Home

Mirac PC CNC Lathe User`s Manual.

Contents

1. Lubrication Point Lubricating System Frequency Recommended Oil Grease Quantity Slideways Pump action Weekly BP CS 68 As required Ballscrews and oil can Shell Vitrea 68 Auto Toolpost Castrol Perfecto NN Headstock Grease Seal On maintenance Kluber Isoflex NBU 15 4 cc Bearing of headstock Axis Bearings Grease Seal Once a year BP LS 3 2 cc Bearing Shell Alvania No 3 Coolant Pneumatic pump As required Cincinnati Millacron Fill to spray mist CNC software Simcool 60 max mark on system controlled Dilution minimum 2 5 storage tank Mirac PC CNC Lathe User s Manual Section 7 Maintenance 59 7 Maintenance Schedule Daily Clean and remove any swarf Check that all slides are lubricated Clean tooling and toolpost Weekly Clean the machine eCheck all exposed screws and nuts for tightness Oilallslides and ballscrews and optional automatic toolpost carousel Bi annually eCheck and clean the machine thoroughly eCheck the condition of any electrical connections eCheck all cables for kinks and breaks Remove the chuck jaws and clean the chuck Clean the slide sensors eCheck and adjust the saddle and cross slide gib strips Annually eCheck the slides for wear Grease axis bearings eCheck machine alignments and accuracy eCheck headstock bearing adjustment eCheck spindle and axis drive belts for tension and wear Change air filters
2. If your CNC machine is used intensively we recommend that the maintenance tasks listed in the above schedule are performed on a more regular basis 60 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Cleaning and Inspecting the X Axis Ballscrew and Slideways The two X axis slideways are located on the leftand rightsides of the aac saddle and cross slide Run the cross slide fully up exposing the y use a mirror to help inspect lower portion of the saddle slideways as shown below left Using a parts of the machine soft bristled brush carefully clean any swarf and debris away from both that are hard to reach sides of each slideway to a location where itcan be removed from the working area Inspecteach slide for damage or wear Run the cross Location TNX Slide fully down to expose the remaining upper portion of the slideways and repeat the process Look at the left and right sides of the saddle and under the i e coverplate behind the Balscren ae ani toolpost r t amp Right Slideway Right side of saddle Slideway Left Slideway The X axis ballscrew runs centrally from top to bottom along the underside ofthe cross slide The X axis ballscrew is fully enclosed by the saddle and cross slide metalwork so itis not subject to swarf build up The ballscrew can be inspected for damage or wear by removing the cover plate attached on the portion of th
3. Immediately after establishing a communication link between the CNC control software and the Mirac PC both axes of the CNC lathe mustbe homed Homingine CNC lathe defines The constraints of three dimensional co ordinate grid system used for plotting any programmed movements effectively the working envelope of the CNC lathe The machine datum the zero reference point for the CNC lathe so the controlling software can calculate where the tool is positioned in relation to the working envelope The process is commonly referred to as homing the machine or datuming each axis During the process both machine axes are sent to their fixed zero positions After homing the machine the zero position of the three dimensional co Ordinate grid system is referred to as the machine datum You can find the position of the machine datum by switching the co ordinate display in your CNC control software to read Machine Co ordinates The position of the machine datum is achieved when the X and Z panels of the co ordinate display all read zero this assumes thatno offsets are loaded In addition to homing the CNC lathe after ithas first been switched on we also recommend homing after loading or configuring any offsets 4 Co ordinate Display Systems All Modes 34 CNC Machine Operation Section 4 The co ordinate display can be changed according to datum zero position required e Machine Co ordinates Display System The co ordina
4. cessessssesssssesssessessssssssssessssusssssssssussssssssesssssnssessssssnssesssssesesss 107 Section 11 Glossary GIOS SANY riasin e ar A T eoxbuts dens A A AA 109 Section 12 Index Inde Xan na araa a dain a N avi sn hander ahaa 113 Warning Notices Warranty Disclaimer The Warranty on your Mirac PC CNC lathe will be invalidated if any modifications additional ancillary equipmentis fitted or any adjustments made to the controlling devices without prior notification from Denford Limited Please referto the information held in your separate Warranty pack for specific details Do not carry out any portable appliance testing PAT on any ofthe supplied equipment Maintenance Disclaimer Always obtain permission from the person responsible for machinery in your establishment before accessing your Mirac PC CNC lathe and or the electrical panels within the machine casing to carry outany maintenance work All work mustbe carried out by personnel suitably qualified foreach maintenance task to avoid damage to both the machine systems and the maintenance personnel Denford Limited cannot accept responsibility for any damage and or loss that may occur through incorrect maintenance of your CNC machine Ad Foreseen Use of Machine Your Mirac PC CNC lathe is designed for tuming wax plastics acrylics copper aluminium and steel In each case the appropriate tooling spindle speeds and feedrates should be used as recommended by the
5. e Always secure the work in the chuck and if necessary tailstock e Ensure that the correct cable for the power source is used e Ensure the power is switched off before starting any maintenance work on the machine e If power fails turn off the yellow red isolator found on the electrical control box front door immediately e Hazardous voltages can still exist immediately after switching the electrical control box isolator to the OFF position Always wait at least5 minutes before attempting to open the electrical control box or access any electronic components in the machine e Lubricate the required machine areas at the intervals specified in this manual to prevent the axes from seizing see the Maintenance section for further details Observe caution when adding or removing machine tooling e When an emergency stop is required press the circular red emergency stop button located on the operators control panel Mirac PC Series CNC Lathe User s Manual Section 2 Safety Features 11 2 Safety Features Emergency Stop Button Location of emergency stop button mounted on the front operators panel positioned on the left side of the machine cabinet To active an emergency stop press the button fully in until it clicks A circular red emergency stop button is mounted on the front operators panel positioned on the left side of the machine cabinet When pressed ithas the effect of stopping all axis and spind
6. X movements of the toolpost are towards the centreline of rotation ie down and towards the front of the machine Positive X movements of the toolpost are away from the centreline of rotation ie up and towards the rear of the machine Mirac PC Series CNC Lathe User s Manual Section 4 CNC Machine Operation 35 4 Manually Control M Codes J og Mode Note The sequence of events required to manually enter an M code will depend on the type of CNC control software being used In addition many of these miscellaneous functions may be controlled directly using buttons and commands available in your CNC control software Please refer to your separate CNC Control Software User s Manual for specific details M codes are used to control the miscellaneous functions of the machine such as switching the spindle on and off or operating optional equipment such as the automatic indexing toolpost M codes can be manually entered for immediate operation when the machine controlling software is operating in og Mode Note thatM codes are automatically called when written into a CNC program that is subsequently run in Auto Mode List of M Codes for Standard amp Optional Equipment The following M codes call the miscellaneous functions listed below M03 Spindle forward standard on all versions M04 Spindle reverse standard on all versions M05 Spindle stop standard on all versions M06 Tool
7. During the maintenance work period display a suitable notice Stating thatthe machine is under maintenance and should not be used until the notice is removed e Safety mustbe a priority when carrying out any maintenance work Covers and safety guards that are removed during the maintenance work mustbe replaced after the task is completed Allwork mustbe carried out by suitably qualified personnel When replacing electrical components ensure the new parts are of Suitable replacementspecification Allwork completed on the machine whether progressive or preventative should be logged to ensure a complete service record is available for future referral We recommend the following two pages are used to log any maintenance tasks undertaken When maintenance work has been completed check that the replaced or serviced parts work correctly before allowing general operation of the machine Mirac PC CNC Lathe User s Manual Section 7 Maintenance 55 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed 56 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed Mirac PC CNC Lathe User s Manual Section 7 Maintenance 57 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out
8. If necessary cut yellow plastic sealing tag Door lock Electrical diagrams are held in either 1 a folder on the inside face of the electrical control box door as shown above or 2 supplied separately in the standard equipment box supplied with your machine 78 Machine Electronics Section 8 Mirac PC CNC Lathe User s Manual 8 Electrical Layout EuroStep Controller The photo below labels all important electrical components inside the electrical control box on EuroStep controlled CNC lathes Please note thatthe layout of your electrical panel may differ from the photo depending on components and options fitted to your Mirac PC Layout of the Electrical Panels EuroStep Controller ame j E Ferrite a Core ATA MAS Standard p Space S E 1 0 Unit eee for mA s optional SS 1 0 Unit aa be eee EuroStep Custom Space Z Axis X Axis Control Motion Card for 24V Drive Drive Transformer Control 1 0 Board Board Board Card Mirac PC CNC Lathe User s Manual Section 8 Machine Electronics 79 8 The EuroStep Motion Control Board Location a X Look in the bottom left corner of the control box from the right EuroStep Motion Control Board Seven y Segment LED E Display The EuroS tep motion control board is mounted in the bottom left corner of the electrical control box fitted into th
9. Link cable is he long thin cable fitted with a 9 pin Control D female connector at one end and a Box 25 pin D male connector at the opposite end Connect the 25 pin D male end of he RS 232 cable to the 25 pin D female RS 232 port on the end panel of the electrical control box Connect he remaining 9 pin D female end of he RS 232 cable to the 9 pin D male Cables exiting from the electrical control box COM2 port on your PC Note a 9 pin to 25 pin adapter may Larger diameter corrugated cable machine power also be required if your COM port has Smaller diameter corrugated cable machine signals a 25 pin connection Thin electrical cable mains power Note the physical layout of components on individual boxes may vary Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 27 4 Using your Mirac PC Overview Several steps must be completed before the final manufacture of a part The flowchart below lists the general steps that should be followed for CNC file creation simulation and final part manufacture in the recommended order However miscellaneous factors may warrant the user to complete the steps in a different order to that shown A Switch on the Mirac PC then startthe CNC Control S oftware For more detailed information regarding see section 4 pages 32 and see Note left these steps please refer se Ye to your separate CNC TB Home the machine then load
10. Location of equipment indicated but item not shown in photograph Headstock including spindle drive Manual chuck Cross slide Saddle Tailstock pneumatic chuck X axis Mirac PC Series CNC Lathe User s Manual Section 4 CNC Machine Operation 31 4 Switching the Mirac PC On Follow these instructions to switch on your Mirac PC CNC lathe 1 Check the Denford machine Link cable is fitted securely between the serial COM2 portsocketon the machine controller PC and the RS 232 socketon the Mirac PC electrical control box 2 When fitted check the RS 232 serial cable is fitted securely between the serial COM1 portsocketon the machine controller P C and the RS 232 socket on the DeskTop Tutor controller keypad 3 Check the larger diameter corrugated machine power cable is fitted securely into the right fixing bracket mounted on the back panel of the Mirac PC cabinet 4 Check the smaller diameter corrugated machine signal cable is fitted securely into the left fixing bracket mounted on the back panel of the Mirac PC cabinet 5 Check the electrical control box door is closed and locked 6 When fitted check the air pipe connections for any optional compressed air driven equipmentare secure then switch on the air compressor Check and adjust the air pressure if necessary 7 Plug the mains supply cable standard electrical flex from the electrical control box into an available power socket Switch the power s
11. Manual 8 The NextStep Motion Control Board Th x LED Status and Fault Display Codes A The status of the motion control can be determined from the LED display mounted on the leftside of the NextStep board Hazard Voltages exist Errors are all shown with a flashing dot in the bottom right corner of the within the machine LED displa when removing the Py electrical panel cover Whilst NextStep is powering up plate always isolate fz eee eee ndicates FPGA has booted successfully the power and leave all electronic ENEAS ndicates FPGA walking ones test on FPGA scratchpad has failed HALT component untouched di d d ber test ll of RAM has failed HALT for at least 5 minutes l acana ndicates pseudo random number test on all o as failed Many electronic z cisions ndicates CAN controller reset has failed HALT components are 3 E en E E ndicates walking ones test on the CAN controller has failed HALT sensitive to electrostatic damage 5 Rans ndicates that power up test did not find any valid Firmware in Flash device ensure components and or personnel are EHH ndicates that new firmware is being loaded into the NextStep control suitably earthed to minimise this risk When NextStep has powered up Normal indication that card is powered up Figure 2 is the default card NODE number AI Axes disabled normally after downloading Mint MEX file for the first time before starti
12. Mirac PC Series CNC Lathe User s Manual 5 Automatic Indexing Tooling System 3 Place the drill collet assembly into the numbered station in the correctorientation Revolve the drill colletassembly so the flat section of the colletis positioned directly under the grubscrew holes 4 Tighten the grubscrews until they just begin to grip the flat surface of the drill colletassembly Continue to tighten each grubscrew by one quarter turn Continue this procedure until both grubscrews are fully tightened and the drill colletassembly is held securely Removing an End Internal Working Tool Profile from the Toolpost 1 Using a 2 5mm allen hex key unscrew the two grubscrews C shown in the photograph on the previous page on the side of the appropriate numbered toolpost station When directly viewing the top of the grubscrews turn counter clockwise to loosen or clockwise to tighten them 2 Withdraw the drill colletassembly Ifthe cutting tool has been recently used take care itmay still be HOT Requesting P rogramming a Tool Change The Miscellaneous Function M06 is used to program a tool change operation Please refer to Section 4 CNC Machine Operation pages codes for manual 36 and 37 for further details control of optional neumatic equipment 10 Chuck open vice 11 Chuck close vice 25 Tailstock quill extend 26 Tailstock quill retract 38 Door open safety guard door 39 Door close
13. PC cabinetis both secure and balanced before lifting Perform an assisted lift whereby the hoist operator can manually monitor the balance and security of the load as is itmoved To transport your Mirac PC cabinetover longer distances use a suitably sized wheeled trolley control box weight 70KG 154 Ib Use a professional hoist to lift the machine Thread one single 5 metre 200 500 KG 1120 Ib rated nylon sling as shown right Front machine foot section Rear lifting hooks To lift the electrical control box use a porters trolley Exercise caution when attempting to lift the electrical control box since itweighs 70 KG 154 Ib Always use Sensible lifting precautions in accordance with Health and Safety Regulations in your establishment 14 CNC Machine Installation Section 3 Mirac PC Series CNC Lathe User s Manual 3 Deciding on a Site for your Mirac PC Note TeX Site your Mirac PC in a well ventilated room The Mirac PC is a bench doimala mounted machine so itshould be sited ona bench of sturdy tables and industrial construction to take the weight of the machine and of a height which cabinets designed enables comfortable operating and programming to take place specifically Torte Ideally the user will operate the machine when standing atits front with Mirac PC series are i i available from Denford a Clear view of both the machine working area through the transparent Limited guard wi
14. Process Example The sequence shown below defines the main steps involved in producing a component using a CNC system 1 A part program is written using G and M codes This describes the sequence of operations that the machine must perform in order to manufacture the component 2 The part program is loaded into the machines computer called the controller At this stage the program can still be edited or simulated using the machine controller 3 The machine controller processes the part program and sends Signals to the machine components These direct the machine through the required sequence of operations necessary to manufacture the component What are the advantages of CNC CNC systems are automated and very accurate Once programmed a CNC machine will perform repeat tasks until instructed to stop Each component produced will be exactly the same size and shape saving money on designing any jigs and fixtures that might have otherwise been required Using CNC machines can reduce waste material since a CNC machine is much less likely to make an error than a human operated machine CNC machines can also run 24 hours a day if necessary with no signs of fatigue Companies can estimate the manufacturing costs for CNC production much more accurately compared to a production line with conventional production machines J argon Buster CNC refers to Computer Numerical Control the automatic system used to control a machine
