OPERATING INSTRUCTIONS FOR
RADIAL DRILLING MACHINE VO 50
Serial No.: .................... ver. 2.01
Manufacturer:
Telephone exchange Sale department Service Spare parts
Joint-Stock Company KOVOSVIT MAS, a.s. náměstí Tomáše Bati 419 391 02 Sezimovo Ústí Czech Republic
Telephone
Fax
E-mail
+420 381 631 111 +420 381 632 520, 381 632 521 +420 381 632 575, 381 632 576 +420 381 632 521
+420 381 743 515 +420 381 634 469 +420 381 744 452 +420 381 634 469
[email protected] [email protected] [email protected] [email protected] [email protected]
0 INTRODUCTION 0.1
Preface
We are pleased that you have preferred the trade mark MAS by purchase of our product radial drilling machine. We believe that this machine will behave reliably to fully satisfy you in accordance. The machine is designed to be in operation most safety, ecologically desirable, friendly to operator, with minimum need for maintenance. We are submitting to you this accompanying documentation, which should furnish you with all required technical data, general machine description and maintenance procedures, that are necessary for the machine correct operation. It is very important to be familiar with all machine parts and their attendance prior to putting the machine into operation. The special care must be paid to connection to the mains, its lubrication and the maintenance.
Will you study all the statements in these operating instructions carefully, namely the sections dealing with safety of operation. If all the statements of these operating instructions will be kept, the accuracy, reliability and performance of the machine will fully satisfy you. We reserve possibilities of changes in machine design, dimensions, weight and circuit diagram resulting from a continuous improving of our machines. Therefore, all the illustrations, description and numerical data need not be fully corresponding in details to the last modification of the machine and they are not binding consequently As the machine producer, we reserve the right for the first putting the machine into operation at the customer’s, or for installation performed by workers of the supplier’s firm trained at the machine producer.
The machine is adequately safety on conditions corresponding to normal and by machine producer established machine use. The machine safety and its design meet the following European directives and standards: No. 2006/42/ES, 2006/95/ES, 2004/108/ES EN 12717, EN 12100-1,2, EN 954-1, EN 349, EN 1088, EN 60204-1, EN 61000-6-2, EN 61000-6-4. Introduced in the Czech Republic as follows: NV No. 176/2008 Sb., NV No. 17/2003 Sb., NV No. 616/2006 Sb. ČSN EN 12717, ČSN EN 12100-1,2, ČSN EN 954-1, ČSN EN 349, ČSN EN 1088, ČSN EN 60204-1, ČSN EN 61000-6-2, ČSN EN 61000-6-4. Joint-stock company KOVOSVIT MAS, a.s. Sezimovo Ústí, Czech Republic
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VO 50
Notice for our customers For the purpose of increasing surface finish resistance against cutting fluids and cooling liquids as well as against mechanical tear and wear of the surface finish a product final spraying is carried out with a new kind of coating composition– polyurethane enamel We suppose it is advantageous and suitable to acquaint you with the application of the polyurethane enamel enamel for the event of touch-up or correction of coating. The damaged spots must be perfectly degreased, cleared of dust and other solid impurities. The polyurethane enamel is a two-component type coating composition. Prior to t o application it has to be mixed with a hardener in a weight ratio of 4:1. Only the needed amount of coating composition is to be prepared for the intended touch-up or coating correction. The mixed paint must be used within 4 hours after mixing with the hardener at the latest. After the aforementioned period of time thickening and gelation comes into existence and this polyurethane enamel shall be neither applied nor stored. The polyurethane coatings dry out within 24 hours at the temperature of 24°C and after hardening they are impermeable.
© MAS 2005
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0.2
List of articles in manual manual for for radial radial drilling drilling machine machine VO 50
0
Introduction...............................................................................................................0-1 0.1 0.2
1
Preface.....................................................................................................................................0-1 List of articles in manual manual for radial drilling machine machine VO 50 ..................................................0-3
MAIN DATA ............................................. .................................................................... .............................................. .........................................1-1 ..................1-1 1.1 1.2 1.3 1.4
2
Design Features and Technical Description of Machine.........................................................1-1 Informative Machine Data.......................................................................................................1-2 Machine dimensions................................................................................................................1-2 Records of machine dislocations.............................................................................................1-2
Technical data................................................... data........................................................................... ................................................ .................................2-1 .........2-1 2.1
3
Technical data of machine with standard accessories ..................................................... ............................................................ ....... 2-1
DESCRIPTION.................... DESCRIPTION ........................................... .............................................. .............................................. .......................................3-1 ................3-1 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14
4
Machine conception ............................................................ ................................................................................................................ ....................................................3-1 3-1 Kinematic diagram diagram /f ig . 7/ ................................................................... .................................................................................................... ................................. 3-1 Control elements /fig. 5, 6/......................................................................................................3-1 Operation of of drilling head /fig. 5,6/........................................................................................ 5,6/........................................................................................ 3-2 Safety clutch /fig. 17/ ..................................................................... .............................................................................................................. .........................................3-4 3-4 Adjustment of run-up clutch and spindle brake /fig. 12/.........................................................3-5 Headstock clamping and its adjustment /fig. 14/.....................................................................3-6 Mantle clamping and its adjustment /fig. 15/..........................................................................3-6 Headstock traversing along along arm and its adjustment /fig. 5,14/ ............................................... ...............................................3-7 3-7 Swivelling, lifting and lowering of arm /fig. 5,6/ ............................................................... ...............................................................3-8 3-8 Automatic elimination of lifting screw backlash /fig. 15/...................................................3-8 Sleeve with spindle dismantling /fig. 10,13/.......................................................................3-8 Spindle balancing /fig. 13/ 13/ ............................................................................. .................................................................................................. ..................... 3-9 Electrohydraulic control of machine /fig. 7a, 8/ ............................................................. ................................................................. .... 3-9
MACHINE INSTALLATION INSTALLATION ............................................. ..................................................................... ....................................4-1 ............4-1 4.1 4.2 4.3
Packing transport and storage /fig. 2/......................................................................................4-1 Machine positioning on on foundation and working area reguired /fig.3,3a,3b/ ......................... 4-2 ELECTRICAL PART ................................................................... ............................................................................................................. ..........................................4-3 4-3
4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6
5
Description of machine electrical equipment conception ............................................................ 4-3 Machine connection to the mains................................. ................................................................ 4-4 Labour safety and protection against against electrical accident ................................................... ......... 4-5 Description of machine electrical outfit /fig. 22/................................................ .......................... 4-6 Specification of electric devices devices and their functions ........................................................... ......... 4-7 Instructions for electroinstallation electroinstallation servicing failures, safety of work............................ ............ 4-14
MACHINE SERVICING ............................................. ................................................................... ............................................5-1 ......................5-1 5.1 5.2 5.3 5.4 5.5
6
General principles for operation, safety and health protection at work...................................5-1 Testing operation of machine after its settlement /fig.5/.........................................................5-2 Machine lubrication /fig. 4/.....................................................................................................5-3 Cooling equipment /fig. 4a/.....................................................................................................5-6 Faults and their remedy...........................................................................................................5-6
WORKING POSSIBILITIES POSSIBILITIES ............................................. .................................................................... .....................................6-1 ..............6-1 6.1 6.2 6.3 6.4 6.5
7
Machine working possibilities................................................................................................. possibilities.................................................................................................6-1 6-1 Standard equipment.................................................................................................................6-2 Optional equipment.................................................................................................................6-2 Example of machine operation without without use of program .........................................................6-3 Example of work with use of program....................................................................................6-4
SPARE PARTS................................................. PARTS....................................................................... ............................................ ...................................... ................ 6 7.1 7.2
List of bearings, sealing rings and wearable parts...................................................................... 6 Instructions for spare spare parts ordering........................................................................................... ordering........................................................................................... 6 0-3
VO 50
1 MAIN MAI N DATA DATA 1.1
Design Features and Technical Description of Machine
Radial drilling machine VO 50 is designed for drilling, boring, reaming and counterboring operations of holes (with suitable tool – jig) in medium size and intricate machine parts from steel, cast iron, non-ferrous materials and plastics. Right-hand and left-hand threads can be tapped. If suitable jigs are used the machine can eliminate, in many cases, necessity to use a precise boring machine. machine. The machine is designed as a compact transportable model, i.e., all parts of the machine including a electrical cabinet forms one compact unit. The machine can be delivered in two models differing from each other by sizes - with the headstock overhang 1600 mm or 1250 mm (i.e. maximum distance of spindle axis from the jacket guideways). guideways). The machine manufacturer may deliver the machine with a machine software (software) for spindle speeds pre-selection pre-selection and as the case may be, be, drilling depths. The machine base made up of a frame that is formed of a platform onto which a column with a rotary seated seated jacket is bolted; along the column column an rigid arm parallel to the platform is shifted vertically. A box-shaped drilling head with an extendable drilling spindle is traversing along the arm. A switch board cabinet, with electrical devices necessary for the control of single machine functions, is fixed on the rear part of the jacket. Most of machine functions is controlled by means of pushbuttons and change-over switches, but there is only one single lever which provides a command for shifting advance selected spindle speeds and feeds and start of the spindle rotation in right-hand or left-hand direction. The pre-selection of spindle speed and feed is carried out by depressing of appropriate pushbuttons. All functions necessary to operate the machine are executed by electrical or hydraulic elements so the machine operation is easy and undemanding from physical effort point of view.
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VO 50
1.2
Informative Machine Data
Type of machine: machine Model: Manufacturer: Year of manufacture:
Radial
drilling
VO 50 KOVOSVIT a.s. .
…………………… ….. Drilling head sweep: Weight: O peration voltage: Total machine input: power
1600 mm
1250 mm
4550 kg 4200 kg according to order order 6 kW
Filled in by the customer Inventory No.:
…………………..
Supplier:
KOVOSVIT a.s.
Order No.:
…………………..
Warranty expiry date:
…………………..
Installation place and date:
…………………..
1.3
Machine dimensions
Machine dimensions are depicted in fig. No. 1. 1.4
Records of machine dislocations
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VO 50
2 TECHNICA TECH NICAL L DAT DATA 2.1
Technical data of machine with standard accessories
Maximum drilling diameters Drilling dia in solid steel steel with tensile strength 600 MPa
mm
50
Drilling dia in solid cast iron with tensile strength 250 MPa
mm
60
Boring dia without tool guiding into steel with tensile strength 600 MPa
mm
120
Boring dia with tool guiding in steel of 600 MPa tensile strength
mm
200
Tapping in steel with tensile strength 600 MPa
M50 x 1,5
Max. thread of basic series in steel with tensile strength 600 MPa
M30
Tapping in cast iron with tensile strength 250 MPa
M60 x 2
Max. thread of basic series in cast iron with tensile strength 250 MPa
M42
Main dimensions drilling head sweep Max. distance distance of spindle axis to jacket guiding
mm
1600
1250
mm
1600
1250
Min. distance of spindle axis to mantle guiding
mm
Max. pitch dia of drilled holes
mm
Min. pitch dia of drilled holes
mm
Max. distance of spindle faxe to base plate
mm
Min. distance of spindle face to base plate
mm
Vertical displacement of arm
mm
875
750
Drilling head travel along arm
mm
1280
930
Swing of arm from – to and back
320 3735
3039 1208
1505
1380 320
0°
±
180°
Spindle Diameter of spindle nose
mm
75h6
S pindle diameter in front bearing
mm
55
Taper in spindle
Morse
5
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VO 50
S pindle travel
mm
310
r.p.m
16 28-2500
Spindle feeds: number of steps feed range
mm/rev.
