DONAUMERIC 440 Original Operating Instructions
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DONAUMERIC 440 Original Operating Instructions

Cnc rapid radial drilling machine
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Machine-No./Construction Year:
Original Operating Instructions
CNC Rapid Radial Drilling Machine
DONAUMERIC 440

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Summary of Contents for DONAUMERIC 440

  • Page 1 Machine-No./Construction Year: Original Operating Instructions CNC Rapid Radial Drilling Machine DONAUMERIC 440...
  • Page 2 Operating Instructions DONAUMERIC 440 Inquiries and orders should be directed to: Donau Werkzeugmaschinen GmbH Harald-Friedrich-Straße 2 - 8 D-83352 Altenmarkt (Germany) Phone: + 49 (0) 8621/ 88 0 Fax: + 49 (0) 8621/ 88 413 Homepage: www.donau-wzm.de E-mail: donau@donau-wzm.de...
  • Page 3 Operating Instructions DONAUMERIC 440 Altenmarkt, 2015-01-07 Conformity Declaration in the sense of the EC-guidelines for machines 2006/42/EC, annex II, No. 1A Design of the machine/system: Radial Drilling Machines DONAUMERIC 440 Machine number: The machines have been conceived and built in conformity with the regulations under the following EC-guidelines: „Machines“...
  • Page 4 Operating Instructions DONAUMERIC 440...
  • Page 5 Operating Instructions DONAUMERIC 440...
  • Page 6 Operating Instructions DONAUMERIC 440...
  • Page 7 These operating instructions are designed to familiarize you with the machine and its intended use. -Description of the System The Donau-Rapid Radial Drilling Machine of the type DONAUMERIC 440 is designed, manufactured, tested and documented according to the state of the art and in compliance with the relevant safety standards.
  • Page 8 Operating Instructions DONAUMERIC 440...

  • Page 9: Table Of Contents

    Operating Instructions DONAUMERIC 440 Contents of the Operating Instructions GENERAL INFORMATION ..................12 1.1 Technical Specifications of the Machine....................12 SAFETY ..............................2.1 Safety Instructions and their Explanations..................14 2.2 Safety-Related Information ........................15 2.3 Possible Hazards Arising from the Machine ..................16 2.4 Intended Use ............................17 2.5 Sources of Danger ..........................18...
  • Page 10 Operating Instructions DONAUMERIC 440 5.8 Alignment of the Machine ........................45 OPERATION AND HANDLING OF THE MACHINE IN RADIAL MODE .....46 6.1 Functional Description of Control Elements..................46 6.2 Operation of the Machine in Radial Mode ....................51 6.2.1 Select Radial Mode ........................51 6.2.2...
  • Page 11 Operating Instructions DONAUMERIC 440 7.7 Disposal ..............................73 APPENDIX ........................73 8.1 Machine Accessories/Special Features/Options .................73 8.1.1 Angle Table..........................73 8.1.2 Inclinable Swivel Table (option 2.40) ..................74 8.1.3 Clamping Cubes Swiveling from 0-90 Degrees ..............75 8.1.4 Floor Plate ..........................76 8.1.5 Coolant System Design B for Machines with Floor Plate .............78 8.1.6...

  • Page 12: General Information

    Operating Instructions DONAUMERIC 440 1 GENERAL INFORMATION 1.1 Technical Specifications of the Machine Standard Version - Tapping Device - 2 T-slots 18 mm at the supporting structure of the machine rear - 2 T-slots 18 mm at the supporting structure of the machine left...
  • Page 13 Operating Instructions DONAUMERIC 440 Machine-Specific Forces Spindle torque max. Constant from rev/min 15-200 Clamping Radial 5000 Axial 5500 Quill force 12000 Electrical Data Operating voltage V ∼/Hz 400/50 Control voltage = 65 ° AC spindle motor, frequency controlled ν ∆...

  • Page 14: Safety

    Operating Instructions DONAUMERIC 440 2 Safety 2.1 Safety Instructions and their Explanations The following safety instructions and warnings are intended to prevent hazards to life and health of users and maintenance personnel as well as material damage. The terms used for the purposes of these operating instructions have the following...

