Home

Triac Series CNC Machine User`s Manual.

1. 148 Index Section 12 Triac Series CNC Machine User s Manual
2. This example assigns a subprogram number of 20 to the program named FRED then calls the subprogram 0209 TOOLDEF This directive sets the length and diameter of a cutting tool The length of a tool is the distance from the spindle nose to the bottom of the cutter Example G21 TOOLDEF T1 D8 Z65 This example defines tool number 1 as being 8mm in diameter and 65mm long Triac Series CNC Machine User s Manual Section 10 Appendix 135 10 Denford Directives 136 Appendix Section 10 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 prompt it to move to the next line this continues until the program is instructed to stop this function The directive applies to both simulation and actual machining with a program 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 INOSHOW This directive stops the machining operations from being graphically Simulated on screen Triac Series CNC Machine User s Manual EC Declaration of Conformity The responsible person MrJ M Boyle Business Name Denford
3. The oil lubricator unitis used to blend a fine mist of oil with the compressed airstream The rate of flow is presetatthe factory according to the various pneumatic options fitted to your Triac atthe time of manufacture This rate should NOT require adjustment through normal day to day use of the CNC machine Check the oil level ona daily basis To top up the oil level in the air lubricator unit unscrew and withdraw the entire oil container positioned directly below the oil flow adjustment screw and cap Refill the container using oil grade ISO VG 32 Further details regarding parts of the compressed air connection unit are explained in Section 3 CNC Machine Installation pages 25 to 28 Triac Series CNC Machine User s Manual Section 7 Maintenance 105 7 Flood Coolant System Maintenance Location Tax he flood coolantsystem is supplied as an option with the Triac PC or FI Triac VMC Coolantis driven from the storage tank under the machine ood coolant system f i A a storage tank floor to the coolant delivery hose on the right side of the machine b coolant delivery hose column using an electric pump to the right of the machine column i 7 Clean each partof the flood coolantsystem and check the security of e viewing window any screws hoses and connections on a weekly basis and drain plug To fill or top up the tank open the safety guard door then pour the m A required amountof coolant mix directly int
4. MACHINE DATUM A fixed zero reference point set by the machine manufacturer The machine datum is used to define the co ordinate based grid system of the CNC machine All machining co ordinates originate from this point However this point can be temporarily moved using the machine offset facility MDI ciiirt Manual Data Input A method used for manually inserting data into the control system ie Desktop Tutor qwerty keyboard etc MITEEBITE CLAMP Method of securing work to the machine table using the series of machine table T channels MODAL iainta 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 ianiai minani a Numerical control OFFSET nanninannan 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 machine to ensure machining occurs in the correct place on the billet Offsets are used to shift parts of the three dimensional co ordinate based grid system used by the CNC machine PART DATUM seeseeeeee Used as a zero reference point in a CNC file All machining co ordinates originate from this point PART PROGRAM ssassn 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 PCan pnan Personal comp
5. sesessessestssesseessessesseenieetesnseaeen 79 Option Pneumatic Safety Guard DOO wees 81 Section 7 Maintenance Planning Procedure for Maintenance Work sssr 82 Maintenance L0g icici endian canine 83 Maintenance Schedule s ssssssssariirnrntnnnnnnnnrnnnnrarnnentnrererenrererenrnre 85 Lubrication Charticnienia nia ritennmnmann anrasan 86 General Work Area Cleaning sessies 87 Lubrication of Ballscrews and Slideways ssecsennneccsssnn 88 Cleaning and Inspecting the X Axis Ballscrew and Slideways 89 Cleaning and Inspecting the Y Axis Ballscrew and Slideways 90 Cleaning and Inspecting the Z Axis Ballscrew and Slideways 92 Cleaning and Inspecting the X Axis Datum Microswitch 93 Cleaning and Inspecting the Y Axis Datum Microswitch 94 Cleaning and Inspecting the Z Axis Datum Microswitch 95 Gib Strip Adjustment u csindii ie saad agen 97 X Axis Gib Strip Adjustment scenes 98 Y Axis Gib Strip Adjustment cscesesscesssssrsssssssnsrssseetsrssnsenees 99 Z Axis Gib Strip Adjustment oc scescescestesescssesssstssessessseessseseersees 100 Automatic Tool Changer Maintenance csscssssssssssssneeessesseenees 102 Pneumatic Safety Guard Door Maintenance cscsessssesesssreseens 104 Hydraulic Vice Maintenance sneer 104 Compressed Air Connection Unit Maintenance ssssssesseeesees 105 Flood Coolant System Maintenance csccceseseseeeeeesieee 106 Triac Series CNC Machine User s Manual
6. Drive Drive Drive Transformer Control 1 0 Board Board Board Board Card Triac Series CNC Machine User s Manual Section 8 Machine Electronics 109 8 The Eurostep Motion Control Board The eurostep motion control board is mounted in the bottom left corner of the electrical control box fitted into the far left slots of the card rack In conjunction with the custom card and axis drive boards it controls the motors that drive the three CNC machine axes Location a X Left panel f electri Look in the bottom left Ad corner of the control box from the right hand side control box Seven Segment LED Display 110 Machine Electronics Section 8 Triac Series CNC Machine User s Manual 8 The Eurostep Motion Control Board Location Jax Eurostep S Look in the bottom left Motion corner of the control box contol S from the front Custom Card Seven Segment L D Display LED Status and Fault Display Look directly at the end of the eurostep motion control card to read the seven segment LED display Display Meaning No comms board address fault Servo power off Servo power up and idle Cam profiling subscript symbol Cam table superscript symbol Circular interpolation Encoder following mode Flying shear static symbol Homing datuming J ogging velocity mode Offset mode Linear positional mode Torque control mode Stop asserted Pulse followi
7. 11 7 16 Cross travel Y axis 170mm 6 11 16 Vertical travel Z axis 235mm 9 1 4 Spindle taper ISO 30 Spindle speed range programmable 100 to 4000 rpm e Spindle speed override potentiometer 50 to 120 e Maximum feedrate X Y 2500mm min Maximum feedrate Z 1000mm min Feedrate override potentiometer 0 to 150 e Machine resolution 0 01mm 0 0004 System resolution 0 005mm 0 0002 Weights Machine weight 320 KG 705 Ib Electrical control box weight 70KG 154 Ib Electrical Details e Mains supply required 240 Volts AC 1 Phase 50 Hz 13 AMP Spindle motor 1 1 Kw DC 1 5 hp e Stepper motors 200 steps rev DC Compressed Air Connection Presetin the factory at 1 PSI 6 6 Bar e Maximum pressure 15 PSI 9 9 Bar Tooling Tool type ATC BT30 Tool capacity ATC 8 Section 10 Appendix 129 10 What Is a Part Program 130 Appendix Section 10 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 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 par
8. 2 Safety Features Interlock Guard Switch _ Model shown Triac PC with optional ATC pneumatic Guard door guard and vice lock plate Location of interlock guard switch mounted on the righthand side panel of the machine casing An interlock safety switch is fitted to the guard door on the righthand side panel of the machine cabinet The switch must be manually released to enter the working area when the 24 volt circuit has failed and the door is clamped electrically Note For manual interlock release the power supply must be switched off 1 Remove security screw A B or C whichever is easiest to reach using the supplied Torx T 20 adapter 2 Insert a 2 5mm diameter tool such as a small flat screwdriver into the hole until it pushes the manual release lever 3 Whilst holding the tool against this manual release lever open the guard 4 Remove the tool from the hole and replace the security screw Interlock Trip Lever Triac Series CNC Machine User s Manual Section 2 Safety Features 15 3 Unpacking amp Lifting your Triac DataPanel EiiaJeg Machine Weights Standard Triac PC 240 KG 529 Ib Triac PC with optional ATC 320 KG 705 Ib Triac VMC 320 KG 705 lb Electrical control box weight 70KG 154 Ib Use one single 5 metre x 500 KG nylon sling with a professional hoist to lift Cut the top of the delivery box open and remove any packaging carefully To obtain
9. 24 CNC Machine Installation Section 3 Lax PC version shown in photo below The electrical diagrams are held in a folder on the inside face of the door Note that the door cannot be opened with the mains isolator switch set in the on I position Depending on the CNC machine specification some electrical control box doors may be fitted with locks VMC version The electrical diagrams are stored in the base of the control box or supplied separately in the standard equipment box Supplied with your machine PC version The electrical diagrams are held in a folder attached to the inside face of the electrical control box door Triac Series CNC Machine User s Manual 3 Option Compressed Air Connection Unit Compressed Air Connection Unit The compressed air A compressed air connection unit is fitted to the back panel of the connection unit is fitted Triac cabinet comprising of three main elements as standard to the Triac VMC The air supply connection and isolator valve The compressed air The air pressure regulator and air filter regulator unit connection unit is fitted to the Triac PC when e The air lubricator unit any of the following The single airline connection supplies compressed air for the options are included standard automatic lubrication system the optional pneumatic guard ATC door and the optional hydraulic vice yara ece The air compressor must be fitted with a SCHR
10. Before Beginning to Setup The following optional equipment may also be supplied with or ordered for your Triac Series CNC machine 12 Introduction Section 1 IBM or 100 compatible PC keyboard mouse and monitor PC version 8 station automatic tool changer and tooling PC version Flood coolantsystem PC version Desk top tutor PC version Spray mistcoolantsystem Hydraulic vice Pneumatic safety guard door Upgrade pack for integration into Denford FMC FMS or CIM systems Courseware and project books Various tooling packages Additional training packages Additional CNC control software licences Machine work bench Video conferencing system Triac Series CNC Machine User s Manual 2 Safety Features Overview and Precautions Safety Features Overview The following safety features are standard on your Denford Triac CNC machine Emergency stop button Totally enclosed guard door with interlock switch Electronic shear key built into spindle controller Axis limit microswitches adjustable on Z slide Automatic tool retraction and spindle stop during a tool change operation on the optional Automatic Tool Changer Option on control software to check CNC programs prior to machining 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 h
11. Contents Section 8 Machine Electronics Accessing the Electrical Diagrams sessssessssessesssessssssrersseeees 107 Interior Layout of the Electrical Control BOX ssssscessesessesseseesees 108 The Eurostep Motion Control Board c cscsssssessessssesssareeen 110 The Spindle Drive Board cccssscsesssessssssessessssesssseeeessseen 112 Interior Layoutofthe Machine Connection BOX ues 113 Section 9 Technical Support Technical S ppott ininsert 114 Troubleshooting VR CNC Milling Software oes 115 Troubleshooting DOS CNC Milling Software wees 118 Troubleshooting Cutting Problems saene 121 Troubleshooting Mechanical Problems ccssssssssesseseesseseees 122 Troubleshooting Electrical Problems csscesssssessessstessesssesesseees 124 Section 10 Appendix Specification ofTriac PC v sscsussessesessesssesessssssrsssssssnesssseeeerssess 126 Sp cification of IMAC VM Co ironescht 128 Whatis a Part Program essien 130 Composition ofa PartP rogram sssccsecnnerrincnirisni 131 G Codes Liste eiiiiinhigaivaeva n a 132 MCodes Listaan a e R E ait 133 Listof Program Address Characters sssrin 134 Denford Directives oceans 135 EC Declaration of Conformity c sssscsssssssrssessessrsssssesssrsssssneeesees 137 Triac Series Noise Level TestRe Sults o c cesccsseseeeeeseeseeenee 139 Section 11 Glossary GOSS alae cei tate teil dnt ae 141 Section 12 Index MOEK a a a a a Aaa a 145 AON S PEA EEEE EAEN A EEE SENE 148 Triac
12. Photograph features optional and column connection unit changer equipment Location of optional i indi i Machine equipment indicated but item TP connection box Enclosed safety not shown in photograph guard door Connector plug for cable from separate electrical control box Automatic slide lubrication Hydraulic system intensifier Triac Series CNC Machine User s Manual Section 4 CNC Machine Operation 37 4 General Location of Triac Components Door E lectric a mas lock Control Ki Mains supply cable B OX connects to mains O plug socket CD ROM and Photograph depicts a floppy drives Triac PC electrical VMC versions control box only Machine power cable connects to CNC machine RS 232 connection on hidden end panel PC versions Door Mains isolator Electrical control lock switch box door working f Machine Machine column iuta Worklight tool changer carousel Flood Pneumatic vice coolant pipe Table Flood coolant pump near back of column Photograph features Flood Machine Machine equipment coolant column spindle Saddle Location of optional drain grill base under Flood equipment indicated but item table coolant not shown in photograph drain grill 38 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 Switching the Triac On Warning Tax Follow these instructions to swit
13. Section 1 Introduction Introducing your Triac Series CNC machine sssssssesreeessss 8 Triac Series Model Variants ois esrisriereeneneenen 9 Whatis CNC rintainen tanine na 10 Before Beginning to Setup ssecsrecrsecrresnieriirerni 11 Section 2 Safety Features Safety Features Overview and Precautions uo 13 The Emergency Stop Button cssssssssssssssssessssssrsrsssesssseessees 14 The Interlock Guard Switch westerns 15 Section 3 CNC Machine Installation Unpacking amp Lifting your Triac sessies 16 Deciding on a Site for your Triat cscsssssessesessessssresseeessssserssseees 17 Levelling YOUR LMC devtiventeetndawilatiwita With iin sida 18 PC version only Connecting your computer to the Triac PC 18 Connecting the Mains Supply essescresrrnerrincnienrinnni 21 Electrical Diagrams iiini 24 Option Compressed Air Connection Unit cece 25 Operation of the Compressed Air Connection Unit see 26 Option Flood Coolant System n se 29 Automatic Slide Lubrication System tececeseseseseseeseseesseeneenes 31 Removal of Protective CoatingS oo 33 ComponentConnection Schematic Diagram wo cece 34 Section 4 CNC Machine Operation Using your Triac OV rVICW essersi 36 General Location of Triac COMPONENTS oo cseeceseeee eee 37 Switching the Thiac ON s tAsecciseuiwuth angina sindusnioneneve 39 Switching the Triac Off esscccsecrnessnnersinernin 40 Homing the Machine Axes Home Mode a essusesccessssessesreeeesseees 41 Manuall
14. door shown open dotted Electrical Control Bo oF ascent Plan View showing Ideal Machine Operating Positions PC version shown Total width 600mm 23 5 8 Total height 780mm 30 11 16 Total depth 360mm 14 3 16 Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 17 3 Levelling your Triac Your Triac 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 Triac is to be situated 3 PC version only Connecting your computer to the Triac PC Warning A Do not connect cables between any electrical hardware with the mains power switched on since this could seriously damage components inside your personal computer and or CNC machine Lax The RS232 connection is not fitted to Triac VMC electrical control boxes since these versions have a hard wired permanent link between the CNC machine and the controller computer 18 CNC Machine Installation Section 3 Your Triac PC is controlled using a standard IBM compatible personal computer In this role the computer can be referred to as the machine controller Ideally the computer you intend to use should be placed next to your Triac and its electrical control box with easy access to a mains power supply Your computer must be equip
15. 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 the Notes section in this manual Triac Series CNC Machine User s Manual VR CNC Milling Software Communications Troubleshooting Tax 1 PC versions Your computer communicates with Triac PC versions using an RS232 serial cable Check the RS232 cable is securely plugged into a valid COM porton the computer Note that COM ports are sometimes labelled as serial ports Identify whether the COM port being 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 VMC versions The RS232 connection is not fitted since VMC versions have a hard wired permanent link between the CNC machine and the controller computer 2 All versions Check all mains power connections are correctly fitted and secure Power up the Triac using the yellow isolator Switch mounted on the electrical control box door position on position O off If no power is present switch off the mains Supply then wait at least 5 minutes before attempting to open the electrical control box door Check the condition of the isolator Switch and
16. 5 Triac Series CNC Machine User s Manual 5 Setting Tools in the ATC Tool Holder Warning X Never open the safety guard door and enter the working area when the spindle or machine axes are moving Adjusting the Tool Depth Stop Screw A tool depth stop screw is fitted to the inside of the ATC tool holder Rotating this screw allows the user to define the amount of tool that protrudes from the bottom of the tool holder Tools required Flat blade screwdriver To adjust the position of the depth stop screw remove the nut on the bottom of the ATC tool holder together with the collet and the tool Note that the tool depth stop screw runs along a lefthand thread Position the flat blade screwdriver in the slot on the face of the depth stop screw and turn the screw anticlockwise to move the depth stop up or clockwise to move the depth stop down when looking at the tool holder from the bottom ie imagining the toolholder is fitted to the machine spindle Refit the collet and tool to check if the desired tool position has been obtained Always ensure that the collet is fully seated in the tool holder and the tool itself is touching the depth stop screw Readjust the depth stop screw again if necessary Finally refit the nut on the bottom of the ATC tool holder j ATC Tool Holder Body Tool Depth Stop Screw 3 F n lt x View looking into the bottom of the Adjusting
17. Hardware Section 5 Triac Series CNC Machine User s Manual 5 Setting Tools in the Easychange Tool Holder Diagram showing layout of Easychange Tool Holder components and fitting tools Easychange tool holder body depth stop screw inside body Collet 45 50mm C Spanner for nut around collet assembly Cutting tool 2mm Allen 30 32mm Key for C Spanner depth stop for tool holder adjustment body Nut for holding collet assembly Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 55 5 Setting Tools in the Easychange Tool Holder Fitting Tools to the Collet Each cutting tool must be fitted into the appropriate sized collet before attempting to fit the assembly into the tool holder The collet is the tubular split metal casing especially designed to fit securely in the tool holder Different sized collets are available to accept the various sizes of cutting tool shaft diameters A Collet i Assembly ready to fit to a the Tool Holder Cutting Tool Changing the Collet Assembly The collet assembly is changed using the nutat the bottom ofthe Easychange tool holder body The easiest method for changing collet assemblies is when the tool holder is fitted to the CNC machine since the changing procedure is a two handed operation Tools required 30 32mmC Spanner this fits around the middle segmentof the Easychange tool holder body 45 50mmC
18. Machine Power Cable A continued Do not connect cables between any electrical hardware with the mains power switched on since this could seriously damage components inside your personal computer and or CNC machine Male pin layout on Female pin layout on machine machine power cable connection box bracket Warning axy The male and female connector plugs are shaped so they can only be connected in the correct orientation the cutaway parts of the A connector housings and the numbered segments printed on the pin Do not attempt to fitthe faces must match in order to achieve an electrical connection Decors Position the male connector Roller clips circled secure the lug against the bracket together the wrong way plug on the end of the p ug agal round This could machine power cable tie damage the connector against the female bracket pins on the machine connection box in the correct orientation the flexible machine power cable hose should exit the male connector plug facing directly a C down as shown in the photo Cable opposite Push the nie connector plug fully into the facing bracket Ft Tighten the electrical connection by using the two roller clips located at the top and bottom of the bracket Fully press each roller clip until they click against the locating pins on the outside surface of the male connector plug then check the junction is secure 22 CNC Machine Installation
19. Mechanism and Cylinders Apply a light coating of oil to both cylinders above the ATC carousel mechanism as shown below left Lubricate the pivot points and segments on the cam driven mechanism in the centre ofthe ATC carousel as shown below right Operate the ATC carousel to distribute the oil evenly across all surfaces Location ca X Look at ATC carousel f ATC cover Oil each segment a ATC carousel ATC arm in ATC arm out ATC arm down ATC arm up Drawbar unclamp Drawbar clamp ATC reset carousel Carousel CW Carousel CCW Carousel 1 2 tum ATC carousel jo 102 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Automatic Tool Changer Maintenance ATC Cylinder Damping Mechanisms The ATC is fitted with self damping pneumatic cyclinders The level of damping is presetatthe time of CNC machine manufacture Under normal conditions no adjustmentis required to the amount of damping or cushioning provided by each cyclinder Ifa clunk sound is being heard when a toolchange is performed the self damping features on the ATC pneumatic cylinders may require adjustment Adjustmentscrews are fitted beside the air supply ports at both ends of each cylinder To increase the damping effect eliminating the noise turn the adjustmentscrews clockwise Smee x ATC Tool Holder Pull Studs A Check for slack in each of the pull studs Cauti fitte