16 0,05-2
Max. torque of spindle
Nm
310
Max. drilling force
N
15000
Spindle speeds: number of steps speed range
Max. bore: drill ø50 mm, 125 r.p.m., 0,28 mm/rev. mm/r ev. material tensile strength 600 MPa Base plate Base plate dimensions
mm x mm
Base plate height
mm
Dimensions of clamping area
mm x mm
Number, size and and pitch of T-slots
mm
3 x 28 x 200
Drive Total input power
kW
50Hz/60Hz 6
Main motor output
kW
4
Main motor speed
r.p.m
1430/1720
Lifting motor output
kW
2,2
Lifting motor speed
r.p.m
1400/1670
Motor output of hydraulic unit
kW
0,55
Motor speed of hydraulic unit
r.p.m
1400/1680
Output of coolant pump motor
kW
0,09
Speed of coolant pump motor
r.p.m
2880/0,42 l/s
Machine dimensions Drilling head sweep Machine floor area
1600mm mm x mm
1250mm 3250 x 1120 2900 x 1120
Height of machine
mm
3396
3271
Weight of machine Weight of machine with electrical outfit and standard accessories
kg
4550
4200
Weight of machine with packing
kg
5200
4850
2-2
2640 x 1000 2290 x 1000 230 1820 x 986
1470 x 986
VO 50
3 DESCRIPTION 3.1
Machine conception
A column is bolted on a base plate which, at the same time, serves as a clamping surface for machined components. A box shaped jacket with switch board cabinet rotates on the column being carried in bearings. An arm is moved vertically on the jacket guideway. Vertical movement of the arm is power operated by means of a separate motor, through a worm gearing, a lifting nut and a lifting screw. A safety nut has been provided to prevent the arm from falling down in case that the threads of the arm lifting nut are stripped. Axial backlash between the lifting screw and nut is eliminated automatically. Vertical movement of the arm is secured by means of limit switches in the extreme positions of the arm. The drilling head is moved along the arm. Its position is changed by means of a handwheel and the required position is secured hydraulically. Spindle speed gearbox provides 16 speed steps. Spindle start and stop is carried out by an electric command given by the control lever. Spindle speeds may be pre-selected by a pushbutton system or changed by a program control. Spindle feeds changing is carried out in the same way and there is the same number of steps. Six upper feed steps are interlocked with five upper spindle speed steps. The machine is equipped with a pre-selection and a program control of speeds and feeds, with a program device for setting-up of drilling depths and a dead stop. Clamping of the drilling head and the jacket is hydraulic operated. 3.2
Kinematic diagram /f ig . 7/
It shows gearing ratios in the spindle speed and feed gearbox. Function of the spindle power feed and manual feed is described in the section No. 3.4 and 3.5 Arm lifting and lifting screw backlash elimination elimination is described in the article No. 3.11 /fig. 15/. 15/. 3.3
Control elements /fig. 5, 6/
Parts for machine operation: 1. Main switch 2. Switch for coolant pump electric motor 3. Handle of lubrication pump 4. Device for programmed programmed setting-up of drilling drilling depths 5. Pushbutton pre-selection of feeds 6. Setting-up of stops on the program drum for spindle speeds speeds and feeds 7. Pushbutton pre-selection of spindle speeds 8. Dial of program steps 9. Wheel for fine manual feed 10. Pushbutton for drilling head and jacket locking 11. Handwheel for drilling head positioning 12. Speed Speed changing and starting lever 13. Levers for starting of power feed and manual feed 14. Pin for securing of locked jacket when drilling head is released 15. Switch for lighting 16. Change-over switch for engaging of pre-selection or program
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17. Scale fixing nut 18. Vernier scale 19. Lever for fine adjustment of scale to drilled depth 20. Depth scale 21. Lever for engaging the dead stop 26. Pushbutton for arm lifting 29. Pushbutton with indication light for control voltage cutting-in 30. CENTRAL STOP 31. Pushbutton for lowering l owering arm (downwards). 3.4
Operation of drilling head /fig. 5,6/
There is no reversing disc clutch in the drilling head gear chain. Start and stop of the spindle is carried out directly by electric motor which is controlled by the control lever 12 /fig. 5/. Direction of spindle rotation is consistent with the position of lever 12.
Changing of speeds and feeds is carried out as follows : In using pre-selection the required spindle speeds and feeds are advance selected by the pushbutton on the scale 7 for pre-selection of speeds and spindle feeds 5. The control lever 12 is to be placed into its middle position and shifted upwards. After being returned to its central position the spindle can be started in the required direction of rotation. The lever 12 cannot be shifted directly in the horizontal direction from its neutral middle position, but it is necessary to perform deflection of the lever slightly downwards (to the position of increased resistance) and only then it is possible by horizontal shifting of the lever to engage left-hand or right-hand spindle rotation. This safety measure prevents any undesirable start of the spindle rotation. Spindle sp speed eed and feed changing cycle cycle is automatic and if the control lever is shifted into spindle starting position and speed changing cycle has not been finished yet the spindle will not start running. After the cycle have been finished the spindle starts running up automatically. If the cycle has not been finished yet yet and the spindle does does not start running the lever is to be shifted shifted into its central position and lifted again, due to this operation a new impulse is provided for finishing the speed changing cycle. In order to gain a smoother shifting of gears when changing from 28 rpm. to 2500 rpm. it is recommended to put in any of the middle speed steps first. If a machine is equipped with program for pre-selection of spindle speeds and feeds is prepared as follows: Stops 2 /fig.9/ are set up by means-of the sliders 6 /fig. 5 - fig. 9 it is No.l/ on the program drum 4 against the required speed resp. feed on the respective scale. By depressing of the control lever 12 /fig. 5/ downwards, the program drum indexes through one position and simultaneously an impulse for engaging of the selected speed and feed is given. Together with the program drum for adjustment of drilling depths indexes. It is located in space 4 /fig. 5/. Function and adjustment of the program for drilling depths is shown in fig. 11. When depressing the control leveller by hand downwards, pawl 2 turns the Ratchet 3 which turns the t he shaft 11 and simultaneously the program drum indexes by one stop position. Travel of stop finger 7 is derived from the spindle feed by helical gearing 13 and 14. On the worm shaft 13 there is the screw 5 on which the nut 6 shifts and in which the spring-loaded finger 7 is located against the stop 4. If the finger 7 touches the locked stop 4 the program drum 9 is
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shifted axially and by means of the switch 8 power feed of the spindle is stopped or the spindle is reversed according to position of the levers for power and manual feed. The overswitch 16 /fig. 6/ must be in the position labelled "B" when the drilling depth program is used. Adjustment of the stops 4 is automatic during during manufacture of the first workpiece. workpiece. By means of the overswitch 16 /fig. 6/ the command circuit is switched off from the drilling depths program drum. The lever 17 /fig. 11/ is shifted to its right-hand position. The stops are loosened by securing screws 10 and the moving finger 7 sets the stop into the respective position. After adjustment the stops are fixed by the screws 10 and the lever 17 is returned to its original position. If it is necessary to drill a hole deeper than the one set up by the stop 4, during manualfeed, the finger 7 is swung away automatically and so the finger 7 bypasses the stop 4. The drilling depth program drum has 20 positions just as the drum for speeds and feeds. The drilling depths program is used with advantage for drilling blind holes is hydraulic blocks of distribution bodies etc. For more accurate jobs /for example counterboring facing / the dead stop is used. The whole function of the drilling depths program device depends on position of the levers 18 /fig. 10/ for engaging of power feed and manual feed. If the levers are in position 1 and the spindle reaches, by manual feed, the set-up, the spindle changes sense of its rotation. This method is applicated for thread tapping. If the levers are in position 3 power feed is disengaged as soon as the spindle reaches the set-up depth. In position 2 the drilling depth program device is out of action and fine manual feed by means of the wheel 14 can be carried out. Beside the drilling depth program the machine is equipped with a positive stop for drilling up to a required depth. It consists of two hardened pins, one of which is fixed on the headstock, while the second one 27 /fig. l0/ moves along with the depth scale and it is possible to disengage it with the positive pin. This is to be carried out always when scale rotation through more then 360° is required. The pin 27 is to be shifted in when drilling using the positive stop is intended. Drilling pressure, at which the clutch disengages, is setup as described in the article 3.5. Adjustment of the required drilling depth, e.g. 20 mm is carried out as follow /both machine executions/: Drill tip touches drilled material surface. After loosening of the nut 17 /fig. 6/ the hardened pin is pulled out from the claw clutch of depth scale by means of the lever 19 and by its rotation in the proper direction the required depth is set up with an accuracy of 0,1 mm against the zero mark on the vernier scale 18. In this position the lever 19, and the depth scale 20 as well, are fixed by the nut 17. After spindle power feed has been started /by levers 13, fig. 5/ by shifting them into their limit position in the direction from the machine, the machine starts drilling and disengages automatically automatically when mark O on the depth scale reaches the mark O on the vernier scale. The levers are shifted into their central position and the machine is allowed to finish drilling operation. In this position it is possible to finish drilling operation by the hand wheel too. The pin of the fixed stop must be pulled out of course. After shifting the levers in the direction towards the machine it is possible to retract tool manually from the workpiece. Operator has to use a metal hook to remove flow chips if such a case occur.
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3.5
Safety clutch /fig. 17/
A claw type clutch is used. The lower part 14 of the clutch is seated on the worm shaft 9, the upper part 8 of the clutch is i s being mounted on the output shaft 5 of the feed box. The clutch is engaged by means of an electromagnet 1. Movement of the magnet core is transmitted by leverage and thrust bearing 2 to the stick 4 which, with aid of the pin 6 and the inner bush 11, through the locking pin 12 shifts the upper part 8 of the clutch into engagement with the clutch lower part 14. When the clutch is engaged, the inner bush 11 is interlocked with the upper part 8 of the clutch. It is unlocked before, but close to the moment the clutch is completely engaged by the ball 13 shift out of the recess in the shaft 5 and by pushing pins 12 out of the hole of the inner bush 11. When the electromagnet 1 is switched of, the upper part 8 of the clutch together with the inner bush 11 is shifted out of mesh with the lower part 14 of the clutch by means of springs 3 and 7, pin 6 and the stick 4. If during drilling operation the positive stop has been reached or an overloading occurs, the clutch is disengaged by shifting the upper part 8 of the clutch on the inner bush 11 into the upper arrestment, the electromagnet 1 being still switched on. If the electromagnet is now switched off, the inner bush of the clutch 11 is shifted to its upper position and the ball of the upper part 8 reaches the lower arrestment. The balls 13 get into a recess of the shaft and the locking pin 12 into the hole in the inner bush 11. Due to this the clutch is ready to be engaged again. The safety clutch has been already adjusted for the maximum drilling output by the manufacturer. New adjustment is executed by means of the screw 15 so that the clutch remains engaged when loaded by drilling operation using a properly sharpened drill of 50 mm dia for drilling in solid steel of 600 MPa tensile strength and 125 r.p.m. spindle speed and 0,28 mm per rev. spindle feed. If the spindle fee 0,35 mm per rev. is applicated the clutch disengages after a few millimetres of drilling depths. Some chattering may arise if maximum drilling output occurs especially when the headstock is positioned close to the arm end. In such a case follow the instructions in the paragraph 5.5 "Faults and their remedy". In regard to the operation voltage it is important to check engagement of the safety clutch at high speeds and feeds /by shifting of the control levers pos 18, fig. 10 in the position 3 away from the machine/. machine/. A reliable engagement is obtained by by adjustment of the resistor R4 circuit of the magnet Y4. This resistor is located l ocated in the switch board cabinet. In case of dismantling the machine or replacing the safety clutch electromagnet it is necessary to adjust the clutch again according to following instructions: Check if there is a clearance /0,3-0,8mm/ between clutches parts when the electromagnet is disengaged. Value of this clearance can be set by means of nuts which are on the extension of electromagnet core. Proper function adjustment of the clutch upper part is carried out in the following way: Low speed and low feed are engaged. Overcurrent circuit breaker is switched off, control lever is set in the starting position, control levers of power feed are shifted into engaged position /direction away from the machine/. Due to this the clutch is engaged without its rotation. The upper part 8 of the clutch must be shifted in the upper position by turning a little the handwheel 16. Claws of the clutch are out of mesh now. In case the clutch is jumping only, it is the sign that iri the engaged position the upper part of the clutch is interlocked with
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the bus 11. In this case correct adjustment can be gained by means of nuts on the extension of the electromagnet core in upwards direction. If, when engaging the clutch, a claw hits opposite claw and the upper part 22 of the clutch has been unlocked; consequently, the clutch is not engaged, in this case adjusting of the clutch is done by setting the nuts downwards on the magnet core extension. This way of adjustment may result, in the same time, in a change of clearance between two parts of the clutch. If this setting is done so that the clearance is not satisfying the complete lower part of the clutch including the worm shaft must be reset to height by means of screws in the flange 17. Such a resetting comes into consideration mainly after replacement of a complete clutch. To check clearance between both parts of the clutch serves a hole on the rear side of the headstock which is accessible after the headstock has overpassed the dead stop on the arm. If the clutch does not engage safely, sometimes when high speeds and feeds are being engaged, pressure of the spring 3 is to be increased by means of setting screw in axis of the bar 4 after the electromagnet and leverage have been removed. Command for the clutch engagement is given by switching on of the microswitch 5A14 /fig. 11/ which is controlled by the levers 13 /fig. 5/ or directly by switching on of the switch 5A12 /fig. 11/ which is controlled by the control lever 1 /fig. 11/. When machines are equipped with the program outfit machine functions depend on the overswitch 16 /fig. 6/ selected position. This overswitch is of three positions:
Position B: Drilling depth program is functional in this position. Electromagnet of the clutch is energised by means of the microswitch SA14. Fine finish drilling, manually, by means of the wheel 9 /fig. 5/ can be carried out after the control levers 13 /fig. 5/ have been shifted into their central position. Position A: Drilling depth program is out of function in this position. For fine manual drilling applies the same as for the position B. Position C: Drilling depth program is also out of function but manual fine finish drilling cannot be carried out. The clutch is engaged directly by the switch S12 which is activated by the control lever 1 /fig. 11/. In this position the clutch engages smoothly and due to this its service life becomes longer. It is used predominantly at high speeds and feeds without utilisation of the program. 3.6
Adjustment of run-up clutch and spindle brake /fig. 12/ 12/
If the clutch does not transmit the required torque /drill 50 mm dia., 125 r.p.m., feed 0,28 mm per rev., steel 600 MPa tensile strength, drilling drilling in solid/, adjusting is to be done as follows: The cover on the rear part of the headstock is unscrewed, the recessed safety pin 5 is lifted with the aid of a screw driver and by turning the nut the required torque is adjusted to fulfil conditions mentioned in the paragraph 3.5 for safety clutch adjustment. The pin 5 is released and it will drop into the nearest locking hole in the nut. If the spindle brake is not efficient enough after a longer service period, it has to be reset in the following way: The cover on the right-hand side of the headstock is unscrewed and the feeler gauge 0,3 mm thick is inserted into the gap marked 0,3. The control lever is then shifted into thearrested
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intermediate position /in the middle between neutral and limit position/ and so the magnet, located in the coil body is energised. The armature 2 is attracted and the feeler gauge determines an air gap. The nut 3 is turned to the right till the feeler gauge can be easily removed. The nut is secured by the catch 1 in a tapered hole of the armature 2. Function of the brake is to be checked after adjustment. If it is adjusted correctly, it must not generate heat if spindle is running. 3.7
Headstock clamping and its adjustment /fig. 14/
The headstock is locked on the arm simultaneously with locking of the mantle on the column and it is carried out hydraulically. It is controlled by means of the pushbutton 10 /fig. 5/ which is situated in the centre of the handwheel for the headstock traversing. Signal light in the pushbutton is on if locking has been actuated. Movement of the piston 8 in the cylinder is transmitted through the swinging locking blocks 10 to the wedges 12 and 13 and so locking force is generated. Unclamping of the headstock and the mantle remaining locked see chapter 3.8. Locking can be adjusted as follows: The headstock is released. The screw, after the nut 14 has been loosened, is shifted towards the headstock centre to increase breaking effect of the locking system. High clamping effect has been reached by means of the locking blocks. The nut 14 is to be tightened again after adjustment has been finished. Force 4000N must not cause any headstock shifting on the arm if the headstock is locked. The right oil level is, as well, a condition to keep clamping system reliable. The reservoir is to be filled up to the half of the oil level gauge. 3.8
Mantle clamping and its adjustment /fig. 15/
A correct clearance for easy swivelling of the arm is adjusted by means of the eccentric pins 26 which are provided with hexagons. Thesupporting bearings are fitted on the pins. By careful turning of the eccentric pins 26, after loosening of the locking screws 28, the right position of the mantle on the column is set up. Position of the eccentric pins is secured again by retightening of the scres 28. Adjustment is always executed by the manufacturer and resetting is usually necessary only after years of service, usually during an overhaul. Adjustment must be done very carefully in order to prevent overloading of the bearings 27 leading to their damage. Geometrical accuracy of the machine may be influenced by incorrect adjustment. The arm is to be dismounted if clearance adjustment by means of eccentric pins is carried out. The mantle is locked on the column hydraulically. Command for locking of the mantle and the headstock is given by depressing of the pushbutton 10 /fig.5/ which is located in the handwheel axis 11 /fig. 5/. Signal light in the pushbutton is on if locking has been actuated. The hydraulic cylinder 8 is located in the bottom part of the mantle under the electrical installation cabinet. Movement of the piston is transmitted through the piston rod 11, locking blocks 12, hardened supports 13 to the locking belt 21. The safety pin 10 is to be pulled out of the hole in the piston rod 11. 11. If releasing of the headstock is required whereas the mantle remains locked the following is to be done: Shifting of the pin 10 /fig. 15/ out is carried out prior to locking of the headstock and the mantle by means of pushbutton 10 /fig. 5/. The pin l0 is pushed into the hole in the piston rod 11 and by depressing of the pushbutton 10 /fig. 5/ the headstock is released on the arm. The mantle remains locked. If now releasing of the mantle is required first of all locking by means 3-6
VO 50
of pushbutton 10 must be done. Then the pin 10 is pulled out of the hole in the piston rod 11 and by following depressing of the pushbutton 10 /fig. / fig. 5/ the headstock and the mantle as well are released. Adjustment of clamping pressure is to be carried out so that, if the mantle is locked, the arm must not be swivelled even if static force of 1800N is applied on the arm end. On the other hand, if the mantle is released then swivelling of the mantle with the arm must not be braked by clamping system system at all. Adjustment therefore must be arranged so that the locking blocks are in horizontal level or 2° - 3 ° below it when the mantle is locked. Due to this maximum utilisation of locking system stroke is secured. In the supports there are notches for the blocks and these notches are adjusted against the notches in the piston roll with the aid of the two screws 31. They serve for adjustment of position of the blocks 12 so that they are horizontal while the mantle is locked. This adjustment has been carried out by the manufacturer and there is no need to do it again. After eventual dismounting and following mounting again of the stirrup I6 it is to be carried out as follows: First of all the headstock and the mantle is to be released. The machine is to be disconnected from the mains. Only then it is possible to begin with dismounting. The headstock must be close to the mantle. Access to the locking stirrup is gained after the cover 25 is taken off. The front insert 20 is taken out after unscrewing of the screw 19 and the blocks 12 are taken out as well. The mantle is swivelled so that the locking stirrup gets in a hole where a terminal board is located. In this position it is possible to unscrew the screws 31 and to take them out. As soon as the locking cylinder 8 and the locking pin 10 have been removed the locking stirrup is free and can be taken out. Simultaneously Simultaneously with the stirrup 16 the washers 30 are taken out too. Reassembling is carried out in reverse order. Adjusting of locking force must be carried out step by step, the locked and unlocked positions being repeatedly checked and position of the locking blocks is checked as well. Intensity of locking force is adjusted with the aid of the screw 14 after the screws 15 have been loosened. As soon as the adjustment is correct the screw 14 is secured again. If the locking blocks 12 fall out, during adjusting operation, following proceeding should be done: The screw 17 is tightened and by means of the pushbutton 10 /fig. 5/ the headstock and the mantle are released. The piston rod moves to its upper position and the blocks are taken out. Notches on the supports 13 are filled with grease and the blocks are inserted into the notches of the suppors 13 and into the piston rod notches. The mantle and the headstock are locked by means of the pushbutton 10 /fig. 5/. A new adjustment is arranged in accordance with preeeding instructions. 3.9
Headstock traversing along arm and its adjustment /fig. 5,14/ 5,14/
The headstock is traversed manually by means of the wheel 11 after its unlocking by the pushbutton 10 /fig. 5/. 5/.
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The headstock is guided on the arm in one dovetail and one flat guideway by means of two rollers /ball bearings/ which are seated on the eccentric pins 15. These pins can be turned when the headstock is released and after the locking screws 16 have been loosened to enable adjusting of clearance so that the guideway surfaces of the arm and of the headstock are in contact uniformly all over the whole length. Running clearance may be 0,02 mm. After adjustment the pins 15 are secured again by the screws 16. 3.10 Swivelling, lifting and lowering of arm /fig. 5,6/
The arm can be swivelled manually after the mantle and headstock have been released by the pushbutton 10 /fig. 5/. Lifting and lowering of the arm is actuated by pushbuttons 26 and 31. By depressing of the pushbutton 26 /fig. 6/ the arm is moving upwards, arm movement is stopped after releasing of the pushbutton. By depressing of the pushbutton 31 the arm is moving downwards, arm movement is stopped after releasing of the pushbutton. 3.11 Automatic elimination of lifting screw screw backlash /fig. 15/
On the lifting screw there is beside the lifting and safety nut also the nut 1, serving for backlash elimination, which is permanently lifted by the wedges 3, 4. The wedge 4 is pushed by the spring 5 under the wedge 3 and this wedge lifts the eliminating nut I. When the arm is moving the lower wedge 4 performs swinging motion and, due to this, self- locking capacity of the wedges is neutralised. The eliminating nut may then move in both directions of the screw axis and adjust itself to the thread profile. Pressure of the eliminating nut against the lower thread profile is determined by compression of the spring 5 actuated by the screw 6. 3.12 Sleeve with spindle dismantling dismantling /fig. 10,13/
When dismantling the sleeve with the spindle it is necessary to remove a sheet rectangular cover on the arm end, to traverse the headstock till it comes over the arm end and to secure it by suspension on a crane. Dismantling is carried out as follows: The cover 11 is removed, conductors from the locking pushbutton 10 /fig. 5/ are disconnected, screws 12 are loosened and the pipe 6 including the locking pushbutton for locking is taken out. The nut 21 is loosened, the hand wheel 20 is taken off, the screw 17 is unscrewed and the pins 16 of the hand levers 18 are taken off. After all that being done the pin 25 is unscrewed and pulled out and the head 26 can be pulled out, with all components fitted on it, from the shaft 4. The catch 15 is to be taken out after unscrewing of the adjusting screw. The scale 28 is taken out, screws of the flange 1 are unscrewed, and after dismounting of the drilling depth program /fig. 11/, the flange can be shifted out. After dismantling components of the engaging device including a wedge on the shaft 4 the clutch 13 /fig. 10/ can be pulled out together with the worm gear 2. Now it is possible to take the worm wheel out of mesh. On the rear side of the headstock the bracket 10 is dismounted and, after a circlip is removed, the intermediate gear engaging with a rack /not shown in the picture/ can be taken taken out. Screws of the cover 8 are unscrewed and it is pulled out together with the gear 9 and the shaft 5. Now the circlip 7 can be taken out and the pinion 4 can be pushed out of mesh with the
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VO 50
sleeve rack. Prior to the above the sleeve is pushed into its highest position to release the balancing spring 3 /fig. 13/. The pin, on which the intermediate gear has been mounted, is taken out and now the sleeve can be shifted out of the headstock. Dismantling of the sleeve with the spindle is carried out in case of exchange of spindle bearings. After the sleeve has been shifted out of the headstock the screw is released, both nuts 4 are dismounted dismounted and the ring 9 /fig. 13/ as well. By slight hammering on face of the spindle splinted end the spindle is shifted out of the sleeve.
Adjustment of the front bearing /fig. 13/ After the screw 11 has been released dismounting of the nut 6, distance ring 7, bearing 8 and ring 10 is carried out. After thering faces have been ground off by the required value the ring is again mounted on the spindle. After mounting of the bearing 8 and distance ring 7 the nut 6 is screwed on. The nut is tighten hard and is secured by the screw 11. In correctly adjusted bearing may be maximum radial clearance clearance 0,002 mm or up to 0,002 mm interference interference max. 3.13 Spindle balancing balancing /fig. 13/ 13/
Spindle balancing is performed by the helical springs 3 and 15. These springs are tensioned by the cam 2 during the spindle stroke which ensures uniform balancing force along the whole spindle stroke. If heavy tools are used it is possible to increase the tension force of the springs by means of the adjusting screw l. Balancing is adjusted for 20-22 kg of max. tool weight. By turning of the screw 1 to the right balancing force of springs is being increased and the spindle can beloaded with a heavier tool. By turning it to the left the balancing force is decreased - lighter tools can be used.
CAUTION - Be very careful if turning the screw 1 in the left hand direction as there is a possibility to damage the securing ring 12 and due to this there is danger of the sprocket 13 collision with the tube 14. 3.14 Electrohydraulic control control of machine /fig. 7a, 8/ 8/
Basic diagram of machine hydraulics is shown in fig. 7a. Engaging of gears in speed box and feed box and headstock locking on on the arm together with the mantle mantle locking on the column are controlled electrohydraulicaly. Gear changing is the headstock and locking or unlocking of the machine frame can be carried out by steps after the previous function has been finished. If simultaneous signals are given for engaging and locking or unlocking, only one function is executed because of a suddenly increased oil consumption. The other function is to be iniciated once more. The bottom part of the headstock forms an oil reservoir, from which oil is sucked by the lubrication pump 7 or by the pressure pump 9. Suction piping is provided on its end with the suction basket 1 with a ball back valve and a filter sieve. This piping leads to the distribution block 5 with two back valves. This block is located on the bottom of the speed gear box. The pump 7, driven by the first shaft of the gearbox, sucks oil from fr om there for lubrication of rotary r otary parts in the headstock and the pressure pump 9 sucks oil for gears engaging and locking. The pump 9 is driven by by a separate motor motor which is located on the rear side of the speed speed gear box. box.