  • Page 15: Safety-Related Information

    Operating Instructions DONAUMERIC 440 2.2 Safety-Related Information WARNING When electrical or electronic equipment and devices are in operation, certain components of these devices are under hazardous voltage. Unqualified intervention or non-compliance with the warnings can lead to severe personal injuries or material damages. Only qualified and trained personnel are allowed to perform necessary interventions.

  • Page 16: Possible Hazards Arising From The Machine

    2.3 Possible Hazards Arising from the Machine The DONAU-Rapid Radial Drilling Machine of the type DONAUMERIC 440 is designed, manufactured, tested and documented according to the state of the art and in compliance with the relevant safety standards.

  • Page 17: Intended Use

    Operating Instructions DONAUMERIC 440 2.4 Intended Use The Rapid Radial Drilling Machine of the type DONAUMERIC 440 is designed, manufac- tured, tested and documented according to the state of the art and in compliance with the relevant safety standards. The machine is intended for use in an industrial environment and must not be operated outdoors.

  • Page 18: Sources Of Danger

    Operating Instructions DONAUMERIC 440 2.5 Sources of Danger DANGER Danger due to rotating tool/spindle and drawing in or winding up. Do not reach into the rotating tool. Plying in an unprotected work area is prohibited. Parts of clothing can be drawn in by the rotating tool or the rotating spindle. Serious personal injuries, death, or material damages are the result.

  • Page 19: Dangers Due To Accessories

    Operating Instructions DONAUMERIC 440 CAUTION Danger due to blows to the upper body and head from traversing boom. No other person may remain in the work area when working in manual mode. No one may remain in the work area during automatic mode.

  • Page 20: Emissions

    Operating Instructions DONAUMERIC 440 2.7 Emissions Measurement setup (measurement according to DIN 45 635) Measuring conditions • The machine is ready for operation. • The main drive will traverse in its complete speed range. • The distance of the measuring device from the enveloping surface of the machine is 1 metre, the measurement height is 1.7 metres.

  • Page 21: Work Areas And Safety Areas

    Operating Instructions DONAUMERIC 440 2.8 Work Areas and Safety Areas General • The machine must always be operated only by a qualified person under consideration of all relevant safety information. • The individual work areas of the machine are to be colour-coded on the floor. If needed, barriers shall be installed to prevent unauthorized access.
  • Page 22 The machine is operated manually, the axis drives are shutdown and decoupled mechani- cally. Concerning DONAUMERIC 440: The drill feed is limited to 0.7 mm/rev; the W-axis can be operated in jog mode with reduced speed. In radial mode, work can be performed without limitation in all work areas/fields.
  • Page 23 Operating Instructions DONAUMERIC 440 Work Mode Single Piece Work Area: Limitation of the boom travelling range by 3 partially overlapping work areas (1; 2 and 3). Start Criterion: Actual and target position must be located in the same work area.
  • Page 24 Operating Instructions DONAUMERIC 440 Pendulum machining on the front of the work table Pendulum machining allows setup in parallel with machining time. Work Area: The work area consists of two symmetrical work areas at a distance of 800 mm. Start Criterion: At program start, the spindle must be stationary, the actual position in work area 1 and target position in work area 2.
  • Page 25 Operating Instructions DONAUMERIC 440 Pendulum machining front/side Work Area: The work area includes two work areas, each 600 mm wide, front and left. Start Criterion: At program start, the spindle must be stationary, the actual position in work area 1 and target position in work area 2. With respect to the drilling coordinates of a part, the start and target points must be in the same range.
  • Page 26 Operating Instructions DONAUMERIC 440 Multiple operation (multiple single parts in one clamping) This work mode allows no setup in parallel with machining time. Work Area: Work area limited to the front of the table. Start Criterion: All zero and target points must lie in the travelling range. In case of a zero shift, positioning to the next workpiece is performed via spindle stop only.

  • Page 27: Personal Protective Equipment

    Operating Instructions DONAUMERIC 440 2.9 Personal Protective Equipment • Protective goggles to protect eyes from ejected workpiece, tool or coolant particles. • Work boots. • Chip hook with hand guard for removal of chips. • Protective gloves for handling the workpieces.

