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INSTRUCTION
MANUAL
V11 Series
VR3425XP
WARNING!
READ THE MANUAL
AND BE SURE
EVERYTHING IS
FULLY UNDERSTOOD
BEFORE
TURNING ON THE POWER
KEEP FOR REFERENCE
TAKUMI MACHINERY CO., LTD
NO. 50, 35TH RD,
TAICHUNG INDUSTRIAL PARK,
TAIWAN, R.O.C.
TEL: 886-4-23583838
FAX: 886-4-23580176
SEPTEMBER 2012 VERSION 1
MILLTRONICS USA
1400 MILL LANE
WACONIA, MN
55387 USA
TEL: 952-442-1410
FAX: 952-442-1407
JULY 31, 2015 VERSION 1
I
Contents
1 Safety Precautions ................................................................................. 1-1
1.1 General Safety Reminders ............................................................................... 1-1
1.2 Safety Precaution for This Machine ................................................................ 1-1
1.3 Safety Precaution For Electricity..................................................................... 1-2
1.4 Dangerous Area in the Machine ...................................................................... 1-4
1.5 Lubrication Frequency of this Machine........................................................... 1-6
2 Overall Description ............................................................................... 2-1
2.1 Machine Size.................................................................................................... 2-1
2.2 Machine Specification ..................................................................................... 2-2
2.3 Noise Level ...................................................................................................... 2-2
2.4 Lighting Level.................................................................................................. 2-2
2.5 Automatic Tool Changer (ATC)...................................................................... 2-3
2.6 Tools Information ............................................................................................ 2-4
2.7 Travels.............................................................................................................. 2-5
3 Transit and Installation.......................................................................... 3-1
3.1 Requirement of Environment........................................................................... 3-1
3.2 Requirement of The Foundation ...................................................................... 3-1
3.3 Requirement of Power Source ......................................................................... 3-2
3.4 Packing and Unpacking ................................................................................... 3-2
3.5 Handling........................................................................................................... 3-2
3.6 Machine Installation......................................................................................... 3-3
3.7 Power on Safety Check.................................................................................... 3-4
3.8 Check before work........................................................................................... 3-4
4 Setting and Adjustment ......................................................................... 4-1
4.1 Spindle System................................................................................................. 4-1
4.2 Pneumatic circuit Unit ..................................................................................... 4-2
4.3 Slide-way and Ball Screws Lubrication........................................................... 4-4
4.4 Coolant Unit..................................................................................................... 4-4
4.5 Ball screw cooling system ............................................................................... 4-5
5 Machine Maintenance ........................................................................... 5-1
5.1 General precautions ......................................................................................... 5-1
5.2 Daily maintenance ........................................................................................... 5-1
5.3 Weekly maintenance........................................................................................ 5-1
5.4 Monthly maintenance....................................................................................... 5-1
5.5 Maintenance every season ............................................................................... 5-2
5.6 Half-yearly maintenance.................................................................................. 5-2
5.7 Yearly maintenance ......................................................................................... 5-2
II
Chapter 1 Safety Precautions
1-1
1 Safety Precautions
This machine is for metal cutting. Please do not use it for unintended purposes. If
you have any difficulties operating this product please contact us.
1.1 General Safety Reminders
1). Make sure to read and fully understand the instruction manual and the
programming manual. Ensure that no persons are in danger areas or around
this machine before switching power on.
2). The location of “Emergency-Stop” push-button should be memorized so that
is may be operated at any time. Use it to prevent accidents from happening.
3). Please use safety protective equipment such as security shoes, goggles, to
operate machine. Do not wear loose or baggy clothing to prevent being pulled
into the machine.
4). Do not touch any switch with wet hands, or an electric shock may be
experienced.
5). If a job is to be done by two or more operators, the signal of each step should
be given for each operator. Unless a signal is given and well known, the next
step should not be taken.
6). Never contact a turning spindle or workpiece in any way and never touch tool
nose and cutting chips with bare hands.
7). Never attempt to scrape or remove any signs on machine, and if they become
unlegible, please contact us and replace with a new one.