15. The Denford Machine Link cable Supplied with your CNC lathe must always be used since this cable features crossovers on some of the pin connections You must also configure the CNC machine control software to recognise which numbered COM port is being used by the Denford Machine Link machine lead Details on this procedure are outlined in your separate CNC machine control software manual The Parallel port on your PC may be labelled as the Printer port The printer port has a 25 pin FEMALE connector Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 17 3 Connecting your PC to the CNC Lathe Warming Tax 4 Connectthe remaining 9 pin D female end of the Denford Machine Link cable to the 9 pin D male COM porton your PC ideally COM A 2 Most computers usually have two COM ports situated on the Do not connect cables back panel of your PC Ifyou cannotidentify any of the ports on between any electrical riainal PC manuf me atin hardware with tre your PC please refer to your original PC manufacturers operating mains power switched manual for further guidance Note thatolder computers may be fitted on since this could with a 25 pin D male COM port which may require the fitting ofan seriously damage additional 9 to 25 pin adaptor to your Denford Machine Link cable components inside your CNC lathe Long PCI card Short mounted 25 pin D standard 9 pin D COM port 25 pin D male 25 pin D female
16. axis ballscrew is fully enclosed by the two black corrugated flexible covers to the left and rightof the saddle so it is notsubjectto swarf build up The ballscrew can be inspected for damage or wear by driving the saddle to the appropriate end of the Z axis releasing sufficientspace to carefully lift each of the covers Replace the covers after finishing the inspection procedure ensuring that the slideway edges are covered 62 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Inspecting the X Axis Datum Sensorswitch Location Tay hesensorswitch defining the X axis datum is maintenance free and mounted under a cover plate positioned behind the toolpost when viewed from the front of the machine The cover plate usually prevents swarf and debris from building up around the sensor fitted to the switch However the switch may require cleaning when the machine has been used in extreme operating conditions Look at the top of the cross slide behind the T Right oh side of cross ke slide Drive the saddle down the X axis This will make is easier to gain access to the top portion of the cross slide and the coverplate Using a 2 5mm allen hex key turn each of the three cap head screws counter clockwise to remove them and withdraw the cover plate Inspectthe exposed sensorswitch and trigger for any signs of damage or wear If necessary use a soft bristled brush to carefully clean any swarf and de
17. change standard manual or optional auto toolpost M08 Coolant on optional spray mist coolant system M09 Coolant off optional spray mist coolant system M10 Chuck open optional pneumatic vice M11 Chuck close optional pneumatic vice M13 Coolanton and spindle forward optional spray mistcoolantsystem M14 Coolanton and spindle reverse optional spray mistcoolant system M25 Tailstock quill extend optional tailstock M26 Tailstock quill retract optional tailstock M38 Door open optional pneumatic safety guard door M39 Door close optional pneumatic safety guard door 4 Requesting a Tool Change J og Mode 36 CNC Machine Operation Section 4 Programming a Tool Change The Miscellaneous Function M06 is used to program a tool change operation The M06 code instructs the machine thata tool change is required before continuing with the program This is followed by the codeT _ __ indicating the number of the new tool the firsttwo numerical digits and the tool length offset file number the last two numerical digits For example M06 T0305 This command is read instructtool change from the current tool number to tool number 3 using tool length offset file number 5 Mirac PC Series CNC Lathe User s Manual 4 Requesting a Tool Change J og Mode Safety First gax A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Safet
18. connector 9 pin D female 9 pin D male connector fitted to Denford Machine connector fitted to connector fitted to pc Link cable using a 9 to Denford Machine fitted to pc back panel 25 pin adaptor Link cable back panel 5 Do notconfuse the 25 pin D female parallel printer porton yourPC with the 25 or 9 pin male D COM ports If your CNC machine control software is supplied with a security key the 25 pin D male connector of this key must be fitted to the 25 pin D female parallel port as shown right Security keys are also referred to as dongles A schematic diagram illustrating these 25 pin D male 25 pin D component connections is shown on pages Connector on female 26 to 27 security key connector dongle fitted to pc back panel 18 CNC Machine Installation Section 3 Mirac PC Series CNC Lathe User s Manual 3 Option Compressed Air Connection Connection Procedure Anair supply isolator and air filter regulator is fitted to the back panel of the Mirac PC cabinet when your CNC lathe is fitted with the following compressed air driven equipment Pneumatic Guard Door Pneumatic Vice Spray MistCoolantS ystem The air compressor must be fitted with a SCHRADER quick release connector The connection fitted onto the machine air filter regulator and isolator is SCHRADER part number SC 8051 11 1 8 BSP MALE or Denford part number BI 914515 The female connector required on the 1 4 pipe leading
19. data is organised FANUC Lathe file extension fnl Contains G and M codes describing the machine and cutting operations A preparatory code function in a CNC program that determines the control mode eg a Cutting operation A metal or plastic strip often tapered that is attached to one edge of a slideway Used to compensate for any free play that occurs in a slideway through wear Equipment such as the machine tool the controller or the computer Hexagon shape commonly used on bolts and accessed using a hex key Sometimes referred to as allen bolts or allen keys Mirac PC Series CNC Lathe User s Manual 11 Glossary HOME si eiiinistiinaiiins Operation to send the axes of the CNC lathe to their extreme limits of movement Defines the machine datum also called the home position INCREMENTAL wee Incremental programming uses co ordinate movements that are related from the previous programmed position Signs are used to indicate the direction of movement INDEXING TOOLPOST See programmable turret INPUT ccccccessccneatstecnconitedgane The transfer of external information data into a control system The medium through which the control computer directs the machine tool A miscellaneous code function in a CNC program that determines an auxiliary function eg coolant on tool change etc MACHINE CODE uu The code obeyed by a computer or microprocessor system with no need for further translation MACHIN
20. external tools must be fitted with the cutting edge facing down Cutting Tip Profile Cutting Tool Tip Holder and Shank 2 Using a 4mm allen hex key sufficiently unscrew centre grubscrew B on the appropriate numbered toolpoststation Using a 5mm allen hex key tighten the two bolts A 3 or 4 turns When directly viewing the top of the grubscrew or bolts turn counter clockwise to loosen or Above Centre grubscrew B and clockwise to tighten them outer bolt A locations circled continued 48 Preparing Tooling Hardware Section 5 Mirac PC Series CNC Lathe User s Manual 5 Automatic Indexing Tooling System 3 Place the toolholder into the numbered station in the correct orientation with approximately 21mm protruding from the outer end face of the angled clamping block as shown in the diagram below Note that diameter turning external tools must be fitted with the cutting edge facing down lt C Section CC clamping block Angled clamping Grubscrew B block _ 21mm 4 Ensure thatthe toolholder and the angled clamping block are Square with the turret head then evenly tighten each of the two bolts A in one quarter turn operations Continue this procedure until both bolts are fully tightened and the toolholder is held securely Removing a Diameter Turning E xternal Working Tool Profile to the Toolpost 1 Sufficiently loosen the two bolts A shown in the
21. held also referred to as an automatic indexing toolpost programmable toolpost or ATC automatic tool changer An 8 station programmable turret could hold a maximum of 8 tool profiles The tool being used to machine the billet can be automatically changed for any other tool fitted to the programmable turret using software or CNC commands Mirac PC Series CNC Lathe User s Manual Section 11 Glossary 111 11 Glossary SADDLE irorun The fixture that moves along the bedways Z axis onto which the cross slide is mounted SPINDLE SPEED The rate of rotation velocity of the chuck measured in RPM SOFTWARE savwcneaivcavavss Programs tool lists sequence of instructions etc STATION ccisesteictentarvetiorviies The position of a tool profile in a programmable turret eg station 3 would refer to position number 3 on the programmable turret TOOL oriei The interchangeable part of the machine that cuts the material On automatic indexing toolposts cutting tools must be mounted facing down On quickchange manual toolposts cutting tools must be mounted facing up TOOL OFFSET utes When machining allowances must be made for the different sizes of tools used The tool offset is the amount the X and Z value must be moved or offset so that all the different cutting tool tips used with the same CNC program line up with each other against a common reference point TOOLPOST riire The area on the CNC lathe where tool profiles are held M
22. material supplier Only use water based soluble oil cutting fluids do notuse parafinic or potentially explosive cutting fluid Do notattemptto use your Mirac PC CNC lathe for manual operations If you have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the rightto change the specification and or operating features regarding this CNC machine without notice or documentation Mirac PC Series CNC Lathe User s Manual Contents 5 About this Manual Using this manual Disclaimer Language Contact 6 Contents This manual provides information describing how to transport site setup operate and maintain the features of your Denford Mirac PC CNC lathe including any optional equipment associated with the Mirac PC series This manual does not provide any information regarding the software packages used to control your Denford Mirac PC CNC lathe please refer to your separate CNC machine control software manual Please note that the electrical diagrams for your Mirac PC CNC lathe are held in a folder fixed inside the electrical control box door or delivered separately in the standard equipment box supplied with your machine Hazard Voltages existin the electrical control box only attemptto access these diagrams after isolating the power and leaving the electrical control box untouched for atleast 5 minutes If you
23. photograph on the previous page When directly viewing the top of the bolts turn counter clockwise to loosen them 2 Unscrew the centre grubscrew B shown in the photograph on the previous page to ejectthe angled clamping block When directly viewing the top ofthe grubscrew turn counter clockwise to loosen 3 Withdraw the toolholder Ifthe cutting tool has been recently used take care itmay still be HOT Mirac PC Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 49 5 Automatic Indexing Tooling System Fitting an End Internal Working Tool Profile to the Toolpost Onan eightstation toolpost end internal working tool profiles such as boring bars or drills must be fitted to the even numbered stations 2 4 6 8 Left Positions available circled for fitment of end internal working tool profiles 1 Each tool profile should be fitted to the correct size collet such as the example shown below To secure the drillinside the collet use a 2 5mm allen hex key to tighten the two hae Collet grubscrews in a clockwise grubscrews direction et 2 Using a 2 5mm allen hex key unscrew the two grubscrews C onthe side of the appropriate numbered toolpost station When directly viewing the top of the grubscrews turn counter clockwise to loosen or clockwise to tighten them Above Grubscrew C locations continued 50 Preparing Tooling Hardware Section 5
24. plate to gain access to the oiling point as shown below The cross slide cover plate is located on the upper partof the cross slide behind the toolpost Left side of cross Slide Using a pump action oilcan pump oil directly into the oiling point Run the cross slide up and down the full length of the X axis to distribute the oil along the ballscrew 66 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Z Axis Ballscrew Lubrication Location BEE The Z axis ballscrew runs centrally from right to left between the two Z axis bed slideways To lubricate the ballscrew use the middle of the three oiling points mounted on the right edge of the saddle as shown Look at the right edge of the saddle ps Using a pump action oilcan pump oil directly into the oiling point Run the machine saddle leftand rightalong the full length of the Z axis to distribute the oil along the ballscrew Mirac PC CNC Lathe User s Manual Section 7 Maintenance 67 7 X Axis Slideways Lubrication The two X axis slideways are located on the leftand rightsides of the saddle and cross slide To lubricate the slideways use the oiling points Look at th left and right ie ENA mounted on the upper rightand leftsides of the saddle as shown behind the toolpost below Location Jes ivory tN pO Right Slideway SE OilingPoint E a Left Slideway Oiling Point ew aN Using a pump action oilcan pum
25. printing Nov 2002 Section 10 Appendix 101 10 List of Program Address Characters N refers to the Program Sequence line block number X refers to the absolute distance travelled by the slide tool in the X axis direction U refers to the incremental distance travelled by the slide tool in the X axis direction Z refers to the absolute distance travelled by the slide tool in the Z axis direction W refers to the incremental distance travelled by the slide tool in the Z axis direction G refers to Preparatory functions G codes M refers to Miscellaneous functions M codes T refers to the tooling management tool number and tool offset S refers to the Spindle speed F refers to the Feed rate 102 Appendix Section 10 Mirac PC Series CNC Lathe User s Manual 10 Denford Directives Directives are program terms defined by Denford Limited They are used to help generate the 2D and 3D graphics used by the machine controlling software BILLET This directive allows a billet that appears in a simulation window to be given a size The billet definition should be placed atthe start ofa program after the units of measurementhave been set Example G21 BILLET X30 0 290 0 This sets the measure to metric Note if set to Imperial the units would be inches and defines the billetlength Z at90mm with a diameter X of 30mm Note that the length value does notinclude the extra material requ
26. release the lockbolt on the toolholder height adjustment screw shown right When directly viewing the A top of the bolthead turn counter clockwise to loosen Ifyou intend Lee to raise the height of the toolholder you must unscrew the bolt u the working area when further to allow toolholder movement the spindle or machine View axes are moving ee Loosen toolholder height adjustment screw by turning CCW 2 Loosen the double flanged locknuton the toolpost body if tight When directly viewing the top of the locknut turn counter clockwise to loosen show below left Check that the single flange on the toolholder height adjustment screw is still held between the two flanges on the toolpost locknut shown below right Check toolholder height adjustment screw is still held Loosen double flanged locknut by turning CCW continued Mirac PC Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 45 5 Quickchange Manual Tooling System Toolholder Height Adjustment continued Hoea 4X B 3 Holding the knurled collar turn the height adjustment screw to raise or lower the toolholder When directly viewing the top of the screw A turn counter clockwise to lower or clockwise to raise the toolholder Never open the safety guard door and enter the working area when To raise PES To lower the spindle or machine gt toolholder turn 2 toolholder turn axes are m
27. safety guard door Mirac PC Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 51 6 Manual Chuck Operation Introduction The manual 3 jaw self centring chuck is supplied as standard with the Mirac PC CNC lathe unless an optional pneumatic chuck has been fitted The system comprises of three basic elements i The backplate which is secured against the spindle nose ii The chuck body which is secured againstthe backplate iii One setof external chuck jaws fitted to the chuck shown below and one setof internal chuck jaws Three jaws are provided in each set Manual Chuck Mounting and Removal The chuck backplate has a mounting taper of 42mm dia x 727 with a register to suitthe chuck To mounta chuck body thoroughly clean the spindle nose backplate and chuck register before assembly Mount the chuck backplate to the spindle nose and secure using the three M8 cap head screws Mountthe chuck body to the backplate and secure using the three M10 cap head screws through the front face of the chuck To remove a chuck body perform the reverse of the procedure outlined above 52 Work Holding Section 6 Mirac PC CNC Lathe User s Manual 6 Manual Chuck Operation Safety First T X A Never leave the chuck key fitted in one of the locating holes If the Spindle is switched on it could hit the operator or machine and cause serious damage M codes for manual control of the optional pn
28. sssr 37 S Safety emergency stop button eee 12 interlock guard switch 13 OVELVIEW sssr 11 precautions ll Siting your Mirac PC wien 15 Slideways maintenance x axis cleaning and inspection e 61 X AXIS lubrication issn z axis cleaning and inspection Z AXIS lubrication ssn 69 Specification sses Spindle drive belt adjustment Spindle Speed override control Spray mist coolant system 38 Standard equipment sscccccrsnrrnn 9 Switches X axis datum SENSOFSWIECH sss 63 z axis datum sensorswitch z axis overtravel microswitch Switching the machine off 33 Switching the machine on 732 T Tailstock pneumatic operation ee 54 Technical support sss 87 Tool change requests ssscserererers 36 Tooling automatic SyStem sssesesererrrrrr 47 quickchange System sessseserrrrrrrr 41 Troubleshooting cutting problems ou eects 95 DOS CNC milling software 91 electrical problems 94 eurostep electronics mechanical problems nextstep electronics VR CNC milling software wees 88 U Unpacking your Mirac PC wees 14 Ww Warming Notices A s nianie necedi 5 Whatsis CNC ioin aitearnieniniesatias 8 Work Piece co ordinates display system 34 Mirac PC Series CNC Lathe User s Manual
