1 General Precautions

“Ten minutes”to help you obtain information.

1.1 Basic information

All basic information and instructions for the machine tool.

1.1.1Operating manual

1.1.1.1 Overview

This manual contains important precautions for safe, standardized and economical operation of the machine tool. Please be sure to follow the provisions in these precautions in order to：

avoid dangers.
reduce maintenance costs and the duration of faults.
improves the reliability and longevity of the machine tool.

This manual must always be kept at the machine tool site for reference.

All employees working with this machine tool must have read this manual and applied these operating instructions.

Attention must be paid to complying with provisions in this manual.

In addition to this manual, the followings must be observed:

Mandatory regulations on accident prevention measures and environmental protection in the user’s country and place should be observed.
Recognized rules for safe and professional work should be observed.

1.1.1.2 Content

This manual includes:

technical instructions of the machine tool.
instructions for machine tool operation and maintenance during the scheduled maintenance period.
safety instructions to avoid dangers for people and machine tool.

If you need additional information that is not included in this manual or have other questions, please ask your agent for help.

1.1.1.3 Symbols

This symbol indicates that useful information and application tips are available for optimal operation and utilization of the machine tool.

Symbols and warning words should be used:

If the hazard cannot be avoided, a less dangerous risk that may result in minor or moderate injury to person or damage to property should be marked.

Symbols and warning words should be used:

If the hazard cannot be avoided, a moderate dangerous risk that may result in the possibility of death or serious injury to person should be marked.

Symbols and warning words should be used:

If the hazard cannot be avoided, a great dangerous risk that may result in direct death or serious injury to person should be marked.

1.1.2 Concept of “main switch”

The concept of "main switch" is explained in the DIN EN 60204-1, Section 5.3 and is replaced by the concept "power-disconnect device".

Both the two concepts are used in this manual.

1.1.3 Basic notes

The machine tool manufactured by our company complies with the EG-EU Machine Standard 2006/42/EG and is manufactured to the latest technical standards, thus guaranteeing safe and reliable operation.

The perfection and reliable operation of this machine tool is based on the following prerequisites:

Carry as required.
Professional installation and commissioning.
Handle with care and caution.
Comply with safety tips.

1.1.3.1 Prerequisites

The machine tool is a solid, efficient and technically demanding machine that requires careful contact.

Only professionally trained personnel are allowed to operate the machine.

The required knowledge can be acquired through professional training. In addition to this, the operator must understand the basics of the cutting process (e.g. tools, materials, cutting data, coolants).

They must also have basic knowledge and operating skills of machine tool and CNC processing.

The staff assigned to work on this machine must have read and understood the contents of this manual, especially the safety precautions, before starting work.

1.1.3.2 Environmental protection and water protection

The machine tool described here is classified as HBV-equipment (equipment to which substances contaminating water are applied) according to the WHG 19g.

When operating, shutting down or disassembling the machine tool or parts, attention must be paid to comply with the requirements of the Water Source Protection Act (WHG). For details, please refer to the "Regulations for Equipment with Substances Contaminating Water” in the locality where the equipment is installed.

1.1.3.3 Enterprise position responsibility system

It must be clearly confirmed within the company: who is responsible for the machine tool (factory manager) and who is allowed to work on the it(operator).

The post responsibilities of personnel involved in transportation, placement, installation, commissioning, operation, repair and maintenance and overhaul must be clearly confirmed. The implementation of the provisions must be checked.

Users in Germany must comply with the obligations of Section 4 of the Operational Safety Norm and Section 4 of the Labour Protection Act, as well as the EU Norm 2009/104/EG and 89/655/EG.

The owner of the machine tool must:

know the effective labor protection regulations and comply with them.
conduct hazard assessment to the workplace where the workpiece is to be processed.
identify the hazard during the process of specialized processing of workpieces.
take additional protective measures when necessary.
stipulate the operating instructions of the machine.

1.1.3.4 Qualification of personnel

Only qualified and authorized personnel are allowed to work on this machine.

Training is available:

in the training center in our company.
by vocational training schools.
in the company.

1.1.3.5 Maintenance

The maintenance and repair work can only be conducted based on the instructions in the operating manual.

Please be sure to observe all provisions in relevant safety precautions.
Exemptions will exempt the manufacturer from responsibilities:

when using the machine tool improperly in various ways.
when the machine tool is not being operated in a technically sound condition.
when faults that can cause serious safety hazards are not removed before the machine tool is put into production.
if the machine tool is modified, short-circuited or out of function with respect to its functional integrity and full availability, as well as active and passive safety devices.

Maintenance

Injury to personnel and/or damage to property may result from failure to comply with the provisions in the operating manual and all relevant safety instructions.

