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Safety Section - 1.5MB - Flint Machine Tools, Inc.

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1. 31 4 3 1 MAXIMUM TOOL DIAMETER 2 0 c selle 31 4 3 2 MAXIMUM RPM 32 44 COMBINEDSHAPES 33 HOINDEX lues eee c GK c ecc ecmc ec c6 34 5 1 ALPHABETICAL ORDER 34 5 2 NUMERICAL ORDER OF PARTNO 36 lil TABLE OF CONTENTS MAN O113R1 rana MACHINING CENTERS i 1 0 SAFETY WARNINGS 1 KEEP DOORS CLOSED WHILE MACHINING 2 DO NOT DISCONNECT THE FRONT DOOR SAFETY SWITCHES 3 The front door is equipped with an interlock to prevent automatic of the VMC from when the door is open Under no circumstances should the operator disable or remove the interlocks If power is lost to the VMC the spindle may coast for 30 seconds or more Under no circumstances should the operator open the door before the spindle stops rotating completely 4 READ AND UNDERSTAND THE OPERATOR s MANUAL before using the VMC 5 WARNING WEAR ANSI or CE APPROVED SAFETY GLASSES AT ALL TIMES when operating machine Everyday glasses are not designed for protection Only ANSI or CE approved safety glasses have impact resis tant lenses 6 WEAR PROPER APPAREL Do not wear loose clothing gloves neckties rings bracelets or other jewelry that might get caught in moving parts or areas of potential electric shock Non slip foot
2. Sette HT TUE Vly n pals SEY 3 cag Dane meee i nq rura T tol aln 2x dl m ws q DRESS TETTE Pv Hp pressi d jar ETE ly via aie arb cds prat 15 mineng pire Sb way Una pair a doa pi anr Floren ar ibas mach es rge ee anpupzter inge eben coa enin uds tp eni itn D UE il sime ru ness rr ca perra eel gea cn zz bo bos Spas THAT mobs Get gatets ana MP SUL Sb pa Een CET HO Earth pts Has ped s d Bek cl pr Pape gm DEN SI rT catta rtr ia lp e i ai T TER cd hoagie ncurze 37 cecnmperzeeoc i pa Da oa PER ee Pa i Ly a uthaczez och pesa H UT resp tao 1 Sin Safety Instruction 1 MARCH 2005 3 0 US SAFETY LABELS 8 of 37 rana MACHINING CENTERS i SAFETY INSTRUCTIONS A DANGER AII milling machines contain hazards from rotating cutting tools belts and pulleys high voltage electricity noise and campresser air Rotating cutting tools can sev
3. INSTRUCTIONS os vac eq canbe RERO Pad RSV CREE RE 8 3 1 2 ROTATING CUTTING TOOLS o ego races 10 Seo MOVING PARTS oc as a EUR ACRI EUER IUD dr 11 3 1 4 HAZARDOUS VOLTAGES dcos d RC RR E d 11 319 ROTATINGGUTTING TOOLS 12 3 1 6 SPINDLE HEAD IS NOT COUNTERBALANCED 12 VER MGA PTT 13 3 1 8 AUGER AND GONVEY OUR 44248505044 4055545 d dd eee PR sees 14 31 9 PALLET DOOR 204 2000 opens beg 14 WARNING kiss s Ya as qaa pu k send eee sewer aa QW as 15 3 2 1 SHARP EDGES ON CUTTING TOOLS 15 3 2 2 HAZARDOUS VOLTAGES a RR RR n 15 3 2 3 READ OPERATOR S MANUAL mmn 16 3 2 4 EYE AND EAR PROTECTION sud imm aded dosage SOR oer OR cti o ns 16 VERMCAL ANS m 17 3260 COMPRESSED AIR uu aa saan ru 16 CAUNION ao a qa AG Zaa 19 ou dcum P P TT 19 3 4 OIHERWARNINGS RR RR 3 20 3 4 1 HAZARDOUS VOLTAGES RO EUR op Ra eed bee ES 20 3 4 2 SERVICE BY AUTHO
4. 4 0 CE SAFETY LABELS MAN OII3R1 4 1 11 FROM ABOVE Impact from Above Machinery moves vertically Do not stand or work in area below moving machinery Serious injury can result This labelindicates a hazard posed by the vertical axis of the HMC 4 1 12 CRUSH FROM ABOVE Crush from Above Machinery moves vertically Do not work in area below moving machinery Crush hazard can cause serious injury or death This label indicates a hazard posed by the vertical axis of the HMC MARCH 2005 4 0 CESAFETY LABELS 28 of 37 rana MACHINING CENTERS i 42 CIRCLES CIRCLE indicates mandatory actions or prohibitions 4 2 1 NO OPEN OR REMOVED GUARDS No Open or Removed Guards Do not operate the machine with the open doors or removed guards Moving machinery and rotating cutters can seriously injure or kill 4 2 2 WEAR EYE PRO TECTION Eye Protection Flying objects can injure Always wear safety glasses when operating the machine 29 of 37 4 0 CE SAFETY LABELS MAN OII3R1 4 2 3 WEAR EAR PRO TECTION Ear Protection Noise from the machine can cause the problems with hearing Always wear ear protection when operating the machine 4 2 4 READ OPERATOR S MANUAL Reading Operator s Manual Read and understand the Operator s Manual before operating the machine The machine must be operated only by qualified personnel MARCH 2005 4 0 CE SAF
