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Meteor CNC Lathe User`s Manual.

1. DENFORD Total Commitment to Education and Training WorldWide Meteor CNC Lathe User s Manual approved Denford Limited reserves the right to alter any specifications and documentation without prior notice No part of this manual or its accompanying documents may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Denford Limited All brands and products are trademarks or registered trademarks of their respective companies Copyright Denford Limited Version 1 11 02 All rights reserved Contact Information Address Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK Telephone General Enquiries 01484 728000 Fax 01484 728100 Website www denford co uk Forum www denfordata com bb e mail for sales enquiries contact sales denford co uk for machine servicing enquiries contact service denford co uk for customer services contact customerservices denford co uk Technical Support Telephone 01484 728000 e mail customerservices denford co uk Monday to Friday 8 30am 4 30pm GMT Notes 2 Contents Meteor Series CNC Lathe User s Manual Contents Preface COE GL TIC ea NOI ratte atte tet e AGT ee ont le i ee Rap neha lence Aenea ae 2 WVU WORGOS EEA A E A A EA AE E A AAE A E EE A EE 5 ADOULNIS MANUA esiones repna enne E a EERE e Eaa EEEE TR 6 Section 1 Introduction introducing your Meteor CNG TAU x
2. 10X 1 Your computer communicates with Meteor versions using the Denford Machine Link cable Check the Denford Machine Link 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 RS232 port located on the side panel of the electrical control Dox 2 Check all mains power connections are correctly fitted and secure Power up the CNC lathe using the yellow isolator switch mounted on the electrical control box door position l 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 Start the VR CNC Turning software from the default installation click Start Programs Denford VR Turning From the main menubar at the top of the VR CNC Turning software screen click Setup Setup Machine Parameters You may be required to enter a password The default password is denny Type the password and click OK The Machine Properties window will continued Meteor Series CNC Lathe User s Manual 9 Troubleshooting VR CNC Turning Software Note Any optional equipment fitted to your CNC l
3. Checking the Condition Of the Gib Stips u sciceenedcsespnacsnincbeaxssixvexenenstaledudassaducbnaieetetadanbenixeusnedsaineubndeataeannesntateins 70 A AXIS GIB Stip AGUSE Misrin aeaaea AAEE RENEE Sueded 71 LAXIS GID Sip AC USUMENE onssas nen NR nse rin E Eaei LO EA OR Oa AEA ia Maintenance of the Automatic Indexing Toolpost cccccsssssseseccsssssssseseecssssssssseseecssssssseseeesesscasissseeeesesecesasesetes 15 Spindle Drive Belt ACiUSIMENE c cccceccsncssdeccesndindnesicmndesitadiacantecimemanpanctSndnnxailiitawslianlbsiliedaasabenincancads Stiedeminshitensbantadlonrd 76 Section 8 Machine Electronics Accessing the Electrical Panel and Diagrams sissicsesccacisidin wesnvasicvartnteadwrctiaulescsuatiiantsdaaesisosiaeti tavisnvatieitdavnatsibewd nual 78 Electrical Layout EuroStep Controller s cccsccssnecesanenssesessnacanedsysearsivedesaeocshedekabossislhdeslensbaadcestesanslasraeyonandiadenanediceseacte 79 The EuroStep Motion Control Board csicccccsiscssincedssscnveasueasiuionedacatencntednacbtinnsdebsabbosiheatebdvinedetainoascGeaslancerdeuishoaseseesiwwedse 80 Eurostep Elecironics Troubleshooting sinis dnnctzenrvninendnstinansctidulnsseaasanidnnsatirilliclnlsasie esia aaea eaa Ea iai 82 Electrical Layout NextStep Gon Olen s cccsctcsscsecnslanascuesseonaviesssasenieessanettsuserndetvaeatsalenotdotcaaldnanadddesbaonselitaadnanadiceskeetse 83 The NextStep Motion Control Board sscteccctezasccscenzetcoescesseacusssbecescenasbanetcecstgeies tear t
4. External Tool Size12mm x 12mm 15 32 x 15 32 Internal Tool Size 25mm 1 Index time station to station 0 65 seconds Index time full revolution 1 75 seconds Safety Features Manual operation totally enclosed interlocked safety guard door Emergency stop button 2D and 3D simulation graphics to verify part programs prior to machining Isolator switch Dimensions SS m y l A 1000mm 39 3 8 m K B 610mm 24 Fg C 565mm 22 1 4 l D 745mm 293 8 E 495mm 19 7 16 l ii F 955mm 37 5 8 R J B Jl Max machine width 1000mm 39 3 8 Max machine height guard door open 955mm 37 5 8 Max machine depth 610mm 24 Electrical control box width 600mm 23 5 8 Electrical control box height 780mm 30 3 4 Electrical control box depth 360mm 14 1 8 Weights Machine weight 220KG 485 Ibs Electrical control box weight 70KG 154 Ibs Electrical Details Mains supply required 50 60 Hz 1 Phase 240 Volts Spindle motor 0 75 KW 1 5 HP AC Axis stepper motors 200 steps rev Meteor Series CNC Lathe User s Manual Section 10 Appendix 97 10 What is a Part Program 98 Appendix Section 10 A Part Program is a list of coded instructions which describes how the designed part or component will be manufactured This part program is also called the CNC File These coded instructions are called data a series of letters and numbers The part p
5. PUNO MOOG sisareen E Automatic indexing toolpost fitting a diameter working tool ccee fitting an end working tool PC QUCUON reasoners MaAN ENANCE aa crsanspctentmenncisnasnisshiaaaratenchaasamectia removing a diameter working tool removing an end working tool 0 requesting a tool change system fitting tools 0 0 ceeeeeeeeseteeeeeeeeeees Auxiliary input output SOCKet cecceeeceeeees Axis definitions cecssecssssesesessssscssseseseeseesees Axis limit switch override sssnsaseneeneeneeeeeeeee B Ballscrew maintenance x axis Cleaning and inspection ccceee X axis lubrication eerren z axis cleaning and inspection ccceee Z AXIS lubrication oo eee eeeeeeeeeeeceesenseeeeeteeeeeeees C Chuck manual bar feed hole au acdsndedsinceissenwnrarienceuredentidanstemensten COMPONEN S siccis ia fitting the billet ccs mounting ANd removal s s s Chuck pneumatic operation Cleaning DANS OWS gernuan e protective coatings upon delivery SIG WAYS oscine opioa ii SWING IOS sseccenecseenteceurariaictesesteuciacnceckiibednaei CNC definition and OverVieW c ccceeeeceees Co ordinate display systems cceeeeeeeees Connecting a compressed air supply ccceceeeeeeees machine power Cable ccsssesssesesees machine signal cable cesseseereen MAINS Supply Cable s ccasscccvanetiei
6. Section 7 Meteor CNC Lathe User s Manual T Inspecting the X Axis Datum Sensorswitch eA The sensorswitch defining the X axis datum is maintenance free and mounted under a cover plate positioned behind the toolpost when viewed from the front of the machine The cover plate usually prevents swarf and debris from building up around the sensor fitted to the switch However the switch may require cleaning when the machine has been used in extreme operating conditions Look at the top of the cross slide behind the toolpost 4 Left side iim To of cross a a side a_i iin Drive the saddle down the X axis This will make is easier to gain access to the top portion of the cross slide and the coverplate Using a 2 5mm allen hex key turn each of the three cap head screws counter clockwise to remove them and withdraw the cover plate nspect the exposed sensorswitch and trigger for any signs of damage or wear f necessary use a soft bristled brush to carefully clean any swarf and debris away from the sensorswitch to a location where it can be removed from the working area Take care not to disturb any wires or the sensor itself Replace the cover plate after finishing the inspection procedure N lt Trigger k s Meteor CNC Lathe User s Manual Section 7 Maintenance 63 T Inspecting the Z Axis Datum Sensorswitch If necessary use a mirror to help inspect parts of the machine that are hard to rea
7. ceeeeeeeeees 66 X axis GIG SUID esengo anepo 71 x axis slideways lubrication ccceeeeeees 68 z axis ballscrew lubrication cceeeeee 67 2 axis OID SiP eenen n 73 z axis slideways lubrication ccceeeeeees 69 Manufacturing a part OVervieW cccceeeeees 28 N NextStep electrical control box layout cceeeee 83 led StAtUs COUSS cesis ecctcandraetranecteies 85 motion Control DOIA i005 scnscescecoocsceccerstoseecess 84 MOUBIESOOUNG essiiisiseosoinonneniss 86 Noise level test results ccccsceeeseeseteeees 107 O Opening the electrical control DOX ceceeeeees 24 Opening the safety guard door ccceeceeeeeees 38 Operators Panel ccccccscesseeteseteeeeeeeeees 39 Optional equipment ccecceseeetececssteteeseeeees 10 Overriding the spindle speed or feedrate 40 P Partmanutact re CHECKISE ssruisisiieiinrssoeissiia 37 Part program address characters ccccccceecseesseesseeee 102 COMP OSINOM 2 x cccuecotercceuceneeter te tewanaaeen 99 OPINION cecececccetecscssseseesesstecetseeeeeseeeees 98 PC connections to your CNC lathe 008 16 Pneumatic equipment control Codes 06 20 Q Quickchange manual tooling system fitting a tool to the toolholder ceeee 42 fitting the toolholder to the toolpost 43 IPO QUICHION ccc scatestcocerencscasternumtoenennntonennous 41 requesting a tool change 37 system f
8. connector plug next to the right fixing bracket arranged in the correct orientation For correct alignment the plug cable will point down as shown in the diagram left Push the male connector plug fully onto the female fixing bracket 2 Close the junctions by pushing the top and bottom fixing bracket roller clips onto the male 3 Connecting the Machine Signal Cable The machine signal cable must be connected from the electrical control box to the machine The machine sinal cable is housed in the smaller black corrugated hose approximately 20mm in diameter The connector housing is fitted with one vertical pin on the top and one vertical pin on the bottom One end of the machine signal cable is permanently connected to the electrical control box whilst the free end is fitted with a male connector plug The back panel of the Meteor cabinet is fitted with a bank of two fixing brackets that contains the female connector plugs The machine signal cable fits to the left female connector plug when viewed directly from the back of the machine 22 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Connecting the Machine Signal Cable Warning HELI 7 Position the machine signal connector plug A co next to the left fixing Do not fit the male and bracket arranged in eee Come a Pua the correct orientation together the wrong 5 j way round This could For correct alignment damage the
9. control of optional pneumatic equipment M10 Chuck open vice M11 Chuck close vice M25 Tailstock quill extend M26 Tailstock quill retract M38 Door open safety guard door M39 Door close safety guard door raise or lower the toolholder When directly viewing the top of the screw turn counter clockwise to lower or clockwise to raise the To lower toolholder turn knurled collar CCW To raise toolholder turn knurled collar 4 Tighten the double flanged locknut on the toolpost body turn clockwise then screw in and tighten the lockbolt on the toolholder height adjustment screw turn clockwise Requesting Programming a Tool Change The Miscellaneous Function M06 is used to program a tool change operation Please refer to Section 4 CNC Machine Operation pages 36 and 37 for further details 46 Preparing Tooling Hardware Section 5 Meteor Series CNC Lathe User s Manual 5 Automatic Indexing Tooling System Introduction The optional Automatic Indexing Toolpost designed to automatically change cutting tools is driven by an electric motor and controlled using M codes Each numbered toolpost station or slot is designed to contain one tool holder which in turn contains the cutting tool Even numbered circular hole stations are used for end internal tool profiles Odd numbered straight slot stations are used for diameter turning external tool profiles This will direct
10. required will depend on the type and condition of the air compressor being used Optional Pneumatic Equipment Control Codes The following M codes are used to call the miscellaneous functions listed below M06 Tool change standard manual or optional auto toolpost M08 Coolant on optional spray mist coolant system M09 Coolant off optional spray mist coolant system M10 Chuck open optional pneumatic vice M11 Chuck close optional pneumatic vice M13 Coolant on and spindle forward optional spray mist coolant system M14 Coolant on and spindle reverse optional spray mist coolant system M25 Tailstock quill extend optional tailstock M26 Tailstock quill retract optional tailstock 20 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Electrical Control Box Cable Connections The mains power supply is fed to the electrical control box which in turn is connected to the Meteor cabinet There are three electrical connections that exit the electrical control box 1 The machine power cable the larger diameter corrugated cable which connects to the right bracket on the back panel of the Meteor cabinet 2 The machine signal cable the smaller diameter corrugated cable which connects to the left bracket on the back panel of the Meteor cabinet 2 The mains supply cable the thin standard electrical cable Machine Machine Power Signal Cable Cable Male Male Plug Plu
11. the nut turn counter clockwise to loosen or clockwise to tighten Fitting the Toolholder to the Toolpost Body 1 Using the supplied toolpost hex socket key turn the appropriate double flanged locknut so the flanges are pointing towards the centre of the toolpost Double flanged locknut closed pointing away from the centre of the toolpost Double flanged locknut open pointing towards the centre of the toolpost Double flanged locknuts continued Meteor Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 43 5 Quickchange Manual Tooling System Fitting the Toolholder to the Toolpost Body continued 2 Aligning the guides on the toolholder with the guides and spring loaded bracket on the toolpost body slide the toolholder down into the toolpost bracket shown below left Lower the toolholder until the single flange on the toolholder height adjustment screw Never open the safety guard door and enter the working area when is level with the space between the two flanges on the toolpost ocknut shown below right the spindle or machine axes are moving Slide the toolholder onto the toolpost tinen align the single flange 3 Turn the toolpost locknut so the single flange on the toolholder height adjustment screw is loosely held between the two flanges on the toolpost locknut At this stage do not fully tighten the locknut since this will prevent any toolholder a
12. the zero position of the three dimensional co ordinate grid system is referred to as the machine datum You can find the position of the machine datum by switching the co ordinate display in your CNC control software to read Machine Co ordinates The position of the machine datum is achieved when the X and Z panels of the co ordinate display all read zero this assumes that no offsets are loaded n addition to homing the CNC lathe after it has first been switched on we also recommend homing after loading or configuring any 4 Co ordinate Display Systems All Modes 34 CNC Machine Operation Section 4 The co ordinate display can be changed according to datum zero position required e Machine Co ordinates Display System The co ordinate position values are displayed relative to the fixed machine datum The co ordinate display always shows the true position of the machine e 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 Meteor Series CNC Lathe User s Manual 4 Manual Control Axis Definitions Jog Mode The keys for manual axis movement will depend on the type of CNC control software be
13. 3 2 cc Bearing Shell Alvania No 3 Coolant Pneumatic pump As required Cincinnati Millacron Fill to spray mist CNC software Simcool 60 max mark on system controlled Dilution minimum 2 5 storage tank Meteor CNC Lathe User s Manual Section 7 Maintenance 59 7 Maintenance Schedule e Clean and remove any swart e Check that all slides are lubricated e Clean tooling and toolpost e Clean the machine e Check all exposed screws and nuts for tightness Oil all slides and ballscrews and optional automatic toolpost Bi annually e Check and clean the machine thoroughly e Check the condition of any electrical connections e Check all cables for kinks and breaks e Remove the chuck jaws and clean the chuck e Clean the slide sensors Annually e Check the slides for wear e Grease axis bearings e Check machine alignments and accuracy e Check headstock bearing adjustment e Check spindle and axis drive belts for tension and 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 60 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 Cleaning and Inspecting the X Axis Ballscrew and Slideways oX If necessary use a mirror to help inspect parts of the machine that are hard to reach Location HELI Look at the left and right sides of the saddle and under the coverplate behind the toolpost
14. CNC Control Software message windows that machining can be resumed 4 Running a CNC Program Auto Mode The sequence of events required to begin part manufacture on the Meteor 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 Meteor Series CNC Lathe User s Manual Auto mode is used for controlling the CNC lathe when running a CNC program Part Manufacture Checklist Before beginning to manufacture your part check to see that the following tasks have been completed 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 CNC control software switched to Auto mode Section 4 CNC Machine Operation 37 4 Option Spray Mist Coolant System M codes can be manually entered for immediate operation when the machine controlling software is operating in Jog Mode or called automatically when written into a CNC program that is subsequently run in Auto Mode The air compressor must be switched on in order to use the optional Spray mist coolant system If necessary open and set any air connections see Section 3 CNC Machine Installation pages 19 to 20 Open the coolant tap and posi
