Operating Instructions
Contents
1. 17 1 51502320 Gear belt 18 1 51004020 00022 Toothed belt pulley Z12 19 1 51402115 0001 Terminal box 20 2 16191200004030 Screw 21 1 51500706 Terminal clamp 22 1 51500122 Multiphase motor 23 1 Cover guide head stock contained in cabin 24 1 10600616 Bearing cover 25 2 16191200003006 Screw 26 1 51002020 0004 Tailstock stopper 27 2 16191200005012 Screw 28 1 16091300006006 Threaded pin 29 1 51007250 0001 Push piece 30 1 51004035 0007 Setting nut 31 2 51502112 Ball bearing 32 1 10600615 Support bearing rear 33 1 51502517 Lubrication nipple 34 2 16112500008001 Washer 35 2 16191200008025 Screw 36 1 51006940 0001 Support for CNC limit switch 37 1 51007250 0001 Push piece 38 1 16191200006010 Screw 39 1 51500633 0002 End switch 40 2 16191200004020 Screw 37 WABECO MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 3 Cross slide with saddle apron gt s Ls WABELD 16 16 3 Part No co JO TV POD 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Items po 0 sch NYO sch D ck ck BR P sch KS MM CO HR B 099 nnm sch sch sch H ck sch YN HSH ck KH HO 00 Drawings and legends Order No 51007176 0001 16063250005040 16091300006010 16193400006000 51505210 0005 51004020 0014 51502113 106000316 16191200006020 51502113 51004050 0001 51007250 0001 16091300006006 51001017 0003 106007012. Operating Instructions CNC lathe With slant bed CC D6200 hs WABELU MASCHINENMANUFAKTUR seit 1885 WABELD MASCHINENMANUFAKTUR seit 1885 Please read before putting into operation for the first time Every person that operates the machine maintains or repairs it must have read the operating instructions and in particular the safety notes prior to putting the machine into operation Please store these documents for subsequent use Original version in German translation in English Status at 04 2015 Dear Customer With the purchase of the WABECO machine you have decided in favour of a quality tool This machine has been manufactured with the greatest of care and subject to precise quality controls These operating instructions are designed to help you to use your new machine safely and correctly For this reason we ask you to read the appropriate notes through attentively and to take care to observe them After unpacking the tool check whether any transportation damages have occurred Complaints whatever their nature should be communicated immediately Subsequent claims cannot be recognised For all queries and replacement part orders please always specify the machine number see type plate Reprinting and reproductions of any kind even extracts require the written permission of WABECO Disposing of the machine The transportation and protective packaging is made of the following materials Corrugated car
3. The moving of the camlock bolt 2 and thus the removal of the chuck or holding flange is only possible if both markings point to one another Remove the chuck or the holding flange 20 2 Blocking a chuck or holding flange on the camlock main spindle lug Ensure that the markings on the clamping tappets 4 point to those markings on the main spindle 1 Place the chuck or holding flange on the main spindle in doing so insert the camlock bolt 2 into the holes drilled in the main spindle Tighten the three clamping tappets 4 located around the circumference of the main spindle 1 using an Allen key in size 10 mm not included in the scope of delivery so that the chuck or holding flange pulls towards the main spindle 55
4. WABELD MASCHINENMANUFAKTUR seit 1885 14 Operational faults and the elimination of such Operational faults Possible cause Remedy Machine cannot be switched on 230V voltage is not present Plug is not fitted correctly Check the fuse for the socket Emergency off switch not unlocked Unlock the emergency off switch Main spindle motor no longer starts after the unlocking of the emergency off switch Motor controller must be unlocked Wait approx 5 seconds after unlocking the emergency ON OFF switch before reactivating machine with ON OFF switch Also the manual operating field of the software has to be closed and the machine must be reloaded Tool skid cannot be moved or can only be moved with considerable force Clamping of the tool skid is on Open the clamping Guide play is set too narrowly Adapt the guide play Transverse cannot be moved or can only be moved with considerable force Guide play is set too narrowly Adapt the guide play Rust on work pieces of machine parts when using coolant lubrication Wrong coolant set Check the mixing ratio of the coolant and correct if required never cool with water alone Tool holder cannot be inserted into the main spindle reducing sleeve of the main spindle An incorrect tool taper of the tool holder has been used in combination with the reducing sleeve Only use the appropriate tool holders for the m
5. 10600390 10600388 16191200004010 10600391 10600328 16193300008025 16091300006012 16193400006000 10600383 10600382 10600376 10600719 10600714 16091300006025 51505226 16191200005020 16191200006012 106003417 16191200005016 51505210 0005 16191212012035 16191200008045 16191200005012 51006425 0001 51500633 0001 16191200004020 MASCHINENMANUFAKTUR seit 1885 Cross slide with saddle apron Description Transverse skid upper section Oylinder pin Threaded pin Nut Ball screw spindle with ball screw nut Reducing bush Ball bearing Spindle bearing transverse skid Screw Ball bearing Toothed belt wheel Z30 Push piece Threaded pin Adjustment bar Transverse skid lower section Felt Felt clamp Screw Setting bar Guide bead Screw Threaded pin Nut Felt clamp Felt Guide bar Ball nut bracket Lock plate Threaded pin Ball nut with ball spindle Screw Screw Guide Screw Ball nut with ball spindle Screw Screw Screw Limit stop switch End switch Screw 39 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 4 Tailstock 40 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 4 Tailstock PartNo Items Order No Description 1 1 10600401 Tailstock upper section 2 1 10600402 Tailstock lower section 3 1 10600403 Clamping piece 4 1 10600404 Sleeve 5 1 51004020 0019 Spindle 6 1 51006550 0001 Flange 7 2 16191200005012 Screw 8 1 10600408