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VO 50
In the headstock there is used bearing oil OL-22, viscosity 19,8-24,2 mm 2.s-1, 40° C, the first exchange of which is to be done after 6 week of operation and the next exchange should be done after 2000 hours of operation. Oil from the pressure pump is led into the distribution block 32 with two slide valves 11, 17 /fig.8/. The slide valves are shifted by pressure oil and their limit position are determined by the sticks 28,31 which are controlled by the electromagnet 19. In the distribution block there is, as well, the safety valve 29 which switches off the microswitch B1 if pressure reaches 2,5 MPa. The slide valve 11,17 are shown in the diagram in their basic position not subjected to oil pressure and electromagnets are not energised. The slide valves are pushed by the springs 10,16 against a shoulder of the screw 12. A command for locking of the t he headstock on the arm and the mantle on the column is iniciated by the pushbutton 10 /fig. 5/. Due to this the electromagnet 19 is energised and simultaneously the pump 9 is put into operation. This pump delivers oil through the distribution block 32 to the clamping cylinder 13 of the headstock and clamping cylinder 35 of the mantle. The light in the pushbutton is on. The slide 17 valve is shifted by oil pressure into position which is limited by the stick 18 and connects, by its hole through right hand annulus recess, pressure pipe with the left hand side of the headstock clamping cylinder 13 and with the upper side of the mantle clamping cylinder 35. By oil pressure the piston 14 if the clamping cylinder 13 is moving in the right hand direction, the piston 36 of the mantle clamping cylinder is moving downwards and so the headstock is locked on the arm and the mantle on the column. After locking has been finished the pressure switch switches off the pressure pump 9 and light in the pushbutton 10 is on /fig. 5/. Command for unlocking of the headstock on the arm and for unlocking of .the mantle on column is given by depressing of the pushbutton 10 /fig. 5/, lighted pushbutton lamp is switched off. Due to this the electromagnet 19 is energised and simultaneously the hydraulic pump 9 is put into operation. The stick 18 is lifted by the activated electromagnet 19 and pressure oil shifts the slide valve 17 to its right hand limit position. Pressure oil from the pump 9 is led to the right hand side of the piston 14 of the clamping cylinder 13 and to bottom side of the piston 36 of the mantle clamping cylinder. Left hand side of the clamping cylinder 13 and upper side of the mantle clamping cylinder 35 is connected with left hand annulus recess of the slide valve 17 to drain. After unlocking has been finished the pressure switch B1 switches of F the pushbutton 10 /fig . 5/ is switched off. Gears are shifted by differential pistons 20 in the engaging cylinders 8 and 6. Pressure oil is led, during engaging, by the pipe 24 at the bottom side of all differential pistons /in speed and feed gear boxes/. Upper sides of pistons are connected by independent pipes 25 with a control distribution block 2. Pressure oil is led to this block by the pipe 24. Slide valves 4, being in their left hand limit position, connect the upper sides of pistons in engaging cylinders 6 and 8 by pipes to drain. Pressure oil acts only on the bottom side of differential pistons and so pistons with shifters move upwards. Slide valves 4, being in their right hand limit position connect he upper sides of pistons in engaging cylinders 8 and 6 with pressure oil source. Pressure oil acts now on the upper side and, as well, on the bottom sides of differential pistons - pistons with shifters move downwards. Command for shifting of gears in speed and feed boxes into positions, which correspond with preselected or programmed spindle speed and spindle feed is given by shifting of the control lever 1 /fig. 11/ into its upper respectively into its lower limit position. After the lever 1 has 3-10
VO 50
been shifted into its upper position, engaging cyclus is started by the switch SA 11 and, by pushbuttons preselected speeds speeds and feeds, are engaged. After the lever 1 has been shifted into its lover limit position; then on machines equipped with program, the program drums are turned by one program position first by means of the pawl 2 /fig. 11/ and the ratchet 3 and then the switch SA 11 starts the engaging cyclus. When shifting gears in the gear box and in the feed box the electromagnet 30, which lifts the stick 31, is energised. Pressure oil shifts the slide valve 11 to its left-hand limit position and connects the delivery piping with piping 24. At the same time the stick 28 locks movement of the slide valve 17. Shifting of gears in the gearbox is an automatic engaging cycle. The spindle will not start turning until all sliding gears are meshing correctly and this is so even if operator moves the control lever l /fig. 11/ from the position for engaging into position "start" in a rapid sequence. The blocking switch S20 /fig. 8/ serves for this purpose and it remains switched on until all the gears are in mesh. If the gears shit against each other during shifting, the pressure switch B1 cannot - in spite of increased pressure - switch off the engaging relay as it is held on by the switch 520, but it gives an impulse to a special electrical inching system, for the gears to turn a little. After inching the sliding gears get easily into mesh. As soon as gear shifting has been finished, the pressure switch B1 switches off the hydraulic pump and the electromagnet 30. Positions of gears and preselected pins during engaging of single speed and feed steps can be seen in fig. 8a.
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VO 50
4 MACHINE INSTALLA INSTALLATION TION 4.1
Packing transport and storage /fig. 2/
The machine is dispatched as one unit including a switchboard cabinet. It is screwed down to a wooden base and floor joists. Method of machine preservation and packing is chosen according to consignment place of destination and in respect to an agreement with the customer: - packing is a combination of wood and galvanised sheet /PE foil/ - all-wood packing, packing, matched lumber with PE foil - all-wood base with skids, machine covered by a canvas. It is necessary to follow the marks on the packing and adhere to instructions in this manual for packing, preservation and loading the machine. Machine must be carefully and properly fixed on a transport vehicle. After the consignment has been delivered it is necessary to carry out the following activities: 1. No sooner that checking if the packing is not damaged unpacking of the machine may be performed followed immediately immediately by checking checking its state. 2. Incidental damage of the packing or the machine is to be reported immediately to respective forwarders. 3. Check if the equipment of the machine is complete complete and match the order. 4. Incompleteness of the consignment consignment shall be reported to the supplier immediately. immediately. Apparent defects must be reclaimed till 14 days after the consignment has been received. Claims lodged later will be ignored. 5. Length of warranty period is subject matter of purchase contract made between the supplier and the customer. Warranty is not applicable on damages resulting from: - damage of the machine machine due due to force majeure or or due to outside unforeseen influences - unprofessional assembly, handling, installation installation or by putting into operation which has not been carried out out in accordance with the the respective chapters chapters in this manual - not observing observing safety safety rules and instructions instructions mentioned mentioned in this manual - unprofessional storing in a customer’s warehouse - not placing placing an order regarding regarding or not performing performing restore works works after elapsing storage time as stated in this manual - interventions, changes changes or or repairs which have been been carried out out without agreement agreement with the manufacturer or supplier
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- Operation of the machine in a way way different from that stated stated in this manual. manual. Headstock and mantle are fixed by means of machine clamping devices during transport. In addition, clamping of the mantle is mechanically secured against accidental loosening by means of the pin 14 which is shifted in during the machine transport /fig. 5/. The headstock headstock as well as the arm are fixed by using retaining bracket with the base plate so that entire safety during transport is secured. Vibration damper must be taken off from the upper face of the mantle after the screws 6 /fig. 3b/ have been removed. The machine is suspended on a crane by means of joint eyes, fig. 2, which are bolted to the base plate, and a steel rod, which is shifted through the mantle. Protecting steel hoses on the arm rear side are protected by a wooden frame against deformations, which may be caused by a rope during lifting of the machine. For machine lifting it is necessary to respect cross sections, lengths and loading capacity of ropes and method of suspension as it can be seen in fig. 2. Ropes must be made from steel and provided with joint eyes to t o avoid slipping of the machine. If the machine after taking over is stored by the customer then for time of storing it must be protected against any damage caused by weathering, penetration of dust or unsuitable storing room. For long periods of storing, such a storing space must meet conditions of the Standard ČSN 330300 of the Czech republic chapter 3.1.1, i.e. basic environment is understood the environment of indoor rooms where air temperature changes range from -5°C to +30° C, air does not contain more than 15g H2O per cubic meter and relative humidity does not exceed 80 %/. Machined surfaces must be protected against corrosion by suitable preservation agent. Twelve months is maximum period of time for preservation renewal. During long-term storing it is necessary to conduct checking checking the machine machine and to perform restoring works in every 12 months. The machine must be kept in such a position that no deformation can arise which may have influence on the machine functions and precision. 4.2
Machine positioning on foundation and working area reguired /fig.3,3a,3b/
To secure guaranteed precision and quiet machine run the drilling machine must be installed on a concrete foundation. Prior to installing the machine on the foundation the bolts must be inserted in holes in the base plate and a pair of levelling wedges laid down on the foundation in cross direction. If bearing capacity of a concrete floor is sufficient then it is not necessary to build a whole foundation. In such a case only holes for anchoring bolts are drilled and conduits for electrical cables for power supply for the machine are made in the floor. Prior to putting the machine into operation it is necessary to remove preservation agent from the machine, clean the machine properly and lubricate it. Sufficient lubrication by manual pump on the arm and checking of the mantle guideways lubrication located is especially important. For preservation removal it is required to use cleaning liquids according to environment in which the machine is located e.g. benzin, paraffin and the like. Cleaning liquids which may damage top painting are not allowed e.g. synthetic acetone and spirits thinning agents. For the purpose of machine installation there is a set of anchoring bolts and levelling wedges as an optional equipment.
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Although machine is installed and connected by the customer’s own means according to instructions set forth in this manual the customer may ask the manufacturer to do it for him under conditions negotiated in advance. The support bracket, securing the machine during transport, is removed from the base plate. Electric motors are mounted on the machine (if dismounted prior to transport). The headstock is filled with the prescribed oil according to the paragraph 5.3. The machine is connected to the mains according to the paragraph 4.3 and the headstock is unlocked on the arm and the mantle is unlocked on the column - see paragraph 3.8. The arm is to be located into the middle position on the mantle guideways and the headstock is located in the middle position of the arm guideways length and both is clamped. The machine is levelled by means of wedges 1 /fig. 3/ and precision water level gauge in crosswise direction with permissible error 0,03 - 0,05 mm per l m. Then the machine is levelled, by means of wedges 2, lengthwise to meet the record about machine accuracy testing - measuring No. G O. Wedges 3 serve for supporting of the column weight only and may not be used, in any case, for lifting of the base rear part. After levelling the base can be grouted by concrete and holes with screws as well. As soon as concrete is hard-set the nuts of the foundation bolts are tightened and during this operation levelling in crosswise and lengthwise direction is checked continually. Swivelling of the arm outside the base plate is forbidden if the machine is not anchored properly by means of foundation bolts to avoid possibility of the machine overturning. In case of the machine relocating again it is necessary to secure the machine during its transport by means of a support bracket mounted to both the base plate and the headstock. The machine (the headstock, the mantle and the arm) has to be always reinforced. The damper must be dismounted from the mantle! The machine is provided with vibration damper, which is located on top face of the swiveling mantle (see fig. 3b). For machine transport the vibration damper is dismounted and after the machine installation on a foundation it is necessary to mount it back on the machine. The damper is transported by crane over the fixing plate 2 on the mantle and it is fixed to the plate by 4 screws, which are to be tightened properly. Preloading of the springs 7 is carried out by the manufacturer by means of screws 8 and there is no need to change it during machine operation. At last the cover 9 is fixed. By means of adjusting screws 10 (10 pcs) the clearance is taken up to fall within the interval from 0.5 to 1 mm for free travel of the damper 5. No sooner this operation is over the screws 10 are fixed in their adjusted positions by means of adjusting screws 11 (10 pcs). 4.3 4.3.1
ELECTRICAL PART Description of machine electrical equipment conception
Radial drilling machine VO 50 is a type of machine tool produced in the design possessing transport capabilities. Electrical set is installed in a switchboard cabinet, which is located on the side of the column mantle. Electrical set and electrical equipment meet the Standard ČSN 33 2200 of the Czech republic and IEC 204 - 1 - 1981 or as the case may be EN 60204-1, VDE 0113. Two copies of as-built wiring diagram accordant accordant exactly exactly with the delivered machine are inserted into the switchboard cabinet.
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4.3.2
Machine connection to the mains
Machine connecting terminals to electrical supply mains are located in the rear bottom part of the column in a terminal box. They are accessible after cover removal. Electrical supply terminal block is covered by means of detachable caps. After the supply cable has been connected the caps must be returned into their original places. If machine location is stable it is the best way to arrange power supply through a floor conduit by means of an armoured cable or by a cable in a steel conduit. Electrical supply phase conductors are connected to the terminals denoted U, V, W, middle conductor should be connected to the terminal N and protection ground conductor to the terminal PE. In case there is a current system with earthed neutral conductor then the terminals N and PE are interconnected.
CAUTION! Only a person appropriately educated and trained in accordance safety regulations for service and operation of electrical equipment is allowed to perform connecting the machine to the mains. In the Czech Republic these activities shall be in compliance with the Czech Standard ČSN 34 3100. Prior to connecting the machine it is necessary to make sure if operation voltage and frequency stated on the label, which is i s placed on the machine switchboard cabinet, is the same as voltage and frequency of the mains to which the machine is to be connected. Machine must not be connected if voltage or frequency is different from that stated on the label. For short circuit protection of the machine with respect to motor starting current the manufacturer recommends protection In: 50A for mains 3x220 V 35A for mains 3x380 V, 3x415 V, 3x440 V 25A for mains 3x500 V Recommended cross section of the supply cable is 4x6 mm 2 Cu. It is unconditionally necessary to make sure that the machine has been connected in the right phase sequence! The right sequence can be checked by spindle rotation. After the control lever has been shifted in direction to the arm the spindle must rotate in right hand direction. If opposite case, spindle rotates in left hand direction, it is necessary to switch the machine off at once and to interchange any two of the phase conductors of the supply terminals Wrong phase sequence connection may cause damaging of the machine.
Imperfect machine connection to protecting conductor of mains can result in injury of operator by electric current. Prior putting the machine into operation the initial inspection of electrical set and equipment shall be carried out. (in accordance with the standard ČSN 331500 of the Czech Republic.
