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Novaturn CNC Lathe - Denford CAD CAM CNC Forum

1. Coolant Spray Mist System As required Cincinnati Millacron As required Simcool 60 Dilution 2 5 Novaturn CNC Lathe User s Manual Section 7 Maintenance 49 7 Maintenance Areas on the Novaturn Quickchange Manual Toolpost Model Z Axis Gib Strip Z Axis Gib Strip Locking Screw Adjusting Screw behind Saddle behind Saddle Location of X Axis Slideways and Ballscrew Lubrication Points on Cross Slide Location of X Axis Gib Strip Adjusting Screws on Cross Slide Z Axis Slide Sensor behind Saddle Location of Z Axis Slideways and Ballscrew Lubrication Points on Saddle X Axis Slide Sensor on top of Saddle Location of X Axis Gib Strip Adjusting Screws on Cross Slide Safety First X ly BEN Pad yin X Axis Slide Sensor OL on top of Saddle A Caution Automatic Never open the safety Indexing guard door and enter the working area when Toolpost the spindle or machine axes are moving M odel If the cutting tool has been recently used it may still be HOT 50 Maintenance Section 7 Novaturn CNC Lathe User s Manual 7 Z Axis Ballscrew and Slideways Lubrication The bedway ballscrew and slideways run parallel in the direction of the Z axis as shown in the diagram below V R Slid k 5 Y i The slideways are located at the top and bottom of the slanted bedway and can be directly viewed by lifting the f
2. Length of cable between machine and S electrical control box Plan View showing Ideal Machine Operating Positions 1500mm 59 14 CNC Machine Installation Section 3 Novaturn CNC Lathe User s Manual 3 Levelling your Novaturn Your Novaturn rests level on the two hollow sections which run beneath the machine cabinet The machine itself has been levelled to the machine cabinet prior to dispatch so itis only necessary to level the table on which the Novaturn is to be situated 3 Connecting your PC to the Novaturn A Warning Do not connect any cables with the mains power switched on since this could damage the electrical components of your Novaturn and or your pc Your Novaturn 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 Ideally the PC you intend to use should be placed next to your Novaturn and its electrical control box with easy access to a mains power supply Your PC must be equipped with hardware that allows it to 1 run the CNC Machine Control software 2 be physically connected to the Novaturn electrical control box The specification of PC required to control your Novaturn 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 required Novaturn CN
3. When transporting the Novaturn over longer distances Denford recommends use of either a suitably sized wheeled trolley or a professional hoist When lifting with a professional hoist use two 5 metre x 100 KG slings arranged as shown in the diagram right Before fitting the slings always remove the safety guard the pressure of the slings may cause the guard to crack The guard is held in position using two nuts and bolts Some machines will also have a side mounted safety interlock switch This should be set open on delivery of the machine to allow the guard to be removed but must be set closed when the machine operates Remember to refit the guard when the machine has been sited Ensure that your Novaturn is both secure and balanced before lifting and transporting Data Panel Lifting Data Diagram Lifting Option 1 Lifting Points mirrored on Opposite end Usea Diagram professional Lifting hoist to lift the Option 2 machine NOTE THE GUARD MUST BE REMOVED Wrap two reinforced BEFORE LIFTING straps round the machine as shown ER gt Ss 2 YA Oey i Machine weight 88 KG 195 Ib Electrical control box weight 35 KG 77 Ib Lift using either two persons one per end of the machine or a professional hoist with two 5 metre x 100 KG slings Novaturn CNC Lathe User s Manual Section 3 CNC Machine Installation 13 3 Deciding on a Site for your Novaturn Remember when
4. Auxiliary output 2 on M64 Auxiliary output 1 off M65 Auxiliary output 2 off M66 Wait for auxiliary output 1 on M67 Wait for auxiliary output 2 on M76 Wait for auxiliary output 1 off MTT vss Wait for auxiliary output 2 off M98 mu Sub program call M99 Sub program end and return Code listing full and correct at the time of printing Sept 2001 Novaturn CNC Lathe User s Manual 10 List of Program Address Characters N refers to the Program Sequence line block number X refers to the absolute distance travelled by the slide tool in the X axis direction U refers to the incremental distance travelled by the slide tool in the X axis direction Z refers to the absolute distance travelled by the slide tool in the Z axis direction W refers to the incremental distance travelled by the slide tool in the Z axis direction G refers to Preparatory functions G codes M refers to Miscellaneous functions M codes T refers to the tooling management tool number and tool offset S refers to the Spindle speed F refers to the Feed rate Novaturn CNC Lathe User s Manual Section 10 Appendix 75 10 Denford Directives 76 Appendix Section 10 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
5. manual tooling OD x axis Slideways lubrication ey z axis ballscrew lubrication Jv ol zaxis JBS perina 57 ZANXIS SENSOM aan aaa ia 53 z axis slideways lubrication aO Maintenance schedule 49 Manual chuck operation osser 46 Section 12 Index 85 12 Index M Manual tooling axis definitions 30 basic layout eee 29 fitting a tool to the toolholder 37 fitting the toolholder to the toolpost 38 fitting TOO IS ea a 37 introduction ss 36 tool change request 34 toolholder height adjustment 40 toolpost body angle adjustment 38 Manufacturing a part overview nsee 28 N Noise level test results ssis 79 0 Operation air Supply ue machining overview manual chuck sses aa part manufacture checklist 34 pneumatic chuck sses 48 pneumatic guard door 48 Switching the machine off 233 Switching the machine OM eee 32 Override fe drate sindene atasi 35 Spindle Speed iisas 35 P Part program address characters serrin 75 composition definition PC connections to your Novamill esses 15 Pneumatic chuck operation 2 48 Pneumatic control cable connection 20 Pneumatic guard door operation 48 Potentiometer controls sss 35 Protective coatings removal sss 25 86 Index Section 12 R Removal of protective coatings oes 25 S Safety emergency stop button interlock guard switch OVEIVIEW sires
6. preca tons siia irinin 10 Sensor x axis automatic tooling sssr 54 X axis manual tooling sses 55 TAN A RE E A A 53 Siting your Novaturn n se 14 Slideways x axis Z axis Specification Switching the machine off Switching the machine ON vu T Technical Support eeseessessecsecseesseesseesseesseetses 64 Tool change requests a 34 Toolholder manual sssrin 37 Troubleshooting dos cnc turning software communications 67 vr cnc turning software communications 65 U Unpacking your NOV tUIN sees 13 Ww Warning notices sesen 5 Whati CNE iii iiine 8 Novaturn CNC Lathe User s Manual
7. Maximum servo following error exceeded L Limit switch open 62 Machine Electronics Section 8 Novaturn CNC Lathe User s Manual 8 The Spindle Drive Board The spindle drive board mounted in the bottom righthand corner of the electrical control box controls the motor for the programmable Spindle Two Spindle Drive Status LEDs Spindle Drive LED Status The two spindle drive status LEDs are mounted in the top lefthand corner of the spindle drive board Display Meaning ON LED Spindle drive board operational If this is not lit check the spindle drive board fuse shown in the diagram above then the fuse labelled F1 on the main fuse rack see the diagram on page 111 STALLLED Motor stall This indicates a faulty motor or component on the spindle drive board Novaturn CNC Lathe User s Manual Section 8 Machine Electronics 63 9 Technical Support Denford Limited provides unlimited telephone Technical Support on this CNC machine 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 FAQs Frequently Asked Questions and Technical Support Documents on our website http www denford com When you request support please be at your CNC machine with your hardware and software documentation to hand To minimis
8. Toolpost shown Look behind the top right side of the saddle Quickchange Manual Toolpost Model shown A Z Use a 2 5mm allen hex I key to turn the gib strip a adjusting grubscrews 4 Traverse the cross slide up and down across the saddle to ensure that the X axis movement is smooth 5 If the movement is not smooth loosen the gib strip by repeating Steps 1 to 3 but turn the gip strip adjustment grubscrews counter clockwise Run the cross slide up and down across the saddle again to assess the smoothness of movement 60 Maintenance Section 7 Novaturn CNC Lathe User s Manual 8 Electronics Panel Layout The photo below labels all important areas of the Novaturn CNC lathe electrical panel contained in the electrical control box Please note that the layout of your electrical panel may differ from the photo depending on components and options fitted to your Novaturn Before commencing any work refer to the schematic diagram of the electrical panel contained in the folder behind the electrical control box door A Warning Never attempt to open the electrical control box door with the mains power switched ON Note that hazardous voltages can still exist immediately after switching the isolator to the OFF position Always wait at least 5 minutes before entering the electrical control box Novaturn Electronics Panel Layout The electrical diagrams for your Novaturn are held in a folder inside
9. be given a size The billet definition should be placed at the start of a program after the units of measurement have been set Example G21 BILLET 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 98mm 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 8280 FRED M98 P 2 This example assigns a subprogram number of Z to the program named FRED then calls the subprogram 0209 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 INO STEP This directive runs an on screen program without single steps This means the program will run as originally intended with no pausing unless a pause is requested from within the program itself The directive applies to both simulation and actual machining with a program SHOW This directive allows the machining operations to be graphically simulated on screen INOSHOW This directive stops the machining
10. cutting edge facing down as 3 Place the cutting tool toolholder into the numbered station in the orrect orientation Diameter turning external tools must be fitted with the cutting edge facing down 4 Tighten the grubscrews until they just begin to grip the cutting tool toolholder Continue to tighten each grubscrew by one quarter turn Continue this procedure until both grubscrews are fully tightened and the cutting tool toolholder is held securely a Novaturn CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 43 5 Automatic Indexing Tooling System Height Adjustment of the Automatic Indexing Toolpost Cee oxy Any height adjustments made to the toolpost will be applied equally to all tool profiles used in the various numbered toolpost stations A To adjust the height of the toolpost Never open the safety guard door and enter 1 Using a 5mm spanner release the locknut on the lower the working area when grubscrew mounted on the toolpost side facing the front of the the spindle or machine machine Next release the locknut on the upper grubscrew AKES ATE MANNY mounted on the toolpost side facing the rear of the machine When directly viewing the face of a locknut turn the spanner in an anticlockwise direction to unscrew Vn Back of machine Back of machine BOTATE TURRE PURING ADJUST ME Above The upper locknut grubscrew Above The lower locknut grubscrew circle