20. Series CNC Machine User s Manual Contents 5 Warning Notices A Warranty Disclaimer The Warranty on your Denford Triac CNC machine will be invalidated if any modifications additional ancillary equipment is fitted or any adjustments made to the controlling devices without prior notification from Denford Limited Please refer to the information held in your separate Warranty pack for specific details Do not carry out any portable appliance testing PAT on any of the supplied equipment A Maintenance Disclaimer Always obtain permission from the person responsible for machinery in your establishment before accessing your Denford Triac CNC machine and or the electrical panels in the control box to carry out any maintenance work All work must be carried out by personnel suitably qualified for each 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 A F oreseen Use of Machine Your Denford Triac CNC machine is designed for milling non hardened ferrous metals aluminium hard woods and plastics In each case the appropriate tooling spindle speeds and feedrates should be used as recommended by the material supplier Only use water based soluble oil cutting fluids do not use parafinic or potentially explosive cutting fluid Do notattemptto use yourCNC machine
21. a CNC program Before starting to run your CNC program we recommend that you number each easychange tool holder then fitthe appropriate tool profile to each holder according to the number profile combinations used in yourCNC program The tool profiles allocated to each tool number are listed at the beginning of your CNC program and may also be programmed into your CNC control software This will reduce the possibility of the incorrect tool number profile being placed into the machine head when the first tool change operation is called On reading a tool change requestin your CNC program all three machine axes will move to their home positions via an intermediate point if programmed Atthis point the CNC control software will pause the CNC program and a message window will be displayed prompting you to manually change tools Wait for all machine movements to stop before opening the safety guard door then change to the new tool number profile requested Close the Safety guard door and confirm via any CNC control software message windows thatmachining can be resumed 60 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 The Automatic Tool Changer System The ATC Automatic Tool Changer is supplied as standard with the Triac VMC oras an option with the Triac PC The system is designed to automatically transfer tools when required between the machine head and the storage carousel positioned to the
22. a S te Ss ee d Billet Billet e Move the Tool over the chosen Tool Offset Reference Position Take care not to damage the cutting tip when manoeuvring the tool 48 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 Running a CNC Program Auto Mode The sequence of events required to begin part manufacture on the Triac 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 Auto mode is used for controlling the CNC machine when running a CNC program Part Manufacture Checklist Before beginning to manufacture your part check to see that the following tasks have been completed e Billet mounted and secure Tools prepared and numbered ready for use according to your CNC file Safety guard door closed e CNC file loaded and checked via simulation e Workpiece and Tool Offset files configured or loaded e Machine homed datumed e CNC control software switched to Auto mode Triac Series CNC Machine User s Manual Section 4 CNC Machine Operation 49 4 Front Machine Operators Panel Axis limit switch Optional override pneumatic Model stiown button guard optona fod door Emergency coolant button stop Feedrate button override Spindle potentiometer speed control override potentiometer control The Machine Operators Panel The panel contains the following control
23. better access to the Triac and any additional pieces of equipment remove all the sides from the delivery box leaving the Triac standing on its wooden delivery pallet Lift the Triac from the packaging Use a professional hoist and a single 500KG 1120 Ib 5 metre 200 endless nylon sling to lift the Triac arranged as shown in the diagram below Always use sensible lifting precautions in accordance with Health and Safety Regulations in your establishment Use caution when removing the separate electrical control box since it weighs 70 KG 154 lb If possible lift the electrical control box using a porters trolley Ensure that your Triac is 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 it moved To transport your Triac over longer distances use a suitably sized wheeled trolley Use a professional A hoist to lift the machine c lt ae Thread one single 5 metre 200 500 KG 1120 Ib nylon sling through the eyebolt on the top of the machine column 16 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Deciding on a Site for your Triac TeX Site your Triac in a well ventilated room The Triac is a bench Gutionalimachinastables mounted machine so it should be sited on a bench of sturdy and industrial cabinets construction to take the weight of the machine and of a he
24. call Denford Customer Services for assistance Warning Risk of electric shock Note that in order to check the readout the CNC machine must be powered up with the electrical control box open Exercise extreme caution do not touch 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 116 Technical Support Section 9 Triac Series CNC Machine User s Manual 9 Troubleshooting VR CNC Milling Software 7 All versions Check the COM port on your pc is functioning correctly Consult your IT person or Computer Support Centre for help with these issues Check the COM port settings 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 but the port is not seen by any external devices VMC versions The main body of the machine controller computer is mounted on the inside face of the electrical control box door 8 When all else fails PC versions Thoroughly check the condition of the RS232 cable If the cable is bad communication will not occur Try using a different pc to connect to the CNC machine All versions Check for help on the technical support FAQ and download secti
25. check if the desired tool position has been obtained Always ensure that the collet is fully seated in the tool holder and the tool itself is touching the depth stop screw Readjust the depth stop screw again if necessary Finally refit the nuton the bottom of the E asychange tool holder Easychange Tool Holder Body Tool Depth Stop Screw 2mm hexagon hole 2mm Allen View looking into the bottom of the Adjusting the tool depth stop Easychange tool holder screw 58 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 Requesting a Tool Change Easychange Te OX Manually Calling an Easychange Tool Change A Before calling the tool change we recommend you home all three Never open the safety machine axes When all three machine axes are attheir home guard door and enter positions the maximum amountof free space will be available in the the working area when working area allowing easier access to the tool holder and the spindle or machine Easychange collar axes are moving There are two methods used to manually call an Easychange tool change 1 Switch your CNC control software to J og mode and use the manual A tool change function commands Caution 2 Write and execute a small M06 tool change program in your CNC lf the cutting tool has control software editor see the section on the next page been recently used it may still be HOT Always wait for the spindle
26. control clockwise when viewed from above to increase the vice pressure or anticlockwise when viewed from above to decrease the vice pressure Push the rotary control down to relock it in its new position Increase air pressure Nao SNS Decrease air pressure View Direction Pressure adjuster oh OE PARP Air pressure dial continued Triac Series CNC Machine User s Manual Section 6 Work Holding 79 6 Option Hydraulic Vice Operation Lubrication unit z Add oil to the 7 t semn a FA Eae lubrication Vice jaws I i unit through pressure ok top filler cap regulator i unit 3 2 The hydraulic intensifier unit includes a lubrication unit which automatically distributes oil to the hydraulic system and the vice To top up the lubrication unit lift the cap on the top of the oil storage reservoir and pour in the required amount of oil Refill the reservoir using oil grade ISO VG 32 M Codes for Hydraulic Vice Operation The sequence of events The following M codes can be manually entered to control the required to manually eurai antaran Mecode wil operation of the optional hydraulic vice 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 U
27. electrical control box which in turn is connected to the Triac CNC machine There are two A electrical connections that exit the control box Do not connect cables The machine power cable this is the large diameter flexible hose between any electrical The mains supply cable the small diameter cable hardware with the mains power switched on The Machine Power Cable ir ae The machine power cable must be attached to the Triac CNC components inside your Machine The machine power cable is housed in the large black personal computer and flexible hose approximately 30mm in diameter or CNC machine One end of the machine power cable is permanently connected to the side panel of the electrical control box whilst the free end is fitted with a male connector plug as shown in the diagram below left The back panel of your Triac PC is fitted with a machine connection box containing a fixing bracket with the female connector plug as shown in the diagram below right The male connecter plug is located on the The female connector plug is free end of the fitted to the fixing bracket machine power mounted on the side of the cable fitted to machine connection box the side panel located on the back panel of of the electrical the Triac cabinet control box continued Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 21 3 Connecting the Mains Supply CA 7x The
28. feedrate is ignored A sequence of events or commands The zero point co ordinate from which a series of measurements are taken The L shaped bracket used to help locate pieces of work in position on the machine table Triac Series CNC Machine User s Manual Section 11 Glossary 141 11 Glossary DESKTOP TUTOR wu 142 Glossary Section 11 The input control keypad for the machine Keypad overlays are interchangeable according to the type of controller required 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 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 he symbol or indicator that defines the end of a block of data The equivalent of the pc return key The deviation of an attained value from a desired value The programming language understood by the machine controller The rate in mm min or in min at which the cutting tool is advanced into the workpiece For milling and drilling the feedrate applies to the reference point on the end of the axis of the tool An arrangement of
29. hole is facing away from the grubscrew then the hexagon washer is slack against the work ie the miteebite is open If the bolt is then turned through 180 degrees so that the allen key hole is now facing towards the grubscrew then the hexagon washer will be tight against the work ie the miteebite is closed Continual turning of the bolt is unnecessary since the full range of movement for the hexagon washer is covered in a single 360 degree rotation of the bolt In this respect the hexagon washer will not tighten further if the bolt is continually turned clockwise Bolt both the head and the allen key holes are machined Hexagon Slightly off centre washer Grub screw passes through the base of the Tee nut To loosen grubscrew turn anticlockwise viewed from above To tighten grubscrew turn clockwise viewed from above Tee nut 76 Work Holding Section 6 Triac Series CNC Machine User s Manual 6 Using Miteebite Clamps The example used in the description below explains the fitting procedure for a temporary lt MDF sub table onto which a ms plastic Sheet can be attached using double sided tape Set the Datum Plate into position then place the temporary MDF Sub table onto the machine table so itis located correctly against the edges of the datum plate Next position the miteebites into their respective T channels and Slide them along until they touch the sub table Ensure that one of the six flat si
30. instructions or information usually referring to work or control settings The pattern or way that data is organised Flexible Manufacturing Cell Flexible Manufacturing System FANUC Miller file extension fnc Contains G and M codes describing the machine and cutting operations A preparatory code function in a CNC program that determines the control mode Equipment such as the machine tool the controller or the computer Operation to send the axes of the CNC machine to their extreme limits of movement Defines the co ordinate based grid system of the CNC machine Commonly referred to as homing the machine or sending the machine to its home position Incremental programming uses co ordinate movements that are related from the previous programmed position Signs are used to indicate the direction of movement The transfer of external information data into a control system The medium through which the control computer directs the machine tool Triac Series CNC Machine User s Manual 11 Glossary JOG CONTROL Manual movement mode for the machine axes using very small pre defined movements called jog steps One stepped movement is applied per movement key button press M CODE siina A miscellaneous code function in a CNC program used to indicate an auxiliary function ie coolant on tool change etc MACHINE CODE sss The code obeyed by a computer or microprocessor system with no need for further translation
31. limit switch override control is a square green push button If an axis limit switch has been activated to move the axis in question press and hold the axis limit switch override button and at the same time jog move the axis away from the switch using the appropriate axis jog key Pneumatic Guard Door optional equipment M codes for manual f i operation of the The control for the optional pneumatic guard door is a square green pneumatic guard door push button When the CNC control software is operating in Home M38 Guard open or J og Mode press the button to open or close the pneumatic guard M39 Guard close door Spindle Speed and Feedrate Override Controls Spindle Speed and or Eeedate oveiide The spindle speed and feedrate of the Triac can be manually changes will only be overridden during a machining operation using the potentiometer registered when an controls fitted to the operators panel On machines where these actual spindle speed or controls are not fitted or disabled the spindle speed and feedrate P Po must be overridden using the CNC control software please refer to T SAED your separate CNC Control Software User s Manual for details regarding this feature Waring Sr The spindle speed can be overridden between 50 and 120 A The feedrate can be overridden between 0 and 150 To increase the spindle speed or feedrate rotate the appropriate control clockwise Never attempt to open the safety gua
32. plate attached to the front of the machine column as shown below The coverplate is held in position using two screws accessible from the underside of the machine head using a 2 5mm allen hex key Machine i Machine 1 REEE head 2 head l underside underside f Remove two SCTeWS 3 Inspect ballscrew condition 92 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Cleaning and Inspecting the X Axis Datum Microswitch The microswitch defining the X axis datum is mounted in a small alcove on the left front upper corner of the saddle when viewed from the front ofthe machine Drive the machine table fully to the left This will make is easier to gain access to the left side of the saddle where the condition of the microswitch can be checked as shown below Using a soft bristled brush carefully clean any swarf and debris away from the microswitch to a location where it can be removed from the working area Inspect the microswitch for damage or wear View looking at left side of saddle Location X Look at left side of saddle from below al B The trigger forthe X axis microswitch is mounted under the left front side ofthe machine table as shown below 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 Location ea e Look at lef
33. s Manual Section 5 Preparing Tooling Hardware 69 6 Option The Datum Plate The datum plate is an L shaped bracket used for helping to remove and replace work in identical positions on the machine table This allows projects to be configured using the same workpiece and tool offsets since the billet can always be placed accurately in position on the machine table hence the name datum plate Itis fixed against the machine table using two tee nut assemblies which can be moved to the required position for the datum plate The tee nuts slide along T shaped channels that run horizontally along the machine bed these trap the datum plate in position when the allen headed bolts are tightened gm To loosen bolts turn anticlockwise viewed Wy from above EM To tighten bolts turn ad clockwise viewed from above Allen headed bolt O Datum Plate L shaped work locating bracket Tee nut 70 Work Holding Section 6 Triac Series CNC Machine User s Manual 6 Fitting and Removing the Datum Plate Removal of Datum Plate To remove the datum plate loosen the 2 allen headed bolts by turning them in an anticlockwise direction Slide the datum plate along the machine table until the Tee nuts are released from their channels then withdraw the datum plate from the machine table Fitting of Datum Plate To fit the datum plate in position on the machine table place it at the end of
34. screwdriver for m eau depth stop adjustment 64 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 Setting Tools in the ATC Tool Holder Fitting Tools to the Collet Each cutting tool must be fitted into the appropriate sized collet before attempting to fit the assembly into the tool holder The collet is the tubular split metal casing especially designed to fit securely in the tool holder Different sized collets are available to accept the various sizes of cutting tool shaft diameters A Collet Assembly ready to fit to Pie the Tool Holder Cutting Tool Changing the Collet Assembly The collet assembly is changed using the nut at the bottom of the ATC tool holder body The easiest method for changing collet assemblies is when the tool holder is fitted to the CNC machine since the changing procedure is a two handed operation Tools required e 45 50mm C Spanner this fits around the middle segment of the ATC tool holder body e 24mm Spanner this fits around the nut at the bottom of the ATC tool holder body continued Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 65 5 Setting Tools in the ATC Tool Holder Warning a X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Warning a X A Caution If the cutting tool has been recently used it may still be HOT
35. the 25 pin D female the 9 pin D male COM port on your computer ideally COM 2 Most computers usually have two COM ports situated on the back panel If you cannot identify any of the ports please refer to your original computer manufacturers operating manual for further guidance Note that older computers may be fitted with a 25 pin D male COM port which may require the fitting of an additional 9 to 25 pin adaptor to your RS 232 cable Short standard 9 pin D COM port Long PCI card mounted 25 pin D COM port 25 pin D male 25 pin D female 9 pin D female 9 pin D male connector fitted connector fitted to connector connector fitted to computer RS232 cable using a fitted to to computer back panel 9 to 25 pin adaptor RS 232 cable back panel parallel printer port on your computer with the 25 or 9 pin male D COM ports J If your CNC machine control software is yy 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 component connections is shown on 25 pin D male 25 pin D female connectoron connector fitted pages 32 to 33 security key to computer dongle back panel 20 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Connecting the Mains Supply Warning Tax The mains power supply is fed to the
36. the software to operate in jog mode 4 On CNC machines fitted with pneumatic powered safety guard doors check the compressed air connection unit is functioning correctly the air compressor is connected and switched on and the correct air pressure level is set 1 PSI or 6 6 Bar see Section 3 CNC Machine Installation pages 25 to 28 Check the security and condition of all hose connections The ATC system is not working effectively Check the following 1 The compressed air connection unit is functioning correctly the air compressor is connected and switched on and the correct air pressure level is set 1 PSI or 6 6 Bar 2 Check the security and condition of all hose connections 3 The slides cylinders and pivot points on the ATC may require cleaning and lubrication The ATC system does not have an automatic lubrication system unlike the axis slides and ballscrews 4 Ifa clunk sound is being heard when a toolchange is performed the self damping features on the ATC pneumatic cylinders may require adjustment Adjustment screws are fitted beside the air Supply ports at both ends of each cylinder To increase the damping effect eliminating the noise turn the adjustment screws clockwise 122 Technical Support Section 9 Triac Series CNC Machine User s Manual 9 Troubleshooting Mechanical Problems The hydraulic vice is not holding the billet Check the following 1 The correct pressure has been set fo
37. the spindle When a tool change is requested the ATC will release the currently held tool holder into this empty space before rotating and installing the new tool holder in the empty machine head Carefully align the top surface of the tool holder double flange the widest partofthe tapered body against the top surfaces of the two spring loaded cylindrical grippers on the carousel pocket a Align the top surface of the tool DA b Horizontally push the tool holder holder flange with the top surfaces into the pocket the two grippers of the cylindrical grippers will automatically separate c Ensure the single flange inside the pocket aligns with the groove around the tool holder Push the tool holder into the pocket ensuring thatthe groove between the tool holder flanges aligns with the single flange inside the carousel pocket Check the tool holder is correctly seated as shown in the photo opposite you should not be able to move the tool holder vertically Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 63 5 Setting Tools in the ATC Tool Holder Diagram showing layout of ATC Tool Holder components and Pul fitting tools stud ATC tool holder body depth stop screw inside body Collet 24mm spanner for nut around collet assembly Cutting tool 45 50mm C spanner for tool holder body Nut for holding collet assembly Flat blade