All provisions in the relevant safety precautions must be observed.

1.1.4 Warranty

All other details and agreed warranty time should be obtained from the procurement contract.

1.1.5 Seller is not liable for absolute warranty obligations for the quality of the goods

If one of the following occurs, our company will neither bear legal responsibility nor provide warranty:

The user of the machine tool does not comply with the provisions of the operating and programming manuals, the original circuit data, transport and installation instructions.
The machine tool, its attachments and peripheral equipment are not maintained and repaired as required.
The maintenance work was not performed and documented in accordance with the maintenance instructions.
Incorrect operation of safety devices.
The seal on the terminal of the machine tool running hours counter is damaged.
Incorrect operation of the machine tool, its attachments and peripheral equipment.
Technical or functional modifications of any kind without the permission of the manufacturer of this machine tool.
The set user data access right is altered so that it is no longer possible to guarantee access to the data by the installers from our company.

1.1.6 Standard

This machine tool applies to the following criteria and standards:

1.1.6.1 EG European Union Guidelines

The latest revision of EU Machine Tool Guidelines 2006/42/EG.

The latest revision of EU EMV EMC Guidelines 2004/108/EG.

The latest revision of EU Pressure Vessel Guidelines 97/23/EG.

1.1.6.1 EN European Norm

EN 12100.

1.1.7 Use of the machine tool

Cutting operations are performed with the help of a rotating tool/workpiece with at least one geometrically defined cutting edge on it.

This machine tool is only allowed to be used for the following processing:

milling
drilling
turning
the machine tool, including the option configuration, is confirmed to be used with:
rotating tools/workpieces.
carrying workpieces, blanks and tools, e.g. by peripheral units connected to and supplied with the machine tool.

1.1.7.1 Materials

The following materials can be processed while the machine tool is running:

metals
plastics

Warming! Explosion-hazardous materials!

There exist injury risks due to the processing of flammable and explosive materials (e.g., magnesium, silicon) that could result in possible death or serious personal injury.

Processing of these materials is not allowed without proper safety protection measures.

1.1.7.1 Declaration of conformity

If the safety instructions are not followed, the declaration of conformity supplied with the machine conforming to the EU Machine Tool Regulation 2006/42/EG and the European Standards Committee markings installed on the machine are invalid.

Prototype

The exact name, model and serial number of the machine tool can be obtained from the operating manual and the description on the machine model nameplate.

1.2 In and on the machine tool

All basic instructions for operating the machine.

1.2.1 Virus scanning software

If a virus scanning software is installed, it can start running only when the machine is not being processed.

our company is not liable for incorrect hard disk contents resulting from the installation of external software and the upgrade or addition of applications.

The after-sales service can be provided by our company and the cost will be borne by the user if the program or data is changed.

1.2.2 Processing spindles

Magnetized shank.

Property damage due to bonding and clamping of ferrite chips.

Permanent magnets must not be placed close to the scope of the tool clamping hole.

The micrometer magnetic base must not be attached to the tool clamping hole.

1.2.3 Regular inspection of the pressure accumulator

What items must be inspected?

Method	Recommended Inspection Period
External Inspection	No inspection required
Internal Inspection	After 10 years 1)
Emphasized Inspection	After 10 years 1)

Regular inspection time

The machine tool user determines the time of the regular inspection based on the results of previous regular inspections and experience with dosing and operating conditions in accordance with Section 2, Article 10 of the Pressure Vessel Regulations. At this point, the user can rely on the recommendations of the manufacturer and experts, or on the relevant experience of professional and technical personnel inside and outside the enterprise, especially in the case of mass-produced equipment.

Carry out the inspection of pressure accumulators in all EU countries in accordance with local laws and regulations.

1.2.4 Thermal operation of spindle

Due to the unstable thermal state, no clamping of the working spindle, including the spindle bearing, this spindle must be operated in a thermal state after the downtime specified by the machine manufacturer. During this period, no high-speed processing is allowed. This measure can protect the machine tool and thus extends the spindle bearing life. Spindle standstill time should be collected in real time. If the 2-hour limit time set by the manufacturer is exceeded, the spindle will run in thermal state after the spindle is powered up and an alarm message will be issued indicating SPINDELWARMLAUF AKTIV (spindle thermal operation is valid).