6. 30 1 51508481 31 4 16091300008010 32 8 16091500008016 33 4 16191200008025 34 4 160635250006020 35 1 36 1 37 1 38 1 39 1 51502036 40 1 16191200005010 41 1 51502602 42 1 16091300006010 43 4 16191200006020 44 3 51007250 0001 45 3 16091300005006 MASCHINENMANUFAKTUR seit 1885 Description Cover hood Counter nut Cable screw Worm gear Spacer Ratchet wheel Capstan nut Tapered roller bearing Main spindle contained in tool changer Parallel key Parallel key Nilos ring Tool carrier disc Threaded pin Threaded pin Screw Cylinder pin Spacer disc contained in tool changer Ratchet contained in tool changer Bolt contained in tool changer Bolt contained in tool changer Tension spring Screw Worm gear Threaded pin Screw Push piece Threaded pin 45 WABELD 16 Drawings and legends 16 8 Safety cabin hood M SN SS ia SS Wa Ve SS Ve SS ISIS SS S HUUU 444774 HUUU 444777 PartNo Items Order No 1 1 51402020 0001 2 2 3 1 51500642 4 1 5 1 51500638 6 2 51507006 7 1 51402030 0001 8 1 51402030 0002 9 1 46 MASCHINENMANUFAKTUR seit 1885 Description Cabin hood Sliding door guide included in cabin 51402020 0001 Activator for safety switch Bracket activator contained in cabin 51402020 0001 Safety switch Ball handle Sliding door front Sliding door rear Drive protection door included in cabin 51402020 0001 WABELD MASCHINENMANUFAKTU
7. WABELD MASCHINENMANUFAKTUR seit 1885 10 Readjustment of the bearing clearance of the lead screw On the right side the lead screw is axial mounted This mount enables the lead screw 1 to be set without play If adjustment to the mount is required please proceed as follows 1 Undo the threaded pin 4 2 Turn the setting nut 3 clockwise against the ball bearing 2 until the lead screw 1 has no more axial play 3 Then tighten the threaded pin 4 securely 11 Tool skid The tool skid is positioned at the front on a prismatic guide and at the rear on a flat guide The skid is held onto the bed from below with the guide bar 9 and can be set to without play using the setting bar 12 If adjustment to the setting bar 12 is required please proceed as follows 1 Undo the hexagonal nuts 11 2 Using an Allen key tighten the threaded pins 10 in such a way that the skid is still able to move easily 3 After setting tighten the hexagonal nuts 11 back up again WABELD MASCHINENMANUFAKTUR seit 1885 11 Tool slide The possibly occurring axial clearance of spindle 6 can be adjusted in spindle bearings If adjustment is required please proceed as follows 1 Open cable conduit 1 far enough for the cable to pulled through easily Loosen the four screws 2 Pull off hood 3 from motor support plate by simultaneous release of motor cable Release set screw 4 Turn belt wheel 5 clockwise unt
8. can be obtained from the supplier or manufacturer Observe all safety regulations set out in these operating instructions in particular those that refer to the safe handling of coolants In order to ensure reliable operation of the coolant pump a minimum coolant filling level is required in the coolant tank The capacity of the coolant system is approximately 19 litres a The maximum filling level should be just below the shelf insert The minimum filling level is approximately 15 mm below that To fill remove the shelf insert and fill to the maximum filling level with a suitable coolant whilst observing all safety regulations a After filling replace the shelf insert 21 WABELD MASCHINENMANUFAKTUR seit 1885 6 Coolant system 6 3 Operating the coolant system 4 Switch for coolant pump Switch position 0 gt Pump switched off Switch position 1 gt Pump switched on Caution Coolant flow is controlled with the coolant shut off valve 6 4 Positioning the segmented coolant hose The flexible segmented hose shown in blue is made up of individually adjustable elements and can be shaped by hand or set as required The segmented hose and the nozzle are to be positioned in such a way that the coolant flows as directly as possible onto the blade of the cutting tool of the lathe Attention should be paid to ensure that the nozzle does not come into contact with the cutting tool 22 WABELD MASCHINE
9. Key for circuit diagram Color code by IEC 60757 BK Black PK Pink BN Brown RD Red BU Blue VT Violet GN Green WH White GY Grey YE Yellow OG Orange YG Yellow Green A2 Socket 230VAC B2 Machine lamp F1 Noise filter M2 Coolant pump M3 Fan for industrial screen MA Axis motor 3H8221 624 6A XYZ axis M5 Axis motor t axis 103H7123 0740 3 ADC M8 Main spindle motor 2 0 KW high speed N1 Power plug N3 9 pin plug N4 Axle motor terminal block N5 15 pin Sub D plug P2 CNC control board PE Protection against electrical shock R2 10 kO ohm potentiometers spindle speed S1 Emergency switch off S2 Main switch with low voltage trigger S3 Selection switch S4 Switch coolant S5 End switch safety cabin S7 End switch S8 Main switch with CNC control status display S9 Switch for machine lamp T3 Encoder for spindle revolutions T4 Lock for operator door with query X1 10 Cabling terminal block 54 WABELD MASCHINENMANUFAKTUR seit 1885 20 Camlock main spindle optional 20 1 Undoing a chuck or holding flange from the camlock main spindle lug Open the three clamping tappets 4 located around the circumference of the main spindle 1 using an Allen key in size 10 mm not included in the scope of delivery After opening the markings of the clamping tappets must as shown point to the markings on the main spindle
10. Morse taper MK2 Sleeve adjustability 65 mm Scale ring read accuracy 0 1 mm Thread cutting Tumbler gear drive For left right thread 2 automatic longitudinal feeds 0 085 and 0 16 mm revolution Change gear set for thread cutting Metric 0 25 7 0 mm imperial 10 40 G WABELD MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 3 Technical data Positioning accuracy t 0 015 mm Travel speed fast mode x and y axes 30 1 000 mm min Toolchanger cross section for 4 external machining tool 10x 10 mm location bore for 4 internal machining tools 16 mm Safety cabin volume coolant 27 litre feed pump 230 Volt 50 60 Hz WABELD MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 4 Dimensions 17 WABELLD MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 5 Revolution changer The potentiometer 8 of the control panel allows the infinite setting of the revolutions of the tool spindle from 50 to 4800 rpm 2 level default setting In order for the revolutions to be activated correctly via software the potentiometer must be set to 100 During the operation it can be used to minimally adjust the revolution according to the processing conditions If the lower revolutions of 50 2500 rpm 1st setting are required the drive belt must be applied To do this proceed as follows 1 Open the gea