5. TABLE AND HEAD SUPPLY GREASE UNTIL IT COMES OUT FROM THE BALL SLIDE OR BALL NUT AREA MOVE SADDLE TABLE AND HEAD A FEW TIMES THROUGH FULL TRAVEL TO SPREAD THE GREASE THROUGHOUT THE SYSTEM WIPE OFF EXCESS GREASE THAT ACCUMULATES AT THE END OF THE RAILS AND BALL SCREW SHAFTS REPLACE X Y AND Z WAY COVERS LBL 0486A Maintenance Label 2 21 of 37 3 0 US SAFETY LABELS MAN 0113R1I FADAL MAINTENANCE AND LUBRICATION DAILY 1 CHECK AIR PRESSURE 80 90 5 2 CHECK AIR FILTER DRAIN AND CLEAN WATER SEPARATOR 3 REMOVE CHIP BUILD UP FROM GUARDS AND WAY COVERS 4 CLEAN MACHINE WORK AREA EVERY 6 MONTHS 1 LUBE THE RAILS AND BALL SCREWS WIPE OFF OLD GREASE AND ACCUMULATED FOREIGN OBJECTS B USE MOBIL TEMP SHC 32 GREASE C GREASE EVERY LUBRICATION PORT THE SADDLE TABLE AND HEAD SUPPLY GREASE UNTIL IT COMES OUT FROM THE BALL SIDE SLIDE OR BALL NUT AREA 0 MOVE SADDLE TABLE AND HEAD A FEW TIMES THROUGH FULL TRAVEL TO SPREAD THE GREASE THROUGHOUT THE SYSTEM WIPE OFF EXCESS GREASE THAT ACCUMULATES AT THE END OF THE RAILS AND BALL SCREW SHAFTS LBL 0518A Maintenance Label 3 Daily and weekly maintenance is essential to the continued performance and safety of the machine Read and follow the maintenance label on your machine 3 4 4 GROUNDING REQUIREMENTS FADAL VMC GROUNDING REQUIREMENTS FADAL VMC machines shall be grounded by any of the methods listed in ar
6. compressed air systems 4 1 6 COMPRESSED AIR SKIN PUNCTURE Compressed Air Compressed air can seriously injure Do not perform maintenance on pressurized systems Disconnect air source before performing maintenance Always wear eye protection and gloves when performing maintenance on compressed air systems 25 of 37 4 0 CE SAFETY LABELS MAN OII3R1 4 1 7 AUGER AND CON VEYOR LEG BODY ENTAGLEMENT Auger and Conveyor The chip auger can seriously injure or kill Keep body parts out of the auger system at all times The chip conveyor is slightly less dangerous but still can inflict serious injuries Turn off the machine and lockout the power before doing maintenance inside the enclosure Do not use hands to unblock chips 4 1 8 MOVING PARTS HAND CRUSH Moving Parts The automatic pallet changer door can crush hands Stay clear when the door is closing MARCH 2005 4 0 CE SAFETY LABELS 26 of 37 rana MACHINING CENTERS 4 1 9 FORCE FROM SIDE HAND CRUSH Force from the Side The automatic pallet changer can crush hands or fingers Do not hands or other parts of the body in the path of a moving pallet or near the pallet rails 4 1 10 DRAWING IN BODY INJURY Drawing In The machinery behind the guard so marked can pull the operator in causing severe injury Do not remove or reach under the guard Do not do any service or maintenance unless the machine is off 27 of 37
7. no control over the applications the operator may use the VMC for and is not responsible for injuries or equipment damage Read and understand the Operator s Manual The safe use and disposal of all hazardous materials processed or used by the VMC is the responsibility of the user All safety warnings and procedures must be followed It is the sole responsibility of the user to comply with all local state national Federal international and environmental safety laws and regulations applicable to the VMC and its use This manual contains information that will assist qualified operators and maintenance personnel Unqualified operators should never attempt to operate or perform maintenance on the VMC Pictorials are used within warnings to rapidly communicate a hazard to the reader The pictorials and their meaning are given in this section The most serious potential hazards associated with the VMC are rotating cutting tools electric shock Sharp edges on cutting tools noise compressed air Rotating cutting tools used by the VMC create potential hazards of entanglement A cutting hazard is also possible if the operator comes into contact with rotating cutting tools The Poly carbonate shield is equipped with an interlock to prevent the VMC from operating when the shield is opened 2 0 GENERAL 4 of 37 rana MACHINING CENTERS i Under no circumstances should operators disable or remove the interlocks If the inte
8. 8 14 LBL 0163 16 LBL 0187 22 LBL 0234 14 LBL 0235 12 LBL 0263 20 LBL 0430 25 LBL 0431 23 0432 23 LBL 0433 26 LBL 0434 23 LBL 0435 24 LBL 0436 26 LBL 0437 31 LBL 0438 31 LBL 0439 29 LBL 0440 30 LBL 0441 29 LBL 0442 30 LBL 0443 27 LBL 0460 25 LBL 0461 20 LBL 0466 31 LBL 0468 27 LBL 0474 12 LBL 0486 21 LBL 0509 17 LBL 0510 13 LBL 0516 9 C C C C Q OOOOOOOOOQOOOOOOGOGO MARCH 2005 5 0 INDEX 36 of 37 rana MACHINING CENTERS i LBL_0517 17 LBL 0518 22 LBL 0531 28 CE LBL 0532 28 CE LBL 0558 14 CE 37 of 37 5 0 INDEX MAN 01135R1
9. Due to danger of slips or falls on a wet or oily surface table and enclosure floor should be clean and dry before using them for maintenance access 39 Contact FADAL or your local distributor for all repair parts and service 40 USE PROPER SAFETY GLOVES WHEN HANDLING SHARP OR JAGGED EDGES Do not wear gloves around rotating machinery 41 The Poly carbonate viewing panels are an integral part of safety enclosure for the VMC They must be inspected at least monthly for any signs of reduced effectiveness such as cracking or crazing and replaced immedi ately if such signs or other indications of reduced effectiveness are noticed Furthermore tests have indicated that coolants can reduce the effectiveness of the panels over a period of time therefore the panels should be replaced regardless of condition at least every two years 3 of 37 1 0 SAFETY WARNINGS MAN 0113R1 2 1 WARNINGS AND CAUTIONS 2 2 PICTORIALS 2 3 POTENTIAL HAZ ARDS TO PERSONNEL 2 3 1 ROTATING CUT TING TOOLS MARCH 2005 2 0 GENERAL A carelessly or improperly operated VMC can cause serious injury or death as well as damage or destruction of equipment The emergency and safety procedures in this manual are to help users operate the VMC in a safe manner The warnings in this manual follow accepted industry safety practices Tasks involving toxic materials must be reviewed and approved by an industrial hygienist or safety engineer Fadal has