15. Codes The status of the motion control can be determined from the LED display mounted on the left side of the NextStep board Errors are all shown with a flashing dot in the bottom right corner of the LED display Whilst NextStep is powering up Pesto ates Indicates FPGA has booted successfully TEAT Indicates FPGA walking ones test on FPGA scratchpad has failed HALT ME Indicates pseudo random number test on all of RAM has failed HALT E Indicates CAN controller reset has failed HALT aas Indicates walking ones test on the CAN controller has failed HALT Ta ni Indicates that power up test did not find any valid Firmware in Flash device A m Indicates that new firmware is being loaded into the NextStep control When NextStep has powered up E Normal indication that card is powered up Figure 2 is the default card NODE number e EE Axes disabled normally after downloading Mint MEX file for the first time before starting Denford S W a eee Flashing E whilst Flash memory is being erased and mint MEX file is being downloaded When Mint is running and Denford Software is connected Note that these figures relate to axis 0 specifically ie the X axis J T Axis is enabled PRE nE Flashing E A general error has occurred possible Mint failure PEER A SPLINE move is being executed E A circular move is being executed EN S A Flying shear used in lathe threading moves is being executed EE TAT Axis is in hom
16. E A E A 33 Homing the Machine Axes Home Mode csssscssssssssscssssssssssssssesssessesssssecsssesacsesesesessesassesesesacessesaeeesesasensees 34 Co ordinate Display Systems All Modes siis 2isicavisisentsanucrsdiadentinsunisnncaciintdanittauniisnsantdtadeainsaniaasacidnideuidixontiausaixanise 34 Manual Control Axis Definitions Jog Mode ci iscsiasczscieaccectstuanatessdsdsndswgvaldsadsadnsdaadecstsucsase lt naddenddbuisdeandidenssissomers 35 Manually Control M Codes Jog Mode ic cciccasseseivtes eacceeca sccuicetonatyemniutieanncebube seseante iisen nsi 36 Requesting a Tool Change Jog Mod sissiscicveniascdsannsiniiusnoiewaniapendsinsbeanndasiesysbonsawcisseniaseniaannssviudaxoncesaadamantaaiiinalss 36 Running a GNC Program Auto MOJE seis sssnccstsdcsaenssszacsdnndiestenenucstoussanasnsndcsdevassdcabatusstdeandgussadesbe tomiadesatientddctandens 37 Option Spray Mist Coolant System scscenccccacccxscocstescne tancicenecoteatesoacees cesoniidcnes apaia eiia aa eiii 38 Opening the Saby Guard DOOP seims nna aana Enin Sates aa eD e aE nin eane 38 Front Machine Operators Paneb oa zcasaiseets ccescisincs tcaynad eBinscanescptasinsstdi tueslaeddtistasleibncsth aa n i ia T Ea 39 Section 5 Preparing Tooling Hardware Quickchange Manual Tooling System Introduction ccesscssesssssssssssesssessesssssscssessesssesessssesassesesesaseeessaeess 41 Quickehange Tooling Fitting TOONS 2 uccsixavctuennetsctnscheu desivestaxatehurkid a 4
17. The feedrate can be overridden between 0 and 150 To increase the spindle speed or feedrate rotate the appropriate control clockwise To decrease the spindle speed or feedrate rotate the appropriate control anticlockwise The degree of adjustment applied to each value is displayed in the CNC control software Meteor Series CNC Lathe User s Manual 5 Quickchange Manual Tooling System Introduction The quickchange manual tooling system is supplied as standard with the Meteor CNC lathe unless an optional automatic indexing toolpost has been fitted The system comprises of two elements i The toolpost body which is mounted to the Meteor cross slide The quickchange tool holder ii The tool holder which is fitted to one of the two location slots on the sides of the toolpost body Tool holders are held in position using a spring loaded slide and bracket assembly to allow easy manual removal and replacement of tools when necessary Height adjustment is achieved using a grooved nut and collar Meteor Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 41 5 Quickchange Manual Tooling System Manual Tooling System Fitting Tools The following tools are used to fit and adjust the components of the quickchange manual tooling system UN Never open the safety guard door and enter the working area when the spindle or machine axes are moving A Caution If the cutting tool has been recent
18. The mode used for altering the content of a CNC program via the Desktop Tutor or qwerty keyboard The symbol or indicator that defines the end of a block of data The equivalent of the pc return key The rate in mm min or in min at which the cutting tool is advanced into the workpiece An arrangement of instructions or information usually referring to work or control settings The pattern or way that data is organised FANUC Lathe file extension fnl Contains G and M codes describing the machine and cutting operations A preparatory code function in a CNC program that determines the control mode eg a cutting operation A metal or plastic strip often tapered that is attached to one edge of a slideway Used to compensate for any free play that occurs in a slideway through wear Equipment such as the machine tool the controller or the computer Hexagon shape commonly used on bolts and accessed using a hex key Sometimes referred to as allen bolts or allen keys Meteor Series CNC Lathe User s Manual 11 Glossary HOME sxicscizencastisonstincesttsanscods Operation to send the axes of the CNC lathe to their extreme limits of movement Defines the machine datum also called the home position INCREMENTAL ee Incremental programming uses co ordinate movements that are related from the previous programmed position Signs are used to indicate the direction of movement INDEXING TOOLPOST See pro
19. Tooling automate SYSTEM sessssssiactsesranteasaseaadiantasuamutins 47 Quickchange system s s s 41 Troubleshooting ctin DFO DOING inrano 95 DOS CNC milling software cccseeee 91 electrical problems ccccccseeseseeeeeees 94 eurostep electronics ccc 82 mechanical problems c cceccsecsesceseeees 94 nextstep electronics c cccceccessseeeeeers 86 VR CNC milling software ceeceeeeeees 88 U Unpacking your Meteor cceessseseseereen 14 W Waming MOUCES secreniisaiienarna es 5 WAS GNG orrien ie tecge death Sea tat she 8 Meteor Series CNC Lathe User s Manual
20. are not included in this manual They are either delivered separately in the standard equipment box supplied with your machine or stored in a folder attached to the inside of the electrical control box door Further electrical schematics are available on request 24 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Option 3 Option Auxiliary Input Output Socket Input Output Socket Your electrical control box may be fitted with an Auxiliary Input Output socket allowing external control of your Meteor in FMS and CIM systems Auxiliary I O via a cable connection as shown Socket below left To run your Meteor as a Chained stand alone machine remove your Blanking Plug external system cable and fit the blanking plug which is chained to the 3 Removal of Protective Coatings Warning A XJ Once your Meteor has been sited and connected electrically the protective coatings must be removed to prepare the machine for A running Potential risk of ignition 1 The protective plastic sheeting on the guard windows should be explosion removed and the glass and perspex cleaned with an antistatic Do not use any aerosol cleaner based flammable l l l l l products to lubricate your 2 Remove any optional equipment boxes together with any internal CNC lathe packaging used to prevent movement of components within the Carefully read and working area during transit follow any instructions 7 fv
21. be used since this cable features crossovers on some of the pin connections You must also configure the CNC machine control software to recognise which numbered COM port is being used by the Denford Machine Link machine lead Details on this procedure are outlined in your separate CNC machine control software manual The Parallel port on your PC may be labelled as the Printer port The printer port has a 25 pin FEMALE connector Section 3 CNC Machine Installation 17 3 Connecting your PC to the CNC Lathe 4 Connect the remaining 9 pin D female end of the Denford Machine Link cable to the 9 pin D male COM port on your PC A ideally COM 2 Most computers usually have two COM ports Do not connect cables situated on the back panel of your PC If you cannot identify PEMPEM ANY SIECUCA any of the ports on your PC please refer to your original PC hardware with the mains power switched manufacturers operating manual for further guidance Note that on since this could older computers may be fitted with a 25 pin D male COM port seriously damage which may require the fitting of an additional 9 to 25 pin adaptor CNC lathe components inside your to your Denford Machine Link cable Long PCI cafd Sho mounted 25 pin D COM port 25 pin D male 25 pin D female connector 9 pin D female 9 pin D male connector fitted to Denford Machine connector fitted to connector fitted to pc Link cable using a 9to 25 Denford Machine fit
22. centreline and X forwards and backwards at right angles to the chuck centreline Combinations of both allow precise co ordinates to be described E E A T T The base of the CNC lathe BEDWAYS scssissnsnnssecacsenensstns The Z axis of the machine BIELE siere The actual material being machined sometimes referred to as the workpiece or stock BLOCKS ciciernbantoaneudinecaseat A collection of program words that collectively describe a machining operation A single program line in the CNC file CAROUSEL sccctsinonzsnscaresass The rotating section of a programmable turret containing a number of stations Also referred to as the turret disc CHARACTER eceeeeeceees Anumber letter or symbol as entered into a CNC program CHUG steraacnoheustinaen eset The clamping system that holds the billet driven by the spindle CIRCULAR INTERPOLATION G code term for a programmed arc movement COMMAND sosisini A signal or group of signals instructing one step operation to be carried out CONTEXT SENSITIVE When shortcut keys are used to call a Context Sensitive helpfile the pages displayed relate directly to the current active elements within the software CO ORDINATES Positions or relationships of points or planes Co ordinates are usually described using two numbers referring to the X and Z axes eg the co ordinate X 14 Z 10 means 14 units along the X axis and 10 units along the Z axis ING a Computer Numer
23. control for the optional pneumatic guard door is a square green push button mounted on the front machine operators panel When the CNC control software is operating in Home or Jog Mode press the button to open or close the pneumatic guard door The following Miscellaneous Function codes can be programmed to control the optional pneumatic guard door M38 Guard Door Open M39 Guard Door Close Meteor Series CNC Lathe User s Manual 4 Front Machine Operators Panel The front operators panel contains the following controls listed from left to right when looking at the panel e Axis Limit Switch Override e Pneumatic Guard Door optional e Emergency Stop Feedrate Override a en el OVERRIDE OVERRIME Axis Limit Switch Override The axis limit switch override control is a square green push button lf the Z axis limit switch has been activated press and hold the axis limit switch override button whilst jogging moving the axis away from the switch using the Z axis jog key Pneumatic Guard Door optional equipment The control for the optional pneumatic guard door is a square green push button When the CNC control software is operating in Home or Jog Mode press the button to open or close the pneumatic guard Meteor Series CNC Lathe User s Manual Section 4 CNC Machine Operation 39 4 Front Machine Operators Panel Activating an emergency stop will also trigger the interlock guard switch This
24. folder fixed inside the electrical control box door or delivered separately in the standard equipment box supplied with your machine Hazard Voltages exist in the electrical control box only attempt to access these diagrams after isolating the power and leaving the electrical control box untouched for at least 5 minutes f 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 We take great pride in the accuracy of information given in this manual but due to nature of hardware and software developments be aware that specifications and features of this product can change without notice The information contained in this manual is correct at the date of printing only November 2002 No liability can be accepted by Denford Limited for loss damage or injury caused by any errors in or omissions from the information supplied in this manual This manual is written using European English Any comments regarding this manual should be referred to the Meteor Series CNC Lathe User s Manual 1 Introducing your Meteor CNC lathe The Meteor is a versatile 2 axis CNC bench turning centre ideal for all levels of education and technical training Developed with a powerful 0 75KW spindle motor and accurate ax
25. put S Ae eD ERE ONE 99 O eS geese hagas E A E A N 100 RE E E EE AEE E re ae ne er A E E E ee ee A ee ee ET 101 Listof Program Address CharaciatS sessnurcsnissiuiserisknsaenaani niania NRE tieiiewlaaitd dane EE AAE rE SENEE 102 PROS MS encer screened E che E A E A 103 EC Declaration OF G OMONMI sasriiigsnapnssao nn neisa Sa S Ea tes atelatac ameeseaseeentane 105 Meteor Series Noise Level Test RESUItS cscsssssssscsssssssssssssscesessssessseseesesssesssecaesesssssesesecaeasesesseserssasaserenes 107 Section 11 Glossary Scio p eee ome nee A erent re te eee E ene Seer Ree Mee eee eee ner eee 109 Section 12 Index Warning Notices A Warranty Disclaimer The Warranty on your Meteor CNC lathe 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 Meteor CNC lathe and or the electrical panels within the machine casing 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 ma
26. saad svisizsndedtsesnacecstasssnengeiesanielsstss sine a a a Eaei a iaa T War CNG p E E E E a eee ee ee 8 Belors Beginning O SSUP a eae nearest nee a EAS 9 Section 2 Safety Features Safety Features Overview and Precautions cccscssssssssssssssssssssssssssssssscscssssessesesacsesseseesesesasaeaseseesesesaeasatessesaess 11 EMEN y Op BUNG a eee ee ere 12 manoek Guard WN renin mee ee ern teen eet eee ee eee rt 13 Section 3 CNC Machine Installation Unpacking and Liting VOU METCOP ssa cscs sccctessssisnavosecssanciescatsensuetacneseeeesdapsanennssnpheceeisseasesa ease niovassodaetocasessnttecgedsdenie 14 Deciding on a Site for your Meteor cases sscxniisde ht tensa ssi aohaeic tliat nse irik aa akea ditt KEENE aE baa deel 15 EE E E E EIA AE A E EN E OA P AAN A A A A 16 Connecting your PG 16 The CNC LaMNe 1a ssesassacssnaiastossauctesstosercdastoteaustussoatinceastntesnstasshacendeaststdeuptantavaebtentebeseblacsine 16 Option Compressed Air Connection sciences ciecstscncescaltuapieccem tines newe nnieruas aeania anane eniai Eii iae 19 Electrical Control Box Cable Connections c csscssssssssssssssssssssssssscsessesessesesacseasessesesesacaeaseseesesevacaeaseseesesesaeaees 21 Connecting the Machine Power Cable 5 c scssceocesaceiazancseasacnosensssnsnenetunesanencansseacahmantosicenasachnaieusaastAaeaveseatancateanties 22 Connecting the Machine Signal Cable tiinisxanicacosviiwet ocedawaaivwivtsininst untenasle inneitinnstnnawsinsetsnactgls
27. the example shown below The stations in the All diameter turning auto toolpost accept standard 12x12 tooling external tools must be fitted with the cutting edge facing down Cutting Tip Profile Cutting Tool Tip Holder and Shank 2 Using a 4mm allen hex key sufficiently unscrew centre grubscrew B on the appropriate numbered toolpost station Using a 5mm allen hex key tighten the two bolts A 3 or 4 turns When directly viewing the top of the grubscrew or bolts turn counter clockwise to loosen or Above Centre grubscrew B and outer clockwise to tighten them bolt A locations circled continued 48 Preparing Tooling Hardware Section 5 Meteor Series CNC Lathe User s Manual 5 Automatic Indexing Tooling System 3 Place the toolholder into the numbered station in the correct orientation with approximately 21mm protruding from the outer end face of the angled clamping block as shown in the diagram below Note that diameter turning external tools must be fitted with the cutting edge facing down Section CC 4 Ensure that the toolholder and the angled clamping block are square with the turret head then evenly tighten each of the two bolts A in one quarter turn operations Continue this procedure until both bolts are fully tightened and the toolholder is held Removing a Diameter Turning External Working Tool Profile to the Toolpost 1 Sufficiently loosen the two bolts A sh
28. toth ki fth hi th Senone included wih o gain entry to the working area of the machine power must be lubrication products supplied to the machine in order to release the switch that locks the safety guard door Insert the mains supply plug into an available socket then power up the machine using the mains isolator switch mounted on the front door of the electrical control box 3 Before using the Meteor the protective coatings applied to the slideways and bright surfaces must be removed using a kerosene based solvent No not attempt to move the CNC lathe axes until all protective coatings have been removed Once all protective coatings have been removed all untreated surfaces should be coated with a light covering of machine oil grade BP CS 68 Only use kerosene based solvents in accordance with the solvent manufacturers instructions and safety recommendations Ensure that no naked flames are present and adequate ventilation is provided To avoid the potential risk of ignition explosion ensure that all solvent vapours can exit fully from any enclosed areas on the CNC lathe Wait at least 1 hour before attempting to Meteor Series CNC Lathe User s Manual Section 3 CNC Machine Installation 25 3 Component Connection Schematic Diagram Ancillary Equipment such as this printer connects to the Parallel port on the PC Personal Computer Port Security Key dongle when required Denfor