  • Page 28: Protective Devices

    Operating Instructions DONAUMERIC 440 3 Protective Devices 3.1 Protective Devices for the Operator Operator Safety in "Manual Mode" The machine can be operated as a hand-held column-type drilling machine, whereas a power-operated feed drive is also possible. The axis drives X and Y are separated mechanically.

  • Page 29: Protective Devices For The Machines And Their Components

    Operating Instructions DONAUMERIC 440 3.2 Protective Devices for the Machines and their Components • All motors are protected against overload by motor protecting switches. • The individual circuits are protected by automatic circuit breakers. • Motors and control cabinets are designed in IP 54.

  • Page 30: Transport Of The Machine

    Operating Instructions DONAUMERIC 440 Keep these safety devices in place and in their function! DANGER Non-compliance causes risk of drawing in/winding up/cutting/colliding! Perform a monthly function test: Fold drill protection in case of a stationary spindle => machine cannot be started.
  • Page 31 Operating Instructions DONAUMERIC 440 The machine must generally be transported and loaded with a crane, minimum capacity 4,5 tons. The loading gear consists of: 1 lifting rod Ø 60 mm, length 1800 mm with welded safety rings 1 lifting rod Ø 50 mm, length 1800 mm with safety rings 2 lifting rods Ø...
  • Page 32 Operating Instructions DONAUMERIC 440 Transport Plan F min = 4.5 tons (4500kg) 1 steel wire rope with 2 loops, 176 kN, length 1000 mm, DIN 3060 Boom support Edge protection 2 lifting rods Ø 40 mm length 1300 mm...
  • Page 33 Operating Instructions DONAUMERIC 440 Transport Plan F min = 4.5 tons (4500kg) 1 lifting sling yellow 3 tons, 1 lifting rod Ø 70 mm, length 1500 mm length 6000 mm, DIN 61360 with welded safety rings Lifting sling yellow 3 tons, length 4800 mm,...

  • Page 34: Installation And Commissioning Of The Machine

    Operating Instructions DONAUMERIC 440 5 Installation and Commissioning of the Machine 5.1 Requirements to the Location of Use General Requirements • The floor has to have a sufficient capacity (weight of the machine and the position as well as size of the installation site see foundation plan). The permissible unevenness of the base is 5 mm.

  • Page 35: Space Requirements/Dimensions

    Operating Instructions DONAUMERIC 440 5.3 Space Requirements/Dimensions Workfield III Max. radius spindle head Max. radius drilling spindle Wall or fence Work field I Work area Work field I Safety area Travel path The space for tool and workpiece deposits is to be planned by the user according to his operational requirements and circumstances.
  • Page 36 Operating Instructions DONAUMERIC 440 Space Requirements/Dimensions The maximum working height L max of the machine is 2950 mm. The required working height for any extra installation work is 3500 mm. If an operational crane system is located above the machine, a clear height of at least...
  • Page 37 Operating Instructions DONAUMERIC 440 Space Requirements/Dimensions t = Boom travel path (1050 mm)

  • Page 38: Foundation Of The Machine

    Operating Instructions DONAUMERIC 440 5.4 Foundation of the Machine The machine must only be anchored with a concrete floor of 250 mm mini- thickness. The maximum permissible unevenness of the concrete floor is 5 within the installation site. If the concrete floor shows a layer of screed, a wooden floor or anything similar, these layers must be removed or bypassed.
  • Page 39 Operating Instructions DONAUMERIC 440 Foundation plan for machine with work table 600 x 1800 mm A = electro-terminal box; height from floor: approx. 400 mm Foundation design according to: DIN 1045; DIN 1054; DIN 1055 Floor load/machine tool = 10...
  • Page 40 Operating Instructions DONAUMERIC 440 Foundation plan for machine with work table 750 x 1200 mm A = electro-terminal box; height from floor: approx. 400 mm Foundation design according to: DIN 1045; DIN 1054; DIN 1055 Floor load/machine tool = 10...
  • Page 41 Operating Instructions DONAUMERIC 440 Foundation plan for machine with work table 600 x 1200 mm A = electro-terminal box; height from floor: approx. 400 mm Foundation design according to: DIN 1045; DIN 1054; DIN 1055 Floor load/machine tool = 10...
  • Page 42 Operating Instructions DONAUMERIC 440 Other fastening elements may include: • BW-fixators in the appropriate size and design • Reaction mortar dowels • Heavy duty dowels; it is imperative to remove the required, very precise clearance from the machine. Due to mass eccentricity when swiveling the machine, no vibrating elements may be used.