11. n DENFORD Total Commitment to Education and Training WorldWide Novaturn CNC Lathe User s Manual CE approved Denford Limited reserves the right to alter any specifications and documentation without prior notice No part of this manual or its accompanying documents may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Denford Limited All brands and products are trademarks or registered trademarks of their respective companies Copyright Denford Limited Version 1 09 01 All rights reserved Contact Information Address Telephone Fax e mail Notes Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK General Enquiries 44 0 1484 712264 Customer Services 44 0 1484 722733 Sales Enquiries 44 0 1484 717282 44 0 1484 722160 for sales enquiries contact sales denford co uk for machine servicing enquiries contact service denford co uk for customer services and technical support contact customerservices denford co uk Use this page to make a note of any parts of the software you have changed or configured for example common tooling set ups machine parameters changes to installation paths or passwords etc 2 Contents Novaturn CNC Lathe User s Manual Contents Preface CONACENTOMMAUON rere ar are eea t aae thosstibon dite A cheviest
12. 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 locknut so the double flanges are pointing towards the centre of the toolpost as i shown left and p S Double below ail p flanged s locknuts Ao Double flanged locknut closed Double flanged locknut open continued 38 Preparing Tooling Hardware Section 5 Novaturn CNC Lathe User s Manual 5 Quickchange Manual Tooling System Fitting the Toolholder to the Toolpost Body continued SENGE CNX 2 Aligning the guides on the toolholder with the guides and spring loaded bracket on the toolpost body slide the toolholder down A into the toolpost bracket shown below left Lower the toolholder Never open the safety until the single flange on the toolholder height adjustment screw gard doorand enter is level with the space between the two flanges on the te toolpost the working area when the spindle or machine locknut shown below right axes are moving Slide the toolholder onto the toolpost then 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 Atthis stage do not fully tighten the locknut since this will prevent any toolholder adjustment from being carried out Turn the locknutt
13. schematic diagram sssrin 26 the MAINS SUPPLY iinne 22 the PC to the Novaturn sssrin 15 Contact information oo 2 Contents il Control box Seal is arstist 24 D Denford directives s s s 76 Denstep motion control board oo 62 Dimensional data DISCIAIMEL si einega E EC declaration of conformity Electrical diagrams sssrinin Electronics denstep motion control board sss 62 Opening the Electrical Control Box 61 panel layo t iiinn spindle drive board Emergency stop button Novaturn CNC Lathe User s Manual F Feedrate override ssiri 35 G EG ef ol of SSU IS FEDERER SEERE SE SENSE ESS SE RSS SES 73 Gib Strip Checking condition Of sssr 56 Gib strip introductions a X AXIS adjustment sisirin z axis adjustment l Interlock guard SWitch 0 esses 12 Introduction NOVAU cctsccssscceecstosiccectvecsservsefdveeriesstesentetse 7 What is CNC irinari oiean 8 L Layout of basic components iseer 29 Levelling your Novaturn 435 Lifting data we wold Lifting your Novaturn sssserrrrrrrre 13 Lubrication chartra taian x axis ballscrew x axis slideways Z AXIS DallScre Wonnen z axis slideways Micodes listwiaies certain waniieuis 4 74 Mains supply cable connection Details irinn rarere era ende Maintenance ANAS anarian A DRE RESEN ERR 50 x axis ballscrew lubrication oo eset 52 X AXIS GID Strip ees 59 x axis sensor automatic tooling D4 x axis sensor
14. the electrical control Denstep Isolator box Further electrical Motion schematics are Control ae or available on request Board rn Relay Toolpost i Modules Control Board Depending on the when fitted specification of the Main machine some Fuse Spindle Drive electrical cabinet doors Rack Board may be fitted with locks Depending on your machine spec the 24V Control Spindle Ferrite power supply may be Transformer Choke Core fitted below the Denstep motion control board to the left of the bank of relay modules Novaturn CNC Lathe User s Manual Section 8 Machine Electronics 61 8 The Denstep Motion Control Board The denstep motion control board is mounted in the top lefthand corner of the electrical control box It controls the motors that drive the two CNC lathe axes Display Fuse LED Status and Fault Display The LED display is mounted on the lefthand side of the denstep motion control board Display Meaning No comms board address fault Servo power off Servo power up and idle Cam profiling Cam table Superscript Circular interpolation Encoder following mode Flying shear static symbol Homing datuming J ogging velocity mode Offset mode Linear positional mode Torque control mode Stop asserted U Pulse following mode Errors are all shown with a flashing dot Display Meaning nog OCLemNymAAN 3 e External error E Software abort or interpreter error F
15. the small flexible pneumatic control cable is fitted securely into the fixing bracket mounted on the right hand side panel of the pneumatic control box attached to the rear of the machine 5 Check the electrical contro box door is closed and locked 6 When fitted check the air pipe connections for any optional equipment are secure then switch on the air compressor Check and adjust the air pressure if necessary 7 Plug the mains supply cable 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 O position to its on I position shown below You should hear the Novaturn begin its power up routine 9 Switch on the machine controller PC and start the CNC Control Software Establish a communication link with the Novaturn please refer to your separate CNC Control Software User s Manual for details outlining this procedure To switch on the Novaturn turn the isolator switch mounted on electrical control box door one quarter turn clockwise from the off 0 position to the on I position The photo opposite shows the isolator switch in the off position If the Novaturn does not power up turn the isolator switch to its off 0 position then check all connections and fuses to see that proper power and communication is established to the CNC machine 32 CNC Machine Operation
16. C Lathe User s Manual Section 3 CNC Machine Installation 15 3 Connecting your PC to the Novaturn To connect your PC to the Novaturn 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 Novaturn electrical control box using the supplied RS 232 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 RS 232 Cable 9 PinD 25 Pin D Female Male Connector Connector 25 pin D female 25 pin D male connector fitted to connector electrical control box fitted to side panel RS 232 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 RS 232 cable supplied with your machine The RS 232 cable supplied with your machine must always be used since this cable features crossovers on some of the pin connections You must also configure the m
17. I toolpost as shown left Location Ja x Automatic Indexing Toolpost Model Look in the middle of the cross slide M sf y e Location Quickchange Manual Ear i Toolpost Model Lubrication is delivered to the ballscrew and slideways using the line Look in the middle of of three oil points positioned horizontally in the middle of the saddle ESS SNE The left point delivers oil to the left slideway The middle point delivers oil to the ballscrew The right point delivers oil to the right slideway Pump oil into each of the three oiling points Traverse the cross slide up and down along the X axis to distribute the oil along the full length of the ballscrew and slideways 52 Maintenance Section 7 Novaturn CNC Lathe User s Manual 7 Cleaning amp Checking the Z Axis Slide Sensor The bedway slide sensor defining the Z axis datum is attached behind the top right corner of the saddle when viewed from the front of the machine To check the condition of the sensor gently pull the flexible bedway cover away from the top slideway Clean any dust and debris away from the sensor using a soft bristled brush Location CH X All Models Automatic Toolpost shown Look behind the top right side of the saddle aa mm y The bedway slide sensor trigger is attached to the right end of the top bedway slideway when viewed from the front of the machine To check the condition of the t
18. LIDE cniras The fixture that moves across the saddle X axis onto which the toolpost is mounted Novaturn CNC Lathe User s Manual Section 11 Glossary 81 11 Glossary 82 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 A sequence of events or commands The zero point co ordinate from which a series of measurements are taken The input control keypad for the machine Keypad overlays are interchangeable according to the type of controller required Replaces the qwerty keyboard and mouse An area of a disk containing the names and locations of the files it currently holds A computer information storage device examples C drive is usually the computers hard internal disk and A drive is usually the floppy portable 3 5 diskette disk Disk Operating System The controller unit for a disk system An operation used to test how a CNC program will function without driving the machine itself A programmed time delay The mode used for altering the content of a CNC program via the Desktop Tutor or qwerty keyboard The symbol or indicator that defines the end of a block of data The equivalent of the pc return key The rate in mm min or in min at which the cutting tool is advanced into the workpiece An arrangement of instructions or information u
19. Operation The following Miscellaneous Function a o codes are used to manually control ceed the optional pneumatic guard door M38 Guard Door Open M39 Guard Door Close y Pneumatic Guard Door Cylinder 48 Work Holding Section 6 Novaturn CNC Lathe User s Manual 7 Maintenance Schedule and Charts Maintenance Schedule Daily Clean and remove any swarf e Check that all slides are lubricated Clean tooling and toolpost Weekly Clean the machine e Check all exposed screws and nuts for tightness Oil all slides and ballscrews 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 Clean the slide sensors Annually e Check the slides for wear eCheck and adjust gib strips Note ca X 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 Lubrication Chart Lubrication Point Lubricating System Frequency Recommended Oil Grease Quantity Slide ways amp Pump action As required BP CS 68 As required Ballscrews oil can Shell Vitrea 68 Castrol Perfecto NN Headstock Grease Seal On change Kluber Isoflex NBU 15 4 cc Bearing of bearings Axis Bearings Grease Seal Once a year BP LS 3 2 cc Bearing Shell Alvania No 3
