SC-32 OPERATION MANUAL NCT Ipari Elektronikai Kft. 1 / 29 Dátum: 2013.09.27.
CONTENTS 1. ACCURACY RECORD... 2 2. SAFETY PRECAUTIONS... 2 2.1. Safety Rules... 2 2.2. Warning label attaching positions... 2 3. DESCRIPTION OF THE MACHINE... 2 3.1. Specifications... 2 3.2. Machine overall dimensions... 2 3.3. Main components of the machine... 2 3.3.1. Spindle belt... 2 3.3.2. Spindle collet... 2 3.4. Recommended Spare Parts... 2 3.5. Machinable materials... 2 3.6. Machining capacity... 2 3.7. Movement... 2 3.8. Block position... 2 3.9. Installation... 2 3.9.1. Power supply and environmental demand... 2 3.9.2. Oil requirement... 2 3.9.3. Maintenance... 2 3.10. Machine installation... 2 3.10.1. Installation place... 2 3.10.2. Machine cleaning... 2 3.10.3. Installation steps... 2 3.10.4. Spindle speed setting... 2 3.10.5. Precaution for program executing... 2 4. SUB-SYSTEMS...2 4.1. Hydraulic system... 2 4.2. Air pressure system... 2 4.3. Trouble shooting... 2 4.4. Three-jaw hydraulic chuck installation procedure... 2 5. PART LIST... 2 5.1. Base unit... 2 5.2. X-axis slide unit... 2 5.3. Z-axis slide unit... 2 5.4. Spindle unit... 2 5.5. Tool unit... 2 5.6. Coolant unit... 2 5.7. Side live tool... 2 5.8. Front side live tool... 2 5.9. Coolant tank unit...2 5.10. Hydraulic unit... 2 NCT Ipari Elektronikai Kft. 2 / 29 Dátum: 2013.09.27.
1. ACCURACY RECORD No. Parameter measured Illustration Tolerance [mm] Measuring result [mm] 1 Radial run-out of the spindle taper hole 0,005 2 Radial run-out of the spindle nose 0,010 3 Axial run-out of the spindle flange 0,015 4 Radial run-out of the spindle hole (measured on gauging mandrel) a 0,005 b 0,005 along the length of 100 mm 5 Straightness of the X axis slide way 0,005 6 Straightness of the Z-axis slide way 0,005 7 Radial run-out of the cylinder adapter 0,010 NCT Ipari Elektronikai Kft. 3 / 29 Dátum: 2013.09.27.
2. SAFETY PRECAUTIONS 2.1. Safety Rules Please read carefully the following safety instructions in order to prevent personal injuries and material damage. Do not install the machine near vibration and heat source, and on explosion dangerous area. There shall be a fire extinguisher near the working place. The machine shall be connected to a 3Ph / 230 V/ 50 Hz power network. Just in case of running-down the accumulator, take a backward copy of all the parameters. When the charging level of the accumulator is low, an alarm message will be displayed on the screen. Charge the accumulator weekly. Any modification of the machine is prohibited. Before adjusting, checking and cleaning of the machine turn the main switch off. Before operating the machine check proper operation of the safety elements. Before operating the machine check the level and pressure of the coolant; improper use of coolant can cause fire hazard. Before operating the machine close the door of the electric box in order to avoid electric shock. Before operating the machine check the proper clamping and position of workpiece, tools and attachments, and their balanced rotation. Before operating the machine close the door of the workspace; the door interlock device protects the operator during operation of the machine. When the door is open the machine can be hand-operated only. If the operator changes over to automatic operating mode, the machine displays an error message and turns off the Cycle Start knob. When the machine is running do not open the door and do not touch tools and workpiece. Running NC programs containing wrong parameters and values could cause several failures. After maintenance procedure always do test run. During maintenance procedure, be careful with sharp components. 2.2. Warning label attaching positions Inside the electric box and the control there are high-voltage units there, improper handling can cause electric shock; only well-trained serviceman and repairman is allowed to enter into this space. Replace the label if it frays or disappears. NCT Ipari Elektronikai Kft. 4 / 29 Dátum: 2013.09.27.
1 2 3 4 5 6 7 8 9 NCT Ipari Elektronikai Kft. 5 / 29 Dátum: 2013.09.27.