10. ETY LABELS 30 of 37 rana MACHINING CENTERS i 4 2 5 LOCKOUT ELEC TRICAL POWER Lockout Electrical Power Whenever servicing the machine turn the machine off and lockout the power Turn off the machine and lockout the power before working in this cabinet 4 3 INFORMATION 4 3 1 MAXIMUM TOOL DIAMETER 76 mm gt lt 100mm LBL 0136 LBL 0466 Maximum Tool Driver The maximum allowable diameter of tools is dependent on the tool changer installed Do not use tools larger than the marked maximum diameter 31 of 37 4 0 CE SAFETY LABELS MAN OII3R1 4 3 2 RPM 10000 min LBL 0137 LBL 0139 Maximum RPM The maximum RPM of the spindle of the spindle is stated on by a label on the spindle head MARCH 2005 4 0 CE SAFETY LABELS 32 of 37 rana MACHINING CENTERS i 4 4 COMBINED Multiple shapes may be combined to express a more complex message A SHAPES Warns of moving pulleys or belt and requires power to be off and locked out before service A Warns of sharp rotating cutters and prohibits opening the door while is in motion A Warns of noise and flying objects and requires eye and ear protection 33 of 37 4 0 CE SAFETY LABELS MAN 0113R 1 EE 5 1 ALPHABETICAL ORDER OF LABELS MARCH 2005 5 0 INDEX A Auger and Conveyor 14 26 CE B Belt or Chain Driver 23 CE C Caution 19 Circl
11. NG DANGER Hazardous voltages in this enclosure can kill Servicing hy qualified personnel only Lockout before Servicing yes Hazardous Voltages The electrical cabinet contains voltages that can be lethal The machine should only be serviced by qualified personnel and power should be off and locked out before service 11 of 37 3 0 US SAFETY LABELS MAN 0113R1 3 1 5 ROTATING CUT TING TOOLS DO NOT REMOVE OR MODIFY COM PONENTS 3 1 6 SPINDLE HEAD IS NOT COUNTERBALANCED MARCH 2005 SAFEIY SECTION 4 DANGER Cutting tools can seriously injure or kill Do not remove or modify com ponents in this cabinet LBL 0235 Rotating Cutting Tools The components and controls in the electrical cabinets are specially designed or selected for their function Any change of the components can result in a loss of safety Do not change or modify any components Service should be performed by factory trained personnel only DANGER Spindle head is counter balanced Support or pin spindle head before working po under spindle head or loosening Z axis coupler or motor Not Counterbalanced Spindle Head Many of the machine models use a brake built into the vertical axis servo motor instead of a counterweight to hold the vertical axis against the power of gravity when the machine is off When working under the spindle head or when working on the servo motor or couple
12. RIZED PERSONNEL ONLY 20 3 4 3 MAINTENANCE LABELS a cesses e orc dh dese gH Fae beds ioa 21 3 4 4 GROUNDING REQUIREMENTS ec eee sk d 22 MARCH 2005 TABLE OF CONTENTS ii rana MACHINING CENTERS i 4 0 CE SAFETY LABELS 23 4 4 TRIANGLES ooa oa a 23 4 1 1 ROTATING CUTTING TOOLS 23 4 1 2 BELT CHAIN DRIVE oooi aoa a 23 4 1 3 HAZARDOUS VOLTAGES ouuu aaa aaa 24 4 14 EYE AND EAR PROTECTION ouaaa aa aaa lll llli 24 4 1 5 EYE PROTECTION 25 4 1 6 COMPRESSED AIR oaia aaa aa a a 25 4 1 7 AUGER CONVEYOUR 26 4 1 8 MOVING PARTS aiaia eel es es leal 26 4 1 9 FORCE FROM SIDE 27 4 1 10 DRAWING IN 27 44 11 IMPACT FROM ABOVE 28 4 1 12 CRUSH FROM ABOVE oaaao aaa 28 29 4 2 1 REMOVED GUARDS celsa lean 29 422 WEAR EYE leases 29 4 2 3 WEAR EAR PROTECTION 30 4 2 4 30 4 2 5 LOCKOUT ELECTRICAL POWER 31 A3INFORMATION
13. V OR MOBIL VACTRA 2 ONLY CHECK WAY LUBE SYSTEM FOR ADEQUATE FLOW TO ALL WAYS WITH THE TOOL IN SPINDLE BLOW CHIPS FROM AROUND AND SLIDE NEVER BLOW CHIPS FROM THE AREAS DURING AUTOMATIC TOOL CHANGE OR WITHOUT A TOOL IN THE SPINDLE REMOVE HEAVY CHIP BUILD UP FROM GUARDS AND WAY COVERS WASH AND MACHINE WORK AREA WEEKLY CHECK SPINDLE COOLER PUMP AND REFRIGERATION UNIT FOR PROPER OPERATION CLEAN A T C SLIDE ACTIVATE OPTIONAL THRU TOOL COOLANT SYSTEM FOR 2 3 MINUTES LUBRICATE Y AXIS TELESCOPING BALLSCREW COVER WITH WAY LUBE INSPECT ALL COOLING FANS CLEAN IF NECESSARY CLEAN REFRIGERANT PUMP FILTER YEARLY 1 SERVICE WAY LUBE FILTER A REPLACE BRONZE ELEMENT IN EXTERNAL FILTER Maintenance Label FADAL EMC MAINTENANCE AND LUBRICATION DAILY 1 CHECK AIR PRESSURE 80 90 PS 2 CHECK AIR FILTER DRAIN AND CLEAN WATER SEPARATOR WITH TOOL IN SPINDLE BLOW CHIPS FROM AROUND AND SLIDE NEVER BLOW CHIPS FROM AROUND THESE AREAS DURING AUTOMATIC TOOL CHANGE OR WITHOUT A TOOL IN THE SPINDLE 4 REMOVE HEAVY CHIP BUILD UP FROM GUARDS AND WAY COVERS 5 CLEAN A T C AND MACHINE WORK AREA WEEKLY 1 INSPECT COOLING FANS CLEAN FAN SCREENS IF NECESSARY EVERY 6 MONTHS 1 LUBE THE RAILS AND BALL SCREWS REMOVE X Y AND Z WAY COVERS WIPE OFF OLD GREASE AND ACCUMULATED FOREIGN OBJECTS USE MOBILTEMP SHC 32 GREASE GREASE EVERY LUBRICATION PORT AT THE SADDLE