20. Section 4 Novaturn CNC Lathe User s Manual 4 Switching the Novaturn Off Follow these instructions to switch off your Novaturn CNC lathe 1 Wait for the Novaturn to fully complete any machining or processing of any operational instructions 2 Open the guard door and remove any finished parts from the working area 3 To close down the communication link between the Novaturn and your PC exit the CNC Machine Controlling Software as described in your separate CNC Control Software User s Manual 4 To cut power to the machine rotate the isolator switch on the Novaturn electrical control box door one quarter turn anticlockwise from its on I position to its off 0 position Note that cutting the machine power will trigger the closing of the interlock guard switch mounted on the side panel of the Novaturn see page 12 This will lock a closed guard door in position preventing access to the machine working area The interlock guard switch will reopen when power is next supplied to the Novaturn AWarning Hazardous voltages can still exist immediately after switching the isolator to the OFF O position Always wait at least 5 minutes before attempting to enter a Novaturn electrical control box that has just been switched off Novaturn CNC Lathe User s Manual Section 4 CNC Machine Operation 33 4 Part Manufacture Checklist amp Tool Changing Safety First T X A Never open the safety guard door and enter th
21. achine control software to recognise which numbered COM port is being used by the RS 232 machine lead Details on this procedure are outlined in your separate CNC machine control software manual The Parallel port on your PC may be labelled as the Printer port The printer port has a 25 pin FEMALE connector 16 CNC Machine Installation Section 3 Novaturn CNC Lathe User s Manual 3 Connecting your PC to the Novaturn 4 Connect the remaining 9 pin D female end of the RS 232 cable to the 9 pin D male COM port on your PC ideally COM 2 Most computers usually have two COM ports situated on the back panel of your PC If you cannot identify any of the ports on your PC please refer to your original PC manufacturers operating manual for further guidance Note that older computers may be fitted with a 25 pin D male COM port which may require the fitting of an additional 9 to 25 pin adaptor to your RS 232 cable Long PCI card Short standard mounted 25 pin D 9 pin D COM COM port 25 pin D male 25 pin D female connector 9 pin D female 9 pin D male connector fitted to RS232 cable using connector fitted connector fitted to pc a 9 to 25 pin adaptor to RS 232 cable fitted to pc back panel back panel 5 Do not confuse the 25 pin D female parallel printer porton 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
22. al For example Windows and the BIOS may show that the COM ports are fine but the portis not seen by any external devices 7 When all else fails a Thoroughly check the condition of the RS232 cable If the cable is bad communication will not occur b Try another computer c Check for support on the Denford website www denford com 68 Technical Support Section 9 Novaturn CNC Lathe User s Manual 10 Specification of Novaturn CNC Lathe Standard Equipment Novaturn CNC lathe Electrical power box Quick change toolpost and holder Manual self centring 3 jaw chuck Set of internal and external jaws Swart tray CNC lathe operating software CNC lathe and controller software manuals Set of maintenance tools and spare parts list Extra Equipment 8 Station programmable turret Automatic Tool Changer Various tooling packages Additional CAD CAM software Additional offline machine controller software licenses Machine work bench Video conferencing system Training PC amp PC workstation Pneumatic vice Pneumatic safety guard door Spray Mist Coolant Tailstock Compressor Mechanical Details Swing over bed 160mm 6 1 4 Swing over cross slide 80mm 3 Distance between centres 270mm 10 5 8 Travel X axis 140mm 5 1 2 Travel Z axis 225mm 8 7 8 Spindle bore 21mm 3 4 Spindle taper No 3 Tailstock taper No 2 Ballscrews X amp Z 16mm 5 8 diame
23. al provides information describing how to transport site setup operate and maintain the features of your Denford Novaturn CNC lathe This manual does not provide any information regarding the software packages used to control your Denford Novaturn CNC lathe please refer to your separate CNC machine control software manual Please note that the Electrical Diagrams for your Novaturn CNC lathe are held in a folder fixed inside the electrical control box 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 If you have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating features regarding this CNC lathe 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 September 2001 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 E
24. ally 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 slideway Any excessive movement will indicate that the slideway in question requires adjustment To accurately assess the condition of each slideway Denford recommends the use of a dial gauge Note that a slight degree of movement will always be present in every slideway If there is no free movement whatsoever then the Slideways would be too tight to move 56 Maintenance Section 7 Novaturn CNC Lathe User s Manual 7 Z Axis Gib Strip Adjustment The Z axis gib strip is adjusted using the two screws one locking one adjusting positioned behind the back of the saddle 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 side 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 t
25. ard Splash guard on Not Applicable Machine mounting Bench mounted Additional equipment None Test positions 4 Back of Machine Plan View Front of Machine 2 6 Background Noise i 51 dB A Maximum Spindle Speed 1809 revs min Spindle Direction Clockwise Feed Sound Levels dB A mm rev Position 3 4 5 180 500 1000 1500 1800 N A 53 52 52 N A 53 53 53 N A 54 53 54 N A 54 53 54 N A 55 54 54 Back of the Novaturn Series Noise Level Test Results Certificate 80 Appendix Section 10 Novaturn CNC Lathe User s Manual 11 Glossary ABSOLUTE iiien In absolute programming zero is the point from which all other dimensions are described ALLENS innisin nh See hex AR Genrer ere seere A portion of a circle ATIC arnie See programmable turret AUTOMATIC CYCLE A mode of control operation that continuously runs a cycle or stored program until a program stop or end of program word is read by the controller AUXILIARY FUNCTION The function of the CNC lathe ie F S T M codes etc other than co ordinate based commands AXIS AXES aniren The planes of movement for the cutting tool usually referred to as Z left and right parallel to the chuck centreline and X forwards and backwards at right angles to the chuck centreline Combinations of both allow precise co ordinates to be described BED iirin iia The base of the CNC lathe BEDWAY Seinnim iiinn Th
26. ations Component Layouts ssssssnrrrsssiirr 29 Novaturn Variations Axis Definitions scenerne 30 Switching the Novaturn ON vcs deiiinadsnimiainmininsltnaiieensnanianiiecs 32 S witching the NovatumiO ffri cnnan inmanat AETA EN RITET 33 Part Manufacture Checklist amp Tool Changing sssssssssssssssssrssrersssirrenssssrirrnsninrrersnsrnerne 34 Part Manufacture Overriding the Spindle Speed and Feedrate oie 35 Section 5 Preparing Tooling Hardware Quickchange Manual Tooling System pages 36 to 41 Introduction seers 36 Manual Tooling System Fitting Tools c sssssssssessssessssessescssrssssrsssssnssssnsarsrsssnsessssees 37 Fitting a Tool to the Toolholder cscesessessessnssessessessessssrsssescsssssserssssersssssnsarsssansessenses 37 Toolpost Body Angle Adjustment ssssssssssssssirerrerssssssnrsrntntetensnnnnnnnntntnninnnnennnnananinnnenne 38 Fitting the Toolholder to the Toolpost Body c sssssessscssesessesssssssssssssesssessnsarssnsenees 38 Toolholder Height Adjustment sc css da ad ede raa 40 Automatic Indexing Tooling System pages 42 to 45 Introduction vcs 42 Automatic Tooling System Fitting TOOIS 2 serene 43 Fitting a Toolholder to the TOOIPOSE ssscssscsssessstssssrsssssssrsrsssnssessnssnssessnsrssseesseeees 43 Height Adjustment of the Automatic Indexing Toolpost nesses 44 Novaturn CNC Lathe User s Manual Contents 3 Contents Section 6 Work Holding Manual Chuck IntroductO nw rear rr reel eee adel
27. attached to the inside of the electrical control box door Auxiliary 1 0 Plug when fitted Your electrical control box may be fitted with an Auxiliary Input Output socket allowing external control of your Novaturn in FMS and CIM systems via a cable connection as shown below left To run your Novaturn as a stand alone machine remove your external system cable and fit the blanking plug which is chained to the socket Auxiliary 1 0 Socket Plug 24 CNC Machine Installation Section 3 Novaturn CNC Lathe User s Manual 3 Mains Supply Details Data Panel Electrical Connection Data Mains supply required 50 60 Hz Single Phase 220 240 Volts 10 AMP Cable required 3 Core 1 5mm per core Spindle motor 1 5 HP Axis stepper motors 200 steps rev gax The Mains Supply The electrical control box is delivered with the mains supply cable connected directly into the isolator including approximately 3 metres of standard mains specification cable The cable should be fitted with a standard 13 amp plug suitable for the mains power supply A Warning Do not connect cables between any electrical hardware with the mains power switched on since this could damage the hardware All electrical connections should only be made by a suitably qualified electrical engineer 3 Removal of Protective Coatings Novaturn CNC Lathe User s Manual Once your Novaturn has been sited and connected elect
28. be fitted to the 25 pin D female parallel port as shown right Security keys are also referred to as dongles A schematic diagram illustrating these 25 pin D 25 pin D component connections is shown on page male enale 26 to 27 connector on connector security key fitted to pc dongle back panel Novaturn CNC Lathe User s Manual Section 3 CNC Machine Installation 17 3 Compressed Air Connection Air Connection when fitted An air supply isolator and air filter regulator is fitted to the back panel of the machine cabinet when your Novaturn is fitted with the following compressed air driven equipment Pneumatic Guard Door Pneumatic Vice 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 PSI 6 6bar Air supply isolator Pressure Adjuster To SCHRADER connection on air compressor Air Supply Isolator and Filter R egulator mounted on the back panel of the machine cabinet Air filter regulator unit 18 CNC Machine Installation Section 3 Novaturn CNC Lathe User s Manual 3 Operation of the Air Supply Isola
29. d mounted on the toolpost side facing circled mounted on the toolpost side the back of the machine is used to release facing the front of the machine is used the toolpost height adjusting mechanism to adjust the height of the toolpost 2 Using a 2 5mm allen key unscrew the upper grubscrew mounted on the toolpost side facing the rear of the machine by 3 or 4 complete revolutions When directly viewing the face of a grubscrew turn the allen key in an anticlockwise direction to unscrew 3 Using your CNC machine control software enter a tool change request that will allow the turret to revolve Ideally this will be the number of the tool to be adjusted continued 44 Preparing Tooling Hardware Section 5 Novaturn CNC Lathe User s Manual 5 Automatic Indexing Tooling System Sen 4 Whilst the turret is in motion adjust the height of the toolpost by turning the lower grubscrew mounted on the toolpost side A facing the front of the machine When directly viewing the face of Never open the safety a grubscrew turn the 2 5mm allen key in an anticlockwise guard door and enter direction to increase the toolpost height or in a clockwise the working area when ae t hainht the spindle or machine direction to decrease the toolpost hein axes are moving Warning Do not attempt to adjust the height of the toolpost when the turret is stationary This could result in serious damage to the locking plate inside the toolpos