  • Page 43: Electrical Connection Of The Machine

    Operating Instructions DONAUMERIC 440 5.5 Electrical Connection of the Machine WARNING Electrocution causes death and severe injuries. The electrical connection of the machine is to be carried out exclusively by a qualified electrician. The circuit diagram is generally to be observed.

  • Page 44: Removing The Boom Support

    Operating Instructions DONAUMERIC 440 5.6 Removing the Boom Support Sequence of Operations • Loosen screw joints of the boom support with the machine 1 cylinder screw M 12 x 30 in boom 2 hex screws M 16 x 40 in table SERVICE •...

  • Page 45: Alignment Of The Machine

    Operating Instructions DONAUMERIC 440 5.8 Alignment of the Machine • Loosen nuts of the chemical anchors (do not remove) • Place level on work table in central position with an accuracy of 0.02 mm/1 metre in longitudinal direction to the T-slots •...

  • Page 46: Operation And Handling Of The Machine In Radial Mode

    Operating Instructions DONAUMERIC 440 6 Operation and Handling of the Machine in Radial Mode The work area of the operator is the entire pivoting range of the boom in front of the con- trol panel. The pivoting range is 330° .
  • Page 47 Operating Instructions DONAUMERIC 440 Screen with control keyboard and its significance The Cursor Keys (Position Display Keys): These keys control the movement between the various fields of an editor. They also move the display of the workpiece in the menu program.
  • Page 48 Operating Instructions DONAUMERIC 440 ESCAPE: Is commonly used for returning to the previous menu. It can sometimes also be used to cancel an edit/action. NEXT: Sometimes more soft keys are used than there are keys. In such cases, another plane of soft keys can be selected with NEXT. The key lights up in this case.
  • Page 49 Operating Instructions DONAUMERIC 440 CLEAR: This button allows entering a field from the beginning (i.e. after a typ- ing error). ENTER: Allows you to enter a value into a field and jump to the next field. This button is also selected for confirming a process with a cancellation option.
  • Page 50 Operating Instructions DONAUMERIC 440 Information regarding the machine keys Icon/Description Explanation (Colour red) EMERGENCY STOP push button I (control supply ON) Confirm EMERGENCY STOP Drive column upward Drive column downward STOP Stop START Start When drilling: Feed ON/OFF when threading: Change the direction of rotation clockwise/counter-clockwise rotation.

  • Page 51: Operation Of The Machine In Radial Mode

    Operating Instructions DONAUMERIC 440 6.2 Operation of the Machine in Radial Mode 6.2.1 Select Radial Mode • Turn on the main switch • Press the button; white indicator light on the front of the left control cabinet must be flashing.

  • Page 52: Insert Tool/Tool Change

    Operating Instructions DONAUMERIC 440 6.2.4 Insert tool/tool change CAUTION Risk of injury from tools. Danger of cutting due to sharp tool edges. Wear personal protective equipment. The insertion of the tool or tool change must occur only when drilling spindle is stationary.
  • Page 53 Operating Instructions DONAUMERIC 440 Setup Instructions The collet may be set to the specified setting dimensions only in release position! Release Position The collet is factory-set in release position to the specified setting dimensions of • 93.6±0.1 mm. The setting dimensions should be checked after 100 load cycles and corrected if •...
  • Page 54 Operating Instructions DONAUMERIC 440 • Insert tool: - Initial state: Spindle is stationary; -button flashes, there is no tool in the spindle - Clean the tool holder of the spindle with conus cleaning agent or cloth - Press button (button flashes)

  • Page 55: Tool Tray For Radial Mode

    Operating Instructions DONAUMERIC 440 6.2.4.1 Tool Tray for Radial Mode • In the radial mode menu, there are 10 tools stored under F 8 , which can be used and referred to during radial drilling. • Browsing forward within this tool tray is also done via F 8. Browsing backward and skip- ping multiple tools is not possible.