Attention must be paid:

Here, the spindle speed should be reduced to half of the possible maximum speed of the motor-driven spindle
The operator must ensure that a suitable tool is available on the machining spindle.
If a tool is installed on the spindle, SPINDELWARMLAUF NICHT MÖGLICH (thermal operation of the spindle is not possible) is displayed.
The alarm message SPINDELWARMLAUF AKTIV (spindle thermal operation valid) and feed blockage appear during spindle thermal operation. The alarm message is automatically deleted and the feed is allowed after reaching approximately 3 minutes of thermal operation.
The speed will be automatically limited if the programmed speed exceeds the specified limit value.
The user can make the thermal operation of axis in fast forward G0 and that of the spindle with the allowable maximum speed after changing tool.
Operation No feed forbidden will be triggered during the process of G0 fast shift and this speed will be automatically reduced.

Monitoring of spindle warm-up operation can be canceled at the request of the user.

It should be recorded if the spindle thermal operation is not activated.

1.2.5 Description of the continuous operation of the axis

1.2.5.1 Circular axis in CNC-Rotary table

The circular axis in the CNC-Rotary Table on the machine tool is designed to be inserted into the running positioning axis within the lower limit of the speed. Circular axis is not suitable for continuous operation at maximum speed or the upper limit of the speed.

Continuous operation may cause the CNC-rotary table to heat up and consequently cause geometrical changes. Related to this, the machine tool accuracy has to be taken into account.

In this sense, these instructions apply to all table variants and indexers with circular axes.
These instructions do not apply to CNC-Milling/Turning tables.

1.2.5.2 Work spindles and linear axis

The continuous operation of the highest speed work spindle and the maximum acceleration linear axis may cause the machine tool components and the entire machine tool to heat up and geometric changes may occur as a result. Related to this, machine tool accuracy must also be taken into account.

1.3 In the production process

All basic instructions for production.

1.3.1 Notes for processing accuracy

The following notes are based on the given conditions and experience regarding the influence of temperature on the workpiece, tool and machine tool. Whether these notes are taken seriously or not has a direct impact on the achievement of machine accuracy. The problems arise in process within a small accuracy scope helps to discover other influencing factors.

1.3.1.1 Temperature

The smaller the temperature difference (difference between ambient temperature and initial temperature) when processing a workpiece, the smaller the variation in the machine, tool and workpiece. The best way to obtain high precision processing is to keep the ambient temperature as constant as possible.

The following temperature values must be maintained at the location where the machine tool is positioned:

In order to achieve the guaranteed accuracy, the temperature change must not exceed 0.5 K per hour and 2 K per day.
The temperature change in space must not exceed 0.4 K/m3.

1.3.1.2 Location

If the machine tool is located at the entrance area of the workshop and exchanges air with the outside when opening and closing the door, there will certainly be corresponding fluctuations in ambient temperature that adversely affect the processing results. If this happens when the door of the processing area is open, there will be significant fluctuations in the temperature of the workpiece and the work spindle.

1.3.1.3 Warming up the machine tool

The friction of the bearings mainly causes the work spindle to heat up and contributes to a constant temperature. If a constant temperature is achieved by warming up the machine tool before starting processing, only small temperature fluctuations will occur during processing.

1.3.1.4 Tool temperature

If a sharp tapered cold tool is replaced into an already warm work spindle, the cold tool will be inserted deeper than the warm tool due to the change in temperature of the work spindle tool holder. It is also important to note this when working with a probe when the machine tool has been warmed up. If the tool holder is equipped with an end face, this effect does not occur.

1.3.1.5 Oil mist/ emulsion mist separator

Equipped depending on machine tool configuration。

Evaporative heat absorption will occur after the separator and the cooling lubricant supply device are connected.

The evaporative heat absorption adversely affects the processing accuracy of the machine tool.

1.3.2 Acceptance of existing components

1.3.2.1 Processing procedures

Utilizing existing procedures.

Damage caused by corrosion.

It should be checked whether the procedure is suitable for this machine tool.
Attention should be paid to the programming functions, processing period and processing room size in accordance with this manual.
In the absence of material, the first program is run by reducing the operation action.
Contact your suppliers if you have questions

1.3.2.2 Equipment

Utilizing existing equipment.

The damage is caused because the processing room is too small or is altered.

It should be checked whether the device can be used unconditionally or whether software adjustment is required.
In the absence of material, the first program is run by reducing the operation action.
Contact your suppliers if you have questions.

1.3.3 Collision

1.3.3.1 In the warranty period

Contact the after-sales service department of our company when the machine collides in the warranty period.

The effect of the quality warranty may be affected if not taken care of.

The following data must be saved:

CNC-Program:
- Imported program，
- Subroutines
Tool parameters.
Zero drift.
A tool management device is possibly needed.
Parameters are possibly needed.
Recording data as an archive.

Additional requested information

The machine tool and
- the whole screen,
- the machine tool,
- current collision position,
- processing room,
- adapter position of the tool magazine (if installed),
- workpiece pallet changer (if installed).

