part program before executing it in AUTO mode.
  • Page 106 OPTIMUM Test Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Press the “Machine” key on the PPU. Press the “Prog. cont.” SK on the PPU.
  • Page 107 OPTIMUM Machine Pieces Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machine Pieces Basic Theory Description Time Make sure the machine has been referenced before This unit describes how to use the Time counter function and how to machine pieces and...
  • Page 108 OPTIMUM Machine Pieces Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Piece- Make sure the program is correct before machining “Cycle time” shows how long the program...
  • Page 109 OPTIMUM Machine Pieces Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Step 2 Set the tool length wear parameter of axis X in ”Length X”, the sign determines the...
  • Page 110 OPTIMUM Program Restart Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Program Restart Basic Theory Description Block This unit describes how to restart the part program after a tool has been changed due to Search damage, or remachining has to be performed.
  • Page 111 OPTIMUM Program Restart Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Press the “CYCLE START” key on the MCP to execute the program. Turn the feedrate override on the MCP gradually to the required value.
  • Page 112 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Additional Information Part 1 SEQUENCE Description RS232 is used to transfer the programs to and from...
  • Page 113 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE You can continue sending the part program. Transfer a part program to a PC from the PPU.
  • Page 114 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE SEQUENCE A shared network drive can be made using an ethernet “USB” is used to transfer the programs to and from the NC.
  • Page 115 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE In the "local configuration data" Set the PC's static IP address. in the relevant parameters.
  • Page 116 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE On PC create a shared folder. Step 3 In the “Network Drive Configuration” Enter PC...
  • Page 117 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE If the connection is lost select the drive path and You can now see the press “Connect.”...
  • Page 118 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y A shared network drive can be made using an ethernet Manual face connection between the PC and the PPU so the transferring and...
  • Page 119 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Step 2 Press “Face cutt.” SK on PPU. Enter appropriate data in the ”Face Milling”...
  • Page 120 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Below shows the connection between program and “R variables” status windows parameters Press the “Offset” key on the PPU.
  • Page 121 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE You can change the time on the control if required when the clocks Time changes from summer time to winter time.
  • Page 122 OPTIMUM Additional Information Part 1 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Gear change When a machine has a manual gearbox on the spindle, it is the responsibility of the operator to change gear at the correct place in the part program.
  • Page 123 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Additional Information Part 2 SEQUENCE In MDA mode, you can enter and execute single and multiple Description lines of NC codes.
  • Page 124 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Subprogram function Frequently used machining sequences, e.g. certain contour shapes, are stored in The M function initiates switching operations, such as "Coolant ON/OFF".
  • Page 125 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Polar coordinates Main program Sequence MAIN 123 In addition to the common specification in Cartesian coordinates (X, Y, Z), the points of a workpiece can also be specified using polar coordinates.
  • Page 126 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Machine Additive G110 Pole specification relative to the setpoint position last programmed (in the plane,...
  • Page 127 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Machine coordinate Scaling User Coordinate system rotation interface ROT AROT A scale factor can be programmed for all axes with SCALE, ASCALE. The path is The programmable rotation ROT, AROT can be used: enlarged or reduced by this factor in the specified axis.
  • Page 128 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE SUPA G00 Z300 D0 SUPA→cancel all settable offsets SUPA G00 X0 Y0 User...
  • Page 129 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Program execution N10 G0 X...Z... Program jump NC programs process their blocks in the sequence in which they were arranged when N40 GOTOF LABEL0;...
  • Page 130 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Method 2 Program skip Press the “Machine” key on the PPU. Press the “Auto” key on the MCP.
  • Page 131 OPTIMUM Additional Information Part 2 Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y SEQUENCE Press this SK to delete the contents in the calculator. Machine coordinate Calculator Press this SK to exit the calculator screen.
  • Page 132 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Sample Program Drawing Description Milling Make sure all the preparations and safety measures This unit shows three typical program examples of frequently used milling cycles and the...
  • Page 133 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machining Process ; =======Repeat rectangular pocket milling 3 ② ③ ④ ; ====Repeat rectangular pocket G17 G90 G54 G60 ROT...
  • Page 134 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machining Process Drawing N290 back to workpiece zero point N290 G0 X0 Y0 ; =====Start circular pocket roughing===== Milling ;...