14. d clean for best performance and reduction of the risk of injury Follow instructions for lubri cation and for changing accessories 20 DO NOT FORCE TOOL Tools are designed to perform properly and safely at proper rates Keep tools sharp 21 USE THE CORRECT TOOL Do not attempt to use tools or attachments to perform a job for which they were not designed 22 DO NOT OVERREACH Keep proper footing and balance at all times Use a steady object for support when reaching over the machine 23 ALWAYS DEBUG A NEW PROGRAM before running it in the AUTO mode See DEBUG PROGRAM in the User s Manual 24 DO NOT OPERATE THE MACHINE IN AN UNSAFE ENVIRONMENT Do not use the machine in damp or wet locations or expose to rain Keep the work area well lighted Do not turn the VMC on or try to operate it if there are explosive or flammable gases present 25 The machine is not intended for use with flammable or harmful substances 26 Take appropriate additional safety precautions and measures when work ing with magnesium wood or other combustible materials 2 Dust removal equipment is needed when working with dust producing materials or procedures 28 REDUCE THE RISK OF UNINTENTIONAL STARTING Power off the machine at the main disconnect switch and use the proper lockout tagout procedures while working within the chip enclosure 29 NEVER WORK ON LIVE ELECTRICAL CIRCUITS Power off the machine at the main disconnect switch and lock out
15. eavy Depending on the weight two men may be required For heavier heads an overhead crane or other lifting device is needed Do not over exert 19 of 37 3 0 US SAFETY LABELS MAN OII3R1 3 4 OTHER WARNINGS 3 4 1 HAZARDOUS VOLT AGES 3 4 2 SERVICE BY FAC TORY AUTHORIZED PER SONNEL ONLY MARCH 2005 Hazardous Voltages This symbol indicates the presence of potentially lethal voltages It is placed on enclosures that contain such voltages and sometimes near terminals Any terminal in a cabinet so marked may have lethal voltages Terminals that are not marked but which are in such a cabinet may still be lethal Power off and lock out before opening any cabinets with this symbol This label comes in 3 sizes ATTENTION Service Attention Proper service and maintenance is required to maintain the performance and safety of the machine Factory authorized personnel are trained to perform such service and have the spare parts to maintain performance and safety Only factory authorized personnel should service the machine 3 0 US SAFETY LABELS 20 of 37 FADAL MACHINING CENTERS 3 4 3 MAINTENANCE LABELS VMC amp HMC MAINTENANCE AND LUBRICATION EMC amp TRM DAILY 1 CHECK AIR PRESSURE A RIGHT REGULATOR 120 PSI MAX TOOL OUT ONLY B LEFT REGULATOR 80 90 PSI CHECK AIR FILTER A DRAIN AND CLEAN WATER SEPARATOR CHECK WAY LUBE LEVEL USE CASTROL MAGNA SHELL TONNA 68
16. erely injure you NEVER place any part of your body near rotating cutting tools Inspect cutting tools for damage before operating this machine DO NOT operate this machine unless workplace is firmly secured to table Rotating pulleys and belts can severely injure you NEVER place any part of your body near rotating ar moving parts ALWAYS ensure guards are in place before operating this machine High voltage electricity can severely injure or kill you NEVER attempt to adjust or repair electrical circuits unless you are familiar with the circuits and are qualified to work safely the electrical circuits ALWAYS lock aut electrical circuits before attempting to work on this machine Exposure to loud or long term noise can lead to permanent hearing loss DO NOT operate this machine without hearing protection ALWAYS wear hearing protection that meets Occupational Safety and Health Administration OSHA standards for noise attenuation Compressed air can injure you DO NOT work on compressed air systems without first disconnecting the source of compressed air ALWAYS wear eye protection when performing maintenance on compressed air systems ONLY authorized qualified personnel familiar with the compressed air system should perform maintenance on the compressed air system LBL 0516A Safety Instruction 2 This label summarizes the hazardous situations that could result in serious injury or death when using the machine Read the warning