  • Page 56: Selecting The Speed

    Operating Instructions DONAUMERIC 440 6.2.5 Selecting the Speed The speed is infinitely adjustable throughout the entire range. The speed range is divided into two speed steps. Switching from step 1 to step 2 and back occurs automatically. Speed step 1 (high torque): approx.

  • Page 57: Selecting The Feed

    Operating Instructions DONAUMERIC 440 6.2.7 Selecting the Feed The feed value in radial mode is always entered in mm/rev. Maximum feed value: 9.999 mm/rev Minimum feed value: 0.001 mm/rev To enter you must place the cursor on the square behind FEED. The value is entered us- ing the numeric keypad.

  • Page 58: Drilling And Threading

    Operating Instructions DONAUMERIC 440 6.2.9 Drilling and Threading 6.2.9.1 General The machine is operated via operator guidance. Functions that are logically in order are displayed flashing. Selecting and working with the tools from the tray is a smooth process when the cur- rent workpiece height of the previous workpiece as well as the tool length matches.

  • Page 59: Threading

    Operating Instructions DONAUMERIC 440 6.2.9.3 Threading In principle, only screwing chucks with overload protection may be used. • Insert tool (Ch. 6.2.4.) • Select F 2 "Threading" • Enter speed (Ch. 6.2.5.) • Enter thread depth • Check direction of rotation (Ch. 6.2.6.) •...

  • Page 60: Maintenance And Repair

    • Supporting structure - Hoist gear for column movement 440 V - AC servo motor via toothed belt and feed screw. The upper and lower end position of the lifting column is secured by limit switches. - Column: The column guide in the supporting structure consists of plastic coating SKC 60.

  • Page 61: Machine Image

    Operating Instructions DONAUMERIC 440 7.2 Machine Image...

  • Page 62: Safety Instructions For Maintenance And Repair

    Operating Instructions DONAUMERIC 440 7.3 Safety Instructions for Maintenance and Repair DANGER! Turn off main switch and secure against accidental startup before performing any maintenance and repair work (install padlock for example). Install warning sign. Maintenance and repair work on electrical and hydraulic systems may be per- formed only by trained personnel.

  • Page 63: Maintenance

    Operating Instructions DONAUMERIC 440 7.4 Maintenance 7.4.1 Preventive Maintenance Regular cleaning of the machine and compliance with the lubrication and maintenance instructions in the designated time intervals are essential for the operational safety and durability of the machine. Depending on the duration of use and age of the machine, the following components must regularly be inspected and tested at least 1 x per month: •...

  • Page 64: Adjusting The Guide Arm Of The Column Up And Down Movement

    Operating Instructions DONAUMERIC 440 7.4.2 Adjusting the Guide Arm of the Column up and down Movement For adjusting the guide arm, the cover (4) at the rear of the supporting structure of the machine is to be removed. • Move column up or down via push button, so that the belt tightener (3) is visible in an opening of the supporting structure.

  • Page 65: Re-Clamping Of The Return Spring For The Drilling Spindle

    Operating Instructions DONAUMERIC 440 7.4.3 Re-Clamping of the Return Spring for the Drilling Spindle The measuring devices, the limit switches for the Z-axis and the return spring for the quill with drilling spindle are located at the drill head on the left side.

  • Page 66: Replacing Wear Parts

    Operating Instructions DONAUMERIC 440 7.4.4 Replacing Wear Parts 7.4.4.1 Toothed belt Replacement on Drilling Spindle Drive (see Drawing Next Page) • Turn off main switch and secure against accidental startup. • Remove mounting screws (1) 4 x DIN 933. • Release lower belt tension (2) by means of eccentric.
  • Page 67 Operating Instructions DONAUMERIC 440 Sectional drawing of the drilling spindle head...