  • Page 135 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machining Process SUB_PART_2.SPF ***CONTOUR**** G17 G90 G60 G54 G17 G90 T1 D1 ;FACEMILL D50 tool 1 is milling tool, diameter 50 mm G0 X3 Y3 G2 X3.27 Y-40.91 I=AC(-52.703) J=AC(-19.298)
  • Page 136 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Drawing Machining Process G17 G90 G54 G71 Machine Part of the cycles in the program are taken as...
  • Page 137 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machining Process N430 SUPA G00 Z300 D0 N430 N440 SUPA G00 X300 Y300 N440 N270 SUPA G00 Z300 D0 N270 ;...
  • Page 138 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machining Process N790 SUPA G00 Z300 D0 N790 N800 SUPA G00 X300 Y300 N800 N580 SUPA G00 Z300 D0 N580 ;...
  • Page 139 OPTIMUM Sample Program Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Machining Process SUB_PART_3.SPF ***CONTOUR**** G17 G90 DIAMOF G0 X7 Y0 G1 Y61.35 G2 X13.499 Y86 I=AC(57) J=AC(61.35) G1 X63 RND=2 M2;/* end of contour */...
  • Page 140 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y ISO Mode Basic Theory Description Siemens standard machining codes are implemented in DIN mode. The 808D also provides appropriate functions for...
  • Page 141 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory ISO code All the ISO codes described in this unit can be After pressing “OK”, the system...
  • Page 142 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Code In DIN mode, the tool length is H01→Offset value 20.0 activated automatically, but in ISO H02→Offset value -30.0...
  • Page 143 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Brief introduction of typical fixed cycle codes in ISO mode. Frequently used letter meanings of typical fixed cycle codes in ISO mode.
  • Page 144 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Boring cycle application example program: Drilling cycle (countersink drilling) application example program: Common programming structures: Common programming structures: G76 X—Y—Z—R—Q—P—F—K...
  • Page 145 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Tapping cycle execution operation graphic: boring cycle execution operation graphic: Common programming structures: With command G99 without operation in red line...
  • Page 146 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory ISO program execution operation graphic: The ISO mode function provided by the 808D can Boring cycle Ⅰ...
  • Page 147 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Program execution Step 3 Beginning of the program Common ISO program 808D ISO program...
  • Page 148 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory ISO programs can be executed in the 808D as follows: Sample program Step 5...
  • Page 149 OPTIMUM ISO Mode Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Basic Theory Standard Siemens programming. Machining the same workpiece as described above (can be compared with the ISO code).
  • Page 150 OPTIMUM Appendix Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Appendix Content Functions Group 1: Modally valid motion commands Name Meaning Functions Rapid traverse G01 * Linear interpolation...
  • Page 151 OPTIMUM Appendix Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Group 3: Programmable frame Group 8: Settable zero offset Name Meaning Name Meaning TRANS Translation G500 *...
  • Page 152 OPTIMUM Appendix Brief instruction 808D Milling M A S C H I N E N - G E R M A N Y Group 13: Workpiece measuring inch/metric Group 44: Path segmentation with SAR modally effective Name Meaning Name Meaning...
  • Page 153 OPTIMUM M A S C H I N E N - G E R M A N Y M - Code list, M functions M-function for milling machines according to PAL Function Function Opening a lock Programmed stop Selected stop...
  • Page 154 OPTIMUM M A S C H I N E N - G E R M A N Y Function Function F150 TC CNC Page 154 Original operating instructions Version 1.0 dated 2015-5-27...
  • Page 155 OPTIMUM M A S C H I N E N - G E R M A N Y G functions to PAL Travelling in rapid traverse Linear interpolation during process Circular interpolation clockwise Circular interpolation anti-clockwise Retention period Accurate stop...
  • Page 156 OPTIMUM M A S C H I N E N - G E R M A N Y Notes, messages and error messages All messages and alarms are displayed in plain text on the control panel. The alarm text con- tains the date, time and a suitable symbol for the cancel criterion.
  • Page 157 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message 700028 Tool is not locked 700029 Reminding information for 1st service plan 700030 Alarm for 1st service plan 700031 Magazin not in spindle pos. or original pos.