10 11 12 13 3. DESCRIPTION OF THE MACHINE 3.1. Specifications SC-25 SC-32 Max. swing diameter Ø25 mm Ø32 mm Three-jaw chuck dimension - Ø100 mm (0-3000 rpm) Max. turning length 105 mm Min. adjustable travel 0,001 mm Tool shank dimension 12 mm or 16 mm Max. drill bit diameter Ø20 mm Number of tools turning tool, 6 pcs; boring tool, 4 pcs; servo motor live tool, 1 pc (11 tools in all) Max. spindle speed 6000 rpm X-axis travel 345 mm Z- axis travel 115 mm X/Z-axis rapid feed 18 m/min Spindle motor 3 kw 4 kw X/Z motor 0,75 kw Hydraulic pump motor 0,75 kw Coolant pump motor 0,56 kw Oil tank capacity 130 l Machine overall dimensions 1830 x 1300 x 1760 Machine weight 1600 kg Power supply AC / 3Ph / 220 V/ 8 kw NCT Ipari Elektronikai Kft. 6 / 29 Dátum: 2013.09.27.
3.2. Machine overall dimensions NCT Ipari Elektronikai Kft. 7 / 29 Dátum: 2013.09.27.
3.3. Main components of the machine No. Title 1 Spindle motor 2 Basic seat 3 Slide set of Z-axis 4 Slide set of X-axis 5 Single hole attachment 6 Double hole attachment 7 O. D. Turning tool holder 8 Spindle NCT Ipari Elektronikai Kft. 8 / 29 Dátum: 2013.09.27.
No. Title No. Title 1 Electric box 8 Coolant tank 2 Control panel 9 Power switch 3 Three-colour alarm lamp 10 Coolant pump motor 4 Machine main cover 11 Two-way component 5 Back side door of the spindle 12 Automatic lubrication oil filter 6 Activity door 13 Part collection box 7 Hydraulic tank 3.3.1. Spindle belt 3.3.2. Spindle collet Model Max. rpm Specification SC-25 3000 rpm HTD-800-8M-23W SC-32 3000 rpm HTD-800-8M-23W FUJI #1825 Dimensions (steel): d = 35 mm L = 124 mm D = 49 mm α = 15 M33 x 1,5 SC-25 NCT Ipari Elektronikai Kft. 9 / 29 Dátum: 2013.09.27.
FUJI #1832 Dimensions (steel): d = 43 mm L = 137 mm D = 57,5 mm α = 15 M40 x 1,75 SC-32 3.4. Recommended Spare Parts Spindle belt Fuse (8A, 4A) Proximity switch 3.5. Machinable materials The machine is applicable to cut the following materials: General steel Normal iron Cast iron Aluminium alloy Copper-brass alloy Plastic CAUTION! Other material should be selected carefully. Do not use this machine to cut magnesium work-piece. 3.6. Machining capacity Straight turning Boring Drilling and tapping Cut off Inside and outside threading Arc and spherical turning Slotting (optional) NCT Ipari Elektronikai Kft. 10 / 29 Dátum: 2013.09.27.
3.7. Movement 3.8. Block position NCT Ipari Elektronikai Kft. 11 / 29 Dátum: 2013.09.27.
3.9. Installation 3.9.1. Power supply and environmental demand Voltage of input power: AC 230V ± 10% 50 Hz ± 1% three-phase power network Recommend wire cable size 6-8mm 2 If the power source is higher or lower than above voltage, transformer shall be used to get required voltage. Power consumption: 10 kva Ground wire: The machine should be grounded by wire cable to PE terminal. The machine should be grounded suitably to prevent electric shock. Environment requirements: Do not install the machine where it may be exposed to direct sunlight. Do not install the machine in uneven, vibrating, heated, and potentially explosive area. Working area temperature: 0-45 C. Storage temperature: -20-60 C Humidity <30% (without air conditioner). Altitude Sea level: 1000 m. Setting machine in suitable place which keeps surrounding 1 m empty. NCT Ipari Elektronikai Kft. 12 / 29 Dátum: 2013.09.27.