30. 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 Companies can estimate the manufacturing costs for CNC production much more accurately compared to a production line with conventional production machine
31. e delay please be prepared to provide the following information CNC Machine Serial Number Registered user s name company name The controller software name and version number e The wording of any error messages that appear on your computer screen if applicable e A list of the steps that were taken to lead up to the problem e A listof any maintenance work that has been carried out on the CNC machine Contact Details Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK Telephone 01484 712264 Fax 01484 722160 ISDN 01484401157 01484401161 E mail service denford co uk Technical Support Monday to Friday 8 30am 4 30pm GMT For USA please contact Denford Inc 815 West Liberty Street Medina Ohio 44256 USA Telephone 330 7253497 Fax 330 7253297 E mail service denford com Technical Support Monday to Friday 8 30am 4 30pm Eastern 64 Technical Support Section 9 Novaturn CNC Lathe User s Manual 9 VR CNC Turning Software Communications Troubleshooting The password used to access the Machine Properties window can be changed by the user Remember that the default password listed here will not be recognised if you have changed it If you change any passwords we recommend you make a note of them in the Notes section in this manual If Novaturn is NOT listed with a tickmark as the active machine right click over the Novaturn title to display a pop u
32. e Z axis of the machine BILL Einin The actual material being machined sometimes referred to as the workpiece or stock BLOCK citiis nioa A collection of program words that collectively describe a machining operation A single program line in the CNC file CAROUSE briata The rotating section of a programmable turret containing a number of stations Also referred to as the turret disc CHARACTER 560 ektra A number letter or symbol as entered into a CNC program CHUCK oiera aiana The clamping system that holds the billet driven by the spindle CIRCULAR INTERPOLATION G code term for a programmed arc movement COMMAND wees A signal or group of signals instructing one step operation to be carried out CONTEXT SENSITIVE When shortcut keys are used to call a Context Sensitive helpfile the pages displayed relate directly to the current active elements within the software CO ORDINATES use Positions or relationships of points or planes Co ordinates are usually described using two numbers referring to the X and Z axes eg the co ordinate X 14 Z 10 means 14 units along the X axis and 10 units along the Z axis CNG aripa noo a Computer Numerical Control CNG FILE Sirari The sequence of commands describing the manufacture of a part on a CNC lathe written using G and M codes also called the CNC program CUTTING SPEED Mens The velocity of the rotating workpiece relative to the stationary cutting edge of the tool GROSS S
33. e electrical control box to the machine The machine power cable is housed in the large black flexible hose approximately 30mm in diameter The connector housing is fitted with two pins on the top and two 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 righthand side panel of the machine is fitted with a fixing bracket that contains the female connector plug 8 Back of 7 machine The male connecter plug is located on the free end of the machine power cable fitted to the electrical control box The female connector plug is located on the fixing bracket mounted on the righthand side panel of the machine 22 CNC Machine Installation Section 3 Novaturn CNC Lathe User s Manual 3 Connecting the Mains Supply Cable AA Warning 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 To connect the machine power cable to the Novaturn Back of machine 1 Lay the machine power connector plug next to the fixing bracket fitted to the side panel of the machine Check that the male a
34. e working area when the spindle or machine axes are moving Safety First X AN Caution If the cutting tool has been recently used it may still be HOT 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 and machine switched on CNC file loaded and checked via simulation Workpiece and Tool Offset files configured or loaded Machine homed datumed Requesting a Tool Change The Miscellaneous Function M06 is used to program an automatic tool change operation The M06 code activates the machine toolpost and is followed by the code T__ _ _ instructing it to move to the stated tool number the first two numerical digits using the stated tool length offset file number the last two numerical digits For example M06 T0305 This command is read change automatically from the current tool number to tool number 3 using tool length offset file number 5 Automatic Indexing Toolpost When an automatic indexing toolpost is fitted to the Novaturn 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 s
35. ee section 5 Preparing Tooling hardware page 42 Quickchange Manual Tooling System When a quickchange manual tooling system is fitted to the Novaturn 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 CNC Control Software message windows that machining can be resumed 34 CNC Machine Operation Section 4 Novaturn CNC Lathe User s Manual 4 Part Manufacture Overriding the Spindle Speed and Feedrate Spindle Speed and or Feedrate override changes will only be registered when an actual spindle speed or feedrate is being applied by the machine controlling software Using Potentiometer Controls to override the Spindle Speed and Feedrate SS S T 2 The right side of the front panel when viewed from the front of the machine contains the spindle speed and feedrate override potentiometer controls SPINDLE FEEDRATE OVERRIDE OVERRIDE The spindle speed and feedrate of the Novaturn can be manually overridden during a machining operation using the potentiometer controls fitted on the lower front panel of the machine illustrated above On machines not fitted with these controls the software can be used to override both spindle speed and feedrate please refer to your separate CNC Control Software User s Manual for deta
36. elected at the time of ordering see below 1x Guard door interlock switch torx bit 1x Electrical control box key 1x 80mm 3 jaw chuck key 1x Setof internal and external jaws 1x Quick change manual toolpost standard toolholder and toolpost hex wrench 1XRS 232 serial link cable 25 25 or 25 9 pin connection 1x Set of metric allen keys 1 5mm 2mm 2 5mm 3mm 4mm 5mm 6mm 1x Setof fuses 20mm 3 15A 20mm 6 3A 1x Novaturn CNC machine warranty pack e 1x Novaturn CNC machine inspection certificate 1x Novaturn CNC machine manual this book 1x CNC Machine Control Software manual 1x CNC Machine Control Software CD ROM and or floppy disks 1x Mousemat The following optional equipment may also be supplied with your Novaturn CNC lathe please refer to your separate order documentation for confirmation Programmable Turret Automatic Tool Changer in place of standard Manual Toolpost Pneumatic Safety Guard Door Pneumatic Chuck Electrical Control Box with Air Connection Various Tooling Packages CAD CAM Software Additional and or On site Training Courses Section 1 Introduction 9 2 Safety Features Overview and Precautions Safety Features Overview The following safety features are standard on your Novaturn CNC lathe Emergency stop button Totally enclosed high visibility guard door with interlock switch Toolpath graphics to verify program
37. ens 46 Manual Chuck Fitting the Billet in a Manual 3 J aw CHUCK sssri 47 Pneumatic Chuck Operation srerseressss renere ears an ran 48 Pneumatic Guard Door Operation voces arterne nnan 48 Section 7 Maintenance Maintenance Schedule i screenet re dl a aaa iieii 49 LUBRICATION Charissa on aratan ei eea DRS SS BANE RESENS ESS AANA 49 Maintenance Areas on the Novaturn secure renerne Z Axis Ballscrew and Slideways Lubrication cscscsessessessssesssessesssseessseeserssneersees X Axis Ballscrew and Slideways Lubrication 2 arrene Cleaning amp Checking the Z Axis Slide Sensor Cleaning amp Checking the X Axis Slide Sensor Automatic Tooling csssscseseeen 54 Cleaning amp Checking the X Axis Slide Sensor Manual Tooling c cscssseseseseeeen 55 Gib Strip Adjustment Introduction csessssussscsssesssssssssssssssssnssssssasresssesseeen 56 Checking the Condition of the Gib Strips csscssesssessesssssessessssseessrsssserssssssersseeeetes 56 ZAMS Gib S Mip AGUS UM ONG ys suset esset cerventerestevertsosatecasesertiturrectarecaseasfevertateecieateceveceys 57 X AXIS GIDS Tp ACJUSUMONE aina err irna EiT AEAN TETEA RASS 59 Section 8 Machine Electronics Electronics Panel Layout seinem mannanna N 61 The Denstep Motion Control Board c cccsssssessessscssesssssssssssssssrssssrsesssnsessnsssesens 62 The Spindle Drive Board neieiet artic REGN Ares ENE EGER 63 Section 9 Technical Support Te hnical SUpport ra rr El rr
38. er Inner blocks until replaced or G92 sw are Thread Cutting Cycle cancelled by a G code G94 inn Leeda Cutting Cycle B End Face Cycle from their particular G96 eee V RRE Assessed Surface Speed Control Wie eee GIR i ee Assessed Surface Speed Control Cancel by an asterisk 9 are G98 cm Teas ates Feed Per Minute reactivated as defaults G99 sc II eiis Feed Per Revolution when the machine Code listing full and correct at the time of printing Sept 2001 started Novaturn CNC Lathe User s Manual Section 10 Appendix 73 10 M Codes List Notall M codes listed are available all M codes marked with an asterisk will be performed at the end of a program block ie after any axis movement 74 Appendix Section 10 Note Not all M codes may apply to your CNC machine M code Function M Program stop M 1 Optional stop M 2 End of program M 3 Spindle forward clockwise M 4 Spindle reverse counter clockwise M 5 Spindle stop M 6 Automatic tool change M 8 Coolant on M 9 Coolant off M10 Chuck open MIL Chuck close M13 we Spindle forward and coolant on M14 Spindle reverse and coolant on M25 wee Tailstock quill extend M26 Tailstock quill retract M3 su Program stop and reset M38 ann Door open M39 Door close M4 uu Parts catcher extend MAL su Parts catcher retract M 2 Auxiliary output 1 on M63
39. g the top of the A screw turn counter clockwise to lower or clockwise to raise the Never open the safety toolholder guard door and enter the working area when CA LISTEN the spindle or machine Ky axes are moving View View Direction To raise Direction Tol A toolholder A i sk aie i turn knurled turn knurled collar CW collar CCW 4 Tighten the double flanged locknut on the toolpost body then screw in and tighten the lockbolt on the toolholder height adjustment screw Novaturn CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 41 5 Automatic Indexing Tooling System Introduction The optional Automatic Indexing Toolpost is designed to automatically change cutting tools when required Each numbered toolpost station or slot is designed to contain one tool holder which in turn contains the cutting tool profile On an eight station toolpost diameter turning external working tool profiles such as roughing or threading profiles must be assigned to the odd numbered stations 1 3 5 7 End internal working tool profiles such as boring bars or drills must be assigned to the even numbered stations 2 4 6 8 This will directly 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 whi