29. the upper cross slide cover plate Note If the X axis movementis not smooth loosen the gib strip but this time turn the gib strip adjustmentscrew counter clockwise to introduce a little slack back into the system Run the cross slide up and down along the saddle again to assess the smoothness of movement 72 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Z Axis Gib Strip Adjustment Location Jax Look at the top left corner of the saddle The Z axis gib strip is adjusted using the two screws one locking one adjusting positioned on the left and right back corners of the saddle near the upper Z slideway Z Axis Gib Strip Adjustment Method 1 Using a flat bladed screwdriver loosen the gib strip locking screw about one half revolution to release the gib strip The locking screw is positioned behind the top left corner of the saddle as shown below Left side of Eo saddle Turn in a counter clockwise direction to loosen the screw Easier access to the locking screw can be obtained by gently pulling the flexible bedway cover away from the upper Z slideway continued Mirac PC CNC Lathe User s Manual Section 7 Maintenance 73 7 Z Axis Gib Strip Adjustment Gestion 2 Usinga flat bladed 7 lt a _ eee quite e A corner of the saddle EP play in the Z axis by tightening the gib strip TE adjustmentscrew one half side of revolution The adjusting saaie scre
30. to the air compressor is SCHRADER part number 9793C 12 1 4 BSP FEMALE or Denford part number BI 1128S AIR SUPPLY i 1 00 PSI 6 6bar Air supply isolator Pressure Adjuster To SCHRADER connection on air compressor Air Supply Isolator and Filter Regulator mounted on the back panel of the Mirac PC cabinet Air filter regulator unit Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 19 3 Option Compressed Air Connection M codes can be manually entered for immediate operation when the machine rolling software is con ope rating in og Mode or called automatically when writ en into a CNC program that is subsequently run in AY 20 CNC Machine Installation Section 3 o Mode Operation of the Air Supply Isolator Turn the control anticlockwise when viewed from above to allow the air to flow Turn the control clockwise when viewed from above to cut the air Supply and drain the air pressure from the system Operation of the Air Filter Regulator The normal operating pressure as supplied preseton the machine is 100 PSI 6 6 Bar Maximum pressure for the air regulator is 150 PS1 9 9 Bar Always check the main supply pressure before adjusting pressure at the regulator To adjust the pressure pull up the rotary control to unlock it from its current position Turn the control clockwise when viewed fro
31. 44 and remove first 0 in each city code Mirac PC Series CNC Lathe User s Manual Section 9 Technical Support 87 9 Troubleshooting VR CNC Turning Software VR CNC Turning Software Communications Troubleshooting ND Tox 1 Yourcomputer communicates with Mirac PC versions using the Your screen may display the message Error 50 Mint 3 28 Disconnect or similar depending on the hardware fitted The password used to access the Machine Properties window can be changed by the user Remember that the default password listed here will not be recognised if you have changed it If you change any passwords we recommend you make a note of them in Notes the last page of this manual 88 Technical Support Section 9 Denford Machine Link cable Check the Denford Machine Link cable is securely plugged into a valid COM porton the computer Note thatCOM ports are sometimes labelled as serial ports Identify whether the COM portbeing used is labelled as COM1 or COM2 The opposite end of this cable is securely plugged into the RS232 port located on the side panel of the electrical control box 2 Check all mains power connections are correctly fitted and secure Power up the CNC lathe using the yellow isolator switch mounted on the electrical control box door position I on position O off If no power is present switch off the mains supply then waitatleast5 minutes before attempting to open the electrical c
32. Control Software User s Manual Note that hazardous 4 To cut power to the CNC lathe rotate the isolator switch on the eh stat di Mirac PC electrical control box door one quarter turn anticlockwise switching off the power from its on I position to its off 0 position ee n Note that cutting the machine power will trigger the closing of the peasy bn wait at interlock guard switch mounted on the side panel of the Mirac PC least 5 minutes before This will lock a closed guard door in position preventing access to attempting to access i any electronic the working area The interlock guard switch will reopen when components power is nextsupplied to the Mirac PC Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk Mirac PC Series CNC Lathe User s Manual Section 4 CNC Machine Operation 33 4 Homing the Machine Axes Home Mode The sequence of events required to home the Mirac PC will depend on the type of CNC control software being used please refer to your separate CNC Control Software User s Manual for specific details The CNC control software og and Auto Modes will not become available until the machine has been configured by homing both machine axes The machine datum position is set by Denford and can never be moved since it defines the physical movement capability of the CNC machine
33. DEN FORD Total Commitment to Education and Training WorldWide Mirac PC CNC Lathe User s Manual CE approved Denford Limited reserves the right to alter any specifications and documentation without prior notice No part of this manual or its accompanying documents may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Denford Limited All brands and products are trademarks or registered trademarks of their respective companies Copyright Denford Limited Version 1 11 02 All rights reserved Contact Information Address Denford Limited Birds Royd Brighouse WestYorkshire HD6 1NB UK Telephone General Enquiries 01484 712264 ISDN 01484401157 01484401161 Fax 01484 722160 e mail for sales enquiries contact sales denford co uk for machine servicing enquiries contact service denford co uk for customer services contact customerservices denford co uk Technical Support Telephone 01484 722733 e mail customerservices denford co uk Monday to Friday 8 30am 4 30pm GMT Forintemational dialling 44 and remove first 0 in each city code Notes 2 Contents Mirac PC Series CNC Lathe User s Manual Contents Preface Contact Information Warning Notices es ADOUE THIS Manualen eoa aansen eataa i A A ASE N en A A E A OT a YA teste te d NA 6 Section 1 Introduction Introducing you
34. E DATUM A fixed zero reference point used to define the co ordinate based grid system of the CNC lathe All machining co ordinates originate from this point MD raean Manual Data Input A method used for manually inserting data into the control system ie Desktop Tutor qwerty keyboard etc MODAL nsiru Modal codes entered into the controller by a CNC program are retained until changed by a code from the same modal group or cancelled NG uarniannatanaeaniy Numerical control OFFSET ananasi Combination of two types of file the workpiece offset and the tool offset Used to describe the workpiece datum a zero reference used on the CNC lathe to ensure machining occurs in the correct place on the billet Offsets shift the entire co ordinate based grid system of the CNC lathe so the machine recognises our moveable workpiece datum as zero rather than the fixed machine datum PART DATUM useesteeteeeee Used as a zero reference point in a CNC file All machining co ordinates originate from this point within the program Commonly set at the centreline on the X axis and the face end of the billet on the Z axis PE otaa aa Personal computer PRORILE Sotaan The outside shape of an object The term tool profile is used to describe the shapes of the different cutting tool tips PROGRAM sivctresitiescclvcatees A systematic arrangements of instructions or information to suit a piece of equipment PROGRAMMABLE TURRET Area where cutting tools are
35. For example ifyour CNC program used a roughing profile finishing profile and drill odd tool numbers must be assigned to the roughing profile and finishing profile whilstan even number mustbe assigned to the drill profiles Denford recommends thatyou establish a standardised numbering system for the most common tool profiles used with your CNC programs Automatic Tooling System Fitting Tools The following tools are used to fit and adjust the components on the automatic indexing toolpost 5mm Allen f 4mm Allen 2 5mm Allen Hex Key Hex Key Hex Key Mirac PC Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 47 5 Automatic Indexing Tooling System Fitting a Diameter Turning E xternal Working Tool Profile to the Toolpost aoa cnx Onan eightstation toolpost diameter turning external working tool profiles such as roughing or threading profiles must be fitted to the odd A numbered stations 1 3 5 7 Never open the safety guard door and enter the working area when the spindle or machine axes are moving Left Positions available circled for fitment of diameter turning external tools Smee T X A Caution If the cutting tool has been recently used it may still be HOT 1 Each cutting tool profile should be fitted to an appropriate tip holder such as the example shown below The stations in the auto toolpost All diameter turning accept standard 12x12 tooling
36. NC Lathe User s Manual Section 11 Glossary 109 11 Glossary 110 Glossary Section 11 Constant Surface Speed The spindle is automatically adjusted according to the diameter being machined so that the material always passes the cutting edge of the tool at a constant rate Clockwise Counter C lockwise A sequence of events or commands The zero point co ordinate from which a series of measurements are taken The input control keypad for the machine Keypad overlays are interchangeable according to the type of controller required Replaces the qwerty keyboard and mouse An area of a disk containing the names and locations of the files it currently holds A computer information storage device examples C drive is usually the computers hard internal disk and A drive is usually the floppy portable 3 5 diskette disk Disk Operating System The controller unit for a disk system An operation used to test how a CNC program will function without driving the machine itself A programmed time delay The mode used for altering the content of a CNC program via the Desktop Tutor or qwerty keyboard The symbol or indicator that defines the end of a block of data The equivalent of the pc return key The rate in mm min or in min at which the cutting tool is advanced into the workpiece An arrangement of instructions or information usually referring to work or control settings The pattern or way that
37. OCK citiis nioa A collection of program words that collectively describe a machining operation A single program line in the CNC file CAROUSE briata The rotating section of a programmable turret containing a number of stations Also referred to as the turret disc CHARACTER sssiicdeassincte A number letter or symbol as entered into a CNC program CHUCK oiera aiana The clamping system that holds the billet driven by the spindle CIRCULAR INTERPOLATION G code term for a programmed arc movement COMMAND wees A signal or group of signals instructing one step operation to be carried out CONTEXT SENSITIVE When shortcut keys are used to call a Context Sensitive helpfile the pages displayed relate directly to the current active elements within the software CO ORDINATES use Positions or relationships of points or planes Co ordinates are usually described using two numbers referring to the X and Z axes eg the co ordinate X 14 Z 10 means 14 units along the X axis and 10 units along the Z axis CNG aripa noo a Computer Numerical Control CNG FILE Sirari The sequence of commands describing the manufacture of a part on a CNC lathe written using G and M codes also called the CNC program CUTTING SPEED s The velocity of the rotating workpiece relative to the stationary cutting edge of the tool GROSS SLIDE siiscccnaviiccnes The fixture that moves across the saddle X axis onto which the toolpost is mounted Mirac PC Series C
38. ale connector plug when viewed directly from the back of the machine 22 CNC Machine Installation Section 3 Mirac PC Series CNC Lathe User s Manual 3 Connecting the Machine Signal Cable Warning aX A Do not fit the male and female connector plugs together the wrong way round This could damage the connector pins The male and female connector plugs are shaped so they can only be connected in the correct orientation the cutaway parts of the connector housings and the numbered segments printed on the pin faces must match in order to achieve an electrical connection 1 Position the machine signal connector plug nextto the leftfixing bracket arranged in the correctorientation For correct alignment the plug cable will point down as shown in the diagram above Push the male connector plug fully onto the female fixing bracket 2 Close the junction by pushing the single fixing bracket roller clips onto the male connector plug housing pins until they click 3 Check the security of both plug connections and route the cables to avoid the possibility of users tripping over them 3 Connecting the Mains Supply Cable Warning Tex The electrical control box is inspected then sealed with a plastic yellow A Never attempt to access the electronic hardware systems in the CNC lathe or electrical control box with the mains power switched ON Sealing tag Ifthis seal is br
39. anual toolposts can only hold one tool at a time An automatic indexing toolpost can hold a number of different tools and change between them automatically See programmable turret TRAVERSE cirrosis Movement of the cutting tool through the 2 machine axes between cutting settings TURRET aistinatitioiicinie See programmable turret UXT ia renias Standard Windows text only file extension txt WORK WORKPIECE The actual material being machined The work is sometimes referred to as the a billet or stock WORKPIECE DATUM Used as a zero reference point on the real billet All machining co ordinates originate from this point when offset files are used WORD iiien A combination of a letter address and digits used in a CNC program ie G01 M03 etc VIRTUAL REALITY 1 A fully interactive three dimensional computer based simulation of a real world object or event 112 Glossary Section 11 Mirac PC Series CNC Lathe User s Manual 12 Index A Address characters list 102 Advantages Of CNC wisest 8 Air supply isolator and filter regulator 19 AUO MOIE sented id Satish ons one AN 37 Automatic indexing toolpost fitting a diameter working tool 48 fitting an end working tool esses 50 INTOCUCHON ix nerves aA Arh 47 MAINTENANCE sire diteeraianirarddiicn 15 removing a diameter working tool 49 removing an end working tol 51 requesting a tool change sesse
40. bris away from the sensorswitch to a location where itcan be removed from the working area Take care notto disturb any wires orthe sensor itself Replace the cover plate after finishing the inspection procedure Mirac PC CNC Lathe User s Manual Section 7 Maintenance 63 7 Inspecting the Z Axis Datum Sensorswitch The sensorswitch defining the Z EET axis datum is maintenance free ies and mounted behind the upper mirror to help inspect parts of the machine Slideway on the bed casting that are hard to reach towards the tailstock end ofthe aN machine Its position usually cross slide prevents swarf and debris from r building up around the sensor Look under the top of fitted to the switch However the the right flexible cover switch may require cleaning when the machine has been used in extreme operating conditions Location Ja X Drive the saddle fully to the left This will make is easierto gain access to the right side of the bed where the condition of the sensorswitch and trigger can be checked Using a soft bristled brush carefully clean any swarf and debris away from the sensorswitch to a location where itcan be removed from the working area Take care not to disturb any wires orsensors Inspectthe sensorswitch for damage or wear gt Right bed flexible cover 64 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Inspecting the Z Axis Overtravel Microswitch Locati
41. ccessfully Ifno offsets have been configured the CNC machine will use the machine datum as the starting point for any machining co ordinates read 2 The X and Y values entered in the workpiece offset file are correct Poor surface finishes are obtained Check the following 1 The correct feedrates and spindle speeds are being used appropriate for the cutting tool profile and type of material being machined Recommended feed and speed values should be available from your tool and material supplier Note that running incorrectfeeds and speeds can severely shorten the life expectancy of your tools 2 The workpiece is held securely in the chuck 3 The correcttool profile appropriate to the finish required is being used Check that the cutting edges are sharp and undamaged 4 Any machine drive belts are correctly tensioned and notslipping 5 The tool profile is held securely in the tool holder Mirac PC Series CNC Lathe User s Manual Section 9 Technical Support 95 10 Specification of Mirac PC CNC Lathe Standard Equipment Mirac PC CNC lathe Electrical control box Quick change toolpost and holder Manual self centring 3 jaw chuck Set of internal and external jaws LoVo light Serial and parallel port Outlet and link to external monitor CNC machine control software CNC lathe and controller software manuals Set of maintenance tools and spare parts list Extra Equipment Various workholding systems
42. d as standard with the Mirac PC CNC lathe unless an optional automatic indexing toolpost has been fitted The system comprises of two elements i The toolpostbody which is mounted to the Mirac PC cross slide The quickchange O toolpost body The quickchange tool holder ii The tool holder which is fitted to one of the two location slots on the sides of the toolpost body Tool holders are held in position using a spring loaded slide and bracketassembly to allow easy manual removal and replacement of tools when necessary Height adjustmentis achieved using a grooved nutand collar bolt Mirac PC Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 41 5 Quickchange Manual Tooling System Manual Tooling System Fitting Tools The following tools are used to fit and adjust the components of the quickchange manual tooling system Toolpost Hex Socket Key 4mm Allen Hex Key Fitting a Tool to the Toolholder Moen Ta 1 Using a 4mm allen hex Diameter turing key unscrew the four external tools must be A lockbolts or grubscrews ted with the cutting edge facing up a ad a safety on the toolholder When guara aoor an enter 4 A ihe working area Whe directly viewing the top the spindle or machine of the bolt heads turn axes are moving counter clockwise to loosen or clockwise to ee xy tighten them ae A Slot for Caution cutting tool If the cutting tool has b