Levelling adjustment: To keep the accuracy and to maintain the good condition of lifetime of this machine, levelling adjustment is one of the important factors. Please carry out leveling by adjusting the leveling bolts at the bottom of machine base after installation. Please use accurate level 150 mm length with a minimum scale of 0.02 mm on the worktable, and then turning the leveling bolts to make the deviation within 0.02 mm/m. 3.9.2. Oil requirement Check point Supplied way Assigned oil Qty Using time 1 Spindle Daub by hand Grease - - 2 X/Z-axis When Supply by lubricator Slide way oil G68 2 l linear guide way lubricant 3 X/Z-axis warning light Supply by lubricator Slide way oil G68 2 l ball screw is on. 4 Milling device Supply by lubricator Slide way oil G68 2 l - 5 Chuck Daub by hand Normal use oil Proper - Replace once 6 Hydraulic system Inspect visibly after first Hydraulic oil 32# 20 l month; then (FINA) replace once every 6 month 7 Coolant Inspect visibly Cutting fluid SP- M22 200 l - 8 Lubricant Inspect visibly Slide way oil G68 (FINA) 2 l - NCT Ipari Elektronikai Kft. 13 / 29 Dátum: 2013.09.27.
Spindle Bearings in the spindle are forced lubricated the assembling by grease. This highspeed grease is low-temperature and prolong, especially for high-speed rolling bearings or high load. When the machine is not operated for a long time (more than 6 days), user should run the spindle at low speed about 30 minutes before operation. Please not mix and use the specified oil above to avoid any possible damage to machine. If not use our recommended oil, please read following remarks carefully. Suggestion for coolant selection: Ferrous materials: ARAL SAROL345 Cast iron: ARAL MULTROL 820 Any suitable coolant with no harm to health and not with low flash point. Any suitable coolant that will not cause any paint peeling, rusting, and packing swelling by mixing with lubricant. It might result in corrosion of lubrication unit by mixing the lubricant with coolant or hydraulic oil. The corrosion might cause lubrication failure, which, in turn, leads to damages on the slide-way surfaces. 3.9.3. Maintenance Frequency Daily Weekly Monthly Every three month Every six month Inspection items Check oil level through the oil level gauge in the hydraulic unit, slide-way lubrication oil tank. Check gripping pressure of the hydraulic power collets through the oil level gauge. Check lubricated conditions of bed and slide-way surfaces. All safety devices. Clean and wash the filter of heat exchange. Shorter the clean period if the surrounding full of dust. Check the bed-ways for level and straightness. Check all belts. Change X, Z-axis linear motion guide or slide-way. Change hydraulic oil in the hydraulic power unit. Check and adjust all of belt s tension. 3.10. Machine installation 3.10.1. Installation place Setting machine in suitable place which keeps surrounding 1 m empty. 3.10.2. Machine cleaning All machine surfaces are covered with rust preservative, which must be thoroughly cleaned before moving any parts of the machine. Only mild solvent and soft rags can be used for cleaning. NCT Ipari Elektronikai Kft. 14 / 29 Dátum: 2013.09.27.
3.10.3. Installation steps To remove all stopper used to prevent the machine moving in transportation and to check if the machine is rusted, damaged, shape transformed, or broken, etc. Fix the leveling bolts and nuts. To check the power source is 3 phase 220V AC, if not, the transformer must be used. To connect the machine power with ground wire. To confirm the coolant tank is connected with coolant pipe. To check if all the safety devices are properly functional. Any fault must be corrected before operating the machine. To fill in designated quantities of the specified oil to every reservoir. To check the indicator of the air and hydraulic pressure line is functional. To check the installed conditions of collet and tool. Any loose condition is not allowed. To confirm the tool /zero offset setting. To confirm the spindle speed and feed rate override dial settings; they must be 100%. 3.10.4. Spindle speed setting The maximum spindle speed is 6,000 rpm. Never turn the spindle over 6,000 rpm. We can control the maximum spindle speed by inputting command in G50 (TYPE A) in function Constant surface speed control. For example, G50 S5000 means the maximum spindle speed is limited as 5,000 rpm. Remember to avoid any imbalance during rotating because increased centrifugal force will reduce the clamping force. 3.10.5. Precaution for program executing With a new program, never attempt to start actual cutting operation from the beginning. First to run the program without setting a work-piece on the machine to check machine operation and interference, after making sure that the work-piece can be cut without problems in the single block mode operation or in MPG simulation mode operation, then the automatic mode operation may be started. Remember to make sure that the work-piece is securely clamped in the collet or clamp device. Switch on the main power and press POWER ON. Take the reference points of all axes and then warm up the machine for 15 minutes. NCT Ipari Elektronikai Kft. 15 / 29 Dátum: 2013.09.27.