40. he G and M N 21 X12 codes required to manufacture the component N 22 G Z2 x N 23 GO1Z0 N 24 X4 N 25 Z 5 N 26 M3S2829 N 27 X9Z 10 N 28 2 14 N 29 X12 N 3 GOOZ2 N 31 M5 N 32 G28U W FREE N 33 M3 a N a 72 Appendix Section 10 Novaturn CNC Lathe User s Manual 10 G Codes List Note Not all G codes may apply to your CNC machine GCode Group Function GODS lee Positioning Rapid Traverse G L su Leet Linear Interpolation Feed G R wee ke Circular Interpolation CW G 3 sum RESSERER Circular Interpolation CCW GO4 su O ee ieee Dwell G28 ween Bivins Inch Data Input GRIE dies O uniia Metric Data Input G28 O iria Reference Point Return G40 me T etun Tool Nose Radius Compensation Cancel GYL sum Pirates Tool Nose Radius Compensation Left GAZ ainiin Tiaoa Tool Nose Radius Compensation Right G50 we r ETER Work Co ordinate Change Max Spindle Speed setting GT su D oale Finishing Cycle GT Liss coves Ds cciseciia casts Stock Removal in Turning X G codes from group G72 vere IBENS Stock Removal in Facing Z are non modal they Glinik Orii Pattern Repeating must be programmed G74 snan D anioia Peck Drilling in Z Axis BE aene aTe G75 sc Oa hiini Grooving in X Axis All other G codes are GIB ure E Multiple Thread Cutting Cycle modal they remain G81 ee de ated Deep hole drilling No FANUC oe ee a GID wae eee ee Diameter Cutting Cycle A Out
41. he 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 Novaturn CNC Lathe User s Manual Section 10 Appendix 71 10 Composition of a Part Program Part Program example Lathe CAM Designer S LCD Novaturn lathe metric 08859 N O16 G21 BILLET X1 220 Denford Directive Example BILLET N 2 G98 N 3 G28U W 7 N04 MeTO101 AN N S M3S2546 N G G X1 Z2 N N T X12 N 8 X10 N J G 1Z 13 5F1 N L X12 110 G Z2 12 X8 13 M3S3183 S lt 140 G 1Z 8 26 7 g e ee pras aa 150 X10 a 168 GOOZ2 170 X6 A componentis designed using a CAD CAM software 180 M3S4009 package such as Lathe CAM Designer N 19 G 1Z 6 26 The CAD CAM software package automatically N 2 X8 generates the part program including all t
42. here 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 Movement of the cutting tool through the 2 machine axes between cutting settings See programmable toolpost Standard Windows text only file extension tt 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 Novaturn CNC Lathe User s Manual 12 Index A Address characters list sssssesseesesrnneesseess 75 Advantages of CNC Air supply operation Automatic tooling AXIS definitions mresing 31 DASIC layouta a 29 fitting a toolholder to the toolpost a43 fitting tools sesser 43 height adjustment sssri 44 INFO UUO Nietoren a a ts begedne 42 tool change request s is 34 Auxiliary 1 0 plug heinien isisisi 24 AXIS CefIMIGONS arenans aa 30 B Ballscrew X aX nnan an aan aR 52 EN AE EE EET AEE 51 Cc Checklist prior to MACHINING sssr 34 CNC definition and overview esses 8 Connecting a compressed air SUPPLY esses 18 Pneumatic Control cable lissi 20
43. ils regarding this feature The spindle speed can be overridden between 50 and 120 The feedrate can be overridden between 0 and 150 To increase the spindle speed or feedrate rotate the appropriate control clockwise To decrease the spindle speed or feedrate rotate the appropriate control anticlockwise Novaturn CNC Lathe User s Manual Section 4 CNC Machine Operation 35 5 Quickchange Manual Tooling System Introduction The quickchange manual tooling system is supplied as standard with the Novaturn 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 Novaturn cross slide 36 Preparing Tooling Hardware Section 5 The Quickchange Lathe Toolholder The Quickchange Toolpost Body 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 bolt Novaturn CNC Lathe User s Manual 5 Quickchange Manual Tooling System Manual Tooling System Fitting Tools The following tools are used to fit and adjust the components of the quickchange manual tooling system Toolpost Hex Socket Key 4mm Allen Hex Key Fitting a Tool to the Toolh
44. in order to achieve an electrical connection To connect the pneumatic equipment control cable to the Novaturn Back of machine 1 Lay the pneumatic equipment control connector plug next to the fixing bracket mounted on the side panel of the small pneumatic control box Check that the male and female plugs are arranged in the correct orientation as outlined above and on the previous page For correct alignment the pneumatic equipment control cable will point towards the front of the machine as shown in the diagram above Push the connector plug fully onto the fixing bracket 2 Close the junction by pushing the single fixing bracket roller clips onto the male connector plug housing pins until they click A schematic diagram illustrating these component connections is shown on pages 26 to 27 Novaturn CNC Lathe User s Manual Section 3 CNC Machine Installation 21 3 Connecting the Mains Supply Cable The mains power supply is fed to the electrical control box which in turn is connected to the Novaturn There are two electrical connections that exit the electrical control box 1 The machine power cable the largest diameter flexible hose On machines fitted with pneumatic equipment do not confuse this with the pneumatic control cable this is a smaller diameter flexible hose 2 The mains supply cable the smallest diameter cable The Machine Power Cable The machine power cable must be connected from th
45. ine 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 up and towards the rear of the machine Positive X movements of the toolpost are away from the centreline of rotation ie down and towards the front of the machine Novaturn CNC Lathe User s Manual Section 4 CNC Machine Operation 31 4 Switching the Novaturn On Follow these instructions to switch on your Novaturn CNC lathe 1 Check the RS232 machine lead is fitted securely between the serial COM2 port socket on the machine controller PC and the RS 232 socket on the Novaturn electrical control box 2 When fitted check the RS232 controller lead is fitted securely between the serial COM1 port socket on the machine controller PC and the RS 232 socket on the DeskTop Tutor controller keypad 3 Check the large flexible machine power cable is fitted securely into the fixing bracket mounted on the right hand side panel of the Novaturn cabinet 4 When fitted check
46. ipment control cable must be connected from the main electrical control box to the small pneumatic control box attached to the rear of the machine The pneumatic equipment control cable is housed in the small black flexible hose approximately 15mm in diameter The connector housing is fitted with one pin on the top and one pin on the bottom One end of the pneumatic equipment control cable is permanently connected to the main electrical control box whilst the free end is fitted with a male connector plug The side panel of the small pneumatic control box attached to the rear of the machine is fitted with a fixing bracket that contains the female connector plug Back of 7 machine The male connecter plug is located on the free end of the pneumatic equipment control cable fitted to the main electrical control box The female connector plug is located on the fixing bracket mounted to the side panel of the small pneumatic control box fitted to the rear of the machine 20 CNC Machine Installation Section 3 Novaturn CNC Lathe User s Manual 3 Connecting the Pneumatic Control Cable AA Warning 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
47. itecreneenvoule 2 Warming Notices in innn kv eck oei Peitret editie test bee EAEN EEEE ETETE 5 Aboutthis Manualer ror atter Ende aa diseicdet ete 6 Section 1 Introduction Introducing your Novaturn CNC lathe cscscssssssessessssssssessssssesssssessssnserssnsssessenees 7 Wihatis CNG prrs eaa aana EENE seat rnturtauncaniaaats 8 Before Beginning to S etU arrene eter ert ne ruge anaa 9 Section 2 Safety Features Safety Features Overview and Precautions ssssscsesesersssrar eneret rear er treerne 10 Emergency Stop EURON sis raide REE AE EIR 11 interlock Guard Switch iss eeren ana EA ES aAa ARE none 12 Section 3 CNC Machine Installation Unpacking amp Lifting your Novaturn sesssssscsssssssressssssssssssessnssrsssssnsssssnsersresssessesees 13 Deciding on a Site for your NoVaturn 2 nerne treerne 14 Levelling YOUrIN ovat inni hnnain nei EEA EATA anA NEAN Teti 15 Connecting your PC to the Novaturn 2 senere rarere 15 Compressed Air Connection anientar iir eO a i a SEEE E 18 Operation of the Air Supply Isolator and Regulator sssrini 19 Connecting the Pneumatic Control Cable ceeceseeeeneeseseeeeeeieeeien 20 Connecting the Mains Supply Cable oo ccseeseeesesiseumeeneereeisricsies 22 Electrical Control Box Mains Supply Details Removal of Protective Coatings Component Connection Schematic Diagram cscs 26 Section 4 CNC Machine Operation Using your NOVaturn Overview ecrsersnncnsnccniensnicnirnnennni 28 Novaturn Vari
48. k into the system Run the saddle left and right along the bedway again to assess the smoothness of movement 58 Maintenance Section 7 Novaturn CNC Lathe User s Manual 7 X Axis Gib Strip Adjustment The X axis gib strip is adjusted using the five combined locking nuts and grubscrews positioned on the right side of the cross slide X Axis Gib Strip Adjustment Method 1 Using a 5mm spanner release each of the five locking nuts on the gib strip adjusting grubscrews To loosen turn each locking nut in a counter clockwise direction Location CH X Location of the five cross slide locknuts and adjusting grubscrews All Models Automatic Toolpost shown Look behind the top right side of the saddle Quickchange Manual Toolpost Model shown 2 Using a 2 5mm allen hex key reduce any free play in the X axis by tightening each of the five grubscrews evenly To tighten turn each grubscrew in a clockwise direction Do not overtighten these grubscrews Run through the same sequence of tightening each of the five grubscrews until a slight drag is experienced on movement of the slideway continued Novaturn CNC Lathe User s Manual Section 7 Maintenance 59 7 X Axis Gib Strip Adjustment 3 Re tighten the five locking nuts whilst holding their grubscrew positions steady with the allen hex key To tighten turn each locking nut in a clockwise direction Location CH x All Models Automatic
49. kplate Chuck Body Chuck Chuck Billet Key Jaw Hole 46 Work Holding Section 6 Novaturn CNC Lathe User s Manual 6 Manual Chuck Operation Fitting the Billet in a Manual 3 J aw Chuck 1 The chuck jaws are adjusted using a chuck key a T shaped bar with a square locating peg shown below This fits into one of Safety First 1 X the three square holes equally spaced around the perimeter of A the chuck body Never leave the chuck key fitted in one of the locating holes If the TA spindle is switched on it could hit the operator or machine and cause serious damage 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 to open jaws WIT 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 Novaturn CNC Lathe User s Manual Section 6 Work Holding 47 6 Pneumatic Chuck Operation The following Miscellaneous Function _ codes are used to manually control M the optional pneumatic chuck O M10 Chuck Open M11 Chuck Close 2 6 Pneumatic Guard Door