11. Now crank the tailstock sleeve back to push the tool out Use of tools without ejector lugs is possible by screwing a suitable threaded pin into place which extends the length of the tool backwards 32 WABELD MASCHINENMANUFAKTUR seit 1885 15 Operating elements 1 Emergency off switch Mode selection switch CNC operation Idle position Set up mode ON OFF switch with low voltage trigger Coolant ON OFF Switch not occupied available for further functions Legend to diodes and reset switch Diodes to display the status of the controller o na pm F om Potentiometer rotating knob for speed selection of the electrical drive motor A plug 2 is located at the rear of the control panel which can be used to power a notebook or computer screen The control panel contains a storage compartment 1 which can hold the notebook power pack and or spare cables If tne machine alone is connected to a 16A secured socket a user with a performance of max 700W can be connected to the power plug 2 of the control panel 33 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 1 Headstock with Motor 34 WABELLD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 1 Headstock with motor PartNo Items Order No Description 1 1 10600154 Spindle input 2 1 10600106 Main spindle 3 1 10600171 Parallel key 4 3 16191200006012 Screw 5 1 10600105 Oil scraper ring 6 1 10600
12. by an electrical specialist before hand 12 The safety socket or connection box must be close enough to the machine that the power cable is not under strain 13 When carrying out maintenance and cleaning work the machine must be switched off and the grounded plug pulled out 14 Set up work is only to be carried out with the machine switched off 15 Do not reach into the operating machine 16 Always switch the machine off when you are not using it 17 Remain with the machine until it has come to a standstill WABELD MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 4 Safety regulations for proper use 18 Only have repairs carried out by a qualified specialist Repair work may only be carried out by persons who are qualified for the relevant repairs and who are familiar with the appropriate health and safety requirements 19 Protect the machine from damp 20 Constantly check the machine for damages Replace damaged parts only with original parts and have these replaced by a specialist The guarantee and warranty is voided if accessories and replacement parts are use that are not designed for the machine 21 Do not remove the generated shavings with your hand Use the appropriate tools hand held sweeper hook brush 22 Tools and work pieces may never be changed when the machine is running 23 Do not brake work pieces and bush using your hand or another object 24 Never leave the chuck key fitted even
13. seit 1885 Declaration of conformity We hereby declare in the name of the manufacturer Walter Blombach GmbH Tool and machine factory with registered office in Remscheid and Neuerburg D 42871 Remscheid P O Box 12 01 61 Phone 02191 597 0 Fax 02191 597 40 D 54673 Neuerburg WABECO Str 1 10 Phone 06564 9697 0 Fax 06564 9697 25 that the following named CNC lathe Type CC D6200 hs in the serial version meets the following relevant regulations EU Machine Directive 2006 42 EC EMC Directive 2004 108 EC EU Low Voltage Directive 2006 95 EC In order to fulfil implement the requirements of the directives named above the already published and applicable standards were drawn upon EN ISO 12100 2010 DIN EN 60204 1 2006 EN ISO 23125 2010 Proxy for the compilation of the technical documentation is the operational head of the above named manufacturer Mr Christoph Schneider D 54673 Neuerburg 2015 Place and date of issue Chop S chins de Betriebsleiter Christoph Schneider WABELD MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 1 Intended use The lathes described in these operating instructions are designed for the processing of metal plastic and timber only To ensure safe operation of the lathes the regulations set out in the chapter Safety regulations must be observed 1 2 Improper and incorrect use The lathes described in these operating instructions have been developed
14. 104 Flange 7 2 51502109 Tapered roller bearing 8 2 51502517 Lubrication nipple 9 1 10600101 Headstock 10 1 10600104 Flange 11 3 16196500006012 Screw 12 1 51004055 0003 Bush with collar 13 1 10600137 Toothed wheel 14 1 51004055 0004 Sleeve 15 1 51006600 0001 Gear wheel 16 1 16091300006008 Threaded pin 17 1 10600140 Nut 18 1 51502300 Belt 19 1 1062800 Rotary encoder complete 20 4 16112500010000 Washer 21 4 16193300010050 Screw 22 1 Headstock cover contained in cabin 23 1 16191200006020 Screw 24 1 16167980006000 Fanned washer 25 1 51004025 0024 Pressure washer 26 1 51006675 0001 Gear wheel motor 27 1 51500128 00041 Motor with pulley 35 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 2 Bed with lead screw NG ah 21 sl a2 tal Gei WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 2 Bed with lead screw PartNo Items Order No Description 1 1 10600601 Bed 2 3 16196500004008 Countersunk screw 3 1 51006555 0020 Sleeve 4 1 51502112 Ball bearing 5 1 51006555 0007 Bearing flange 6 1 10600602 Support bearings front 7 4 16191200005016 Screw 8 1 51402152 0001 Cover lead spindle bearing 9 4 16191200005012 Screw 10 1 51505226 Ball screw with ball nut 11 1 51502656 Coupling 12 1 161705A0018000 Adjusting ring 13 1 51004040 001 1 Feed shaft 14 1 51402150 0001 Motor bracket Z axis 15 1 51502518 Lubrication nipple M5 16 1 51004050 0013 Toothed belt pulley