29. 2 Quickchange Tooling Fitting a Tool to the Toolholder cceeesecesecsessssssseseecsessssseeseecssssasesseeeeesssssasstereeseeens 42 Quickchange Tooling Toolpost Body Angle Adjustment ccesscssssssssssssssssssssscssssssssesssessssesassesesesaseeeesasess 43 Quickchange Tooling Fitting the Toolholder to the Toolpost Body cssceseccssssssseeeecsessesesteeseessesssseeeeseens 43 Quickchange Tooling Toolholder Height Adjustment cccccccssssseseccsessssssssseessesssssseeseecssssessseeteesssssasseteeeeasens 45 Quickchange Tooling Requesting Programming a Tool Change ccccccceeessscesecsseesseeceesesesesssseeesssseeeeesaeees 46 Meteor Series CNC Lathe User s Manual Contents 3 Contents Section 5 Preparing Tooling Hardware continued Automatic Indexing Tooling System INtroduction ccescsssssssssssssssssssssesssssssescsesessssessesesesessseesecessesasaeereesenes 47 Automatic TOCA FUNG TOOS enirir E E EEEE RE EEE 47 Automatic Tooling Fitting a Diameter Turning External Working Tool Profile to the Toolpost cccccsseeseeees 48 Automatic Tooling Removing a Diameter Turning External Working Tool Profile to the Toolpost ccccce 49 Automatic Tooling Fitting an End Internal Working Tool Profile to the TOOIPOSt ccccccccseressssesesssseessseeeeeeees 50 Automatic Tooling Removing an End Internal Working Tool Profile from the TOOIDOSt ccs
30. 5 HP AC Meteor Series CNC Lathe User s Manual Section 3 CNC Machine Installation 23 3 Opening the Electrical Control Box Warning ax If power is being supplied to the Meteor turn the isolator switch A counter clockwise to the off 0 position Never attempt to access the electronic hardware systems in the CNC To cut mains power to the CNC lathe Isolator Position 0 lathe or electrical control Power OFF box with the mains Isolator Position I power switched ON Power ON Note that hazardous voltages can still exist immediately after Using the supplied key turn the top and bottom door locks one switching off the power l quarter counter clockwise then open the electrical control box door M a Note the safety warning left bef ing work Once th previously been ote the safety warning left before commencing work Once the switched on wait at work has been completed close and lock the door before attempting least 5 minutes before to power up the CNC lathe attempting to access any electronic components To unlock the electrical control box door Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk Depending on the specification of the machine some electrical cabinet doors may be fitted with additional door locks 3 Electrical Diagrams The electrical diagrams for your Meteor
31. Equipment Meteor CNC lathe Electrical control box Quick change toolpost and holder Manual self centring 3 jaw chuck Set of internal and external jaws LoVo light Serial and parallel port Outlet and link to external monitor CNC machine control software CNC lathe and controller software manuals Set of maintenance tools and spare parts list Extra Equipment Various workholding systems including 8 station programmable turret pneumatic chuck tailstock Various tooling packages Spray mist coolant system Pneumatic safety guard door Option of including in FMS CIM system Additional CAD CAM and offline machine controller software licenses Video conferencing system Machine and software training PC amp PC workstation Mechanical Details Swing over bed 250mm 9 7 8 Travel X axis 85mm 3 3 8 Travel Z axis 155mm 6 1 8 Maximum Turning Diameter 160 mm 6 1 4 Maximum Turned Length 180 mm 7 1 16 High Precision Anti Backlash Ballscrews fitted to both Axes Bed Hardened and Ground and of Slant Design Spindle bore No 3MT 21mm 13 16 Spindle Nose A2 Type 42 mm 1 11 16 Spindle speed programmable 0 5000 RPM Spindle speed override potentiometer 50 120 Feedrate programmable 0 3000 mm min Feedrate override potentiometer 0 150 Meteor Series CNC Lathe User s Manual 10 Specification of Meteor CNC Lathe Mechanical Details continued Optional 8 Station Turret
32. Meteor Series CNC Lathe User s Manual 5 Automatic Indexing Tooling System 3 Place the drill collet assembly into the numbered station in the correct orientation Revolve the drill collet assembly so the flat section of the collet is positioned directly under the grubscrew holes 4 Tighten the grubscrews until they just begin to grip the flat surface of the drill collet assembly Continue to tighten each grubscrew by one quarter turn Continue this procedure until Removing an End Internal Working Tool Profile from the Toolpost 1 Using a 2 5mm allen hex key unscrew the two grubscrews C shown in the photograph on the previous page on the side of the appropriate numbered toolpost station When directly viewing the top of the grubscrews turn counter clockwise to loosen or clockwise to tighten them 2 Withdraw the drill collet assembly If the cutting tool has been recently used take care it may still be HOT Requesting Programming a Tool Change The Miscellaneous Function M06 is used to program a tool change operation Please refer to Section 4 CNC Machine Operation M codes for manual pages 36 and 37 for further details control of optional pneumatic equipment M10 Chuck open vice M11 Chuck close vice M25 Tailstock quill extend M26 Tailstock quill retract M38 Door open safety guard door M39 Door close safety guard door Meteor Series CNC Lathe User s Manual Section 5 Prepari
33. NC machine paying special attention to the working area according to the Maintenance A Schedule listed on page 60 In particular ensure the build up of Never open the safety swarf and debris in the following areas is prevented guard door and enter the working areawhen The Z axis ballscrew running parallel to the front of the machine the spindle or machine between the two Z bed slideways RE E e The two Z axis slides partially enclosed by the saddle and the two flexible corrugated black covers Nama mxi The Z axis datum sensor switch mounted behind the right upper A side of the bedway casting Caution e The Z axis overtravel microswitch mounted behind the left upper If the cutting tool has side of the bedway casting been recently used it may still be HOT e The X axis ballscrew running parallel to the sides of the machine between the two X saddle slideways e The two X axis slides either side of the saddle covered by the cross slide casting e The X axis datum sensor switch mounted behind the coverplate at the rear of the toolpost e The chuck and optional tailstock e The components of the tooling system 7 Lubrication Chart Slideways Pump action BP CS 68 As required Ballscrews and oil can Shell Vitrea 68 Auto Toolpost Castrol Perfecto NN Headstock Grease Seal On maintenance Kluber Isoflex NBU 15 4 cc Bearing of headstock Axis Bearings Grease Seal Once a year BP LS
34. T Address example G Word example G01 Block example N0140 G01Z 8 26 A component is designed using a CAD CAM software package such as Lathe CAM Designer The CAD CAM software package automatically generates the part program including all the G and M codes required to manufacture the component Section 10 Appendix 99 10 G Codes List Note Not all G codes may apply to your CNC machine G Code Group Function GOO Mainat Positioning Rapid Traverse OOT sezsa E Linear Interpolation Feed Ca M reena Circular Interpolation CW G03 seindeceses n IER Circular Interpolation CCW G04 C PAT Dwell G20 n a One Inch Data Input G21 wo oe Metric Data Input G28 2 0 ee Reference Point Return G40 oo eee ee Tool Nose Radius Compensation Cancel G41 wo eera Tool Nose Radius Compensation Left G42 we Pee Tool Nose Radius Compensation Right B50 iniri Oranen Work Co ordinate Change Max Spindle Speed setting GTO oiris a Finishing Cycle ETa eens EE Stock Removal in Turning X G codes from group 0 GZ cone aes Stock Removal in Facing Z are non modal they cc AES Oi erties Pattern Repeating must be programmed G74 oe OE Peck Drilling in Z Axis aoa r aa cy oe Grooving in X Axis when required Alpeiner G codes G10 EP OD Multiple Thread Cutting Cycle are modal they G81 ainan Tae Deep hole drilling No FANUC remain active through EO E Diameter Cutting Cycle A Outer Inner ear Cesena
35. The two X axis slideways are located on the left and right sides of the saddle and cross slide Run the cross slide fully up exposing the lower portion of the saddle slideways as shown below left Using a soft bristled brush carefully clean any swarf and debris away from both sides of each slideway to a location where it can be removed from the working area Inspect each slide for damage or wear Run the cross slide fully down to expose the remaining upper portion of the slideways and repeat the process 7 PA Ballscrew hF h f ii F nes oe Right Slideway S B Right F Left Slideway gt I Right side of i 4 dj saddle The X axis ballscrew runs centrally from top to bottom along the underside of the cross slide The X axis ballscrew is fully enclosed by the saddle and cross slide metalwork so it is not subject to swarf build up The ballscrew can be inspected for damage or wear by removing the cover plate attached on the portion of the cross slide behind the toolpost as shown above right Using a 2 5mm allen hex key turn each of the three cap head screws counter clockwise to remove them and withdraw the cover plate nspect the exposed portion of the ballscrew and bearing for damage or wear Replace the cover plate after finishing the inspection procedure Meteor CNC Lathe User s Manual Section 7 Maintenance 61 7 Cleaning and Inspecting the Z Axis Ballscrew and Slideways Note The two Z axis TEE sl
36. artment General Machine Test Conditions Chuck on size Standard Splash guard on Not Applicable Machine mounting Floor Additional equipment None Test Positions Back of Machine Plan View T Front of Machine continued on reverse Meteor Series Noise Level Test Results Test Conditions Spindle speed 3 000 RPM Spindle Direction Counter clockwise Ambient background noise lt 61 dB A Spindle Speed Sound Levels dB A RPM Range ster ToT 62 62 62 62 62 61 A Test Conditions Spindle speed 3 000 RPM Spindle Direction Clockwise Ambient background noise lt 61 dB A Spindle Speed Speed Sound Levels dB Sound Levels dB A RPM Range es Viean 108 Appendix Section 10 Meteor Series CNC Lathe User s Manual 11 Glossary ABSOLUTE seccctsatenceosatie In absolute programming Zero is the point from which all other dimensions are described ALLEN cessie See hex ARG ae A portion of a circle PTG cane a Automatic Tool Changer See programmable turret AUTOMATIC CYCLE A mode of control operation that continuously runs a cycle or stored program until a program stop or end of program word is read by the controller AUXILIARY FUNCTION The function of the CNC lathe ie F S T M codes etc other than co ordinate based commands AXIS AXES nasses The planes of movement for the cutting tool usually referred to as Z left and right parallel to the chuck
37. athe can be configured using the options available in the Machine Properties window Warning AN Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk X Always refer to your electrical schematic diagrams for the definitive labelling and placement of components and fuses Information contained on this page is correct at the time of printing November 2002 but is liable to change through continuous development of our products Meteor Series CNC Lathe User s Manual 4 The Machine Properties window will open with the name of the current active CNC lathe highlighted and its listing expanded Note that there are a number of versions to choose from The active machine name in the software must match the name and version of your Meteor series CNC lathe this information is printed on the CE identification panel usually applied to the side panel of the electrical control box or end panel of the main machine cabinet For example if Meteor is printed on your CE identification panel the VR CNC Turning software must have Meteor set as the active machine 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 Turning software Re open the Machine Prope
38. ch Location Look under the top of the right flexible cover r xJ The sensorswitch defining the Z axis datum is maintenance free and mounted behind the upper slideway on the bed casting towards the tailstock end of the machine lts position usually prevents swart and debris from building up around the sensor fitted to the switch However the switch may require cleaning when the machine has been used in extreme operating conditions Drive the saddle fully to the left This will make is easier to gain access to the right side of the bed where the condition of the sensorswitch and trigger can be checked Using a soft bristled brush carefully clean any swarf and debris away from the sensorswitch to a location where it can be removed from Right bed flexible cover 64 Maintenance Section 7 Meteor CNC Lathe User s Manual T Inspecting the Z Axis Overtravel RET The limit microswitch used to control overtravel on the Z axis is maintenance free and mounted behind the upper slideway on the bed casting at the headstock end of the machine Its position usually prevents swarf and debris from building up around the microswitch mechanism However the switch may require cleaning when the machine has been used in extreme operating conditions Look under the top of the left flexible cover Using a soft bristled brush carefully clean any swarf and debris away from the switch to a location where it can be rem
39. ck panel as shown in the diagram below Ensure the Meteor cabinet 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 Meteor cabinet over longer distances use a suitably sized wheeled trolley Usea professional hoist to lift the machine Thread one single 5 metre 200 500 KG 1120 Ib rated nylon sling as shown right Front machine foot section Rear lifting hooks To lift the electrical control box use a porters trolley Exercise caution when attempting to lift the electrical control box since it weighs 70 KG 154 Ib Always use sensible lifting precautions in accordance with Health and Safety Regulations in your establishment 14 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Deciding on a Site for your Meteor Site your Meteor in a well ventilated room The Meteor is a bench mounted machine so it should be sited on a bench of sturdy construction to take the weight of the machine and of a height which enables comfortable operating and programming to take place Optional machine tables and industrial cabinets designed specifically for Die Me Or ale Ideally the user will operate the machine when standing at its front with a clear view of both the machine working area through the transparent guard window and the compu
40. connector N a the plug cable will point pins The male and f down as shown in the female connector plugs diagram above Push are shaped so they can only be connected in the the male connector plug correct orientation the fully onto the female cutaway parts of the fixing bracket connector housings and the numbered segments 2 Close the junction by printed on the pin faces pushing the single fixing must match in order to WE bracket roller clips onto ane eee gt g N the male connector plug connection housing pins until they click 3 Check the security of both plug connections and route the cables to avoid the possibility of users tripping over 3 Connecting the Mains Supply Cable Warning ales The electrical control box is inspected then sealed with a plastic yellow sealing tag If this seal is broken on delivery inform the A suppliers immediately The seal should only be broken for the initial Never attempt to access mains power connection E te The Meteor is delivered with standard mains specification cable lathe or electrical control Connected directly into the isolator The cable should be fitted with a box with the mains standard 13 amp plug suitable for the mains power supply All electrical Pe connections should be completed by suitably qualified electrical engineers Mains supply required 50 60 Hz 1 Phase 240 Volts Cable required 3 Core 2 5mm per core Spindle motor 0 75 KW 1
41. crew all the cap head fixing screws on the removable panel located at the headstock end of the machine Turn the screws in a counter Headstock end of machine with coverplate removed clockwise direction to loosen them and withdraw the panel as shown below Apply pressure to the drive belt in the area indicated by the Belt deflection 25mm 1 continued 76 Maintenance Section 7 Meteor CNC Lathe User s Manual Spindle Drive Belt Adjustment To adjust the tension of the spindle drive belt use an 8mm allen hex key to slightly unscrew the three bolts A B C on the lower right bracket shown below left Turn the bolts in an counter clockwise direction to loosen them ore Using an 8mm allen hex key unscrew the two bolts D E on the lower left bracket shown above right Turn the bolts in an counter clockwise direction to loosen them to the extend where the bracket can just be moved Move the lower left bracket towards the back panel of the machine to tighten the spindle drive belt as shown below a Se j Move bracket B towards back to tighten belt Lower Left Bracket Tighten all five bolts and check the belt tension When the correct tension has been achieved replace the panel at the headstock end of the machine Meteor CNC Lathe User s Manual Section 7 Maintenance 77 8 Accessing the Electrical Panel and Warning TEX O
42. d Machine Link Cable PC Terminology The COM ports on your PC may be labelled as Serial ports Most COM ports have a 9 pin D MALE connector though some older computers may be fitted with 25 pin D MALE connectors Desktop Tutor when The Parallel port on your PC may be labelled as the Printer ordered connects to port The printer port has a the PC port labelled 25 pin FEMALE connector COM 1 and should only be used for connection of the security key dongle when supplied 26 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Component Connection Schematic Diagram Denford Meteor CNC s _ A Machine Power x W Connector Machine Signal Connector Mains Power Supply Plug Denford Machine Link Cable a er The Denford Machine Link cable connects the electrical control box to Meteor the PC port labelled COM 2 Electrical To the The Denford Machine Link cable is Port the long thin cable fitted with a 9 pin Control labelled D female connector at one end and Box a 25 pin D male connector at the RS 232 A opposite end ne ai Connect the 25 pin D male end of the RS 232 cable to the 25 pin D female RS 232 port on the end panel of the electrical control box Connect the remaining 9 pin D female end of the RS 232 cable to the 9 pin D male COM2 Cables exiting from the electrical control box ponon youn Larger diamete