4. SUB-SYSTEMS 4.1. Hydraulic system Hydraulic unit is used for chuck open and close. Please make sure the pressure is in the right range, otherwise it will result in abnormal damage to the machine. Hydraulic unit pump pressure range: 25-35 kg/cm² Hydraulic unit chuck pressure range: 10-30 kg/cm² NCT Ipari Elektronikai Kft. 16 / 29 Dátum: 2013.09.27.
4.2. Air pressure system Pressure source is used for open and close of the income feeder and blowing device. Please make sure the pressure is in the right range, otherwise it will result in abnormal damage to the machine. Air source pressure range: 4-7 kg/cm² NCT Ipari Elektronikai Kft. 17 / 29 Dátum: 2013.09.27.
4.3. Trouble shooting 1. Rotary cylinder doesn t work a) Stop the spindle if it is still running b) Raise the hydraulic pressure to approx. 5kg/cm.sq, and to switch the collet clamping ON/OFF, then to confirm cylinder motion again. c) If the cylinder still doesn t work, to increase the pressure gradually (by approx. 5kg/cm.sq each time) and repeat the same procedures as described in b), then to confirm the cylinder motion. The maximum collet pressure is 30% increasing. If the cylinder works in normal operation, return the pressure to original set. d) If cylinder still doesn t work after above procedures, please turn off the power. Then wait till the cylinder temperature is as down as surroundings and repeat the procedures above to recheck the cylinder motion. e) If the cylinder doesn t work after above procedures, please dismount the draw-bar nut and take off the cylinder unit to check the motion. 2. Piston doesn t work a) Check all pressure hose with hydraulic pressure. b) Check if all the connected pipes are correct. c) After remedy or correct the connection, please re-do above procedure. 3. Insufficient pressure a) Apply a pressure gauge near the inlet of cylinder to check if the pressure follows the specified value. b) If the drain flow is more than normal, it is possible that the inside O-ring is wearing away. Replace it then check again. 4. Pump noise a) Avoid air suction. b) Check the hydraulic oil level and refill it. c) Clean the filter and remove the dirt inside oil tank. d) Pump was worn away. 4.4. Three-jaw hydraulic chuck installation procedure a) Shift the tool slide on Z-axis slide base back from spindle a length, then lock it after adjusting the parallelism of the tool slide and the spindle by dial indicator. b) Assemble the three-jaw hydraulic chuck on the spindle. c) Replace the draw bar, ring, spindle pulley, and belt (6000 rpm 3000 rpm) for threejaw chuck. C32 - collet C32 - three-jaw chuck Description 6000 3000 Spindle maximum speed, rpm 4500 1200 Spindle acceleration time, ms NCT Ipari Elektronikai Kft. 18 / 29 Dátum: 2013.09.27.
5. PART LIST NOTE: The part list of the Manufacturer s original manual does not use the number 8 for numbering the main parts. NCT Ipari Elektronikai Kft. 19 / 29 Dátum: 2013.09.27.
5.1. Base unit No. 1.1 Base fixing block 1.2 Base Title NCT Ipari Elektronikai Kft. 20 / 29 Dátum: 2013.09.27.
5.2. X-axis slide unit No. 2.1 X-axis servo motor 2.2 Oil seal 2.3 Coupling 2.4 Lock nut 2.5 Spacing ring 2.6 Bearing cover 2.7 Oil seal 2.8 Bearing 2.9 Key 2.10 X-axis ball screw 2.11 Bearing cover 2.12 Ball screw case 2.13 Stop Title NCT Ipari Elektronikai Kft. 21 / 29 Dátum: 2013.09.27.