50. lation Section 3 Novaturn CNC Lathe User s Manual 3 Component Connection Schematic Diagram Denford Novaturn Ensure the following CNC Lathe connectors are fitted in the correct orientation Electrical Control Box Pneumatic Control if fitted Pneumatic Control Connector Electrical Control m Box Connector Mains Power Supply Plug The RS 232 serial cable connects the Microturn to the PC port labelled COM 2 The RS 232 cable is the long thin cable fitted with a 9 pin D female connector at one end Port and a 25 pin D male connector at the opposite ahi labelled Connect the 25 pin D male end of the RS 232 RS 232 cable to the 25 pin D female RS 232 port on the righthand side panel of the Microturn Connect the remaining 9 pin D female end of the RS 232 cable to the 9 pin D male COM2 porton your PC Note a 9 pin to 25 pin adapter may also be Novaturn Electrical required if your COM port has a 25 pin Control Box ee Note the physical Mains power is supplied from the Electrical layout on individual Control Box to the Novaturn using the boxes may vary largest black flexible corrugated cable Novaturn CNC Lathe User s Manual Section 3 CNC Machine Installation 27 4 Using your Novaturn 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 simulatio
51. lexible bedway cover The ballscrew lies between the two slideways and can also be directly viewed by lifting the flexible bedway cover Location ox Lubrication is delivered to All Models Automatic gt the ballscrew and slideways Toolpost shown hsm using the line of three oil Look at the left side of Oiling Point points positioned on the The middle point delivers oil to the bottom slideway cle Traverse the saddle distribute the oil along the the saddle 4 right side of the saddle The upper point delivers oil onna oint to the top slideway Bu to the ballscrew TE i The lower point delivers oil ERR Oiling Point oe Pump oil into each of the P three oiling points assembly right and left along the Z axis to full length of the ballscrew and slideways Novaturn CNC Lathe User s Manual Section 7 Maintenance 51 7 X Axis Ballscrew and Slideways Lubrication The cross slide ballscrew and slideways run parallel in the direction of the X axis as shown in the diagram below LS i f Right Slideway FF a F Automatic Indexing Toolpost Left Slideway H gt Model shown The slideways are located on the left and right of the cross slide mounted on the saddle The ballscrew lies between the two slideways Note The line of three oiling points are positioned just above a quickchange manual f toolpost or just below Automatic an automatic indexing Indexing
52. lst an even number must be assigned to the drill Denford recommends that you establish a standardised numbering system for the most common tool profiles used with your CNC programs Even numbered circular hole stations are used for end internal tool profiles Odd numbered O straight slot stations are used for diameter turning external tool profiles 42 Preparing Tooling Hardware Section 5 Novaturn CNC Lathe User s Manual 5 Automatic Indexing Tooling System Automatic Tooling System Fitting Tools The following tools are used to fit and adjust the components on the automatic indexing toolpost PO ir soe 4mm Allen 2 5mm Allen Hex Key Hex Key Fitting a Toolholder to the Toolpost Mint TI 1 lf required fit the cutting tool profile in an appropriate toolholder 2 Using a 4mm allen hex key unscrew the two grubscrews on the A appropriate numbered toolpost station When directly viewing the Never open the safety top of the grubscrews turn counter clockwise to loosen or the working area when the spindle or machine axes are moving guard door and enter clockwise to tighten them SILVA AICS B X Caution Da If the cutting tool has been recently used it Grubscrew may still be HOT locations K straight slot 3 Grubscrew stations locations This is the currently active cutting tool Diameter turning external tools must be nd fitted with the
53. n and final part manufacture in the recommended order However miscellaneous factors may warrant the user to complete the steps in a different order to that shown A Switch on the Novaturn then start the CNC Control Software For more detailed information regarding see section 4 pages 32 to 33 and see Note left these steps please refer Se Joes to your separate CNC TB Load or create the CNC program see Note left Control S oftware User s Manual C Configure the tooling files in the CNC Control Software see Note left D Simulate the CNC program in 2D or 3D see Note left E Establish communications and home the CNC machine see Note left F Prepare any tooling hardware for the Novaturn see section 5 pages 36 to 45 G Load the billet into the chuck see section 6 pages 46 to 48 H Configure the workpiece and tool offset files see Note left Manufacture the part see section 4 pages 34 to 35 and Note left 28 CNC Machine Operation Section 4 Novaturn CNC Lathe User s Manual 4 Novaturn Variations Component Layouts Standard Novaturn with Manual Chuck and Manual Toolpost Headstock Cross Slide X axis Bedway Manual Toolpost Z axis tool tips mounted face up Novaturn with Pneumatic Chuck and Automatic Indexing Toolpost Automatic Indexing Toolpost tool tips mounted face down Headstock Pneuma
54. nb a 64 VR CNC Turning Software Communications Troubleshooting ecccsrcccccccnnsn 65 DOS CNC Turning Software Communications Troubleshooting cesses 67 Section 10 Appendix Specification of Novaturn CNC Lathe woes 69 Whatiis a Part Program inini iaire iiaa tiana AEA EE E EE E 71 Composition of a Part Programas ne ee aa a sin diated RAREN EE 72 G COMES Listonin i En aE enter deinevanen 73 M Codes EiS ienris riena AEA EAE TTE i E EAA NA DAEN ane 74 List of Program Address Characters nesssssccrccccrcrerernnnnnnnnreennn 75 Denford Dire Ctives ssccsctcvsciecrsdeasstvtons shevtsuivtavetensadsd eatin cavinevtes cLetave caneasenrecstovarteneanasranevests 76 EC Declaration of Conformity cscsesscssssesssssssrssessssssssssssssssssssessssssssssnssessnsesssseensess 71 Novaturn Series Noise Level Test Results sssssssssssssssssssssnsnsnnnnsnnnnnonononnnnononnrnrnnrnrnrnrnrnnna 79 Section 11 Glossary GIOSSANV E E Me Win diated anae Anal le igh Gad in daa aake hls 81 Section 12 Index E E EA ation EET ERE T 85 4 Contents Novaturn CNC Lathe User s Manual Warning Notices A Warranty Disclaimer The Warranty on your Novaturn 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 applia
55. nce testing PAT on any of the supplied equipment Maintenance Disclaimer Always obtain permission from the person responsible for machinery in your establishment before opening the electrical control box or Novaturn CNC lathe casings to carry out any maintenance work All work must be carried out by personnel suitably qualified for each maintenance task to avoid damage to both the machine systems and the maintenance personnel Denford Limited cannot accept responsibility for any damage and or loss that may occur through incorrect maintenance of your Novaturn CNC lathe A F oreseen Use of Machine Your Novaturn 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 Novaturn 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 regarding this CNC lathe without notice or documentation Novaturn CNC Lathe User s Manual Contents 5 About this Manual Using this manual Disclaimer Language Contact 6 Contents This manu
56. nd female plugs are arranged in the correct orientation as outlined above and on the previous page On a standard Novaturn the machine power cable will exit towards the rear of the machine as shown in the diagram above Push the connector plug fully onto the fixing bracket 2 Close the junction by pushing the two fixing bracket roller clips onto the male connector plug housing pins until they click A schematic diagram illustrating these component connections is shown on pages 26 to 27 Novaturn CNC Lathe User s Manual Section 3 CNC Machine Installation 23 3 Electrical Control Box Depending on the specification of the machine some electrical cabinet doors may be fitted with locks The electrical control box is inspected then sealed with a yellow Seal If this seal is broken on delivery inform the suppliers immediately The seal should only be broken for the initial mains power connection AdAccessing the Electrical Diagrams Warning The Electrical Diagrams for your machine are held in a folder fixed inside the electrical control box Never attempt to access these diagrams with the mains power switched ON Note that hazardous voltages can still exist immediately after switching the isolator to the OFF position Always wait at least 5 minutes before entering the electrical control box Isolator Position 0 Power OFF Isolator Position I Power ON The electrical diagrams are held in a folder
57. nglish Any comments regarding this manual should be referred to the following e mail address customerservices denford co uk Novaturn CNC Lathe User s Manual 1 Introducing your Novaturn CNC lathe Novaturn CNC Lathe User s Manual Congratulations on your purchase of a Novaturn series CNC lathe In this manual you will learn how to setup and use the features fitted to your Novaturn The Novaturn is a compact two axis CNC training machine Ithas been designed with you in mind making the processes involved both safe and easy to use Main Features Designed specifically for Education and Training Manufactured to Industrial Standards Capable of cutting resistant materials such as wax plastics acrylics copper aluminium and steel Links to various CAD CAM software packages Totally enclosed high visibility interlocked guard CE approved for safety Programming via International Standards Organisation format Optional 8 station programmable turret available Option of including in Flexible Manufacturing Cells and Computer Integrated Manufacturing systems Section 1 Introduction 7 1 What is CNC 8 Introduction Section 1 CNC Computer Numerical Control is the general term used for a system which controls the functions of a machine using coded instructions processed by a computer CNC machines are a very important part of the modern manufacturing process Indeed many of the
58. o its closed position holding the toolholder in position Novaturn CNC Lathe User s Manual Section 5 P reparing Tooling Hardware 39 5 Quickchange Manual Tooling System A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Toolholder Height Adjustment SENDES nx 1 Using a 4mm allen hex key LS release the lockbolt on the toolholder height adjustment ane Rei screw shown right When A height directly viewing the top of the bolt adjustment head turn counter clockwise to screw by loosen If you intend to raise the ph height of the toolholder you must unscrew the bolt further to allow toolholder movement 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 Check toolholder height adjustment screw is still held Loosen double flanged locknut by turning CCW continued 40 Preparing Tooling Hardware Section 5 Novaturn CNC Lathe User s Manual 5 Quickchange Manual Tooling System Toolholder Height Adjustment continued SENGEN IX 3 Holding the knurled collar turn the height adjustment screw to raise or lower the toolholder When directly viewin