17. es 29 CE Combined shapes 33 CE Compressed Air CE compliance 6 18 25 CE Crush from above 28 CE D Danger 8 Drawing in 27 CE E Eye and ear protection 16 24 CE Eye protection 25 CE Electric shock 5 F Force from side 27 CE G Grounding requirements 22 H Hazardous voltages 11 15 20 24 CE Impact from above 28 CE L Lockout electrical power 31 CE M Maintenance labels 21 Maximum tool diameter 31 CE Maximum RPR 32 CE 5 0 INDEX 34 of 37 rana MACHINING CENTERS i Moving parts 11 26 CE N No open or removed guards 29 CE Noise CE compliance 5 P Pallet door 14 Physical enviromental and operating conditions CE specifications 6 Pictorials 4 Potential hazards to personnel 4 R Read operator s manual 16 30 CE Rotating cutting tools 4 10 12 23 CE S Safety instructions 8 Safety warnings 1 Service by factory authorized personnel only 20 Sharp edges on cutting tools 5 opindle head not counterbalanced 12 T Triangles 23 V Vertical axis 13 Vertical axis movement 17 W Warning 15 Warnings and cautions 4 Wear ear protection 30 CE Wear eye protection 29 CE Weight 19 35 of 37 5 0 INDEX MAN 01135R1 5 2 NUMERICAL LBL 0036 21 ORDER OF PART NO LBL 0108 19 LBL 0109 19 LBL 0123 8 LBL 0124 10 LBL 0125 11 LBL 0126 18 LBL 0127 15 LBL 0128 15 LBL 0129 11 LBL 0130 16 LBL 0131 20 LBL 0136 31 LBL 0137 32 LBL 0138 32 LBL 0139 32 LBL 015
18. freed it may move suddenly 3 1 9 PALLET DOOR HAND CRUSH 4 DANGER Automatic Pallet door WILL CRUSH hands STAND CLEAR when door is closing LBL 0158 Pallet Door When the pallet is in operation the operator and all others should keep away from the moving pallet and the automatic pallet door Serious injury could result MARCH 2005 3 0 US SAFETY LABELS 14 of 37 FADAL MACHINING CENTERS 3 2 WARNING 3 2 1 SHARP EDGES ON CUTTING TOOLS 3 2 2 HAZARDOUS AGES DO NOT OPERATE WITH DOOR OPEN 15 of 37 WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury Exposed cutting tool edges can cause serious cuts DO NOT put hands near exposed cutting tool edges LEL 0127 Cutting Tool Edges Cutting tools can be very dangerous even when not moving Keep hands and other parts away from all sharp edges Do not handle sharp tools without gloves Hazardous vollages in lhis enclosure can kill DO NOT operate with door open Servicing by qualifiea personnel only I E 2 Hazardous Voltages Potentially lethal voltage are present in the electrical cabinets Keep the doors closed Only factory trained personnel should service the machine 3 0 USSAFETY LABELS MAN OII3R1 3 2 3 READ OPERATOR S MANUAL To avoid serious injury or death to you or others This machine must be operated oy qualified perso
19. hazard Vertical axis movement Do not operate with door open 3 2 5 VERTICAL AXIS MOVEMENT Lockout before servicing Vertical Axis The vertical axis of the HMC poses an impact hazard from the back of the machine It also poses a more serious crush hazard Do not operate the machine with the guard to this area open 17 of 37 3 0 US SAFETY LABELS MAN OII3R1 AMLLLLLLLLLLLLLLLLLLLGLGAK LILLL ZU Turn off the machine and lockout power before doing any service or maintenance in this area Campressed air can seriously impure DO NOT perform maintenance on pressurized systems Disconnect air source before maintenance l ee Compressed Air some of the systems on the machine use compressed air Hoses can break or come loose Wear eye protection Never perform maintenance on systems that are pressurized Disconnect the air source to the machine before performing any maintenance MARCH 2005 3 0 US SAFETY LABELS 18 of 37 rana MACHINING CENTERS i 3 3 CAUTION CAUTION indicates a potentially hazardous situation which may result in minor or moderate injury 3 3 1 WEIGHT LIFTING HEAVY DEVICES Table weights DS DO NOT lift this table manually or you may be injured ALWAYS use an overhead crane or approved lifting device when lifting this table FIXTURE WEIGHS 165 LBS Moving heavy objects alone may injure you Two man lift required Weight 1 Weight 2 Rotary heads are h
20. levels and are not necessarily safe working levels While there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of the workforce include characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent processes Also the permissible exposure level can vary from country to country This information however will enable the user of the machine to make a better evaluation of the hazard and risk Compressed air poses a potential hazard from flying debris Under normal conditions the compressed air may not present a hazard to the operator Failure of any component of a compressed air system may cause parts to be ejected at high speed Operators and maintenance personnel must always wear eye protection that meets OSHA standards and ANSI standard Z87 1 or CE standards when working on systems that use compressed air The operator may also use their shop s compressed air to remove debris from material being machined If shop air is used for this purpose it must be done in accordance with OSHA or CE standards Alternative means of debris removal such as debris rakes should be considered UNDER NO CIRCUMSTANCES SHOULD THE OPERATOR ATTEMPT TO REMOVE DEBRIS WHILE THE VMC IS RUNNING Consult a qualified industrial hygienist or safety engineer to insure debri