43. ddress 3F8 using interrupt 4 COM 1 These addresses can be edited according to the COM number required using the table below COM1 3F84 COM2 2F83 COM3 3E8 4 COM4 2E83 Meteor Series CNC Lathe User s Manual Section 9 Technical Support 93 9 Troubleshooting Mechanical Problems The safety guard door cannot be opened n 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 CNC lathe cabinet Check the following 1 Mains power is reaching the CNC machine Check the mains plug is fitted to an available power socket and the socket is switched on Check the mains power isolator on the electrical control box door is switched on 2 The emergency stop button is not pressed in To release push and turn the button counter clockwise until it springs back out to its ready position 3 No CNC program is running Wait for all machining operations to finish then switch the software to operate in jog mode 9 Troubleshooting Electrical Problems Please refer to Section 8 Machine Electronics 94 Technical Support Section 9 Meteor Series CNC Lathe User s Manual 9 Troubleshooting Cutting Problems The part is being cut at an incorrect depth Check the validity of the following 1 The Z value entered in the tool length offset 2 The Z value entered in the workpiece offset file 3 The number siz
44. djustment from being carried out 44 Preparing Tooling Hardware Section 5 Meteor Series CNC Lathe User s Manual 5 Quickchange Manual Tooling System Toolholder Height Adjustment ZAR cx 1 Using a 4mm allen hex key release the lockbolt on the toolholder height adjustment screw shown right When directly Al viewing the top of the bolt head turn counter clockwise to loosen Never open the safety If you intend to raise the height of the toolholder you must guard door and enter unscrew the bolt further to allow toolholder movement the working area when the spindle or machine axes are moving Loosen toolholder height adjustment screw by turning CCW 2 Loosen the double flanged locknut on the toolpost body if tight When directly viewing the top of the locknut turn counter clockwise to loosen show below left Check that the single flange on the toolholder height adjustment screw is still held between the two flanges on the toolpost locknut shown below right Loosen double flanged locknut by turning CCW continued Meteor Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 45 5 Quickchange Manual Tooling System Toolholder Height Adjustment continued AAE CX P 3 Holding the knurled collar turn the height adjustment screw to A Never open the safety guard door and enter the working area when the spindle or machine axes are moving M codes for manual
45. dware or technician inspecting the equipment Remember to shutdown the CNC machine then close and lock the electrical continued Section 9 Technical Support 89 9 Troubleshooting VR CNC Turning Software 7 Check the COM port on your controller computer 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 port itself 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 8 When all else fails Thoroughly check the condition of the Denford Machine Link cable If the cable is bad communication will not occur Try using a different controller computer to connect to the CNC lathe Check for help on the technical support FAQ and download sections of the Denford websites and or contact Denford Customer Services see the details on the first page of this 90 Technical Support Section 9 Meteor Series CNC Lathe User s Manual 9 Troubleshooting DOS CNC Turning Software DOS CNC Turning Software Communications Troubleshooting 1 Your computer communicates with Meteor versions using the Denford Machine Link cable Check the Denford Machine Link cable is securely plugged into a valid COM port on the computer Note that COM ports are
46. e 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 and spindle speeds are being used appropriate for the cutting tool profile and type of material being machined Recommended feed and speed values should be available from your tool and material supplier Note that running incorrect feeds and speeds can severely shorten the life expectancy of your tools 2 The workpiece is held securely in the chuck 3 The correct 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 Meteor Series CNC Lathe User s Manual Section 9 Technical Support 95 10 Specification of Meteor CNC Lathe 96 Appendix Section 10 standard
47. e is required before continuing with the program This is followed by the code T_ _ __ Indicating the number of the new tool the first two numerical digits and the tool length offset file number the last two numerical digits For example M06 T0305 This command is read instruct tool change from the current tool number to tool number 3 using tool length offset file number 5 Meteor Series CNC Lathe User s Manual 4 Requesting a Tool Change Jog Mode Safety First Never open the safety guard door and enter the working area when the spindle or machine axes are moving Safety First Caution If the cutting tool has been recently used it may still be HOT oX Ax Automatic Indexing Toolpost When an automatic indexing toolpost is fitted to the Meteor the entire sequence will be performed automatically Ensure the correct tooling hardware has been fitted and the tool holders have been placed in the correct numbered toolpost stations according to the tooling specification described at the beginning of your CNC program see section 5 Preparing Tooling hardware Quickchange Manual Tooling System When a quickchange manual tooling system is fitted to the Meteor a message window will be displayed whenever a tool change is required Wait for all machine movement to stop before opening the safety guard door then change to the new tool number requested Close the safety guard door and confirm via any
48. e manual release lever 3 Whilst holding the tool against this manual release lever open guard switch supply the guard power to the machine The emergency stop 4 Remove the tool from the hole and replace the security screw button is fully pressed in To release the lock push in and turn the emergency stop button counter clockwise until it springs back out to its ready position Machining is taking place The interlock guard switch will release when the machining operations have been completed and the machine controlling software is operating in Jog Mode Meteor Series CNC Lathe User s Manual Section 2 Safety Features 13 3 Unpacking and Lifting your Meteor Machine Weights Standard Meteor 220KG 485 Ibs Standard electrical control box weight TOKG 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 better access to the Meteor cabinet and the separate electrical control box remove all the sides from the delivery box leaving both pieces of equipment standing on the wooden delivery pallet To lift the Meteor cabinet from the packaging use a professional hoist and a single 500KG 1120 Ib rated 5 metre 200 endless nylon sling Loop the front of the sling below the cabinet just in front of the machine foot section and the back of the sling under the two lifting hooks on the ba
49. eatevanddRbsatioemeechaluaie aeree 84 NextStep Electronics Trouble SHOOUNG ss sasis acsssccsisasints sessncwsstsibnawdnhacientawpbnasesnuatie bainisawisiatidsviwindadeinactiietidleawtdasisiabiiens 86 Section 9 Technical Support Requesting Technical SUD DON a2i2c cncsecscssacsaescssesasarencusaosdseacsucieadosieiecbarsadenesiilebiccthbbas caasisiopedeneateoeckseinaeetdeseeaeaindentes 87 Troubleshooting VR CNC Turning SOMW ANG ies casuenvanesacneahaonsniutenenpedieanaindadsdehabnntiediuitlaeannidsliinlden serinndnbiuetewanies 88 Troubleshooting DOS CNC Turning Software sssssssssssssscssesssssssssssscsssssssssssseceesesecsssesesesessesaseeesessesesaserees 91 Troubleshooting Mechanical Problems ssiiiassivsinidsnxsunriigoscovisdatoensnbinteanshwnndasarcoontoddcanalpnaidadetaninikdanteinatabuintureiiebate 94 Troubleshooting Elecimcal Problems saiis siniiaticvcinssicinsn nusidaisninsmneduuns sisivhsacnbadaactnunianacelnstatiaieitneuiabeiniaeadatanansisiwiats 94 Troubleshooung Cutting Problems c cescscckcascanctaseastsensesestdesuadeasedndstanslean iasueseuainh E O EE NE EEE SEE OTENE 95 4 Contents Meteor Series CNC Lathe User s Manual Contents Section 10 Appendix Specification of Meteor CNC Lathe s5 c ascteisctaaceslncac luctetsetencessseanedessausesenesneibarsesasteutsetectaseleaieshancteuielutendendennune 96 Warsa Pan Progra l aiea E A nutans c akeuaee emcees testi ttat 98 0 IO SION ora Fan Fe COC CAIN arinei nan naain enok stil
50. ectrical Panels NextStep Controller Ferrite Core ee PAG A i a j Filter f Tei i A Tr a mo BY solic Bil aie E S 7 Ur i P j H i R ek a lt J ue Spindle Drive i Board NextStep Motion Control Board i s gali Por options L 7 sees Terminal pam T Ei Block 7 X Axis fi Z Axis on rn fa Board Board rt Control Transformer i E Meteor CNC Lathe User s Manual Section 8 Machine Electronics 83 8 The NextStep Motion Control Board oS Location hae i Look on the left side of the middle panel a e E rr mi F Eni aa The NextStep motion contro board processes the step and direction signals which are then passed to the separately fitted axis drive units used to control the two machine axes The NextStep motion control board is mounted on the left side of the middle panel in the electrical control box 84 Machine Electronics Section 8 Meteor CNC Lathe User s Manual 8 The NextStep Motion Control Board A Hazard Voltages exist within the machine when removing the electrical panel cover plate always isolate the power and leave all electronic components untouched for at least 5 minutes Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk Meteor CNC Lathe User s Manual LED Status and Fault Display
51. efer to your separate order documentation for confirmation e Machine controller IBM or 100 compatible PC keyboard mouse and monitor e Programmable 8 station indexing turret in place of standard manual toolpost e Spray mist coolant system e Pneumatic safety guard door e Pneumatic chuck e Tailstock e Various tooling packages e Various workholding packages e Machine table e Upgrade pack for integration into Denford FMC FMS or CIM systems e On screen representation of industrial control systems and optional link to industrial Keypad FANUC 21i e Video conferencing system e CAD CAM software and manuals e Additional and or on site training courses Meteor Series CNC Lathe User s Manual 2 Safety Features Overview and Precautions Safety Features Overview The following safety features are standard on your Meteor CNC lathe Emergency stop button Totally enclosed high visibility guard door with interlock switch Toolpath graphics to verify program prior to machining Isolator switch Safety Precautions Safety is very important when working with all forms of machinery but particularly when working with CNC equipment due to the hazardous voltages speeds and forces that exist in the hardware Follow the rules below at all times when using your Meteor CNC lathe General Safety Precautions Wear clothing suitable for machine operation and follow the safe working procedures in place at your es
52. els EuroStep Controller Se ee y Ferrite Core Se ee enna a Tike Terina H ies eat i nad l F Standard a Space for i dO Unit ama we optional FES TE ki _ O Unit S py Beokoiene JE TE EuroStep ae Zee mn L o4 im ies oe Control Motion Drive rive EOR kA kA Board Card Meteor CNC Lathe User s Manual Section 8 Machine Electronics 79 8 The EuroStep Motion Control Board Location Look in the bottom left corner of the control box from the right hand side EuroStep L if eB Motion i Fuses E 4 Control gs T EE Board gomen i i U or i Se Custom pee teenies Card E zi Board anaa Seven lS i H a Segment I LED Display 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 two CNC machine axes 80 Machine Electronics Section 8 Meteor CNC Lathe User s Manual 8 The EuroStep Motion Control Board Look in the bottom left corner of the control box from the front 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 super
53. er fuse labelled F5 on the components and or main fuse rack personnel are suitably i ee earthed to minimise In addition refer to the electrical schematic diagrams to confirm this risk specific fuse details and labelling Always refer to your electrical schematic diagrams for the definitive labelling and placement of components and fuses Information contained on this page is correct at the time of printing November 2002 but is liable to change through continuous development of our products 86 Machine Electronics Section 8 Meteor CNC Lathe User s Manual 9 Technical Support Denford Limited provides unlimited telephone Technical Support on this CNC lathe to registered users On site visits by our engineers may be chargeable Please refer to the information held in your separate Warranty pack for specific details Denford Limited provides unlimited telephone and e mail Technical Support on this CNC lathe to registered users On site visits by our engineers may be chargeable Please refer to the information held in your separate Warranty pack for specific details Before contacting Denford for support please read your hardware and software manuals and check the Denford websites for support Internet access technical support and FAQ sections Denford UK http www denford co uk Denford USA http www denford com Forum http www denfordata com bb When you request support please be at your CNC lathe wit
54. esmsescieexercponids schematic GiaQraAM csecscssescsesesseseesees the PC to the CNC lathe cesses Contact information c ccccceeceeeecesseeeeseeeees D Denford GireCtiVeS c cccccccecccessccersesecsesenseeeneres Dimensional data c0 ccccccccccccceeeeeseeeeeeeneeees PSUS aorin isorinis iE E Meteor Series CNC Lathe User s Manual E EC declaration of conformity cccseeeeeeeeerees Electrical control box auxiliary input output socket ee layout eurostep Controller ccceeseeeee layout nextstep Controller cccececeeeeees OC FUNG A A Electrical diagrame sesser Electronics eurostep motion controller cceceeeees nextstep motion Controller ceseeseeeees WOUDIESNOGUNG assesses naene Emergency stop button csssseseseesereen EuroStep electrical control box layout ceeee led status codes cccesecescseetesseseeesseersnees motion control board siiscsccaziscateccsestinsascaceacenecs WOUDIESMOOUN G2 caictinstactseatrcatincarwwctdnantbonnidains F Feedrate override control onc G Eeo ci gt E E EE General layout of electrical control box General layout of Meteor cabinet cc8 General layout of Working area cceececeeeees Gib strip CHECKING condition OF sssini WMOGUGUON ccs seucescetsesscoteenssidiennesenndenadeae X axis ACIUSUMGNE s tesnessrsbsravcsensisaesetapsieneecs z axis adjustme
55. fitted securely between the serial COM1 port socket on the machine controller PC and the RS232 socket on the DeskTop Tutor controller keypad 3 Check the larger diameter corrugated machine power cable is fitted securely into the right fixing bracket mounted on the back panel of the Meteor cabinet 4 Check the smaller diameter corrugated machine signal cable is fitted securely into the left fixing bracket mounted on the back panel of the Meteor cabinet 5 Check the electrical control box door is closed and locked 6 When fitted check the air pipe connections for any optional compressed air driven equipment are secure then switch on the air compressor Check and adjust the air pressure if necessary 7 Plug the mains supply cable standard electrical flex from the electrical control box into an available power socket Switch the power socket on 8 Rotate the isolator switch on the electrical control box door one quarter turn clockwise from its off 0 position to its on I position shown below You should hear the Meteor begin its power up routine 9 Switch on the machine controller PC and start the CNC Control Software Establish a communication link with the Meteor please refer to your separate CNC Control Software User s Manual for details outlining this procedure To supply mains power to the CNC lathe Isolator Position 0 Power OFF Isolator Position I Power ON does not power up turn the
56. ftware User s Manual for specific details AEE M codes are used to control the miscellaneous functions of the machine such as switching the spindle on and off or operating optional equipment such as the automatic indexing toolpost M codes can be manually entered for immediate operation when the machine controlling software is operating in Jog Mode Note that M codes are automatically called when written into a CNC program that is subsequently run in Auto Mode List of M Codes for Standard amp Optional Equipment The following M codes call the miscellaneous functions listed below MO3 Spindle forward standard on all versions M04 Spindle reverse standard on all versions M05 Spindle stop standard on all versions M06 Tool change standard manual or optional auto toolpost M08 Coolant on optional spray mist coolant system M09 Coolant off optional spray mist coolant system M10 Chuck open optional pneumatic vice M11 Chuck close optional pneumatic vice M13 Coolant on and spindle forward optional spray mist coolant system M14 Coolant on and spindle reverse optional spray mist coolant system M25 Tailstock quill extend optional tailstock 4 Requesting a Tool Change Jog Mode 36 CNC Machine Operation Section 4 Programming a Tool Change The Miscellaneous Function M06 is used to program a tool change operation The M06 code instructs the machine that a tool chang
57. g Hlectrical Mains Supply Cable 3 om Cat Machine Signal Cable 2 Machine Machine Power Signal Cable Cable Female Female Connector Connector cabinet Meteor Series CNC Lathe User s Manual Section 3 CNC Machine Installation 21 3 Connecting the Machine Power Cable Warning oX A Do not fit the male and female connector plugs together the wrong way round This could damage the connector pins The male and female connector plugs are shaped so they can only be connected in the correct orientation the cutaway parts of the connector housings and the numbered segments printed on the pin faces must match in order to achieve an electrical connection The machine power cable must be connected from the electrical control box to the machine The machine power cable is housed in the larger black corrugated hose approximately 30mm in diameter The connector housing is fitted with two horizontal pins on the top and two horizontal pins on the bottom One end of the machine power cable is permanently connected to the electrical control box whilst the free end is fitted with a male connector plug The back panel of the Meteor cabinet is fitted with a bank of two fixing brackets that contains the female connector plugs The machine power cable fits to the right female connector plug when viewed directly from the back of the machine 1 Position the machine power