15. NMANUFAKTUR seit 1885 6 Coolant system 6 5 Positioning the segmented coolant hose Coolant shut off valve in the open position gt Maximum coolant flow Rotation of the coolant shut off valve clockwise 5 Flow is reduced Coolant shut off valve in the closed position 2 Coolant flow stopped 23 WABELD MASCHINENMANUFAKTUR seit 1885 T Maintenance A long lifetime of the machine will depend on the appropriate care and maintenance All maintenance and repair tasks may only be carried out with the grounded plug pulled The machine must be cleaned after each use Ifthe machine is set up in a wet room all exposed parts must be oiled after each use to prevent corrosion Always lubricate all moving parts well Inthe event of bearing or skid play immediately adjust in order to prevent it from destroying the bearing or skid guide Approximately every 100 operating hours Check the tension of the poly V and gear belt and adjust if necessary Check the play in the guides and feed spindles and set if necessary 8 Lubrication of the machine The lubrication process Reduces wear and friction Increases the lifetime The metal surface are protected from corrosion We recommend Aclass 2NLGI multi purpose grease for lubrication a A lubrication oil with a viscosity of 100 mm s for oiling The lathe is to be lubricated every 8 hours of operation in accordance with the lubrication plan T
16. R seit 1885 16 Drawings and legends 16 9 Safety cabin interior Partno Item Order no Description 1 1 Interior cabin contained in cabin 51402020 0001 2 Coolant tray contained in cabin 51402020 0001 1 Coolant tray left included in cabin 51402020 0001 4 1 Coolant tray pump included in cabin 51402020 0001 1 510001 19 0007 Coolant pump 1 Clamping slide motor included in cabin 51402020 0001 1 51401481 0001 Control box 1 Control palatine nccad professional 1 51400485 0001 Protective plate spindle passage 10 1 Cover plate bed rear included in cabin 51402020 0001 11 1 Cover plate bed front included in cabin 51402020 0001 47 WABECO MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 10 Operating console 48 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 10 Operating console Partno Item Order no Description 1 1 51401485 0001 Operating console 2 1 16191200004025 Screw 3 1 51501304 Symbol for mass connection 4 1 51500624 0001 Emergency Off button complete 5 1 51500600 Turn switch 6 1 51500606 On Off switch 7 2 51500601 Toggle switch 8 1 LED s with switch included in control packet 9 1 51500801 0001 Potentiometer 10 1 51500772 Power socket 11 4 16196500004009 Countersunk screw 12 2 16193400004000 Groove 13 2 16197980004000 Fanned washer 14 7 16179810003095 Screw 49 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 11
17. Scale ring 9 1 51502131 Steel ball 10 1 51502009 Pressure spring 11 1 51004045 001 1 Dial 12 3 51007250 0001 Push piece 13 3 16091300006010 Threaded pin 14 1 16091500006016 Threaded pin 15 1 16193300010070 Screw 16 2 16191300008040 Threaded pin 17 1 16112500010000 Washer 18 1 16193400010000 Nut 19 1 10600419 Scale tape 20 2 51502517 Lubrication nipple 21 1 51507022 0001 Ball crank 22 1 16073430003018 Spiral tensioning pin 23 1 51507033 Tensioning lever 24 1 10600424 Sleeve clamping element top 25 1 10600425 Sleeve clamping element bottom 26 3 16193400010000 Nut 27 1 16091300010050 Stud bolt 28 1 10600428 Clamping bush 29 1 10600429 Scale 30 2 16191200003006 Screw 31 1 10600431 Clamping strap 32 1 10600432 Eccentric shaft 33 1 10600433 Washer 34 1 16073430003024 Spiral tensioning pin 35 1 10600435 Lever 36 1 10600436 Handle 41 WABELD 16 16 5 42 Drawings and legends CNC drive X axis Items zk P BR A MM sch O HR B A lt Order No 51402151 0001 16191200004010 16112500004000 16191200005016 16112500005000 51500122 51004020 00022 51502321 51402153 0001 16167980005000 16193400005000 16191200005012 16191200006030 51006491 0001 Description Motor cover Screw Washer Screw Washer Motor CNC drive X axis Gear belt Bracket Fanned washer Nut Screw Screw Motor bracket MASCHINENMANUFAKTUR seit 1885 WABECO MASCHINENMANUFAKTUR seit 1885 16 Drawing
18. Support arm for control panel Partno Item Order no Description 1 1 51002130 00041 Base plate with joint to support arm 2 1 51002416 00021 Square pipe with joints 3 2 51004020 0024 Guide bush to support arm 4 4 51004020 0010 Washer 220x8 1x3 5 2 16198500008000 Groove 6 2 16091300008030 Threaded pin 7 2 16193300008025 Screw 8 2 51507031 Clamping lever 9 2 16112500010000 Washer 10 2 16191200010030 Screw 50 WABELD MASCHINENMANUFAKTUR seit 1885 16 Drawings and legends 16 12 Base cabinet optional Partno Item Order no Description 1 1 1120268 Base cabinet 2 1 Door contained in Art No 1120268 3 1 Lock contained in Art No 1120268 4 1 Door contained in Art No 1120268 5 4 Hinge contained in Art No 1120268 51 WABELLD MASCHINENMANUFAKTUR seit 1885 17 Circuit diagram 17 1 Overall connection diagram p E RET hi a x HRE SGA Rae aS age cee en me Ss g s r v S E 2 II VI E Qe t lt 1 ze SS uw SE see legend for circuit diagrams 17 3 22 WABELD MASCHINENMANUFAKTUR seit 1885 17 Circuit diagram 17 2 A Axis motors and rotary encoders 3H8221 624 BA 103H7123 0740 3ADC see legend for circuit diagrams 17 3 53 WABELD MASCHINENMANUFAKTUR seit 1885 17 Curcuit diagram 17 3
19. achine Inner cone of the reducing sleeve or outer cone of the tool holder is contaminated Clean the relevant cone Doors of the safety cabin cannot be opened Machine is not switched off and or switch for operating modes in zero position Machine switched of switch for operating modes on CNC operation of set up mode Main spindle is running Main spindles stops 31 WABELD MASCHINENMANUFAKTUR seit 1885 14 Operational faults and the elimination of such Operational faults M gliche Ursache AbhilfemaBnahme Tool overheated Revolutions too high Reduce the revolutions Feed too high Reduce the feed Working without coolant Use coolant Insufficient coolant feed at the Align the coolant hose cutting edge correctly Tool blunt Sharpen tool or use a new tool Increased friction caused by Remove the shavings from the shaving build up in the tensioning hole more frequently groove of the tool drilling work withdraw Use a coated tool Wash the processing area with coolant Unsuitable tool chosen for the Only use the suitable tool for material to be processed the relevant material Tool cannot be removed from Tailstock sleeve is not fully Fully crank back the tailstock the tailstock sleeve cranked back sleeve to automatically eject tools with ejector lugs Use tool without ejector lugs Place a soft and sufficient wide inlay between the tool and tailstock front