43. dle Drive Belt Adjustmentcciscacsausnccseieccuntesscatducaskovecsiceatinn cennsicisnt e A E cea haraa nen ce 76 Section 8 Machine Electronics Accessing the Electrical Panel and Diagrams 0 78 Electrical Layout EuroStep Controller The EuroStep Motion Control Board EuroStep Electronics Troubleshooting Electrical Layout NextStep Controller The NextStep Motion Control Board shes NextStep Electronics Troubleshooting oo cescescesssesseesssesssesssesscesscesssesscessessessesseesesseesessessessessesseeteesreesten Section 9 Technical Support Requesting Technical SUpPOTt sesssssssssssessuessssssseseseeesstansessssseseereeeetsaanmessseseerereesetianmessseseeeerereetaqcaansents 87 roubleshooting VR CNC Turning Software 88 Troubleshooting DOS CNC Turning Software ae OL Troubleshooting Mechanical Problems wn 94 Troubleshooting Electrical Problems aa 94 Troubleshooting Cutting Problems misiniz aeir E EE daevdacviss 95 4 Contents Mirac PC Series CNC Lathe User s Manual Contents Section 10 Appendix Specification of Mirac PC GNC Cathe issiran a A 96 What is Part Program si craint Eit EA ANEA ENARA ENNA ENA EANA tiny Aea ded clea 98 Composition of a Part Program i G Codes List 00 M Codes List 01 List of Program Addre 02 Denford Directives s 03 EC Declaration of Conformity sses 105 Mirac PC Series Noise Level Test Results
44. e switched on wait at CNC lathe least 5 minutes before f attempting to access To unlock the electrical control box door any electronic components Locate the Many electronic door lock components are key for the iti two door Door sensitive to ieks pog electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk Depending on the specification of the machine some electrical cabinet doors may be fitted with additional door locks 3 Electrical Diagrams The electrical diagrams for your Mirac are not included in this manual They are either delivered separately in the standard equipment box supplied with your machine or stored in a folder attached to the inside of the electrical control box door Further electrical schematics are available on request 24 CNC Machine Installation Section 3 Mirac PC Series CNC Lathe User s Manual 3 Option Auxiliary Input Output Socket Your electrical control box may be fitted with an Auxiliary Input Outputsocket allowing external control of your Mirac PC inFMS and CIM systems via a Auxiliary cable connection as shown below left HR To run your Mirac PC as a stand alone Chained machine remove your external system Blanking cable and fit the blanking plug which is Plug chained to the socket 3 Removal of Protective Coatings Warning Tax Once your Mirac PC has been sited and connected electrically the protective coa
45. e cross slide behind the toolpost as shown above right Using a 2 5mm allen hex key turn each of the three cap head screws counter clockwise to remove them and withdraw the cover plate Inspect the exposed portion of the ballscrew and bearing for damage or wear Replace the cover plate after finishing the inspection procedure Mirac PC CNC Lathe User s Manual Section 7 Maintenance 61 7 Cleaning and Inspecting the Z Axis Ballscrew and Slideways Note If necessary use a mirror to help inspect parts of the machine that are hard to reach Location Ja x Look under the flexible covers on the left and right sides of the The two Z axis slideways are located on the upper and lower sides ofthe bedway and the saddle Run the saddle towards the right until sufficient space has been released to liftthe black flexible cover positioned on the left Upper Slideway side of the saddle N paling Uoper Slideway Using a softbristled x brush carefully clean any swarf and debris _ eines BallSCrew away from the exposed upper and lower sides of each slideway to a location where itcan be removed from the working area Inspect each slide for damage or wear Run the saddle towards the left liftthe black flexible cover positioned on the right side of the saddle and repeatthe process The Z axis ballscrew runs centrally from right to left between the two Z axis bed slideways The Z
46. e far leftslots of the card rack In conjunction with the custom card and axis drive boards it controls the motors that drive the two CNC machine axes 80 Machine Electronics Section 8 Mirac PC CNC Lathe User s Manual 8 The EuroStep Motion Control Board Location y lt a Look in the bottom left corner of the control box from the front Re EuroStep Motion lt a Bee LED Status and Fault Display Look directly atthe end of the EuroStep motion control card to read the seven segment LED display Display Meaning Linear positional mode Torque control mode Stop asserted Pulse following mode Errors are all shown with a flashing dot Display Meaning External error S oftware abortor interpreter error Maximum servo following error exceeded Limit switch open o No comms board address fault Servo power off 8 Servo power up and idle Cam profiling subscript symbol c Cam table superscript symbol C Circular interpolation 3 E ncoder following mode F Flying shear static symbol H Homing datuming J J ogging velocity mode Offsetmode P q 5 U munam Mirac PC CNC Lathe User s Manual Section 8 Machine Electronics 81 8 EuroStep Electronics Troubleshooting Warning Tax The spindle drive is not working A Check the validity of the following Never attempt to 1 Check the emergency stop button is notdepressed access the electron
47. e machine power cable is permanently connected to the electrical control box whilst the free end is fitted with a male connector plug The back panel of the Mirac PC cabinets fitted with a bank of two fixing brackets thatcontains the female connector plugs The machine power cable fits to the right female connector plug when viewed directly from the back of the machine 1 Position the machine power connector plug next to the right fixing bracket arranged in the correctorientation For correct alignment the plug cable will point down as shown in the diagram left Push the male connector plug fully onto the female fixing bracket ose the junctions by pushing the top and bottom fixing bracket roller clips onto the male connector plug housing pins until they click 3 Connecting the Machine Signal Cable The machine signal cable must be connected from the electrical control box to the machine The machine sinal cable is housed in the smaller black corrugated hose approximately 20mm in diameter The connector housing is fitted with one vertical pin on the top and one vertical pin on the bottom One end of the machine signal cable electrical control box whilst the free e is permanently connected to the nd is fitted with a male connector plug The back panel of the Mirac PC cabinetis fitted with a bank of two fixing brackets that contains the fema e connector plugs The machine signal cable fits to the left fem
48. e manually released to enter the working area when the 24 volt circuithas failed and the dooris clamped electrically Note For manual interlock release the power supply mustbe switched off 1 Remove security screw A B or C whichever is easiest to reach using the supplied Torx T 20 adapter 2 Inserta 2 5mm diameter tool such as a small flat screwdriver into the hole until it pushes the manual release lever 3 Whilstholding the tool againstthis manual release lever open the guard 4 Remove the tool from the hole and replace the security screw Section 2 Safety Features 13 3 Unpacking and Lifting your Mirac PC PROM cnx Cutthe top of the delivery box open and remove any packaging Hachi TE carefully To obtain better access to the Mirac PC cabinetand the achine Weights Standard Mirac PC separate electrical control box remove all the sides from the delivery 220KG 485 Ibs box leaving both pieces of equipment standing on the wooden delivery Standard electrical pallet To liftthe Mirac PC cabinetfrom the packaging use a professional hoist Deien and a single 500KG 1120 Ib rated 5 metre 200 endless nylon gle 5 ee metre x 500 KG nylon Sling Loop the front of the sling below the cabinet justin front of the sling with a machine foot section and the back of the sling under the two lifting hooks professional hoist to lift on the back panel as shown in the diagram below Ensure the Mirac
49. een recently used it f i may still be HOT 2 Place the cutting tool into the toolholder in the correctorientation Note that diameter turning external tools must be fitted with the cutting edge facing down i 3 Tighten the lockbolts until they just begin to grip the upper surface of AU diameter timing the cutting tool body Tighten each boltused by one quarter turn external tools must be fitted with the cutting Continue this procedure until all bolts are fully tightened and the edge facing down cutting tool is held securely 42 Preparing Tooling Hardware Section 5 Mirac PC Series CNC Lathe User s Manual 5 Quickchange Manual Tooling System Safety First T X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Toolpost Body Angle Adjustment To adjust the angle of the toolpost body use a 10mm spanner to Toolpost body release the locknut located on the locknut hole central toolpostmounting stud fitted to the cross slide The position of the locknuthole on the toolpost body is shown arrowed right When directly viewing the top of the nut turn counter clockwise to loosen or clockwise to tighten Fitting the Toolholder to the Toolpost Body 1 Using the supplied toolpost hex socketkey turn the appropriate double flanged locknutso the flanges are pointing towards the centre of the toolpost Double flanged locknut cl
50. elling your Mirac PC Your Mirac PC rests level on the two hollow sections which run beneath the machine cabinet The machine itself has been levelled to the machine cabinet prior to dispatch so itis only necessary to level the table on which the Mirac PC cabinetis to be situated 3 Connecting your PC to the CNC Lathe Warning Tay Your CNC lathe is controlled using a standard IBM compatible PC personal computer In this role the PC can be referred to as the A machine controller computer Do not connect cables Ideally the PC you intend to use should be placed nextto your Mirac between any electrical PC cabinetand its electrical control box in a position which will not nare wate With ine interfere with routine maintenance and machine operation mains power switched on since this could Your PC mustbe equipped with hardware thatallows itto seriously damage 1 run the CNC machine control software components inside your CNC lathe 2 be physically connected to the Mirac PC electrical control box The specification of PC required to control your CNC lathe will depend upon the type of CNC machine controlling software being used Please refer to your separate CNC machine controlling software manual for details regarding the exactP C specification required 16 CNC Machine Installation Section 3 Mirac PC Series CNC Lathe User s Manual 3 Connecting your PC to the CNC Lathe Warning Tax y To connectyour PC to the Mi
51. ent in the slides should be rectified by adjusting the gib strips as described on the next four pages Checking the Condition of the Gib Strips As the gib strips wear down varying degrees of free play will become noticeable in each of the two machine axes You can quickly judge the slack available in each slideway by holding the cross slide or saddle at their extreme ends Try to move or wobble them from side to side across the width of the slideway Any excessive movement will indicate that the slideway in question requires adjustment To accurately assess the condition of each slideway Denford recommends the use of a dial gauge Note that a slight degree of movement will always be present in every slideway If there is no free movement whatsoever then the Slideways would be too tight to move 70 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 X Axis Gib Strip Adjustment Location BEA The X axis gib strip is adjusted using the two screws one locking one i adjusting positioned on the frontand back left corners of the saddle ook at the top of E cross slide behind the nearthe leftX slideway X Axis Gib Strip Adjustment Method amp 1 The gib strip locking screw is hidden by the upper cross slide cover MN plate Drive the saddle down the X axis This will make is easier to gain access to the top portion of the cross slide and the coverplate fixing screws Using a 2 5mm allen hex key turn each of
52. eumatic safety guard door M38 Door open M39 Door close The manual chuck has a recommended safe maximum spindle speed of 3800rpm Fitting the Billet in a Manual 3 J aw Chuck 1 The chuck jaws are adjusted using a chuck key a T shaped bar with a square locating peg shown below This fits into one of the three square holes equally spaced around the perimeter of the chuck body Chuck Key 2 Open the chuck jaws by turning the chuck key in a counter clockwise direction until there is sufficient space to fit the billet as shown below 3 Place the billet between the chuck jaws If possible try to position the billet so that the largest amount of material is held inside the chuck or by the chuck jaws 4 Whilst supporting the billet inside chuck body close the chuck jaws by turning the chuck key in a clockwise direction 5 Check the billet is held securely in the chuck jaws Remove the chuck key from the square locating hole Mirac PC CNC Lathe User s Manual Section 6 Work Holding 53 6 Bar Feed Hole for Longer Length Billets Facility is provided for feeding longer billet lengths through the centre of the chuck Remove the cap from the lower right headstock panel of the machine as shown below to reveal the bar feed hole Remove coverplate to reveal bar feed hole 6 Pneumatic Chuck Operation The following M codes call the miscellaneous functions used to manually control t
53. evolution when the machine Code listing full and correctatthe time of printing Nov 2002 started 100 Appendix Section 10 Mirac PC Series CNC Lathe User s Manual 10 M Codes List Note Notall M codes may apply to your CNC machine M code Function MO00 Program stop M01 Optional stop M02 End of program M03 Spindle forward clockwise M04 Spindle reverse counter clockwise MO05 Spindle stop M06 Automatic tool change MO08 Coolanton M09 Coolantoff M10 Chuck open M11 uw Chuck close M13 Spindle forward and coolant on M14 Spindle reverse and coolant on M25 wee Tailstock quill extend M26 Tailstock quill retract M30 Program stop and reset M38 we Door open M39 Door close M40 Parts catcher extend M4l Parts catcher retract M62 sii Auxiliary output 1 on M63 wee Auxiliary output 2 on M64 Auxiliary output 1 off M65 wee Auxiliary output 2 off M66 Wait for auxiliary output 1 on Not all M codes listed are available all M codes marked with an asterisk will be performed at the end of a program block ie after any axis movement Mirac PC Series CNC Lathe User s Manual M67 Wait for auxiliary output 2 on M76 wee Wait for auxiliary output 1 off M77 wesc Wait for auxiliary output 2 off M98 Sub program call M99 Sub program end and return Code listing full and correct at the time of
54. fers to a specific cutting movement command or machine function The programming language recognised by the CNC the machine controller is an International Standards Organisation code which includes the G and M code groups Each program word is composed from a letter called the address along with a number These terms are illustrated on the following pages Mirac PC Series CNC Lathe User s Manual 10 Composition of a Part Program Part Program example Lathe CAM Designer 0050 LCD Novaturn lathe metric 00050 N0010 G21 BILLET X10 220 Denford Directive Example BILLET N0020 G98 N0030 G28U0W0 TF N0050 M3S2546 N0060 G00X1022 N0070 X12 5 N0080 X10 N0090 G01Z 13 5F 10 N01 N0110 G00Z2 0120 X8 0130 M353183 0140 G01Z 8 26 0150 X10 0 0 0 0 ae Er ae a _ 160 G00Z2 170 X6 A componentis designed using a CAD CAM software N0180 M3S4000 package such as Lathe CAM Designer N0190 G01Z 6 26 The CAD CAM software package automatically N0200 X8 generates the part program including all the G and M N0210 X12 codes required to manufacture the component N0220 G00Z2 ES N0230 G01Z0 N0240 X4 N0250 Z 5 N0260 M3S2829 N0270 X9Z 10 N0280 Z 14 N0290 X12 N0300 G00Z2 N0310 M5 N0320 G28U0WO D N0330 M30 e N 7 li Fa TA gt r E al aios z a e e a Lajes e 2 Mirac PC Series CNC Lathe User s Manual Sec
55. file usually supplied on floppy disk defines the computer settings and drivers used by the DOS CNC turning control software The file indicates the order in which the drivers are loaded into memory when the system first starts up Example FLSTEP GO File Example FLSTEP GO file listed below IBM RS21 3F8 4 MACHINE DENFORD KBD 1 18 2 2F8 3 EGA CRT 0 FLSTEP APP The example FLSTEP GO file listed above would be used when the CNC lathe is connected to COM 1 and the Denford DeskTop Tutor linked to COM 2 The COM ports on your PC are sometimes referred to as Serial ports Editing the FLSTEP GO File Some drivers require a number of additional lines as parameters The amount of lines required by the driver is shown by a number written after the driver name In the example shown above the number 1 listed after the IBM RS2 driver entry indicates that one additional line follows In this example itloads the MACHINE CNC lathe driver to address 3F8 using interrupt 4 COM 1 These addresses can be edited according to the COM number required using the table below COM1 3F84 COM2 2F8 3 COM3 3E84 COM4 2E8 3 The lastline in the file executes the software specified ie FLSTEP APP Mirac PC Series CNC Lathe User s Manual Section 9 Technical Support 93 9 Troubleshooting Mechanical Problems The safety guard door cannot be opened In mostcases this is because the interlock guard switch has locked the door in the closed po
56. from separate electrical control box from left to right machine signal machine power Safety guard door locking switch Lifting hook Compressed air connection unit Front and rear machine cabinet support feet sections hook Mirac PC Series CNC Lathe User s Manual Section 4 CNC Machine Operation 29 4 Electrical Control Box Component Locations Front 3 4 View Photograph features optional equipment Location of optional equipment indicated but item not shown in photograph Electrical control box door Mains isolator on off power switch Machine power cable connects to bracket on back Q panel of Mirac PC y F fy lock cabinet Machine signal cable connects to bracket on back panel of Mirac PC Mains supply cable cabinet connects to mains plug socket B a ck 3 4 y iew Electrical control box door Photograph features optional equipment Location of optional equipment indicated but item not shown in photograph G Machine Cooling 0 fae ane fan inlet identification panel Ui iit ili Auxiliary 1 0 socket RS 232 connection Denford machine link cable 30 CNC Machine Operation Section 4 Mirac PC Series CNC Lathe User s Manual 4 Working Area Component Locations F ro nt 3 4 V lew Bedway Automatic indexing 8 station Photograph features optional Worklight Z axis toolpost manual toolpost equipment