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During machine operation life at the customer’s, it is necessary to carry out regular inspections of electrical set and equipment of the machine installation (in accordance with the standard ČSN 331500 valid in the t he Czech Republic). 4.3.3
Labour safety and protection against electrical accident
Electrical set and equipment of the machine has been designed to meet requirements of electrical standards, first of all the standards ČSN 33 2200, IEC 204-1-1981. VDE0113, EN 60204-1. It is necessary to keep unconditionally the main switch in off position during any intervention into electrical set and equipment. From the labour safety point of view it is unconditionally necessary to observe the following requirements and cautions: Personnel who will operate the machine must be well acquainted with machine documentation, first of all with machine operating instructions manual. The machine, already having been put into operation, may be operated by an operator properly trained and knowledgeable in machine control. While working on the machine the operator is not exposed to any danger of an electric shock. All alive parts of the electrical installation are protected against dangerous touching by suitable guard or insulation. During all machine repairs the principles for labour safety shall be adhered to. The main switch must be switched off and must be locked in the switched off position if any repairs of electric installation are to be carried out. Even if the main switch is switched off some circuits remain alive this fact must be respected during any inspection or repair in the switchboard cabinet. These circuits are:
l. 2. 3. 4. 5.
Main electrical electrical supply supply terminal board (terminals U,V,W). U,V,W). Electrical supply terminals in the switchboard switchboard cabinet (terminals U,V,W). Electrical supply terminals terminals of the main switch QS1. Interconnecting conductors conductors between the above above mentioned devices. Connecting cable between the main electrical supply terminal board and electrical supply terminals of the switchboard cabinet.
All these devices are protected against dangerous touch by a guard labelled with a warning triangle. In case of any work to be done in these circuits the electrical supply cable on the customer’s mains side must be disconnected.
Maximum arm swivelling is allowed to be done + 180° from the arm basic position /the arm over the base plate longitudinal axis/. The base plate must be fixed to the foundation by foundation bolts. If 360° or more arm swivelling occurs the connecting cable, between the main supply terminal board and the switchboard cabinet and is led through the column, is twisted and can be damaged. This cable is alive even if the main switch is switched off and, due to this, there is a danger of electric shock injury.
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VO 50
Repair work on machine electrical outfit may be carried out by a person with adequate qualification i.e. expert or informed person according to ČSN 33 3200 /resp. IEC 204-11981/ and under precondition of adhering to safety regulations of universal validity.
Any additional changes in connection or interference into electrical installation are not allowed as they could result in a serious breakdown of the machine or an accident of operator. 4.3.4
Description of machine electrical outfit /fig. 22/
1. Electromagnet of clutch for spindle power feed. 2. Electromagnetic spindle brake. 3. Main electromotor for spindle. 4. Microswitch for preselection of lacking or unlocking unlocking of the mantle and the the headstock. headstock. 5. Upper connection terminal box on the headstock. 6. Electromotor for hydraulic pump. 7. Distribution box on the arm. 8. Metal flexible flexible hose hose for conductors and hydraulics supply into the headstock. 9. Limit switch for upper limit position of the arm. 10. Stop of arm lower limit position. 11. Cover of controls for hydraulic distribution. distribution. 12. Electromagnet for for releasing of mantle and headstock. 13. Microswitch watching finishing of gears gears engaging. 14. Electromagnet for spindle speed engaging. engaging. 15. Microswitch for indication of hydraulic pressure. pressure. 16. Pushbutton with signal lamp commanding commanding locking or unlocking of mantle mantle and headstock. 17. Control panel. 18. Pushbutton for control of of arm lifting. 19. Pushbutton for control of of arm lowering. lowering. 20. Rotary switch for coolant coolant pump switching on on and off . 21. Rotary switch for spot lamp switching on and off . 22. Pushbutton control control for emergency emergency stop of machine. 23. Over switch of of work mode /use of program equipment/. 24. Spot lamp lamp for working area. area. 25. Microswitch of of drilling depth program. 26. Microswitch for control of power feed clutch. 27. Limit switch for spindle speed engaging. engaging. 28. Limit switch for engaging engaging of left-hand and right-hand right-hand spindle rotation. 29. Limit switch for spindle speed speed start and spindle spindle brake. 30. Lever for control control and engaging engaging of spindle spindle speed. 31. Stop of arm upper upper limit position. 32. Limit switch of arm lower limit position. position. 33. Pushbutton with signal signal lamp for switching on on of control voltage. 34. Main switch. 35. Coolant pump. 36. Switchboard cabinet. 37. Socket for connection of coolant pump. 38. Sealed outlet P21 P21 for machine machine connection to mains. 39. Detachable cover of supply terminal terminal board. 4-6
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40. Electromotor for arm lifting and lowering. lowering. 4.3.5
Specification of electric devices and their functions
A.
Specification
Devices located in switchboard cabinet Diagram design.
Name
Type
Manufacturer
QS1
Main switch
VBFO – 25A
SCHNEIDER
QF2
Circuit breaker for spindle motor
C60H 20D/3
SCHNEIDER
QF3
Circuit breaker for hydraulics, arm lifting, coolant pump
C60H 16D/3
SCHNEIDER
QF5
Circuit breaker for transformer primary circuit
C60H 6D/2
SCHNEIDER
QF11
Circuit breaker for clutch electromagnet
C60H 6D/2
SCHNEIDER
QF6
Circuit breaker for halogen lamp
C60H 4C/1
SCHNEIDER
QF7
Circuit breaker for control circuit 110V
C60H 2C/1
SCHNEIDER
QF8, QF9
Circuit breaker for rectifier bridge V1
C60H 4D/2
SCHNEIDER
QF10
Circuit breaker for rectifier V1 output
LSN-DC-4C/1
SCHNEIDER
FA1
Thermal protector hydr. motor pump EP 1 R 09306
SCHNEIDER
FA3
Thermal protector arm lifting motor EP-1-R 09310
SCHNEIDER
FA4
Thermal protector coolant pump motor
EP-1-R 0903
SCHNEIDER
FA31
Thermal protector clutch electromagnet
EP 1 R 09306
SCHNEIDER
KM1
Contactor for motor hydraulic pump EP 1C 0901 F7
SCHNEIDER
KM2
Reversal contactor for spindle motor EP 1C 1201 F7
SCHNEIDER
4-7
VO 50
KM3
Reversal contactor for spindle motor EP 1C 1201 F7
SCHNEIDER
KM4
Contactor for clutch electromagnet
EP 1C 0910 F7
SCHNEIDER
KM5
Contactor for spindle motor delta switching
EP 1C 1201
SCHNEIDER
KM6
Contactor for spindle motor star switching
EP 1C 2301 F7
SCHNEIDER
KM7
Contactor for inching spindle motor EP 1C 2310 F7
SCHNEIDER
KM8, KM9
Reversal contactor arm lifting motor EP 1C 0901 F7
SCHNEIDER
KM11
Contactors – protection against spontaneous start
EP 1C 0901 F7
SCHNEIDER
KM12
Contactor for indicat. headstock locking or unlocking
EP 1C 0901 F7
SCHNEIDER
KM13
Contactor for spindle
EP 1C 0901 F7
SCHNEIDER
KM14
Contactor for headstock unlocking
EP 1C 0901 F7
SCHNEIDER
KM18
Contactor for blocking of reversing
EP 1C 0901 F7
SCHNEIDER
KM27
Contactor for coolant motor pump
EP 1C 0901 F7
SCHNEIDER
KP17
Relay for inching of spindle motor
RP700PC 24 Vss SIEMANS, +socket MR 78 700 SCHRACK
KP20
Relay for delay of impulse spindle motor
RP700PC 24 Vss SIEMENS, +socket MR 78 700 SCHRACK
KP29
Relay – protection against spontaneous spindle start
RP700PC 24 Vss SIEMENS +socket MR 78 700 SCHRACK
T1
Control circuits Transformer
400 VA, IP20, 50/60 Hz
ELTEK
V1
Rectifier bridge
250V / 8A
GM
V2
Diode
1N 5408, 1000V/3A GM
V4
Diode
1N 5408, 1000V/3A GM
V5
Diode
1N 5408, 1000V/3A GM
V6
Diode
1N 5408, 1000V/3A GM 4-8
VO 50
R2
Resistor
TR 556 1K2K
TESLA
R3
Resistor
TR 556 1K2K
TESLA
R4
Resistor
TR 629 56RK
TESLA
R5
Resistor
TR 234 200RK
TESLA
R6
Resistor
TR 234 200RK
TESLA
R7
Resistor
TR 234 100RK
TESLA
R8
Resistor
TR 234 100RK
TESLA
R9
Resistor
TR 556 1K2K
TESLA
R12
Resistor
UR 006 560Ω,15W TESLA
R13
Resistor
TR 512 12K,15W
TESLA
R14
Resistor
TR 234 200RK
TESLA
C04,C05,C06 Interference eliminating condensor
TC 208, 0,1 µF/K
TESLA
C1
Condensor
E 47M / 50V
GM
C5
Condensor
E 470M / 50V
GM
C6
Condensor
TC 845A 4µF/K
TESLA
C7
Condensor
E 470M / 50V
GM
C12
Condensor
S.L.C.E
SEMIC PRAHA
KA21
Thermistor relay drilling motor
LT3-SA00M
SCHNEIDER
SB4, HA1
Pushbutton with light, control circuits switching on
XB-AW 33B5
SCHNEIDER
Limit switch for spindle speed engaging Limit switch for spindle start and braking
AT-11-1-i
MOELLER
AT-11-1-i
MOELLER
Limit switch for left-hand and right-hand spindle rev.
AT-11-1-i
MOELLER
Devices in control lever aren SA11 SA12 SA13
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VO 50
SA14
Microswitch for power feed clutch
E72-40H
CHERRYBALLUF
SA15
Microswitch for depth program
D4MC-5000
OMRON
Devices on control panel S3
Overswitch of work mode
č.v. 480/51621-41
SPRECHER+ SCHUH
SB01
Pushbutton light on
ZB5 – AD 2
SCHNEIDER
SB5
Pushbutton – emergency stop
ZB5 – AT 84
SCHNEIDER
SB6
Pushbutton for coolant pump on
ZB5 – AD 2
SCHNEIDER
SB8
Pushbutton for arm lifting
ZB5 – AA2
SCHNEIDER
SB9
Pushbutton for arm lowering
ZB5 – AA2
SCHNEIDER
Devices in hydraulic distribution space Y1
Electromagnet spindle speed engaging
EVJ 1151 (110V)
MEZ POSTŘ ELMOV ELMOV
Y2
Electromagnet for mantle and headstock unlocking
EVJ 1151 (110V)
MEZ POST Ř ELMOV ELMOV
SA20
Microswitch for engaging finishing
D4MC-5000
OMRON
B1
Microswitch oil pressure indication
D4MC-5000
OMRON
D4MC-5020
OMRON
Devices located on machine SA21
Microswitch preselect. locking or unlocking mantle and headstock
SA18
Limit switch for arm upper position ATO-11-1-i
MOELLER
SA19
Limit switch for arm lower position ATO-11-1-i
MOELLER
SB1
Pushbutton with lamp for locking XB5-AW31B5 and unlock. of mantle and headstock
SCHNEIDER
Y3
Electromagnetic spindle brake
KSÚ
480/S419 4-10
VO 50
Y4
Electromagnet spindle power feed clutch
EVJ 5142 /220/
MEZ POSTŘ ELMOV ELMOV
E01
halogen lamp
INDUSTRY II ZVG ČERNOCH 27-75 RSL-KS1-P9
Specification of electromotors Diagram design.
Function
Output
R.p.m
M2
Drilling
4 kW
1430 min-1/1720
M3
Arm lifting
2,2kW
1400 min-1/1670
M1
Hydraulic unit
0,55 kW
1400 min-1/1680
M4
Coolant pump
0,09kW
2880 min -1/0,42 l/s
B. Description of function Preparation before machine starting After the main switch 34 /fig. 22/ has been switched on the contacts of QS1 are switched on and power circuits of electric installation are alive from this moment. By depressing of the pushbutton SB4 therelays KM11, KM30, KM31 are switched on and signal lamp HA1lights on. Relays KM11 serves as protection against spontaneous machine start in case the mains has been switched off and the machine main switch is i s not switched off. Function is redundant. In this case the mains is again alive, the machine cannot start as the relays KM11 have switched off. The machine can be put into operation by depressing of the pushbutton SB4 /without any manipulation with the main switch/. Before the pushbutton is being depressed /SB4/ it is necessary to check the control lever 30 in fig. 22 is in its zero neutral position. The control lever controls the relay KP29 by means of the limit switch SA12. If the control lever is in one of its limit positions, the relay KP29 is switched on, and it by its break contact is blocking switching on of the relay KM11. The relay KP29 acts as protection against spontaneous start of the spindle rotation.
Lifting and lowering of arm By depressing of the pushbutton SB8 18, /fig. 22/ the contactor KM8 is switched on which starts the motor M3 and, due to this, the arm starts moving upwards. By depressing of the pushbutton SB9 19, /fig. 22/ the contactor KM9 is switched on and it changes over two phases and starts the motor M3 and, due to this, the arm starts moving downwards.