38. tool 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 not slipping 5 The tool profile is held securely in the tool holder which in turn is held securely in the machine spindle 6 Ifa poor surface finish is still being obtained after completing checks 1 to 5 itis possible that one or more axis gib strips need adjusting see Section 7 Maintenance pages 97 to 101 Triac Series CNC Machine User s Manual Section 9 Technical Support 121 9 Troubleshooting Mechanical Problems The safety guard door cannot be opened In most cases this is because the interlock guard switch has locked the door in the closed position The interlock guard switch is mounted on the right end panel of the Triac cabinet Check the following 1 Mains power is reaching the CNC machine Check the large flexible machine cable is fitted securely to the machine connection box on the back of the Triac cabinet Check the mains plug from the electrical control box is fitted to an available power socket and the socket is switched on Check the isolator on the electrical control box is switched on 2 The emergency stop button is not pressed in To release push and turn the button counterclockwise until it springs back out to its ready position 3 No CNC program is running Wait for all machining operations to finish then switch
39. your CNC M09 Coolant off optional flood coolant system control software M10 Vice open optional hydraulic vice oe ak MiL Vice close optional hydraulic vice coftare Users Manual M13 Coolanton and spindle forward optional flood coolant system for specific details M14 Coolant on and spindle reverse optional flood coolant system M20 ATC arm in towards machine spindle optional ATC M21 ATC arm out away from machine spindle optional ATC M22 ATC arm down from beneath storage cover optional ATC M23 ATC arm up into storage cover optional ATC M24 Drawbar Unclamp release tool holder optional ATC M25 Drawbar Clamp grip tool holder optional ATC M27 ATC reset carousel optional ATC M32 Rotate carousel clockwise viewed from above optional ATC M33 Rotate carousel counter clockwise viewed from above optional ATC M34 Rotate carousel one half turn optional ATC M38 Guard open optional pneumatic safety guard door M39 Guard close optional pneumatic safety guard door M62 Auxiliary output number 1 on option M63 Auxiliary output number 2 on option M64 Auxiliary output number 1 off option M65 Auxiliary output number 2 off option M66 Wait auxiliary output number 1 on option M67 Wait auxiliary output number 2 on option M76 Wait auxiliary output number 1 off option M77 Wait auxiliary output number 2 off option 44 CNC Machine Operation Se
40. 120 Technical Support Section 9 Triac Series CNC Machine 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 cut used 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 offset files have been configured and applied successfully If no 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 spindle speeds and coolant 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 incorrect feeds speeds or no coolant can severely shorten the life expectancy of your tools 2 The billet being machined is securely clamped 3 The correct
41. 9 9 Bar See Section 3 CNC Machine Installation pages 25 to 28 for detailed information on the compressed air connection unit M Codes for Pneumatic Safety Guard Door Operation The following M codes can be manually entered to control the operation of the optional pneumatic safety guard door M38 Guard open M39 Guard close Section 6 Work Holding 81 7 Planning Procedure for Maintenance Work Safety First T X A Caution Wear safety glasses and a suitable respiratory mask when cleaning the machine Smee 1 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 outany 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 relevantto 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 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 Safety must be a priority when carrying out an
42. ADER quick release s e neumaucdoor connector The connection fitted onto the end of the unit is SCHRADER part number SC 8051 11 1 8 BSP MALE The female connector required on the 1 4 pipe leading to the air compressor is SCHRADER part number 9793C 12 1 4 BSP FEMALE Pressure adjuster Air lubrication adjustment screw Air supply isolator SCHRADER connection To machine Air lubricator unit Air drain exhaust valve Removable air lubrication oil container Compressed airline valve Air pressure Air filter Air filter dial regulator water container drain plug To compressed air source Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 25 3 Option Operation of the Compressed Air Connection Unit Air Supply Isolator Unit The air supply isolator unit is used to pressurise or drain the compressed air system To pressurise Switch on the system turn the control fully anticlockwise when viewed from above until the flat surface of the handle aligns with the general airflow direction To depressurise Switch off the system turn the control fully clockwise when viewed from above until the flat surface of the handle lies at ninety degrees to the general airflow direction When the system is depressurised the conical air drain exhaust valve positioned directly under the air supply isolator is used to dump any remaining air pressure
43. CNC Machine Installation 27 3 Option Operation of the Compressed Air Connection Unit Air Lubricator Unit The oil lubricator unit is used to blend a fine mist of oil with the compressed airstream The unit eliminates the potential damaging effects of any moisture that may be present and automatically lubricates any hardware within the air system The amount of oil blended with the pressurised air can be adjusted using the screw set inside the plastic cap To increase the oil flow use a flat bladed screwdriver to turn the screw anticlockwise when viewed from above To decrease the oil flow use a flat bladed screwdriver to turn the screw clockwise when viewed from above The rate of flow is preset at the factory according to the various pneumatic options fitted to your Triac at the time of manufacture This rate should NOT require adjustment through normal day to day use of the CNC machine To refill the air lubricator unit you must unscrew and withdraw the entire oil container positioned directly below the oil flow adjustment screw and cap Refill the container using oil grade ISO VG 32 View Oil flow adjustment screw Direction set into plastic cap Decrease oil flow e eee PSS lt Increase oil flow Removable air lubrication oil container 28 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Option Flood Coolant System The System Coolant is driven
44. Cincinnati Millacron Storage tank flood system CNC software Simcool 60 capacity controlled Dilution minimum 2 5 14 75 litres Optional ATC Pump oilcan Weekly BP CS 68 As required and or pneumatic manual Shell Vitrea 68 safety guard door Castrol Perfecto NN Optiona Automatic Check level daily ISO VG 32 Top up as compressed air lubricator unit required connection unit Optiona Hydraulic intensifier Check level daily ISO VG 32 Top up as hydraulic vice lubricator unit required Warning A Risk of Ignition or Explosion Denford recommends that aerosol based lubrication products should NOT be used since these products may cause potentially explosive vapours to build up in enclosed areas of the CNC machine 86 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 General Work Area Cleaning aoea ax Thoroughly clean and lubricate the CNC machine paying special attention to the working area according to the Maintenance Schedule A listed on page 85 In particular ensure the build up of swarf and debris Never open the safety in the following areas is prevented guard door and enter f i f the working area when The X axis leadscrew running under the machine table the spindle or machine e The two X axis slides running under the machine table axes are moving j R 2 x r The X axis microswitch mounted in the front leftside of the crosslide end casing eee ST The two Z a
45. DEN FORD Total Commitment to Education and Training WorldWide Triac Series CNC Machine 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 06 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 customer _services denford co uk Technical Support Telephone 01484 722733 e mail customer_services 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 Triac Series CNC Machine User s Manual Contents Preface Contact NfOrMatiOns irssi issiria 2 Waming NOCES mraint tis ccevs eies ite 6 Aboutthis Manual ssssssesssssrersnsrinronsrunnnsnnnrinnnnnunnnnennrnrnnnnsnrnrenns 7
46. Limited Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Declares that the machinery described Manufacturer Denford Limited Model Name Triac Series CNC Milling Machine Serial Number please refer to warranty card and or machine casing conforms to the following directives The EC machinery directive 89 392 EEC as ammended 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 oo cscssesesseesesseecseneesiesseessesseesnsenseaneeieeseeseesnesnseass Signature Position within company Senior Design Engineer Signed at Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Back of the EC Declaration of Conformity Certificate 138 Appendix Section 10 Triac Series CNC Machine User s Manual Triac Series Noise Level Test Results Test Report No NL TR5 01 Machinery Manufacturer Denford Limited Machinery Type M odel Triac Series CNC Milling Machine Date compiled 14 12 94 Test site Inspection Dept Test specification In accordance with BS4813 1972 Equipment Meter ref Cirrus CRL 2 35A 1 off Denford Triac Series CNC machine 1 off General Machine Test Conditions Chuck on size Standard Splash on guard Standard Machine mounting Floor Additional equipment None Test Positions Diagram Ke
47. NC program from a traditional engineering drawing or automatically set by a CAD CAM software package For example if you used the CAD CAM software package Denford MillCAM Designer your design would have been drawn within a fixed area representing the size of the billet you intend to use The software would then have generated the CNC program automatically setting the front left upper corner of this imaginary billet as the part datum In this case you would need to position the workpiece datum in the front left upper corner of the real billet on the machine table What happens if don t use any offsets with my CNC file If no offset is programmed the machine controlling software will use the machine datum as the starting point zero reference for any co ordinate movements it receives Since itis unlikely that the position of the machine datum is the place where you want any machining to begin your CNC machine will attempt to manufacture your design in the wrong place in its working area Offsets are very important because without them the CNC machine will not know where to begin cutting on your billet Offsets must always be configured before manufacturing the part Are standard offset files supplied No you must set your own We DO NOT supply any standard offset files with your CNC control software However once you have configured and saved your offset files the same files may be used over and over again so long as the f
48. Please refer to your separate CNC Control Software User s Manual M14 Coo ant off anton and spindle reverse for specific details 30 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Automatic Slide Lubrication System The automatic slide lubrication system located on the back panel of the Triac cabinet is comprised from an oil reservoir tank and an The automatic slid Se a automatic pump unit The system is designed to automatically ubrication system is fitted as standard to all Supply oil to the slides and ballscrews on the X Y and Z axes only SOENEN Oil is automatically pumped to the required areas upon activation of he system does not automatically lubricate the machine head spindle Do not let the oil level drop below the the slides on Automatic minimum mark printed on the side of the reservoir tank ne To top up the slide lubrication system lift the yellow filling cap and versions optional on PC POUT Sufficient oil into the reservoir tank Take care NOT to overfill versions the system The reservoir tank has a maximum capacity of 0 5 litres Refill the reservoir using oil grade BP CS 68 Filling the automatic slide lubrication system Location of automatic slide lubrication system Plastic filling oil cap Low oil level marker Triac Series CNC Machine User s Manual Section 3 CNC Machine Installa
49. Removing a Collet Assembly Place a soft cloth under the tool holder incase the collet assembly unexpectedly falls out of the tool holder during the operation Using the 24mm spanner loosen the nut at the bottom of the ATC tool holder body by turning in a clockwise direction when viewed from above Position the 45 50mm C spanner on the middle segment of the tool holder in the opposite direction to stop the tool holder from rotating on the spindle see the lefthand diagram below Adding a Collet Assembly Insertthe collet containing the new tool profile as far as it will travel into the bottom of the tool holder Continue to slide the tool itself up inside the collet until ithits the depth stop screw The depth stop screw determines how much of the tool will protrude from the bottom of the tool holder see the next page for details on how to adjust the depth stop screw Hand turn the nut atthe bottom of the ATC tool holder body anticlockwise when viewed from above until it grips the collet assembly Using the 24mm spanner continue to tighten the nut by turning in an anticlockwise direction when viewed from above Position the 45 50mmC spanner on the middle segment of the tool holder in the opposite direction to stop the tool holder from rotating on the spindle see the righthand diagram below Removing a Collet Assembly Adding a Collet Assembly 24mm spanner 24mm spanner 66 Preparing Tooling Hardware Section
50. S 232 connection is not fitted since VMC versions have a hard wired permanent link between the CNC machine and the controller computer 2 All versions Check all mains power connections are correctly fitted and secure Power up the Triac using the yellow isolator Switch mounted on the electrical control box door position on position O off If no power is present switch off the mains supply then wait at least 5 minutes before attempting to open the electrical control box door Check the condition of the isolator Switch and fuses For more information refer to Section 8 Machine Electronics 3 All versions The DOS CNC Milling software is started by executing the FANUC GO file Check the COM port being used on your machine controller computer matches the COM port number specified in the FANUCMD 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 RS232 cable is plugged into COM1 the line should read 3F 8 4 MACHINE Ifthe RS232 cable is plugged into COM2 the line should read 2F8 3 MACHINE Change the line to read the correct port number being used then save the file 4 All versions Remove the HIMEM SYS line from the CONFIG SYS file Often times environmental factors will interfere with proper communication continued 118 Technical Support Section 9 Triac Series CNC Mac
51. Section 3 Triac Series CNC Machine User s Manual 3 Connecting the Mains Supply Warning aX Mains supply cable O A connects to mains Do not connect cables plug socket between any electrical hardware with the mains Machine power power switched on cable connects to since this could CNC machine seriously damage components inside your personal computer and or CNC machine Depending on the CNC Plastic yellow Mains isolator Electrical control machine specification sealing tag switch box door some electrical control box doors may be fitted Electrical Control Box Seal with locks The electrical control box is inspected then sealed with a plastic yellow sealing tag If this seal is broken on delivery inform the w X aa os a HEE suppliers immediately The seal should only be broken for the initial A mains power connection Never attempt to access the electronic hardware systems in the CNC Connecting the Mains Supply machine or electrical control box with the The electrical control box is delivered with the mains supply cable mains power switched connected directly into the isolator including approximately 3 metres ON of standard mains specification cable The cable should be fitted Note that hazardous f voltages can still exist with a standard 13 amp plug or equivalent suitable for the mains immediately after power supply switching off the power If the mac
52. Series CNC Machine User s Manual Section 12 Index 145 12 Index G G COMESMISE ful iinne General layout of Triac components Gib Strip adjustment theory ou esses 97 X AXIS adjustMent eerren 98 y axis adjustMent eeeeereee 99 z axis adjustment at GlOSSa Niaren H Help technical support oo 114 Home mode sites tits a A aT 41 Hydraulic vice asjusting the pressure of the vice jaws 79 COMPONENLS wastes lubrication unit maintenance 4 Operating m codes preparing the compressed air supply 79 troubleshooting oes eeseeseeseesesesteeseeseesnees 123 l Installation automatic slide lubrication system 31 before yo stafts asasena 11 component connection schematic diagram 34 compressed air connection Unit eee 25 flood coolant system nsss levelling your Triac sssr 1 mains supply connection as removal of protective coatings iee 33 Siting your THA anrora 17 Interlock guard SWIC testes 15 Introduction Triac Series ANd variants esscr 8 what is CNC wee 10 Isolator MAINS SWIECH sssi 24 J Jog mode kinesine iiaii 42 L Layout of Triac components sssssssereeeee Levelling your Triat ceseesceeseeseesseesteeseeesteeeee Lifting your Tia Ci iinitan Location of Triac components photo ik L brication charts aduanan 146 Index Section 12 M codes list partial cece 44 M codes listing full esee 133 Machine co ordinates display sys
53. Spanner this fits around the nutat the bottom of the Easychange tool holder body continued 56 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 Setting Tools in the Easychange Tool Holder Warning aX A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Warning X A Caution If the cutting tool has been recently used it may still be HOT Removing a Collet Assembly Place a soft cloth under the tool holder incase the collet assembly unexpectedly falls out of the tool holder during the operation Using the 30 32mmC spanner loosen the nutatthe bottom of the Easychange tool holder body by turning ina clockwise direction when viewed from above Position the 45 50mmC spanner on the middle segment of the tool holder in the opposite direction to stop the tool holder from rotating on the spindle see the lefthand diagram below Adding a Collet Assembly Insert the collet containing the new tool profile as far as it will travel into the bottom ofthe tool holder Continue to slide the tool itself up inside the colletuntil ithits the depth stop screw The depth stop screw determines how much of the tool will protrude from the bottom of the tool holder see the next page for details on how to adjust the depth stop screw Hand turn the nut atthe bottom of the Easychange tool holder body anticlockwise when viewed fro
54. View L RENN Direction zy A to pressurise the system to drain air pressure 26 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Option Operation of the Compressed Air Connection Unit Air Filter Regulator Unit The air regulator unit is used to adjust the air pressure level with a readout being displayed on the dial gauge The normal operating pressure as supplied preset on the machine is 18 PSI 6 6 Bar Maximum pressure for the air regulator is 15 PSI 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 from above to increase pressure or anticlockwise when viewed from above to decrease pressure Push the rotary control down to relock it in its new position Increase air pressure PSS fae SON N NA Decrease air pressure Air filter water drain plug The air filter unit positioned below the dial gauge cleans and removes any water particles from the compressed airstream Regularly drain any water collected in the filter container the bottle below the dial using the removable plug positioned at the bottom of the container The interval at which this operation is required will depend on the type and condition of the air compressor being used Triac Series CNC Machine User s Manual Section 3
55. ae horizontally forwards and backwards when viewed from the front of User s Manual for the machine specific details Minus Y movements run towards the front of the machine and positive Y movements run towards the back of the machine Z Axis The Z axis slides runs at 90 degrees to the X and Y axes vertically up and down when viewed from the front of the machine Minus Z movements run down towards the floor of the machine and positive Z movements run up away from the floor of the machine 42 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 Manually Controlling the Triac J og Mode Machine Co ordinates Display System The co ordinate 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 offset facility Offsets temporarily shift the entire co ordinate based grid system of the machine It is common to configure the workpiece datum as the location from which all machining co ordinates will be taken Triac Series CNC Machine User s Manual Co ordinate Display Systems The co ordinate display can be changed according to datum zero position required Positive Z co ordinates amp Location of the Machine Da
56. and machine axes to stop moving before attempting to open the safety guard door On calling a tool change the CNC control software will pause and a message window will be displayed prompting you to manually change tools Ensure the new tool profile thatis placed in the machine head matches the tool profile expected by your CNC control software After changing to the new tool number profile requested close the Safety guard door then confirm via any CNC control software message windows that machine control can be resumed Warning X Manual Pneumatic Safety Guard Door Control The following M codes can be manually entered to control the operation of the optional pneumatic safety guard door M38 Guard open M39 Guard close Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 59 5 Requesting a Tool Change Easychange Manually writing a Tool Change Program The Miscellaneous Function M06 is used to program a manual tool change operation The M06 code activates the request for a tool change and is followed bythecodeT ___ indicating the new tool number the firsttwo numerical digits using the stated tool length offset file number the last two numerical digits For example M06 T0305 This command is read requesta tool change from the current tool number to tool number 3 using tool length offset file number 5 Automatic Calling of an Easychange Tool Change during the running of