21. nnel only Read and completely understand Operator s Manual before operating this machine LBL C1G3 rew Reading Operator s Manual The operator s manual contains information that is vital to the safe operation of the machine Read and understand the manual before operating the machine Only trained and qualified personnel should be allowed to operate the machine 3 2 4 EYE AND EAR PRO TECTION Flying objects from this machine may injure ALWAYS wear safety qlasses when operating this machine Noise from this machine can damage hearing ALWAYS wear ear protection when operating this machine DO NOT operate this machine with the doors open or with enclosures removed Lockout before servicing LB TET Eye and Ear Protection 1 MARCH 2005 3 0 US SAFETY LABELS 16 of 37 FADAL MACHINING CENTERS objects this machine injure ALWAYS wear safety glasses when operating this machine Noise from this machine can damage hearing ALWAYS wear ear protection when operating this machine DO NOT operate this machine unless workplace is firmly secured to table Lockout before servicing LBL 0517A Eye and Ear Protection 2 Flying chips and loud noise are unavoidable consequences of machining Always wear eye and ear protection The eye and ear protection 1 label is used on all machines except for the TRM The eye and ear protection label 2 is used only for the TRM EE A WARNING 9 Impact
22. of your body near rotating or moving parts Always insure that guards are in place before operating this machine 23 of 37 4 0 CE SAFETY LABELS MAN OII3R1 4 1 3 HAZARDOUS VOLT AGES ELECTRIC SHOCK 4 1 4 EYE AND EAR PRO TECTION FLYING DEBRIS AND LOUD NOISE MARCH 2005 Hazardous Voltages Hazardous voltages in the enclosures marked with this symbol can kill Do not operate with the door open Servicing should be done by qualified personnel only Lockout the power before servicing This symbol is also used near hazardous terminals However terminals not marked may still be lethal Maintenance and service personnel must assume that any terminal wire or circuit board may contain lethal voltages when the cabinet is marked Eye and Ear Protection Flying objects from the machine can injure your eyes Always wear safety glasses when operating the machine Do not operate the machine with the open doors or with the removed enclosures Also noise from the machine can cause the problem with hearing Always wear ear protection while operating the machine 4 0 CE SAFETY LABELS 24 of 37 rana MACHINING CENTERS i 4 1 5 EYE PROTECTION FLYING DEBRIS AND COMPRESSED AIR Eye Protection Flying debris and compressed air can cause eye injury Do not perform maintenance on pressurized systems Disconnect the air source before performing maintenance Always wear eye protection when performing maintenance on
23. r make sure that the head is locked in 3 0 US SAFETY LABELS 12 of 37 rana MACHINING CENTERS i place Some machines use a large pin to accomplish this Most use set screws that are built into the side of the spindle head 3 1 7 VERTICAL AXIS CRUSH HAZARD DANGER Crush Hazard axis moves Stay clear of this area Support pr pin spina head befare working under spindle motor meee Vertical Axis When the vertical axis of the HMC moves it includes the spindle motor which can be accessed from the back of the HMC A guard restricts access to this area When access to this area is required the HMC must not be moving Never work under the spindle motor unless the machine is off and power is locked out 13 of 37 3 0 US SAFETY LABELS MAN OII3R1 SAFETY SECTION 3 1 8 AUGER AND CON VEYOUR W eq Exposed Conveyor can cause severe i jury Keep body parts out of conveyor system Auger can seriously injure or kill Keep body parts out of Auger system at all times Lockout before servicing LBL O558A at all times LBL 0234 Auger Conveyor Chips removal systems are very dangerous Never try to unblock chips with your hand Never stand in or near the auger or conveyor Turn off and lock out power before doing any service on the auger or chip conveyor If auger is jamme beware of stored energy in the auger When
24. rana MACHINING CENTERS ii SAFETY SECTION FADAL MACHINING CENTERS LLC Corporate Office phone 818 407 1400 fax 618 407 0020 Service phone 818 727 2100 fax 618 407 1004 Programming Support phone 818 727 2100 fax 818 407 0061 support fadal com 20701 Plummer Street Chatsworth California 91311 USA Drawings in this manual are for reference only and do not necessarily depict the latest revision 1 0 EE TABLE OF CONTENTS 1 0 SAFETY WARNINGS a i Date e e d 1 2 2 1 WARNINGS AND CAUTIONS beard 4 22 4 2 3 POTENTIAL HAZARDS PERSONNEL 4 2 3 1 ROTATING CUTTING TOOLS IRR IIIS 4 209 2 ELEC IISIC OC butane ce ee re ee 5 2 3 3 SHARP EDGES ON CUTTING TOOLS 2 cee ee mmm m nnn 5 2 3 4 NOISE CE COMPLIANCE 00 c cece RR RR HR HR hh us 5 2 3 5 COMPRESSED AIR CE COMPLIANCE 0 0 0 eee II 6 2 4 PHYSICAL ENVIROMENTAL AND OPERATING CONDITIONS 6 3 0 US SAFETY 8 OO tlc P 8 Sw