58. g toolposts cutting tools must be mounted facing down On quickchange manual toolposts cutting tools must be mounted facing up When machining allowances must be made for the different sizes of tools used The tool offset is the amount the X and Z value must be moved or offset so that all the different cutting tool tips used with the same CNC program line up with each other against a common reference point The area on the CNC lathe where tool profiles are held Manual toolposts can only hold one tool at a time An automatic indexing toolpost can hold a number of different tools and change between them automatically See programmable turret Movement of the cutting tool through the 2 machine axes between cutting settings See programmable turret Standard Windows text only file extension txt The actual material being machined The work is sometimes referred to as the a 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 combination of a letter address and digits used in a CNC program ie G01 M03 etc A fully interactive three dimensional computer based simulation of a real world object or event Meteor Series CNC Lathe User s Manual 12 Index 1mmam w Address characters list ccccsccsessserssseees Advantages of CNC ccscsscssssssseeseseeeen Air supply isolator and filter regulator
59. grammable turret INPUT wcostenateenscetesensteeeene The transfer of external information data into a control system INTERFACE lt ccsisscessencnsseereiss The medium through which the control computer directs the machine tool WOE siyani A miscellaneous code function in a CNC program that determines an auxiliary function eg coolant on tool change etc MACHINE CODE The code obeyed by a computer or microprocessor system with no need for further translation MACHINE DATUM A fixed zero reference point used to define the co ordinate based grid system of the CNC lathe All machining co ordinates originate from this point B ET E oer ete Manual Data Input A method used for manually inserting data into the control system ie Desktop Tutor qwerty keyboard etc MODAL araser Modal codes entered into the controller by a CNC program are retained until changed by a code from the same modal group or cancelled IGS r Numerical control OPPSETT gee Combination of two types of file the workpiece offset and the tool offset Used to describe the workpiece datum a zero reference used on the CNC lathe to ensure machining occurs in the correct place on the billet Offsets shift the entire co ordinate based grid system of the CNC lathe so the machine recognises our moveable workpiece datum as zero rather than the fixed machine datum PART DATUM eeeee Used as a zero reference point ina CNC file All mach
60. h your hardware and software documentation to hand To minimise delay please be prepared to provide the following information e CNC lathe serial number from the machine ID panel e Registered user s name company name The CNC machine control software name and version number e The wording of any error messages that appear on your computer screen if applicable e Alist of the steps that were taken to lead up to the problem e A list of any maintenance work that has been carried out on the CNC lathe Contact Details Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK Telephone 01484 728000 Fax 01484 728100 E mail customerservices 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 Meteor Series CNC Lathe User s Manual Section 9 Technical Support 87 9 Troubleshooting VR CNC Turning Software Your screen may display the message Error 50 Mint 3 28 Disconnect or similar depending on the hardware fitted The password used to access the Machine Properties window can be changed by the user Remember that the default password listed here will not be recognised if you have changed it If you change any passwords we recommend you make a note of them in Notes the last page of this manual 88 Technical Support Section 9 VR CNC Turning Software Communications Troubleshooting
61. he screw 4 Traverse the saddle left and right along the bedway to ensure that the Z axis movement is smooth 5 Continue points 1 to 4 until all slack has been eliminated from the Z axis Note If the Z axis movement is not smooth loosen the gib strip but this time turn the gib strip adjustment screw counter clockwise to introduce a little slack back into the system Run the saddle left and right along the bedway again to assess the smoothness of movement 74 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 Maintenance of the Automatic Indexing Toolpost To maintain smooth operation of the automatic toolpost check the operation and if necessary lubricate the rotating mechansim of the carousel on a weekly basis To lubricate the mechansim of the automatic toolpost carousel use the oiling point mounted on the upper surface of the toolpost body as shown below oiling Using a pump action oilcan pump oil directly into the oiling point Run the rotating mechansim of the automatic toolpost carousel to distribute the oil across any internal surfaces Meteor CNC Lathe User s Manual Section 7 Maintenance 75 7 Spindle Drive Belt Adjustment To maintain smooth operation of the spindle check and if necessary adjust the tension of the spindle drive belt on an annual basis To gain access to the spindle drive belt turn of and disconnect power to the machine Using a 2 5mm allen hex key uns
62. ical Control CNG FILE gamnenmunasa The sequence of commands describing the manufacture of a part on a CNC lathe written using G and M codes also called the CNC program CUTTING SPEED sussidi The velocity of the rotating workpiece relative to the stationary cutting edge of the tool GROSS SLIDE wcirnscuneitinnnss The fixture that moves across the saddle X axis onto which the toolpost is mounted Meteor Series CNC Lathe User s Manual Section 11 Glossary 109 11 Glossary 110 Glossary Section 11 Constant Surface Speed The spindle is automatically adjusted according to the diameter being machined so that the material always passes the cutting edge of the tool at a constant rate Clockwise Counter Clockwise A sequence of events or commands The zero point co ordinate from which a series of measurements are taken The input control keypad for the machine Keypad overlays are interchangeable according to the type of controller required Replaces the qwerty keyboard and mouse An area of a disk containing the names and locations of the files it currently holds A computer information storage device examples C drive is usually the computers hard internal disk and A drive is usually the floppy portable 3 5 diskette disk Disk Operating System The controller unit for a disk system An operation used to test how a CNC program will function without driving the machine itself A programmed time delay
63. icated but item not shown in photograph Machine power cable connects to bracket on back panel of Meteor cabinet Back 3 4 View Photograph features optional equipment Location of optional equipment indicated but item not shown in photograph Door lock Electrical control box door Mains isolator on off power switch Panel ter Door pek panel of Meteor Mains supply cable cabinet connects to mains plug socket Electrical control Cooling fa Maching inlet identification panel Auxiliary I O socket RS 232 connection Denford machine link cable 30 CNC Machine Operation Section 4 Meteor Series CNC Lathe User s Manual 4 Working Area Component Locations F ront 3 4 View Bedway Automatic indexing 8 station Photograph features optional Worklight Z axis toolpost manual toolpost equipment Location of equipment indicated but item not shown in photograph Headstock including spindle drive Manual chuck Cross slide Saddle Tailstock pneumatic chuck X axis Meteor Series CNC Lathe User s Manual Section 4 CNC Machine Operation 31 4 Switching the Meteor On Follow these instructions to switch on your Meteor CNC lathe 1 Check the Denford machine Link cable is fitted securely between the serial COM2 port socket on the machine controller PC and the RS232 socket on the Meteor electrical control box 2 When fitted check the RS232 serial cable is
64. ideways are located Do bd mirror to help inspect on the upper and parts of the machine lower sides of the that are hard to reach bedway and the oa saddle Run the Balscrew ea Left side of Location A Xi saddle towards the pene Look under the flexible ght until sufficient i covers on the left and space has been Lower Slideway right sides of the saddle released to lift the black flexible cover positioned on the left E side of the saddle Besser Upper Slideway Using a soft bristled N brush carefully clean any swarf and debris away from P A the exposed upper and lower sides of tt each slideway to a e location where it can be removed from the working area Inspect each slide for damage or wear Run the saddle towards the left lift the black flexible cover positioned on the right side of the saddle and repeat the process The Z axis ballscrew runs centrally from right to left between the two Z axis bed slideways The Z axis ballscrew is fully enclosed by the two black corrugated flexible covers to the left and right of the saddle so it is not subject to swarf build up The ballscrew can be inspected for damage or wear by driving the saddle to the appropriate end of the Z axis releasing sufficient space to carefully lift each of the covers Replace the covers after finishing the inspection procedure ensuring that the slideway edges are covered 62 Maintenance
65. ine 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 machines can also run 24 hours a day if necessary with no signs of fatigue Compa
66. ing sequence atan C a positional linear move Flashing sequence Emergency Stop has been pressed On Denford S W this is a solid S symbol Section 8 Machine Electronics 85 8 NextStep Electronics Troubleshooting Warning leq X The spindle drive is not working A Check the validity of the following Never attempt to access 1 Check the emergency stop button is not depressed the electronic hardware 2 Check the spindle drive fuse labelled F3 on the main fuse rack seal de 3 Check the primary control transformer fuse labelled F1 on the switched ON main fuse rack Note that hazardous 4 Check the secondary control transformer fuse labelled F5 on the voltages can still exist immediately after main fuse rack switching off the power 1 addition refer to the electrical schematic diagrams to confirm If the machine has a Switched on wait at least 5 minutes before attempting to open the slechical panel cover The axis drives do not respond plate Check the validity of the following 1 Check the emergency stop button is not depressed 2 Check the axis drive primary fuse labelled F2 on the main fuse rack W X ae ol 3 Check the axis drive secondary fuse labelled F4 on the main A fuse rack Many electronic 4 Check the primary control transformer fuse labelled F1 on the components are main fuse rack sensitive to electrostatic damage ensure 5 Check the secondary control transform
67. ing used please refer to your separate CNC Control Software User s Manual for specific details tax Diagram showing Axis Definitions Z Axis The centre of the Z axis runs along a line between the spindle and tailstock or in other words the centreline of rotation of the spindle parallel with the longest edges of the bedways Minus Z movements of the toolpost are left towards the headstock area of the machine ie towards the chuck face Positive Z movements of the toolpost are right towards the tailstock area of the machine ie away from the chuck face X Axis The X axis runs at 90 degrees to the Z axis or in other words perpendicular to the Z axis parallel with the longest edges of the cross slide Minus X movements of the toolpost are towards the centreline of rotation ie down and towards the front of the machine Positive X movements of the toolpost are away from the centreline of rotation ie up and towards the rear of the machine Meteor Series CNC Lathe User s Manual Section 4 CNC Machine Operation 35 4 Manually Control M Codes Jog Mode 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 So
68. ining co ordinates originate from this point within the program Commonly set at the centreline on the X axis and the face end of the billet on the Z axis PP aoe Personal computer PR ORE sctscenstacesatesssecsetgens The outside shape of an object The term tool profile is used to describe the shapes of the different cutting tool tips PROGRAM ecceeeeteeeeeees A systematic arrangements of instructions or information to suit a piece of equipment PROGRAMMABLE TURRET Area where cutting tools are held also referred to as an automatic indexing toolpost programmable toolpost or ATC automatic tool changer An 8 station programmable turret could hold a maximum of 8 tool profiles The tool being used to machine the billet can be automatically changed for any other tool fitted to the programmable turret using software or CNC commands SADDLE sradan The fixture that moves along the bedways Z axis onto which the cross slide is Meteor Series CNC Lathe User s Manual Section 11 Glossary 111 11 Glossary SPINDLE SPEED sises SOFTWARE seiseanan STATON esnia anini 112 Glossary Section 11 mounted The rate of rotation velocity of the chuck measured in RPM Programs tool lists sequence of instructions etc The position of a tool profile in a programmable turret eg station 3 would refer to position number 3 on the programmable turret The interchangeable part of the machine that cuts the material On automatic indexin
69. intenance personnel Denford Limited cannot accept responsibility for any damage and or loss that may occur through incorrect maintenance of your CNC machine f Foreseen Use of Machine Your Meteor CNC lathe is designed for turning wax plastics acrylics copper aluminium and Steel 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 not attempt to use your Meteor CNC lathe for manual operations If you have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating features Meteor Series CNC Lathe User s Manual Contents 5 About this Manual Using this manual Disclaimer Language Contact 6 Contents This manual provides information describing how to transport site setup operate and maintain the features of your Denford Meteor CNC lathe including any optional equipment associated with the Meteor series This manual does not provide any information regarding the software packages used to control your Denford Meteor CNC lathe please refer to your separate CNC machine control software manual Please note that the electrical diagrams for your Meteor CNC lathe are held in a
70. ion of the Denford Machine Link cable If the cable is bad communication will not occur Try using a different controller computer to connect to the CNC lathe Check for help on the technical support FAQ and download sections of the Denford websites and or contact Denford Customer Services see the details on the first page of this 92 Technical Support Section 9 Meteor Series CNC Lathe User s Manual 9 Troubleshooting DOS CNC Turning Software The FLSTEP GO file The FLSTEP GO file usually supplied on floppy disk defines the computer settings and drivers used by the DOS CNC turning control software The file indicates the order in which the drivers are loaded into memory when the system first starts up Example FLSTEP GO File Example FLSTEP GO file listed below IBM RS2 1 3F8 4 MACHINE DENFORD KBD 1 18 2 2F8 3 EGA CRT 0 FLSTEP APP The example FLSTEP GO file listed above would be used when the CNC lathe is connected to COM 1 and the Denford DeskTop Tutor linked to COM 2 The COM ports on your PC are sometimes referred to as serial ports Editing the FLSTEP GO File some drivers require a number of additional lines as parameters The amount of lines required by the driver is shown by a number written after the driver name In the example shown above the number 1 listed after the IBM RS2 driver entry indicates that one additional line follows In this example it loads the MACHINE CNC lathe driver to a
71. is stepper motors the Meteor offers improved speeds and feeds to meet the increased demands of modern machining Machine control is achieved via a Windows based PC not included as standard An optional 8 station programmable indexing turret and pneumatic safety guard door can be specified together with additional tooling and workholding packages allow each machine to be individually configured according to your requirements see page 10 for options All Meteor CNC lathes are supported by courseware CAD CAM software and comprehensive operation manuals Designed specifically for Education and Training e Manufactured to industrial standards e Capable of cutting resistant materials such as wax plastics acrylics copper aluminium and steel Links to a range of CAD software eg AutoCAD Pro DESKTOP Techsoft via QuickCAM turning software or with Lathe Cam Designer introductory CAD CAM software e Totally enclosed high visibility interlocked guard e Feedrate and spindle speed override controls e CE approved for safety e Flexible workholding capabilities e Optional software allows programming via ISO Format incorporating controls such as FANUC Option of inclusion in FMC FMS CIM systems Meteor Series CNC Lathe User s Manual Section 1 Introduction 7 1 What is CNC 8 Introduction Section 1 CNC Computer Numerical Control is the general term used for a system which controls the functions of a mach