57. ar align the two locating slots on the tool holder with the two driving dogs on the Easychange collar Push the tool holder up into the Easychange collar Easychange collar Quick release pin Driving dog The spring loaded mechanism will close to grip the new tool holder securely Tool holder If the spring loaded mechanism in the Easychange collar is closed Locating slot before the new tool holder is fitted press and hold the quick release Tool and collet pin Push the tapered end of the assembly tool holder into the empty Easychange collar as far as it will travel Begin to turn the tool holder in an anticlockwise direction when viewed from above the machine head whilst continuing to push the tool holder upwards At the same time turn the Knurled collar in a clockwise direction when viewed from above the machine head to reopen the spring mechanism When the driving dogs on the Easychange collar and the locating slots on the tool holder align the tool holder will move up into the collar and the spring mechanism will close View N Direction Fitting a tool holder in a closed Easychange collar A Press and hold the quick release pin B Push the tool holder upwards and hold it against the closed Easychange spring mechanism Rotate the knurled collar clockwise and the tool holder anticlockwise both when viewed from above machine head a 54 Preparing Tooling
58. ardware Follow the rules below at all times when using your Denford Triac CNC machine Genes Safety Precautions 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 Never try to clean the machine if any part of itis rotating or in motion Always secure the work on the table or in a fixture or vice Ensure that the correct cable for the power source is used If power fails turn off the yellow red isolator found on the front of the electrical control box immediately e Hazardous voltages can still exist immediately after switching the electrical control box isolator to the OFF position Always wait at least 5 minutes before entering the electrical control box e Ensure the power is switched off before starting any maintenance work on the machine Always posta warning informing others that the machine is undergoing essential maintenance 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 When an emergency stop is required press the circular red emergency Stop button located on the front machine operators panel Triac Series CNC Machine User s Manual Section 2 Safety Features 13 2 Safety Fe
59. arefully liftthe flexible cover Inspect the trigger for damage or wear 94 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Cleaning and Inspecting the Z Axis Datum Microswitch The microswitch defining the Z axis datum is mounted on the lower rightside of the machine column Drive the machine head fully upwards This will make is easier to gain access to the left side of the machine column where the condition of the microswitch can be checked as shown below Using a soft bristled brush carefully clean any swarf and debris away from the microswitch to a location where it can be removed from the working area Inspect the microswitch for damage or wear Location ax Look at lower right side of machine column Worklight Back panel of machine View from right side of machine continued Triac Series CNC Machine User s Manual Section 7 Maintenance 95 7 Cleaning and Inspecting the Z Axis Datum Microswitch The trigger for the Z axis microswitch is mounted on the right side of the machine head as shown below Using a soft bristled brush carefully clean any swarf and debris away from the trigger to a location where it can be removed from the working area Inspect the trigger for damage or wear Location X Look at right side of machine head Machine head Machine column KX The moveable io microswitch trigger position is set at the Vie
60. atum plate Address characters list components aa 10 Advantages of CNC ia fitting well Automoderna ats TEMOVING esse ied Automatic slide lubrication system setting methods eeseecsecseeseestesseesseeseeeeeetee 73 filling the reservoir n 31 Denford directives list 0 135 hand priming the pump 32 Disclaimers 7 maintenance ss 88 troubleshooting oes eeseestesstesstessteeseseesneesnees 123 E Automatic tool changer system Easychange system adding a Collet assembly ws adding a collet assembly vases 57 adding tool holders to the carousel sss adjusting the depth Stop SCrOW vse 58 adjusting the depth Stop SCEW sssssessesseees calling a tool change automatically 60 calling a tool change automatically calling a tool change manually a59 calling a tool change manually o description v sssesesesesesssesesesees ay GOSCHIPTION ne arenan fitting the tool holder 1 54 fitting tools to the collet fitting tools to the collet 56 MAINTENANCE ssssessscsessessesessssees i removing a collet assembly wu eset 57 preparing the compressed air supply 61 removing the tool holder sssssesssssesesssvassses 53 removing a collet assembly ose 66 tool holder components i removing tool holders from the carousel 62 EC declaration of conformity s sssssssssssseseseee 1 tool holder COMPONENES escsssssseeeseseeeeeesns 64 Electrica
61. atures Emergency Stop Button Location of Emergency Stop Button Triac PC without flood coolant Mounted on the vertical operator panel which is located on the front right side of the machine cabinet Triac PC with flood coolant Mounted on the operator panel housing which is located on the front right side of the machine cabinet Triac VMC Mounted on the operator panel which is located on the front right side of the monitor housing The monitor housing is attached to the right end of the machine cabinet To active an emergency stop press the button fully in until it clicks Emergency stop Model shown Triac PC with button located on optional flood operator panel coolant A circular red emergency stop button is mounted on the front operators panel When pressed it has the effect of stopping all axes toolchanger and spindle 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 active 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 clockwise until it springs back out 14 Safety Features Section 2 Triac Series CNC Machine User s Manual
62. been sited and connected electrically the protective coatings must be removed to prepare the machine for A running The protective coatings applied to the slideways and bright surfaces can be removed using a kerosene based solvent The coatings Potential risk of ignition explosion Do not use any aerosol based flammable must be removed from the slideways before any attempt to move products to lubricate them is made Only use kerosene based solvents in accordance your CNC machine with the solvent manufacturers instructions and safety Caret ly read ana recommendations Ensure that no naked flames are present and follow any instructions d ilation i ided id th ial risk of or notices included with adequate ventilation is provided To avoid the potentia risk 0 lubrication products ignition explosion ensure that all solvent vapours can exit fully from any enclosed areas on the CNC machine Wait at least 1 hour before attempting to operate the CNC machine Once all protective coatings have been removed all untreated surfaces should be coated with a light covering of machine oil grade BP CS 68 The protective plastic sheeting on the guard windows should be removed and the glass and perspex cleaned with an anti static cleaner Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 33 3 Component Connection Schematic Diagram Vp Ancillary Equipment such as printers 4 or scanners may also be
63. ch on your Triac A Do not connect cables between any electrical hardware with the mains power switched on since this could seriously damage components inside your CNC machine Warning X A Never attempt to access the electronic hardware systems in the CNC machine or electrical control box with the mains power switched ON Note that hazardous voltages can still exist immediately after switching off the power If the ma vious itched 5 minute 0 access any electronic components Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk 1 PC versions only Check the RS232 machine lead is fitted securely between the serial COM port socket on the machine controller personal computer and the R S232 socket on the separate black electrical control box 2 PC versions only Check the RS 232 controller lead is fitted securely between the serial COM port socket on the machine controller personal computer and the RS 232 socket on the DeskTop Tutor controller keypad 3 All versions Check that all access panels and doors are in position and securely fastened 4 All versions Check that all inlet exhaust vents are clear from obstructions 5 Compressed air equipped versions only Switch on the air compressor Open the compressed airline valve and adjust the pressure if necessary 6 A
64. ck ie M98 Sub Program Call after any axis M99 Sub Program End and Return movement Code listing full and correct at the time of printing Triac Series CNC Machine User s Manual Section 10 Appendix 133 10 List of Program Address Characters N Program Sequence line number X Primary motion in X axis Y Primary motion in Y axis Z Primary motion in Z axis G Preparatory functions Incremental distance parallel to X axis J Incremental distance parallel to Y axis K Incremental distance parallel to Z axis R Radius M Miscellaneous functions T Tool numbers S Spindle speeds F Feed rates 134 Appendix Section 10 Triac Series CNC Machine 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 at the start of a program after the units of measurement have been set Example G21 BILLET X198 0 Y90 0 220 0 This sets the measure to metric Note if set to Imperial the units would be inches and defines the billet as1 mm long by 99mm wide with a depth of 28mm SUBPROGRAM This directive allows a program with a non numeric name to be called as a subprogram Example SUBPROGRAM 28 FRED M98 P 2
65. connected to the Parallel port on the PC Personal Computer 9 to 25 Pin Connectors if required Security Dongle if required Notes for Triac PC connections The COM ports on your PC may be labelled as Serial ports All COM ports have a 25 pin adaptor required or 9 pin MALE connector The Parallel port on your PC may be labelled as the Printer port The printer port has a 25 pin FEMALE connector Desktop Tutor when The RS232 cable connects the Electrical ordered connects to Control Box to the PC port labelled COM 2 the PC port labelled The RS232 cable is the long thin cable fitted COM 1 with a 9 pin female connector at one end and a 25 pin male connector at the opposite end Connect the male end of the RS 232 cable to the 25 pin RS232 female port on the electrical control box Connect the remaining female end ofthe RS 232 cable to the 9 pin male COM2 porton your PC 34 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Component Connection Schematic Diagram Denford Triac Series CNC Machine PC version with Ensure the male ATC pneumatic connector plug is fitted guard and to the female bracket on j hydraulic the machine connection vice shown box in the correct orientation Male connector Mains Power Supply Plug Mains power is supplied from the Electrical Control Box to the Triac using the machine power cable 4 Notes for Tr
66. ction 4 Triac Series CNC Machine User s Manual 4 Understanding Offsets Beles What are offsets Offsets are a collection of numerical values used to describe the location of the workpiece datum The moveable workpiece datum defines the zero point on the billet the material you want to machine This is the starting point for any cutting co ordinates Supplied by the machine controller Two types of offset file are used in combination to describe this location i The workpiece offset file This file allows global offset values to be set for the X Y and Z axes In other words every tool profile ill use the workpiece offset values ii The tool length offset files Every tool has its own individual tool length offset file containing a single Z offset value They are used to compensate for the differences in length between tools How is a workpiece datum calculated The X position of the workpiece datum is defined by the X value Further information regarding configuration of workpiece and tool length offsets can be found in your separate CNC Machine Control Software User s Manual oO entered into the workpiece offset fi The Y position of the workpiece da entered into the workpiece offset fi The Z position of the workpiece da of the Z value entered into the wor entered into the tool length offset f currently in use e tum is defined by the Y value e tum is defined by the combination kpiece of
67. d to the top ofthe ATC tool holders Memovaoie auon i pull stud If the cutting tool has each week The pull studs are tightened Turn the spanner in a clockwise direction when viewed from above the top of the ATC tool holder as shown in the diagram below been recently used it using a 13mm spanner may still be HOT ATC Turn clockwise to i tighten the pull stud Triac Series CNC Machine User s Manual Section 7 Maintenance 103 7 Pneumatic Safety Guard Door Maintenance Location Ten xy The pneumatic safety guard door is Look at left side of supplied as an option with the Triac PC machine column orTriac VMC Operation of the door is achieved through use of a pneumatic cylinder driven from the compressed air system The cylinder circled right is mounted to the left of the machine column Each week clean if necessary then lubricate the cylinder using oil grade BP CS 68 in a manual pump action oilcan RecN Xp Check the security of any screws hoses and connections Open and close the M38 Guard open ase Column base M39 Guard eee pneumatic safety guard door to distribute the oil evenly across the cylinder surface 7 Hydraulic Vice Maintenance Location Tay The hydraulic vice is supplied as an option with the Triac PC or Triac VMC The vice jaws are driven using a hydraulic intensifying cylinder mounted on the back panel of the Triac cabinet The intensifier itself is driven
68. der containing 4mm slot cutter Carousel P ocketNumber 5 Tool holder containing Engraving cutter Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 61 5 Setting up the ATC Warning X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Warning X A Caution If the cutting tool has been recently used it may still be HOT Removing Tool Holders from the Carousel The tool holder is lightly held in the carousel pocket by two cylindrical grippers Markers on the top surface of these grippers indicate the number of the carousel pocket The tool holder cannot be withdrawn vertically since a single flange on the inside of the carousel pocket engages with the groove around the tool holder body Remove the tool holder by pulling it horizontally away from the centre of the ATC carousel To remove a tool holder gently pull the tool holder body horizontally away from the inside of the pocket The two cylindrical grippers will automatically separate Withdraw the tool holder taking care notto damage the cutting tool tip on any part of the machine casings 62 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 Setting up the ATC Tee x Adding Tool Holders to the Carousel A If a tool holder is held in the machine head never place a tool holder in the carousel pocket directly facing
69. des of the hexagon washers press against the sub table not one of the hexagon points The hexagon washers should be positioned at this stage so they are open ie the off centre allen key holes on the bolts should be facing away from the grubscrews Now tighten the grubscrews in each miteebite to lock them firmly in position At this stage it should still be possible to remove the sub table Remember the grubscrews only lock the miteebites in position on the machine table itis the hexagon washers which actually lock the sub table in position To lock the temporary MDF bed firmly in place turn the bolts with the off centre allen key holes 180 degrees so the hexagon washers are in the closed position ie the off centre allen key holes on the bolts should now be facing towards the grubscrews Now that the miteebites have been set the sub table can be continually withdrawn from the machine table then replaced always to the same position This is an advantage for jobs involving the repeat milling of pieces of work such as a small production run ora college class group project Hexagon washer set Hexagon washer set in open position in closed position Triac Series CNC Machine User s Manual Section 6 Work Holding 77 6 Option Hydraulic Vice The hydraulic vice shown right is Supplied as an option with the Triac PC or Triac VMC The vice jaws are driven using a hydraulic intensifying cylinder circled l
70. directly vertical Combinations of all 3 allow precise co ordinates to be described Axes are also referred to as slides or Slideways BILLET cresccsiriesteriesteoteetenn The actual material being machined sometimes referred to as the workpiece or stock BLOCK aininn A collection of program words that collectively describe a machining operation A single program line in the CNC file CHARACTER seeseeseeseseee A number letter or symbol as entered into a CNC program CIM iea Computer Integrated Manufacturing System CIRCULAR INTERPOLATION G code term for a programmed arc movement COMMAND shassi A signal or group of signals instructing one step operation to be carried out CONTEXT SENSITIVE When the type of input signal of an event automatically changes the output signal CO ORDINATES wee Positions or relationships of points or planes Co ordinates are usually described using three numbers referring to the X Y Z axes e g the co ordinate 23 35 45 means X axis 23 units Y axis 35 units and Z axis 45 units CN Cochin eee t Computer Numerical Control CNC FILE The sequence of commands describing the manufacture of a part on a CNC machine written using G and M codes also called the CNC program CUTTER SPEED niini The velocity of the cutting edge of the tool relative to the workpiece With circular tools the cutting speed is related to the tool when new maximum cutting diameter Usually the effect of
71. e left A B Load or create the CNC program see Note left A C Configure the tooling files in the CNC Control Software see Note left r D Simulate the CNC program in 2D or 3D see Note left r E Establish communications and home the Triac see section 4 page 41 and see Note left F Prepare any tooling hardware for the Triac see section 5 Preparing Tooling Hardware pages 52 to 69 G Load the billet into the Triac see section 6 Work Holding pages 70 to 81 H Configure the workpiece offset file and tool length offsets see section 4 pages 45 to 48 and see Note left HEME e l Manufacture the part see section 4 pages 49 to 51 and see Note left 36 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 General Location of Triac Components Machine Machine F ro nt V iew Machine head column Photograph features optional spindle equipment Automatic tool Location of optional changer equipment indicated but item Guardmaster interlock switch not shown in photograph Enclosed safety guard door Flood coolant drain plug and level viewing window Pneumatic vice Safety guard door handle Front and rear Operators panel feed and machine cabinet spindle overrides emergency support feet stop button axis override and sections Pneumatic guard buttons R ea r y lew Machine head Compressed air Automatic tool
72. e right side The X axis ballscrew runs centrally along the underside of the machine table Run the machine table fully to the left exposing the left portion of the ballscrew as shown top then carefully clean any swarf and debris away using a softbristled brush Inspectthe ballscrew for damage or wear Run the machine table fully to the right as shown above to expose the remaining portion of the ballscrew and repeat the process Triac Series CNC Machine User s Manual Section 7 Maintenance 89 7 Cleaning and Inspecting the Y Axis Ballscrew and Slideways Two Y axis slideways are located under the sides of the flexible cover atthe base of the machine column Run the machine table and saddle fully back againstthe machine column Liftthe cover sides as shown below then using a soft bristled brush carefully clean any swarf and debris away from the crosslides to a location where itcan be removed from the working area Inspect each slide for damage or wear Location OX Lift flexible cover at View from right side of machine machine column base View from leftside of machine crosslide s Column base front Run the machine table and saddle fully forwards and repeatthe process for the remaining parts of the slides continued 90 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Cleaning and Inspecting the Y Axis Ballscrew and Slideways The Y axis ballscrew is f
73. e port is not seen by any external devices VMC versions The main body of the machine controller computer is mounted on the inside face of the electrical control box door 8 When all else fails PC versions Thoroughly check the condition of the RS232 cable If the cable is bad communication will not occur Try using a different pc to connect to the CNC machine All versions Check for help on the technical support FAQ and download sections of the Denford websites and or contact Denford Customer Services see page 114 for details Triac Series CNC Machine User s Manual Section 9 Technical Support 119 9 Troubleshooting DOS CNC Milling Software The FANUCMD GO file The FANUCMD GO file usually supplied on floppy disk defines the computer settings and drivers used by the DOS CNC control software The file indicates the order in which the drivers are loaded into memory when the system first starts up Default FANUCMD GO file listed below IBM RS2 2 3F8 4COM1 3E8 4 MACHINE DENFORD KBD 1 18 2 2F8 3 EGA CRT 0 FANUCMD APP 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 For example The IBM RS2 driver loads COM1 at the address 3F 8 using interrupt 4 and MACHINE at the address 3E8 using interrupt 4 The last line in the file executes the software specified ie FANUCMD APP
74. eferring to the electrical schematic diagrams see Section 7 Machine Electronics pages 107 to 109 Triac Series CNC Machine User s Manual Section 9 Technical Support 125 10 Specification of Triac PC Standard Equipment a Features Triac PC CNC milling machine Manual operation totally enclosed Electrical power box interlocked safety guard door Easychange toolholder Emergency stop button CNC machine control software e Axis limit microswitches adjustable on Z Installation maintenance and instruction Slide manuals 2D 3D toolpath graphics to verify part e Set of maintenance tools and spare parts programs prior to machining list e Automatic tool retraction amp spindle stop Machine commissioning and basic for tool changing instruction e Training UK Only CAD CAMI CNC Software options MIIICAM Designer pion Extra Equipment Techsoft 2D Design Tools IBM or 100 compatible PC keyboard MiniCAM mouse and monitor e AutoCAD and additional Autodesk 8 station automatic toolchanger and products tooling e MasterCAM Flood coolant system Pro DESKTOP Spray mist coolant system CNC Tutor Desk top tutor ArtCAM Hydraulic vice Pneumatic safety guard door Upgrade pack for integration into Denford FMC FMS or CIM systems Courseware and project books Various tooling packages Additional training packages Additional CNC machine control software licences e Machine