20. and manufactured for the purpose named above Walter Blombach GmbH accepts no responsibility for property damage and personal injury caused as a result of not intended and incorrect use of the lathes 1 3 Modifications to the machine For reasons of safety it is forbidden for the user to make modifications of any type to the lathe Walter Blombach GmbH accepts no responsibility for property damage and personal injury caused as a result of any modifications to the lathe by the user that have not expressly been authorised by the company 1 4 Safety regulations for proper use The machine may represent a source of danger if it is not used correctly For this reason it is important that the following safety regulations are read attentively and observed carefully Every person that operates the machine maintains or repairs it must have read the operating instructions and in particular the safety notes prior to putting the machine into operation In order to fulfil these requirements these operating instructions must accompany the machine throughout its entire lifetime and be available for research In the event that the machine changes owners the operating instructions must thus be passed on to the new owner along with the machine WABELD MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 4 Safety regulations for proper use Only spcedially trained persons may operate the machine The guarantee and warranty are voided if da
21. ble control computer pay attention to the system prerequisites of the control software These are listed on the rear of the CD case sent with the machine Follow the instructions in the start manual of the software to install the control software on the computer The start manual can be found in the CD case of the control software included with the machine In the next step the software must be adapted to your machine To do this follow the instructions sent with the machine which detail the editing of the parameters When the software has been successfully installed on the control computer and all parameters have been adapted successfully the control computer must be connected with the machine controller The machine controller communicates with the computer via the serial interface COM port In order to establish a connection between the machine controller and the computer connect the end of the interface cable that is on the machine console to the COM port of the computer CAUTION The axis cable of the multiphase motors and the serial interface cable may only be plugged or unplugged with the control switched off Otherwise damages to the control the machine or the control computer may occur WABELD MASCHINENMANUFAKTUR seit 1885 4 Information regarding the machine 4 1 Identification of the model The precise model designation of your machine can be found on the type plate attached to the machine 4 2 Noise emission declara
22. d Polystyrene without Freon a Polyethylene foil Timber as single use pallet untreated Euro pallet multiple use packaging If you no longer need the items or you do not want to reuse them dispose of these items at the officially recognised recycling points The machine is manufactured in such a way that 98 of the used materials that can be recycled for example steel cast iron aluminium and only 296 are chemical materials e g cable sleeves of electrical cables PCBs If you have any difficulties in disposing of these parts properly we would be happy to help with prior agreement we will take back the machine in full and dispose of it You must however cover the costs of sending it to us wabeco rs de ORFHO Walter Blombach GmbH Tel 49 0 2191 597 0 all d 42899 Remscheid Fax 49 0 2191 597 40 Am Blaffertsberg 13 E Mail info wabeco remscheid de Germany WABELD MASCHINENMANUFAKTUR seit 1885 Contents Declaration of conformity CC D6200 hs 5 1 Important safety notes 6 1 1 Intended use 6 1 2 Improper and incorrect use 6 1 3 Modifications to the machine 6 1 4 Safety regulations for proper use 6 1 5 Safety features 9 1 6 Explanations of the symbols 10 2 Delivery and set up 10 2 1 Transporting the machine 11 2 2 Setting up 12 3 Putting into operation 13 3 1 Setting up and connecting the control computer 13 4 Specifications regarding the machine 14 4 1 Identification of the model 14 4 2 Noise emissi
23. ed zero floating for X axis in direct entry field G54 X 15 20 Enter New value in position display 2 X 15 20 20 WABELD MASCHINENMANUFAKTUR seit 1885 6 Coolant system 6 1 Safety regulations for the handling of cooling lubricant 1 Pay particular attention to leaked coolant as this can quickly cause people to slip and caused accidents as a result 2 Secure your coolant system in such a way that it cannot be switched on by children Persons who have not been trained may not operate the coolant system 3 Ensure you have a clean workplace dirty areas can quickly lead to accidents 4 Never use the coolant system when processing magnesium alloys In combination with water mixed coolants this may result in flammable gas mixtures which may explode under certain circumstances Avoid longer skin contact with the coolant Use skin protecting creams when handling coolants Regularly monitor the concentration of the water mixed coolant Regularly monitor the pH value of the coolant o o x o9 o Make sure that the coolant is only disposed of in an environmentally friendly way in accordance with the relevant guidelines Coolant is a special waste product 6 2 Filling the coolant system A number of protective measures must be observed and taken in order to ensure that the handling of coolant does not cause health risks or environmental loads Always observe the datasheet and the safety regulations of the coolant being used