  • Page 158 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message 700063 User alarm 64 700064 User alarm 65 700065 User alarm 66 700066 User alarm 67 700067 User alarm 68...
  • Page 159 OPTIMUM M A S C H I N E N - G E R M A N Y SINUMERIK 808 D The Sinumerik 808D complete documentation consists of the manuals listed below, which are accompanying the machine separately. Manuals are strictly necessary for the operator, CNC programmer and also for the maintenance and repair personnel of the F3.
  • Page 160 Take this criterion into account when selecting your cooling lubricant. The company Optimum Maschinen Germany GmbH does not assume any guarantee for sub- sequent damages due to unsuitable cooling lubricants. The flashpoint of the emulsion must be higher than 140°C.
  • Page 161 The selection of cooling lubricants and slideway oils, lubricating oils or greases as well as their care are being determined by the machine operator or operating company. Therefore, Optimum Maschinen Germany GmbH cannot be held liable for machine damages caused by unsuitable coolants and lubricants as well as by inadequate maintenance and servic- ing of the coolant.
  • Page 162 OPTIMUM M A S C H I N E N - G E R M A N Y Only qualified personnel should carry out maintenance and repair work on the CNC machine. Validation Check and maintain all safety-relevant stop, control and measuring devices (validation).
  • Page 163 OPTIMUM M A S C H I N E N - G E R M A N Y 10.3 Inspection and maintenance The type and level of wear depends to a large extent on the individual usage and operating conditions. Any indicated intervals therefore are only valid for the corresponding approved con- ditions.
  • Page 164 OPTIMUM M A S C H I N E N - G E R M A N Y Check Interval Where? What? How?  Fill level status con- Check for liquid level, concentration, pH value, trol bacteria and fungal decay.
  • Page 165 OPTIMUM M A S C H I N E N - G E R M A N Y Check Interval Where? What? How?  Check Check the wipers on the slides. Replace Replace if damaged immediately.  Cleaning "Cleaning the electrical cabinet“ on page 166 Inspection Connections on the servo motors.
  • Page 166 OPTIMUM M A S C H I N E N - G E R M A N Y 10.3.2 Cleaning the electrical cabinet Although the electrical cabinet is con- structed to shut off external air, foreign parti- cles such as dust and dirt may enter the cabinet when the door is open.
  • Page 167 OPTIMUM M A S C H I N E N - G E R M A N Y 10.5 Cooling lubricants and tanks CAUTION! The cooling lubricant can cause diseases. Avoid direct contact with cooling lubricant or parts covered in cooling lubricant.
  • Page 168 OPTIMUM M A S C H I N E N - G E R M A N Y 10.5.1 Inspection plan for water-mixed cooling lubricants Company: No.: Date: used cooling lubricant size to be checked Inspection methods Inspection Procedure and comment...
  • Page 169 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteile - Spare parts - F3 11.1 Ersatzteilbestellung - Ordering spare parts Bitte geben Sie folgendes an - Please indicate the following : Seriennummer - Serial No.
  • Page 170 11.4 Gehäuse - Housing Abb.11-1: Gehäuse - Housing...
  • Page 171 11.5 Unterbau - Substructure Abb.11-2: Unterbau - Substructure...
  • Page 172 OPTIMUM M A S C H I N E N - G E R M A N Y 11.6 Fräskopf - Milling head Abb.11-3: Fräskopf - Milling head DE | GB Ersatzteile - Spare parts - F3 Originalbetriebsanleitung Version 1.0 2015-05-27...
  • Page 173 11.7 Frästisch - Milling table Abb.11-4: Frästisch - Milling table...
  • Page 174 11.8 Frästisch - Milling table Abb.11-5: Frästisch - Milling table...
  • Page 175 11.9 Säule - Column Abb.11-6: Säule - Column...
  • Page 176 OPTIMUM M A S C H I N E N - G E R M A N Y Teileliste - Parts list - F3 Menge Grösse Artikelnummer Bezeichnung Description Qty. Size Item no. Schaltschrank Switch cabinet 0350041001 Tür A Door A 0350041002 Tür B...