72. isolator switch to its off 0 position then check all connections and fuses to see that proper power and communication is established to the CNC 32 CNC Machine Operation Section 4 Meteor Series CNC Lathe User s Manual 4 Switching the Meteor Off Warning BEE Follow these instructions to switch off your Meteor CNC lathe 1 Wait for the Meteor to fully complete any machining or processing A of any operational instructions eve emi access 2 Open the guard door and remove any finished parts from the e electronic hardware systems in the CNC working area aloe eine airs 3 To close down the communication link between the CNC lathe power switched ON and your PC exit the CNC Machine Controlling Software as Note that hazardous described in your separate CNC Control Software User s Manual eri 4 To cut power to the CNC lathe rotate the isolator switch on the switching off the power Meteor electrical control box door one quarter turn anticlockwise If the machine has from its on I position to its off 0 position previously been Note that cutting the machine power will trigger the closing of the switched on wait at least minies benie interlock guard switch mounted on the side panel of the Meteor attempting to access any This will lock a closed guard door in position preventing access electronic components Many electronic components are sensitive to electrostatic damage ensure components and or personnel are s
73. itting tools seeeseseseseseseeeereseees 42 toolholder height adjustment ce 45 toolpost body angle sdjustment 43 114 Index Section 12 R Removal of protective coatings ccceseceeees 25 Running a CNC program or S Safety emergency stop button cc eeeeeeeeeeeeeees 12 interlock guard switch s s s 13 aE E A EIO OE IAE O 11 eclectig DAEN E 11 Siting your Meteor ccsacacceacarcssscesmensoacenenesnniccaeneneais 15 Slideways maintenance x axis Cleaning and inspection cececeeee 61 X axis IUDNCAUOM sisiseasisecatscadincasivesnsteensenanceens 68 z axis Cleaning and inspection cccccee 62 Z axis AUD ACAM ON sissandi ieia 69 DPS CINCATON xcxsaccacescnacscudesohoeseiendsolaewasurosvarsesdsens 96 Spindle drive belt adjustment cceecseeees 76 Spindle Speed override control cceeeeeeees 40 Spray mist Coolant SYStEM ccccessseeceeeseeeeees 38 Standard equipment ccccccceessssescseeeeeeeeeeees 9 Switches X axis datum SensoOrswitch cceeeeeeees 63 z axis datum SENSOFSWIICH ceeeeeeeeeeeeees 64 Z axis overtravel M CrosWiteh eessen 65 Switching the machine Off cceeseeeeseeeeeees oo Switching the machine ON cccseseeeeeeeeeeesees 32 T Tailstock pneumatic Operation 54 Technical SUD OM sacsetscsasensassexassevelocnuctendssenacexsels 87 Tool change requests siccaicssisisersonisasussainaadnincngans 36
74. ld not be used until the notice is removed Safety must be a priority when carrying out any 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 e 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 that the Meteor CNC Lathe User s Manual Section 7 Maintenance 55 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed 56 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed Meteor CNC Lathe User s Manual Section 7 Maintenance 57 7 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed 58 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 General Work Area Cleaning Safety First EEES Thoroughly clean and lubricate the C
75. lideway Any excessive movement will indicate that the slideway in question requires adjustment To accurately assess the condition of each slideway Denford recommends the use of a dial gauge Note that a slight degree of movement will always be present in every slideway If there is no free movement whatsoever then the 70 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 X Axis Gib Strip Adjustment Location X The X axis gib strip is adjusted using the two screws one locking f one adjusting positioned on the front and back left corners of the ook at the top of orase slide behind tha saddle near the left X slideway toolpost X Axis Gib Strip Adjustment Method 1 The gib strip locking screw is hidden by the upper cross slide cover plate Drive the saddle down the X axis This will make is easier to gain access to the top portion of the cross slide and the coverplate fixing screws Using a 2 5mm allen hex key turn each of the three cap head screws counter clockwise to remove them and withdraw the cover plate as shown below Ba BS aA gt p Left side Screw c of cross slide Location XE 2 Using a 5mm allen hex Look at the right top key loosen the gib strip corner of the saddle with locking screw about one half the cross slide cover revolution to release the gib plate removed strip The gib strip locking screw Is positioned behind the right top corner of the saddle as sh
76. ly affect how tool numbers are assigned to the cutting tool profiles used by your CNC program For example if your CNC program used a roughing profile finishing profile and drill odd tool numbers must be assigned to the roughing profile and finishing profile whilst an even number must be assigned to the drill profiles Denford recommends that you establish a standardised numbering system for the most common tool profiles used with your CNC programs Automatic Tooling System Fitting Tools The following tools are used to fit and adjust the components on the automatic indexing toolpost Five Wee 4mm Allen a FOX KEY Hex Key Hex Key Meteor Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 47 5 Automatic Indexing Tooling System Fitting a Diameter Turning External Working Tool Profile to the Toolpost On an eight station toolpost diameter turning external working tool Safety First X profiles such as roughing or threading profiles must be fitted to the Al odd numbered stations 1 3 5 7 Never open the safety Left Positions available circled for fitment of diameter turning external tools guard door and enter the working area when the spindle or machine axes are moving SElCNMmI a T X A Caution If the cutting tool has been recently used it may still be HOT 1 Each cutting tool profile should be fitted to an appropriate tip holder such as
77. ly into the oiling points a a ees Right f E Upper Slideway uu g l Ey wall Mill E ii side of saddle 7 2 n AB Lower Slideway ae eon f r i i Run the machine saddle left and right along the full length of the Z axis to distribute the oil along the slideways Meteor CNC Lathe User s Manual Section 7 Maintenance 69 7 Gib Strip Adjustment A gib strip is an section of metal or plastic which is fitted to one side of a machine slideway One gib strip is fitted to each of the two machine axes on your Meteor Each gib strip is tapered along its length The gib strip can be driven along the slideway to decrease the amount of free play in the axis using a locking and adjusting screw arrangement During the day to day use of your Meteor 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 annually Any slack present in the slides should be rectified by adjusting the gib strips as described on the next four pages Checking the Condition of the Gib Strips As the gib strips wear down varying degrees of free play will become noticeable in each of the two machine axes You can quickly judge the slack available in each slideway by holding the cross slide or saddle at their extreme ends Try to move or wobble them from side to side across the width of the s
78. ly used it may still be HOT All diameter turning external tools must be fitted with the cutting edge facing down 42 Preparing Tooling Hardware Section 5 Toolpost Hex Socket Key 4mm Allen Mex Key Fitting a Tool to the Toolholder 1 Using a 4mm allen hex Diameter turning key unscrew the four a ce lockbolts or grubscrews sy setae on the toolholder When directly viewing the top of the bolt heads turn counter clockwise to loosen or clockwise to tighten them Four lockbolts 2 Place the cutting tool into the toolholder in the correct orientation Note that diameter turning external tools must be fitted with the cutting edge facing down 3 Tighten the lockbolts until they just begin to grip the upper surface of the cutting tool body Tighten each bolt used by one quarter turn Continue this procedure until all bolts are fully tightened and the cutting tool is held securely Meteor Series CNC Lathe User s Manual 5 Quickchange Manual Tooling System Toolpost Body Angle Adjustment CMGI TX 10 adjust the angle of the toolpost body use a 10mm spanner to TIT release the locknut located on the Never open the safety central toolpost mounting stud fitted BIE to the cross slide The position of guard door and enter the working area when ihe ai machine the locknut hole on the toolpost axes are moving body is shown arrowed right When directly viewing the top of
79. nce this could seriously damage components inside your CNC lathe RS232 connector for the Denford Machine Link cable on electrical Meteor Series CNC Lathe User s Manual To connect your PC to the Meteor electrical control box 1 Connect the elements of your PC together as described in your original PC manufacturers operating manual At this stage your PC should not be switched on 2 The PC must be physically connected to the separate electrical control box using the supplied Denford machine Link cable This is the long thin serial link cable fitted with a 25 pin D male connector at one end and a 9 pin D female connector at the opposite end as shown below right 3 Connect the 25 pin D male end of the RS 232 cable to the 25 pin D female port mounted on the electrical control box as shown below left This port is labelled RS 232 ECTE Connector Connector 25 pin D female connector fitted to electrical control box end panel 25 pin D male connector fitted to Denford Machine Link cable PC Terminology The COM ports on your PC may be labelled as Serial ports Most COM ports have a 9 pin D MALE connector though some older computers may be fitted with additional PCI COM cards having a 25 pin D MALE connection In this case a 9 to 25 pin adaptor cable can be added to the Denford Machine Link cable supplied with your CNC lathe The Denford Machine Link cable supplied with your CNC lathe must always
80. neeinatbanoxdiesdiuncubiainceniasiiuicnen 22 Connecting the Mains Supply Cable cscssssssssscsssssssssssssscssssessssssssscaee sesesesesacaesssssesesevasacaseseesesesasesesesersaess 23 Opening Me Electrical onor BOX vaiscse 2 522s0scsshezendsestsssasesesshavesdeeateseandsanstacauitustaeshesesthaseastantenecuotanbtaccaesentebedtosansias 24 ESV Ie MIAN AN cutee wc Sele hat er igi ee ate ee Me een eed 24 Option Auxiliary Input Output SOCKET aisrececadueascnssersricanstdcwanacsnesisencnanatadansnmnlacienssaneiddeasmens isedaaacepanduessateaceceanaansdenase 25 Removal Of PrOTE CIV Coatings 15 c lt 2scsscecxdsaesiasavedsnstazateegesnennonapaiauaeadapha S AEE EAE TNE AER ETES 25 Component Connection SCHEMANC DIAQKAN icicesnvicianasdansiv wcieldainndi aedinnsiuidonetadsssinastauiisinalad shednsewbusitionattveaneesinbnbliloen 26 Section 4 CNC Machine Operation Using your Meteor OVenViE W aNaener tenets tenon ea Nerina ere ee ee e ere eee tee een ee eee ee 28 Meteor Cabin t Component Locations scscci csc ccencaeducecnndanaspnddsdnaddtcdentshbsaictendnudinsdentdesliarxebedennalsandeusnachaslsusketsanisdlacnonlse 29 Electrical Control Box Component LOCAUONS siaccscscsscccszssadsaszsesednncsissenedieusdasistcsesduatebcanteas dedeeilaiastacisduendidductexeteckss 30 eli lel Area Component Locations esrara R nret are Rte eerste 31 SVC IA Me MEEO ON ieniisiarena ananas anon eiaa ani naia bees sariani CPES AENEA NEDES TE 32 SUMMING Me Melgorn IMesias AE Ea
81. ng Tooling Hardware 51 6 Manual Chuck Operation Introduction The manual 3 jaw self centring chuck is supplied as standard with the Meteor CNC lathe unless an optional pneumatic chuck has been fitted The system comprises of three basic elements i The backplate which is secured against the spindle nose ii The chuck body which is secured against the backplate iii One set of external chuck jaws fitted to the chuck shown below Chuck Key Hole IL 3 Fia F EN y e ig aE a j m i a a iT a J F 5 Manual Chuck Mounting and Removal The chuck backplate has a mounting taper of 42mm dia x 7 7 with a register to suit the chuck To mount a chuck body thoroughly clean the spindle nose backplate and chuck register before assembly Mount the chuck backplate to the spindle nose and secure using the three M8 cap head screws Mount the chuck body to the backplate and secure using the three M10 cap head screws through the front face of the chuck To remove a chuck body perform the reverse of the procedure 52 Work Holding Section 6 Meteor CNC Lathe User s Manual 6 Manual Chuck Operation Never leave the chuck key fitted in one of the locating holes If the spindle is switched on it could hit the operator or machine and cause serious damage M codes for manual control of the optional pneumatic safety guard door M38 Door open M39 Door close The manual chuck has a recommended
82. nies can estimate the manufacturing costs for CNC production much more accurately compared to a production line with conventional production machines Jargon 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 AG and M code isa series of letters and numbers that make up the language used by CNC machinery Meteor Series CNC Lathe User s Manual 1 Before Beginning to Setup The standard equipment listed here is correct at the time of printing November 2002 but is liable to change through continuous development of our products Please refer to your invoice for the definitive list of standard equipment shipped with your machine Short 9 25 pin serial link adaptor cables can be used to convert the Denford Machine Link cable connectors according to the type of COM port fitted to your computer Before beginning to setup your Meteor CNC lathe please 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 Services as soon as possible The following equipment is supplied as standard with your Meteor e Denford Meteor CNC lathe No
83. nition should be placed at the start of a program after the units of measurement have been set Example G21 BILLET X30 0 290 0 This sets the measure to metric Note if set to Imperial the units would be inches and defines the billet length Z at 90mm with a diameter X of 30mm Note that the length value does not include the extra material required to physically hold the billet in the chuck jaws SUBPROGRAM This directive allows a program with a non numeric name to be called as a subprogram Example SUBPROGRAM 0200 FRED M98 P0200 This example assigns a subprogram number of 0200 to the program named FRED then calls the subprogram 0200 STEP This directive runs an on screen program in single steps This means the program will run one program line then wait for the operator to 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 continued Meteor Series CNC Lathe User s Manual Section 10 Appendix 103 10 Denford Directives NO STEP This directive runs an on screen program without single steps This means the program will run as originally intended with no pausing unless a pause is requested from within the program itself The directive applies to both simulation and actual machining with a program SHOW This directive allows the machining operations to be graphically sim
84. nt sccssrsiicriasiadacdsciivntanniumniaanns GIOSSAY seipsa ananena TEE a EAEAN EENE H Home PIOUS eerren Installation levelling your Meteor cescceseessseessees removal of protective coatings cceeee Siting your Meteor sesers unpacking and lifting your Meteor 0 Interlock guard switch Introduction Levelling your Meteor sssssseseeerereen Lifting your Meteor ssiazcsecsxsiesnscsssseosetdsnissascacessansncs Lubrication automatic indexing toolpost ceeceneees C ea EAEE x axis ballscrew eeeeserr x axis slideways eeeeeereerses Z axis balls CreW sssini Z AXIS SIQEWAYS sccccctsszencseatacenussessaneresessiarents Section 12 Index 113 12 Index M M codes IS a anleernctidncscedndaillenetigesntsdouededanetionniden sta 101 M codes list paral enanas 36 Machine co ordinates display system 34 Machine power cable connections c 000 22 Machine signal cable connections 0008 22 Mains supply cable Connections 23 Maintenance automatic indexing toolpost eee 15 ballscrew cleaning and inspection 61 general work area cleaning 59 log 56 NIB VUG AMON ONIM scaireanna 59 planning procedure csecsssessssescsseeseseeees 55 TAG ON sisese 60 slideways cleaning and inspection 61 switch cleaning and inspection ccee 63 x axis ballscrew lubrication
85. odes call the miscellaneous functions used to EEs manually control the optional pneumatic tailstock M codes can be M25 Tailstock quill extend manually entered for l i immediate operation M26 Tailstock quill retract when the machine controlling software is operating in Jog Mode or called automatically when written into a CNC program that is subsequently run in Auto Mode 54 Work Holding Section 6 Meteor CNC Lathe User s Manual 7 Planning Procedure for Maintenance Work SNe Sa TT X A Caution Wear safety glasses and a Suitable respiratory mask when cleaning the machine Safety First Eitm X A Never open the safety guard door and enter the working area when the spindle or machine axes are moving SElCNA a Samm TT X A Caution If the cutting tool has been recently used it may still be HOT When carrying out any maintenance pay special attention to the following items ensuring safe and correct working procedures in accordance with Health and Safety Regulations in your establishment e Before starting any maintenance work define the task and obtain the information relevant to carry out the maintenance Also define the time period needed to complete the task to obtain the correct tools and order any spare parts if required e During the maintenance work period display a suitable notice stating that the machine is under maintenance and shou
86. oved from the working area Carefully inspect the switch for damage or wear particularly the moveable contact pointer The trigger for the limit microswitch is mounted under the back left side of the saddle Using a soft bristled brush carefully clean dust and debris away from the trigger to a location where it can be removed from the working area Inspect the trigger for damage or Meteor CNC Lathe User s Manual Section 7 Maintenance 65 7 X Axis Ballscrew Lubrication Per The X axis ballscrew runs centrally from top to bottom along the eeey underside of the cross slide The ballscrew cannot be directly cross slide behind the lubricated since it is fully enclosed by the saddle and cross slide metalwork To lubricate the ballscrew remove the circular plastic blanking plug in the middle of the cross slide cover plate to gain access to the oiling point as shown below The cross slide cover plate is located on the upper pare of the cross slide behind the Balsorow a Oiling Point pa toolpost Using a pump action oilcan pump oil directly into the oiling point Run the cross slide up and down the full length of the X axis to 66 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 Z Axis Ballscrew Lubrication Location AX The Z axis ballscrew runs centrally from right to left between the two Z axis bed slideways To lubricate the ballscrew use the middle Look at the right edge of 7 ina saddle of the