24. h are also included in the scope of delivery to the hex bolts Subsequently insert the screws equipped with nuts into the four provided threads from below in the base cabinet The base cabinet can now be adjusted by tightening or loosening the screw Once the base cabinet is adjusted you can counter the hexagon bolts with the nuts on the screws to secure their position Good work results and low vibration running are only possible if the above mentioned prerequisites for mounting are complied with 12 5 4x M10 4x WABECO MASCHINENMANUFAKTUR seit 1885 3 Putting into operation Use a dry cloth to remove the corrosion protection that was applied to all exposed parts for transport Inthe event of marine impregnation of exposed parts it is recommended you spray them with oil allow it to work and then remove the impregnation with a dry cloth Once set up properly see the section on delivery and set up connect the grounded plug directly to a safety socket and the 230 V 50 60 Hz optional 110 V 60 Hz mains power supply a Provision of sufficient coolant for the operation of a coolant system Check all electronic operating elements for example ON OFF switch emergency off switch potentiometer bush protection hood etc for functionality When putting CNC machines into operation for the first time always read the start up manual 3 1 Setting up and connecting the control computer When selecting a suita
25. he lubrication points Bed guide Dovetail guide cross slide Dovetail guide traverse slide Tailstock sleeve Are lubricated with the help of an oil can and an ordinary lubrication oil by moving the skid or sleeve backwards and forwards All other lubrication points are lubricated with a grease press at the designated lubrication nipples 4 Eis Every 8 hours of operation 2 CH Every 8 hours of operation 24 WABECO MASCHINENMANUFAKTUR seit 1885 8 Lubrication oft he machine END er Y e m gt 25 WABELD MASCHINENMANUFAKTUR seit 1885 9 Readjusting the main spindle The headstock is screwed to the lathe bed The headstock contains the main spindle with two adjustable precision tapered roller bearings If adjustment is required proceed as follows 1 Open the gear cover hood by undoing the safety screw with the supplied special key 2 Undo the stud screw 1 in the setting nut 2 3 The setting nut 2 is located at the rear end of the main spindle 4 Rotate the setting nut 2 clockwise until the bearings run free again it must be possible to rotate the main spindle by hand easily e Tighten the stud screw 1 back up again 6 If the tapered roller bearings are set too tightly they will quickly become unusable 7 Close the gear cover hood by tightening the safety screw with the supplied special key 26
26. il there is no more axial clearance Refasten set screw 4 The spindle 6 has to turn easily after subsequent adjustment o Au em ko hb Reassemble parts in reverse sequence after adjustment 28 WABELD MASCHINENMANUFAKTUR seit 1885 12 Tailstock a The tailstock can be moved on the lathe bed a By moving the clamping lever 3 the tailstock can easily be secured in any position The tailstock is made up of an upper and lower section The upper section can be moved by a maximum of 10 mm in order to turn long slim tapers To do this proceed as follows 1 Undo the hexagonal nut 6 2 With the help of both threaded pins 8 slide the upper section into the required direction The central position of the tailstock is shown by the scale mark 7 Turn a sample to see whether the work piece is cylindrical correct the tailstock setting if necessary Tailstock sleeve The solid tailstock sleeve has a millimetre scale To read off the distance of travel of the tailstock sleeve there is a scale ring 9 One mark on the scale corresponds to an adjustment of 0 1 mm One turn of the ball crank 5 corresponds to a distance of 2 mm Centre point drill or drill chucks are automatically ejected when turning back Tool holder There is an inside cone MK 2 which is designed to hold tools and is incorporated in the sleeve 1 Tightening the clamping lever 2 ensures that the sleeve may be easily clamped i
27. itch the machine off via the ON OFF switch wait 5 seconds and reactivate WABELLD MASCHINENMANUFAKTUR seit 1885 5 Setup tools First the correction values for all 8 tools have to be set to 0 00 in the tool memory in X and Z Parameter gt CAM tool memory Tool 1 is the 0 tool The adjusted amounts are here generally maintained at X 0 and Z O Run machine reference Select tool T1 to random diameter in X and run to beginning of workpiece in Z if required clamp turned part and turn splint Leave X axis at turned diameter in X and set Z axis to beginning of workpiece Here work piece zero point sets keyboard combination Ctrl X Ctrl Z Position display X 0 00 Z 0 00 Selecttool T3 Move to same position in X and Z with tool T3 where zero was set previously with T1 in X to turned diameter and in Z to workpiece starting point The new position value of X axis is not X 0 00 at the turned diameter but e g X 10 80 a Enter in tool memory at T3 New position value in X 10 80 Radius is 2 5 40 Adjusted amount in X 5 40 a The new position value of display Z axis at start of work piece is e g Z 8 00 Enter at T3 in tool memory New position value in Z 8 00 Adjusted amount in Z 8 00 5 1 Set workpiece zero point Select T1 Drive with workpiece T1 to turned diameter in X axis Position display in X axis 0 00 Measured turned diameter e g 15 20 Now enter the requir
28. kaging shows damages to be reported or 2 Whether the machine shows transportation damages to be reported If this is the case we ask you to communicate this information immediately Subsequent claims cannot be recognised The machine must be set up on a suitable even and firm surface Suitable surfaces are for example a A tool cabinet available optionally A separate workbench with a level surface spirit level that is strong enough to carry the weight of the lathe without bending a A steel plate with a level surface spirit level The machine must be screwed securely to the surface it is set up on There are holes in the base of the machine that are designed for this purpose Good working results and low vibration operation can only be ensured when the prerequisites for fixture as set out above are maintained WABECO MASCHINENMANUFAKTUR seit 1885 2 Delivery and set up The place of set up should be selected in such a way that there is sufficient lighting the electrical supply cable with socket outlet with earthing contact and O conductor is installed close enough to the machine that the supply line is not subjected to any tensile load The machine has to be screwed to the installation surface and or provided with a safe stand by using level elements For this purpose the base cabinet of the machine has four fixation thread bores M10 as well as four fixation bores O 12 5 mm The doors of the safety cabin ca