75. eft mounted on the back panel of the Triac cabinet The intensifier itself is driven from the compressed air system The hydraulic vice is designed to automatically clamp a billet during the running of a CNC program through the calling of the appropriate vice open or close M code function The same M codes are also used to manually control the operation of the vice jaws The vice body itself is secured to the machine table using a series of allen headed bolts and tee nuts and can be repositioned as necessary 78 Work Holding Section 6 Triac Series CNC Machine User s Manual 6 Option Hydraulic Vice Operation Preparing the Compressed Air Supply Before switching on your air compressor check all air hose connections are secure and the correct operating pressure is seton the regulator mounted on the back panel of the Triac cabinet The normal operating pressure as supplied preset on the machine is 10 PSI 6 6 Bar Maximum pressure for the air regulator is 15 PSI 9 9 Bar See Section 3 CNC Machine Installation pages 25 to 28 for detailed information on the compressed air connection unit Adjusting the Pressure of the Vice aws The compressed air passes through a separate pressure regulator unit before reaching the hydraulic intensifier This regulator unit is used to adjust the clamping pressure of the vice jaws To adjust the vice pressure pull up the rotary control to unlock it from its current position Turn the
76. ep repeating these steps moving the pointer forwards and backwards along the datum plate edge until a Suitable degree of accuracy has been obtained Fora final check the pointer can be moved above and along one of the datum plate edges which run parallel to the X axis Finally tighten the allen headed bolts to fix the datum plate firmly in place Triac Series CNC Machine User s Manual Section 6 Work Holding 73 6 Setting the Datum Plate Datum Plate Setting Method 4 Machine Table Datum Plate Set up the machine so a dial gauge is held in place of the cutting tool Align the dial gauge so itis positioned along one of the 2 sides of the datum plate which run parallel with the Y axis Start with the dial gauge near the back of the datum plate edge you have chosen Move the dial gauge towards the front of the datum plate checking that the values indicated on the dial gauge do not alter If the values do alter readjust the position of the datum plate until the values are constant Keep repeating these steps moving the dial gauge forwards and backwards along the datum plate edge until a suitable degree of accuracy has been obtained Finally tighten the allen headed bolts to fix the datum plate firmly in place 74 Work Holding Section 6 Triac Series CNC Machine User s Manual 6 Option Miteebite Clamps Miteebite clamps are a quick and versatile method of securing most pieces of work to the machine table In the exa
77. er manufacturers operating manual At this Do not connect cables stage the computer should not be switched on between any electrical hardware with the mains 2 The computer must be physically connected to the Triac electrical power switched on control box using the supplied RS232 cable This is the long since this could thin serial link cable fitted with a 25 pin D male connector at one seriously damage end and a 9 pin D female connector at the opposite end as components inside your personal computer and shown bottom right or CNC machine 3 Connect the 25 pin D male end of the RS 232 cable to the 25 pin D female port mounted on the side panel of the Triac electrical control box as shown below and right The portis labelled RS 232 25 pin D female 25 pin D male connector fitted to connector electrical control box fitted to side panel RS232 cable RS 232 Cable Location of RS 232 9 Pin D 25 Pin D port on electrical Female Male control box Connector Connector Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 19 3 PC version only Connecting your computer to the Triac PC Warning Tax 4 Connect the remaining 9 pin D female end of the RS 232 cable to A Do not connect cables between any electrical hardware with the mains power switched on since this could seriously damage components inside your personal computer and or CNC machine 5 Do not confuse
78. esolution 0 005mm 0 0002 Weights e Machine weight non ATC 240 KG 529 Ib e Machine weight with ATC 320 KG 705 Ib Electrical control box weight 70KG 154 Ib Electrical Details e Mains supply required 240 Volts AC 1 Phase 50 Hz 13 AMP e Spindle motor 1 1 Kw DC 1 5 hp e Stepper motors 200 steps rev DC Compressed Air Connection e Presetin the factory at 1 PSI 6 6 Bar e Maximum pressure 15 PSI 9 9 Bar Tooling Tool type ATC BT30 Tool capacity ATC 8 Tool type non ATC Quick Easy Change Section 10 Appendix 127 10 Specification of Triac VMC Standard Equipment Triac VMC CNC milling machine Electrical power box 8 station automatic toolchanger and tooling Flood coolant system CNC machine control software Installation maintenance and instruction manuals Set of maintenance tools and spare parts list Machine commissioning and basic instruction Training UK Only Optional Extra Equipment IBM or 100 compatible PC keyboard mouse and monitor Spray mist coolant system Hydraulic vice Pneumatic safety guard door Upgrade pack for integration into Denford FMC FMS or CIM systems Courseware and project books Various tooling packages Additional training packages Additional CNC machine control software licences Machine work bench Video conferencing system 128 Appendix Section 10 Safety Features Manual operatio
79. fication 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 product can change without notice The information contained in this manualis correct atthe date of printing only May 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 Please note that any screenshots are used for explanation purposes only Any numbers wording window or button positions may be different forthe configuration of the CNC machine control software being used to control your Denford Triac CNC machine This manual is written using European English Any comments regarding this manual should be referred to the following e mailaddress customerservices denford co uk Triac Series CNC Machine User s Manual Contents 7 1 Introducing your Triac Series CNC machine 8 Introduction Section 1 Congratulations on your purchase ofa Denford Triac Series CNC machine In this manual you will learn how to setup and use your CNC machine The Triac is a versatile three axes CNC milling machine suitable for all levels of Education Training and Prototyping Traditionally a metal cutting machine itis also suitable for prototyping complex 3D designs i
80. for manual operations Never attempt to fit an abrasive wheel to the machine spindle 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 right to change the specification and or operating features regarding this CNC machine without notice or documentation 6 Contents Triac Series CNC Machine User s Manual About this Manual Using this manual Disclaimer Screenshots Language Contact This manual provides information describing how to transport site setup and operate the basic functions of your Denford Triac CNC machine including any optional equipment associated with the Triac series This manual does not provide any information regarding the software packages used to control your Denford Triac CNC machine please refer to your separate CNC machine control software manual Please note that the Electrical Diagrams for your Triac CNC machine are held in a folder fixed inside the electrical control box Hazard Voltages existin the electrical control box only attemptto access these diagrams after isolating the power and leaving the electrical control box untouched for atleast5 minutes If you have any doubts and or questions regarding the specification servicing or features of your Triac CNC machine please contact Denford Customer Services Denford Limited reserves the right to change the speci
81. from the compressed air system Clean the vice surfaces the components of the hydraulic intensifier and check the security of any screws hoses and connections on a weekly basis The hydraulic intensifier unit includes a lubrication unit which automatically distributes oil to the hydraulic system and the vice Check E the oil level on a daily basis To top up the lubrication unit liftthe cap Hydraulic intensifier on On the top of the oil storage reservoir and pour in the required amount back panel of cabinet ofoil Refill the reservoir using oil grade ISO VG 32 Further details regarding the parts of the hydraulic vice system are explained in Section 6 Work Holding pages 78 to 80 DOPAUR NEI X Vice mounted on machine table Ey M10 Vice open M11 Vice close 104 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Compressed Air Connection Unit Maintenance Location Tay The compressed air connection unitis fitted as standard to the Triac Compressed air connection on back panel of cabinet VMC supplying the standard ATC system The compressed air connection unitis fitted to the Triac PC when any of the following options are included ATC hydraulic vice pneumatic safety guard door The components of the compressed air connection unitare mounted on the back of the Triac cabinet Clean each unitand check the security of any screws hoses and connections on a weekly basis
82. from the storage tank under the machine floor to the flood hose pipe on the right side of the machine column using an electric pump When operating coolant is continually circulated around this system The Pump The electric pump is located inside the working area of the machine Back panel against the back panel and to the O Pump right of the machine column The easiest method of accessing the pump is by opening the safety guard door and reaching in around the table towards the back of the machine Machine floor Righide of j Coolant Delivery Hose machine head Pe Angle the flexible coolant N delivery hose towards the cutting tool tip ensuring that the piping is routed where possible to avoid hitting any part of the billet Adjust the rate of flow using the tap full flow is achieved by positioning the flat section of the tap handle in line The Storage Tank with the direction of coolant flow When not being used coolantis through the pipe stored in a tank located in the base of the machine cabinet The tank capacity is 14 75 litres Coolant delivery nozzle Flexible hose Drain grill Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 29 3 Option Flood Coolant System Checking the Coolant Level To check the coolant level use the viewing window positioned in the lower part of the
83. fset file and the value ile belonging to the tool profile How is the workpiece datum used The software uses the workpiece datum as the starting point zero reference for any co ordinate movements it receives These co ordinate movements are read from the loaded CNC file In other words the position of the workpiece datum will determine the place on the CNC machine where the part is manufactured What actually happens when I program my workpiece datum position Configuring the workpiece datum position shifts or offsets the entire three dimensional co ordinate grid machine The workpiece datum w machine as its zero position rathe system used by the CNC ill now be read by the CNC r than the machine datum The machine datum is a fixed point defined when you first switch on and home the CNC machine Triac Series CNC Machine User s Manual Section 4 CNC Machine Operation 45 4 Understanding Offsets Tax Where should position the workpiece datum on my billet Further information This depends on the position of the part datum set in your CNC regarding configuration program The part datum is the zero reference or starting point of workpiece and tool used when plotting all the co ordinates that describe the shape of length offsets can be your design found in your separate CNC Machine Control The part datum could have been set by the programmer when Software Users Manual manually writing the C
84. fuses For more information refer to Section 8 Machine Electronics Tox 3 PC versions Start the VR CNC Milling software from the default installation click Start Programs Denford VR Milling From the main menubar at the top of the VR CNC Milling 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 machine attached to your pc and any COM portsettings from this window VMC versions The VR CNC Milling software will load automatically continued Section 9 Technical Support 115 9 Troubleshooting VR CNC Milling Software 4 All versions The Machine Properties window will open with Aaronin egisi the name of the current active machine highlighted and its fitted to your Triac can listing expanded Note that there are a number of Triac versions be configured using the to choose from The active machine name in the software must options available in the match the name and version of your CNC machine this Machine Properties information is printed on the CE identification panel usually window applied to the side panel of the electrical control box For example if Triac PC is printed on your CE identification panel the VR CNC Milling software must have Triac PC setas the active mac
85. gineers 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 support and FAQ sections Denford UK _ http www denford co uk Denford USA http www denford com When you request support please be at your CNC machine with your hardware and software documentation to hand To minimise delay please be prepared to provide the following information CNC Machine 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 A list of the steps that were taken to lead up to the problem A list of any maintenance work that has been carried out on the CNC machine Contact Details Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK Telephone 01484 722733 Fax 01484 722160 ISDN 01484401157 01484401161 E mail customer_services denford co uk Technical Support Monday to Friday 8 30am 4 30pm GMT For international dialling 44 and remove first 0 in each city code 114 Technical Support Section 9 Triac Series CNC Machine User s Manual 9 Troubleshooting VR CNC Milling Software Your screen may display the message Error 50 Mint 3
86. he 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 all three 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 Triac Series CNC Machine User s Manual Immediately after establishing a communication link between the CNC control software and the Triac all three axes of the CNC machine must be homed Homing the CNC machine defines The constraints of three dimensional co ordinate grid system used for plotting any programmed movements effectively the working envelope of the CNC machine The machine datum the zero reference point for the CNC machine so the controlling software can calculate where the tool is positioned in relation to our working envelope The process is commonly referred to as homing the machine or datuming each axis Each of the three machine axes are sent to their fixed zero positions as shown in the diagram right The Z axis moves to the furthest position available on its slide The X axis moves to the furthest position available on its slide Machine Table The Y axis moves to the furthest position available on its slide After homing the machine the zero p
87. he machine table Use the true flat face of a section of material such as a piece of flat steel bar Press the steel bar firmly against the front edge of the table and adjust the datum plate so its front face also touches the surface of the steel bar Tighten the allen headed bolts Note that although this method is quick itis also fairly inaccurate Datum Plate Setting Method 2 Datum Plate Machine Table Engineers Square To obtain a better degree of accuracy use an engineers square lined up against the front edge of the machine table Adjust the datum plate so it touches the engineers square and tighten the allen headed bolts This method has the added advantage of allowing the datum plate to be fixed further into the middle of the machine table 72 Work Holding Section 6 Triac Series CNC Machine User s Manual 6 Setting the Datum Plate Datum Plate Setting Method 3 Pointer Tool Machine Table Datum Plate Setup the machine so a pointer is held in place of the cutting tool Align the pointing tool so itis positioned slightly above one of the 2 edges of the datum plate which run parallel with the Y axis Start with the pointer near the back of the datum plate edge you have chosen Move the pointer towards the front of the datum plate checking that the tip of the pointer is still lined up exactly over the edge you have chosen Ifthe pointer does not align readjust the position of the datum plate Ke
88. hes 3 Check the axis drive fuse F4 referring to the electrical schematic diagrams see Section 7 Machine Electronics pages 107 to 111 4 Check the axis override on pendant The worklight is not working Check the validity of the following 1 Check the bulb 2 Check the worklight fuse F6 referring to the electrical schematic diagrams see Section 7 Machine Electronics pages 107 to 109 124 Technical Support Section 9 Triac Series CNC Machine User s Manual 9 Troubleshooting Electrical Problems No ATC is not working Always refer to your Check the validity of the following electrical schematic 1 Work through the mechanical troubleshooting section first A 2 Check the ATC fuse F5 referring to the electrical schematic placement of diagrams see Section 7 Machine Electronics pages 107 to components and fuses 109 Information contained on this page is correct at the time of printing The flood coolant system is not working A Check the validity of the following continuous development 1 Check the flood coolant system fuse F8 referring to the of our products electrical schematic diagrams see Section 7 Machine Electronics pages 107 to 109 The machine controller computer is not working Check the validity of the following 1 Ensure the computer is plugged in switched on and all cables and connections are secure 2 On VMC versions check the computer fuse F9 r
89. hine If the correct machine name is NOT listed as the active machine right click over the required machine name title to display a pop up menu Click Make Active then click OK and restart the VR CNC Milling software Re open the Machine Properties window to check that the changes have been applied 5 All versions In the Machine Properties window click the Communications property title Change the COM Port setting to match the number of the COM port being used by your pc Note that the 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 must be 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 the property listings 6 All versions Check the LED display status on the Eurostep Motion Control Board The card is located in the bottom of the electrical control box on the far left of the card rack For more information refer to Section 8 Machine Electronics A problem with this card can cause problems with communications Look for the LED display mounted on the main control card A blinking dot with an L or the number 8 should be shown If the LED is not lit check the control board fuse If no display continues to be shown
90. hine User s Manual 9 Troubleshooting DOS CNC Milling Software 6 All versions Check the LED display status on the Eurostep Motion Control Board The card is located in the bottom of the electrical control box on the far left of the card rack For more information refer to Section 8 Machine Electronics A problem with this card can cause problems with communications Look for the LED display mounted on the main control card A blinking dot with an L or the number 8 should be shown Ifthe LED is not lit check the control board fuse If no display continues to be shown call Denford Customer Services for assistance Warning Risk of electric shock Note that in order to check the readout the CNC machine must be powered up with the electrical control box open Exercise extreme caution do not touch 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 All versions Check the COM port on your pc is functioning correctly Consult your IT person or Computer Support Centre for help with these issues Check the COM port settings 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 but th
91. hine has previously been switched on wait at least 5 minutes before attempting to access any electronic components Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 23 3 Connecting the Mains Supply Warning A Do not connect cables between any electrical hardware with the mains power switched on since this could seriously damage components inside your personal computer and or CNC machine gax Electrical Connection Data e Mains supply required 240 Volts AC 1 Phase 50 Hz 13 AMP Cable required 3 Core 1 5mm per core Spindle motor 1 1 Kw DC 1 5 hp Stepper motors 200 steps rev DC Mains Isolator Switch The CNC machine is switched on off using the isolator switch mounted on the electrical i control box door The photo right shows the isolator switch in the off 0 position Isolator Position 0 Power OFF Isolator Position I P ower ON 3 Electrical Diagrams Warning A Never attempt to access the electrical diagrams folder with the mains power switched ON Note that hazardous voltages can still exist immediately after switching the isolator to the OFF position Always wait at least 5 minutes before attempting to open the electrical control box door
92. hines 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 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 Triac Series CNC Machine User s Manual 1 Before Beginning to Setup The standard equipment listed here is correct at the time of printing J une 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 RS232 connectors according to the type of COM port fitted to your computer Triac Series CNC Machine User s Manual Before beginning to setup your Denford Triac CNC machine take a momentto check your separate order documentation making sure that all items have been delivered to your establishment Any missing or damaged items should be reported to Denford Customer Service
93. iac VMC connections Ignore all references and connections to the PC shown on pages 18 to 20 The RS232 connection is not fitted to Triac VMC f To the Port electrical control boxes since these labelled RS 232 versions have a hard wired permanent link between the CNC Triac Electrical Control Box machine and the controller computer Note the physical layout on The operator controls are mounted individual boxes may vary in a separate housing on the right side of the Triac cabinet Triac Series CNC Machine User s Manual Section 3 CNC Machine Installation 35 4 Using your Triac Overview For more detailed information regarding these steps please refer to your separate CNC Machine Control Software User s Manual Steps F and G are not required when working with a simulated CNC machine for example Virtual Reality Billet data is taken from Denford directives written in the CNC program step B Tooling data is taken from the configuration of the software tooling step C 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 Triac then start the CNC Control Software see section 4 page 39 and see Not