87. own in the photograph on the previous page When directly viewing the top of the bolts turn counter clockwise to loosen them 2 Unscrew the centre grubscrew B shown in the photograph on the previous page to eject the angled clamping block When directly viewing the top of the grubscrew turn counter clockwise to loosen 3 Withdraw the toolholder If the cutting tool has been recently Meteor Series CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 49 5 Automatic Indexing Tooling System Fitting an End Internal Working Tool Profile to the Toolpost On an eight station toolpost end internal working tool profiles such as boring bars or drills must be fitted to the even numbered stations 2 4 6 8 Left Positions available circled for fitment of end internal working tool profiles 1 Each tool profile should Drill be fitted to the correct size collet such as the example shown below Collet To secure the drill inside the collet use a 2 5mm allen hex key to tighten Flaton gt Collet collet grubscrews the two grubscrews in a clockwise direction 2 Using a 2 5mm allen hex key unscrew the two grubscrews C on the side of the appropriate numbered toolpost station When directly viewing the top of the grubscrews turn counter clockwise to loosen or clockwise to tighten them Above Grubscrew C locations continued 50 Preparing Tooling Hardware Section 5
88. own right Turn in a counter clockwise direction to loosen the continued Meteor CNC Lathe User s Manual Section 7 Maintenance 71 7 X Axis Gib Strip Adjustment Re 3 Using a 5mm allen hex key adjust any free play in the X axis by tightening the gib strip adjustment screw one half revolution The Look at the right bottom i vy c merai ine caddie adjusting screw is positioned at the right bottom corner of the saddle as shown below l Ww i y A Adjusting j N M Right ee side of i cross 7 slide Turn in a clockwise direction to tighten the screw Do not overtighten this screw A slight degree of movement must be left in the slideway to allow X axis movement 4 Re tighten the gib strip locking screw Turn in a clockwise direction to tighten the screw 5 Traverse the cross slide up and down along the saddle to ensure that the X axis movement is smooth 6 Continue points 1 to 4 until all slack has been eliminated from the X axis Replace the upper cross slide cover plate Note If the X axis movement is not smooth loosen the gib strip but this time turn the gib strip adjustment screw counter clockwise to introduce a little slack back into the system Run the cross slide up and down along the saddle again to assess the smoothness of movement 72 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 Z Axis Gib Strip Adjustment The Z axis gib strip is adjusted using the
89. pen the electrical control box to Door cannot be opened unless the A access the electri isolator switch is in the off 0 position Never attempt to access panel ahd electrical the electronic hardware di lagrans systems of the machine 9 with the mains power switched ON Note that hazardous voltages can still exist immediately after switching off the power If necessary cut yellow plastic If the machine has sealing tag 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 lar p V p T ee E et Po Bas a j Electrical 2 par eee Panels So E al diagrams are neld in enner 1 a folder on the inside face of the electrical control box door as shown above or 2 supplied separately in the standard equipment box supplied with your machine 78 Machine Electronics Section 8 Meteor CNC Lathe User s Manual 8 Electrical Layout EuroStep Controller The photo below labels all important electrical components inside the electrical control box on EuroStep controlled CNC lathes Please note that the layout of your electrical panel may differ from the photo depending on components and options fitted to your Meteor Layout of the Electrical Pan
90. r corrugated cable machine power Note a 9 pin to 25 pin adapter may f also be required if your COM port has a Smaller diameter corrugated cable machine signals 25 pin connection Thin electrical cable mains power Note the physical layout of components on individual boxes may vary Meteor Series CNC Lathe User s Manual Section 3 CNC Machine Installation 27 4 Using your Meteor Overview Several steps must be completed before the final manufacture of a part The flowchart below lists the general steps that should be followed for CNC file creation simulation and final part manufacture in the recommended order However miscellaneous factors may warrant the user to complete the steps in a different order to that Note CX A Switch on the Meteor then start the CNC Control Software For more detailed see section 4 page 32 and see Note left information regarding these steps please refer f to your separate CNC Control Software User s Manual B Establish communications and home the CNC machine C Load or create the CNC program see Note left left D Configure the tooling files in the CNC Control Software see Note left left di see section 4 page 34 and see Note left E Prepare any tooling hardware for the Meteor see section 4 pages 34 to 37 and section 5 pages 41 to 51 F Simulate the CNC program in 2D or 3D see Note left G Load the billet into the chuck
91. re available all M M76 Wait for auxiliary output 1 off COCE RAE O M77 Wait for auxiliary output 2 off A ges M98 Sub program call performed at the end of a program block M99 Sub program end and return Ie after any axis Code listing full and correct at the time of printing Nov 2002 movement Meteor Series CNC Lathe User s Manual Section 10 Appendix 101 10 List of Program Address Characters 102 Appendix Section 10 N refers to the Program Sequence line block number X refers to the absolute distance travelled by the slide tool in the X axis direction U refers to the incremental distance travelled by the slide tool in the X axis direction Z refers to the absolute distance travelled by the slide tool in the Z axis direction W refers to the incremental distance travelled by the slide tool in the Z axis direction G refers to Preparatory functions G codes M refers to Miscellaneous functions M codes T refers to the tooling management tool number and tool offset S refers to the Spindle speed F refers to the Feed rate Meteor Series CNC Lathe User s Manual 10 Denford Directives Directives are program terms defined by Denford Limited They are used to help generate the 2D and 3D graphics used by the machine controlling software BILLET This directive allows a billet that appears in a simulation window to be given a size The billet defi
92. ressure Adjuster i p gt Air Supply Isolator equator M and Filter Regulator unit mounted or the back panel of the Metear cabinet Meteor Series CNC Lathe User s Manual Section 3 CNC Machine Installation 19 3 Option Compressed Air Connection M codes can be manually entered for immediate operation when the machine controlling software is operating in Jog Mode or called automatically when written into a CNC program that is subsequently run in Auto Mode Operation of the Air Supply Isolator Turn the control anticlockwise when viewed from above to allow the air to flow Turn the control clockwise when viewed from above to cut the air supply and drain the air pressure from the system Operation of the Air Filter Regulator The normal operating pressure as supplied preset on the machine is 100 PSI 6 6 Bar Maximum pressure for the air regulator is 150 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 the pressure Push the rotary control back down to relock it in its new position Regularly drain any water collected in the filter bottle using the cap in the base of the bottle The interval at which this operation is
93. rogram includes all the geometrical and technological data to perform the required machine functions and movements to manufacture the part The part program can be further broken down into separate lines of data each line describing a particular set of machining operations These lines which run in sequence are called blocks A block of data contains words sometimes called codes Each word 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 Meteor Series CNC Lathe User s Manual 10 Composition of a Part Program Part Program example Lathe CAM Designer 0050 LCD Novaturn lathe metric 00050 N0010 G21 BILLET X10 220 N0020 G98 N0040 M6T0101 N0050 M3S2546 N0060 G00X102Z2 N0070 X12 N0080 X10 N0090 G01Z 13 5F 10 N0100 X12 N0110 G00Z2 N0120 X8 N0130 M3S3183 N0140 G01Z 8 26 N0150 X10 N0170 X6 N0180 M3S4000 N0190 G01Z 6 26 N0200 X8 N0210 X12 N0220 G00Z2 N0230 G01Z0 N0240 X4 N0250 Z 5 N0260 M3S2829 N0270 X9Z 10 N0280 Z 14 N0290 X12 N0300 G00Z2 N0310 M5 N0320 G28U0W0 N0330 M30 Meteor Series CNC Lathe User s Manual Denford Directive Example BILLE
94. rties window to check that the changes have been applied 5 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 EuroStep Controller Cards Check the LED display status on the EuroStep Motion Control Board the main card on the electrical panel For more information refer to Section 8 Machine Electronics A problem with this card can cause problems with communications Look 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 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 har
95. safe maximum spindle speed of 3800rpm Fitting the Billet in a Manual 3 Jaw Chuck 1 The chuck jaws are adjusted using a chuck key a T shaped bar with a square locating peg shown below This fits into one of the three square holes equally spaced around the perimeter of 2 Open the chuck jaws by turning the chuck key in a counter clockwise direction until there is sufficient space to fit the billet as shown below Turn key CCW to open jaws P 3 Place the billet between the chuck jaws If possible try to position the billet so that the largest amount of material is held inside the chuck or by the chuck jaws 4 Whilst supporting the billet inside chuck body close the chuck jaws by turning the chuck key in a clockwise direction 5 Check the billet is held securely in the chuck jaws Remove the chuck key from the square locating hole Meteor CNC Lathe User s Manual Section 6 Work Holding 53 6 Bar Feed Hole for Longer Length Billets Facility is provided for feeding longer billet lengths through the centre of the chuck Remove the cap from the lower right headstock panel of the machine as shown below to reveal the bar feed hole Remove coverplate reveal bar 6 Pneumatic Chuck Operation The following M codes call the miscellaneous functions used to manually control the optional pneumatic chuck M10 Chuck Open M11 Chuck Close 6 Pneumatic Tailstock Operation The following M c
96. scesesesesseeeeeeeeeees 51 Automatic Tooling Requesting Programming a Tool Change ssssssssssesssssssssesssssssesssesssssssseceseesesseersesenes 51 Section 6 Work Holding Manual Chuck Operation Introduction es iiczasceiissstsas cacdensestavutscetndeudeadenssdedesdlbadacsenanbesentnsimandaauadsenh dessdlelentedsladsbendauthius 52 Manual Chuck MOUNTING ANG Removal ssc cessstvecusstastteeesacectsl cs ebeiseuasde eine a a EEEE EAEE TS EE EE EEEE E E 52 Manual Chuck Operation snsnennneesnensrsesininsesnersrsrsennnrnaninararnrnnsrnnnininatinnrnnnrtnninininanannrannnnnnunanunatunannnnennnnneennn 5 Fitting the Biletin a Mangal 3 Jaw CHUCK a t aiiscnsiuedeatwonsebasecennslaies nanan saaana ankeaa oana 53 Bal Feed Hole for Longer Lengih Bets scssesisiseonrtas iira raen Ea ESEE EE ETNEN 54 Pheumati e Vie MO s 2i 2 oer ennenennene nna ettent ase tee iaaea neia aana nate etre ee ean ere nen ene eee ee 54 Pneumatic Tailstock Operation eat23 ccs ceaatstieem seus vane daansatenctandesann dati feitanplbacutucandakstepaisb curinpedniatsilseshtacsutananteistcieounbeenndtd 54 Section 7 Maintenance Planning Procedure for Maintenance Work csccscsssssssssssssssssssssesssssssssessseessesssessesaesesesaeessesausesesarsesesseesersass 55 MAIMGNANIG SLOG sctesacscoszaxscsnaneanncessansinseccnctacsncnseebsteadnak aia Oi EEEE EATR TERN OTE O E 56 General Work Area Cleaning xsascaistnentsieuesnanesietedonedandtsinestatebcdndsbisiawexon
97. script symbol Circular interpolation Encoder following mode Flying shear static symbol Homing datuming Jogging velocity mode Offset mode Linear positional mode Torque control mode Stop asserted U Pulse following 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 un oto L ac n Luts Ain po 7 Fs r Tm Meteor CNC Lathe User s Manual Section 8 Machine Electronics 81 8 Eurostep Electronics Troubleshooting 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 power If the machine has previously been switched on wait at least 5 minutes before attempting to open the electrical panel cover plate x Warning A oX Many electronic components are sensitive to electrostatic damage ensure components and or personnel are suitably earthed to minimise this risk Always refer to your electrical schematic diagrams for the definitive labelling and placement of components and fuses Information contained on this page is correct at the time of printing November 2002 but is liable to change through continuous development of our products 82 Machine Electronics Section 8 The spindle dri
98. see section 6 pages 52 to 54 H Configure the workpiece and tool offset files AAE see section 4 pages 34 to 37 and see Note left Manufacture the part see section 4 pages 37 to 40 and Note left 28 CNC Machine Operation Section 4 Meteor Series CNC Lathe User s Manual 4 Meteor Cabinet Component Locations Front 3 4 View Photograph features optional equipment Enclosed safety Location of equipment Spindle guard door Toolpost indicated but item not shown in drive photograph Removable Safety guard door headstock end locking switch panel Front operators panel from left to right axis limit switch override pneumatic guard emergency stop button feed override spindle override Front and fear Safety guard door machine cabinet andle support feet sections Back 3 4 View Photograph features optional Enclosed safety equipment guard door Location of equipment indicated but item not shown in photograph emale connector plugs for cables from separate electrical control box from left to right machine signal machine power Safety guard door locking switch Lifting hook connection unit support feet sections Lifting hook Meteor Series CNC Lathe User s Manual Section 4 CNC Machine Operation 29 4 Electrical Control Box Component Locations Front 3 4 View Photograph features optional equipment Location of optional equipment ind
99. 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 2 Check all mains power connections are correctly fitted and secure Power up the CNC lathe using the yellow isolator switch mounted on the electrical control box door position l 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 The DOS CNC Turning software is started by executing the FLSTEP GO file Check the COM port being used on your machine controller computer matches the COM port number specified in the FLSTEP GO file If you are unsure assume the COM port being used is COM1 The GO file can be opened using Notepad on a Windows system Find the line ending with the word MACHINE If the Denford Machine Link cable is plugged into COM1 the line should read 3F8 4 MACHINE If the Denford Machine Link cable is plugged into COM2 the line should read 2F8 3 MACHINE Change the line to read the correct port number being used then continued Meteor Series CNC Lathe User s Manual Section 9 Technical Support 91 9 Troubleshooting DOS CNC Turning Soft
100. sracenan Thread Cutting Cycle cancelled by a G code G94 ee E Cutting Cycle B End Face Cycle from their particular G96 0 0 TANE Assessed Surface Speed Control group GOT sorses eee Assessed Surface Speed Control Cancel are cea EC a Feed Per Minute cote oe Cc he paneer Prea Feed Per Revolution when We macnine Code listing full and correct at the time of printing Nov 2002 started 100 Appendix Section 10 Meteor Series CNC Lathe User s Manual 10 M Codes List Note Not all M codes may apply to your CNC machine M code Function M00 Program stop M01 Optional stop MO02 End of program MO3 Spindle forward clockwise M04 Spindle reverse counter clockwise M05 Spindle stop MO6 Automatic tool change MO8 Coolant on M09 Coolant off M10 Chuck open M11 Chuck close M13 Spindle forward and coolant on M14 Spindle reverse and coolant on M25 Tailstock quill extend M26 Tailstock quill retract M30 Program stop and reset M38 Door open M39 Door close M40 Parts catcher extend M41 Parts catcher retract M 2 Auxiliary output 1 on M63 Auxiliary output 2 on M64 Auxiliary output 1 off M60 Auxiliary output 2 off M66 Wait for auxiliary output 1 on Not all M codes listed M67 Wait for auxiliary output 2 on a
101. tablishment 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 it is rotating or in motion Always secure the work in the chuck and if necessary tailstock Ensure that the correct cable for the power source is used Ensure the power is switched off before starting any maintenance work on the machine If power fails turn off the yellow red isolator found on the electrical control box front door immediately Hazardous voltages can still exist immediately after switching the electrical control box isolator to the OFF position Always wait at least 5 minutes before attempting to open the electrical control box or access any electronic components in the machine 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 operators control panel Meteor Series CNC Lathe User s Manual Section 2 Safety Features 11 2 Safety Features Emergency Stop Button Location of emergency Stop button mounted on the front operators panel positioned on the left side of the machine cabinet To active an emergency stop press the button fully in until it clicks A circular red emergenc