29. mages are caused by improper operation 1 We remind you that no liability will be accepted for damages caused by not observing these operating instructions 2 The operator of the machine is to ensure that at least one copy of the operating instructions is stored in the immediate vicinity of the machine and available to the people who work with the machine 3 The operator is to ensure that the safety and danger notifications on the machine are observed and that the signs are kept in a legible state 4 Do not work without goggles 5 Wear close fitting clothing and if you have long hair wear a hair net Do not wear loose fitting or loose items ties shirt sleeves jewellery etc 6 Gloves may not be worn 7 In the event of an emission noise level as of 80 dB A at the workplace ear defenders must be worn 8 The machine may not operate without supervision 9 Secure your machine in such a way that it cannot be switched on by children Persons who have not been trained may not operate the machine 10 Before using the machine make sure it is in good working condition Pay special attention to any damage to the grounded plug or the electrical connections Never operate the machine with a defective crushed or exposed cable 11 Plug the grounded plug into a suitable socket for the machine The cable for the machine may only be connected to a safety socket or a connection box Have the safety socket or connection box checked
30. n any position The sleeve is moved axially by the hand crank 5 by way of the threaded spindle 4 29 WABELD MASCHINENMANUFAKTUR seit 1885 13 3 and 4 jaw lathe chuck The 3 jaw lathe chuck Is used to tension circular three and six edged work piece centrally to the spindle axis The 4 jaw lathe chuck Is used to tension square work pieces centrally to the spindle axis Risk of accidents Do not attempt to clamp work pieces that are over the permitted clamping range The clamping force is thus too low and the jaws may come undone The maximum revolution range specified on the lathe chuck may not be exceeded Mounting the jaws 1 The jaws and guides are numbered from 1 3 or 1 4 2 Openthe lathe chuck with the key in such a way that the drilling jaws are released sequence 3 2 10r4 3 2 1 Insert turning jaw 1 into guide 1 4 Push turning jaw 1 in the direction of the chuck centre point and at the same time turn the chuck key clockwise 5 When the coil has caught turning jaw 1 insert turning jaw 2 into guide 2 6 Repeat the procedure with jaws 2 3 and 4 for a four jaw lathe chuck 7 Then visually check the positions of the jaws These must meet centrally Mounting the drilling jaws 1 If you wish to use the drilling jaws again the process is the repeated in the same order 2 Three jaw lathe chuck First jaw 1 then 2 then 3 3 Four jaw lathe chuck First jaw 1 then 2 then 3 then 4 30
31. n only be opened if the machine is switched to operation modes CNC or set up if the main spindle is not moving 2 1 Transport of machine To transport the machine it is advisable to lift it at the lower cabinet with a forklift or platform trolley at the base cupboard of the safety cabin and carefully move it to the desired location For this purpose use wide forks max 1260 mm We recommend using an intermediate plate for optimal load distribution and the protection of the machine For example a Euro pallet of 1200 x 800 mm is suitable Machine with safety cabin and base cabinet Pallet for better load distribution lift truck pallet truck WABELD MASCHINENMANUFAKTUR seit 1885 2 Delivery and installation 2 2 Installation The appropriate bores for the installation of the safety cabinet onto a WABECO machining tool cabinet are already provided The machining tool cabinet ensures secure positioning of the lathe and or safety cabin If the safety cabin is installed on another suitable installation surface the 8 through bores have to be drilled in the customers installation surface The positions of the 8 fixation threads thread M8 of the safety cabin are illustrated below The diameter of the through bores in the installation surface has to be at least 9 mm The hexagon bolts M10 included in the scope of delivery of the base cabinet can be used for adjustments For this purpose first screw the hex nut M10 whic
32. on declaration 14 4 3 Technical data 15 4 4 Dimensions 17 4 5 Revolution selection 18 4 6 Electrical equipment 19 5 Set up tools 20 5 1 Set work piece zero point 20 6 Coolant system 21 6 1 Safety regulations for the handling of cooling lubricant 21 6 2 Filling the coolant system 21 6 3 Operating the coolant system 22 6 4 Positioning the segmented coolant hose 22 6 5 Controlling the flow of coolant using the coolant shut off valve 23 7 Maintenance 24 8 Lubrication of the machine 24 9 Readjusting the main spindle 26 10 Overload coupling 27 11 Tool skid 27 12 Tailstock 29 13 3 and 4 jaw lathe chuck 30 14 Operational faults and the elimination of such 31 15 Operating elements 33 WABELD MASCHINENMANUFAKTUR seit 1885 Contents 16 Drawings and legends 34 16 1 Headstock with motor 34 16 2 Bed with lead screw 36 16 3 Transverse skid with lock plate 38 16 4 Tailstock 40 16 5 CNC drive X axis 42 16 6 Speed sensor 43 16 7 CNC 8 fold tool changer 44 16 8 Safety cabin hood 46 16 9 Safety cabin interior 47 16 10 Operating console 48 16 11 Bracket arm for operating console 50 16 12 Axis motor and rotary encoder 51 17 Circuit diagram 52 17 1 Overall connection diagram 52 17 2 Axis motor and rotary encoder 53 18 Camlock main spindle optional 54 18 1 Undoing a chuck or holding flange from the camlock 54 Main spindle lug 18 2 Blocking a chuck or holding flange on the camlock 54 Main spindle lug WABELD MASCHINENMANUFAKTUR