5.3. Z-axis slide unit No. 3.1 Z- axis servo motor 3.2 Oil seal 3.3 Coupling 3.4 Lock nut 3.5 Spacing ring 3.6 Bearing cover 3.7 Oil seal 3.8 Bearing 3.9 Key 3.10 Z-axis ball screw 3.11 Joint 3.12 C type ring 3.13 Bearing 3.14 Bearing cover 3.15 Ball screw case 3.16 Stop Title NCT Ipari Elektronikai Kft. 22 / 29 Dátum: 2013.09.27.
5.4. Spindle unit No. 4.1 Spindle motor 4.2 Spindle motor support block 4.3 Motor pulley 4.4 Timing belt 4.5 Spindle fixing ring 4.6 Spindle base 4.7 Collets 4.8 Rotation shaft 4.9 Protection cover 4.10 Dust seal 4.11 Dust seal 4.12 Bearing 4.13 Bearing O.D. bush 4.14 Bearing I.D. bush 4.15 Spindle body 4.16 Bearing inner bush 4.17 Bearing 4.18 Dust seal 4.19 Cover 4.20 Nut 4.21 Spindle pulley 4.22 Nut 4.23 Rotary hydraulic cylinder 4.24 Draw bar 4.25 Nut 4.26 Ring Title NCT Ipari Elektronikai Kft. 23 / 29 Dátum: 2013.09.27.
5.5. Tool unit No. 5.1 Tool holder fixing block 5.2 Lathe tool spacer 5.3 Lathe tool holder 5.4 Tool slide 5.5 Stop bar 5.6 Drill holder 5.7 ER16 shaft 5.8 Drill holder 5.9 Tool holder fixing block 5.10 X-axis slide 5.11 Joint Title NCT Ipari Elektronikai Kft. 24 / 29 Dátum: 2013.09.27.
5.6. Coolant unit No. 6.1 Elbow bends 6.2 Bent clamp 6.3 Hose 6.4 T-adapter 6.5 Threaded coupler 6.6 Flexible hose 6.7 Distributing element Title NCT Ipari Elektronikai Kft. 25 / 29 Dátum: 2013.09.27.
5.7. Side live tool No. 7.1 Servo motor 7.2 Coupling 7.3 Lock nut 7.4 Arbor body 7.5 Cover 7.6 Bearing 7.7 Bearing 7.8 O-ring 7.9 Bearing cover 7.10 Oil seal 7.11 Rotation shaft 7.12 ER nut 7.13 Protection hood cover 7.14 Cover 7.15 Adjusting board 7.16 Adjusting screw 7.17 Hi-Lo adjusting block 7.18 Key 7.19 Dovetail fixing block 7.20 Tool holder fixing block 7.21 Spacer Title NCT Ipari Elektronikai Kft. 26 / 29 Dátum: 2013.09.27.
5.8. Front side live tool No. 9.1 Servo motor 9.2 Coupling 9.3 Lock nut 9.4 Front live tool body 9.5 Bearing 9.6 Bearing 9.7 O.ring 9.8 Bearing cover 9.9 Oil seal 9.10 Rotation shaft 9.11 ER type nut 9.12 Cover 9.13 Hi-Lo adjusting block 9.14 Screw 9.15 Cover 9.16 Protection hood cover 9.17 Cover 9.18 Key 9.19 Dovetail fixing block 9.20 Tool holder fixing block 9.21 Spacer Title NCT Ipari Elektronikai Kft. 27 / 29 Dátum: 2013.09.27.
5.9. Coolant tank unit No. 10.1 Coolant tank 10.2 Chip case 10.3 Chip case cover 10.4 Chip case cover 10.5 Chip case cover 10.6 Filter 10.7 Pump 10.8 Chip case cover Title NCT Ipari Elektronikai Kft. 28 / 29 Dátum: 2013.09.27.
5.10. Hydraulic unit No. 11.1 Pump motor 11.2 Pump 11.3 Return filter 11.4 Filter 11.5 Oil level 11.6 Check valve 11.7 Gauge manometer 11.8 Pressure switch 11.9 Oil tank 11.10 Air cooler 11.11 Solenoid 11.12 Reducing valve 11.13 Stopcock valve 11.14 Manifold block 11.15 Hose Title NCT Ipari Elektronikai Kft. 29 / 29 Dátum: 2013.09.27.