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VO 50
Limit positions of the arm secured by limit switches SAS18 and SA19 are secured. Break contacts of contactors KM8 and KM9 in coil circuits of the contactors KM8 and KM9 secure that only one contactor will be switched on and not both in the same time in case of failure. The pushbuttons SB8 and SB9 are in switched on positions only for the time they are being depressed. After they are being released the arm motion is stopped.
Lighting of working area The rotary switch SBO1 21, /fig. 22/ switches on and off the halogen lamp EO1 24, /fig. 22/.
Control of coolant pump Rotary switch SBS6 20, /fig. 22/ switches on and off the contactor KM27 which controls the coolant pump motor M4.
Locking, unlocking of headstock and mantle Locking By depressing of the pushbutton SB1 16, /fig. 22/ the contactor KM1 is switched on via the made contact of the relay KM12 /in unlocked position the relay KM12 is switched on/. Contactor KM1 starts the electromotor Ml for hydraulic pump and it is held in switched on position by the pressure switch B1. Locking is done by hydraulic hydraulic pressure and simultaneously simultaneously themicroswitch SA21 /4, fig. 22/ is shifted over. As soon as locking is finished, pressure of hydraulic oil increases and so the pressure switch B1 is switched off and, due to this, the contactor K1 and electromotor M1 as well are switched off. Signal lamp in the pushbutton SB1 is switched on and oil pressure drops. Locking is finished.
Unlocking By depressing of the pushbutton SB1 the relay KM14 is switched on via the break contact of the relay KM12 /in locked position the relay KM12 is switched off/ and simultaneously the electromagnet Y2 is switched on. Relay KM14 switches on the contactor KM1 which holds itself by its contact via the pressure switch B1. In the same time a made contact of KM1 holds on the relay KM14 and the electromagnet Y2 via the pressure switch B1. As soon as unlocking is finished, oil pressure increases and the pressure switch B1 switches off the relays r elays KM14, KM1 and Y2. Overshifting of the microswitch SA21 is done an so the relay KM12 is switched on and it disconnects circuit of the signal lamp HA2. The relay KM12 indicates the locked or unlocked position and preselects circuit for locking.
Engaging of preselected speeds By shifting of the control lever /30, fig. 22/ upwards the limit switch SA11 /27, fig. 22/ switches on the relay KM13 and the electromagnet for engaging Y1. The relay KM13 switches on the contactor KM1 which with its rest contact disconnects circuit of the relay KP20. Dropping of relay KP20 is delayed by means of a circuit which consists of the
4-12
VO 50
condensor C5 and the resistor R3. Resistance of the resistor R3 is adjustable, due to this, time of delay of relay KP20 drop can be adjusted inside some limits. Relay KM13, electromagnet for engaging Y1 and contactor KM1 are held by holding contacts of KM13 and KM1 via the pressure switch B1. The control lever returns into its original position after it has been released. Contactor KM1 switches on the electromotor M1 for hydraulic pump and pressure oil shifts gears. During the whole shifting time, till the moment the gears are in proper mesh, the microswitch SA20 is switched on. If, during shifting, gears hits one another /unfinished engaging occurs/, hydraulic pressure increases and the pressure switch is switched off /B1/ but the microswitch SAS20 is switched on. Hydraulic pump electromotor remains running. Contactors KM6 and KM7 are switched on by the second contact of the pressure switch B1 and rest contact of the time relay KP20 and made contact of KM13. Spindle electromotor M2 is started, for a short time, in "star" connection by switching on of the contactors KM6 and KM7. Length of switching on time of the motor M2 is determined by time delay for switching off of the relays KP17 and KP20. Dropping of the relay KP17 is delayed by the circuit which consists of the condensor C1 and the resistor R2, dropping of the relay KP20 is delayed by the circuit which consists of the condensor C5 and the resistor R3. Short starting impulse of the motor M2 enables to rotate engaged gears a little to reach a position where it is possible to get gears in mesh. Oil pressure increase again and the pressure switch B1 disconnects KM13, KM1 and M1 from supply as the microswitch SA20 is switched off already. Now speed engaging has been finished properly.
CAUTION! Spindle speed engaging and headstock and mantle releasing is not plossible to be done in the same time as for both actions pressure oil is needed. Due to this both actions are mutually blocked by the rest contacts of the relays KM13 and KMl4. Control of right-hand or lleft-hand eft-hand spindle rotation and of electromagnetic brake By shifting of the control lever /30, fig. 22/ in direction to operator in the limit position, the limit switch SA13 switches on the contactor KM2 for left-hand rotation and the contactor KM6 for switching of the motor M2 into "star" connection, so left-hand spindle rotation begins. By shifting of the control lever in direction to the arm, the limit switch SA13 switches on the contactor KM3 for right-hand rotation and the contactor KM5 for switching of the motor M2 into "triangle" connection, so the right-hand spindle rotations begin. In both limit positions of the control lever the limit switch SA12 is always switched on and the relay KP29 is switched on by this limit switch. During shifting it into its middle neutral position the rest contact of the limit switch SAS12 is switched on in both interposition's interposition's of the lever. This contact controls electromagnetic brake Y3 of the spindle. In the middle neutral position of the lever both limit switches switches SA12 and and SA13 switched off.
CAUTION Before machine switch of the gear lever (30, pic. 22) must be remain in position “0”. Spindle power feed with utilisation of drilling depth program /position B/
4-13
VO 50
The overswitch S3 is in position "B". Drilling depth is set up by means of a stop on the program drum. By shifting of the levers 13 /fig. 5/, for engaging of spindle feed, in direction out of the machine /position 3/, the microswitch SA14 switches on the contactor KM4 the relay KM18 is switched on by a contact of the contactor KM4. This relay connects a holding circuit of contactor KM3, KM5 is blocking circuits of contactors KM2, KM6. The contactor KM4 switches on the electromagnetic clutch Y4. If programmed drilling depth has been reached the stop /7, fig. 11/ shifts the bar /4, / 4, fig. 11/ and programming drum of drilling depths /9, fig. 11/ switches off the microswitch SA15. Due to this the contactor KM4 is switched off and spindle feed is stopped. By shifting of the levers for spindle feed in direction towards the machine /position 1/ the microswitch SA14 is switched off. By moving the spindle upwards, the drum together with the microswitch SA15 returns into its starting position. If the control lever is returned into its zero position the relay KM18 is switched off and the spindle is stopped.
Programmed automatic spindle reversation /position B/ Levers 13, for control of spindle power feed, are shifted in direction towards the machine /position 1/. The overswitch S3 is in position "B". After hand spindle feed to adjusted drilling depth a contact of the microswitch SA15 disconnects circuit of contactors of right- hand spindle rotation M3, KM5. Circuit of the contactors KM2, KM6 is closed by make contact of SA15 via theoverswitch S3 and a rest contact of the relay KM18. The contactors KM2, KM6 change sense of rotation of the spindle electromotor M2. Spindle rotation can be stopped by the control lever /12, fig. 5/ which controls the switch SA12.
Position C The overswitch S3 is provided with the position C where the microswitch SA14 is out of function. Electromagnet of the clutch is then controlled directly by the control lever by means of the switch SA12. In this position the drilling depth program is put out of function, but fine drilling by hand is not possible to use. In this position the clutch engages without impacts and, due to this, its life time becomes longer. This position is used mainly for high. spindle speeds and feeds when program is not used. 4.3.6
a)
Instructions for electroinstallation electroinstallation servicing failures, safety of work
Instructions for machine electroinstallation servicing
Electric installation is to maintained clean, protected against dust and humidity. After every year of operation it is necessary to inspect the main and auxiliary contacts of switching devices. Their cleaning is to be done, if needed, exchange can be carried out. If exchange of contacts takes place both fixed and movable contacts must be exchanged simultaneously. Grease in electromotor bearing chanbers is to be replaced after 2200 hours of machine operation. Exchange of grease is carried out after face flanges have been dismounted and old grease has been removed by means of paraffin. Bearing chambers are refilled up to two thirds of volume only by quality bearing grease AV2 or by some equivalent. Grease is to be exchanged even if the machine has been for a long time out of operation. Dismounting and mounting of a motor is done as follows: 4-14
VO 50
After dismounting of a motor from a machine screws on bearing covers are released. The covers are taken out. Screws on flanges are released. Flanges are taken out and rotor is shifted out. Mounting is carried out in reverse way.
b) Failures, their grounds and remedy When looking for a spot of fault it is necessary to prceed carefully with consideration as by thoughtless performing a considerably longer time may be spent for a fault remedy. First we check if fuses, protective relays and circuit breakers are in good order, if some of them are not melted resp. not switched off. If it is ascertained that point of fault is somewhere in a certain control circuit then the point can be found out by help of witing diagram which is also delivered with the machine. The faulty circuit is to be found in this diagram. The circuit is checked by a tester in steps, from number to the other number, from one end of the control line to the other up to the point of fault. Cause of fault is usually an overloaded electromotor or a damaged contact of a relay or contactor. Rarely it is loosen conductor in a terminal etc. A fault may be caused as well by faulty function of some limit switch or microswitch.
Repair works on machine electrical installation may be carried out by a person with adequate qualification only and under precondition of adhering to safety regulations of universal validity.
4-15
VO 50
5 MACHINE SERVICING 5.1
General principles for operation, operation, safety and health protection at work
Reliability and maximum machine precistion will be maintained if the following condition are observed: 1. This machine machine is designed for mild climatic environment environment for mechanical shops in metal industry, for location in closed spaces with natural aeration with standard industrial atmosphere, low dust nuisance and without presence of acid vapour. 2. Chips arising arising from machining during a work shift shift are to be removed from the machine. 3. Pressure air is never used for cleaning of the machine as metal particle can be driven between movable machine parts and, due to this, to jeopardise machine reliability and life. 4. Full attentions to be paid to adhering to instructions especially especially about cleaning and lubrication of the machine. 5. Machine is to be perfectly perfectly cleaned cleaned and serviced serviced after after each work shift and namely namely before weekend. 6. For cleaning of the machine machine never never use synthetic, acetone, acetone, alcohol alcohol or other solvents which may damage machine survace finish eventually start corrosion of unpainted surfaces. Most suitable cleaning cleaning means are paraffin paraffin and technical petrol. 7. In case a coolant coolant is used then valid health regulations regulations must be adhered adhered to and and neutrality of applicated liquid is to be watched to avoid starting of corrosion. 8. Do not put tools on clamping surfaces of the the machine. 9. The machine machine must must not be used for works other than it is mentioned in this handbook. handbook. 10. All instructions in respective chapters of this handbook are to be respected for maintenance and any manipulation with the machine. 11. The level of the emission acoustic acoustic pressure at place of operator does does not exceed the value value of 78 dB(A) and the level of the acoustic power does not exceed the value of 97 dB(A). The measurement is taken in accordance with ČSN EN ISO 3744. The above-mentioned values are emission levels and they do not need to represent the safe working levels. Although the reciprocal relation between the levels of emission and exposure exists, they cannot be reliably used for determination, if subsequent measures should be taken. Factors having having influence on the actual actual exposure exposure level involve involve the properties of the working room, other sources of noise etc. (i.e. other machines, neighbouring processes effect) and time of operator’s exposure to noise. The admissible exposure level may be also different in single countries. Nevertheless this piece of information can help user to evaluate the danger and risk. 12. The machine may be operated only by a person to which the machine keeper provides training for the machine operation and safety at work on. machine tools according to respective regulations 13. If the machine is not anchored properly, by anchoring anchoring bolts, it is forbidden to swivel the arm out off the base plate area as, insuch a case, machine overturning hazard exists.
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VO 50
14. If the machine is anchored anchored properly by anchoring anchoring bolts /article 4.2 and 4.3.3/ 4.3.3/ it is possible to swivel the arm from its basic position /the arm just over the base plate axis/ by 180° forwards and backwards. backwards. The arm must not be turned round i. e . by 360° 360° from its basic position. 15. Before any relocation of the machine it must be properly secured /article 4.2/ and the headstock is be fixed by a support.
5.2
Testing operation of machine after its settlement /fig.5/
Prior to starting of the machine operation it is necessary to remove, first of all, preservation coating from all metal and guiding surfaces. Alcohol or thinning solvents must not be used. Next the headstock is filled with oil of specified viscosity. Oil is to be filled up to the mark provided on the oil level gauge and the whole machine is to be thoroughly lubricated /see article 5.3/. Then the sheet metal reservoir is filled with coolant after the removable cover has been unscrewed. The reservoir capacity is about 30 litres. Before starting the machine operation it is necessary to read carefully the chapter concerning operation of the main machine parts, article 5.3 "Machine lubrication" and article 5.4 "Cooling equipment". Next all the elements necessary for the machine operationare checked if their function is correct. The pin 14 is to be pulled out when the headstock and the mantle are being locked yet. Swivelling of the arm and the headstock traversing is checked. Free motion of the spindle can be found out by rotation of the spindle by hand. Connection of the machine to the mains is to be carried out according to instructions in the article 4.3. The main switch 1 and the pushbutton for control voltage 29 have been switched on. After the control lever 12 has been shifted towards the arm we can see if the spindle rotates in righthand direction.