33. r cover hood by undoing the safety screw with the supplied special key 2 Release the four hexagon nuts 5 this allows the sliding of the clamping sled 4 of the motor 3 Slide the clamping sled incl motor toward the machine this loosens the belt tension and the belt can be relocated 4 Place the drive belt 2 onto the otertransmission oft he belt disks 1 3 Small diameter at motor large diameter at main spindle 5 Pull the clamping sled 4 of the motor away from machine to tension the drive belt 2 and refasten the four hexagon nuts 5 6 Close the protective drive door and secure with both safety screws WABELD MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 5 Revolution changer The following table illustrates the torque of the work spindle depending on the selected gear level and setting of the potentiometer Setting on the potentiometer 1st setting rpm 2nd setting rpm 50 4 Specifications regarding the machine 4 6 Electrical equipment The frequency regulated main drive motor is delivered already installed a the under voltage trigger is integrated in the electronics of the motor The ON OFF switch has to be switched on again also after an interruption of power Inthe event of the main drive motor being overloaded it will switch itself off automatically The main drive motor can only be switched back on again after a short waiting period For this purpose first sw
34. s and legends 16 6 Speed sensor PartNo Items Order No Description 1 1 51500101 0001 Speed sensor 2 1 51006575 0003 Holding flange 3 3 16196500004008 Screw 4 1 51502323 Gear belt 5 1 51004055 0004 Sleeve 6 1 51006555 0002 Toothed belt wheel Z32 7 1 51006555 0001 Toothed belt wheel Z32 8 2 1600000221 4020 Adjusting washer 9 1 16191300005006 Threaded pin 10 2 16191200004010 Screw 11 2 16112500004000 Washer 43 WABELD 16 16 7 Drawings and legends CNC 8 fold tool changer MASCHINENMANUFAKTUR seit 1885 Part No oo NO Om FW DY 11 12 13 14 15 16 17 44 Items KR eck a La a BR a PO A WO WO P sch sch Order No 51508480 0001 1 16193300008020 51508480 00031 16191200005020 16191200004010 51004025 0021 51502118 16047200032000 51004018 0003 51508480 00021 16191200006060 1606885A040425 51502600 0001 51500113 16191200004012 Description Basic body Base plate contained in tool changer Screw Bearing cover Screw Screw Capstan nut Ball bearing Securing ring Spacer ring Cover Screw Parallel key Worm gear contained in tool changer Coupling Motor Screw WABELD 16 Drawings and legends 16 7 CNC 8 fold tool changer PartNo Items Order No 18 1 51401812 0001 19 1 51501505 20 1 51501533 21 1 51502601 22 1 51508480 00051 23 1 51508480 00041 24 1 51004055 0001 25 2 51502108 26 1 27 1 1606885A005020 28 1 6885A080818 01 29 1 51502199
35. tion Noise emission declaration in accordance with DIN EN ISO 3744 Emission values in idle Emission noise level at the workplace at 50 68 0 dB A at 100 73 6 dB A Sound power level at 50 96 77 8 dB A at 100 82 3 dB A With an emission noise level as of 80 dB A at the workplace ear defenders must be worn 14 WABELD 4 Specifications regarding the machine 4 3 Technical data Working areas MASCHINENMANUFAKTUR seit 1885 Distance between centres 600 mm Centre height 135 mm turning above cross slide 170 mm Swing diameter via guide 270 mm Bed width 185 mm Main drive motor Nominal voltage 230 V Nominal frequency 50 60 Hz frequency controlled main drive motor 230 V 50 60 Hz 2 0 kW Spindle revolutions infinite 50 5000 rpm Machine accuracy Concentricity of the spindle lug 0 005 mm Cylindrical rotation on 100 mm overhung 0 01 mm Cylindrical rotation with simple turning on 300 mm between the centres em Headstock Main spindle aperture 20 mm Taper in main spindle MK3 Main spindle lug According to DIN 6350 Tool skid Adjustability of the transverse skid 140 mm Adjustability of the longitudinal skid 60 mm Longitudinal skid can be swivelled by 360 Max turning steel height 20 mm Tailstock with quick adjustment Lateral adjustability of the tailstock upper 10mm Tailstock sleeve With inner
36. when not in operation 25 Pay attention to the spread of the lathe chuck 26 The maximum revolution range specified on the lathe chuck may not be exceeded 27 Always keep safety door to motor closed 28 The safety door to motor may only be opened by trained personnel with a special key by unplugged safety contact pug 29 Turning steels must be firmly tensioned at the correct height and as short as possible 30 Do not measure at the rotating work piece risk of accident measuring tools will be damaged 31 When working between the tips check the locking lever of the tailstock for firm seating 32 When working with the automatic feed always pay attention to ensure that the tool skid does not come up against the lathe chuck or the tailstock WABELD MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 5 Safety features In order to enable you to work safely with our machines we have incorporated the following safety mechanisms These meet the relevant European safety requirements Safety cabin In order fort he machine to operate in CNC mode the door to the safety cabin must be closed a ON OFF switch with under voltage trigger The ON OFF switch is fitted with an under voltage trigger thus in the event of a power failure the machine does not switch itself back on automatically This prevents risks caused by the unexpected motion of the spindle Emergency off switch The emergency off switch acts to quickl
37. y stop the machine Overload protection The machine is fitted with an overload protection feature This overload protection feature switches the main drive motor off automatically when the machine is overloaded The machine can only then be switched on after a waiting period Switch for operating modes only for CNC machines The mode switch has 3 settings CNC mode Idle position Manual mode that can only be selected with a key After selecting the mode the key can be removed in order to prevent a switching of the mode type by unauthorised persons Working in CNC mode is only possible when door is closed The door is locked as soon as the main spindle starts If the door is open the main spindle cannot be started Working in set up mode can be executed while the door is open The switch for operating modes has to be set to set up mode The main spindle can be activated by closed as well as open door WABECO MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 6 Explanations of the symbols With an emission noise level as of 80 dB A at the workplace ear defenders must be worn Caution Always pull the power plug prior to any maintenance work Read the operating instructions prior to initial operation or maintenance work Caution Dangerous electric voltage 2 Delivery and set up The machine is packed with care at the factory The following should be checked after delivery 1 Whether the pac
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