8). Dispose of filter material and cutting fluids according to the local regulations,
to handle it, dispose of properly.
1.2 Safety Precaution for This Machine
1). This machine is used for metal cutting. Do not use it for other non-metal
cutting. Contact us with further questions for better service and safety.
2). Always keep the machine model and serial number handy to enable us to deal
with your requests rapidly and offer you the best assistance.
3). Warm up the machine before use, especially spindle and feed screws by
running them for 10 to 20 minutes at 1000 rpm of spindle and half the
maximum speed of three axes.
4). Stop the machine before replacing a workpiece and provide plenty of distance
between workpiece and spindle tool to avoid impact.
5). Grip workpieces securely before machining to avoid damage of personnel,
machine or workpieces.
6). Do not open the front door, side covers of safety guard when machine is
working. It may cause the risks of ejected objects, impact or crush.
Chapter 1 Safety Precautions
1-2
7). Tooling should conform to the machine specifications, dimensions and types.
(refer to chapter 2)
8). Lubrication oil is specified (refer to chapter 4). non-recommended oil may
result in malfunctions or damage of machine.
9). After electrical power is lost, return to reference point may be necessary.
1.3 Safety Precaution For Electricity
1). Electrical maintenance should be done by qualified person or others competent
to do the job, don’t change these circuits arbitrarily.
2). Ensure personnel and machine will be operated safely; the earth ground must
be done properly. (details refer to section 3.3)
3). Over-travel limit switches, proximity switches, interlock devices and other
safety devices that have been implemented should not be removed or modified.
4). Some control panels, transformers, motors, junction boxes and other parts with
high-voltage, don’t touch after power switch has been turned on, or you may
get an electric shock.
5). Before replacing a fuse, switch off the main power supply, and make sure to
replace with the proper size and value.
6). In the event of external power supply failure, turn off the main circuit breaker
immediately.
7). Do not change parameter values adjusting and other electrical devices setting
unnecessarily. If such changes are unavoidable, record the original values so
that they can be restored.
Chapter 1 Safety Precautions
1-3
1.3.1 Manual tool unclamp nameplate
NOTE:
1. Before unloading the tool, make sure that NC programs, and the spindle
have been stopped.
2. Hold the tool in the spindle before unloading it to prevent it from dropping
1.3.2 Slideway Oils, Spindle cooling, Air Lubricator Unit
Nameplate:
Instruction of Slideway Oils
1. The supply system of guideway oils has been set, please do not adjuste.
2. Please fill up the slideway oils when the operating panel shows shortage of oils.
3. Specification of slideway oils :
CPC Machine way Lubricant.
Castrol Magna BD68.
Mobil Vactra No.2
or equivalent products.
N
OTICE :
non-recommended lubricating oil may result in malfunctions or damage of machine.
Instruction of Spindle Cooling
1. Spindle is cooled with automatic circulation system.
2. Cooling temperature can be set by operators. (Please refer to description of cooler
installation for the detail).
3. Specification of coolant:
CPC Circulation oil.
Castrol AWS 32. Mobil DTE, LIGHT.
or equivalent products.
N
OTICE :
non-recommended lubricating oil may result in malfunctions or damage of machine.
Chapter 1 Safety Precautions
1-4
NOTE:
1. Adjust the pressure by regulators.
2. Please refill the oil and keep in good condition to enhance machine life
3. Labels are stamped on left side of column.
1.4 Dangerous Area in the Machine
Instruction of Air Lubricator Unit
1. Pressure set 6 kg/cm2
2. Specification of oils :
CPC Spindle oil M22.
Castrol AWS 22.
or equivalent products.
N
OTICE :
non-recommended lubricating oil may result in malfunctions or damage of machine.
Chapter 1 Safety Precautions
1-5
NOTE:
1. Keep the space around the machine and ground clear to prevent unexpected
accidents.