57. have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating features regarding this CNC machine without notice or documentation We take great pride in the accuracy of information given in this manual but due to nature of hardware and software developments be aware thatspecifications and features of this productcan change without notice The information contained in this manual is correct atthe date of printing only November 2002 No liability can be accepted by Denford Limited for loss damage or injury caused by any errors in or omissions from the information supplied in this manual This manual is written using European English Any comments regarding this manual should be referred to the following e mail address customerservices denford co uk Mirac PC Series CNC Lathe User s Manual 1 Introducing your Mirac PC CNC lathe The Mirac PC is a versatile 2 axis CNC bench turning centre ideal for all levels of education and technical training Developed with a powerful 0 75KW spindle motor and accurate axis stepper motors the Mirac PC offers improved speeds and feeds to meet the increased demands of modern machining Machine control is achieved via a Windows based PC notincluded as standard An optional 8 station programmable indexing turret and pneumatic Safety gua
58. he property listings 6 EuroStep Controller Cards Check the LED display status on the EuroStep Motion Control Board the main card on the electrical panel For more information refer to Section 8 Machine Electronics A problem with this card can cause problems with communications Look forthe LED display mounted on the main control card A blinking dotwith an L or the number 8 should be shown Ifthe LED is notlit check the control board fuse Ifno display continues to be shown call Denford Customer Services for assistance Warning Risk of electric shock Note thatin order to check the readout the CNC machine must be powered up with the electrical control box open Exercise extreme caution do nottouch any live electrical components since damage may occur to the hardware or technician inspecting the equipment Rememberto shutdown the CNC machine then close and lock the electrical control box door on completion of this step continued Section 9 Technical Support 89 9 Troubleshooting VR CNC Turning Software 7 Check the COM porton your controller computer is functioning correctly Consultyour IT person or Computer Support Centre for help with these issues Check the COM portsettings in Windows by accessing the Device Manager Check the com ports enabled and labelled properly in the computer BIOS Check the physical COM portitself functional For example Windows and the BIOS may show that the COM ports are fine b
59. he optional pneumatic chuck M10 Chuck Open M11 ChuckClose 6 Pneumatic Tailstock Operation The following M codes call the miscellaneous functions used to UT ma nually control the optional pneumatic tailstock M cones can pe M25 Tailstock quill extend manually entered for immediate operation M26 Tailstock quill retract when the machine controlling software is operating in J og Mode or called Note automatically when written into a CNC program that is subsequently run in Auto Mode 54 Work Holding Section 6 Mirac PC CNC Lathe User s Manual 7 Planning Procedure for Maintenance Work Safety First T X A Caution Wear safety glasses and a Suitable respiratory mask when cleaning the machine Safety First T X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Safety First T X A Caution If the cutting tool has been recently used it may still be HOT When carrying out any maintenance pay special attention to the following items ensuring safe and correct working procedures in accordance with Health and Safety Regulations in your establishment Before starting any maintenance work define the task and obtain the information relevant to carry outthe maintenance Also define the time period needed to complete the task to obtain the correct tools and order any spare parts if required
60. ic 2 Check the spindle drive fuse labelled F3 on the main fuse rack peal eee of 3 een primary control transformer fuse labelled F 1 on the main se rack mains power switched ON 4 Check the secondary control transformer fuse labelled F 5 on the Note that hazardous voltages can still exist main fuse rack immediately after me ar switching off the In addition refer to the electrical schematic diagrams to confirm specific power fuse details and labelling If the machine has previously been switched on wait at i i r laast 5 minutes before The axis drives do not respond attempting to open the Check the validity of the following electrical panel cover plate 1 Check the emergency stop button is notdepressed 2 Check the axis drive transformer fuse labelled F 2 on the main fuse r rack warning mE 3 Check the primary control transformer fuse labelled F 1 on the main A fuse rack Many electronic 4 Check the secondary control transformer fuse labelled F5 on the component are main fuse rack electrostatic damage 5 Check the 36V stepper drive supply fuse labelled F1 on the rack Ani componens backplane N A 6 Check the 36V stepper drive supply fuse labelled F 2 on the rack minimise this risk backplane In addition refer to the electrical schematic diagrams to confirm specific fuse details and labelling Always refer to your electrical schematic diagrams for the definiti
61. including 8 station programmable turret pneumatic chuck tailstock Various tooling packages Spray mistcoolantsystem Pneumatic safety guard door Option of including in FMS CIM system Additional CAD CAM and offline machine controller software licenses Video conferencing system Machine and software training PC amp PC workstation Mechanical Details Swing over bed 250mm 9 7 8 Travel X axis 85mm 3 3 8 Travel Z axis 155mm 6 1 8 Maximum Turning Diameter 160 mm 6 1 4 Maximum Turned Length 180 mm 7 1 16 High Precision Anti Backlash Ballscrews fitted to both Axes Bed Hardened and Ground and of Slant Design Spindle bore No 3MT 21mm 13 16 Spindle Nose A2 Type 42 mm 1 11 16 Spindle speed programmable 0 5000 RPM Spindle speed override potentiometer 50 120 Feedrate programmable 0 3000 mm min Feedrate override potentiometer 0 150 Machine Resolution 0 01mm 0 0004 96 Appendix Section 10 Mirac PC Series CNC Lathe User s Manual 10 Specification of Mirac PC CNC Lathe Mechanical Details continued Optional 8 Station Turret External Tool Size12mm x 12mm 15 32 x 15 32 Internal Tool Size 25mm 1 Index time station to station 0 65 seconds Index time full revolution 1 75 seconds Safety Features Manual operation totally enclosed interlocked safety guard door Emergency stop button 2D and 3D simulation graphics to verify part programs prior to machini
62. ing point Run the rotating mechansim of the automatic toolpostcarousel to distribute the oil across any internal surfaces Mirac PC CNC Lathe User s Manual Section 7 Maintenance 75 7 Spindle Drive Belt Adjustment To maintain smooth operation of the spindle check and if necessary adjust the tension of the spindle drive belt on an annual basis To gain access to the spindle drive belt turn of and disconnect power to the machine Using a 2 5mm allen hex key unscrew all the cap head fixing screws on the removable panel located at the headstock end of the machine Turn the screws in a counter clockwise direction to loosen them and withdraw the panel as shown below Headstock end of machine with coverplate removed Apply pressure to the drive belt in the area indicated by the photograph shown below When set correctly the drive belt should be deflected no more than 25mm 1 Belt deflection 25mm 1 lt a continued 76 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Spindle Drive Belt Adjustment To adjust the tension of the spindle drive belt use an 8mm allen hex key to slightly unscrew the three bolts A B C on the lower right bracket shown below left Turn the bolts in an counter clockwise direction to loosen them Ue a Ng vw a TN n E Lower Right MS a a a a a Lower Left Bracket Bolts Bracket Bolts Using an 8mm allen hex
63. ingdom Declares that the machinery described Manufacturer Denford Limited Model Name Mirac PC Series CNC Lathe S N AC6 Serial Number please refer to warranty card and or machine casing conforms to the following directives The Machinery Directive 89 392 EEC as amended by Directive 91 368 EEC and Directive 93 44 EEC and CE Marking Directive 93 68 EEC and the following standards where applicable and complies with the relevant health and safety requirements cecscccesesecseceeceeeesiseesesseteeneeeenieeiseeseetseaeeneense Signature Position within company Senior Design Engineer Signed at Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Back of the Mirac PC Series EC Declaration of Conformity Certificate 106 Appendix Section 10 Mirac PC Series CNC Lathe User s Manual Mirac PC Series Noise Level Test Results Test Report No Mirac PC NL AC6 01 Machinery Manufacturer Denford Limited Machinery Type Model Mirac PC Series CNC Lathe TestS pecification in accordance with BS 4813 1972 Instrumentation used Cirrus CRL 2 35A Test Site Denford Limited Inspection Department General Machine Test Conditions Chuck on size Standard Splash guard on NotApplicable Machine mounting Floor Additional equipment None TestP ositions Back of Machine Plan View T Front of Machine continued on reverse Mirac PC Series Noise Level Test Res
64. ired to physically hold the billetin the chuck jaws SUBPROGRAM This directive allows a program with a non numeric name to be called as a subprogram Example SUBPROGRAM 0200 FRED M98 P0200 This example assigns a subprogram number of 0200 to the program named FRED then calls the subprogram 0200 STEP This directive runs an on screen program in single steps This means the program will run one program line then wait for the operator to promptitto move to the nextline this continues until the program is instructed to stop this function The directive applies to both simulation and actual machining with a program continued Mirac PC Series CNC Lathe User s Manual Section 10 Appendix 103 10 Denford Directives NO STEP This directive runs an on screen program without single steps This means the program will run as originally intended with no pausing unless a pause is requested from within the program itself The directive applies to both simulation and actual machining with a program SHOW This directive allows the machining operations to be graphically simulated on screen NOSHOW This directive stops the machining operations from being graphically simulated on screen 104 Appendix Section 10 Mirac PC Series CNC Lathe User s Manual EC Declaration of Conformity The responsible person MrJ M Boyle Business Name Denford Limited Address Birds Royd Brighouse West Yorkshire HD6 1NB United K
65. itching off the power fuse details and labelling If the machine has previously been switched on wait at i i 3 least 5 minutes before The axis drives do not respond attempting to open the Check the validity of the following electrical panel cover plate 1 Check the emergency stop button is notdepressed 2 Check the axis drive primary fuse labelled F2 on the main fuse rack yarn EEE 3 Check the axis drive secondary fuse labelled F 4 on the main fuse A rack Many electronic 4 Check the primary control transformer fuse labelled F 1 on the main components are fuse rack sensitive to electrostatic damage 5 Check the secondary control transformer fuse labelled F5 on the ere component main fuse rack and or personnel are 4 i Ci suitably earthed to In addition refer to the electrical schematic diagrams to confirm specific minimise this risk fuse details and labelling Always refer to your electrical schematic diagrams for the definitive labelling and placement of components and fuses Information contained on this page is correct at the time of printing November 2002 but is liable to change through continuous development of our products 86 Machine Electronics Section 8 Mirac PC CNC Lathe User s Manual 9 Technical Support Denford Limited provides unlimited telephone Technical Supporton this CNC lathe to registered users On site visits by our engineers may be chargeab
66. key unscrew the two bolts D E on the lower left bracket shown above right Turn the bolts in an counter clockwise direction to loosen them to the extend where the bracket can justbe moved Move the lower left bracket towards the back panel of the machine to tighten the spindle drive belt as shown below AN A EN Move bracket A F towards back to tighten belt Ja j ain Cana Lower Left Bracket S Tighten all five bolts and check the belttension When the correct tension has been achieved replace the panel atthe headstock end of the machine Mirac PC CNC Lathe User s Manual Section 7 Maintenance 77 8 Accessing the Electrical Panel and Diagrams Warning Ten xy Open the electrical A Never attempt to access the electronic hardware systems of the machine with the mains power switched ON Note that hazardous voltages can still exist immediately after switching off the power If the machine has previously been switched on wait at least 5 minutes before attempting to open the electrical control box door Depending on the specification of the machine some electrical control box doors may be fitted with locks Further electrical schematics are available on request from Denford Customer Services control box to access Door cannot be opened unless the the electrical panel isolator switch is in the off 0 position and electrical diagrams Door lock
67. le Please refer to the information held in your separate Warranty pack for specific details Denford Limited provides unlimited telephone and e mail Technical Supporton this CNC lathe to registered users On site visits by our engineers may be chargeable Please refer to the information held in your separate Warranty pack for specific details Before contacting Denford for support please read your hardware and software manuals and check the Denford websites for support Internet access technical supportand FAQ sections Denford UK http www denford co uk Denford USA http www denford com When you request support please be at your CNC lathe with your hardware and software documentation to hand To minimise delay please be prepared to provide the following information CNC lathe serial number from the machine ID panel Registered user s name company name The CNC machine control software name and version number The wording of any error messages that appear on your computer screen if applicable e A listofthe steps that were taken to lead up to the problem e A listof any maintenance work that has been carried outon the CNC lathe Contact Details Denford Limited Birds Royd Brighouse WestYorkshire HD6 1NB UK Telephone 01484 722733 Fax 01484 722160 ISDN 01484401157 01484401161 E mail customerservices denford co uk Technical Support Monday to Friday 8 30am 4 30pm GMT For international dialling
68. le movements immediately The interlock switch will also close When the safety guard door is in its closed position this will prevent access to the working area of the machine To activate an emergency stop press the button in until it clicks The emergency stop button will continue to cut all power to the machine drives and continue to keep the interlock switch closed until the release sequence is performed To release a closed emergency stop button push in and turn the button counter clockwise until itsprings back out 12 Safety Features Section 2 Mirac PC Series CNC Lathe User s Manual 2 Safety Features Interlock Guard Switch A closed machine door cannot be opened when The machine is switched off ie not in use To release the interlock guard switch supply power to the machine The emergency stop button is fully pressed in To release the lock push in and tum the emergency stop button counter clockwise until it springs back out to its ready position Machining is taking place The interlock guard switch will release when the machining Operations have been completed and the machine controlling software is operating in Jog Mode Mirac PC Series CNC Lathe User s Manual Location of interlock guard switch mounted on the right side of the machine cabinet and door Interlock Trip Lever An interlock safety switch is fitted to the rightside panel of the machine cabinet and door The switch mustb
69. m above to increase pressure or anticlockwise when viewed from above to decrease the pressure Push the rotary control back down to relock it in its new position Regularly drain any water collected in the filter bottle using the cap in the base of the bottle The interval at which this operation is required will depend on the type and condition of the air compressor being used Optional Pneumatic Equipment Control Codes The following M codes are used to call the miscellaneous functions listed below M06 Tool change standard manual or optional auto toolpost M08 Coolant on optional spray mist coolant system M09 Coolant off optional spray mist coolant system M10 Chuck open optional pneumatic vice M11 Chuck close optional pneumatic vice M13 Coolanton and spindle forward optional spray mistcoolantsystem M14 Coolanton and spindle reverse optional spray mistcoolant system M25 Tailstock quill extend optional tailstock M26 Tailstock quill retract optional tailstock M38 Door open optional pneumatic safety guard door M39 Door close optional pneumatic safety guard door Mirac PC Series CNC Lathe User s Manual 3 Electrical Control Box Cable Connections The mains power supply is fed to the electrical control box which in turn is connected to the Mirac PC cabinet There are three electrical connections that exit the electrical control box 1 The machine power cable the larger diame
70. n is a circular red push button P ressing the emergency stop button has the effectof stopping all axes and spindle movements immediately The safety guard door will also be locked preventing entry to the working area To active an emergency stop press the button in until itclicks The emergency stop button will remain closed continuing to cutall powerto the machine drives until the button is released To release turn the button clockwise until it springs back out Spindle Speed and Feedrate Override Controls The spindle speed and feedrate of the Mirac PC can be manually overridden during a machining operation using the potentiometer control dials fitted to the operators panel On machines where these controls are notfitted or disabled the spindle speed and feedrate must be overridden using the CNC control software please refer to your separate CNC Control Software User s Manual for details regarding this feature The spindle speed can be overridden between 50 and 120 The feedrate can be overridden between 0 and 150 To increase the spindle speed or feedrate rotate the appropriate control clockwise To decrease the spindle speed or feedrate rotate the appropriate control anticlockwise The degree of adjustment applied to each value is displayed in the CNC control software Mirac PC Series CNC Lathe User s Manual 5 Quickchange Manual Tooling System Introduction The quickchange manual tooling system is supplie