94. ight which designed specifically for enables comfortable operating and programming to take place the Triac CNC machine Ideally the user will operate the machine when standing at its front series are available l i 3 from Denford Limited with a clear view of both the machine working area through the transparent guard window and the computer being used as the controller unit which should be angled towards the user as shown LXE in the diagram below Dimensional Data We recommend the separate electrical control box is sited under the Standard Triac PC machine table leaving a space of at least 1000mm 40 to allow full Dimensions opening of its access door otal machine width a 1285mm 50 5 8 Sufficient room should also be provided for effective maintenance to Total machine height be carried out around the CNC machine itself 1060mm 41 3 4 Total machine depth 900mm 35 7 16 Computer desk monitor keyboard Triac PC with ATC Denford Triac and mouse angled Dimensions PC CNC Milling towards Operator Total machine width 1285mm 50 5 8 Total machine height 1060mm 41 3 4 Total machine depth 935mm 36 13 16 Machine Triac VMC Dimensions Electrical Total machine width Control Box 2120mm 83 15 32 under table VN Total machine height Machine 1060mm 41 3 4 _ Operator Total machine depth 935mm 36 13 16 Electrical Control Box access
95. l control box troubleshooting ssssesssesesesisisisisrrrrirrrsrsrsresse 122 125 connection data AXIS COfINHONS anina eaa 42 interior layout a Axis limit switch override oo 51 openingen aAA 107 outside layout B seal ats Ballscrew Electrical diagrams accessing eccere 107 lUDTiCatON etic wari walied ain 88 Electronics x axis inspecting and cleaning 89 accessing the electrical diagrams 068 107 y axis inspecting and cleaning s 90 eurostep motion control board cee 110 z axis inspecting and cleaning ees 92 interior layout of the electrical control box 108 interior layout of the machine connection box 113 C spindle drive board weenie 112 Co ordinate display systems troubleshooting 124 Component connection schematic diagram 34 Emergency stop DUtEOM essere 14 Compressed air connection unit Eurostep motion control board sssseeeeen 110 air filter regulator unit seerne 27 F air lubricator unit ee ceseeseesseesteeseeeseeeeee 28 air Supply isolator Unt eects 26 Feedrate override control sesir 51 CONNECHION vee 25 Flood coolant system MAINTENANCE woes seeseeeseesseesseestesstesstesseesseeesenees 105 Checking the level scsseceeseesseeseeetesseeeee Computer connections for Triac PC versions 19 components Configuring offsets esses 47 filling and draining site Contact information oo 2 MAINTENANCE ioiii aeisi operating m codes TrOUDIESHOOTING sewisie Triac
96. le to ensure thatthe movementis smooth 6 Ifthe movementis notsmooth loosen the gib strip by repeating steps 1 to 4 butturn the gip strip adjustment screw counter clockwise Run the machine table again to assess the smoothness of movement 98 Maintenance Section 7 Triac Series CNC Machine User s Manual 1 Y Axis Gib Strip Adjustment To adjustthe Y axis gib strip on the crosslide 1 Drive the machine table and saddle to the mid point of the crosslide This will make is easier to gain access to the back of the saddle where the gib strip locking screw is located To access the screw lift the right back section of the flexible cover when viewed from the front of the machine as shown below left 2 Using a flat bladed screwdriver release the gib strip lock screw 3 The gib strip adjustment screw is accessible by lifting the right front section of the flexible cover when viewed from the front of the machine as shown below right Turn the gib strip adjustment screw clockwise until tight Do not overtighten this screw A Slight degree of movement must be left to allow the slide to move 4 Retighten the gib strip lock screw Location aX Look front and back at right side of saddle Gib strip adjustment screw Gib strip locking P screw 4 Flexible cover at Right Rd F lexible side of cover at saddle back of ifan SN saddle front of View looking at back right View looking at f
97. leftofthe machine column Each of the eightnumbered carousel slots or pockets are designed to contain one tool holder Preparing the Compressed Air Supply The ATC is driven using compressed air Before switching on your air compressor check all air hose connections are secure and the correct operating pressure is seton the regulator mounted on the back panel of the Triac cabinet The normal operating pressure as supplied preseton the machine is 1 PSI 6 6 Bar Maximum pressure for the air regulator is 15 PSI 9 9 Bar See Section 3 CNC Machine Installation pages 25 to 28 for detailed information on the compressed air connection unit ATC storage cover carousel and ATC mechanism retracts under this cover when not in use Location of ATC O Machine head m Numbered carousel Tool holder pockets carousel shown in eight down position available 4 nil ele The optional ATC Tool holder Automatic Tool Changer When using the ATC itis essential that the correct tool profiles are placed in the numbered carousel pockets that exactly match the tool profiles and tool numbers used in your CNC program Forexample Ifyour CNC program uses three tool profiles assigned as follows Tool 1 2mm slot cutter Too 2 4mm slot cutter Tool 5 Engraving cutter then the ATC carousel would be set up as follows Carousel Pocket Number 1 Tool holder containing 2mm slot cutter Carousel Pocket Number 2 Tool hol
98. ll versions Plug the mains supply cable from the separate black electrical contro box into an available power socket Switch the power socket on 7 All versions Power up the Triac by turning the yellow isolator Switch from the off 0 position to the on I position The isolator Switch is mounted on the front door of the separate black electrical control box If the Triac does not begin its power up routine switch off the mains power supply to the CNC machine Check all connections and fuses referring to Section 8 Machine Electronics if necessary 8 PC versions only Switch on the machine controller PC and start the CNC control software Establish a communication link between the CNC control software and the Triac please refer to your separate CNC Control Software User s Manual for details outlining this procedure If a communication link cannot be established recheck the connections on the RS232 machine lead followed by the communication settings of your CNC control software referring to Section 9 Technical Support if necessary VMC versions only Note that the integrated computer will start then load the CNC control software automatically Establish a communication link between the CNC control software and the Triac please refer to your separate CNC Control Software User s Manual for details outlining this procedure Triac Series CNC Machine User s Manual Section 4 CNC Machine Operation 39 4 Switching the T
99. m above until it grips the collet assembly Using the 30 32mm C spanner continue to tighten the nut by turning in an anticlockwise direction when viewed from above Position the 45 50mmC spanner on the middle segment of the tool holder in the opposite direction to stop the tool holder from rotating on the spindle see the righthand diagram below Removing a Collet Assembly Adding a Collet Assembly Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 57 5 Setting Tools in the Easychange Tool Holder Warning a X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Adjusting the Tool Depth Stop Screw A tool depth stop screw is fitted to the inside of the Easychange tool holder Rotating this screw allows the user to define the amount of tool that protrudes from the bottom of the tool holder Tools required 2mm allen key To adjust the position of the depth stop screw remove the nut on the bottom of the Easychange tool holder together with the colletand the tool Note that the tool depth stop screw runs along a lefthand thread Insert the 2mm allen key into the depth stop screw and turn the allen key anticlockwise to move the depth stop up or clockwise to move the depth stop down when looking at the tool holder from the bottom ie imagining the toolholder is fitted to the machine spindle Refit the collet and tool to
100. machine right end panel W a EN 4 S Eksa y _ Drain plug Location of viewing window Removing Coolant Old excessively dirty or used coolant should be drained and replaced with a fresh coolant mix To drain off coolant unscrew the drain plug located below the coolant level viewing window Ensure that any unwanted coolant is collected and disposed of in a responsible manner Adding Coolant To fill or top up the tank open the safety guard door then pour the required amount of coolant mix directly into the working area of the machine The coolantis channelled into the storage tank via the two drain grills located in the front right and left corners of the machine floor The grills can be removed for cleaning by unscrewing the allen hex bolts in the centre of each grill Recommended coolant Cincinnati Millacron Simcool C60 New coolant should be mixed in accordance with coolant suppliers instructions Denford The sequence of events recommends using a minimum 2 5 mix required to manually t M code will j eee eae M Codes for Delivery of Flood Coolant CNC control software The following M codes can be manually entered to control the being used operation of the flood coolant system In addition many of these miscellaneous M08 Coolant on functions may be controlled directly using buttons and commands M09 Coo available in your CNC control software M13 Coolant on and spindle forward
101. mple shown below two miteebite clamps are used with a datum plate to clamp a sheet of MDF This MDF is used as a sub table a safety measure to prevent damage occurring to the machine table itself should a problem occur when milling Miteebite clamp shown in closed position Machine Datum Sub table Miteebite table plate eg sheet clamps of MDF Loading the Billet The actual workpiece such as a sheet of plastic would be held in place on the sub table using double sided tape The billet is usually positioned with its front and lefthand edges aligned with the front and lefthand edges of the sub table as shown below Plastic workpiece billet Strips of double sided tape Sub table eg sheet of MDF Towards front of machine table Triac Series CNC Machine User s Manual Section 6 Work Holding 75 6 How does a Miteebite Clamp work The base of the Miteebite clamp consists of a Tee nut with 2 threaded holes passing right through its section from top to bottom One of these threaded holes contains a grubscrew When this is tightened the base of the grubscrew pushes against the surface of the T channel in which it has been placed securing the Tee nut in position The other threaded hole contains a bolt which has its head and allen key hole machined slightly off centre A hexagon washer spins freely around this bolt head The bolt behaves in a similar way to a cam when rotated If the allen key
102. mporary table or platen When machining allowances must be made for the size of tools being used since they all differ in length The tool offset is the amount the Z value must be moved or offset so that all the different cutting tool tips used line up with each other so they can all be used by one CNC file Sometimes referred to as the tool length offset See OFFSET Movement of the cutting tool through the 3 machine axes between cutting settings Standard Windows text only file extension txt The actual material being milled The work is sometimes referred to as the billet or stock Used as a zero reference point on the real billet All machining co ordinates originate from this point when offset files are used A file containing X Y and Z values that can shift the entire three dimensional co ordinate based grid system used by the CNC machine See OFFSET A combination of a letter address and digits used in a CNC program ie G42 M04 etc A fully interactive three dimensional computer based simulation of a real world object or event Denford Compiled CNC file extension xnc A compiled file is a FANUC Miller file that is formatted to allow 3D elements such as the 3D Viewer to run as quickly as possible XNC files can also be used to drive an attached CNC machine when run through the VR CNC Milling software See Tool Offset Triac Series CNC Machine User s Manual 12 Index A D About this Manual D
103. n a wide range of materials Main Features Designed specifically for Education Training and Prototyping Manufactured to industrial standards Capable of cutting resistant materials such as wax plastics acrylics copper aluminium and steel Links to CAD CAM software including Pro DESKTOP ArtCAM Techsoft Mill CAM Designer AutoCAD and other industrial packages Totally enclosed high visibility interlocked guard Feedrate and spindle speed override controls CE approved for safety Programming via International Standards Organisation format Flexible workholding capabilities Easily upgradeable for inclusion in FMC FMS CIM systems Optional software allows programming via ISO F ormat incorporating controls such as FANUC amp Heidenhein Triac Series CNC Machine User s Manual 1 Triac Series Model Variants Triac PC Model shown Triac PC with optional ATC pneumatic guard vice and PC workstation 4 Note Electrical control box A not shown in photograph Main options available 8 station Automatic tool changer Flood coolant e Machine table Pneumatic guard door e Pneumatic vice Triac VMC Note Electrical control box not shown in photograph Main options available e Machine table e Pneumatic guard door Pneumatic vice Triac Series CNC Machine User s Manual Section 1 Introduction 9 1 What is CNC 10 Introduction Section 1 CNC Computer Numerical Contr
104. n totally enclosed interlocked safety guard door Emergency stop button Axis limit microswitches adjustable on Z Slide 2D 3D toolpath graphics to verify part programs prior to machining Automatic tool retraction amp spindle stop for tool changing CAD CAMI CNC Software options MillCAM Designer Techsoft 2D Design Tools MiniCAM AutoCAD and additional Autodesk products MasterCAM Pro DESKTOP CNC Tutor ArtCAM Triac Series CNC Machine User s Manual 10 Specification of Triac VMC Dimensions e Machine width 1285mm 50 5 8 Total machine width including monitor housing 2120mm 83 15 32 Total machine height 1060mm 41 3 4 Total machine height with guard open 1160mm 45 11 16 Total machine depth 935mm 36 13 16 e Electrical control box width 600mm 23 5 8 Electrical control box height 780mm 30 11 16 Electrical control box depth 360mm 14 3 16 Height Depth Height Det dh e Machine table size width X axis 500mm 19 11 16 e Machine table size depth Y axis 160mm 6 5 16 Spindle to table Z axis 275mm 10 13 16 e Spindle centre to column front edge 170mm 6 11 16 e Machine table 3 tee slots 10mm 25 64 width 31 5mm 1 1 4 centres X Y Z ballscrews 16mm 5 8 diameter x 5mm 13 64 pitch Triac Series CNC Machine User s Manual Mechanical Details e Longitudinal travel X axis 290mm
105. ng mode Errors are all shown with a flashing dot Display Meaning External error Software abort or interpreter error Maximum servo following error exceeded Limit switch open nOD oc TwA ANN osc Cc ramno Triac Series CNC Machine User s Manual Section 8 Machine Electronics 111 8 The Spindle Drive Board Location Look in the top right corner of the control box BY BEEEAE The spindle drive board mounted in the top right corner of the electrical control box controls the motor for the programmable spindle Spindle Drive LED Status The two spindle drive status LEDs are mounted in the top left hand corner of the spindle drive board Display Meaning ON LED Spindle drive board operational If this is not lit check the spindle drive board fuse shown in the photo above then the fuse labelled F1 on the main fuse rack positioned behind the isolator bracket STALL LED Motor stall This indicates a faulty motor or component on the spindle drive board 112 Machine Electronics Section 8 Triac Series CNC Machine User s Manual 8 Interior Layout of the Machine Connection Box Warning Taxy The mains power supply is fed to the electrical control box which in turn is connected to the machine connection box via the large A flexible black machine power cable The machine connection box is Never attempt to access mounted on the back panel of the Triac cabinet the electronic hardware systems of
106. nt will indicate that the slide in question requires adjustment To accurately assess the condition of each slide Denford recommends the use ofa dial gauge Note that a slight degree of movement will always be presentin every Slide If there is no free movementwhatsoever then the slides would be too tightto move Triac Series CNC Machine User s Manual Section 7 Maintenance 97 7 X Axis Gib Strip Adjustment To adjust the X axis gib strip on the table slide 1 Drive the machine table to the mid point of the saddle This will make is easier to gain access to the left front side of the saddle where the gib strip locking screw is located as shown below 2 Usinga flat bladed screwdriver release the gib strip lock screw Location Bled ia p View looking Look at front left side of ET under the saddle ekna N machine table at screw the leftside of the saddle Front of E machine 3 The gib strip adjustment screw is accessible from the right front side of the saddle as shown below Turn the gib strip adjustment screw clockwise until tight Do not overtighten this screw A slight degree of movement mustbe left to allow the slide to move Location max ei m Look at front right side un ert s of saddle Gib strip machine table at ae the right side of the saddle Front of machine Right side of saddle 4 Retighten the gib strip lock screw 5 Move the machine table leftand right along the sadd
107. o the working area of the P x machine The coolantis channelled into the storage tank via the two o drain grills located in the front right and left corners of the machine floor Check and clear and obstructions from these grills each week The grills can be removed for cleaning by unscrewing the allen hex bolts in the centre of each grill The storage tank tank has a capacity of 14 75 litres Use coolantgrade Cincinnati Millacron Simcool C60 New coolantshould be mixed in accordance with coolant suppliers instructions Denford recommends using a minimum 2 5 mix Old excessively dirty or used coolant should be drained and replaced with a fresh coolant mix when applicable To drain off coolant unscrew the drain plug located below the coolantlevel viewing window on the rightend panel of the Triac cabinet Ensure thatany unwanted coolantis collected and disposed of in a responsible manner Further details regarding parts of the flood coolantsystem are explained in Section 3 CNC Machine Installation pages 29 to 30 106 Maintenance Section 7 Triac Series CNC Machine User s Manual 8 Accessing the Electrical Diagrams TAx Open the electrical control box to access the electrical diagrams for your Triac Warning 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 po
108. ol is the general term used fora 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 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 mac
109. ol holder M27 ATC reset carousel M32 Rotate carousel clockwise viewed from above M33 Rotate carousel counter clockwise viewed from above M34 Rotate carousel one half turn Manual Pneumatic Safety Guard Door Control The following M codes can be manually entered to control the operation of the optional pneumatic safety guard door M38 Guard open M39 Guard close 68 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 Requesting a Tool Change ATC Manually writing a Tool Change Program The Miscellaneous Function M06 is used to program a manual tool change operation The M06 code activates the request for a tool change and is followed by the code T__ _ _ indicating the new tool number the first two numerical digits using the stated tool length offset file number the last two numerical digits For example M06 T0305 This command is read requesta tool change from the current tool number to tool number 3 using tool length offsetfile number 5 Automatic Calling of an ATC Tool Change during the running of a CNC program Before starting to run yourCNC program ensure the tool profiles that are placed in the numbered carousel pockets exactly match the tool profiles and tool numbers used in your CNC program On reading a tool change operation line in your CNC program the ATC will perform the necessary tool change operations automatically Triac Series CNC Machine User
110. ollowing holds true The same cutting tools are used The next billet to be machined is the same size as the last billet used The next billet to be machined is placed in the working area in exactly the same position as the last billet used 46 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 Configuring a Workpiece Offset oxy lhe workpiece offset file contains three values used to describe the prepa location of your workpiece datum They determine how much you fegatding confauratin want to shift the zero reference position of the CNC machine along of workpiece and tool the X Y and Z axes length offsets can be However if your CNC file uses two or more tool profiles the workpiece offset file will not account for the difference in length between the tools To achieve this you must also configure a tool offset value for each tool profile you intend to use see the next page Before you can begin entering the workpiece offset values you must position the tool over your workpiece datum Move the tool so its cutting tip just touches your chosen workpiece datum position as shown in the diagram below Take care not to damage the cutting tip when manoeuvring the tool found in your separate CNC Machine Control Software User s Manual In this example the workpiece datum is set at the front left upper corner of the billet positioned onto a temporary MDF machine sub table Alternatively if
111. ons of the Denford websites and or contact Denford Customer Services see page 114 for details Incorrect registration of tool offsets when using multiple tools of the same diameter All tool offset data is saved in the tooling library according to the tool diameter rather than the tool number used with the machine This can present problems when you wish to use two or more tools of different lengths but identical tool diameters for example a 4mm roughing tool and a 4mm finishing tool Only one tool offset can be registered since the standard tooling library only contains one 4mm tool In this example separate entries must be created in the tooling library for both the 4mm roughing and finishing tools then each tool added to the machine tooling window to allow separate tool offset values to be registered Triac Series CNC Machine User s Manual Section 9 Technical Support 117 9 Troubleshooting DOS CNC Milling Software DOS CNC Milling Software Communications Troubleshooting 1 PC versions Your computer communicates with Triac PC versions using an RS232 serial cable Check the RS 232 cable is securely plugged into a valid COM port on the computer Note that COM ports are sometimes labelled as serial ports Identify whether the COM port being used is labelled as COM1 or COM2 The opposite end of this cable is securely plugged into the RS 232 port located on the side panel of the electrical control box VMC versions The R