59. ocated on the lower right front panel of the machine 10 Safety Features Section 2 Novaturn CNC Lathe User s Manual 2 Safety Features Emergency Stop Button Location of emergency stop button mounted on the righthand side of the machine lower front panel To active an emergency stop press the button fully in until it clicks A circular red emergency stop button is mounted on the righthand side of the Novaturn CNC machine lower front panel When pressed ithas the effect of stopping all axes toolchanger and spindle movements immediately The interlock switch will also close When the safety guard door is in its closed position this will prevent access to the working area of the machine To 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 counterclockwise until it springs back out Novaturn CNC Lathe User s Manual Section 2 Safety Features 11 2 Safety Features Interlock Guard Switch Location of interlock guard switch mounted on the lefthand side panel of the machine casing An interlock safety switch is fitted to the guard door on the lefthand side panel of the machine casing when viewed from the front The switch must be manually released to enter
60. odels The cross slide sensor defining the X axis datum is attached to the bottom right corner of the saddle when viewed from the front of the machine Check the condition of the sensor then clean any dust and debris away from the sensor using a soft bristled brush ra g Slide Sensor The cross slide sensor trigger is attached to the middle of the right side of the cross slide when viewed from the front of the machine Check the condition of the trigger then clean any dust and debris away from the trigger using a soft bristled brush Novaturn CNC Lathe User s Manual Section 7 Maintenance 55 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 slides on your Novaturn On the Z axis the gib strip is tapered along its length The gib strip is driven further along the top Z slideway to decrease the amount of free play in the axis using a locking and adjusting screw arrangement On the X axis the gib Strip is equal in section along its length and fitted to the right X Slideway Free play is decreased in the X axis using five combination locking nuts and adjustment grubscrews During the day to day use of your Novaturn 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 annu
61. older STENENE ax 1 Using a 4mm allen hex Diameter turning key unscrew the four external tools must be A lockbolts on the Mitea with he icuting dge faci i Never open the safety toolholder When edge tacing up guard door and enter ur the working area when directly viewing the top the spindle or machine of the bolt heads turn axes are moving counter clockwise to loosen or clockwise to ighten them Four SO ag ohte lockbolts A Caution If the cutting tool has been recently used it i may still be HOT 2 Place the cutting tool into the toolholder in the correct orientation Diameter turning external tools must be fitted with the cutting edge facing up 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 Slot for cutting tool Novaturn CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 37 5 Quickchange Manual Tooling System Toolpost Body Angle Adjustment STEDSE Tx To adjust the angle of the toolpost bd body use a 10mm spanner to A release the locknut The locknut is Never open the safety located on the central toolpost mounting stud shown circled right guard door and enter the working area when i Bing the spindle or machine When directly viewing the top of the axes are moving
62. op slideway View Died Automatic Indexing Toolpost Model shown PN Location Jax All Models Automatic Toolpost shown Look behind the top left side of the saddle Locking Screw W y continued Novaturn CNC Lathe User s Manual Section 7 Maintenance 57 7 Z Axis Gib Strip Adjustment 2 Using a flat bladed screwdriver adjust any 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 side of the saddle 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 top slideway Automatic Indexing Toolpost Model shown Location Ja X All Models Automatic Toolpost shown Look behind the top right side of the saddle v 3 Re tighten the gib strip locking screw Turn in a clockwise direction to tighten the screw 4 Traverse the saddle left and right along the bedway to ensure that the Z axis movementis smooth 5 Continue points 1 to 4 until all slack has been eliminated from the Z 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 bac
63. operations from being graphically simulated on screen Novaturn CNC Lathe User s Manual EC Declaration of Conformity The responsible person Mr 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 Novaturn Series CNC Lathe Serial Number please refer to warranty card and or machine casing conforms to the following directives The Machinery Directive 89 392 EEC as amended by Directive 91 368 EEC and Directive 93 44 EEC and CE Marking Directive 93 68 EEC and the following standards where applicable and complies with the relevant health and safety requirements ceccscscesesecseeeeceeesissessesstesneeeenieeiseeseitseneeneense Signature Position within company Senior Design Engineer Signed at Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Back of the Novaturn EC Declaration of Conformity Certificate 78 Appendix Section 10 Novaturn CNC Lathe User s Manual Novaturn Series Noise Level Test Results Spindle RPM Test Report No NL ST5 l Machinery Manufacturer Denford Limited Machinery Type Model Novaturn Series Test Specification in accordance with BS 4813 1972 Instrumentation used Cirrus CRL 2 35A Test Site Denford Limited Demonstration Room General Machine Test Conditions Chuck on size Stand
64. p menu click Make Active then click OK You must restart the VR CNC Turning software Novaturn CNC Lathe User s Manual VR CNC Turning Software Communications Troubleshooting 1 Your computer communicates with your Novaturn using an RS232 serial cable Check the RS232 cable is plugged into a valid COM port on the computer Note that COM ports are sometimes labelled as serial ports Identify whether itis COM1 or COM2 The opposite end of this cable is secured to the RS 232 port on the electrical control box 2 Check all mains power connections between the Novaturn and the electrical control box are correctly fitted and secure Power up the Novaturn using the isolator switch fitted on the electrical control box before starting the VR CNC Turning software 3 Check the COM port being used on your computer matches the COM port number specified in the Machine Properties window From the main menubar at the top of the screen click Setup Setup Machine Parameters You may be required to enter a password The default password is denny Type the password and click OK The Machine Properties window will open with the Novaturn set as the active machine and its listing expanded Click the Communications property title Change the COM Port setting to match the number of the COM port being used by your CNC machine RS 232 cable Note that the hardware resources IRQ etc are those specified in the Windows Con
65. positioning the machine in the room space will be required for opening of the electrical control box door We recommend you leave a gap of atleast 1000mm A 300mm clearance must also be left at the rear of your Novaturn This space will be occupied by the safety guard when in its fully opened position Sufficient room should also be provided for effective maintenance to be carried out around the machine itself The Novaturn 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 Ideally the user will operate the machine when standing at its front with a clear view of both the machine table through the transparent guard window and the computer being used as the controller unit which should be angled towards the user as shown in the diagram Raw Computer desk monitor keyboard and mouse angled towards Operator Denford Novaturn CNC Lathe DataPanel T X Dimensional Data Machine width 820mm 32 3 8 Machine height 560mm 22 Machine depth 690mm 27 1 4 Electrical Control Box Electrical control box under table width 480mm 19 Electrical control box r i height 640mm 25 1 4 Electrical Electrical control box Control Box Machine depth 230mm 9 1 8 door easy i Operator access
66. 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 Novaturn CNC lathe a Safety Precautions Wear clothing suitable for machine operation and follow the safe working procedures in place at your establishment Do not place any objects so that they interfere with the guards or the operation of the machine Never try to clean the machine if any part of 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 front of the electrical contro box 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 entering the electrical control box 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 l
67. r 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 MD Eraser rear Manual Data Input A method used for manually inserting data into the control system ie Desktop Tutor qwerty keyboard etc ODAL ainireti Modal codes entered into the controller by a CNC program are retained until changed by a code from the same modal group or cancelled NG nere Numerical control OFFSET whitewater 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 sees Used as a zero reference point in a CNC file All machining co ordinates originate from this point within the program Commonly set at the centreline on the X axis and the face end of the billet on the Z axis AE TEETE ETNE Personal computer PROFILE aiii The outside shape of an object The term tool profile is used to describe the shapes of the different cutting tool tips PROGRAMS Sinoti A systematic arrangements of instructions or information to suit a piece of equipment PROGRAMMABLE TOOLPOST Area whe
68. re cutting tools are held also referred to as an automatic indexing toolpost programmable turret 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 3 trains The fixture that moves along the bedways Z axis onto which the cross slide is mounted SPINDLE SPEED The rate of rotation velocity of the chuck measured in RPM Novaturn CNC Lathe User s Manual Section 11 Glossary 83 11 Glossary SOFTWARE wesc STATION rare TOOLPOST wwetiiewansitcnnass TRAVERSE vices TUR REM serende 84 Glossary Section 11 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 indexing 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 w
69. rically the protective coatings must be removed to prepare the machine for running The protective coatings applied to the slideways and bright surfaces can be removed using a kerosene based solvent The coatings must be removed from the slideways before any attempt to move them is made Once these protective coatings have been removed all untreated surfaces should be coated with a light covering of machine oil e g BP CS 68 A Warning Only use kerosene based solvents in accordance with the solvent manufacturers instructions and safety recommendations Ensure that no naked flames are present The protective plastic sheeting on the guard windows should be removed and the glass and perspex cleaned with an anti static cleaner 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 39 a To Parallel Port Security Dongle if required PC Terminology The COM ports on your PC may be labelled as Serial ports Most COM ports have a 9 pin D MALE connector though some older computers may be fitted with 25 pin D MALE connectors Desktop Tutor when The Parallel port on your PC dered ts to may be labelled as the Printer ordered connec port The printer port has a 25 the PC port labelled pin FEMALE connector COM 1 26 CNC Machine Instal