  • Page 68: Toothed Belt Replacement On Column Stroke Drive (See Drawing Next Page)

    Operating Instructions DONAUMERIC 440 7.4.4.2 Toothed Belt Replacement on Column Stroke Drive (see Drawing Next Page) Dismantling: • Drive column upward via button • Secure top side of the machine with a wooden bar between boom and table before shutting down. Chock wooden bars and secure against removal! The drop protection is also removed when removing the drive motor.
  • Page 69 Operating Instructions DONAUMERIC 440 Drawing hoist gear...

  • Page 70: Lubrication Schedule

    Operating Instructions DONAUMERIC 440 7.5 Lubrication Schedule Central lubrication is designed as loss lubrication. The lubricating oil is collected in the column guide rack. Cleaning is to be done as part of preventive maintenance measures. During activation of the central lubrication, observe a dwell time of about 30 sec.
  • Page 71 Operating Instructions DONAUMERIC 440 Lubrication Schedule...

  • Page 72: Hydraulic Schedule

    Operating Instructions DONAUMERIC 440 7.6 Hydraulic Schedule...

  • Page 73: Disposal

    • 4 T-slots 18 mm • rotating coolant chute • for mounting in the side or rear T-slots of the machine base • height adjustable 440 mm Application: • for small and medium-sized workpieces which are too high for machining on the front work table •...

  • Page 74: Inclinable Swivel Table (Option 2.40)

    Operating Instructions DONAUMERIC 440 8.1.2 Inclinable swivel table (option 2.40) If your machine is equipped with an inclinable swivel please note the following hints: Mounting / Height adjustment The mounting position of the table might be to the left or to the rear side of the machine body, into the vertical t-slots that are a part of the machine body.

  • Page 75: Clamping Cubes Swiveling From 0-90 Degrees

    Operating Instructions DONAUMERIC 440 8.1.3 Clamping Cubes Swiveling from 0-90 Degrees • Tensioning surface top 550 x 550 mm, tensioning surface side 550 x 410 mm • Alternatively, tensioning surface top 750 x 600 mm, tensioning surface side 750 x 410 mm...

  • Page 76: Floor Plate

    Operating Instructions DONAUMERIC 440 8.1.4 Floor Plate • Tensioning surface 1000 x 1400 mm, height 100 mm with 4 T-slots 18 mm • rotating coolant chute • Mounting with 6 anchors on the side or rear of the workstation of the machine...
  • Page 77 Operating Instructions DONAUMERIC 440 Mounting Adjustment bolt Concrete B25 Base plate (support) O-Ring 45x5 Filler LOCITE 5222 Anchor (Chemical) 905 410161 M16x230 Cartridge 905 416...

  • Page 78: Coolant System Design B For Machines With Floor Plate

    Operating Instructions DONAUMERIC 440 8.1.5 Coolant System Design B for Machines with Floor Plate This design of the coolant system is provided for machines that are equipped with a floor plate with rotating coolant chute. The coolant of all clamping surfaces is returned to a coolant container outside of the machine.

  • Page 79: Separate Coolant Return

    Operating Instructions DONAUMERIC 440 8.1.6 Separate Coolant Return The separate cooling return is a supplement to the coolant system design A (standard). It is primarily used as retrofit solution, or for customers who do not accept coolant system design B for reasons of space.

  • Page 80: Optical Operating Mode Display With Audible Warning Device

    Operating Instructions DONAUMERIC 440 8.1.7 Optical Operating Mode Display with Audible Warning Device A signaling column is mounted at the back of the right control cabinet. The operating modes are displayed. green-continuous light: Main switch ON red and audible signal: EMERGENCY STOP or failure;...

  • Page 81: Splash Guard At The Work Table For Chips And Coolant

    Operating Instructions DONAUMERIC 440 8.1.8 Splash Guard at the Work Table for Chips and Coolant • Single-part for work table 600 x 1200 mm and 750 x 1200 mm • Two-part for work table with 600 x 1800 mm...
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