71. nd Internal Working Tool Profile to the ToolpoSt sss aa 50 Automatic Tooling Removing an End Internal Working Tool Profile from the Toolpost a Dl Automatic Tooling Requesting Programming a Tool Change uu 51 Section 6 Work Holding Manual Chuck Operation Introduction mpanse aa a 52 Manual Chuck Mounting and Removal aD Manual Chuck Operation seee od Fitting the Billet in a Manual 3 J aw Chuck 53 Bar Feed Hole for Longer Length Billets a 54 Pneumatic Chuck Operation s a 54 Pneumatic Tailstock Operation saris casas answnan na a A a AN a 54 Section 7 Maintenance Planning Procedure for Maintenance WOrK csescesessesestecseseeseessessecsseseesssneesessecetesneeneesnssnmssesseeeseatses 55 Maintenance LOG westerns a 56 General Work Area Cleaning w99 Lubrication Chart asss a 59 Maintenance Schedule a 60 Cleaning and Inspecting the X Axis Ballscrew and Slideways 61 Cleaning and Inspecting the Z Axis Ballscrew and Slideways 62 Inspecting the X Axis Datum Se nsorswitch s s s aa 63 Inspecting the Z Axis Datum Sensorswitch Inspecting the Z Axis Overtravel Microswitch sh X Axis Ballscrew Lubrication serres aa 66 Z Axis Ballscrew Lubrication 67 X Axis Slideways Lubrication a 68 Z Axis Slideways Lubrication sss n 69 Checking the Condition of the Gib Strips 70 X Axis Gib Strip Adjustment 71 Z Axis Gib Strip Adjustment uo 3 Maintenance of the Automatic Indexing Toolpost weed Spin
72. ndow and the computer being used as the controller unit which should be angled towards the user as shown in the diagram DECESE T X below l l l Fn Sufficientroom should also be provided for effective maintenance to be Dimensional Data eae Machine width carried outaround the machine itself particularly atthe headstock end 1000mm 39 3 8 to allow for removal of the cover plate We recommend the separate Machine height guard electrical control box is sited under the machine table leaving a space door open of atleast 1000mm 40 to allow full opening of its frontaccess door ae lace the Mirac PC or electrical control box in a position which Machine depth Do notplace the Mirac PC or electrical control box in a position whic 610mm 24 allows any of the vents or fans to be covered Ensure all cables pipes Electrical control box and flexes are routed to avoid the possibility of users tripping over width them 600mm 23 5 8 Computer desk Electrical control box monitor keyboard h 7 eight and mouse angled Denford Mirac towards Operator 80mm 30 3 4 Electrical control box depth 360mm 14 1 8 PC CNC lathe Electrical Control Box under table LY N Machine D Operator Electrical Control Box access door shown open dotted Plan View showing Ideal Machine Operating Positions Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 15 3 Lev
73. ng Isolator switch Dimensions A 1000mm 39 3 8 i B 610mm 24 he C 565mm 22 1 4 L D 745mm 29 3 8 E 495mm 19 7 16 tt F 955mm 37 5 8 Max machine width 1000mm 39 3 8 Max machine height guard door open 955mm 37 5 8 Max machine depth 610mm 24 Electrical control box width 600mm 23 5 8 Electrical control box height 780mm 30 3 4 Electrical control box depth 360mm 14 1 8 Weights Machine weight 220KG 485 lbs Electrical control box weight 70KG 154 lbs Electrical Details Mains supply required 50 60 Hz 1 Phase 240 Volts Spindle motor 0 75 KW 1 5 HP AC Axis stepper motors 200 steps rev Mirac PC Series CNC Lathe User s Manual Section 10 Appendix 97 10 What is 98 Appendix Section 10 a Part Program A PartProgram is a listof coded instructions which describes how the designed part or component willbe manufactured This part program is also called the CNC File These coded instructions are called data a series of letters and numbers The part program includes all the geometrical and technological data to perform the required machine functions and movements to manufacture the part The part program can be further broken down into separate lines of data each line describing a particular set of machining operations These lines which run in sequence are called blocks A block of data contains words sometimes called codes Each word re
74. ng Denford S W Flashing E whilst Flash memory is being erased and mint MEX file is being downloaded When Mint is running and Denford Software is connected Note that these figures relate to axis 0 specifically ie the X axis g Saana Axis is enabled El ENNERT Flashing E A general error has occurred possible Mint failure Z CEANN A SPLINE move is being executed T Sneipas A circular move is being executed E Arari A Flying shear used in lathe threading moves is being executed EER Axis is in homing sequence raadas Axis is performing a positional linear move ete S Flashing sequence Emergency Stop has been pressed On Denford S W this is a solid S symbol Mirac PC CNC Lathe User s Manual Section 8 Machine Electronics 85 8 NextStep Electronics Troubleshooting Warning BES The spindle drive is not working A Check the validity of the following Never attempt to 1 Check the emergency stop button is notdepressed access the electronic 2 Check the spindle drive fuse labelled F 3 on the main fuse rack hardware systems of the machine with the 3 Check the primary control transformer fuse labelled F 1 on the main mains power switched fuse rack ON 4 Check the secondary control transformer fuse labelled F 5 on the Note that hazardous main fuse rack voltages can still exist i immediately after In addition referto the electrical schematic diagrams to confirm specific sw
75. nk serial cable 25 9 pin connection cable including built in crossover Note thatthe CNC machine controller PC notincluded as standard e 1x Guard door interlock switch 1x Operators toolkit metric allen hex keys and spare fuse package e 1x Manual chuck supplied fitted with a set of internal and external jaws e 1x3 jaw chuck key e 1x Manual toolpostwith standard toolholder supplied fitted 1x Toolpost hex wrench e 1xCNC machine warranty pack e 1xCNC machine inspection certificate 1xCNC machine manual this book plus additional OEM product manuals as required 1xCNC machine control software manual e 1xCNC machine control software CD ROM and or floppy disks e Machine commissioning and basic instruction e 1Day training course for 2 persons at Denford Limited UK Section 1 Introduction 9 1 Before Beginning to Setup The following optional equipment may also be supplied with your Mirac PC CNC lathe please refer to your separate order documentation for confirmation The standard equipment listed here is correct at the time of printing November 2002 but is liable to change through continuous development of our products Please refer to your invoice for the definitive list of standard equipment shipped with your machine 10 Introduction Section 1 Machine controller IBM or 100 compatible PC keyboard mouse and monitor Programmable 8 station indexing t
76. ntrol Axis Definitions Jog Mode a Manually Control M Codes J og Mode a 36 Requesting a Tool Change Jog Mode a 36 Running a CNC Program Auto Mode a 37 Option Spray Mist Coolant System Opening the Safety Guard Door a 38 Front Machine Operators Panel sscsicecsvesscessceustescessatsavcsundsaseessbiaccsuatiasyvitiaedevaviscvevabinudcuatiaavevab eter ach vat bedevtdiad 39 Section 5 Preparing Tooling Hardware Quickchange Manual Tooling System Introduction cseecsesseeseeseeseesneeseesneesneesneesneesneesneesneesneesneesnesnses 41 Quickchange Tooling Fitting Tools sss a 42 Quickchange Tooling Fitting a Tool to the Toolholder a 42 Quickchange Tooling Toolpost Body Angle Adjustment a B Quickchange Tooling Fitting the Toolholder to the Toolpost Body Quickchange Tooling Toolholder Height Adjustment cseeeee as Quickchange Tooling Requesting P rogramming a Tool Change sssssccececcccccccccncncnsnnsnn 46 Mirac PC Series CNC Lathe User s Manual Contents 3 Contents Section 5 Preparing Tooling Hardware continued Automatic Indexing Tooling System Introduction Automatic Tooling Fitting Tools i Automatic Tooling Fitting a Diameter Turning E xternal Working Tool Profile to the Toolpost ies Automatic Tooling Removing a Diameter Turning E xternal Working Tool Profile to the Toolpost wee 49 Automatic Tooling Fitting an E
77. ocketon 8 Rotate the isolator switch on the electrical control box door one quarter turn clockwise from its off 0 position to its on I position shown below You should hear the Mirac PC begin its power up routine 9 Switch on the machine controller PC and start the CNC Control Software Establish a communication link with the Mirac PC please refer to your separate CNC Control Software User s Manual for details outlining this procedure To supply mains power to the CNC lathe Isolator Position 0 Power OFF Isolator Position I Power ON Ifthe Mirac PC does not power up turn the isolator switch to its off 0 position then check all connections and fuses to see that proper power and communication is established to the CNC lathe 32 CNC Machine Operation Section 4 Mirac PC Series CNC Lathe User s Manual 4 Switching the Mirac PC Off Warning Biles Follow these instructions to switch off your Mirac PC CNC lathe 1 Waitfor the Mirac PC to fully complete any machining or processing A of any operational instructions Never attempt to access the electronic 2 Open the guard door and remove any finished parts from the hardware systems in working area the CNC lathe or atin i electrical control box 3 To close down the communication link between the CNC lathe and with the mains power your PC exitthe CNC Machine Controlling Software as switched ON described in your separate CNC
78. oken on delivery inform the suppliers immediately The seal should only be broken for the initial mains power connection The Mirac PC is delivered with standard mains specification cable connected directly into the isolator The cable should be fitted with a standard 13 amp plug suitable for the mains power supply Allelectrical connections should be completed by suitably qualified electrical engineers Mains supply required 50 60 Hz 1 Phase 240 Volts Cable required 3 Core 2 5mm per core Spindle motor 0 75 KW 1 5 HP AC Axis stepper motors 200 steps rev Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 23 3 Opening the Electrical Control Box Warning Taxy fpoweris being supplied to the Mirac PC turn the isolator switch counter clockwise to the off 0 position AN To cut mains power to the CNC lathe Never attempt to access the electronic hardware systems in Isolator Position 0 the CNC lathe or oN Power OFF electrical control box L Isolator Position I Power ON with the mains power switched ON Note that hazardous ort Using the supplied key turn the top and bottom door locks one quarter switching ve the power Counter clockwise then open the electrical control box door Note the if the machine has safety warning left before commencing work Once the work has been previously been completed close and lock the door before attempting to power up th
79. olant system M13 Coolanton and spindle forward optional spray mistcoolantsystem M14 Coolanton and spindle reverse optional spray mistcoolant system 6 Opening the Safety Guard Door A closed machine door cannot be opened when The machine is switched off ie not in use To release the interlock guard switch supply power to the machine The emergency stop button is fully pressed in To release the lock push in and tum the emergency stop button counter clockwise until it springs back out to its ready position Machining is taking place The interlock guard switch will release when the machining Operations have been completed and the machine controlling software is operating in J og Mode 38 CNC Machine Operation Section 4 Manual Safety Guard Door Open the door manually using the handle positioned below the front viewing window Pneumatic Safety Guard Door The control for the optional pneumatic guard door is a square green push button mounted on the front machine operators panel When the CNC control software is operating in Home or og Mode press the button to open or close the pneumatic guard door The following Miscellaneous Function codes can be programmed to control the optional pneumatic guard door M38 Guard Door Open M39 Guard Door Close Mirac PC Series CNC Lathe User s Manual 4 Front Machine Operators Panel The frontoperators panel contains the following contr
80. ols listed from left to right when looking at the panel Axis Limit Switch Override Pneumatic Guard Door optional e Emergency Stop Feedrate Override Spindle Speed Override T FEEDRATE SPINDLE OVERRIDE OVERRIDE GUARD Axis Limit S witch Override The axis limit switch override control is a square green push button If the Z axis limit switch has been activated press and hold the axis limit switch override button whilst jogging moving the axis away from the switch using the Z axis jog key Pneumatic Guard Door optional equipment The control for the optional pneumatic guard door is a square green push button When the CNC control software is operating in Home or J og Mode press the button to open or close the pneumatic guard door Mirac PC Series CNC Lathe User s Manual Section 4 CNC Machine Operation 39 4 Front Machine Operators Panel Note aX Activating an emergency stop will also trigger the interlock guard switch This will prevent a closed safety guard door from being Opened Spindle Speed and or Feedrate override changes will only be registered when an actual spindle speed or feedrate is being applied by the CNC control software Warning A Never attempt to open the safety guard door and enter the working area when the spindle or machine axes are moving Lax 40 CNC Machine Operation Section 4 Emergency Stop Button The emergency stop butto
81. on Tay The limit microswitch used to control overtravel on the Z axis is Look under the top of the left flexible cover maintenance free and mounted behind the upper slideway on the bed casting atthe headstock end of the machine Its position usually prevents swarf and debris from building up around the microswitch mechanism However the switch may require cleaning when the machine has been used in extreme operating conditions Using a soft bristled brush carefully clean any swarf and debris away from the switch to a location where itcan be removed from the working area Carefully inspect the switch for damage or wear particularly the moveable contact pointer The trigger for the limit microswitch is mounted under the back left side ofthe saddle Using a soft bristled brush carefully clean dust and debris away from the trigger to a location where it can be removed from the working area Inspectthe trigger for damage or wear Mirac PC CNC Lathe User s Manual Section 7 Maintenance 65 7 X Axis Ballscrew Lubrication Location Beles The X axis ballscrew runs centrally from top to bottom along the i underside ofthe cross slide The ballscrew cannot be directly ook at the top of a cross slide behind the lubricated since itis fully enclosed by the saddle and cross slide toolpost metalwork To lubricate the ballscrew remove the circular plastic A blanking plug in the middle of the cross slide cover
82. ontrol box door Check the condition of the isolator switch and fuses For more information refer to Section 8 Machine Electronics 3 Startthe VR CNC Turning software from the defaultinstallation click Start Programs Denford VR Turning From the main menubar at the top of the VR CNC Turning software screen click Setup Setup Machine Parameters You may be required to enter a password The default password is denny Type the password and click OK The Machine Properties window will open You can configure the type name of CNC lathe attached to your controller computer and any COM portsettings from this window continued Mirac PC Series CNC Lathe User s Manual 9 Troubleshooting VR CNC Turning Software Any optional equipment fitted to your CNC lathe can be configured using the Options available in the Machine Properties window Warning A Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk EEE Always refer to your electrical schematic diagrams for the definitive labelling and placement of components and fuses Information contained on this page is correct at the time of printing November 2002 but is liable to change through continuous development of our products Mirac PC Series CNC Lathe User s Manual mag 4 The Machine Properties window will open
83. or create the CNC program see section 4 pages 34 and see Note left Control Software User s Manual C Configure the tooling files in the CNC Control Software see Note left D Simulate the CNC program in 2D or 3D see Note left E Establish communications and home the CNC machine see Note left F Prepare any tooling hardware for the Mirac PC see section 5 pages 41 to 51 G Load the billet into the chuck see section 6 pages 52 to 54 H Configure the workpiece and tool offset files see Note left Manufacture the part see section 4 pages 38 to 40 and Note left 28 CNC Machine Operation Section 4 Mirac PC Series CNC Lathe User s Manual 4 Mirac PC Cabinet Component Locations Front 3 4 View Photograph features optional equipment Enclosed safety Location of equipment Spindle guard door Toolpost indicated but item not shown drive in photograph Removable headstock end panel Safety guard door locking switch Front operators panel from left to right axis limit switch override pneumatic guard emergency stop button feed override spindle override Front and rear Safety guard machine cabinet door handle support feet sections Back 3 4 View Photograph features optional Enclosed safety equipment guard door Location of equipment indicated but item not shown in photograph O Female P connector plugs for cables
84. ore information refer to Section 8 Machine Electronics 3 The DOS CNC Turning software is started by executing the FLSTEP GO file Check the COM port being used on your machine controller computer matches the COM port number specified inthe FLSTEP GO file If you are unsure assume the COM port being used is COM1 The GO file can be opened using Notepad on a Windows system Find the line ending with the word MACHINE If the Denford Machine Link cable is plugged into COM1 the line should read 3F84MACHINE Ifthe Denford Machine Link cable is plugged into COM2 the line should read 2F 8 3 MACHINE Change the line to read the correct portnumber being used then save the file 4 Remove the HIMEM SYS line from the CONFIG SYS file Often times environmental factors will interfere with proper communication continued Mirac PC Series CNC Lathe User s Manual Section 9 Technical Support 91 9 Troubleshooting DOS CNC Tuming Software 6 EuroStep Controller Cards Check the LED display status on the EuroStep Motion Control Board the main card on the electrical panel For more information refer to Section 8 Machine Electronics A problem with this card can cause problems with communications Look forthe LED display mounted on the main control card A blinking dotwith an L or the number 8 should be shown Ifthe LED is notlit check the control board fuse Ifno display continues to be shown call Denford Customer Ser