25. rlock is not functioning properly qualified maintenance personnel should be notified and the VMC must not be used until it is functioning properly Prior to starting any job the VMC operator should inspect all of the cutting tools being used to ensure they are in good condition and free from defects such as cracks The operator should also insure that only the appropriate cutting tools for the material being machined are present Using the wrong or a damaged tool can result in the failure of the tool or material being machined Failure of either can lead to pieces of either the tool or the material being ejected at extremely high speed Ejection of either can lead to serious injury or death to personnel in the vicinity Major equipment damage could also be sustained 2 3 2 ELECTRIC SHOCK The VMC has numerous subsystems powered by high voltage electricity This electricity is not a hazard during most operations however certain maintenance operations conducted by qualified individuals may require the defeat of interlocks so that power may be maintained during diagnostic or adjustment tasks Under no circumstances should the operator defeat any interlocks Read all applicable manuals and follow their warnings to prevent accidental electric shock Operators must never remove shields or panels nor should operators bypass or otherwise disable interlocks 2 3 3 SHARP EDGES ON Cutting tools have sharp edges that can lead to a serious cut The tools u
26. s carefully and follow the instructions to avoid serious injury or death The safety instruction label 1 is used on all machines except for the TRM The safety instruction label 2 is used only for the TRM 9 of 37 3 0 US SAFETY LABELS MAN OII3R1 3 1 2 ROTATING CUT TING TOOLS DO NOT OPERATE WITH OPEN DOORS MARCH 2005 Cutting tools can seriously injure or kill DO NOT operate uniess doors are closed and interlocks are working 5 0124 Rotating Cutting Tools Rotating cutting tools can cause serious injuries or death Never get close to rotating tool Do not operate the machine unless the doors are closed Make sure that the door interlocks are working In addition to the hazard of cuts and entanglement the cutter can throw chips break and throw part of the cutter or grab and throw the part Any of these can result in a serious injury or death 3 0 US SAFETY LABELS 10 of 37 FADAL MACHINING CENTERS 3 1 3 MOVING PARTS KEEP YOUR HANDS AWAY FROM MOVING PARTS 4 DANGER Moving parts can cause serious injury DO NOT operate with panels removed Keep away from moving parts Lockout power before service Moving Parts Pulleys belts and gears can result in serious injury The machine should not be operated with guards removed Before service the machine should be powered off and power locked out 3 1 4 HAZARDOUS VOIT AGES LOCKOUT BEFORE SERVICI
27. s removal is accomplished in a safe manner and in a manner that complies with local state national Federal and international regulations FADAL VMCs meet or exceed the environmental requirements stated in EN 60204 1 1992 section 4 4 Electromagnetic Compatibility meets or exceeds the levels specified by EN 9008 1 2 1993 and EN 50082 2 1995 Ambient air temperature conforms as specified in EN60204 1 1992 section 4 4 2 5 deg C to 40 deg C Humidity conforms as specified in EN60204 1 1992 section 4 4 3 relative humidity 30 to 95 non condensing Altitude conforms as specified in EN60204 1 1992 section 4 4 4 maximum altitude without derating exceeds 1000 meters above sea level 2 0 GENERAL 6 of 37 rana MACHINING CENTERS i Contaminants conform as specified in EN60204 1 1992 section 4 4 5 Equipment is not intended for use in a corrosive atmosphere Equipment that will be used in an environment with excessive amounts of fine conductive particulate matter e g graphite must be ordered with the graphite restraint package 7 of 37 2 0 GENERAL MAN O113R1 EE 3 0 US SAFETY LABELS DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury 3 1 DANGER 3 1 1 SAFETY INSTRUC 5 SAFETY INSTRUCTIONS 44 DANGER er Ire ER Tu Zn bes
28. sed CUTTING TOOLS on the VMC are stored in a tool tray when not being used Under most circumstances they pose no threat to operator or maintenance personnel It is possible for personnel to come into contact with stationary cutting tools during job setup or when replacing cutting tools for any reason Extreme care must be taken to avoid coming into contact with the sharp edges on cutting tools 2 3 4 NOISE Exposure to occupational hazardous noise or prolonged exposure to noise above 85 decibels may cause permanent hearing damage The sound of noise the VMC produces varies by the type of material speed of the cut and several other factors To prevent loss of hearing from the noise of an operating VMC hearing protection must always be worn by personnel exposed to noise above 85 decibels or above The level of protection required may vary because of variation in the amount of noise being produced by the VMC To insure 5 of 37 2 0 GENERAL MAN 0113R1 2 3 5 COMPRESSED AIR 2 4 PHYSICAL ENVI ROMENTAL AND OPERATING CONDI TIONS CE SPECIFICA TIONS MARCH 2005 adequate hearing protection is attained compliance with CE standards is required Consult a qualified industrial hygienist or safety engineer to insure adequate protection prior to operating the VMC Continuous equivalent A weighted sound pressure at workstation is 77dB A or less when tested according to Annex D of prEN 12417 The figures quoted are emission