2. Keep away from the machine during operation.
Chapter 1 Safety Precautions
1-6
1.5 Lubrication Frequency of this Machine
NOTE:
1. Adjusting the pressure by regulators.
2. Please refill the oil and keep it in good condition to enhance machine life.
Chapter 2 Overall Description
2-1
2 Overall Description
2.1 Machine Size
Chapter 2 Overall Description
2-2
2.2 Machine Specification
ITEM UNIT V11
TABLE
TABLE SIZE mm 1300x650
T Slots (W x No. x Pitch) mm 18x5x125
Table Load (maximum) Kg 1100
TRAVEL
X-axis mm 1100
Y -axis mm 650
Z -axis mm 600
Spindle Nose To Table Surface mm 150-750
SPINDLE
Spindle Taper #50
Spindle Speed Gear Transmission rpm 6000
FEDERATE
Rapid Traverse Rates(X/Y/Z) m/min. 20x20x14
Max. Cutting mm/min. 7000
ATC
Tool Type CAT50
Max. Tool Weight Kg 15
Max. Tool Diameter Full /Adjacent Empty mm 105/200
Tool Selection Random
Tool Shank ISO-B
OTHER
Air Pressure Kg/cm2 6
Machine Weight Kg
Floor Space mm 5520x4210x3150
We reserve the right to change the specification if product is modified, without notice.
2.3 Noise Level
Noise level under 80 dB(A) is checked before the machine leaves our company.
2.4 Lighting Level
Lighting level above 500 Lux is checked before the machine leaves our company.
Chapter 2 Overall Description
2-3
2.5 Automatic Tool Changer (ATC)
1). For the arm type automatic tool changer system:
a). Length: 250mm
b). Diameter: 105mm (empty tools 200mm)
c). Weight: 15kg
NOTE: pocket empty tools (optional)
2). The arm type automatic tool changer system is a Bi-directional random system.
This function can save the time on tool changing
a). Following constrains of tools in magazine must be observed to avoid the
accidents: (Max. tool diameter + Contiguity Max. tool diameter) /2 < Tool
Allow Max. tool diameter
b). b). When the tools diameter is larger then nominal size, it’s called interface
tool. Please register then from T90~T99 for safety.
Chapter 2 Overall Description
2-4
2.6 Tools Information
1). CAT-50 Tool Shank and Pull-Stud
NOTE:
1). Tool holder needs to use keyless slot type
2). Tool holder needs to pass vibration balance test, under class G2.5 or better.
Chapter 2 Overall Description
2-5
2.7 Travels
1). X-axis travel range
2). Y-axis travel range
3). Z-axis travel range
Chapter 3 Transit and Installation
3-1
3 Transit and Installation
3.1 Requirement of Environment
1). Machine should not be installed at the place that near a source of vibration,
heat, sunlight, or EDM machine. (Distance > 10m)
2). Floor must not be slopped, soft ground, or irregular surface.
3). Allow space for maintenance and do not place things near the machine.
3.2 Requirement of The Foundation
1). V11/VM4325 Bolt fix in Foundation diagram：
2). The depth of concrete should be as deep as possible and without cracks.
3). Reinforcing steel bars with the diameter of 19 mm shall be put at the pitch 150
mm in the form of a lattice.
Chapter 3 Transit and Installation
3-2
4). Place foundation bolt holes so that they may be securely fixed to the concrete.
5). If there is no grounding device of power source, please make a grounding
terminal with a copper rod (diameter of 15 mm, length more than 2 M) and
embedded in the ground.
6). Install machine after at least 7 to 10 days from pouring the foundation. (depend
on actual situation)
7). When the primary concrete is dry, level the machine temporarily, and apply
foundation bolts, leveling blocks, etc, then pour secondary concrete into
foundation bolt holes to fasten them. Use concrete that may will not shrink to
fill the foundation bolt holes.
8). Adjust the level accurately after 7 days.
9). It’s done.
3.3 Requirement of Power Source
1). Electric control that include electromagnetic connect, relay, transformer, circuit
breaker, dust keeper device etc.., must follow international electric security
issues.
2). Main power supply 220 V, 3 Phase, 60/50 Hz ; Please refer to the nameplate
located on rear door of electric cabinet.