  • Page 177 OPTIMUM M A S C H I N E N - G E R M A N Y Teileliste - Parts list - F3 Menge Grösse Artikelnummer Bezeichnung Description Qty. Size Item no. Zahnriemen Gear belt 0350041068 Riemenscheibe Pulley 0350041069...
  • Page 178 OPTIMUM M A S C H I N E N - G E R M A N Y Teileliste - Parts list - F3 Menge Grösse Artikelnummer Bezeichnung Description Qty. Size Item no. Kugellager Ball bearing 6201 03500410137 Kugelumlaufspindel Z-Achse...
  • Page 179 OPTIMUM M A S C H I N E N - G E R M A N Y 11.11 Schaltplan Ersatzteile - Spare parts - F3 DE | GB Version 1.0 2015-05-27 Originalbetriebsanleitung...
  • Page 180 OPTIMUM M A S C H I N E N - G E R M A N Y DE | GB Ersatzteile - Spare parts - F3 Originalbetriebsanleitung Version 1.0 2015-05-27...
  • Page 181 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteile - Spare parts - F3 DE | GB Version 1.0 2015-05-27 Originalbetriebsanleitung...
  • Page 182 OPTIMUM M A S C H I N E N - G E R M A N Y DE | GB Ersatzteile - Spare parts - F3 Originalbetriebsanleitung Version 1.0 2015-05-27...
  • Page 183 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteile - Spare parts - F3 DE | GB Version 1.0 2015-05-27 Originalbetriebsanleitung...
  • Page 184 OPTIMUM M A S C H I N E N - G E R M A N Y DE | GB Ersatzteile - Spare parts - F3 Originalbetriebsanleitung Version 1.0 2015-05-27...
  • Page 185 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteile - Spare parts - F3 DE | GB Version 1.0 2015-05-27 Originalbetriebsanleitung...
  • Page 186 Example: not stackable - do not stack further packing case on top of the first one. Consult Optimum Maschinen Germany GmbH if the CNC machine and accessories are stored for more than three months or are stored under different environmental conditions than those ...
  • Page 187 Experiences with the CNC machine, which could be important to other users  Recurring failures  Difficulties with the documentation  Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D-96103 Hallstadt Technical hotline: Fax +49 ( 0 ) 951 - 96555 - 888 email: info@optimum-maschinen.de Appendix Version 1.0 dated 2015-05-27...
  • Page 188 Any further delivery of contractual products to the customer by third parties with or without knowledge of Optimum Maschinen Germany GmbH shall at the same time require the transfer of the export license conditions. The customer shall be completely liable in case of non-observ- ance of the relevant conditions.
  • Page 189 V-belts, ball bearings, illuminants, filters, sealings, etc. - Non reproducible software errors Any services, which OPTIMUM GmbH or one of its agents performs in order to fulfil any  additional warranty are neither an acceptance of the defects nor an acceptance of its obli- gation to compensate.
  • Page 190 OPTIMUM M A S C H I N E N - G E R M A N Y 12.8.1 Decommissioning CAUTION! Used devices need to be decommissioned in a professional way in order to avoid later misuses and endangerment of the environment or persons.
  • Page 191 OPTIMUM M A S C H I N E N - G E R M A N Y 12.8.5 Disposal of lubricants and coolants ATTENTION! Please imperatively make sure to dispose of the used coolant and lubricants in an environmentally compatible manner. Observe the disposal instructions of your municipal waste management companies.
  • Page 192 M A S C H I N E N - G E R M A N Y EC - Declaration of Conformity in accordance with the Machinery Directive 2006/42/EC Annex II 1.A The manufacturer / Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 distributor: D - 96103 Hallstadt...
  • Page 193 OPTIMUM M A S C H I N E N - G E R M A N Y Index for water-mixed cooling lubricants ....168 Installation plan ............. 27 Accident report ............18 Interlock switch sliding door ........ 166 Accuracy ...............21 Alarms ..............156...
  • Page 194 OPTIMUM M A S C H I N E N - G E R M A N Y Tool commissioning ..........58 Tool changer ............22 Tools ..............23 Torques of servo motors ........... 21 Transport .............. 25 Using electronic handwheel ........58 Using lifting equipment .........

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