29. ticle 250 of the National Electric Code see installation chapter of the FADAL VMC Maintenance Manual for details The minimum grounding method recommended by FADAL is as follows Grounding wire must be one continuous conductor solid or stranded no splices Grounding wire must be copper wire with green insulation or a copper wire having green insulation with a yellow stripe Grounding wire must be a No 8 AWG or larger conductor One end of this wire is connected to the protective earth bar in the back cabinet of the FADAL metalworking machine The other end of the wire is connected to an applicable grounding lug in the power distribution panel of the building Grounding Requirements Proper grounding is essential to the safety and performance of the machine NEVER operate a machine that is not properly grounded MARCH 2005 3 0 US SAFETY LABELS 22 of 37 rana MACHINING CENTERS EMEN 4 0 CE SAFETY LABELS The following labels have triangle circle and square or rectangle shapes 4 1 TRIANGLES TRIANGLE warns of hazards 4 1 1 ROTATING CUTING TOOLS CUTTING OFF FIN GERS OR HAND Rotating Cutter Cutting tools can seriously injure NEVER place any part of your body near rotating tools Do not operate this machine unless the doors are closed and the door interlocks are working 4 1 2 BELT OR CHAIN DRIVE HAND INTANGLE MENT Belt or Chain Drive Rotating pulleys and belts can seriously injure NEVER place parts
30. wear is recommended 7 CONTAIN LONG HAIR Tie long hair back and wear protective hair cover ing to contain long hair 8 DO NOT EXCEED THE MANUFACTURER s RECOMMENDED MAXI MUM RPM FOR THE TOOL When tools are placed in the spindle verify the current RPM commanded in the control before starting the spindle 9 HEARING PROTECTION must be worn when operations exceed 90 85 CE decibels 10 USE A NIOSH OR CE APPROVED DUST MASK OR RESPIRATOR Pro tection is recommended when cutting operations are dusty or exceed the permissible exposure limit 11 DO NOT OPERATE THE MACHINE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL PRESCRIBED OR OTHERWISE 12 READ THE SAFETY WARNINGS SUPPLIED WITH ALL TOOLING 13 KEEP WORK AREA CLEAN Good housekeeping practices encourage safety 14 Read SPINDLE MANUALLY LOADING amp UNLOADING A HOLDER in the Operator s Manual of 37 1 0 SAFETY WARNINGS MAN 0113R1 j Jsassco s 15 REMOVE ADJUSTING KEYS AND WRENCHES Always check that keys and wrenches are removed from tools and tooling before starting the machine 16 MAINTAIN TOOLS WITH CARE Keep tools sharp and clean for best per formance and to reduce the risk of injury Follow instructions for lubrication and for changing accessories 17 SECURE TOOLS PROPERLY IN THEIR HOLDERS 18 SECURE WORK Use standard machining practices for holding fixturing material to be machined 19 MAINTAIN THE TOOLS WITH CARE Keep tools sharp an
31. when working inside any of the electronic cabinets 30 USE RECOMMENDED ACCESSORIES Refer to the User s Manual for FADAL recommended accessories Unapproved accessories increase the risk of injury MARCH 2005 1 0 SAFETY WARNINGS 2 of 37 rana MACHINING CENTERS i 31 NEVER STAND ON OR IN THE MACHINE Besides the risk of slipping or falling serious injury can occur if a tool is unintentionally contacted 32 CHECK FOR DAMAGED PARTS Always check all parts for binding breakage and any other condition that will affect the proper operation of the machine and or increase the risk of injury Damaged or missing parts must be repaired or replaced BEFORE operating the machine 33 NEVER LEAVE THE MACHINE UNATTENDED Turn off the power to the machine when leaving the machine unattended Never leave the machine until it comes to a complete stop 34 WIPE UP SPILLS Immediately cover with absorbent material and wipe up coolant and oil spills around the machine Correct the cause of the leakage to prevent any hazards 35 ELECTRICAL INSTALLATION OF THE MACHINE MUST BE DONE BY A QUALIFIED ELECTRICIAN 36 The machine tool MUST BE connected to a grounded metal permanent wiring system or to a system having an equipment grounding conductor 37 ONLY FADAL OR FADAL DISTRIBUTOR FACTORY AUTHORIZED INDI VIDUALS MAY INSTALL THE MACHINE 38 Do not enter enclosure area for service or maintenance unless machine is off and power is locked out

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