112. osition 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 Y and Z panels of the co ordinate display all read zero this assumes that no offsets are loaded In addition to homing the CNC machine after it has first been Switched on we also recommend homing the CNC machine after loading or configuring any offsets Section 4 CNC Machine Operation 41 4 Manually Controlling the Triac J og Mode Jog mode is used for manually controlling the CNC machine moving the three machine axes changing tools operating optional equipment and configuring any offsets lt lt Machine Back L Column slide Z axis Z i Y No KaT Y axis Table slide Crosslide y X X axis Axis Definitions X Axis The X axis slides run at 90 degrees to the Y and Z axes horizontally left and right when viewed from the front of the The keys for manual axis movement will machine depend on the type of Minus X movements run towards the left end of the machine and CNC control software positive X movements run towards the right end of the machine Y Axis The Y axis slides run at 90 degrees to the X and Z axes being used please refer to your separate CNC ne r
113. ped with hardware that allows it to 1 run the CNC machine control software 2 be physically connect to the Triac electrical control box The specification of computer required to control your Triac 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 exact computer specification required 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 RS 232 cable supplied with your machine The RS 232 cable supplied with your machine must always be used since this cable features crossovers on some of the pin connections You must also configure the machine control software to recognise which numbered COM port is being used by the RS 232 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 Triac Series CNC Machine User s Manual 3 PC version only Connecting your computer to the Triac PC Warning Tax To connect your computer to the Triac PC A 1 Connect the elements of your computer together as described in your original comput
114. r Minute Feed per Revolution Return to Initial Point in Canned Cycle Return to R in Canned Cycle Circular Pocket Circular Pocket Rectangular Pocket Rectangular Pocket Code listing full and correct at the time of printing Triac Series CNC Machine User s Manual 10 M Codes List Note Not all M codes may apply to your CNC machine M code Function M Program Stop M 1 Optional Stop M 2 Program Reset M 3 Spindle Forward clockwise M 4 Spindle Reverse counter clockwise M 5 Spindle Stop M 6 Automatic Tool Change M 8 Coolant On MQ9 Coolant Off M10 Vice Work Clamp Open M11 Vice Work Clamp Close M13 Spindle Forward and Coolant On M14 Spindle Reverse and Coolant On M19 Spindle Orientation M20 ATC Arm In M21 ATC Arm Out M22 ATC Arm Down M23 ATC Arm Up M24 ATC Drawbar Unclamp M25 ATC Drawbar Clamp M27 Reset Carousel to Pocket One M3 Program Reset and Rewind M32 Carousel CW M33 Carousel CCW M38 Guard Door Open M39 Guard Door Close M62 Auxiliary Output 1 On M63 Auxiliary Output 2 On M64 Auxiliary Output 1 Off M65 Auxiliary Output 2 Off M66 Wait for Auxiliary Output 1 On M67 Wait for Auxiliary Output 2 On M70 Mirror in X On Notall M codes listed M71 Mirror in Y On are available all M M76 Wait for Auxiliary Output 1 Off codes marked with an M77 Wait for Auxiliary Output 2 Off asterisk will be M8 Mirror in X Off performed at the end of M81 Mirror in Y Off a program blo
115. r the vice jaws The pressure is adjusted using the single air regulator fitted to the left of the hydraulic intensifier on the back panel of the Triac cabinet do not confuse this with the regulator from the compressed air connection unit see Section 6 Work Holding pages 78 to 80 2 The compressed air connection unit is functioning correctly the air compressor is connected and switched on and the correct air pressure level is set 1 PSI or 6 6 Bar see Section 3 CNC Machine Installation pages 25 to 28 3 Check the security and condition of all hose connections No lubrication is being delivered to the machine slides Check the following 1 Oilis supplied by the automatic slide lubrication system mounted to the right of the machine connection box on the back panel of the Triac cabinet Check that oil is filled in the reservoir to the correct level 2 Inspect the lubrication outlets and check they have not become blocked with dust debris or swarf Check the security and condition of all hose connections 3 Check the flow adjustment on the system is set correctly see Section 3 CNC Machine Installation pages 31 to 32 The flood coolant system is not working Check the following 1 Check that coolant is filled in the Triac base reservoir tank to the correct level see Section 3 CNC Machine Installation pages 29 to 30 2 If coolant has been unused for a long period of time check for the presence of an
116. rators panel n se 51 troubleshooting oe eeseestesstestesstesseseeseesnees 122 R Removal of protective coatings oc 33 Running a CNC program S Safety emergency stop button scere 14 interlock guard switch OVENVIEW aaier iratta PFECAUTONS n artieste Schedule maintenance n SUNG YoUr TNA G si cccovsistetessschveerscsitstrsisarddecrssrtedveey Slideways lubrication olee irii oeie x axis inspecting and cleaning y axis inspecting and cleaning ieees z axis inspecting and cleaning ee S pecification PC VEPSION iaaa aiene 126 VMCE Versio iarasi 128 Spindle drive board sssr 112 Spindle Speed override control sses 51 Standard equipment cece 11 Switching the Tride Off einanuiiotetieanaki 40 the Tria Oninin 39 Triac Series CNC Machine User s Manual T Technical support sssri 114 Tooling system Automatic Tool Changer nsss 61 easychange ennea 52 Troubleshooting cutting problems sses 121 DOS CNC milling software 118 electrical problems ssssnsreri 124 mechanical problems we 122 VR CNC milling software oo 115 U Unpacking your Triat oo 16 Ww Warming notices occ What is CNC vee Work Piece co ordinates display system Section 12 Index 147 12 Notes Use this page to make a note of any parts of the software you have changed or configured for example common tooling set ups machine parameters changes to installation paths or passwords etc
117. rd door l gt and enter the working To decrease the spindle speed or feedrate rotate the appropriate area when the spindle control anticlockwise or machine axes are moving The degree of adjustment applied to each value is displayed in the CNC control software Triac Series CNC Machine User s Manual Section 4 CNC Machine Operation 51 5 The Easychange Tooling System Standard Easychange Tooling System The easychange tooling system is supplied as standard with the Triac PC unless the optional ATC Automatic Tool Changer has been fitted The system comprises of two elements i The Easychange collar shown below which is permanently attached to the spindle under the machine head Tool holders are held in the collar using a spring closed mechanism Easychange Tool Collar ii The tool holders shown below containing the different cutting tool profiles Each cutting tool must be fitted into a collet a tubular split metal casing especially designed to fitsecurely in the tool holder Different sized collets are available to acceptthe various sizes of cutting tool shaft diameters Easychange Tool Holder Tool and Collet Assembly 52 Preparing Tooling Hardware Section 5 Triac Series CNC Machine User s Manual 5 Removing an Easychange Tool Holder Removing a Tool Holder from the Tool Collar To physically remove a tool from the Easychange collar grip the knurled collar and fully depress the quick
118. release pin on its circumference Warning X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Tool holder Warning aX A Caution ifthe cutting tool has The mechanism in the Easychange collar is spring loaded The collar been recently used it needs to be rotated approximately one third ofa turn to fully open the may still be HOT mechanism Whilst keeping the quick release pin fully depressed hold the tool holder still and the rotate the collar in a clockwise direction when viewed from above the machine head View eo peann Removing a tool holder from an Easychange collar A Press and hold the quick release pin B Whilst keeping the quick release pin depressed rotate the knurled collar clockwise when viewed from above machine head C Pull the tool holder downwards away from the Easychange spring mechanism Remove the tool holder downwards whilst keeping the quick release pin still depressed This prevents the mechanism in the Easychange collar from closing Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 53 5 Fitting an Easychange Tool Holder Warning X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Fitting a Tool Holder in the Tool Collar To refita new tool holder into the empty Easychange coll
119. riac Off Follow these instructions to switch off your Triac 1 All versions Wait for the Triac to fully complete any machining or processing of any operational instructions 2 All versions Open the safety guard door and remove any finished parts from the working area 3 All versions Close down the communication link between the CNC control software and the Triac then exit the CNC control software as described in your separate CNC Control Software User s Manual 4 PC versions Shut down and switch off the machine controller personal computer VMC versions Close down the Windows operating system on the integrated computer Using the Windows startbar menu click Start Shut Down select the Shut Down option then click the O kay button 5 All versions Power down the Triac by turning the yellow isolator Switch from the on I position to the off 0 position The isolator Switch is mounted on the front door of the separate black electrical control box Note that cutting the machine power will trigger the closing of the interlock guard switch This will lock a closed safety guard door in position preventing access to the machine working area The interlock guard switch will automatically reopen when power is next supplied to the Triac 40 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 Home Mode The sequence of events required to home the Triac will depend on t
120. ries CNC Machine User s Manual BEE Heb a va oe SS Fj Pi Section 10 Appendix 131 10 G Codes List Note Notall G codes may apply to your CNC machine G codes from group are non modal they must be programmed into every program block when required All other G codes are modal they remain active through subsequent program blocks until replaced or cancelled by a G code from their particular group The G codes indicated by an asterisk are reactivated as defaults when the machine Started 132 Appendix Section 10 G Code G G 1 G 2 G 3 G 4 G20 G21 G28 G40 G41 G42 G73 G74 G76 G8O G81 G82 G83 G84 G85 G86 G87 G89 G9 G91 G94 G95 G98 G99 G17 G171 G172 G173 Group 1 Function Positioning Rapid Traverse Linear Interpolation Cutting Feed Circular Interpolation CW Circular Interpolation CCW Dwell Exact Stop Imperial Data Input Inches Metric Data Input M illimetres Reference Point Return Cutter Compensation Cancel Cutter Compensation Left Cutter Compensation Right Peck Drilling Cycle Counter Tapping Fine Boring Canned Cycle Cancel Drilling Cycle Spot Boring Drilling Cycle Counter Boring Peck Drilling Cycle Tapping Boring Cycle Boring Cycle Back Boring Cycle Boring Cycle Absolute Zero Incremental Command Feed pe
121. ront right corner of saddle corner of saddle 5 Move the machine saddle forwards and backwards along the cross Slide to ensure thatthe movementis smooth 6 Ifthe movementis notsmooth loosen the gib strip by repeating Steps 1 to 4 butturn the gip strip adjustment screw counter clockwise Run the machine saddle again to assess the smoothness of movement Triac Series CNC Machine User s Manual Section 7 Maintenance 99 7 Z Axis Gib Strip Adjustment To adjust the Z axis gib strip on the column slide 1 Drive the machine head upwards This will make is easier to gain access to the underside of the machine head where the gib strip locking screw is located under a cover in the back right corner Remove the gib strip locking screw cover as shown below left using a 2 5mm allen hex key 2 Using a flat bladed screwdriver release the gib strip lock screw as shown below right i Underside of machine I head Location X Look under front right edge of machine head iy to access gib strip locking screw Front of machine column View looking under front of machine head continued 100 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Z Axis Gib Strip Adjustment 3 The gib strip adjustment screw is accessible from the back ofthe machine head Using a suitable stepladder work from the back of the machine and reach across the top surface of the machine column to
122. rvoir tank has a maximum capacity of 0 5 litres Refill the reservoir using oil grade BP CS 68 2 Location a X Look at right side of machine back panel r The automatic slide lubrication system P Plastic filling oil cap Low oil level marker If the oil level drops below the minimum level mark the unit must be hand primed before use see Section 3 CNC Machine Installation page 32 for this procedure 88 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Cleaning and Inspecting the X Axis Ballscrew and Slideways Two X axis slideways are located under the machine table Run the machine table fully to the left exposing the left portion of the slides as shown below Using a softbristled brush carefully clean any swarf and debris away from the frontand back table slides to a location where itcan be removed from the working area Inspect each slide for damage or wear Location ax Look under the machine table View from left side r ee Machine table of machine 3 t f Front Table slideway ballscrew slideway a Column base left side ne TAN Run the machine table fully to the right as shown below to expose the remaining portion of the slides and repeat the process View from right Machine table table side of machine aps AAAA LA Back slideway Front Table slideway ballscrew Column bas
123. s e Axis Limit Switch Override Pneumatic Guard Door optional equipment Emergency Stop Feedrate Override e Spindle Speed Override Location of the Panel Additional features on the Triac VMC monitor Triac PC without flood coolant Mounted directly on the front housing right side of the lower machine cabinet A pull out qwerty keyboard is mounted Triac PC with flood coolant Mounted on an extension to the front under the front of the right side of the lower machine cabinet shown in photo above DeskTop Tutor casing Triage VMC Mounted on the front right side of the monitor housing EEE The monitor housing is attached to the right end of the machine right side of the cabinet DeskTop Tutor casing 50 CNC Machine Operation Section 4 Triac Series CNC Machine User s Manual 4 Front Machine Operators Panel Ex Emergency Stop Button Activating an The emergency stop button is a circular red push button Pressing emergency stop will the emergency stop button has the effect of stopping all axes and also trigger the interlock spindle movements immediately To active an emergency stop Sees eh press the button in until it clicks The emergency stop button will guard door from being remain closed continuing to cut all power to the machine drives opened until the button is released To release turn the button clockwise until it springs back out Axis Limit Switch Override The axis
124. s as soon as possible The following equipmentis supplied as standard with your Triac Series CNC machine PC versions Denford Triac PC CNC machine Note thatthe precise specification of your Triac will depend on any options selected atthe time of ordering see next page Separate electrical control box 1x Electrical control box key e 1xRS 232 serial link cable 25 9 pin connection Note CNC machine controller P C notincluded as standard VMC versions Denford Triac VMC CNC machine Note thatthe precise specification of your Triac will depend on any options selected atthe time of ordering see next page Separate electrical control box including built in PC Integrated DeskTop Tutor controller and monitor 8 station automatic tool changer and tooling Flood coolantsystem All versions e 1x Guard door interlock switch torx bit e 1x Operators toolkit metric allen hex keys 2mm 2 5mm 3mm 4mm 5mm 6mm spare fuse package e 1x Easy change toolholder package e 1xTriac Series CNC machine warranty pack e 1xTriac Series CNC machine inspection certificate e 1xTriac Series CNC machine manual this book plus additional OEM product manuals as required e 1xCNC Machine Control Software manual 1xCNC Machine Control Software CD ROM and or floppy disks e Machine commissioning and basic instruction 1Day training course for 2 persons at Denford Limited UK Section 1 Introduction 11 1
125. se note that the layout of your electrical panel may differ from the photo depending on components and options fitted to your Triac PC Before commencing any work refer to the schematic diagram of the electrical panels held in a folder on the inside face of the electrical control box door VMC Version The layout of the electrical panels differs from the Triac PC in the following areas An IBM compatible personal computer is attached to the electrical control box door oppy disk and CD ROM drives are built into the electrical control box door In all other respects layout of the major electrical components are identical to the Triac PC electrical control box photo shown on the next page Before commencing any work refer to the schematic diagram of the electrical panel held inside the electrical control box or supplied separately in the standard equipment box supplied with your machine e mn 108 Machine Electronics Section 8 Triac Series CNC Machine User s Manual 8 Interior Layout of the Electrical Control Box Layout of the Electrical Panels PC Version shown ne D ee Ferrite ore Spindle Drive Board l r ae A g aA AN D aka A ihh k _ a EE sey rly saab A MO Ta acai impae ANA i ON Wu m i Standard WYO Unit G ah wi A f 0 Uni Eurostep Custom Space Z Axis Y Axis X Axis Control Motion Card for 24V
126. ser s Manual for specific details 80 Work Holding Section 6 Triac Series CNC Machine User s Manual 6 Option Pneumatic Safety Guard Door 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 Triac Series CNC Machine User s Manual The pneumatic safety guard door is Supplied as an option with the Triac PC orTriac VMC Operation of the door is achieved through use of a pneumatic cylinder driven from the compressed air system The cylinder circled right is mounted to the left of the machine column The pneumatic safety guard door can be opened or closed automatically during the running of a CNC program through the calling of the appropriate door open or close M code function The same M codes are also used to manually control the operation of the door Preparing the Compressed Air Supply Before switching on your air compressor check all air hose connections are secure and the correct operating pressure is seton the regulator mounted on the back panel of the Triac cabinet The normal operating pressure as supplied preset on the machine is 10 PSI 6 6 Bar Maximum pressure for the air regulator is 15 PSI
127. t front side of b in The moveable microswitch trigger position is set at the table from below time of machine manufacture and should not require adjustment E o N View looking at right front of machine table Triac Series CNC Machine User s Manual Section 7 Maintenance 93 7 Cleaning and Inspecting the Y Axis Datum Microswitch The microswitch defining the Y axis datum is mounted atthe front of the crosslide fully enclosed by the flexible cover so itis not subjectto swarf build up To check the condition of the microswitch drive the machine table and saddle fully back against the machine column This will make it easier to gain access to the front section of the crosslide Carefully liftthe flexible cover and locate the microswitch as shown below Inspectthe microswitch for damage or wear View from right Location CHI X 4 Machine table side of machine Look under front of flexible crosslide cover Microswitch 7 Trigger under Ei saddle Column base right side View from leftside of machine The moveable microswitch trigger position is set at the time of machine manufacture and should not require adjustment z sge Low The trigger for the Y axis microswitch is mounted under the front edge of the saddle hidden from view by the flexible cover so itis notsubject to swarf build up Drive the machine table fully back againstthe machine column then c
128. tem Machine power cable connections MAINS SUPPLY ioina 21 Maintenance automatic slide lubrication system ee 88 general work area cleaning gib strip adjustment LOG ieina lubrication chart planning procedure sssri s hedule neinean x axis ballscrew and slideways X axis datum MICFOSWIECH ssri XANES GID SUP rasian ai y axis ballscrew and slideways y axis datum microswitch y axis gib strip z axis ballscrew and slideways z axis datum microswitch Z AXIS GID SUP arat Manufacturing process Overview seses icroswitch X axis inspecting and cleaning y axis inspecting and cleaning z axis inspecting and cleaning iteebite clamps description sieci iaraa 75 fiting removal and adjustment 76 using example Moving jogging the machine axes N Noise level test results sssrin 139 Notes 0 Offsets Heo iinne anh 45 tool length 48 workpiece 41 Operators panel 50 Optional equipment sssr 12 Overriding the spindle speed or feedrate 51 Triac Series CNC Machine User s Manual 12 Index P Part manufacture checklist ssri 49 Part program composition example cesses 131 COS CHIPUON vss ieg aia 130 Pneumatic safety guard door CES CHIPLON iiie ieioea 81 maintenance 104 Operating M codes ou eee 81 preparing the compressed air supply 81 switch on front ope
129. the T shaped channels Align each Tee nut with its respective channel and slide it into position Slide the datum plate along the machine table to the required position Note that the datum plate can be slightly adjusted forwards and backwards ie parallel to the Y axis if required according to whether the front or back two T shaped channels are used Once the datum plate has been approximately positioned in the correct place tighten each of the allen headed bolts by turning them in a clockwise direction until they just begin to grip the plate to the table surface It must still be possible to move the datum plate since it may require final adjustments if it needs to be lined up square with respect to the machine axes Datum plate L shaped work locating bracket Allen headed bolt Tee nut T shaped channel ba amp Triac Series CNC Machine User s Manual Section 6 Work Holding 71 6 Setting the Datum Plate The following diagrams illustrate the various methods that can be used when positioning the datum plate square with respect to the machine table ie the edges of the datum plate run exactly parallel with the X and Y machine axes Each method varies according to the level of position accuracy required Datum Plate Setting Method 1 ES Flat piece of steel bar This method is useful if the front face of the datum plate can be positioned exactly level with the front edge of t