85. osed pointing away from the centre of the toolpost Double flanged locknut open pointing towards the centre of the toolpost Double flanged locknuts continued Mirac PC Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 43 5 Quickchange Manual Tooling System Fitting the Toolholder to the Toolpost Body continued Tvoga XF 2 Aligning the guides on the toolholder with the guides and spring A loaded bracket on the toolpost body slide the toolholder down into TEE the toolpost bracket shown below left Lower the toolholder until guard bid andenter the single flange on the toolholder height adjustmentscrew is level the working area when with the space between the two flanges on the toolpostlocknut the spindle or machine shown below right axes are moving ES Slide the toolholder onto the toolpost then align the single flange 3 Turn the toolpostlocknut so the single flange on the toolholder height adjustment screw is loosely held between the two flanges on the toolpostlocknut Atthis stage do notfully tighten the locknut since this will prevent any toolholder adjustment from being carried out Turn the locknut to its closed position holding the toolholder in position 44 Preparing Tooling Hardware Section 5 Mirac PC Series CNC Lathe User s Manual 5 Quickchange Manual Tooling System Toolholder Height Adjustment FOEI cx 1 Usinga4mmallen hex key
86. oving View knurled collar View knurled collar Direction CW Direction CCW 4 Tighten the double flanged locknuton the toolpost body turn clockwise then screw in and tighten the lockbolt on the toolholder heightadjustment screw turn clockwise Requesting Programming a Tool Change Torx y The Miscellaneous Function M06 is used to program a tool change operation Please refer to Section 4 CNC Machine Operation pages M codes for manual control of optional 36 and 37 for further details pneumatic equipment M10 Chuck open vice M11 Chuck close vice M25 Tailstock quill extend M26 Tailstock quill retract M38 Door open safety guard door M39 Door close safety guard door 46 Preparing Tooling Hardware Section 5 Mirac PC Series CNC Lathe User s Manual 5 Automatic Indexing Tooling System Introduction The optional Automatic Indexing Toolpost designed to automatically change cutting tools is driven by an electric motor and controlled using M codes Each numbered toolpoststation or slot is designed to contain one tool holder which in turn contains the cutting tool profile Even numbered circular hole stations are used for end internal tool profiles Odd numbered straight slot stations are used for diameter turning external tool profiles This will directly affect how tool numbers are assigned to the cutting tool profiles used by your CNC program
87. p oil directly into the oiling points Run the cross slide up and down the full length of the X axis to distribute the oil along the slideways 68 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 Z Axis Slideways Lubrication Location The two Z axis slideways are located on the upper and lower sides of Look at the right edge the bedway and the saddle To lubricate the slideways use the outer of the saddle two of the three oiling points mounted on the right edge ofthe saddle as shown below Using a pump action oilcan pump oil directly into the oiling pone Upper Slideway Right d PT Oito ront side of saddle Run the machine saddle leftand rightalong the full length of the Z axis to distribute the oil along the slideways Mirac PC CNC Lathe User s Manual Section 7 Maintenance 69 7 Gib Strip Adjustment A gib strip is an section of metal or plastic which is fitted to one side ofa machine slideway One gib strip is fitted to each of the two machine axes on your Mirac PC Each gib strip is tapered along its length The gib strip can be driven along the slideway to decrease the amountof free play in the axis using a locking and adjusting screw arrangement During the day to day use of your Mirac PC wear will occur in each of the gib strips This wear is normal and if checked regularly will not affect the performance of your machine Denford recommends thatthe gib strips be checked annually Any Slack pres
88. r 37 systemi fitting tOOIS irinna 47 Auxiliary input output SOCKet essere 25 AXIS CefIMITIONS asenin e ieas 35 Axis limit switch override ssssssssssirissss 39 B Ballscrew maintenance x axis cleaning and inspection sssr 61 X AXIS TUDTICATION saanuna 66 z axis Cleaning and inspection sses 62 2 akis lubrication 67 c Chuck manual par feed holeccrsccestiarainntaiaainnatien 54 COMPONENTS riia aa 52 fitting the billet mai irnir 53 mounting and removal ssiri 52 Chuck pneumatic operation 54 Cleaning DallSCKOWS innin 61 protective coatings upon delivery 25 SIIDQ WAYS sniuasisannusin SWILGN OS diese eean ONTAN NNE CNC definition and overview sssi 8 Co ordinate display systems c see 34 Connecting a compressed air SUPPLY eeeseeseeseeseeeee 19 Machine power cable sssi 22 Machine signal cable sssri 22 mains supply cable eee 23 schematic diagram eeseseeeerrrerrr 26 the PC to the CNC lathe sssrin 16 Contact information css 2 D Denford directives ssssesssssssecsssesssseeesessns 103 Dimensional data DISCIAIM CG Taari anaita Mirac PC Series CNC Lathe User s Manual E EC declaration of Conformity cscs 105 Electrical control box auxiliary input output socket 12 layout eurostep controller 79 layout nextstep controller OPENING s aa 24 Electrical diagrams wees 24 Electronics eurostep motion controller eee 79 nextstep motion controller a 83
89. r Mirac PC CNC lathe What is CNC arinta n Before Beginning toS tp cciscccccaisccavcevixcgecavssczvcesixcguaassucsevsin a E teresa tested td Section 2 Safety Features Safety Features Overview and Precautions c sessecsecsecsecseeseessessesuseessesusesusesuscsusessesusesusesueesueesueesnesnees 11 Emergency Stop Button 1 Interlock Guard Switch Section 3 CNC Machine Installation won Unpacking and Lifting your Mirae PGosscscccsssavscesbuateesscsavzesstuatsdzvmsansvesbinseszartsnrsnsbiaesszaviansgecbinesdzactaniensbinesdzatbaatexe 14 Deciding on a Site for our Mirac PC indo Levelling your Mirac PC sses a 16 Connecting your PC to the CNC Lathe Option Compressed Air Connection Electrical Control Box Cable Connections Connecting the Machine Power Cable Connecting the Machine Signal Cable Connecting the Mains Supply Cable Opening the Electrical Control Box Electrical Diagrams wees Option Auxiliary Input Output Socket Removal of Protective Coatings Component Connection Schematic Diag Section 4 CNC Machine Operation Using your Mirac PC Overview a 28 Mirac PC Cabinet Component Locations Electrical Control Box Component Locations si Working Area Component Locations w 31 Switching the Mirac PC On 32 Switching the Mirac PC Off i Homing the Machine Axes Home Mode Co ordinate Display Systems All Modes Manual Co
90. rac PC electrical control box A 1 Connectthe elements of your PC together as described in your original PC manufacturers operating manual At this stage your Do Not connect cables PC should not be switched on between any electrical hardware with the 2 The PC mustbe physically connected to the separate electrical mains power switched control box using the supplied Denford machine Link cable This is iN H the long thin serial link cable fitted with a 25 pin D male connector at components inside one end and a 9 pin D female connector atthe opposite end as your CNC lathe shown below right 3 Connectthe 25 pin D male end ofthe RS 232 cable to the 25 pin D female port mounted on the electrical control box as shown below left This portis labelled RS 232 Denford Machine Link Cable Location X RS 232 connector for the Denford Machine Link cable on electrical control box end panel 9 Pin D 25 Pin D Female Male Connector Connector 25 pin D male 25 pin D female connector fitted to connector fitted to Denford Machine electrical control Link cable box end panel PC Terminology The COM ports on your PC may be labelled as Serial ports Most COM ports have a 9 pin D MALE connector though some older computers may be fitted with additional PCI COM cards having a 25 pin D MALE connection In this case a 9 to 25 pin adaptor cable can be added to the Denford Machine Link cable supplied with your CNC lathe
91. rd door can be specified together with additional tooling and workholding packages allow each machine to be individually configured according to your requirements see page 10 for options All Mirac PC CNC lathes are supported by courseware CAD CAM software and comprehensive operation manuals Designed specifically for Education and Training e Manufactured to industrial standards Capable of cutting resistant materials such as wax plastics acrylics copper aluminium and steel e Links to a range of CAD software eg AutoCAD Pro DESKTOP Techsoft via QuickCAM turning software or with Lathe Cam Designer introductory CAD CAM software Totally enclosed high visibility interlocked guard Feedrate and spindle speed override controls CE approved for safety Flexible workholding capabilities Optional software allows programming via ISO Format incorporating controls such as FANUC e Option ofinclusion in FMC FMS CIM systems Mirac PC Series CNC Lathe User s Manual Section 1 Introduction 7 1 What is CNC 8 Introduction Section 1 CNC Computer Numerical Control is the general term used for a system which controls the functions of a machine using coded instructions processed by a computer CNC machines are a very important part of the modern manufacturing process Indeed many of the different types of products you use everyday have been made using some sort of CNC machine The CNC Manufacturing
92. rew cleaning and inspection 61 general work area cleaning a59 lO iiai a56 lubrication chart 59 planning procedure m99 schedule sii 60 slideways cleaning and inspection 61 switch cleaning and inspection 63 x axis ballscrew lubrication 66 X AXIS gib Strip coe will x axis slideways lubrication 68 z axis ballscrew lubrication 67 Z AXIS gib strip eee ned z axis Slideways lubrication 69 Manufacturing a part Overview sss 28 N NextStep electrical control box layout usss 83 led status codes sssi 185 motion control board 84 troubleshooting 86 Noise level test results seserinis 107 0 Opening the electrical control box sssi 24 Opening the safety guard door 138 Operators panel eee 39 Optional equipmen y Overriding the spindle speed or feedrate 40 P Part manufacture checklist sssi 37 Part program address Characters sssi 102 composition 199 definito ser reais 98 PC connections to your CNC lathe 16 Pneumatic equipment control codes use 20 Q Quickchange manual tooling system fitting a tool to the toolholder wee 42 fitting the toolholder to the toolpost 43 IMLFOCUCTION eserci wAl requesting a tool change a37 system fitting tools eects 42 toolholder height adjustment s s s 45 toolpost body angle sdjustment s s s 43 114 Index Section 12 Removal of protective coatings sses 25 Running a CNC program
93. sition The interlock guard switch is mounted on the rightend panel ofthe CNC lathe cabinet Check the following 1 Mains power is reaching the CNC machine Check the mains plug is fitted to an available power socket and the socketis switched on Check the mains power isolator on the electrical control box door is switched on 2 The emergency stop button is not pressed in To release push and turn the button counter clockwise until it springs back out to its ready position 3 No CNC program is running Waitfor all machining operations to finish then switch the software to operate in jog mode 9 Troubleshooting Electrical Problems Please refer to Section 8 Machine Electronics 94 Technical Support Section 9 Mirac PC Series CNC Lathe User s Manual 9 Troubleshooting Cutting Problems The part is being cut at an incorrect depth Check the validity of the following 1 The Z value entered in the tool length offset 2 The Z value entered in the workpiece offset file 3 The number size used for defining the depth of cutused in your CNC program 4 The sign or used for defining the depth of cut used in your CNC program If your workpiece datum is aligned with the upper surface of your billet any Z values cutting into this billet will have a minus sign The machine begins cutting the part at the wrong location Check the following 1 The workpiece and tool offsetfiles have been configured and applied su
94. te position values are displayed relative to the fixed machine datum The co ordinate display always shows the true position of the machine Work Piece Co ordinates Display System The co ordinate position values are displayed relative to the programmed moveable workpiece datum described through use of the offsetfacility Offsets temporarily shiftthe entire co ordinate based grid system of the machine Itis common to configure the workpiece datum as the location from which all machining co ordinates will be taken Mirac PC Series CNC Lathe User s Manual 4 Manual Control Axis Definitions J og Mode The keys for manual axis movement will depend on the type of CNC control software being used please refer to your separate CNC Control Software User s Manual for specific details mex Diagram showing Axis Definitions Z Axis The centre of the Z axis runs along a line between the spindle and tailstock or in other words the centreline of rotation of the spindle parallel with the longest edges of the bedways Minus Z movements of the toolpost are left towards the headstock area of the machine ie towards the chuck face Positive Z movements of the toolpost are right towards the tailstock area of the machine ie away from the chuck face X Axis The X axis runs at 90 degrees to the Z axis or in other words perpendicular to the Z axis parallel with the longest edges of the cross slide Minus
95. ted and secure Tools prepared and numbered ready for use according to your CNC file Safety guard door closed CNC file loaded and checked via simulation Workpiece and Tool Offset files configured or loaded Machine homed datumed CNC control software switched to Auto mode Section 4 CNC Machine Operation 37 4 Option Spray Mist Coolant System Note M codes can be manually entered for immediate operation when the machine controlling software is operating in J og Mode or called automatically when written into a CNC program that is subsequently run in Auto Mode The air compressor mustbe switched on in order to use the optional spray mistcoolantsystem Ifnecessary open and setany air connections see Section 3 CNC Machine Installation pages 19 to 20 Open the coolanttap and position the flexible coolant delivery pipe so no moving part of the machine or workpiece can collide with it Coolant is delivered to the flexible pipe from the resovoir container mounted on the back panel of the machine Ensure that the coolant level is always between the minimum and maximum marks indicated on the resovoir Top up with Cincinnati Millacron Simcool 60 coolant dilution minimum 2 5 he following M codes call the miscellaneous functions used to manually control the optional spray mist coolant system M08 Coolant on optional spray mist coolant system M09 Coolant off optional spray mist co
96. ter corrugated cable which connects to the right bracket on the back panel of the Mirac PC cabinet 2 The machine signal cable the smaller diameter corrugated cable which connects to the left bracket on the back panel of the Mirac PC cabinet 2 The mains supply cable the thin standard electrical cable Machine Machine Signal Cable Power Cable Male Plug Male Plug Electrical Mains Control Supply Cable 3 Signal Cable 2 Machine Power Cable 1 Back panel i Machine Machine eet ie Signal Cable Power Cable j Female Female Connector Connector Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 21 3 Connecting the Machine Power Cable Warning ax A Do not fit the male and female connector plugs together the wrong way round This could damage the connector pins The male and female connector plugs are shaped so they can only be connected in the correct orientation the cutaway parts of the connector housings and the numbered segments printed on the pin faces must match in order to achieve an electrical connection The machine power cable must be connected from the electrical control box to the machine The machine power cable is housed in the larger black corrugated hose approximately 30mm in diameter The connector housing is fitted with two horizontal pins on the top and two horizontal pins on the bottom One end of th
97. the maintenance work work maintenance completed 58 Maintenance Section 7 Mirac PC CNC Lathe User s Manual 7 General Work Area Cleaning Safety First T X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Safety First Xf 0 A Caution If the cutting tool has been recently used it may still be HOT Thoroughly clean and lubricate the CNC machine paying special attention to the working area according to the Maintenance Schedule listed on page 60 In particular ensure the build up of swarf and debris in the following areas is prevented e The Z axis ballscrew running parallel to the front of the machine between the two Z bed slideways The two Z axis slides partially enclosed by the saddle and the two flexible corrugated black covers The Z axis datum sensor switch mounted behind the right upper side of the bedway casting TheZ axis overtravel microswitch mounted behind the left upper side of the bedway casting The X axis ballscrew running parallel to the sides of the machine between the two X saddle slideways e The two X axis slides either side of the saddle covered by the cross slide casting The X axis datum sensor switch mounted behind the coverplate at the rear of the toolpost The chuck and optional tailstock The components of the tooling system 7 Lubrication Chart
98. the three cap head screws counter clockwise to remove them and withdraw the cover plate as shown below B re Right ol side of cross slide Location Ex 2 Using a 5mm allen hex key Look at the right top loosen the gib strip locking corner of the saddle screw aboutone half with the cross slide revolution to release the gib cover plate removed strip The gib strip locking screw is positioned behind the right top corner of the saddle as shown right Turn in a counter clockwise direction to loosen the screw continued Mirac PC CNC Lathe User s Manual Section 7 Maintenance 71 7 X Axis Gib Strip Adjustment Location Tax 3 Using a 5mm allen hex key adjust any free play in the X axis by i i tightening the gib strip adjustment screw one half revolution The ook at the right bottom DIX ae comer of the saddle adjusting screw is positioned atthe right bottom corner of the tr saddle as shown below 5 e Adjusting A Screw Turn in a clockwise direction to tighten the screw Donot overtighten this screw A slight degree of movement must be left in the slideway to allow X axis movement 4 Re tighten the gib strip locking screw Turn in a clockwise direction to tighten the screw 5 Traverse the cross slide up and down along the saddle to ensure thatthe X axis movementis smooth 6 Continue points 1 to 4 until all slack has been eliminated from the X axis Replace