70. rigger gently pull the flexible bedway cover away from the top slideway Clean any dust and debris away from the trigger using a soft bristled brush Location EHX All Models Automatic Toolpost shown Look behind the left side of the top slideway Trigger Top Slideway Y _ __ Novaturn CNC Lathe User s Manual Section 7 Maintenance 53 7 Cleaning amp Checking the X Axis Slide Sensor Location CH x Automatic Indexing Toolpost Model Look on the top right side of the saddle and the middle right side of the cross slide 54 Maintenance Section 7 Automatic Indexing Toolpost Models The cross slide sensor defining the X axis datum is attached to the top right corner of the saddle when viewed from the front of the machine Check the condition of the sensor then clean any dust and debris away from the sensor using a soft bristled brush BY rer The cross slide sensor trigger is attached to the middle of the right side of the cross slide when viewed from the front of the machine Check the condition of the trigger then clean any dust and debris away from the trigger using a soft bristled brush Novaturn CNC Lathe User s Manual 7 Cleaning amp Checking the X Axis Slide Sensor Location Jax Quickchange Manual Toolpost Model Look on the bottom right side of the saddle and the middle right side of the cross slide Quickchange Manual Toolpost M
71. s J argon Buster CNC refers to Computer Numerical Control the automatic system used to control a machine tool A Part Program is a list of coded instructions which describes how the designed part or component will be manufactured The part program is also referred to as the CNC file program or G and M code program A G and M code is a series of letters and numbers that make up the language used by CNC machinery Novaturn CNC Lathe User s Manual 1 Before Beginning to Setup The standard equipment listed here is correct at the time of printing September 2001 butis liable to change through continuous development of our products Please refer to your invoice for the definitive list of standard equipment shipped with your machine Short 9 25 pin serial link adaptor cables can be used to convert the RS232 connectors according to the type of COM port fitted to your computer Novaturn CNC Lathe User s Manual Before beginning to setup your Novaturn 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 Novaturn CNC lathe Novaturn CNC lathe incl separate electrical control box Note that the precise specification of your Novaturn will depend on any options s
72. sually 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 Operation to send the axes of the CNC lathe to their extreme limits of movement Defines the machine datum also called the home position Novaturn CNC Lathe User s Manual 11 Glossary INCREMENTAL wees Incremental programming uses co ordinate movements that are related from the previous programmed position Signs are used to indicate the direction of movement INDEXING TOOLPOST See programmable turret NPU Tiirinen The transfer of external information data into a control system INTERFACE wees The medium through which the control computer directs the machine tool M CODE noniine 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 fo
73. sume the COM port being used is COM1 The GO file can be opened using Windows Notepad Find the line ending with the word MACHINE If the RS 232 cable is plugged into COM1 the line should read 3F8 4 MACHINE Ifthe RS232 cable is plugged into COM2 the line Should read 2F8 3 MACHINE Change the line to read the correct port number being used then save the file 4 Remove the HIMEM SYS line from the CONFIG SYS file Often times environmental factors will interfere with proper communication 5 Check the LED display status on your Novaturn control card The Denstep Motion Control Board The control card is the main electrical board in the Novaturn 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 continued Novaturn CNC Lathe User s Manual Section 9 Technical Support 67 9 DOS CNC Turning Software Communications Troubleshooting continued 6 Check the COM portis 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 function
74. t body Right Turn the lower grubscrew to adjust the height of the toolpost ONLY when the turret is moving 5 Using a 5mm spanner retighten the locknut on the lower grubscrew mounted on the toolpost side facing the front of the machine When directly viewing the face of a locknut turn the Spanner in an clockwise direction to tighten 6 Using a 2 5mm allen key retighten the upper grubscrew mounted on the toolpost side facing the rear of the machine until you feel the grubscrew make contact with the inner plate When directly viewing the face of a grubscrew turn the allen key in an clockwise direction to tighten 7 Finally using a 5mm spanner retighten the locknut on the upper grubscrew mounted on the toolpost side facing the rear of the machine When directly viewing the face of a locknut turn the Spanner in an clockwise direction to tighten Novaturn CNC Lathe User s Manual Section 5 Preparing Tooling Hardware 45 6 Manual Chuck Operation Introduction The manual 3 jaw self centring chuck is supplied as standard with the Novaturn 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 and one set of internal chuck jaws Three jaws are provided in each set Bac
75. ter with 5mm 0 2 pitch Novaturn CNC Lathe User s Manual Section 10 Appendix 69 10 Specification of Novaturn CNC Lathe 70 Appendix Section 10 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 Machine width 820mm 32 3 8 Machine height 560mm 22 Machine depth 690mm 27 1 4 Electrical control box width 480mm 19 Electrical control box height 640mm 25 1 4 Electrical control box depth 230mm 9 1 8 Length of cable between machine and electrical contro box 1500mm 59 Height Height gt N jet VV N t Width S Width S Weights Machine weight 88 KG 195 Ib Electrical control box weight 35 KG 77 Ib Electrical Details Mains supply required 50 60 Hz 1 Phase 220 240 Volts 10 AMP Spindle motor 1 5 HP Axis stepper motors 200 steps rev Novaturn CNC Lathe User s Manual 10 What is a Part Program 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 program includes all the geometrical and technological data to perform the required machine functions and movements to manufacture the part T
76. the working area when the 24 volt circuit has failed and the door is clamped electrically Note For manual interlock release the power supply must be switched off 1 Remove security screw A B or C whichever is easiest to reach using the supplied Torx T 20 adapter 2 Insert a 2 5mm diameter tool such as a small flat screwdriver into the hole until it pushes the manual release lever 3 Whilst holding the tool against this manual release lever open the guard 4 Remove the tool from the hole and replace the security screw 2 2 5mm diameter 3 4 S 2 Ow T 20 12 Safety Features Section 2 Novaturn CNC Lathe User s Manual 3 Unpacking amp Lifting your Novaturn Cut the top of the delivery box open and remove the styrofoam packaging carefully To obtain better access to the Novaturn and the power supply box remove all the sides from the delivery box leaving the Novaturn standing on its wooden delivery pallet Lift the power supply control box from the packaging If possible lift the power supply box using a porters trolley Lift the Novaturn from the packaging The Novaturn can be directly lifted by hand using the lifting points indicated on the diagram right A minimum of two persons should be used to lift the machine positioned one per end Ideally use four persons to lift the machine Always use sensible lifting precautions in accordance with Health and Safety Regulations in your establishment
77. tic Chuck DENFORD el Saddle Bedway Cross Slide Z axis X axis Novaturn CNC Lathe User s Manual Section 4 CNC Machine Operation 29 4 Novaturn Variations Axis Definitions Axis Definitions for a Standard Novaturn with a Manual Toolpost 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 30 CNC Machine Operation Section 4 Novaturn CNC Lathe User s Manual 4 Novaturn Variations Axis Definitions Axis Definitions for a Novaturn with an Automatic Indexing Toolpost Z Axis The centre of the Z axis runs along a line between the spindle and tailstock or in other words the centrel
78. tings 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 portis not seen by any external devices 6 When all else fails a Thoroughly check the condition of the RS232 cable If the cable is bad communication will not occur b Try another computer c Check for support on the Denford website www denford com 66 Technical Support Section 9 Novaturn CNC Lathe User s Manual 9 DOS CNC Turning Software Communications Troubleshooting DOS CNC Turning Software Communications Troubleshooting 1 Your computer communicates with your Novaturn using an RS232 serial cable Check the RS232 cable is plugged into a valid COM port on the computer Note that COM ports are sometimes labelled as serial ports Identify whether itis COM1 or COM2 The opposite end of this cable is secured to the RS 232 port on the electrical control box 2 Check all mains power connections between the Novaturn and the electrical control box are correctly fitted and secure Power up the Novaturn using the isolator switch fitted on the electrical control box before starting the DOS CNC Turning software 3 Check the COM port being used on your computer matches the COM port number specified in the FLSTEP GO file of the DOS CNC Turning software If you are unsure as
79. tor and R egulator 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 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 required will depend on the type and condition of the air compressor being used Novaturn CNC Lathe User s Manual Section 3 CNC Machine Installation 19 3 Connecting the Pneumatic Control Cable The optional pneumatic guard door and vice are controlled using solenoids mounted in the small pneumatic control box attached to the rear of the machine Signals are fed from the electrical control box via a pneumatic equipment control cable The Pneumatic Equipment Control Cable when fitted The pneumatic equ
80. trol Panel Setup Parameters Read Write Options 5 Lathes Ew Cyclone Material Home Feed Spindle Communications Baud rate Com Port Stop Bits C PROGRAM FILES DENFI Polling Delay 0 p foo fur Tool Change Communications Input Output Device Miscellaneous M Code TimeOut M3 M4 M5 M10 M11 M38 T Code TimeOut 60000 l 1 l Machine Capability Mint File Section 9 Technical Support 65 9 VR CNC Turning Software Communications Troubleshooting 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 4 Check the LED display status on your Novaturn control card The Denstep Motion Control Board The control card is the main electrical board in the Novaturn 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 5 Check the COM portis functioning correctly Consult your IT person or Computer Support Centre for help with these issues Check the COM port set

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