Data Transmission

The data and information listed above should be sent to the after-sales service department of our company.

1.3.3.2 Temperature balance compensation for machine tool

CNC-CNC temperature balance compensation is based on the collection of the tool displacement at a given speed over a certain time course. Temperature compensation is mainly used to balance the displacement of the machining spindle after it has been heated.

1.3.4 Reminder: please note in short reciprocating stroke processing

Constant processing reciprocating stroke < 150 mm

In this case, a tool change or programming (the entire stroke of the relevant axis is lubricated) is performed after a maximum of 30 minutes.

Constant processing reciprocating stroke < 10 mm

In this case, a tool change or programming (the entire stroke of the relevant axis is lubricated) is performed after a maximum of 5 minutes.

Constant processing reciprocating stroke < 2 mm

In this case, the machine tool must be equipped with a special structure, that is, the "coated bearing" for the screw rod.

Machine tools with standard configuration are not suitable for short reciprocating stroke process when it is less than 2 mm. This type of process does not fall within the scope of using the machine as specified.

Explanation:

The so-called short reciprocating stroke refers to the reciprocating oscillating axis movement, when the axis reciprocating is very short, so that a single or multiple ball in the machine tool components (feed bearings, ball screws, linear rolling units) cannot be lubricated floatly by the lubrication material, and resulting the loss of (the formation of oil film) oil supply.

If this short stroke dwell time is long, this can lead to a complete exhaustion of the lubricant film between the rollers and the track. In this case, it can lead to direct contact between the ball and raceway (steel to steel), with the consequence of contact wear. The balls and/or raceways will be damaged. This should be avoided in all cases.

1.4 What else are important

All of these are important.

1.4.1 Incorrect usage

1.4.1.1 European Community Machine Regulations

This machine tool is designed and manufactured in accordance with Machine Regulation 2006/42/EG. It is a prerequisite to use this machine tool in accordance with the regulations.

1.4.1.2 Definition of incorrect usage

Rationally foreseeable incorrect use (as per European Standard EN ISO 12100: 2010 Edition, Definition 3.24) can be obtained from the easily foreseeable behavior of personnel who do not use the machine tool in the way specified by the machine designer.

1.4.1.3 Incorrect usage list

Based on the definition, examples of incorrect usage are as follows.

The machine tool is not equipped with appropriate protective devices (e.g., fire and explosion protection) when processing workpiece made of explosive or flammable materials.
The machine tool is operated in unsafe operating modes, such as Mode 3, although it can be operated in Modes 2 or 1.
The machine tool is not equipped with appropriate protective devices (e.g., extractors) when processing workpieces that produce vapors and dusts harmful to health.
Walk synchronously on the moving parts of the machine tool in order to, for example, observe the manufacturing procedure or move quickly from one side to the other.
Use a cooling lubricant that is not permitted, which can damage the machine’s components, although it has, for example, better process characteristics.
Step on the machine tool shield to enter the tool magazine space or the workpiece pallet storage space, but for example when the machine is not stopped very safely.
Repaired by unqualified personnel.
The cleaning work is not carried out in accordance with the methods and procedures described in the operating manual.
Unallowable and inappropriate cleaners were used, although they simplified and shortened the cleaning process.
The machine tool is operated by personnel who have worked on similar machines, but who have not been specifically trained for this machine. This includes, for example, commissioning of workpiece and tools, cleaning and standard maintenance.
Failure to inform those exposed to the machine tool of its particular hazards, such as colleagues and visitors who are unfamiliar with production.
Use the equipment, tools and processing programs that are not suitable for the machine tool or whose function has not been tested and approved in advance by the machine manufacturer.

1.4.4 Recycling and disposal of machine tool

The user factory is responsible for the standard recycling disposal.

The machine tool must not damage the environment during recycling and disposal.
EU guidelines on environmental protection and waste recycling must be compulsively complied with.
Also, all regulations, standards and local regulations in the nation where the machine is located must be complied with.

Liquid

All liquids from machine tool and peripheral equipment circuits should be recycled and disposed of in a professional manner after consensus with the local environmental authorities.

Electrical components

The electrical components should be recycled and disposed of as electrical waste in a professional manner after consensus with the local environmental authorities.

Metal and all non-metal parts

All metal and non-metal parts of the machine tool should be recycled and disposed of after consensus with the local environmental authorities.

Cooling units

The cooling units should be recycled and disposed of in a professional manner after consensus with the local environmental authorities.

Viewing glass in or on process rooms, loading station and other maintenance windows

These glasses are made of polycarbonate and a part of which is a combination of glass and polycarbonate. Which parts of these components are recyclable should be explained to the local authorities.

Thank you for your time.