99. tings must be removed to prepare the machine for A running Potential risk of ignition 1 The protective plastic sheeting on the guard windows should be explosion removed and the glass and perspex cleaned with an antistatic Do not use any aerosol cleaner based flammable products to lubricate 2 Remove any optional equipment boxes together with any internal your CNC lathe packaging used to preventmovement of components within the Carefully read and working area during transit Apa Lae To gain entry to the working area of the machine power mustbe lubrication products Supplied to the machine in order to release the switch that locks the Safety guard door Insert the mains supply plug into an available socket then power up the machine using the mains isolator switch mounted on the front door of the electrical control box 3 Before using the Mirac PC the protective coatings applied to the Slideways and brightsurfaces must be removed using a kerosene based solvent No notattemptto move the CNC lathe axes until all protective coatings have been removed Once all protective coatings have been removed all untreated surfaces should be coated with a light covering of machine oil grade BP CS 68 Only use kerosene based solvents in accordance with the solvent manufacturers instructions and safety recommendations Ensure thatno naked flames are present and adequate ventilation is provided To avoid the potential risk of igni
100. tion explosion ensure that all solvent vapours can exit fully from any enclosed areas on the CNC lathe Waitatleast1 hour before attempting to operate the Mirac PC Mirac PC Series CNC Lathe User s Manual Section 3 CNC Machine Installation 25 3 Component Connection Schematic Diagram Ancillary Equipment such as this printer connects to the Parallel port on the PC Personal Computer ee dl oe e y ICOM z Security Key dongle when required Denford Machine Link Cable PC Terminology The COM ports on your PC may be labelled as Serial ports Most COM ports have a 9 pin D MALE connector though some older computers may be fitted with 25 pin D MALE connectors Desktop Tutor when The Parallel port on your PC may be labelled as the Printer ordered connects to port The printer port has a 25 the PC port labelled pin FEMALE connector and COM 1 should only be used for connection of the security key dongle when supplied 26 CNC Machine Installation Section 3 Mirac PC Series CNC Lathe User s Manual 3 Component Connection Schematic Diagram Denford Mirac PC CNC Lathe y Machine W Power ss Connector Machine Signal Connector Mains Power Supply Plug Denford Machine Link Cable lt he Denford Machine Link cable i connects the electrical control box to Mirac PC he PC port labelled COM 2 Electrical he Denford Machine
101. tion 10 Appendix 99 10 G Codes List Note NotallG codes may apply to yourCNC machine GCode Group Function GOO a aira Positioning Rapid Traverse GOL wa Tini Linear Interpolation Feed G02 wae ieee Circular Interpolation CW G03 we Tarinan Circular Interpolation CCW G04 we O tignan Dwell G20 aes Pasioa Inch Data Input G2I Diret Metric Data Input G28 ves Dremani Reference PointReturn G40 s Teena Tool Nose Radius Compensation Cancel GAL Torrini Tool Nose Radius Compensation Left G42 ws i arene Tool Nose Radius Compensation Right G50 wee Ounces Work Co ordinate Change Max Spindle Speed setting G70 veces Orie Finishing Cycle G7 liris Onani Stock Removal in Turning X G codes from group 0 G72 eere Oinaan Stock Removal in Facing Z are non modal they GIB iii Ontur Pattern Repeating a cline GI nas Ohare ae Peck Drilling in Z Axis bioek wher teauiea GIS sors O vrrrststnn G rooving in X Axis All other G codes are G78 sss Oiana Multiple Thread Cutting Cycle modal they remain G81 we Tiei Deep hole drilling No FANUC n AA G90 wee Tonihi Diameter Cutting Cycle A Outer Inner blocks unti replaced or 0 asies Prena Thread Cutting Cycle cancelled by a G code G94 sns A erence Cutting Cycle B End Face Cycle from their particular G96 wae Dried Assessed Surface Speed Control ee eat G9T ae Daihen Assessed Surface Speed Control Cancel byah astek Mare GIBA see PD etnies Feed Per Minute reactivated as defaults G99 ee eases Feed Per R
102. tool A Part Program is a list of coded instructions which describes how the designed part or component will be manufactured The part program is also referred to as the CNC file program or G and M code program A G and M code is a series of letters and numbers that make up the language used by CNC machinery Mirac PC Series CNC Lathe User s Manual 1 Before Beginning to Setup The standard equipment listed here is correct at the time of printing November 2002 but is liable to change through continuous development of our products Please refer to your invoice for the definitive list of standard equipment shipped with your machine Short 9 25 pin serial link adaptor cables can be used to convert the Denford Machine Link cable connectors according to the type of COM port fitted your computer Mirac PC Series CNC Lathe User s Manual Before beginning to setup your Mirac PC CNC lathe please check your separate order documentation making sure thatall items have been delivered to your establishment Any missing or damaged items should be reported to Denford Customer Services as soon as possible The following equipmentis supplied as standard with your Mirac PC Denford Mirac PC CNC lathe Note thatthe precise specification of your Mirac PC will depend on any options selected at the time of ordering Separate electrical control box e 1x Electrical control box key e 1x Denford Machine Li
103. troubleshooting 1 94 Emergency stop button oss 12 EuroStep electrical control box layout sss 79 led status codes ss Praia motion control board 80 troubleshooting eserse 82 F Feedrate override Control sssini 40 G G COMES liS Erina eaan General layout of electrical control box General layout of Mirac PC cabinet ai General layout of working area wu Gib strip Checking condition Of 70 introduction 10 X axis adjustment will z axis adjustment wel GIOSSORY eniinn E 109 H HomMemo dE ii aiani en iein 34 l Installation levelling your Mirac PC veces removal of protective coatings a Siting your Mirac PC woes unpacking and lifting your Mirac PC 14 Interlock guard SWItCH veces 13 Introduction equipment list auringossa 9 Mirac PC sit What 1S CNC irainei 8 L Levelling your Mirac PC vices 16 Lifting Your Mirac PC ics ssissssicasiasviwssatansaatss 14 Lubrication automatic indexing toolpost sses 75 Chalten uaa a9 x axis ballscrew aa 66 x axis slideways a 68 z axis ballscrew 67 z axis slideways 69 Section 12 Index 113 12 Index M MiscOdeS ills tists nnn N 101 M codes list partial occ 36 Machine co ordinates display system aa 34 Machine power cable connections node Machine signal cable connections w22 Mains supply cable connections sss 23 Maintenance automatic indexing toolpost s s s 75 ballsc
104. ults Test Conditions Spindle speed 3 000 RPM Spindle Direction Counter clockwise Ambientbackground noise lt 61 dB A Spindle Speed Sound Levels dB A Range ks al EENEN SEB Mean Test Conditions Spindle speed 3 000 RPM Spindle Direction Clockwise Ambientbackground noise lt 61 dB A meh EEE ange Ins rev Te 62 62 108 Appendix Section 10 Mirac PC Series CNC Lathe User s Manual 11 Glossary ABSOLUTE iiien In absolute programming zero is the point from which all other dimensions are described ALLENS aniren nk See hex AR E A portion of a circle ATG sates ccetvesiatenssiatetessiotenes Automatic Tool Changer See programmable turret AUTOMATIC CYCLE A mode of control operation that continuously runs a cycle or stored program until a program stop or end of program word is read by the controller AUXILIARY FUNCTION The function of the CNC lathe ie F S T M codes etc other than co ordinate based commands AXIS AXES aniren The planes of movement for the cutting tool usually referred to as Z left and right parallel to the chuck centreline and X forwards and backwards at right angles to the chuck centreline Combinations of both allow precise co ordinates to be described BED iirin iia The base of the CNC lathe BEDWAY Seinnim iiinn The Z axis of the machine BILL Einin The actual material being machined sometimes referred to as the workpiece or stock BL
105. urret in place of standard manual toolpost Spray mist coolant system Pneumatic safety guard door Pneumatic chuck Tailstock Various tooling packages Various workholding packages Machine table Upgrade pack for integration into Denford FMC FMS orCIM systems On screen representation of industrial control systems and optional link to industrial keypad FANUC 21i Video conferencing system CAD CAM software and manuals Additional and or on site training courses Mirac PC Series CNC Lathe User s Manual 2 Safety Features Overview and Precautions Safety Features Overview The following safety features are standard on your Mirac PC CNC lathe Emergency stop button Totally enclosed high visibility guard door with interlock switch Toolpath graphics to verify program prior to machining e Isolator switch Safety Precautions Safety is very important when working with all forms of machinery but particularly when working with CNC equipment due to the hazardous voltages speeds and forces that exist in the hardware Follow the rules below atall times when using your Mirac PC CNC lathe General Safety Precautions e Wear clothing suitable for machine operation and follow the safe working procedures in place at your establishment Do not place any objects so that they interfere with the guards or the operation of the machine e Never try to clean the machine if any part of it is rotating or in motion
106. utthe portis notseen by any external devices 8 Whenallelse fails Thoroughly check the condition of the Denford Machine Link cable Ifthe cable is bad communication will notoccur Try using a different controller computer to connect to the CNC lathe Check for help on the technical support FAQ and download sections of the Denford websites and or contact Denford Customer Services see the details on the first page of this section 90 Technical Support Section 9 Mirac PC Series CNC Lathe User s Manual 9 Troubleshooting DOS CNC Tuming Software DOS CNC Turning Software Communications Troubleshooting 1 Your computer communicates with Mirac PC versions using the Denford Machine Link cable Check the Denford Machine Link cable is securely plugged into a valid COM porton the computer Note thatCOM ports are sometimes labelled as serial ports Identify whether the COM portbeing used is labelled as COM1 or COM2 The opposite end of this cable is securely plugged into the RS232 portlocated on the side panel of the electrical control box 2 Check all mains power connections are correctly fitted and secure Power up the CNC lathe using the yellow isolator switch mounted on the electrical control box door position I on position 0 off If no power is present switch off the mains supply then waitatleast5 minutes before attempting to open the electrical control box door Check the condition of the isolator switch and fuses For m
107. ve labelling and placement of components and fuses Information contained on this page is correct at the time of printing November 2002 but iS liable to change through continuous development of our products 82 Machine Electronics Section 8 Mirac PC CNC Lathe User s Manual 8 Electrical Layout NextStep Controller The photo below labels all important electrical components inside the electrical control box on NextStep controlled CNC lathes Please note thatthe layout of your electrical panel may differ from the photo depending on components and options fitted to your Mirac PC Layout of the Electrical Panels NextStep Controller Ferrite Core iter O a Main Fuse Rack ee Sa Nery alli Ww RY iii NextStep Motion Control Board X Axis Z Axis Drive Drive Board Board Control Transformer al vis Axis Drive Transformer Mirac PC CNC Lathe User s Manual Section 8 Machine Electronics 83 8 The NextStep Motion Control Board Location eax ra N Look on the left side of the middle panel Segment LED Display The NextStep motion control board processes the step and direction signals which are then passed to the separately fitted axis drive units used to control the two machine axes The NextS tep motion control board is mounted on the leftside of the middle panel in the electrical control box 84 Machine Electronics Section 8 Mirac PC CNC Lathe User s
108. vices for assistance Warning Risk of electric shock Note thatin order to check the readout the CNC machine must be powered up with the electrical control box open Exercise extreme caution do nottouch any live electrical components since damage may occur to the hardware or technician inspecting the equipment Remember to shutdown the CNC machine then close and lock the electrical control box door on completion of this step 7 Check the COM porton your controller computer is functioning correctly Consultyour IT person or Computer Support Centre for help with these issues Check the COM portsettings in Windows by accessing the Device Manager Check the com ports enabled and labelled properly in the computer BIOS Check the physical COM portitselffunctional Forexample Windows and the BIOS may show that the COM ports are fine butthe portis notseen by any external devices 8 Whenallelse fails Thoroughly check the condition of the Denford Machine Link cable Ifthe cable is bad communication will notoccur Try using a different controller computer to connect to the CNC lathe Check for help on the technical support FAQ and download sections of the Denford websites and or contact Denford Customer Services see the details on the first page of this section 92 Technical Support Section 9 Mirac PC Series CNC Lathe User s Manual 9 Troubleshooting DOS CNC Tuming Software The FLSTEP GO file The FLSTEP GO
109. w is positioned behind the top right corner of the Screw saddle as shown rightand below y Turn in a clockwise direction to tighten the screw Do not overtighten this screw A slight degree of movement must be left in the slideway to allow Z axis movement Easier access to the locking screw can be obtained by gently pulling the flexible bedway cover away from the upper Z slideway 3 Re tighten the gib strip locking screw Turn in a clockwise direction to tighten the screw 4 Traverse the saddle left and right along the bedway to ensure that the Z axis movementis smooth 5 Continue points 1 to 4 until all slack has been eliminated from the Z 74 Maintenance Section 7 axis Note Ifthe Z axis movementis not smooth loosen the gib strip but this time turn the gib strip adjustment screw counter clockwise to introduce a little slack back into the system Run the saddle leftand right along the bedway again to assess the smoothness of movement Mirac PC CNC Lathe User s Manual 7 Maintenance of the Automatic Indexing Toolpost To maintain smooth operation of the automatic toolpost check the operation and if necessary lubricate the rotating mechansim of the carousel on a weekly basis To lubricate the mechansim of the automatic toolpost carousel use the oiling point mounted on the upper surface of the toolpost body as shown below Using a pump action oilcan pump oil directly into the oil
110. with the name ofthe current active CNC lathe highlighted and its listing expanded Note that there are a number of versions to choose from The active machine name in the software must match the name and version of your Mirac series CNC lathe this information is printed onthe CE identification panel usually applied to the side panel of the electrical control box or end panel of the main machine cabinet F or example if Mirac PC is printed on your CE identification panel the VR CNC Turning software must have Mirac PC setas the active machine Ifthe correct machine name is NOT listed as the active machine rightclick over the required machine name title to display a pop up menu Click Make Active then click OK and restart the VR CNC Turning software Re open the Machine Properties window to check that the changes have been applied 5 Inthe Machine Properties window click the Communications property title Change the COM Port setting to match the number of the COM portbeing used by your pc Note thatthe hardware resources IRQ etc are those specified in the Windows Control Panel The Baudrate must be set to read 19200 Baudrate is the speed at which data can be transferred through your COM ports The Stop Bits mustbe set to read 2 Stop Bits are the data signals sent after each data character has been transferred Click the OK button to save and apply any changes made to t
111. y First 2X A Caution If the cutting tool has been recently used it may still be HOT Automatic Indexing Toolpost When an automatic indexing toolpostis fitted to the Mirac PC the entire sequence will be performed automatically Ensure the correct tooling hardware has been fitted and the tool holders have been placed in the correctnumbered toolpost stations according to the tooling specification described at the beginning of your CNC program see section 5 Preparing Tooling hardware Quickchange Manual Tooling System When a quickchange manual tooling system is fitted to the Mirac PC a message window will be displayed whenever a tool change is required Waitfor all machine movementto stop before opening the Safety guard door then change to the new tool number requested Close the safety guard door and confirm via any CNC Control S oftware message windows that machining can be resumed 4 Running a CNC Program Auto Mode The sequence of events required to begin part manufacture on the Mirac PC will depend on the type of CNC control software being used please refer to your separate CNC Control Software User s Manual for specific details Mirac PC Series CNC Lathe User s Manual Auto mode is used for controlling the CNC lathe when running a CNC program Part Manufacture Checklist Before beginning to manufacture your part check to see that the following tasks have been completed Billetmoun

Download Pdf Manuals

Related Search

Related Contents

Grundig MC 6040  Snapper HZS15423KVE, HZS18483BVE Lawn Mower User Manual  Agilent Technologies Video Gaming Accessories 281 A User's Manual  La communication non violente : mode d`emploi Il n`est pas rare qu  Mode d`emploi    KWC DOMO 10.061.991 User's Manual  Addonics ADCB2SA-E  DVR012取扱説明書  

Copyright © All rights reserved. Failed to retrieve file