3). Voltage fluctuation keep in +10% ~ -15%
4). Frequency fluctuation keep in ± 1 Hz
5). Power requirement of motor : 35KVA
Notice: Never connect the power before ensuring it is correct or damage may
result.
3.4 Packing and Unpacking
The packing and unpacking of this machine will be done by our service engineer.
If any problem, contact to our service department.
3.5 Handling
Transportation by Forklift Truck
a). Only an authorized machine mover should perform machine lifting.
b). Capacity of lift-truck：10000 Kg
c). Keep machine‘s balance and move slowly.
d). Make sure there are no obstacles or personnel along the intended path and
nothing unnecessary is left on the machine.
Chapter 3 Transit and Installation
3-3
3.6 Machine Installation
3.6.1 Machine fixed position
1). Place the pedestals well before machine fixed in location, make sure the
pedestals are in good balance to support machine.
2). Use solvent and cloths to clean up antirust oil on each part, then place
lubrication oil on them.
3). Make sure the power voltage and frequency are phased properly, and is
properly grounded to earth.
4). Adjust source air pressure to 6kg/cm2.
5). Remove the counterweight support bolts at the top o the column.
6). Remove the shipping brackets from the saddle and from table to head.
7). Check that the spindle oil cooler, drawbar, and way lube unit have enough
oil.
8). Adjust the temperature of the spindle cooler unit in 0.
3.6.2 Machine level balance and precision adjust
1). Place two precision “level” on the center of table perpendicularly.
2). Move the work table to the center position, detect the level bubble go left
or right, and then use a wrench to adjust the base of the machine with the
jack bolts until the level bubble is in the center.
3). Detect the level bubble location when the work table on X-axis direction or
Y-axis direction at end point or center of travel distance.
4). Use level to adjust the pads in the machine base with jack bolts until level
is reached.
5). Put two levels on both edge sides of the work table and then move the
X-axis and Y-axis to the center of travel distance, check the level bubble
location.
6). Repeat checks along various locations along the travels.
7). Check and readjust the machine level every 6 months.
Chapter 3 Transit and Installation
3-4
3.7 Power on Safety Check
For the safety of personnel, the life and accuracy of the machine, please check
the following items before operation.
1). Check the wires, pipes and junction are not damaged.
2). Check the supply voltage, frequency and phase are correct.
3). Make sure there are no obstacles around the machine and control system.
4). Make sure control system switches will not be operated unintentionally
and are not blocked.
5). Make sure no personnel on dangerous area. (refer to Chapter 1)
6). Turn on the main power supply switch and be sure there are no alarms on
the screen.
7). Turn off the main power supply before operator leaves.
3.8 Check before work
1). Any maintenance is dangerous while the machine is operating,.
2). While machine is working, circuit breaker should be opened.
3). After switching on the power, inspect the spindle fan to verify it is working
normally.
4). Inspect spindle taper is working normally. (make sure there is no tool
clamped)
5). Inspect that pressure tool release is working normally and the oil is correct.
6). Make sure the constant voltage regulator is working.
Chapter 4 Setting and Adjustment
4-1
4 Setting and Adjustment
4.1 Spindle System
4.1.1 Spindle turning important notice
1). When machine starts, inspect the pressure source whether working normally.
(pressure value 6kg/cm2)
2). Ensure provided spindle air is clean and dry, ensure that air dryer is working
normally.
3). Spindle front valve should release air, inspect the air pressure is working
normally.
4). Avoid spindle damage, tool should be clamped tool before turning.
5). Run the spindle in 1000rpm, check for any abnormal sounds or vibration.
4.1.2 Spindle warm up important notice
1). Start: turn spindle 25% for 10 minutes.
2). Acceleration: turn spindle 50% for 10 minutes.
3). Confirm that spindle temperature and noise are normal.
4). Accelerate up to working speed, proceed with normal operation.
Notice:
1). Do not run spindle without clamping tool.
2). Adjust the tool balance, and the balancing rate is below G2.5.
3). At any spindle rpm, if spindle temperature rises over 10 degrees (C), stop the
machine and check parts for damages.
/