130. the machine A Left The standard Triac PC machine with the mains power connection box contains electrical switched ON erminal blocks and routing for the Note that hazardous automatic slide lubrication system voltages can still exist Triac PC models fitted with compressed immediately after air driven equipment will be fitted with switching off the power he standard Triac VMC machine f connection box illustrated below If the machine has Machine mains cable connection Removable door plate previously been switched on wait at least 5 minutes before attempting to open the machine connection box door Left The standard Triac VMC machine connection box contains electrical terminal blocks routing for the automatic slide lubrication system and air pressure switches for the compressed air driven equipment Note that machine connection box doors are fitted with either a key operated lock or removable door plate Machine mains Below Interior of the standard Triac connection VMC machine connection box sR Mains electrical connection 2 Se be oh be ue t Terminal gt D P Ky x i s E A A ENE o Triac Series CNC Machine User s Manual Section 8 Machine Electronics 113 9 Technical Support Denford Limited provides unlimited telephone and e mail Technical Support on this CNC machine to registered users On site visits by our en
131. the tool depth stop Easychange tool holder screw Triac Series CNC Machine User s Manual Section 5 Preparing Tooling Hardware 67 5 Requesting a Tool Change ATC Ten 20x Manually Calling an ATC Tool Change A Wait for any spindle and machine axis movements to finish before Never open the safety Calling a tool change operation guard door and enter Ensure the tool profiles that are placed in the numbered carousel the working area when Pockets exactly match the tool profiles and tool numbers programmed the spindle or machine axes are moving into your CNC control software There are two methods used to manually call an ATC tool change 1 Switch your CNC control software to og mode and use the manual Warning X tool change function commands A 2 Write and execute a small M06 tool change program in your CNC Caution control software editor see th section on the next page AG a pa After calling a manual ATC tool change the ATC will perform the may still be pe necessary tool change operations automatically Please refer to your separate CNC Control Software User s Manual for further information The following M codes can be manually entered to control the operation ofan ATC M20 ATC arm in towards machine spindle M21 ATC arm out away from machine spindle M22 ATC arm down from beneath storage cover M23 ATC arm up into storage cover M24 Drawbar Unclamp release tool holder M25 Drawbar Clamp grip to
132. this point needs to be inside the boundary of the material a small mark could be made on the surface to identify the proposed location of the workpiece datum Workpiece Datum Billet grey Triac Series CNC Machine User s Manual Section 4 CNC Machine Operation 47 4 Configuring a Tool Length Offset TEX The tool length offset files each contain a single Z value A separate tool length offset file must be configured for every tool we want to reat conic use They allow us to establish a common workpiece datum of workpiece and tool position no matter what length of tool is used with the CNC file length offsets can be Select a point on your billet that can be reached by all the tools you found in your separate intend to use All tool length offsets are configured against this CNC Machine Control common tool offset reference point When values are entered into Software Users Manual each individual Z length tool offset file each tool will use this reference point as their zero co ordinate along the Z axis It is this figure that compensates for the differences in length when various tools are used together on the same job as shown in the diagram Further information below Machine Head Home Position Tool 1 Tool 2 Difference in length between tools 1 and 2 KE E meres roa 5s Tool Length Plane of Tool Length Offset value Tool Offset value for Tool 2 Reference for Tool 1 Position a ete et eee
133. ticular set of machining operations These lines which run in sequence are called blocks A block of data contains words sometimes called codes Each word refers 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 Triac Series CNC Machine User s Manual 10 Composition of a Part Program A component is designed using a CAD CAM software package such as Mill CAM Designer The CAD CAM software package automatically generates the part program including all the G and M codes required to manufacture the component Part Program example Mill CAM Designer triang MCD 3 3 1997 metric Post fanucm 1 2 24 J une 1994 G21 BILLET X8 Y55 Z10 EDGEMOVE X YO TOOLDEF T1 D2 N 1 G91G28XBY O29 N 2 M T1 N 3 G43H1 N 4O M3S1500 N 5 GI G X4 Y 48 N 6 Z2 N O70 G1Z 5F1 00 N 8 X72Y16F 159 N 9I X8 N 1 X4 Y 48 N 11 G Z2 12 X24Y 32 130 G1Z 1F 100 ae oe ara 140 X56F 150 158 X4 Y 16 16 X24Y 32 178 GOZ2 N 18 M5 N 19 G9I1G28XBYHZ0 N 2 M30 en ee ee Triac Se
134. tion 31 3 Automatic Slide Lubrication System The hand priming pump should only be used if the oil level falls below the minimum oil level mark printed on the side of the reservoir tank To prime the system lift and depress the spring loaded hand pump until oil begins appearing on the slideways The amount of oil supplied to the slideways can be adjusted using the hand priming pump Release the locking nut on the top of the hand priming pump so the knurled collar can be freely rotated Turning the knurled collar raises or lowers the sleeve which in turn shortens or lengthens the stroke Note that 5ml graduated marks are machined into the surface of the sleeve to assist setting Automatic slide lu brication Increase oil flow system hand a priming pump eaea P Sleeve locking nut Knurled collar Graduated sleeve To increase the oil flow turn the knurled collar clockwise when viewed from above The sleeve will move down increasing the stroke To decrease the oil flow turn the knurled collar anticlockwise when viewed from above The sleeve will move up decreasing the stroke The rate of oil flow is preset at the time of CNC machine manufacture This rate should NOT require adjustment through normal day to day use of the CNC machine 32 CNC Machine Installation Section 3 Triac Series CNC Machine User s Manual 3 Removal of Protective Coatings Warning max Once your Triac has
135. tum Co ordinate position X 0 Y 0 Z 0 When the machine has been homed and the machine co ordinate system is used Positive Y co ordinates Cutting Too lt w athome position Negative X co ordinates Machine Positive X Datum co ordinates Negative Y co ordinates Negative Z co ordinates Location of the Workpiece Datum When the appropriate machine and tool offsets are loaded Positive Z x yi co ordinates T Cutting Tool at home position Workpiece Positive Y Datum co ordinates Positive X J co ordinates Pa Temporary Machine Sub table Negative X co ordinates Negative Y co ordinates Negative Z co ordinates Billet Section 4 CNC Machine Operation 43 4 Manually Controlling the Triac J og Mode M codes can be manually entered for control of miscellaneous functions such as switching the spindle on and off or operating an The sequence of events ATC automatic toolchanger required to manually enter an M code will depend on the type of i i CNC control sofware Listof M codes for Standard amp Optional Equipment bei d in aadton many of M03 Spindle forward standard on all versions these miscellaneous M04 Spindle reverse standard on all versions functions may be M05 Spindle stop standard on all versions controlled directly using buttons and commands M08 Coolant on optional flood coolant system available in
136. ully enclosed by the flexible cover so itis not Subject to swarf build up Run the machine table and saddle fully back againstthe machine column then liftand move the cover to one side Take care not to overstretch or tear the flexible cover Inspectthe ballscrew for damage or wear View from right side of machine Location X Lift flexible cover at machine column base Machine column t PF Fcrosside balscrew J a Column base right side Machine tabis f Run the machine table and saddle fully forwards and repeatthe process for the remaining part of the ballscrew as shown above Triac Series CNC Machine User s Manual Section 7 Maintenance 91 7 Cleaning and Inspecting the Z Axis Ballscrew and Slideways Two Z axis slideways are fitted to the front right and left sides of the machine column shown below Using a softbristled brush carefully clean any swarf and debris away from the column slides to a location where itcan be removed from the working area Inspecteach slide for damage or wear Location Ja X Look at front of machine column Machine View looking at head i frontof machine underside el ee 2 7 column Right column slideway Left column slideway The Z axis ballscrew is fully enclosed by the machine column metalwork so itis not subjectto swarf build up The ballscrew can be inspected for damage or wear by removing the cover
137. uter Denford CNC Project file extension prj Project files contain global information about user defined settings in the VR CNC Milling software such as toolpost setup tooling library offsets toolbar and window positions etc PROGRAM uuu eseseecsteeteeeeees A systematic arrangements of instructions or information to suit a piece of equipment RAPID TRAVERSE sass Fast movement of the cutting tool through the 3 machine axes between cutting settings REFERENCE POINTS The machine has 3 reference points used in setting the limits of movement for its Slides axes REP Miicds centecsiccenvensceccveeee ceeds Revolutions per minute rev min a measure of spindle speed SIMULATION OFFSET The workpiece offset file only used with VR CNC Milling software 2D and 3D graphics Triac Series CNC Machine User s Manual Section 11 Glossary 143 11 Glossary SUID ES iinan SPINDLE SPEED SOFTWARE wives SUB TABLE wicca TOOL OFFSET wea 144 Glossary Section 11 The 3 machine axes see axis The rate of rotation velocity of the machine head cutting tool measured in RPM Programs tool lists sequence of instructions etc A secondary table that is clamped to the actual machine table The work is then fastened to this secondary table Used as a safety feature to prevent damage occurring to the actual machine table should a problem occur when milling For example a sheet of MDF Sometimes referred to as a te
138. vot points eCheck and tighten ATC tool holder pull studs Bi annually eCheck and adjustthe machine head crosslide and table gib strips eCheck the condition of any electrical connections eCheck and thoroughly clean all components of the tooling system fitted eCheck all cables for kinks and breaks Clean the microswitches Annually eCheck machine alignments and accuracy eCheck spindle bearing adjustment regrease eCheck and regrease axis bearings eCheck spindle drive belt for wear eCheck axis drive belts for wear 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 If you have any doubts concerning any of the above checks please contact Denford Customer Services for clarification and or assistance Triac Series CNC Machine User s Manual Section 7 Maintenance 85 7 Lubrication Chart Lubrication Point Lubricating System Frequency Recommended Oil Grease Quantity Slideways and Automatic pump Activated on BP CS 68 Reservoir Ballscrews lubrication Spindle rotation Shell Vitrea 68 capacity system Check level daily Castrol Perfecto NN 0 5 litres Headstock Grease Seal On maintenance Kluber Isoflex NBU 15 4 cc Bearing of machine head Axis Bearings Grease Seal Once a year BP LS 3 2 cc Bearing Shell Alvania No 3 Coolant Electric pump As required
139. w from right time of machine manufacture and side of machine should not require adjustment 96 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Gib Strip Adjustment A gib strip is an angled section of metal tapered along its length which is fitted to one side ofa machine slide One gib strip is fitted to each of the three machine slides on your Triac Essentially driving one of these metal wedges further along a slide will gradually decrease the amountof free play in the axis The photo below shows a gib strip being fitted to the Z axis of a machine head and column Production of a machine head and column showing Gib strip the fitting of a Z axis gib Strip During the day to day use of your Triac 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 that the gib strips be checked twice a year Any Slack presentin the slides should be rectified by adjusting the gib strips as described on the next 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 three machine axes You can quickly judge the slack available in each slide by holding the table saddle and machine head at their extreme ends Try to move or wobble them from side to side across the width of the slide Any excessive moveme
140. wards the left corner of the machine head Locate the position of the screw as shown below Turn the gib strip adjustment screw clockwise until tight Do not overtighten this screw A slight degree of movement mustbe left to allow the slide to move Location Look at back left of machine head Back of machine Gib strip head adjustment screw Top of machine column View looking at top surface of machine head 4 Retighten the gib strip locking screw and replace the cover 5 Move the machine head up and down the column to ensure thatthe Slideway movementis smooth 6 Ifthe movementis notsmooth loosen the gib strip by repeating Steps 1 to 4 butturn the gip strip adjustment screw counter clockwise Run the machine head again to assess the smoothness of movement Triac Series CNC Machine User s Manual Section 7 Maintenance 101 7 Automatic Tool Changer Maintenance The ATC Automatic Tool Changer is supplied as standard with the Triac VMC oras an option with the Triac PC Clean ifnecessary then lubricate the following parts ofthe ATC system using oil grade BP CS 68 in a manual pump action oilcan ATC Upper and Lower Slides Reaching up under the ATC cover lubricate the upper and lower Slides Run the ATC to distribute the oil evenly across both slides N r Oil upper slide T Ad Oil lower slide Location X Look under ATC cover A View under ATC cover ATC Carousel
141. wer 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 Triac Series CNC Machine User s Manual Door cannot be opened unless the isolator switch is in the off 0 position If necessary cut yellow plastic sealing tag Door lock ws e li aiio SL rm a a ron ait O A Panels PC version shown in photos above Electrical diagrams are held in a folder on the inside face of the door VMC version Electrical diagrams are stored in the base of the control box or supplied separately in the standard equipment box supplied with your machine Section 8 Machine Electronics 107 8 Interior Layout of the Electrical Control Box Warning a X 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 PC Version The photo on the next page labels all important electrical components inside the Triac PC electrical control box Plea
142. work bench e Video conferencing system 126 Appendix Section 10 Triac Series CNC Machine User s Manual 10 Specification of Triac PC Dimensions Total machine width 1285mm 50 5 8 Total machine height 1060mm 41 3 4 Total machine height with guard open 1160mm 45 11 16 Total machine depth non ATC 900mm 35 7 16 Total machine depth with ATC 935mm 36 13 16 Electrical control box width 600mm 23 5 8 Electrical control box height 780mm 30 11 16 Electrical control box depth 360mm 14 3 16 Height Height 2A Wh Machine table size width X axis 500mm 19 11 16 Machine table size depth Y axis 160mm 6 5 16 Spindle to table Z axis 275mm 10 13 16 Spindle centre to column front edge 170mm 6 11 16 Machine table 3 tee slots 10mm 25 64 width 31 5mm 1 1 4 centres X Y Z ballscrews 16mm 5 8 diameter x 5mm 13 64 pitch Triac Series CNC Machine User s Manual Mechanical Details e Longitudinal travel X axis 290mm 11 7 16 Cross travel Y axis 170mm 6 11 16 Vertical travel Z axis 235mm 9 1 4 Spindle taper ISO 30 Spindle speed range programmable 100 to 4000 rpm Spindle speed override potentiometer 50 to 120 e Maximum feedrate X Y 2500mm min Maximum feedrate Z 1000mm min Feedrate override potentiometer 0 to 150 Machine resolution 0 01mm 0 0004 System r
143. xis slides running rightand left down the front of the A machine column Caution e The Zaxis microswitch mounted on the right side of the machine If the cutting tool has column been recently used it f may still be HOT The frontand rear sections of the flexible cover on the crosslide e The upper surface and T shaped channels on the machine table e The optional datum plate and miteebite clamps on the machine table e The optional hydraulic vice The machine head and spindle e The optional Automatic Tool Changer slides and carousel The components of the tooling system used with your CNC machine e The two optional flood coolant drain grills in the front corners of the working area Triac Series CNC Machine User s Manual Section 7 Maintenance 87 7 Lubrication of Ballscrews and Slideways The automatic slide lubrication system located on the back panel of the Triac cabinet is comprised from an oil reservoir tank and an automatic pump unit The system is designed to automatically supply oil to the Slides and ballscrews on the X Y and Z axes only Oilis automatically pumped to the required areas upon activation of the machine head spindle Do notletthe oil level drop below the minimum mark printed on the side of the reservoir tank To top up the slide lubrication system liftthe yellow filling cap and pour Sufficient oil into the reservoir tank Take care NOT to overfill the system The rese
144. y A B C D E and F are measurement positions 1 metre Front of machine from the machine continued on reverse Triac Series Noise Level Test Results Test Conditions Spindle speed 4 000 RPM Spindle Direction Counter clockwise Ambient background noise lt 61 dB A Spindle Speed Sound Levels dB A Range Ins rev EEEE Mean Test Conditions Spindle speed 4 000 RPM Spindle Direction Clockwise Ambient background noise lt 61 dB A Spinde Speed Speed Sound Levels dB A Range SES 140 Appendix Section 10 Triac Series CNC Machine User s Manual 11 Glossary ABSOLUTE anusia In absolute programming zero is the point from which all other dimensions are described ALLEN HEAD wu eee A hexagon shaped hole on the head top of a set screw These are tightened and loosened using allen keys wrenches AR Corsiea ea A portion of a circle AT Ciarain Automatic Tool Changer 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 machine ie F S T M codes etc other than co ordinate based commands AXIS AXES woes The planes of movement for the cutting tool usually referred to as X horizontal left and right parallel to the front of the machine Y horizontal forward and backwards parallel to the side of the machine and Z
145. y Controlling the Triac J og Mode sssr 42 Understanding OffSetS eeesecceeeeteeeeetenerieeieieiteieeitets 45 Configuring a Workpiece Offset csssscessesssssssesssessseeesseeeseeeen 47 Configuring a Tool Length Offset esseccseerrerersren 48 Running a CNC Program Auto Mode sssessusesssssssssnssesseseess 49 Front Machine Operators Panel sssssssersssrsrrerrsrrisrrrrsnirn 50 Triac Series CNC Machine User s Manual Contents 3 Contents 4 Contents Section 5 Preparing Tooling Hardware The Easychange Tooling System vu cesses 52 Removing an Easychange Tool Holder oo 53 Fitting an Easychange Tool Holder sses 54 Setting Tools in the Easychange Tool Holder screen 55 Requesting a Tool Change Easychange sees 59 The Automatic Tool Changer System oo 61 Setting Up he AT Cti pi did uendiassanslenviapaianainiestesoas 62 Setting Tools in the ATC Tool Holder v sessssssssessessessessnsssssesseens 64 Requesting a Tool Change ATC wees 68 Section 6 Work Holding Option The Datum Plate ccssssessssssssessssssssseeseessess 70 Fitting and Removing the Datum Plate c cccscssssssssssseeesseseens 71 Setting the Datum Plate csessesssssssssssssssssssssrssssssesssssterseess 72 Option Miteebite ClaMpS ote eet 75 How does a Miteebite Clamp work sosscccrcccrencnisnnsinn 76 Using Miteebite Cla MpSi tives ccituenstreeneanodnstmnaeietere 71 Option Hydraulic ViC sasina t aaa 78 Hydraulic Vice Operation
146. y air locks in the system 3 Check the security and condition of all hose connections If the coolant is excessively dirty drain flush and refill the system Triac Series CNC Machine User s Manual Section 9 Technical Support 123 9 Troubleshooting Electrical Problems TA A Warning se dante ie Never attempt to access the electronic hardware systems electrical scnematic A A diagrams for the connections or fuses in the CNC machine with the mains isolator definitive labelling and power switched ON placement of Note that hazardous voltages can still exist immediately after components and fuses itchi f th if th hine h iously b Information contained SWitching off the power If the machine has previously been on this page is correct at switched on wait atleast 5 minutes before attempting to access any the time of printing electronic components J une 2002 but is liable to change through continuous development The spindle drive is not working ou Check the validity of the following 1 Confirm that none of the axis drives are on overtravel 2 Check the spindle drive fuse F 1 referring to the electrical schematic diagrams see Section 7 Machine Electronics pages 107 to 110 and page 112 The axis drives do not respond Check the validity of the following 1 Check the emergency stop button is not depressed 2 Confirm that none of the axis drives are on overtravel or tripped their limit switc
147. y maintenance work Covers and safety guards that are removed during the maintenance work must be replaced after the task is completed All work must be carried out by suitably qualified personnel When replacing electrical components ensure the new parts are of Suitable replacement specification All work 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 thatthe replaced or serviced parts work correctly before allowing general operation of the machine 82 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed Triac Series CNC Machine User s Manual Section 7 Maintenance 83 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed 84 Maintenance Section 7 Triac Series CNC Machine User s Manual 7 Maintenance Schedule Daily Clean and remove any swarf eCheck and top up oil level in various reservoirs Clean tooling and tool holders Weekly Clean the machine thoroughly eCheck all exposed screws and nuts for tightness Oil optional ATC slides and pi

Triac Series CNC Machine User`s Manual.

Contents

Download Pdf Manuals

Related Search

Related Contents