It is important to be that he sense of motors rotation rotation especially the arm arm lifting motor, is right and corresponds with function of pushbuttons for the arm lifting and lowering. Otherwise the automatic arm feed interrupting, in the arm extreme positions, would not be active. ATTENTION! Wrong sense of phases connection results in the t he machine breakdown. When starting the machine for the t he first time a few spindle speeds and feeds are engaged, right function of engaging is being tested, and the spindle is let to run idle for half an hou approx. The lubrication system action and temperature of spindle bearings is checked during this period of time. Lubrication can be checked on the oil level gauge 13 /fig. 4/. If everything is in good order then the machine can be put into operation. All control elements are to be movable easily. Spindle speed and feed engaging during the spindle run is not allowed.
5-2
VO 50
5.3
Machine lubrication /fig. 4/
Full attention is to be paid to a proper machine lubrication. It is necessary to look after the machine lubrication in all prescribed spots, by prescribed types of lubricants, in required time periods and the right oil oil levels are maintained and oil levels are checked in oil level level gauges. A few notes in addition to instructions for lubrication as mentioned in tables which are the part of this article and lubrication lubrication diagram fig. 4.
1-
Arm lifting screw The screw is accessible accessible after the cover has been been removed. Forced-feed Forced-feed lubricator is used for lubrication. Applicated oil: A-00
2-4
Worm box arm lifting It is used oil OA - PP44 /29-37 mm 2.s -1 - 100°C/.
5-8
Mantle quiding and elimination wedges It is used oil OL - 100 /90-100 mm 2.s -1 – 40°C/. Operator can check visually the delivered oil volume in the supply tube on the arm.
9-
Spindle sleeve The sleeve is protected by a bellows cover against dust. Checking of spindle sleeve surface can be carried out out after dismounting of the cover. cover. Lubrication is carried out on the shifted out sleeve It is used oil OL-22 /19,8-24,2 mm 2.s-1 40°C/.
10-
Power and manual feed Lubrication is done by dropping of oil between the scale and the headstock. It used oil OL-22 /19,8-24,2 mm 2.s -1 – 40°C/.
11 -
Nut of depth program Lubrication of the depth program nut is carried out after the cover of the depth program has been been open . It is used used oil OL - 22 /19,8-24,2 /19,8-24,2 mm 2 . s -1 –40°C /.
12-15 Headstock Headstock lubrication secures a gear pump, situated in the motor axis below the gear box, which is transporting oil from the basin in the headstock bottom from the suction basket to the multiplate multiplate starting clutch and to the brake and on gears in the gear box. Through one tube oil is running down into the t he oil level gauge 13 /fig. 4/. Oil is filled in through the plug 12 on the upper headstock cover. For headstock lubrication the bearing oil OL 22 /19,8-24,2 mm 2.s-1 - 40°C/ is used. This oil serves simultaneously for hydraulic functions of the machine as well. Oil drain is done by the plug 15. It is a magnetic plug which should be cleaned after being dismounted. Also the dismounted sieve is to be cleaned. The first oil exchange must be carried out after six weeks machine operation, foll8wing exchanges according to the lubrication table fig. 4 are to be done. When changing oil it is recommended to rinse the basin with oil OL - B4 /30-37 mm 2.s -1 50°C/. For oil refilling into headstock through the hole 12 a filter funnel f unnel with up to 50 um filtration filt ration should be used. 16 -
Arm guideways Arm guideways for headstock traversing wiped to remove dust. Lubrication is done by oil which is dropped and spread by felt. It is used oil OL-100 /90-110 mm 2 . s-1 -40°C/.
5-3
VO 50
POROVNÁNÍ OZNAČENÍ OLEJŮ VERGLEICH VERSCHIEDENER OELSORTEN COMPARISON OF OIL DESIGNATIONS TABLEAU COMPARATIF DES HUILES TABLA DE COMPARAGION DE LOS ACEITES
ČR
MOBIL
SHELL
BP
_______________________ __________________________________ _______________________ _______________________ _______________________ _________________ _____ OL-100
VACTRA HEAVY
VITREA 100
ENERGOL CS 100
OL-22
VELOCITE OIL No. 10
MORLINA 22
ENERGOL CS 22
OA-PP44
MOBILGEAR 636
OMALA 320
ENERGOL GR XP 1000
ČR
ESSO
TEXACO
_______________________ __________________________________ _______________________ _______________________ _______________________ _________________ _____ OL-100
NURAY 100
OL-22
SPINESSO 22
OA-PP44
SPARTAN EP 460
A00
MARFA K-00
5-4
VO 50
LUBRICATION INSTRUCTION CHART FIG. 4 w e r c s g n i t a v e l E
Part of machine
Lubrication point Point of act. No
1
Worm box for arm elevating
2
3
4
Sliding surface of mantle and elimination wedge
5
6
7
8
e v e ) e e l s c a e f l r d u s n i ( p S
d d n e a e r f e d w n o a P h
9
10
h t e p m e d m a f r o t g o u r N p
11
s e c ) a p f r u m u d s r a a e g f n o r i p d s i u ( G
Drilling head
12
13
14
15
16
Mark for operator
Necessary operation operation
8
Check of level height
8
8 8
Check of lubrication
2000
Filling
2000
2000
2000
Filling outlet
2000
2000
Check of filling 5-10 strokes by hand-pump By forced-feed lubrication
50 50
50 50
15 drops - by oil can Designation of lubricant
50
A-00
Tank capacity in litres
OA–PP44
OL-100
3
1,5
OL-22
OL-22
50 OL - 22
OL-22
OL-100
4,5
480/K 154 41
5-5
5.4
Cooling equipment /fig. 4a/
Sheet metal reservoir 1 for 30 of coolant is situated beside the base plate and is fixed to it by means of two screws 2. The pump 3 is screwed down to the. reservoir cover and is driven by its own electromotor. The pump outlet is connected to a hose 4 which is led together with the hose for hydraulic oil through a metal protecting hose located on the rear part of the arm. The other end of the hose far coolant is connected to the tube 5 which is provided with the cock 7 and with the adjustable tube 6 on its end. Coolant drain is arranged by collecting channels in the base plate and a tube outlet into the t he reservoir. The reservoir is to be cleaned properly, from time to time, after the cover has been removed. Coolant level in the reservoir can be checked only after the cover has been removed. Upper coolant level should not be higher than 1 cm below the t he upper reservoir edge and the lowest level should not be less than t han 5 cm below the upper reservoir edge. For tool cooling it is necessary to use long life coolant type e.g.: Blasocut-Blaser, Syntilo R-Castrol, Cincinati-Milacron, Lekon-Leleitner, Biorol.
5.5
Faults and their remedy
I. Fault: Arm jerking motion when descending
Cause:
Dirty or not sufficiently lubricated guideways and lifting screw.
VO 50
5.4
Cooling equipment /fig. 4a/
Sheet metal reservoir 1 for 30 of coolant is situated beside the base plate and is fixed to it by means of two screws 2. The pump 3 is screwed down to the. reservoir cover and is driven by its own electromotor. The pump outlet is connected to a hose 4 which is led together with the hose for hydraulic oil through a metal protecting hose located on the rear part of the arm. The other end of the hose far coolant is connected to the tube 5 which is provided with the cock 7 and with the adjustable tube 6 on its end. Coolant drain is arranged by collecting channels in the base plate and a tube outlet into the t he reservoir. The reservoir is to be cleaned properly, from time to time, after the cover has been removed. Coolant level in the reservoir can be checked only after the cover has been removed. Upper coolant level should not be higher than 1 cm below the t he upper reservoir edge and the lowest level should not be less than t han 5 cm below the upper reservoir edge. For tool cooling it is necessary to use long life coolant type e.g.: Blasocut-Blaser, Syntilo R-Castrol, Cincinati-Milacron, Lekon-Leleitner, Biorol.
5.5
Faults and their remedy
I. Fault: Arm jerking motion when descending
Cause: Dirty or not sufficiently lubricated guideways and lifting screw. Remedy: Cleaning and proper lubrication of screw and guideways. II. Fault: Machine excessive vibration during drilling operation
Cause:
1. 2. 3. Remedy: 1. 2. 3. 4.
Badly sharpened sharpened drill with eccentric eccentric tip. Unsuitable relief angle in relation to feed applicated. applicated. Too wide cutting edge edge in relation to drill dia. Concentric ground ground drill tip. Drill proper relief is to be ground. ground. Grinding of a narrower cutting edge. Radial drilling machines are designed with open frame. Under some circumstances a case can occure that a drill of smaller dia causes excessive chattering of th machine. Such a case may occure when drilling is done in soft materials or in predrilled holes. In such a case it is recommended to change spindle speed and, first of all spindle feed. If higher feeds are used a quiet drilling is usually achieved. In such an exceptional case it is not possible to insist on speeds and feeds according to standards.
III. Defect: Uneasy arm swivelling or unsufficient clamping force
Cause: Incompetent handling with locking mechanism. Remedy: Adjustment according to instructions in para 3.8 fig.15 IV. Defect: Headstock is not sufficiently locked
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VO 50
Cause: Due to wearing out or incompetent handling. Remedy: Adjustment according to instructions in paragraph 3.7 fig. 14. V. Fault: Spindle breaking is not sufficient or not effective at all
Cause:
1. Limit switch SA12 is out of order. 2. Brake electromagnet Y3 out of order. 3. Brake plates are worn out. 4. Interrupted conductor for electromagnet Y3. Remedy: Checking of SA12 and electromagnet functions and then adjustment see para 3.6 fig. 12. s peeds and feeds and headstock and mantle locking proceeds procee ds VI. Fault: Engaging of spindle speeds slowly or is not finished at all.
Causes: a) Shortage of oil b) Oil viscosity is higher higher than 19,8-24,2 mm mm 2 . s-1 – 40°C. c) Pressure switch B1 /fig. 8/ is not switching off. d) Switch SA20 permanently switched on. e) Shiftable gear is loosened . f) Oil pump 9 /fig.8/ sucks air. Remedy: a) Refilling with oil OL-22 /viscosity 19,8-24,2 mm 2 . s -1 – 40°C/ up to a mark on oil level gauge – tubes being full. Be careful not to overfill as oil flows slowly from headstock top to its bottom. b) After 3 or 4 engaging cycles time of this cycle is 0,5 – 1 sec. If longer then oil is too thick, is to be replaced. c) Microswitch B1 is to be exchanged. Suction tubing sucks air – tightening of tubefitting. Spring under stick for microswitch is worn out- is to be exchanged. If fault is rare – just switch off and on the main switch. d) Adjusting of screws on bent lever under top cover of headstock. Bent lever controls by means or rocker microswitch S20. It is swivelled by pin 22 in guiding bars of shifters /fig. 8/ and by adjustable screws on lever. If shiftable gears are in their limit positions –S20 is off. e) Shifter is shifted into its right position and secured on piston rod. f) Checking of sealing ring on pump pump shaft GUFERO GUFERO – if worn out exchanges exchanges necessary. VII. Fault: If command for speed engaging is to be repeated very often by control lever shifting upwards, otherwise preselected speed is not engaged completly.
Cause:
Main motor does not turn gears /inching/ if gears impacts each other when engaging. a) Too fast shifting of control lever for speed and feed engaging b) Wrong microswitch SA20 SA20 function controlled by bent lever. Remedy: a) Control lever is to be shitted slowly upwards to engage preselected speeds and feeds. b) Adjustment according according to VI. par d), exchange exchange is necessary necessary if it is damaged VIII. Fault: Spindle plover feed is not engaged after levers 13 /fig. 5/ have been pulled in direction out of machine
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VO 50
Cause:
1. Shifting of gears in gear box is not finished. 2. Microswitch SA20 does not switch on. 3. Clutch electromagnet Y4 /pos. 1 fig. 17/ is damaged – under upper headstock cover. 4. Damaged blocking pin of power feed claw clutch which is located inside headstock in axis of handwheel for fine manual feed 9 fig. 5. The clutch can be seen in fig. 17. Remedy: 1. Repeating of engaging by control lever 12 /fig. 5/ shifting upwards. 2. Adjustable screw for microswitch switching is set up. 3. Checking of electromagnet Y4 function. 4. Upper part of claw clutch for power feed is to be dismounted: a) headstock is shifted shifted over right-hand arm end one half of its width approx. approx. and is secured there. b) upper cover of headstock is removed, clutch electromagnet and transmitting part for clutch control are dismounted. dismounted. c) cover of feed box on front headstock headstock side side together with hinger hinger cover of of depth program are dismounted dismounted – 4 fig. 5. d) auxiliary cover on rear side side of headstock between between headstock headstock guideways is dismounted. e) pinconnecting claw clutch clutch with bar passing passing through through the last hollow shaft of feed box is to be driven out. This shaft is taken out and upper part of clutch is taken off. Blocking ball is to be castched when clutch is shifted out of shaft. f) after dismounting of upper clutch part it is necessary necessary to take out inside bush, pull out spring wire, blocking ball and blocking pin. Hole for blocking ballin inside bush and hole for blocking pin are to be cleaned. Pin is to be exchanged if damaged. Clutch is assembled again. IX. Fault: Locked machine cannot be unlocked.