102. tdataeebnsienieesbnnectiatednnbenincesnedsa ixtubndientatinneunaanies 59 IE 9 afore 01a CMAI oreson tk Renee Serr ne en ean et Oe ree ener ee eer 59 Maintenance SCHOCUIG assesses csesatsancasstncocenstataenesacoctiaszenssciatcenstansavsaecaderanedeans0ivanatal ansnlancatolceuaesidassncasbasiaeedececaumaees 60 Cleaning and Inspecting the X Axis Ballscrew and Slideways ccccccesesssssseecsesessseseescssssasseeeeecssssaseeeeeeesess 61 Cleaning and Inspecting the Z Axis Ballscrew and Slideways cccccccsceccsssesseseeeeescneeecsseeesssenees eieneeeeeeeeess 62 Inspecting the X Axis Datum SEMSOPSWIKCN siczcscsascseis cansssasccnsane sides ecbassusadeasonnedesnutddswnavechcacie er aiii 63 Inspecting the Z Axis Datum Sensorswitch cisissnscssscecnenenscavedesesstvensnacssisesbenedandasbecessinenteatetidvaubseebtanebeseaduvecsnneestaeades 64 Inspecting the Z Axis Overtravel Microswitch cscscsssssssesssssssssssessssessessesssesscsssesarsesesecsesesassesesecessesasaeeneesenes 65 AANS Balio rew LUDICANOR se semessscrsisaceshartansenesahianioncieszennensscisuvasnaiccaintaguiaaiatsaestaasnidvanadsitathdanniansusialcioaan aie 66 Z AXis Ballsorew LUDMGAMON siaisisncaitnnsasecusosiciniesi wnxaiatithasaekatuustseasniiedenetta sectsnaiyelskvatificalacixisindtemiigetiiuatrincieabieuwnpeblanveute 67 X AXIS Slideways EUG GT ese inaiscnrncete erretinaren a r Eaa EEEE ANE EO ENE REEE S ESTEEN RETEA S 68 Z PXS Sideways LUD CAO ssunod a aai E a a aa a a 69
103. te that the precise specification of your Meteor will depend on any options selected at the time of ordering e Separate electrical control box e 1x Electrical control box key e 1x Denford Machine Link serial cable 25 9 pin connection cable including built in crossover Note that the CNC machine controller PC not included as standard e 1x Guard door interlock switch e 1x Operators toolkit metric allen hex keys and spare fuse package e 1x Manual chuck supplied fitted with a set of internal and external jaws e 1x3 jaw chuck key e 1x Manual toolpost with standard toolholder supplied fitted e 1x Toolpost hex wrench e 1x CNC machine warranty pack e 1x CNC machine inspection certificate e 1x CNC machine manual this book plus additional OEM product manuals as required e 1x CNC machine control software manual e 1x CNC machine control software CD ROM and or floppy disks e Machine commissioning and basic instruction Meteor Series CNC Lathe User s Manual Section 1 Introduction 9 1 Before Beginning to Setup The standard equipment listed here is correct at the time of printing November 2002 but is liable to change through continuous development of our products Please refer to your invoice for the definitive list of standard equipment shipped with your machine 10 Introduction Section 1 The following optional equipment may also be supplied with your Meteor CNC lathe please r
104. ted to pc back panel pin adaptor Link cable back panel 5 Do not confuse the 25 pin D female parallel printer port on your PC with the 25 or 9 pin male D COM ports If your CNC machine control software is supplied with a security key the 25 pin D male connector of this key must be fitted to the 25 pin D female parallel port as shown right Security keys are also referred to as dongles A schematic diagram illustrating these i 25 pin D male 25 pin D component connections is shown on omer female pages 26 to 27 security key connector fitted dongle to pc back panel 18 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Option Compressed Air Connection Connection Procedure An air supply isolator and air filter regulator is fitted to the back panel of the Meteor cabinet when your CNC lathe is fitted with the following compressed air driven equipment Pneumatic Guard Door Pneumatic Vice e Spray Mist Coolant System The air compressor must be fitted with a SCHRADER quick release connector The connection fitted onto the machine air filter regulator and isolator is SCHRADER part number SC 8051 11 1 8 BSP MALE or Denford part number BI 1451S The female connector required on the 1 4 pipe leading to the air compressor is SCHRADER part number 9793C 12 1 4 BSP FEMALE or Denford part number BI 1128S AIR SUPPLY 100 PS 6 6bar Air supply isolator P
105. ter being used as the controller unit which should be angled towards the user as shown in the diagram below available from Denford Limited Data Panel oX ar Sufficient room should also be provided for effective maintenance Dimensional Data to be carried out around the machine itself particularly at the headstock end to allow for removal of the cover plate We recommend the separate electrical control box is sited under the machine table leaving a space of at least 1000mm 40 to allow full opening of its front access door Machine width 1000mm 39 3 8 Machine height guard door open 955mm 37 5 8 Machine depth 610mm 24 Electrical control box width 600mm 23 5 8 Electrical control box height 780mm 30 3 4 Electrical control box Do not place the Meteor or electrical control box in a position which allows any of the vents or fans to be covered Ensure all cables pipes and flexes are routed to avoid the possibility of users tripping Computer desk monitor keyboard and mouse angled towards Operator Denford Meteor CNC lathe depth 360mm 14 1 8 Electrical Control Box under table Machine gt Operator Electrical Control Box access door shown open dotted Plan View showing Ideal Machine Operating Positions Meteor Series CNC Lathe User s Manual Section 3 CNC Machine Installation 15 3 Levelling your Meteor Your Meteor rests level on
106. the two hollow sections which run beneath the machine cabinet The machine itself has been levelled to the machine cabinet prior to dispatch so it is only necessary to level the table on which the Meteor cabinet is to be situated 3 Connecting your PC to the CNC Lathe Warning oH Xx A Do not connect cables between any electrical hardware with the mains power switched on since this could seriously damage components inside your CNC lathe Your CNC lathe is controlled using a standard IBM compatible PC personal computer In this role the PC can be referred to as the machine controller computer deally the PC you intend to use should be placed next to your Meteor cabinet and its electrical control box in a position which will not interfere with routine maintenance and machine operation Your PC must be equipped with hardware that allows it to 1 run the CNC machine control software 2 be physically connected to the Meteor electrical control box The specification of PC required to control your CNC lathe will depend upon the type of CNC machine controlling software being used Please refer to your separate CNC machine controlling software manual for details regarding the exact PC specification 16 CNC Machine Installation Section 3 Meteor Series CNC Lathe User s Manual 3 Connecting your PC to the CNC Lathe A Do not connect cables between any electrical hardware with the mains power switched on si
107. three oiling points mounted on the right edge of the saddle as shown below lt a f f i d r 9 Yuti J Ballscrew m i a f j i W Oiling Point Saa Right side of saddle d Using a pump action oilcan pump oil directly into the oiling point Run the machine saddle left and right along the full length of the Z axis to distribute the oil along the ballscrew Meteor CNC Lathe User s Manual Section 7 Maintenance 67 7 X Axis Slideways Lubrication Location x he two X axis slideways are located on the left and right sides of the saddle and cross slide To lubricate the slideways use the oiling Look at the upper left and right of the cross slide points mounted on the upper right and left sides of the saddle as behind the toolpost shown below Right D ea Right side of saddle Ep Using a pump action oilcan pump oil directly into the oiling points Run the cross slide up and down the full length of the X axis to distribute the oil along the slideways 68 Maintenance Section 7 Meteor CNC Lathe User s Manual 7 Z Axis Slideways Lubrication ian AX The two Z axis slideways are located on the upper and lower sides of the bedway and the saddle To lubricate the slideways use the Look at the right edge of ire sadda outer two of the three oiling points mounted on the right edge of the saddle as shown below Using a pump action oilcan pump oil direct
108. tion the flexible coolant delivery pipe so no moving part of the machine or workpiece can collide with it Coolant is delivered to the flexible pipe from the resovoir container mounted on the back panel of the machine Ensure that the coolant level is always between the minimum and maximum marks indicated on the resovoir Top up with Cincinnati Millacron Simcool 60 coolant dilution minimum 2 5 The following M codes call the miscellaneous functions used to manually control the optional spray mist coolant system M08 Coolant on optional spray mist coolant system M09 Coolant off optional spray mist coolant system M13 Coolant on and spindle forward optional spray mist coolant 6 Opening the Safety Guard Door A closed machine door cannot be opened when The machine is switched off ie not in use To release the interlock guard switch supply power to the machine The emergency stop button is fully pressed in To release the lock push in and turn the emergency stop button counter clockwise until it springs back out to its ready position Machining is taking place The interlock guard switch will release when the machining operations have been completed and the machine controlling software is operating in Jog Mode 38 CNC Machine Operation Section 4 Manual Safety Guard Door Open the door manually using the handle positioned below the front viewing window Pneumatic Safety Guard Door The
109. two screws one locking one adjusting positioned on the left and right back corners of the saddle near the upper Z slideway Z Axis Gib Strip Adjustment Method 1 Using a flat bladed screwdriver loosen the gib strip locking screw about one half revolution to release the gib strip The locking screw is positioned behind the top left corner of the saddle as shown below Location Look at the top left corner of the saddle Turn in a counter clockwise direction to loosen the screw Easier access to the locking screw can be obtained by gently pulling the flexible bedway cover away from the upper Z slideway continued Meteor CNC Lathe User s Manual Section 7 Maintenance 73 7 Z Axis Gib Strip Adjustment Be XE 2 Using a flat bladed PET screwdriver adjust any corner of the saddle free play in the Z axis by tightening the gib strip adjustment screw one half revolution The adjusting screw is positioned behind the top right corner of the saddle as shown right and below a Screw pi d Er E gt EN m i Turn in a clockwise direction to tighten the screw Do not overtighten this screw A slight degree of movement must be left in the slideway to allow Z axis movement Easier access to the locking screw can be obtained by gently pulling the flexible bedway cover away from the upper Z slideway 3 Re tighten the gib strip locking screw Turn in a clockwise direction to tighten t
110. uitably earthed to minimise this risk to the working area The interlock guard switch will reopen when power is next supplied to the Meteor Meteor Series CNC Lathe User s Manual Section 4 CNC Machine Operation 33 4 Homing the Machine Axes Home Mode Note The sequence of events required to home the Meteor will depend on the type of CNC control software being used please refer to your separate CNC Control Software User s Manual for specific details The CNC control software Jog and Auto Modes will not become available until the machine has been configured by homing both machine axes The machine datum position is set by Denford and can never be moved since it defines the physical movement capability of the CNC machine mmediately after establishing a communication link between the CNC control software and the Meteor both axes of the CNC lathe must be homed POMNO the CNC lathe defines The constraints of three dimensional co ordinate grid system used for plotting any programmed movements effectively the working envelope of the CNC lathe The machine datum the zero reference point for the CNC lathe so the controlling software can calculate where the tool is positioned in relation to the working envelope The process is commonly referred to as homing the machine or datuming each axis During the process both machine axes are sent to their fixed zero positions After homing the machine
111. ulated on screen NOSHOW This directive stops the machining operations from being graphically 104 Appendix Section 10 Meteor Series CNC Lathe User s Manual EC Declaration of Conformity The responsible person Mr J M Boyle Business Name Denford Limited Address Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Declares that the machinery described Manufacturer Denford Limited Model Name Meteor Series CNC Lathe S N AC6 serial Number please refer to warranty card and or machine casing The Machinery Directive 89 392 EEC as amended by Directive 91 368 EEC and Directive 93 44 EEC and CE Marking Directive 93 68 EEC and the following standards where applicable and complies with the relevant health and safety requirements c cssccesssssssssssesssssseessssesesssseesesseseesesensesersansesesses Signature Position within company senior Design Engineer Signed at Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Back of the Meteor Series EC Declaration of Conformity Certificate 106 Appendix Section 10 Meteor Series CNC Lathe User s Manual Meteor Series Noise Level Test Results Test Report No Meteor NL AC6 01 Machinery Manufacturer Denford Limited Machinery Type Model Meteor Series CNC Lathe Test Specification in accordance with BS4813 1972 Instrumentation used Cirrus CRL 2 35A Test Site Denford Limited Inspection Dep
112. ve is not working Check the validity of the following 1 Check the emergency stop button is not depressed 2 Check the spindle drive fuse labelled F3 on the main fuse rack 3 Check the primary control transformer fuse labelled F1 on the main fuse rack 4 Check the secondary control transformer fuse labelled F5 on the main fuse rack In addition refer to the electrical schematic diagrams to confirm specific fuse details and labelling The axis drives do not respond Check the validity of the following 1 Check the emergency stop button is not depressed 2 Check the axis drive transformer fuse labelled F2 on the main fuse rack 3 Check the primary control transformer fuse labelled F1 on the main fuse rack 4 Check the secondary control transformer fuse labelled F5 on the main fuse rack 5 Check the 36V stepper drive supply fuse labelled F1 on the rack backplane 6 Check the 36V stepper drive supply fuse labelled F2 on the rack backplane In addition refer to the electrical schematic diagrams to confirm specific fuse details and labelling Meteor CNC Lathe User s Manual 8 Electrical Layout NextStep Controller The photo below labels all important electrical components inside the electrical control box on NextStep controlled CNC lathes Please note that the layout of your electrical panel may differ from the photo depending on components and options fitted to your Meteor Layout of the El
113. ware 6 EuroStep Controller Cards Check the LED display status on the EuroStep Motion Control Board the main card on the electrical panel For more information refer to Section 8 Machine Electronics A problem with this card can cause problems with communications Look 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 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 Check the COM port on your controller computer 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 port itself 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 8 When all else fails Thoroughly check the condit
114. will prevent a closed safety guard door from being opened Spindle Speed and or Feedrate override changes will only be registered when an actual spindle speed or feedrate is being applied by the CNC control software Warning al xX Never attempt to open the safety guard door and enter the working area when the spindle or machine axes are moving 40 CNC Machine Operation Section 4 Emergency Stop Button The emergency stop button is a circular red push button Pressing the emergency stop button has the effect of stopping all axes and spindle movements immediately The safety guard door will also be locked preventing entry to the working area To active an emergency stop press the button in until it clicks The emergency stop button will remain closed continuing to cut all power to the machine drives until the button is released To release turn the button clockwise until it springs back out Spindle Speed and Feedrate Override Controls The spindle speed and feedrate of the Meteor can be manually overridden during a machining operation using the potentiometer control dials fitted to the operators panel On machines where these controls are not fitted or disabled the spindle speed and feedrate must be overridden using the CNC control software please refer to your separate CNC Control software User s Manual for details regarding this feature The spindle speed can be overridden between 50 and 120
115. y stop button is mounted on the front operators panel positioned on the left side of the machine cabinet When pressed it has the effect of stopping all axis 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 activate an emergency stop press the button in until it clicks The emergency stop button will continue to cut all power to the machine drives and continue to keep the interlock switch closed until the release sequence is performed To release a closed emergency stop button push in and turn the button counter clockwise until it springs back out 12 Safety Features Section 2 Meteor Series CNC Lathe User s Manual 2 Safety Features Interlock Guard Switch Location of interlock guard switch mounted on the right side of the machine cabinet and door An interlock safety switch is fitted to the right side panel of the machine cabinet and door 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 A closed safety guard using the supplied Torx T 20 adapter IRAD d G 2 Insert a 2 5mm diameter tool such as a small flat screwdriver into the hole until it pushes th

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