Cause:
1. Pushbutton SB1 contact does not switch on 2. Faulty function of electromagnet Y2 or relay KM14 Remedy: 1. Cleaning or treatment of contacts of pushbutton SB1 2. Find out if electromagnet Y2 for unlocking is on after relay KM14 has been switched on. program control is used. X. Fault: Preselected speed s and feeds are not engaged if program
Cause:
To vehement shift of control lever swivels program drum over its right position and following stops cancel engaged speeds. Remedy: Engaging is to be done by not too vehement shifting of control lever downwards. If even in this case pushbuttons are jumping out it is necessary to tighten screw of basll brake which is located under scale scale 8 /fig. 5/. XI. Fault: Depth program is out of order.
Cause:
Mechanical function of program program drum is not right - it does not move downwards or it does not return after it has been depressed. Remedy: Find out if microswitch SA15 is switched off after program drum has been depressed /pos. 1 fig. 11/. Check if shifting and returning of drum in axial direction is easy. If not cleaning and lubrication of bus is to be done.
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VO 50
6 WORKING POSSIBILITIES 6.1
Machine working possibilities
The radial drilling machine VO 50 has been designed for application in all branches of engineering industry as a machine capable of vertical drilling, spot facing around the holes, recessing, counterboring, counterboring, coutersinking (using suitable tools – guiding) and tapping of of righthand and left-hand threads in medium sized and intricate engineering workpieces made from steel, cast iron, non-ferrous metals and plastics. The machine can be employed both in single piece as well as in series production where the programmed control of speed steps, feed rates and depths may be favourably employed. The programmed control has 20 positions and involves all operations even those for more intricated components. Workpieces may be placed either directly on the clamping surface of the base plate or on the box-shaped table or tilting table which are both delivered as optional equipment for application with the machine. Small workpieces may be held in a machine vice (optional equipment as well) which can be fastened either on the box-shaped table or on the tilting table. The box-shaped and tilting tables must be clamped on the base plate if they are used for machining. However, for drilling of smaller holes it is sufficient if the table is supported against angular displacement only. Screws for table fastening are delivered together with the table. Inclining of the tilting table is carried out as follows: By releasing the lock screw 4383 see fig. 19a and turning for table the crank 4313 the required incline can be roughly read off on the scale 4309. After adjustment the table is secured by the lock screw 4383. If accurate adjustment of table incline is required it is necessary to use precise roller, gauge block or sine rule and adjustment is to be checked by a dial deviation gauge. If the arm is supported on its end by a supporting column (optional equipment) it is necessary to block arm movement upwards and downwards to avoid damaging of arm lifting mechanism. For this reason serves the pushbutton SB11 with a lock which is located on one side of the switchboard cabinet. The elevating motor and so the arm movement are blocked by depressing of the pushbutton and its locking in this position by turning the key. The pushbutton with the lock SB11 is not a standard equipment of the machine but it is delivered together with the supporting column. The blocking pushbutton must be mounted prior to supporting column column installation. Assembly procedure: 1. Dismount the pushbutton without function on the side of the contactor box (over the backlit pushbutton SB4, HA1). 2. Pushbutton with a lock is mounted on the the machine. machine. 3. Pushbutton SB11 is connected according to machine electric wiring diagram. - Fuses 301 and 369 are switched off in the contactor box - Circuit-opening contact of the pushbutton SB11 is connected between the terminals 301 and 369. 6-1
VO 50
6.2
Standard equipment
Standard equipment is delivered together with the machine. Machine price includes the standard equipment price. 1. Complete electrical set and equipment including lighting. 2. Tool kit according to packing list. Following technical documentation is delivered with the machine: 1. 2. 3. 4.
6.3
Operating instructions manual – 2 pcs Packing list of accessories – 1 pc Record on accuracy accuracy test – 1 pc Catalogue of spare spare parts parts – 1 pc. pc.
Optional equipment
1. Cooling equipment with electric pump /fig. 4a/ 2. Morse adaptors according to Czech Standard ČSN 24 1240
3x1 – 3x2 5x3 – 5x4
3. Cube-shaped table Vb 50 /fig. 18/ Upper clamping surface Side clamping surface Height Number, width and distance of upper upper clamping slots Number, width and distance of side clamping clamping slots Weight
mm mm mm mm mm kg
550x550 550x420 550 4x22x130 3x22x130 190
4. Cube-shaped table Vb8 /fig. 18a/ Upper clamping surface Side clamping surface Height Number, width and distance of upper upper clamping slots Number, width and distance of side clamping clamping slots Weight
mm mm mm mm mm kg
1000x750 1000x500 500 5x28x160 3x28x160 430
5. Tilting table Vc50 /fig.19/ Upper clamping surface Side clamping surface Height Number, width and distance of upper upper clamping slots Number, width and distance of side clamping clamping slots Weight
mm mm mm mm mm kg
550x550 550x430 550 4x22x130 3x22x130 305
6. Tilting table Vc8 /fig. 19a/ Upper clamping surface Side clamping surface Height
mm mm mm
750x600 750x400 550
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VO 50
Number, width and distance of upper upper clamping slots Number, width and distance of side clamping clamping slots Weight
mm mm kg
5x28x160 2x28x160 360
7. Vice 160 PMV-243136 /fig. 20/ Clamping length Width and height of clamping jaws Weight
mm mm kg
275 160x63 52
8. Cross-axis table Vf4 /fig. 21/ Clamping surface Height Number, width and distance of clamping clamping slots Weight
mm mm mm kg
400x320 220 4x18H7x80 210
9. Supporting column /fig. 23/ Weight
kg
200
10. Anchoring set Set of 6 screws M30 x 400+ 6 nuts and washers. 11. Levelling wedges Set of 6 wedges for machine levelling on foundation.
6.4
Example of machine operation without use of program
Program control of drilling depth can be, according to requirement, switched on or off by means of the change-over switch 16 /fig. 6/ which is situated on the headstock control panel. If drilling depth program control is switched off it is possible either automatic set-up of stop sticks of program drum 4 /fig. 5/ and 9 /fig. 11/ when drilling of the first workpiece is executed or carry out machining without regard to adjusted program. The drum for drilling depth adjustment is put out of operation in this case. Preselection of speeds and feeds is carried out by depressing of respective pushbuttons 7, 5 /fig. 5/ during work on previous operation or close on engaging itself. Spindle stop, engaging and new start is executed by the control lever 12 /fig. 5/ on left-hand bottom part of the headstock as mentioned above. Locking of the headstock and the machine frame is done by depressing of the pushbutton 10 /fig. 5/ after a tool in spindle has been located in required position on the workpiece. Operator approaches a workpiece surface by a tool and now he can set-up the depth scale 20 /fig: 6/ on required drilling depth and can start the spindle. Spindle power feed is engaged by pulling on the control levers 18 /fig. 10/ in direction out of the machine into position 3. Power feed is automatically disengaged as soon as the set up depth on scale has been reached. In case of need it is possible to disengage power feed, during drilling, by shifting the control levers into their middle position 2 /fig. 10/ and finish drilling by turning the hand wheel 14 /fig. 10/ for fine manual feed, or to finish drilling, by shifting of control levers into their third position 1 /fig. 10/, in direction to the machine, by rough manual feed until the stop, set up by the scale, has been reached. During thread tapping operation it is necessary to watch the depth on the scale and, as soon as the required depth has been reached, the control lever 12 /fig. 5/ is to be shifted into position for spindle reversing. Spindle reversing is done by the motor reversation.
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VO 50
Operator can unlock the headstock and the machine frame by depressing again the pushbutton 10 /fig. 5/. 6.5
Example of work with use of program
Stops 2 /fig. 9/, on program drum for speeds and feeds engaging, carry out programmed engaging of speeds and feeds. Disengaging of power feed, when required drilling depth has been reached, eventually spindle reversing, when required tapping depth has been reached, is executed by the adjustable sticks 4 /fig. 5/ and 4 /fig. 11/ in device for adjustment of program for drilling depths. Setting of stops on speed and feed program drum can be done by resetting of sliders 6 /fig. 5/ for speeds and feeds /also 1 in fig. 9/. This resetting can be done for required number of operations before any work on the first workpiece has began. Adjustment of the sticks on the drilling depth program drum 9 /fig. 11/ is automatic. Just before machining of the first workpiece the operator switches off the command circuit of drilling depth program drum by the overswitch 16 /fig. 6/, screws for fixing of the sticks on this drum are released, the lever 17 /fig. 11/ is set into its right-hand position and the program drum is turned, by hand, into its position No. 20 which is i s designated on the knurled wheel 8 /fig. 5/. Required speed and feed, for the first operation, are set up on the pushbutton panel. The tool is i s inserted into the spindle, then it is manually approached to workpiece surface and the depth scale is 20 /fig. 6/ set up to required drilling depth. By depressing of the control lever 12 /fig. 5/ downwards the program drums index to the first position i.e. the first operation. Spindle run is started by the control lever 12 and spindle power feed is engaged by shifting of the control levers for power feed in direction out of the machine. The stick of the depth program drum, for the first operation, is being moved by the lifter 7 /fig. 11/ simultaneously with the spindle feed. After the depth, set up on the depth scale, has been reached, the power feed is either disengaged automatically or it is i s disengaged manually by shifting of the power power feed control levers. The spindle is moved manually into its upper position and is stopped. The same procedure is applied to all following operations. In this way the program for all operation can be set up during manufacturing of the first workpiece. Before any work with adjusted programs can be started the sticks of the drilling depth program drum must be fixed by screws, the lifter 7 /fig. 11/ is set into its original position, command circuit, for program control of drilling depths, is switched on by the overswitch 16 /fig. 6/ and the program drum is turned manually into position No. 20 /in case all positions are are not used/. The machine with the set-up program drums is operated as follows: Operator inserts a tool into the spindle, depresses the control lever and then shifts it into the front or rear position according to required sense of the spindle rotation. He engages spindle power feed. After drilling is finished and the spindle feed is stopped by means of the device for setting-up of the drilling depths program, he shifts the spindle into its upper position manually, and stops the spindle by shifting the control lever into its central position. Operator replaces the tool and carries out the second operation /e.g. 1st operation - drilling, 2nd operation reaming/ by depressing of the control lever, starts the spindle run by shifting it and engages spindle power feed. When changing for the next operation with the program control, 6-4
VO 50
the spindle must be in its upper position. In any other position of the spindle, indexing of the program drums is interlocked as the pin 16 /fig. 11/, against leans the pin 15 /fig. 11/, is in position a. If the spindle is in its upper position and the pin 16 is, due to this, in position b, changing can be carried out by depressing the 1ever downwards. The operation procedure is similar even if character of work requires, for some operations, to unlock and lock the machine frame by depressing of the pushbutton 10 /fig. 5/. For tapping with use of program, the sticks of the program depths drum are set-up during machining the first workpiece similarly as when setting-up the drilling depths. The operator does not, however, engage the power feed, but by manual turning of the levers for spindle feed, he follows a tap feed. After the required depth, set up on the depth scale, has been reached, he shifts the control lever manually to reverse the spindle sense of rotation. The tap is screwed out now. The stick on the program drum is being set up. During thread tapping when program is used, it is sufficient for the operator to follow the tap feed by manual turning of the levers for the spindle feed. After the set-up depth has been reached, the spindle run is reversed automatically. Stopping of the power feed or reversal of the spindle run, after the required depth has been reached, are, therefore, determined by the position of the control levers levers for spindle feed. If the control levers have been shifted in position out of the machine /spindle power feed engaged/ the program drum disengages spindle power feed at, by the stick, set-up depth. If these control levers have been shifted in position towards the machine /for thread talpping the spindle is shifted manually/ the program drum starts reversal of the spindle run at the same, by the stick, set-up depth. Change of spindle sense of rotation, carried out by means of program, is designed for the right-hand cutting tap.
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VO 50
7 SPARE PARTS 7.1
List of bearings, sealing rings and wearable parts
The list is a part of the catalogue of spare parts that is delivered together with the Operation instructions manual for the machine. 7.2
Instructions for spare parts ordering
When ordering spare parts the following data are to be stated: 1. Type of machine. 2. Serial number stamped in the plate mounted on every machine. 3. Nomenclature name of the part in question. 4. Numbers stamped stamped on the part, or or it is possible possible to denote this part in a copy of the picture from the Operation instructions manual and enclose the copy to the order. 5. Assembly group to which the part belongs. 6. Number of pieces ordered. In case of replacement of a complete spindle with spindle sleeve or only spindle sleeve is to be replaced it is necessary for the customer to conduct at least three measurements on the spindle sleeve to be replaced, i.e. to measure three diameters measurement with accuracy at least 0,01 mm and these measurements shall be performed in three different distances from the face and these measured values shall be stated in the purchase order. New sleeve will be delivered with minimum clearance in the drilling head.
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VO 50
